Bacharach Neutronics Mini-ICS User manual

456 Creamery Way, Exton, PA 19341
Phone: [phone] • Fax: [phone] • Email: [e-mail]
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 O2ALARM
20.9
PERCENTOXYGEN
MODEL Mini-ICS O2Controller
Neutronics
!
Reference Manual for
Installation and
Operation Instructions

Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page iii
Table of Contents
TABLE OF CONTENTS.........................................................................................................................III
FOR YOUR SAFETY: ...........................................................................................................................VII
WELCOME...........................................................................................................................................VIII
1CHAPTER 1 –INTRODUCTION AND OVERVIEW.......................................................1-1
1.1 GENERAL.................................................................................................................................1-1
1.2 FEATURES................................................................................................................................1-2
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 ..................................................................................................................1-4
1.3.6 Chassis ...........................................................................................................................1-4
1.4 SYSTEM INPUTS AND OUTPUTS .................................................................................................1-6
1.4.1 Oxygen Sensor Input ......................................................................................................1-6
1.4.2 Flow Switch Status Input.................................................................................................1-6
1.4.3 O2Alarm Relay Output....................................................................................................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 Output.............................................................................................................1-7
1.4.10 Service Port.....................................................................................................................1-7
1.5 FRONT PANEL USER INTERFACE................................................................................................1-1
1.5.1 The “UP” Pushbutton ......................................................................................................1-1
1.5.2 The “DOWN” Pushbutton................................................................................................1-1
1.5.3 The “MODE” Pushbutton ................................................................................................1-1
1.5.4 7-Segment Alphanumeric Display...................................................................................1-1
1.5.5 Normal Indicator LED......................................................................................................1-1
1.5.6 O2Alarm Indicator LED...................................................................................................1-1
1.5.7 Low Flow Indicator LED..................................................................................................1-1
1.5.8 Fault Indicator LED .........................................................................................................1-1
2CHAPTER 2 –SYSTEM INSTALLATION AND START-UP.........................................2-2
2.1 INSTALLING THE ANALYZER .......................................................................................................2-2
2.1.1 Step 1 –Locate and Mount the Analyzer unit.................................................................2-3
2.1.2 Step 2 –Install the Oxygen Sensor ................................................................................2-4
2.1.3 Step 3 –Install the Analyzer...........................................................................................2-4

Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page iv
2.1.3.1 Oxygen Sensor Input...................................................................................................2-6
2.1.3.2 Flow Switch Status Input.............................................................................................2-6
2.1.3.3 Oxygen Alarm Relay Outputs......................................................................................2-6
2.1.3.4 Inert Gas Control Relay Outputs.................................................................................2-7
2.1.3.5 Fault Relay Outputs.....................................................................................................2-7
2.1.3.6 Remote Calibration Relay Outputs..............................................................................2-7
2.1.3.7 Analog Voltage Output ................................................................................................2-8
2.1.3.8 Analog Current Output ................................................................................................2-8
2.1.3.9 Range ID Output..........................................................................................................2-8
2.1.3.10 RS-232 Service Port....................................................................................................2-9
2.1.3.11 Battery Backup............................................................................................................2-9
2.1.3.12 Mains Power..............................................................................................................2-10
2.2 STARTING UP AND COMMISSIONING THE SYSTEM .....................................................................2-11
2.2.1 STEP 1 –Power Up the unit.........................................................................................2-11
2.2.2 STEP 2 –Calibrate the Unit..........................................................................................2-12
2.2.3 STEP 3 –Set Alarms, and Inert Gas Control Limits......................................................2-12
2.2.3.1 Set Oxygen Alarm Level............................................................................................2-12
2.2.3.2 Set High Inert Gas Control limit.................................................................................2-12
2.2.3.3 Set Low Inert Gas Control limit..................................................................................2-12
3CHAPTER 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 calibrate ........................................................................................................3-1
3.2.1.2 What gases to use.......................................................................................................3-1
3.2.1.3 Procedure for calibrating the Model Mini-ICS .............................................................3-2
3.2.2 SET O2ALARM Mode.....................................................................................................3-3
3.2.3 SET HIGH INERT GAS CONTROL LIMIT Mode............................................................3-3
3.2.4 SET LOW INERT GAS CONTROL LIMIT Mode ............................................................3-3
3.2.5 VIEW ACTIVE FAULTS Mode........................................................................................3-3
3.3 RUN MODES............................................................................................................................3-4
3.3.1 NORMAL Mode...............................................................................................................3-4
3.3.2 O2ALARM ACTIVE Mode...............................................................................................3-4
3.3.3 INERTING CONTROL ACTIVE Mode............................................................................3-4
3.3.4 FAULT ACTIVE Mode.....................................................................................................3-5
4CHAPTER 4 –MAINTENANCE AND TROUBLESHOOTING ......................................4-1
4.1 SYSTEM SETUP ........................................................................................................................4-1
4.1.1 System Setup via Front Panel Keypad...........................................................................4-1
4.1.1.1 User Setup 1: ICS and O2 Alarm Relays Failsafe/Non Failsafe.................................4-1
4.1.1.2 User Setup 2: O2 Alarm Relays Ascending Trip.........................................................4-2
4.1.1.3 User Setup 3: Analog Voltage Output Setting.............................................................4-2
4.1.1.4 User Setup 4: Analog Current Output Setting.............................................................4-2

Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page v
4.1.1.5 User Setup 5: Display Range Setup. ..........................................................................4-2
4.1.1.6 User Setup 6: RS-232 Baud Rate...............................................................................4-2
4.1.1.7 User Setup 7: Serial Output Format............................................................................4-2
4.1.1.8 User Setup 8: Sensor Disconnect Detection Test.......................................................4-2
4.1.1.9 User Setup 9: Minimum Analog Output Voltage Concentration..................................4-2
4.1.1.10 User Setup 10: Maximum Analog Output Voltage Concentration...............................4-2
4.1.1.11 User Setup 11: Minimum Analog Output Current Concentration................................4-3
4.1.1.12 User Setup 12: Analog Current Full Scale. .................................................................4-3
4.1.1.13 User Setup 13: Set Current Year. ** NOT ACTIVE FOR THIS RELEASE** .............4-3
4.1.1.14 User Setup 14: Set Current Month. ** NOT ACTIVE FOR THIS RELEASE**...........4-3
4.1.1.15 User Setup 15: Set Current Day. ** NOT ACTIVE FOR THIS RELEASE** ..............4-3
4.1.1.16 User Setup 16: Set Current Hour. ** NOT ACTIVE FOR THIS RELEASE**.............4-3
4.1.1.17 User Setup 17: Set Current Minute. ** NOT ACTIVE FOR THIS RELEASE**..........4-3
4.1.1.18 User Setup 18: Factory Setup Restore. ......................................................................4-3
4.1.2 System Setup via Service Port .......................................................................................4-3
4.1.2.1 RS-232 Service Port Interfacing with HyperTerminal in Microsoft Windows 95 or later4-3
4.1.2.2 Troubleshooting Your HyperTerminal Interface ..........................................................4-4
4.1.2.3 Organization of RS-232 Serial Data............................................................................4-4
4.1.2.4 Standard Level Access................................................................................................4-5
4.1.2.5 Advanced Level 1 Access ...........................................................................................4-8
4.1.2.6 Advanced Level-2 Access...........................................................................................4-8
4.1.2.7 SETTING UP THE MODEL Mini-ICS –The RS-232 User Setup Menu.....................4-9
4.1.2.8 System Information Display.........................................................................................4-9
4.1.2.9 (U20) 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 Menu .................................................................................4-14
4.1.2.14 (U70) Auto Calibration Setup Menu ..........................................................................4-15
4.1.2.15 Sensor Disconnect Test ............................................................................................4-16
4.1.2.16 Set Time-of-Day and Date ** NOT ACTIVE FOR THIS RELEASE**........................4-16
4.1.2.17 Averaging Window Size ............................................................................................4-16
4.1.2.18 Auto Return to Run Mode Time.................................................................................4-17
4.1.2.19 Return all Settings to Factory Delivered Settings......................................................4-17
4.1.3 Change factory settings via Hardware Jumpers...........................................................4-17
4.1.3.1 Analog Voltage Output ..............................................................................................4-17
4.2 ROUTINE PERIODIC MAINTENANCE ..........................................................................................4-19
4.3 TROUBLESHOOTING................................................................................................................4-20
4.3.1 Fault Codes...................................................................................................................4-20
4.3.1.1 Fault Code 0 –Constant Memory Error ....................................................................4-20
4.3.1.2 Fault Code 1 –Low Flow...........................................................................................4-20
4.3.1.3 Fault Code 2 –Sensor disconnected........................................................................4-20
4.3.1.4 Fault Code 4 –Low Sensor Limit higher than Low ICS Limit....................................4-20
4.3.1.5 Fault Code 5 –High ICS Limit lower than Low ICS Limit..........................................4-20
4.3.1.6 Fault Code 6 –Unstable Calibration Sample............................................................4-21
4.3.1.7 Fault Code 7 –Sensor Calibration signal high..........................................................4-21
4.3.1.8 Fault Code 8–Sensor Calibration Signal Low ..........................................................4-21
4.3.1.9 Fault Code 9 –Sensor Analog-to-Digital Converter Time-Out..................................4-21
4.3.1.10 Fault Code 10 –Sensor Operating Signal Low.........................................................4-21
4.3.1.11 Fault Code 11 –Calibration Period too Short ...........................................................4-21
4.3.1.12 Fault Code 17 –Bad cell Calibration Coefficient.......................................................4-22
4.3.1.13 Fault Code 18 –Main-board EEPROM corrupted.....................................................4-22
4.3.1.14 Fault Code 27 –Auto Calibration Mode active..........................................................4-22
4.3.1.15 Fault Code 28 –Calibration Mode active..................................................................4-22
4.3.1.16 Fault Code 29 –Manual Relay Control active...........................................................4-22
4.3.1.17 Fault Code 30 –User Setup Mode active .................................................................4-22

Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page vi
4.3.1.18 Fault Code 31 –Factory Setup Mode active.............................................................4-22
4.3.1.19 Fault Code 32 –Program Starting.............................................................................4-22
5CHAPTER 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 SETTINGS5-4
5.4 APPENDIX D–FRONT PANEL HOT-KEY FUNCTIONS................................................................5-6
5.5 APPENDIX E–WARRANTY.....................................................................................................5-7
INTENDED USE FOR THE MODEL MINI-ICS.......................................................5-7
5.6 APPENDIX F–REFERENCE DRAWINGS...................................................................................5-7
5.7 APPENDIX G–MOUNTING CONFIGURATIONS..........................................................................5-8
5.7.1 Wall Mount Enclosure.....................................................................................................5-8
5.7.2 Rack Mount Enclosure....................................................................................................5-9
5.7.3 Explosion Proof Enclosure............................................................................................5-10

Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page vii
For Your Safety:
PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING
INSTALLATION OR OPERATION! Attempting to operate the Model 1100
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.
•Properly dispose of the Oxygen sensor according 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 analyzer
chassis is not watertight.
•Never expose the MODEL Mini-ICS to flame or high temperatures. Never expose the Model
Mini-ICS analyzer to flammable gases or vapors. The Mini-ICS is not rated Intrinsically Safe.
•Ensure the analyzer unit is mounted in an area with 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.

Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page viii
WELCOME
Thank you for purchasing the Model Mini-ICS Analyzer for
percent range Oxygen measurement.
The Model Mini-ICS 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 recommend that all personnel who use this 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 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
Tel: [phone]
Fax: [phone]
EMAIL: [email protected]
Visit us at www.analyzegas.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 ©2003 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.

1CHAPTER 1–INTRODUCTION AND OVERVIEW
1.1 General
The Model Mini-ICS [Inert Gas Control System] analyzer by Neutronics offers a cost effective
solution in a small package for industrial process Oxygen measurement and inert gas control
applications for flash-fire/explosion prevention, or product quality. The Model Mini-ICS is a custom
analytical instrument, designed to accurately measure 0.1 to 50.0% Oxygen, and provide direct
control of Oxygen levels in your process by controlling inert gas purging.
At the heart 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 fastest response time possible. Neutronics also offers a variety of process
sampling and sample conditioning solutions for sensor reliability and longevity.
Pre-Filter
Sample Conditioning
Package
O2 Sensor
Loss of Sample
Sensor
Inert Gas Input
(Nitrogen)
Vent
Inert Gas
Control Valve
SAFE AREAHAZARDOUS AREA
Analyzer (Control Module)
Safety Barriers
Remote
Cal
Solenoid
Valve
1100-ICS
Gas Head-Space
Industrial Mixer,
Centrifuge, Reactor,
Blender, etc.
Figure 1 –Complete process Oxygen
monitor and control system example

System Hardware Overview
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page 1-2
1.2 Features
The Model Mini-ICS analyzer module is designed to be flush mounted to a panel or console.
Packaging options available from Neutronics Inc. include General Purpose and Explosion Proof
surface-mount enclosures, and custom rack-mount designs. Because of the small size of the
Model Mini-ICS analyzer, the basic panel-mount unit can be integrated into a variety of equipment
or control panels.
MODE
NORMAL FAULT Low Flow O2 Alarm
20.9
PERCENTOXYGEN
MODEL Mini-ICS O2Analyzer
Neutronics
Color Coded LED’s:
NORMAL = Green
FAULT= Yellow
Low Flow = Red
O2 Alarm = Red Large Buttons
for Ramp Up and
RampDown for
Displayand
Mode Control
Large Mode Select
Button for easy
scrollingthrough
menu options
Large LED
Digital Display
Reference Manual for
Installation and
Operation Instructions
!
Other Features Include:
•User-adjustable OxygenAlarm with relay output for process control use
•User-adjustable Inert Gas Control function with relay output for process control use. Inert Gas
Control features user-adjustable high and low set point hysteresis
•Loss of Flow indication for extractive process sampling applications
•Double Redundant system configuration backup file, with automatic repair function
•Convenient Remote calibration relay output for “one-man” calibration in applications where the
Oxygen sensor is a long distance from the Mini-ICS Analyzer
•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
Figure 2 –Analyzer features

