Bacharach Neutronics 5124BE-N1-WO User manual

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

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page iii
Table of Contents
TABLE OF CONTENTS....................................................................................................................................III
FOR YOUR SAFETY: ...................................................................................................................................... IV
THANK YOU FOR PURCHASING THE MODEL 5124BE-N1-WO ANALYZER FOR 0-25 % RANGE OXYGEN
MEASUREMENT................................................................................................................................................V
1CHAPTER 1 –INTRODUCTION AND OVERVIEW...................................................................................1
2CHAPTER 2 –SYSTEM INSTALLATION AND START-UP......................................................................3
STEP 1–ANALYZER INSTALLATION.....................................................................................................................4
STEP 2–SENSOR INSTALLATION........................................................................................................................5
STEP 3–ELECTRICAL INSTALLATION..................................................................................................................7
3CHAPTER 3 –OPERATING INSTRUCTION...........................................................................................15
A. FIRST TIME POWER UP................................................................................................................................15
B. NORMAL POWER UP AND POWER DOWN INSTRUCTIONS ...............................................................................17
C. OXYGEN ALARM LEVEL SETTINGS................................................................................................................17
D. FEATURES..................................................................................................................................................18
Temperature OK Relay..............................................................................................................................18
Fault Relay ................................................................................................................................................18
Oxygen Alarm 1 & Alarm 2 Relays............................................................................................................19
Analog Voltage & Analog Current Output..................................................................................................20
Range ID Voltage ......................................................................................................................................20
RS-232 Port...............................................................................................................................................20
4CHAPTER 4 –MAINTENANCE AND TROUBLESHOOTING.................................................................21
5CHAPTER 5 –SPECIFICATIONS ****.....................................................................................................23
WARRANTY .....................................................................................................................................................25
INTENDED USE FOR THE MODEL 5124BE-N1-WO ...........................................................................................26
APPENDIX A: AMBIENT AIR CALIBRATION..........................................................................................................27
APPENDIX B: SYSTEM FAULTS..........................................................................................................................30
APPENDIX C: OXYGEN ALARM LEVEL SETTINGS................................................................................................32
APPENDIX D: RS-232 PORT ............................................................................................................................33
APPENDIX E: SYSTEM SETUP...........................................................................................................................36
APPENDIX F–SPARE PARTS LIST....................................................................................................................38
APPENDIX G–MSDS MATERIAL SAFETY DATA SHEET.....................................................................................39
APPENDIX H–DECLARATION OF CONFORMITY .................................................................................................40
APPENDIX I–DECOMMISSIONING THE MODEL 5124BE-N1-WO ANALYZER .......................................................41

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page iv
For Your Safety:
PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING
INSTALLATION OR OPERATION! Attempting to operate the Model
5124BE-N1-WO without fully understanding its features and functions
may result in unsafe conditions.
•Always use protective eye wear and observe proper safety procedures when working with
pressurized gases.
•Always assure the pressure of gas entering the Model 5124BE-N1-WO sensor is 1-10 psig.
•Always calibrate the Model 5124BE-N1-WO at an equivalent pressure and flow rate to the
measured gas. Maximum pressure should not exceed 10 psig.
•Always allow the Model 5124BE-N1-WO to cool down before attempting to access the sensor.
•Never expose the Model 5124BE-N1-WO analyzer or the remote sensor chassis to water, high
humidity or moisture. The analyzer chassis is not watertight.
•Never expose the Model 5124BE-N1-WO analyzer or the remote sensor to flame or high
temperatures.
•Never expose the Model 5124BE-N1-WO analyzer or the remote sensor to flammable gases or
vapors. The unit is not rated Explosion Proof, or Intrinsically Safe.
•Never expose the Model 5124BE-N1-WO sensor module directly to unregulated gas lines,
cylinder gas. High gas pressures may cause the sensor components to rupture.
•Ensure the analyzer and the remote sensor 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.

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page v
Thank you for purchasing the Model 5124BE-N1-WO
Analyzer for 0-25 % range Oxygen measurement.
The Model 5124BE-N1-WO Compact Analyzer is a user friendly, microprocessor-controlled
Oxygen measuring instrument. It has many features to offer the user, which will be described
in this manual. We require that all personnel who use the instrument read this manual to
become more familiar with its proper operation.
For further detail regarding the maintenance and in-field service of the Model 5124BE-N1-WO
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]
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 ©2008 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.

