Bacharach Neutronics 5100E User manual

Neutronics Inc.
456 Creamery Way, Exton, PA 19341
Phone: [phone] • Fax: [phone] • Email: [e-mail]
www.neutronicsinc.com
High Purity Instruments
MODEL 5100E
OXYGEN ANALYZER / CONTROLLER –PERCENT RANGE
OPERATIONS MANUAL
File Name: MN-A-0008
Manual Part Number: C5-06-4900-08-0
Revision Level: C Revision Date: 11/27/06
ECO: 8029
REMOTE
SENSOR
MODE
RUN FAULT ALM 1 ALM 2
20.9
PERCENTOXYGEN
MODEL 5100 O2Analyzer
NTRON

Table of Contents
TABLE OF CONTENTS ..................................................................................................................................................III
FOR YOUR SAFETY: ..................................................................................................................................................... V
WELCOME ................................................................................................................................................................. VI
CHAPTER 1 –INTRODUCTION AND OVERVIEW.........................................................................................................1-1
1.1 GENERAL ............................................................................................................................................................ 1-1
1.2 FEATURES ........................................................................................................................................................... 1-1
1.3 SYSTEM HARDWARE OVERVIEW .............................................................................................................................. 1-3
1.3.1 Main Board .............................................................................................................................................. 1-3
1.3.2 Relay Board.............................................................................................................................................. 1-3
1.3.3 Power Supply ........................................................................................................................................... 1-3
1.3.4 Display Board........................................................................................................................................... 1-3
1.3.5 Control Panel ........................................................................................................................................... 1-3
1.3.6 Sensor ...................................................................................................................................................... 1-4
1.3.7 Sensor Flow-Through Head...................................................................................................................... 1-4
1.3.8 Chassis ..................................................................................................................................................... 1-5
1.4 ANALYZER INPUTS AND OUTPUTS............................................................................................................................. 1-7
1.4.1 The Oxygen Sensor Input ......................................................................................................................... 1-7
1.4.2 Alarm-1 Relay Output .............................................................................................................................. 1-7
1.4.3 Alarm-2 Relay Output .............................................................................................................................. 1-7
1.4.4 Fault Relay Output................................................................................................................................... 1-7
1.4.5 Warm-up Relay Output............................................................................................................................ 1-7
1.4.6 Analog Voltage Output............................................................................................................................ 1-7
1.4.7 Analog Current Output ............................................................................................................................ 1-9
1.4.8 Range ID Output ...................................................................................................................................... 1-9
1.4.9 Service Port .............................................................................................................................................. 1-9
1.5 CONTROL PANEL USER INTERFACE............................................................................................................................ 1-9
1.5.1 The “UP” Pushbutton............................................................................................................................... 1-9
1.5.2 The “DOWN” Pushbutton ........................................................................................................................ 1-9
1.5.3 The “MODE” Pushbutton ......................................................................................................................... 1-9
1.5.4 7-Segment Alphanumeric Display.......................................................................................................... 1-10
1.5.5 RUN Indicator LED ................................................................................................................................. 1-10
1.5.6 Alarm-1 Indicator LED............................................................................................................................ 1-10
1.5.7 Alarm-2 Indicator LED............................................................................................................................ 1-10
1.5.8 Fault Indicator LED................................................................................................................................. 1-10
CHAPTER 2 –SYSTEM INSTALLATION AND START-UP ...............................................................................................2-1
2.1 INSTALLING THE ANALYZER ..................................................................................................................................... 2-1
2.1.1 Step 1 –Locate and Mount the Analyzer Unit ......................................................................................... 2-2
2.1.2 Step 2 –Install the Remote Sensor ........................................................................................................... 2-3
2.1.3 Step 3 –Electrical Installation................................................................................................................... 2-6
2.2 STARTING UP AND COMMISSIONING THE SYSTEM...................................................................................................... 2-12
2.2.1 STEP 1 –Power Up the unit.................................................................................................................... 2-12
2.2.2 STEP 2 –Calibrate the Unit .................................................................................................................... 2-14
2.2.3 STEP 3 –Set Alarm-1 and Alarm-2.......................................................................................................... 2-14
CHAPTER 3 –ANALYZER OPERATION........................................................................................................................3-1

