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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

Summary of Contents for 5100 Series

Page 1: ...ual 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: ...trument Co assume responsibility for any injury or damage which may result directly or indirectly from the use of such information This document contains proprietary information which is protected by copyright All rights are reserved No part of the document may be photographed reproduced or translated into another language without the prior written consent of GOW MAC Instrument Co The warranties m...

Page 4: ...s warranty shall not be binding upon GOW MAC unless reduced to writing and approved by an officer of the Company 11 This warranty shall be governed by the laws of the Commonwealth of Pennsylvania LIABILITY Buyer assumes all responsibility for warning and protecting its employees and independent contractors with respect to all hazards to persons and property in any way connected with the Equipment ...

Page 5: ...hout this manual A sample of each statement appears below Within each sample a definition of the statement type and its purpose is given DANGER DANGERS alert you to an immediate hazard that causes serious injury or death and requires special precautions to be taken WARNING WARNINGS alert you to a potential hazard that causes serious injury or death under certain conditions CAUTION CAUTIONS alert y...

Page 6: ...6 5100 Series Continuous Gas Analyzer 03 18 Rev 6 GOW MAC Instrument Co ...

Page 7: ... Section 4 Installation 19 Section 5 Operating Controls 29 Section 6 Operation of Manually Operated 5100 Series 33 Section C Quick Start Up 42 Section D Detailed Start Up 49 Section 7 Electrical Accessories 57 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 ...

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Page 9: ...our instrument Failure to do so could result in damaging the instrument and or yourself Certain sections of this manual pertain to specific options you may or may not have chosen for your instrument Please read them carefully and check the enclosed schematics to ensure proper operation Operate the 5100 Series Continuous TC Gas Analyzer according to the operating procedures stated herein Any questi...

Page 10: ...10 5100 Series Continuous Gas Analyzer 03 18 Rev 6 GOW MAC Instrument Co ...

Page 11: ...ions Your safety and the safety of equipment nearby facilities and personnel require a proper safety attitude and emphasis on safe work procedures This is the essence of any good safety program If at any time you identify safety deficiencies immediately correct them and bring them to the attention of management Before an accident can be prevented it must be anticipated Use pre job discussions with...

Page 12: ...ies Prevent electrical shock Unplug and remove the AC power cord from the rear panel before opening and working on the analyzer Use tools designed for work on electrical equipment Prevent injury Always wear safety glasses and appropriate safety protection Ensure that all tools and instruments used during installation and maintenance are in good condition Be aware that high velocity gas may be rele...

Page 13: ... power and remove the AC power cord from the rear panel 2 Pressure DANGER MISHANDLING OF GAS CYLINDERS COULD RESULT IN DEATH SERIOUS INJURY OR PROPERTY DAMAGE HANDLE AND STORE GAS CYLINDERS WITH EXTREME CARE AND IN ACCORDANCE WITH MANUFACTURER S INSTRUCTIONS Sudden or uncontrolled release of pressurized gas can cause serious injury The hazards of high pressure can be avoided through careful inspec...

Page 14: ...xtreme temperatures are prevalent store cylinders in the shade 8 The valve protection cap should be left on each cylinder until cylinder has been secured against a wall or bench or placed in a cylinder stand and is ready for use 9 Avoid dragging rolling or sliding cylinders even for a short distance Move cylinders by using a suitable hand truck 10 Never tamper with safety devices in valves or cyli...

Page 15: ...ally zeroed When a sample with a lower thermal conductivity than the balance or zero standard gas is introduced an unbalance in the Wheatstone Bridge occurs This unbalance is displayed on the readout and can be calibrated in terms of the composition 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 stabili...

Page 16: ...aster and the sample flow rate is slower 100 200 cm3 min B Flow System The flow system in a single pass unit has a flowing sample and either a static air reference or hermetically sealed reference gas A dual pass unit has a flowing sample and a flowing reference gas The reference sample and calibration gas connections are made at the rear of the instrument One eighth inch 1 8 tube connectors are p...