Installation andOperations Manual
Manual Part Number:
5-06-4900-53-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 1
1CHAPTER 1–INTRODUCTION AND OVERVIEW
The Model 5124BE-N1-WO analyzer is a microprocessor-based instrument for measuring percent
level oxygen in an inert gas background.
The analyzer is based on an amperometric zirconium oxide remote sensor. This sensor assures
reliability and fast response for oxygen concentration measurements, in inert gas backgrounds, in
the percent range. The solid-state sensor offers long life with little maintenance. The sensor is not
affected by dry atmospheres or by extremely cold storage temperatures. It also has a very long
storage life.
The sample gas is flowed through a self-contained external sensor housing. The pneumatic
connections are made to the 3/4"-16 male threaded port for ease of use.
The Model 5124BE-N1-WO analyzer is designed to be flush-mounted to a panel or console.
Because of its small size, the analyzer can be integrated into a variety of equipment or control
panels. Some of the analyzer features include:
•Compact, rapid-response external Zirconia oxygen sensor module
•Two User-adjustable oxygen Alarms with configurable relay outputs for process control use.
•One System Fault relay output.
•One Temperature OK relay output.
•4-20 mAAnalog Current Output, range configurable.
•0-1/5/10 VDCAnalog Voltage Output, range configurable.
•0-10V Range Identification Voltage to be used with the Analog Outputs
•RS-232 Serial Interface Port.

Manual Part Number:
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Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 2
NEMA 4 PANEL
MOUNTING GASKET MOUNTING STUDS
ELECTRICAL
CONNECTION PORT
TO REMOTE
SENSOR
REMOVABLE
TERMINAL BLOCKS
EARTH GROUND
TERMINAL
Figure 1 –Model 5124BE-N1-WO Rear View

Installation andOperations Manual
Manual Part Number:
5-06-4900-53-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 3
2CHAPTER 2–SYSTEM INSTALLATION AND START-UP
Figure 2 –Power Up Sequence
STEP 1:
ANALYZER INSTALLATION
STEP 2:
SENSOR INSTALLATION
STEP 3:
ELECTRICAL CONNECTIONS
STEP 4:
POWER UP
STEP 5:
AIR VERIFICATION/CALIBRATION

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 4
Step 1 –Analyzer Installation
WARNING: The internal components of the Model 5124BE-N1-WO analyzer and
the remote sensor are fragile. Do not drop the analyzer or the remote sensor during
installation. Do not expose the unit to shock or vibration during installation. Failure to
comply may damage the fragile components inside the analyzer and remote sensor
may result in loss of warranty.
The Model 5124BE-N1-WO analyzer is designed to be mounted flush to the surface of an
equipment control panel. Observe the following guidelines when installing the analyzer:
•Allow ample space at the rear of the analyzer for easy access to all electrical and
pneumatic connections.
•Be sure that the analyzer will not be exposed to water, adverse temperature, or shock.
•Be sure that the analyzer has free air flow around the vent slots on the chassis to prevent
overheating.
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 3 –Analyzer Panel Cutout Diagram

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 5
Step 2 –Sensor Installation
All pneumatic connections are to be made to the Model 5124BE-N1-WO remote sensor. The
remote sensor is designed to be screwed-on in-situ to the process vessel at which the oxygen
concentration measurements are to be made.
Drill the Sample Port. Locate the sample point on the process vessel at which the oxygen
concentration measurements are to be taken. Drill a hole at the location. The size of the initial drill
hole should be between 0.68” to 0.70” diameter depending on the wall thickness of the sample
process vessel.
Tap Engagement Threads to the Sample Port. Using a 3/4-16 UNF-2A tap tool, tap the
engagement threads to the sample port. If the process vessel wall is very thick, tap to a minimum
depth of 0.5” to ensure proper engagement of the external sensor to the process vessel.
Thoroughly clean both the sample port and process vessel of any burrs, slivers, or tap oils before
installing the sensor.
Screw the Sensor to the Sample Port. Once the sample port has been properly threaded and
cleaned, screw the sensor to the sensor port. Make sure that the O-ring at the base of the external
sensor port neck is properly compressed between the sensor body and the process chamber ball.
Failure to comply will cause the process gas to leak into the atmosphere.
WARNING: The external sensor is designed to measure oxygen concentrations
in gas form in an inert gas background. If there are fluids in the process vessel, select
a sample location at which the sensor will not be directly exposed to the fluid.
WARNING: The acceptable background gases for oxygen measurements are
nitrogen and argon. Some gases will affect the accuracy of the sensor while others may damage
the sensor permanently. Contact Neutronics if you are not sure about the affect of your process
gases on the external sensor.
WARNING: Do not over pressurize the sample inlet port as this may permanently damage the
internal components of the analyzer. Failure to comply may void the warranty.