3.1 SYSTEM ORGANIZATION......................................................................................................................................... 3-1
3.2 USER MODES ..................................................................................................................................................... 3-1
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
3.3 SYSTEM MODES ................................................................................................................................................... 3-4
3.3.1 Self-Test & Warm-up Mode ..................................................................................................................... 3-4
3.3.2 RUN Mode ............................................................................................................................................... 3-4
3.3.3 ALARM-1 ACTIVE Mode ........................................................................................................................... 3-5
3.3.4 ALARM-2 ACTIVE Mode ........................................................................................................................... 3-5
3.3.5 FAULT ACTIVE Mode ................................................................................................................................ 3-5
CHAPTER 4 –MAINTENANCE AND TROUBLESHOOTING ...........................................................................................4-1
4.1 SYSTEM SETUP..................................................................................................................................................... 4-1
4.1.1 System Setup via Control panel Keypad................................................................................................... 4-1
4.1.2 System Setup via Service Port .................................................................................................................. 4-3
4.1.3 Change factory settings via Hardware Jumpers .................................................................................... 4-16
4.2 ROUTINE PERIODIC MAINTENANCE ........................................................................................................................ 4-18
4.3 TROUBLESHOOTING............................................................................................................................................. 4-19
4.3.1 Fault Codes ............................................................................................................................................ 4-19
CHAPTER 5 –APPENDICES ........................................................................................................................................5-1
5.1 APPENDIX A–SPARE PARTS LIST............................................................................................................................. 5-1
5.2 APPENDIX B-SPECIFICATIONS................................................................................................................................. 5-2
5.3 APPENDIX C–ANALYZER FACTORY CONFIGURATION SETTINGS....................................... 5-4
5.4 APPENDIX D–CONTROL PANEL HOT-KEY FUNCTIONS.............................................................................................. 5-5
5.5 APPENDIX E–RANGE /OUTPUT CHART................................................................................................................. 5-6
5.6 APPENDIX F–MSDS MATERIAL SAFETY DATA SHEET .............................................................................................. 5-7
5.7 APPENDIX G–WARRANTY .................................................................................................................................. 5-8
INTENDED USE FOR THE MODEL 5100E............................................................................................5-8

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.
•Always assure the pressure of gas entering the Model 5100E sensor is 1-10 psig. Not to exceed 20 psig
•Always calibrate the Model 5100E at an equivalent pressure and flow rate to the measured gas.
Maximum pressure should not exceed 10 psig.
•Always allow the Model 5100E to cool down before attempting to access the sensor.
•Ensure the Model 5100E has been properly calibrated before use.
•Never expose the Model 5100E analyzer chassis to water, high humidity or moisture. The analyzer
chassis is not watertight.
•Never expose the Model 5100E to flame or high temperatures.
•Never expose the Model 5100E analyzer to flammable gases or vapors. The unit is not rated Explosion
Proof, or Intrinsically Safe.
•Never expose the Model 5100E directly to unregulated gas lines, cylinder gas. High gas pressures may
cause the sensor components to rupture.
•Ensure the analyzer unit is mounted in an area of free airflow to prevent the chassis from exceeding the
operating temperature specifications. Do not mount the analyzer against hot surfaces. Do not block
the ventilation louver on the analyzer chassis.

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.
For further detail regarding the maintenance and in-field service of the Model 5100E analyzer, please contact
the Neutronics Inc. Customer Service Department. If you have questions or comments, we would like to hear
from you.
Neutronics Inc. Customer Service Department
456 Creamery Way
Exton, PA 19341
Tel: [phone]
Toll Free: [phone] (US only)
Fax: [phone]
EMAIL: [email protected]
Visit us at www.neutronicsinc.com
Equipment Serial Number: ________________
(For faster service, please have this number ready if for any reason you need to contact us about your instrument)
Copyright ©2006 Neutronics Inc.
This work is protected under Title 17 of the US Code and is the sole property of Neutronics Inc. No part of this document may be
copied or otherwise reproduced, or stored in any electronic information retrieval system, except as specifically permitted under US
copyright law, without the prior written consent of Neutronics Inc.