Page 17: ...inch compression Detector Type Filaments Bridge Current Zero Gas Operating Temp Normal Flow Rate Response Time 15 seconds 200 ccpm flowrate Readout Meter Vacuum fluorescent display Calibrated Range Recorder 4 20 mA Dimensions inches W 17 12 without panel mount bracket W 19 0 with panel mount bracket H 15 75 D 23 0 with fittings Weight Net approx 75 lbs Shipping approx 80 lbs Schematics Drawing ___...

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Page 19: ...s 4 Data Recorder with 4 20 mA 1 second response B Unpacking Inspection 1 When unpacking the instrument check it carefully for evidence of shipping damage or rough handling Check to ensure that all components ordered have either been supplied or back ordered Notify the company of any discrepancies The packing box should be retained for use should the instrument ever need to be returned to the fact...

Page 20: ...may prevent ground loops D Mounting if applicable Space and materials required 19 inch rack space or bench top Service access space behind and in front of the analyzer Metal bracket to support the rear side of the cabinet if the analyzer is installed in a cabinet without side support brackets E Gas Connections External Lines The use of refrigerant grade cleaned copper tubing is fine for percent le...

Page 21: ...ow of gas from cylinder for 1 2 minutes at low flow 30 sccm It is also important to cycle purge any regulators to remove air impurities from dead legs 5 Connect the appropriate 1 8 inch o d tubing to the external ZERO SPAN and SAMPLE gas inlet ports on the back of the case Figure 4 3 6 After all connections have been made it is IMPORTANT to check for leaks Refer to Section F for leak testing REFER...

Page 22: ...leaks in the system is through the use of a GOW MAC Gas Leak Detector Model 21 070 NOTE Leak checks should be run periodically but MUST be completed when new tub ing and fittings are installed G Purge Gauge Assembly Optional and Ordered Separately NOTE This instrument purge gauge assembly part number 152 474 is designed to meet the instrument pressurization requirements set forth by the NFPA 496 s...

Page 23: ... 0 1 0 2 0 3 0 4 REGULATOR 4 2 Installation Diagram dimensions in inches 1 Installation refer to Figure 4 2 a The purge gas may be compressed air if it has been filtered for moisture oil and particles Unfiltered compressed air may contain contaminants that will damage the instrument electronics The purge gas supply should include a pressure regulator with 0 60 psi output and a shut off valve b Loc...

Page 24: ... the low pressure port A flame arrestor is installed in both the high and low pressure ports Electrical connections to the switch are made by removing the cover which is attached with four 4 7 16 inch hex screws Use the correct wire gauge for the alarm circuit current rating maximum 15 A Protect the switch from the atmosphere by running the wires to the switch in conduit The conduit connection on ...

Page 25: ...eather Vent on Low Pressure Port 304 stainless steel housing 316 stainless steel 100 micron sintered element 4 Purge Option Replacement Parts Part Number Description 120 239 24 Differential Pressure Switch set 0 07 0 15 inches water 24 VDC 128 269 Differential Pressure Gauge 0 0 5 inches water 141 163 Bracket for gauge 128 269 163 174 Polyethylene tubing 1 4 inch OD 0 062 inch wall 171 392 Breathe...

Page 26: ...t also be properly grounded 4 Connect the 4 20 mA analog recorder output terminals to a recording system if desired The recorder output terminals are located on the terminal strip on the back of the analyzer 5 RS232 refer to wiring schematic for connections Records continuously in CAPTURE Mode Marks OVER RANGE readings Day Count Time 24 hour clock Hours Minutes Seconds ZERO and SPAN on recorded co...