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 6
.
Figure 4 –Sensor mounting detail

Manual Part Number:
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Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 7
Step 3 –Electrical Installation
CAUTION: Be sure all mains power supply is off before attempting the electrical
connections to the analyzer and remote sensor. DO NOT WORK WITH LIVE WIRES!
Do not leave any exposed wire at the connectors or cables. Before applying power,
ensure terminal blocks are fully inserted into the mating connector at the analyzer.
DANGER: The Model 5124BE-N1-WO analyzer and its external sensor are not rated
intrinsically safe or explosion proof. Be certain that no flammable gases are present in the areas
where the analyzer and the external sensor will be installed.
CAUTION: The Model 5124BE-N1-WO analyzer and external housings are not rated
waterproof. Do not mount the analyzer or the sensor in an area where it may contact water or
other liquid elements.
WARNING: The Model 5124BE-N1-WO is not equipped with a circuit breaker. A
disconnecting switch or a circuit breaker must be installed in series with the mains power to the
analyzer.
All electrical connections to the Model 5124BE-N1-WO analyzer is to be made to the three terminal
blocks and sensor interface socket located at the back of the analyzer chassis. A label depicting
the terminal block arrangement and the location of the bayonet connector is affixed to the top of
the chassis as reference. The terminal blocks may be removed for wiring.
The electrical connection to the Model 5124BE-N1-WO external sensor is to be made to the
analyzer interface socket. Use the sensor interface cable provided by Neutronics.

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 8
CAUTION: In order to comply with CE EN61326-1:2006 standards, all electrical
connections to the three terminal blocks on the back of the analyzer are to be made
using shielded cable conductors. Each electrical connection to the terminal blocks
must be looped through the ferrite clamp provided. If more than one shielded cable
conductor is used, the individual wires from the different cables may share the same ferrite clamp.
Strip the cable jacket back about 8 inches to ensure all the individual wires fit through the ferrite
clamp. Additional ferrite clamps may be purchased from Neutronics if necessary (See Appendix F:
Spare Parts).
CAUTION: Also, in order to comply with CE EN61326-1:2006 standards, all shielded cable
conductors must be earth grounded at both ends of the cable. The shield drain wire from the cable
conductors must be connected to the earth ground screw terminal located at the back of the
analyzer. It is also recommended that the exposed drain wire be covered with shrink tubing and
the end be terminated with a #6 ring terminal before connecting it to the earth ground screw
terminal. The recommended shrink tubing size is 1/8” expanded to 1/16” reduced. See Figure 5.

Manual Part Number:
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Revision Level: A
ECO 8541
File Name: MN-A-0177
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Figure 5 –Recommended electrical connection to the analyzer terminal blocks

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Revision Level: A
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File Name: MN-A-0177
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A label depicting the terminal block arrangement is affixed to the top of the chassis for easy
reference during installation and maintenance. The terminal blocks feature screwed terminals.
The terminal blocks are also removable for ease of wiring or removal of the analyzer module.
Figure 6 –Model 5124BE-N1-WO Electrical Connections Label
Figure 7 –Sensor Interface Cable Connection
CUS
MET
SENSOR
ANALYZER

Manual Part Number:
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Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 11
1 2 3
TEMP
TB24 5 6 7 8 9 10 11 12 13 14
FAULT
CNO Alarm 1
CNC NO
Alarm 2
CNC NO
Range
V-Out
+ -
1 2 3
TB34 5 6 7 8 9 10 11
Bat.
BU
+ -
V
Out
+ -
mA
Out
+ -
RS-232
TX RX RTN
12
VDC
no
connection
no
connection
Service
Port
NO = Normally
Open
NC = Normally
Closed
C = Common
VDC POWER INPUT,
18-30 VDC
1 3
TB1
GND
5
VDC+
2 4
COM
CNO
FAILSAFE
Figure 8 –Analyzer chassis electrical connections
The following is a list of all possible electrical connections to the Model 5124BE-N1-WO analyzer:
External Sensor Interface
The Model 5124BE-N1-WO analyzer is electrically connected to the external sensor via the
sensor interface cable. Each end of the sensor interface cable is labeled. The “ANALYZER”
labeled end is to be connected to the sensor interface socket on the analyzer. The
“SENSOR” labeled end is to be connected to the analyzer interface socket on the external
sensor.