Manual Part Number:
C5-06-4900-08-0
Revision Level: C
ECO 8029
File Name: MN-A-0008
Page 1-1
1CHAPTER 1–INTRODUCTION AND OVERVIEW
1.1 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. This
sensor assures reliability and fast response for critical measurements from zero to 100 %. It utilizes a
unique solid-state sensor, which offers long life with little periodic maintenance. It is unaffected by dry
atmospheres, is undamaged by extremely cold storage temperatures, and has indefinite storage life.
The ZR-500E sensor is remote mounted to allow the sensor to be installed close to a sampling point for the
fastest response time possible in process monitoring and control applications. A flow-through mounting
head is supplied for use with all Neutronics Inc. process gas sampling systems. Neutronics also provides a
wide variety of built-to-application, and custom process sampling systems.
1.2 Features
The Compact Series analyzers are designed to be flush mounted to a panel or console. Because of the small
size of the Model 5100E analyzer, it can be integrated into a variety of equipment or control panels. The
Remote Sensor Module should be mounted as close as possible to the sampling point.
Other Features Include:
•Compact, rapid-response Zirconia oxygen sensor
•Two User-adjustable oxygen Alarms with configurable relay outputs for process control use
•Two Analog Outputs: 4-20 mA AND 0-1, 0-5, or 0-10 VDC
•Auto Ranging or Fixed Range Oxygen Measurement (VDC output provided for auto-range identification)
•Bi-directional RS-232 Serial Interface for connection to a PC, terminal, or printer

Model 5100E –Introduction and Overview
Manual Part Number:
C5-06-4900-08-0
Revision Level: C
ECO 8029
File Name: MN-A-0008
Page 1-2
Front view
SHOCK.
SERVICE BY
AUTHORIZED
TECHNICIAN
ONLY.
RISK OF
ELECTRICAL
NEMA4Panel-mountingGasket
Removeable Terminal Blocks RemoteSensor Module Interface
Mounting Studs
Rear view
Chassis
Power SupplyBoard
RelayBoard
Main Board
Display
Board
Control
Panel
Figure 1 –Model 5100E oxygen analyzer
front and rear view
Figure 2 –Basic internal analyzer components

System Hardware Overview
1.3 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.
1.3.2 Relay Board
The Relay Board houses relay contacts for all of the Alarm and Control features of the 5100E. The relays
are mapped discretely to each alarm to provide electrical outputs for reporting, and process control use.
1.3.3 Power Supply
The power supply board is designed to take 110/220 VAC, 50/60 Hz mains power input. The supply is fused
directly on the board. Optional 24 VDC power supply is available for installations where a DC voltage is
required to power the Model 5100E. A 12 VDC battery-backup power input (battery not provided) is also
provided to act as an emergency back up in case of mains power failure.
1.3.4 Display Board
The Display board is designed to generate a digital indication of the concentration of oxygen (Appendix E –
range / output chart), and fault codes (section 4.3.1). The display is a 7-segment, ¾” alphanumeric LED.
1.3.5 Control Panel
The Control Panel serves as the main user interface. The Control Panel features the keypad (ramp-UP,
ramp-DOWN, and MODE keys) and the status LED’s. The control panel is designed to be splash and water-
resistant. There are #8-32 threaded mounting studs at each of the four corners for flush mounting of the
Model 5100E to a control or equipment panel. The gasketed panel is suitable for NEMA type 4 / IP20
environments when properly installed.

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. Unlike many solid-state oxygen sensors, the ZR-500E
does not require a reference gas for normal operation (see calibration requirements).
The sensor is mounted directly onto a printed circuit board that supplies bias and heater voltages to the
sensor element. A small capillary on the sensor surface controls diffusion of oxygen into the sensor. At
operational temperature, oxygen is electrochemically reduced, causing current flow through the solid
electrolyte. Oxygen concentration in the sample gas is determined by measuring the current flowing
through the sensor’s two electrodes.
H
H
S +
S- AAmmeter
(Oxygen Analyzer)
Sensor Bias
Voltage
Heater Power
The robust design of the ZR-500E sensor assures accurate measurement as well as a quick response
characteristic to serve a wide range of oxygen measurement applications. Its expected operating life is 2
years under normal operating conditions, and it has an unlimited shelf life. It is not affected by position,
and it may be exposed to high atmospheric pressures with no ill effect on performance.
1.3.7 Sensor Flow-Through Head
The sensor mounting-base allows the Model ZR-500E sensor to be used for process monitoring. It serves as
both the receptacle for the sensor and the delivery system for a gas sample from a process vessel or
stream. It includes a sample inlet, a flow-through chamber a sample exhaust, and a screw-in receptacle for
the oxygen sensor.
1.3.7.1 Sample Gas Inlet
A sample gas inlet port is provided for installation with a process oxygen sampling system. Gas must be
directed from the measured process to the sample inlet port via positive pressure from the source, or an
external pump. The Model ZR-500E sensor and flow-through head combination can be installed in any
Neutronics Inc. Process Sampling System.
1.3.7.2 Sample Gas Exhaust
A sample gas exhaust port is provided for installation with a process oxygen sampling system. Gas must be
directed from the sample exhaust port to an exhaust at ambient pressure. Any change in pressure to the
exhaust port of the analyzer will affect its reading and accuracy.
Figure 3 –ZR-500E sensor circuit