Page 27: ...AS GAS SAMP SPAN GAS ZERO GAS SAMPLE 50 SERIES THERMAL CONDUCTIVITY GAS ANALYZER INSTRUMENT CO Figure 4 4 Front panel typical c Carefully slide the chassis out of the case d Locate the terminal strip at the back of the chassis shown in schematic e Attach the recorder cable to the terminal strip as specified by the schematic terminal strip is usually located in the upper left corner of wiring schem...

Page 28: ... many options were ordered there may be several groups of terminals mounted to a rail CAUTION READ THE WIRING SCHEMATIC CAREFULLY TO ENSURE PROPER CABLE INSTALLATION DO NOT PLUG THE INSTRUMENT INTO AN OUTLET AT THIS TIME NOTE Leak checks should be run periodically and are a MUST when new tubing and fittings are installed I Installation Checklist After installing the system confirm that 1 All gas a...

Page 29: ...n and analysis 2 Power ON OFF switch Switch on and off AC power to the instrument Switch has a built in magnetic circuit breaker 3 Reference rotameter Displays the reference gas flow rate to the detector 4 Reference manual pressure regulator 5 Reference metering valve Adjusts the reference gas flow rate including shut off WARNING Always have inert gas flowing through the detector before applying b...

Page 30: ...as In 1 8 inch compression 6 Purge Out optional 1 4 inch compression 7 Purge In optional 1 4 inch compression 8 Purge Reference Pressure 1 4 inch compression with tube to transfer purge pressure to pressure switch optional part of purge option 9 Pressure Switch optional part of purge option REFERENCE PURGE IN PURGE OUT OUT SAMPLE OUT SAMPLE GAS SPAN GAS ZERO GAS PRESSURE PURGE REF 5 4 2 3 1 6 ELEC...

Page 31: ...nalyzer 03 18 Rev 6 31 GOW MAC Instrument Co C Bottom shown in Fig 5 3 7 FRONT 9 HIGH PRESS VENT DRAIN LOW PRESS Figure 5 3 Bottom of chassis 7 Purge In optional 1 4 inch compression 9 Pressure Switch optional part of purge option ...

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Page 33: ...n the cylinders for CALIBRATION SAMPLE and ZERO GASES should be set between 60 120 psig 3 Make sure REFERENCE GAS VALVE is OPEN by turning the black knob on the front panel labeled Ref Gas COUNTER CLOCKWISE to the fully open position 4 Adjust flow rate of REFERENCE GASES with Reference METERING VALVES to approximately mid scale NOTE Sample Span and Zero gases all flow through the SAMPLE FLOW METER...

Page 34: ...3 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 _________________________________ IMPORTANT Use F1 to F4 buttons below screen to enter calibration parameters as instructed in the following directions Function descriptions will appear on scr...

Page 35: ...lly practical for users with highly sensitive applications whose environmental conditions are subject to variations over time such as temperature and humidity fluctuations which could affect the analysis results During auto zero the instrument switches to a NOT READY state and the instrument output signals should not be read CONTINUOUS SAMPLE mode the sample gas is analyzed constantly without auto...

Page 36: ...ent will auto zero Be sure to leave enough time for the instrument to return to a stable zero state CONTINUOUS SAMPLE mode the user must enter 0000 for both of these times Esc then Enter can be pressed to skip this step and default to 00 00 2 Set SAMPLE GAS FLOW interval Press ENTER F4 to continue ESC then ENTER to skip AUTO CYCLE mode a Enter SAMPLE VALVE SWITCH ON time CW1 in format XX XX The ti...

Page 37: ...concentration value in format XXX XX For example if your SPAN Standard concentration is 200 00 ppm enter 20000 NOTE The entry format may change depending upon the concentration range requested This value MUST be entered and cannot be skipped Press ENTER F4 to continue 4 EPC Pressure Press ENTER F4 to SET ESC then ENTER to skip Set the EPC pressure for the Sample Span and Zero gases in format XXX A...