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 12
Oxygen Alarm-1 Relay Output
Use 18-22 AWG, shielded cable for the connections. The shielded cable must be grounded
at both ends to comply with EN61326-1:2006 specifications. Loop individual connectors
around the ferrite clamp provided.
Relay Type: Form 1 C, SPDT, 5A @ 250 VAC, 5A @ 30VDC
Connections: Common: Terminal Block TB2 Pin 8
Normally Closed Output: Terminal Block TB2 Pin 9
Normally Open Output: Terminal Block TB2 Pin 10
Oxygen Alarm-2 Relay Output
Use 18-22 AWG, shielded cable for the connections. The shielded cable must be grounded
at both ends to comply with EN61326-1:2006 specifications. Loop individual connectors
around the ferrite clamp provided.
Relay Type: Form 1 C, SPDT, 5A @ 250 VAC, 5A @ 30VDC
Connections: Common: Terminal Block TB2 Pin 5
Normally Closed Output: Terminal Block TB2 Pin 6
Normally Open Output: Terminal Block TB2 Pin 7
System Fault Relay Output
Use 18-22 AWG, shielded cable for the connections. The shielded cable must be grounded
at both ends to comply with EN61326-1:2006 specifications. Loop individual connectors
around the ferrite clamp provided.
Relay Type: Form 1 B, SPST, 5A @ 250 VAC, 5A @ 30VDC
Connections: Common: Terminal Block TB2 Pin 3
Normally Open Output: Terminal Block TB2 Pin 4
Temperature OK Relay Output
Use 18-22 AWG, shielded cable for the connections. The shielded cable must be grounded
at both ends to comply with EN61326-1:2006 specifications. Loop individual connectors
around the ferrite clamp provided.
Relay Type: Form 1 B, SPST, 5A @ 250 VAC, 5A @ 30VDC
Connections: Common: Terminal Block TB2 Pin 1
Normally Open Output: Terminal Block TB2 Pin 2
Range ID Output
Use the Range ID voltage with either the analog voltage or the analog current output to
identify the full span oxygen concentration measurement. Use 20-26 AWG, shielded cable
for the connections. The shielded cable must be grounded at both ends to comply with
EN61326-1:2006 specifications. Loop individual connectors around the ferrite clamp
provided.
Output Voltage: 0 - 10 Volts DC
Connections: Voltage + Output: Terminal Block TB2 Pin 13
Voltage - Output: Terminal Block TB2 Pin 14

Manual Part Number:
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Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 13
Analog Voltage Output
The analog voltage output is factory pre-set to be either 0-1, 0-5, or 0-10 volts. Use 20-26
AWG, shielded cable for the connections. The shielded cable must be grounded at both
ends to comply with EN61326-1:2006 specifications. Loop individual connectors around the
ferrite clamp provided.
Output Voltage: 0 –1, 0 –5, or 0 - 10 Volts DC
Connections: Voltage + Output: Terminal Block TB3 Pin 5
Voltage - Output: Terminal Block TB3 Pin 6
Analog Current Output
The analog current output is a negative ground, non-isolated 4-20 mA current loop. Use 20-
26 AWG, shielded cable for the connections. The shielded cable must be grounded at both
ends to comply with EN61326-1:2006 specifications. Loop individual connectors around the
ferrite clamp provided.
Output Voltage: 4 –20 mA
Maximum Loading: 250 ohms
Connections: Current + Output: Terminal Block TB3 Pin 7
Current - Output: Terminal Block TB3 Pin 8
Battery Backup (Optional)
These terminals may be used to connect the Model 5124BE-N1-WO analyzer to a 12V
battery backup system such as a lead acid battery. Battery backup function is not required
for normal operations.
Input Voltage: 12 volts nominal
Connections: Battery + Terminal: Terminal Block TB3 Pin 3
Battery - Terminal: Terminal Block TB3 Pin 4
RS-232 Service Port
The RS-232 Service Port is used for interfacing with any standard PC computer via the
communications serial port. Use 20-26 AWG, shielded cable for the connections. The
shielded cable must be grounded at both ends to comply with EN61326-1:2006
specifications. Loop individual connectors around the ferrite clamp provided.
SIGNAL
DESIGNATION
AT ANALYZER
ANALYZER TB2
CONNECTION
SIGNAL
DESIGNATION
AT COMPUTER
COMPUTER
DB9 SERIAL
PORT
CONNECTION
TX
Pin 9
RX
Pin 2
RX
Pin 10
TX
Pin 3
RTN
Pin 11
RTN
Pin 5

Manual Part Number:
5-06-4900-65-0
Revision Level: A
ECO 8541
File Name: MN-A-0177
Page 14
Mains Power
Use 18-22 AWG, shielded cable for the connections. The shielded cable must be grounded
at both ends to comply with EN61326-1:2006 specifications. The ground shielding at the
analyzer end is to be connected to terminal block TB1 pin 1. Loop individual connectors
around the ferrite clamp provided.
Mains Power Voltage: 18 –30 Volts DC
Connections: DC +: Terminal Block TB1 Pin 4
DC -: Terminal Block TB1 Pin 2
Earth/Shield Ground: Terminal Block TB1 Pin 1
WARNING: Do not apply mains power to the analyzer or the analyzer until all the
electrical and pneumatic connections to the analyzer and the remote sensor have been
properly installed.