System Hardware Overview
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. Since the Model 5100E is a flush mounted system, the
portion of the instrument housed in the chassis will be located behind the control panel or embedded
within the customer equipment enclosure. The enclosure is general purpose and is not watertight.
Analyzer
Electronics
Package is
inserted here
Figure 5 –
Analyzer chassis
Figure 4 –Sensor
flow-through
head

Model 5100E –Introduction and Overview
RelayBoard
RS-232 COMLine
Mains Power
Input Power
Supply Main Board
Display
Board
Control
Panel
Fault RelayOutputs
Alarm 1 & 2 RelayOutputs
RangeIDOutput
AnalogVoltageOutput
4-20 mAOutput
Remote
Sensor
Figure 6 –Analyzer system configuration

Analyzer Inputs and Outputs
1.4 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. The oxygen sensor input is a female 7-pin DIN connector to mate with the
supplied sensor interface cable connector.
1.4.2 Alarm-1 Relay Output
The Alarm-1 relay is mapped to the Alarm-1 setpoint, and is provided for process control use. The user may
set the oxygen level at which Alarm-1 activates (section 3.2.2). Alarm-1 may be configured as ascending
(highest oxygen level allowable) or descending (lowest oxygen level allowable) action. The relay output
may be configured for failsafe (relay coil de-energized in alarm state) or non failsafe (relay coil energized in
alarm state) action. Factory default settings are ascending, and non failsafe The Alarm-1 relay contacts are
form 1 C (SPDT), voltage-free.
1.4.3 Alarm-2 Relay Output
The Alarm-2 relay is mapped to the Alarm-2 setpoint, and is provided for process control use. The user may
set the oxygen level at which Alarm-2 activates (section 3.2.3). Alarm-2 may be configured as ascending
(highest oxygen level allowable) or descending (lowest oxygen level allowable) action. The relay output
may be configured for failsafe (relay coil de-energized in alarm state) or non failsafe (relay coil energized in
alarm state) action. Factory default settings are ascending, and non failsafe The Alarm-2 relay contacts are
form 1 C (SPDT), voltage-free.
1.4.4 Fault Relay Output
The Fault relay output is used to indicate that there is at least one system fault active on the Model 5100E
analyzer (section 4.3.1 –fault codes and definitions). The relay is configured for contact closure with
applied power. The contacts will remain closed provided no faults occur. The Fault relay contacts are Form
1 B (SPST), voltage-free. During normal operation the contact is closed.
1.4.5 Warm-up Relay Output
The warm-up relay (listed as temp relay), is located at TB2, pins 1 and 2. This is a failsafe relay; during
warm-up the relay will open. Once the temperature of the sensor has stabilized, the contact will close.
Approximate time for contact closure is 60 seconds.
1.4.6 Analog Voltage Output
The Analog Voltage output is a dynamic potential used to indicate to a remote device the displayed oxygen
concentration during normal analyzer operation and system maintenance. The Analog voltage output
follows the oxygen readout displayed on the 7-segment LED display during all system and user modes
except for user setup. For a complete listing of available output levels by analyzer range, refer to Appendix
E –range / output chart.

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).