Page 38: ...e Alarm Control enter 1 which will reveal the Alarm Menu If you do not wish to activate the Alarm Control enter 0 which will skip the Alarm Menu and advance to Filament Fail Safe Setting Skip to 10 a Alarm Menu Alarm 1 Type i Enter 0 to designate Alarm 1 as a LOW ALARM which will be activated if measured concentration value falls below alarm setting value ii Enter 1 to designate Alarm 1 as a HIGH ...

Page 39: ...1 to designate Alarm 3 as a HIGH ALARM which will be activated if measured concentration value increases above alarm setting value iii Enter 2 to turn Alarm 3 off Alarm 4 Type i Enter 0 to designate Alarm 4 as a LOW ALARM which will be activated if measured concentration value falls below alarm setting value ii Enter 1 to designate Alarm 4 as a HIGH ALARM which will be activated if measured concen...

Page 40: ...ter 1 to turn on Filament Fail Safe 0 OFF If turned on the Filament Fail Safe will shut off the detector current and the instrument will switch to a NOT READY state as indicated through the READY OUTPUT CONTACTS if activated by an external device Examples of devices that could trigger the Filament Fail Safe are pressure or flow sensors that monitor the reference or sample gas line flows These devi...

Page 41: ...s when not in calibration it opens Type Contact Closure 100000 cycles Switching Voltage 28 VDC Current 5 A NOTE The Cal Ind Option must be included if the Remote Cal Option is ordered However it can be ordered by itself 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 ...

Page 42: ...mal details Section D will provide extensive details on menu options and screen values When SETUP is correct and complete press RUN Button F2 at bottom center of screen to enter RUN MODE The Zero Span and Sample Gases MUST be open at the cylinders and or source and flowing 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 TC...

Page 43: ...crease TCDCurrent to desired setting 4 Press 7 to change Polarity to 1 This setting should be used if the thermal conductivity of the Sample Gas is less than that of the Reference Gas i e a negative concentration reading is displayed on the screen in Calibration Mode An example would be Nitrogen impurity in Helium base gas Press Shift then 7 to change Polarity to 0 This is the default setting whic...

Page 44: ...ified mA and Polarity is selected press CAPTURE F1 to enter CAPTURE MODE If AUTO CYCLE mode was selected instrument will auto zero for user programmed interval If CONTINUOUS SAMPLE mode was selected CONT will appear at the bottom left of the screen The sample will be continuously analyzed 6 Press SHIFT then 9 to enter CAL mode to Calibrate Be sure the screen displays CALIBRATION MODE ...

Page 45: ... the Standard Concentration STD CONC that was entered in the SETUP section Sec 6 Part B 7 and the S Voltage will be recorded on the display screen S x xxxx V You may Re SPAN with the F3 button as many times as needed 9 Verify Calibration settings a Press 3 to flow ZERO GAS A z will be displayed on the screen between F3 and F4 to indicate zero gas flow Wait for stable ZERO reading on Concentration di...

Page 46: ...utput is now in CLOSED STATE Alarms are active and 4 20 mA output reflects recorded concentration on the screen Begin collecting data If AUTO CYCLE mode was selected and entered in the INITIAL SETUP the analyzer will begin with ZERO ON for the designated timeframe The 4 20 mA output and alarms will be disabled and a NOT READY message will be displayed on the screen The instrument will turn off zer...

Page 47: ...e gas flowing the 4 20 mA output and alarms will be active and a CONT message will be displayed on the screen above the F4 key not active Press 1 on the keypad at any time to display the Main Menu The menu will show you reminder key strokes but will not allow you to make changes while the menu is displayed Press 1 again to close the menu and key the function you wish to execute ...

Page 48: ... Analyzer 03 18 Rev 6 GOW MAC Instrument Co 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 ...

Page 49: ... Press Shift then 3 for SPAN GAS ON This will activate the solenoid valve to allow span calibration gas to flow to TCD Press 4 CURRENT INC to increase TCD bridge current setting to desired value The 4 key should be pressed repeatedly to obtain the current value It will need to be pressed 10 to 12 times before a current change is noticed on the screen Current can only be adjusted in the RUN mode On...