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. For a complete listing of output levels by analyzer range, refer to Appendix E
–range / output chart.
The analog current output may be set to either 0-20 mA or 4-20 mA. Full-scale is fixed at 20 mA. The
Analog current output is scaled according to the analyzer’s selected range, and may be used in conjunction
with the Range ID voltage when the Analyzer is configured for auto-ranging (section 1.4.9).
1.4.8 Range ID Output
The Model 5100E can be configured by the user to automatically switch its measurement range, based on
the concentration of oxygen measured while in-service, to provide the most accurate, and highest
resolution outputs at all times. For a complete listing of analyzer ranges, refer to Appendix E –range /
output chart.
Remote auxiliary devices designed to interpret the Model 5100E Analog outputs over multiple output range
scales require an indication of the analyzer’s selected range at all times for accurate scaling. The Model
5100E features a 0-10 volt Auto-Range Identification output. The range ID output is used in conjunction
with the Analog voltage and Analog current outputs when auto-ranging is used. It provides an indication of
the Analog outputs’ selected full-scale. There are five range ID voltage levels used in the 5100E to
correspond with its five output ranges (Appendix E –range / output chart).
1.4.9 Service Port
The Service port provides a user-friendly means of digital communications with the Model 5100E Analyzer.
Through this port, the unit may be configured, calibrated, and queried for most functions. The RS-232 port
may also be programmed to send out information on a timed basis for users who prefer to use Digital
instead of Analog interfacing with the analyzer. In addition, the service port may be used with a PC based
computer (such as a portable notebook computer) over a standard bi-directional RS-232 serial interface.
1.5 Control panel User Interface
1.5.1 The “UP” Pushbutton
The “UP” pushbutton can be used to program the Model 5100E via the control panel. This momentary
push-button soft key is used to enter incremental information. Its function is menu-driven.
1.5.2 The “DOWN” Pushbutton
The “DOWN” pushbutton can be used to program the Model 5100E via the control panel. This momentary
push-button soft key is used to enter decremental information. Its function is menu-driven.
1.5.3 The “MODE” Pushbutton
The “MODE” pushbutton can be used to program the Model 5100E via the control panel. This momentary
push-button soft key is used to navigate the operational modes available through the control panel. Its
function is menu-driven.

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.
1.5.5 RUN Indicator LED
The purpose of the RUN Indicator LED is to inform the user via the control panel that the Model 5100E is
measuring the concentration of the sample gas and updating the display.
1.5.6 Alarm-1 Indicator LED
The purpose of the Alarm-1 Indicator LED is to inform the user via the control panel that the measured
oxygen concentration has exceeded the alarm-1 threshold; alarm-1 LED and its associated relay are in
active mode.
1.5.7 Alarm-2 Indicator LED
The purpose of the Alarm-2 Indicator LED is to inform the user via the control panel that the measured
oxygen concentration has exceeded the alarm-2 threshold; alarm-2 LED and its associated relay are in
active mode.
1.5.8 Fault Indicator LED
The purpose if the Fault Indicator LED is to inform the user via the control panel that at least one system
fault is active. Note that when the fault Indicator LED is active, the fault relay will also be active (open).

Manual Part Number:
C5-06-4900-08-0
Revision Level: C
ECO 8029
File Name: MN-A-0008
Page 2-1
2CHAPTER 2–SYSTEM INSTALLATION AND START-UP
2.1 Installing the Analyzer
STEP1:
LOCATETHEANALYZER...
PANELCUTOUT
STEP2:
INSTALL THE REMOTE SENSOR…
STEP3:
ELECTRICAL INSTALLATION
Figure 7 –Installation outline

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.
Cut/drill the mounting panel to the specifications in figure-8. Clearance holes for the #8-32 threaded
mounting studs do not need to be tapped. Hex nuts and lock washers are included for securing the unit to
a panel. Trim all burrs or sharp edges in the cutout or mounting-holes, which would interfere with or
damage the gasket on the analyzer control panel.
Slide the analyzer unit into the cutout, rear-chassis first, and seat the control panel gasket on the mounting
surface. The gasket on the analyzer control panel ensures a watertight seal around the control panel
cutout. Secure the threaded mounting studs with the supplied hex-nuts, and internal-tooth lock-washers.
The analyzer control panel is suitable for NEMA Type 4, IP20 environments when properly installed. The
rear electronics chassis is suitable for NEMA Type 1, IP 20 environments.
The analyzer should not be exposed to water, adverse temperature, or shock. Ensure the analyzer unit is
mounted in an area of free airflow to prevent the chassis from exceeding the operating temperature
specifications. Do not mount the analyzer or sensor against hot surfaces. Do not block the ventilation
louver on the analyzer chassis.
PANEL CUTOUT & DRILL PATTERN
4 PLACES
6.62" 16.81cm
6.20" 15.50cm
2.75"
6.99cm
2.91"
7.39cm
.189 DIA. HOLE (.429cm)
Figure 8 –Analyzer mounting

Installing the Analyzer
Manual Part Number:
C5-06-4900-08-0
Revision Level: C
ECO 8029
File Name: MN-A-0008
Page 2-3
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. process Sampling system, built-to-application. NOTE: For instructions on
the installation of a Neutronics Inc. Process Sampling System, please refer to the sampling system
equipment manual.
2.1.2.1 Flow-through Head
Surface-mount the flow through head horizontally (as shown in figure 9) or vertically on a stationary panel.
The sensor flow-through head is 1.25” diameter stainless steel, and is machined to accommodate two # 6-
32 machine-type mounting screws (1-inch on center). Be careful not to over tighten the mounting screws.
Allow sufficient space to screw the Model ZR-500E oxygen sensor into the top threaded port of the flow
through head, and for the sample lines and sample inlet and exhaust fittings.
SENSORRECEPTACLE
O-RINGTOPSEAL
1/8" FNPT-
SAMPLE
EXHAUST
GASKET
MOUNTINGSCREW
INSERT- #6-32
1/8" FNPT-
SAMPLEINLET
THREADEDCONNECTOR- 3/4-16
SENSOR
MOUNTINGHOLES, 2
PLACES, #6-32THREAD
#36(.106)DIA.
7-PINPLUG, DIN
Figure 9 –Sensor mounting detail
2.1.2.2 Sample Inlet Port
Pneumatic connection to the measured process for sample extraction is made at either of the two
interchangeable 1/8” FNPT fitting around the side of the flow-through head. For connecting the flow-
through head to the measured process, use 1/8” or 1/4” rigid tubing, and 1/8” MNPT fittings of a material
compatible with process gas composition. Ensure that no grease, particulate, or solvent is present in the
tubing during installation. Use thread-tape to seal connections, and prevent gauling. Fix all sample tubing
and connectors.
A fixed calibration port may be implemented in the process sampling line by installing a 1/8” or 1/4” 3-way
manual ball valve into the sampling line as in figure-9. Use 1/8” or 1/4” rigid tubing and 1/8” MNPT fittings
of a material compatible with process gas composition. Ensure that no grease, particulate, or solvent is
present in the tubing during installation. Use thread-tape only to seal connections, and prevent galling. Fix
all sample tubing and connectors.

System Installation and Startup
Remote Sensor
Module
Calibration Gas
Sample Gas
1-10 PSIG@1 LPM
Sample Flow
Remote Sensor
Module
Calibration Gas
Sample Gas
1-10 PSIG@1 LPM
Sample
Flow
SAMPLING POSITION
CALIBRATE POSITION
Figure 10 –Calibration gas fixture configuration (typical) –see calibration section (3.2.1) for
calibration procedure details.
2.1.2.3 Sample Exhaust Port
Pneumatic connection to a suitable sample stream vent location is made at either of the two
interchangeable 1/8” FNPT fitting around the side of the flow-through head, but opposite the installed
sample inlet port (section 2.1.2.2). For connecting the sample exhaust to vent, use 1/8” or 1/4” rigid tubing
and 1/8” MNPT fittings of a material compatible with process gas composition. Select a vent location that
is known to be at atmospheric pressure at all times. Use a minimum 2-meters of tubing to prevent back-
flow of vent gas to the sensor. Ensure that no grease, particulate, or solvent is present in the tubing during
installation. Use thread-tape only to seal connections, and prevent galling. Fix all sample tubing and
connectors.
2.1.2.4 Sensor
The ZR-200 sensor pneumatic connection to the process gas stream is made at the 3/4-16 threaded flow-
through head connection with a supplied top seal o-ring and receptacle gasket. Electrical connection to the
Model 5100E is made at the female 7-pin DIN connector with a screw-on capture ring.