Page 50: ...tivated only when the main menu is closed Press 1 to close menu and 9 to activate run mode Press Shift then 9 to enter CAL MODE This is a diagnostic condition which will place the instrument into a NOT READY state to allow ZERO and SPAN calibrations while in capture mode This option can be activated only when the main menu is closed Press 1 to close menu and Shift then 9 to activate cal mode Press...

Page 51: ...inutes and Seconds Detector Current Setting Located at top right of screen as I XXX X mA Zero voltage Z Directly below Current Reading I The voltage recorded as ZERO VOLT Span delta S Directly below Zero Voltage Z The voltage recorded as SPAN VOLTAGE Relative to the programmed concentration Concentration Reading Indicates current sample or standard concentration reading in Parts per Million PPM or...

Page 52: ... 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 on the keypad to flow SPAN GAS An s will be displayed on the screen between F3 and F4 to indicate span gas flow Wait for stable SPAN reading on Concentration display Press hold SPAN F3 button for TWO SE...

Page 53: ...desired See 6 2 a i above Repeat calibration procedure until readings replicate within desired tolerance without having to Re ZERO or Re SPAN instrument It is VERY important to wait for stable readings before zero or span calibration or verifying calibrations 8 Analyze Sample Press 9 to turn RUN MODE ON when calibration is completed The instrument is now analyzing sample READY output is now in CLO...

Page 54: ...t indicates current changes relative to concentration 0 ppm 4 mA 100 ppm 20 mA Application Dependent Usually set as dictated by the cus tomer at the time of manufacture NOTE Ranges can change according to ordered specifications 4 RS 232 Records continuously in CAPTURE Mode Marks OVER RANGE readings Day Count Time ZERO SPAN and alarms on recorded concentration readings Refer to Section 7C not funct...

Page 55: ...the detector for 3 4 hours When the detector is completely cooled to ambient temperature shut OFF ZERO GAS flow WARNING FAILURE TO ALLOW SUFFICIENT TIME FOR THE DETECTOR TO COOL MAY RESULT IN FILAMENT DAMAGE WARNING FOR CERTAIN SAMPLE COMPOSITIONS THAT INTERACT WITH ATMOSPHERICS OXYGEN MOISTURE ETC IT IS NECESSARY TO THOROUGHLY PURGE THE ENTIRE INSTRUMENT OF SAMPLE GAS BEFORE SHUTDOWN USING AN INER...

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Page 57: ...50 ohm load In the industrial environment option 600 can serve as a transmission link between such systems elements as transmitters indicators controllers recorders computers actuators and signal conditioners B Filament Fail Safe optional This circuit provides protection for your thermal conductivity detector It monitors the pressure of the reference and sample gas by way of pressure switches as a...

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Page 59: ...f complete oven assemblies are returned to us To minimize costs remove detector from oven and ship only the TC block to us If you desire the detector can be serviced in the field by the instructions set down in the following paragraphs CAUTION ALWAYS USE MATCHED PAIRS OF FILAMENTS REPLACEMENT OF SINGLE FILAMENTS IS IMPRACTICAL OPEN INDIVIDUAL CONTAINERS WITH CARE DO NOT TOUCH HELIX WITH FINGERS 1 ...

Page 60: ...r replace detector and or filaments if necessary Tighten replacement filaments per instructions found in the accompanying GENERAL SERVICE BULLETIN l Thread filament wires through hole in detector housing and reattach to terminal strip m Replace insulation and detector housing lid n Leak check system o Replace chassis in case 3 TC Detector Replacement a Follow Steps A 1 a i above b Locate and unscr...

Page 61: ...t 1 2 3 4 Figure 8 1 TC Detector in Cell Housing e Gently pull detector out of cell housing f Unscrew insulation block from detector g To replace detector go in reverse order of above steps Leak check system B Maintenance 1 Check zero 2 Check flow rates 3 Observe whether heater indicator is at set temperature ...

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Page 63: ...upply open Replace fuse b Filaments open Replace filaments c Defective power supply Replace power supply d Current not on Turn on current and then increase current 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 Rep...

Page 64: ... Current Setting acquired in span calibration re zero then re span step is locked at 0000 Section 6 C 1 or indicates an OVERRANGE condition Concentration Display a Thermal conductivity of SPAN gas Change POLARITY indicates a negative value may be lower than Reference Gas Section 6 C 1 Menu Options after SPAN ZERO or SPAN readings a Instrument not stable Allow more time for not stable instrument to...

Page 65: ...ant current 115 VAC 123 191 2 230 Power Supply constant current 230 VAC 123 278 1 PCB Controller 123 287 1 PCB personality 123 298 1 PCB 4 20 mA backplane 124 175 Temperature Probe 124 181 Heater 100 Watt 120 VAC 124 182 Heater 100 Watt 240 VAC 124 262 20 50 Detector Temperature Controller programmed 127 406 Filter RFI power line 10 A 250 VAC 128 260 Display vacuum fluorescent 128 269 Gauge pressu...

Page 66: ...ogen rotameter aluminum 180 472 Air rotameter stainless steel 180 928 Carbon monoxide CO rotameter aluminum Note 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 ...

Page 67: ...AMPLING MODE CONTINUOUS SAMPLE no auto zero Set ZERO Gas Flow Interval Press ENTER F4 Set SAMPLE Gas Flow Interval Press ENTER F4 Set ZERO Gas Flow Interval Press ENTER F4 Set SAMPLE Gas Flow Interval Press ENTER F4 Enter ZERO SWITCH ON Time XX XX Enter SAMPLE SWITCH ON Time XX XX Enter ZERO SWITCH OFF Time XX XX Enter SAMPLE SWITCH OFF Time XX XX Enter ZERO SWITCH ON Time Enter 00 00 Enter SAMPLE...

Page 68: ... UP EPC PRESSURE Press ENTER F4 to set Sample Zero and Span flow rate Format XXX Manually set Reference Flow to match Activate ALARM CONTROL Enter 0 to skip alarms Enter 1 to activate Alarm 1 Type 0 Low Alarm 1 High Alarm 2 Alarm 1 OFF Alarm 2 Type 0 Low Alarm 1 High Alarm 2 Alarm 2 OFF INPUT 0 Turn OFF 1 Turn ON Alarm 4 Type 0 Low Alarm 1 High Alarm 2 Alarm 4 OFF Alarm 3Type 0 Low Alarm 1 High Al...

Page 69: ...urn to top of Page 1 to change SETUP Is SETUP COMPLETE and CORRECT PROCEED TO CALIBRATE ANALYZE page 4 Enter Setpoint for ALARM 1 XXX X Enter Setpoint for ALARM 2 XXX X Enter Setpoint for ALARM 3 XXX X Enter Setpoint for ALARM 4 XXX X 5100 Series Quick Start Reference Flow Chart EPC and ALARMS page 3 ...

Page 70: ... MODE Press ESC to exit Capture Mode if desired AUTO CYCLE auto zero CONTINUOUS SAMPLE no auto zero CAPTURE MODE SAMPLING MODE Selected Instrument will auto zero for programmed interval Press 3 to flow ZERO GAS Z will be on display WAIT for stable ZERO reading PRESS HOLD ZERO F4 Were ZERO SPAN verified Press 9 to ANALYZE SAMPLE Is Z 0 1 V AND is R changing Press SHIFT then 3 to flow SPAN GAS S wil...

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Page 73: ...bove boxes are checked the following statements and or questions must be answered 1 Specifically describe where on or in the instrument device part there could be any residual contamination for example blood spill on the surface ____________________________________________________________________________________________ ______________________________________________________________________________...

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