System Hardware Overview
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page 1-3
1.3 System Hardware Overview
Chassis
Power SupplyBoard
RelayBoard
Main Board
Display
Board
Control
Panel
1.3.1 Main Board
The main board houses the microprocessor, and supporting electronics for controlling the
operation of the Model Mini-ICS Analyzer. The main board receives the sensor signal and flow
switch inputs, 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 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 to take 110/220 VAC, 50/60 Hz (90-264 VAC, 47-63Hz). as
input. The supply is internally fused directly on the board. An optional 24VDC (10-30 VDC) power
supply is available for installations where a DC voltage is required to power the Model Mini-ICS. A
12VDC battery-backup power input (battery not provided) is also provided to act as a backup in
case of main power failure.
1.3.4 Display Board
The Display board is designed to generate a digital indication of the concentration of Oxygen, and
error codes. The display is a 7-segment, ¾” Alphanumeric LED for easy viewing from a distance.
Figure 3 –Basic analyzer components

System Hardware Overview
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page 1-4
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. At the four corners of the panel are the #8-32 mounting studs,
which allow flush mounting of the instrument to a control or 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 a general level of
protection against mechanical damage from the local environment. It is also an important
component of the ESD shielding design. Since the Model Mini-ICS 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 4 –Analyzer chassis

System Hardware Overview
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page 1-5
RelayBoard
RS232COMLine
Mains Power
Input
Power
Supply Main Board
Display
Board
Control
Panel
Line
Filter
Fault and RemoteCalibration RelayOutputs
O2Alarm & Inert Gas Control RelayOutputs
RangeIDOutput
Analog VoltageOutput
Sensor
4-20mAOutput
Flow
Switch
Figure 5 –Analyzer system configuration

System Hardware Overview
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page 1-6
1.4 System Inputs and Outputs
1.4.1 Oxygen Sensor Input
The Oxygen Sensor electrical input is used to indicate the Oxygen level concentration in a process
vessel headspace, or a process gas stream. Sensors are available to measure the Oxygen
concentration in percent by volume or partial pressure in the ranges from 0.1% to 25.0%, and 0.1%
to 50.0%. All available Neutronics Inc. Sensors are Intrinsically Safe, remote-mounted devices,
and may be interfaced through electrical safety barriers for hazardous applications,
1.4.2 Flow Switch Status Input
The Flow Switch Status electrical interface is used to indicate the flow status of sample gas from
the process to the Oxygen Sensor, for extractive applications where a Neutronics Inc. Sampling
System has been provided. A closed flow switch indicates sufficient sample flow. An open Flow
Switch indicates that sample flow has dropped below the mechanical set point of the Flow Switch.
In this flow condition, the Oxygen reading may not be representative of the process Oxygen level.
Neutronics Inc. Flow Switches are Intrinsically Safe, and may be interfaced through electrical
safety barriers for hazardous applications.
1.4.3 O2Alarm Relay Output
The Oxygen Alarm relay is mapped to the O2Alarm setpoint, and is provided for process control
use. The user may set the level at which the O2Alarm activates (section 3.2.2). The O2Alarm
may be configured as ascending (highest Oxygen level allowable) or descending (lowest Oxygen
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 settings are ascending, and fail-safe (Appendix C, Factory Configuration). The O2Alarm
relay contacts are form C (DPDT), voltage-free.
1.4.4 Inert Gas Control Relay Output
The Inert Gas Control (ICS) relay is mapped to the Inert Gas Control high and low limit setpoints,
and is provided for process control use. The user may set the levels at which Inert Gas Control
activates (high limit setpoint), and de-activates (low limit setpoint). 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. The factory default setting is fail-safe (Appendix C, Factory
Configuration). The ICS relay contacts are form C (DPDT), voltage-free.
The purpose of the ICS relay is to control the flow of inert gas to the process being monitored, to
keep Oxygen levels in the process within an acceptable range at all times. Purging the process
with inert gas lowers the Oxygen concentration in the process. The Mini-ICS Analyzer will activate
the ICS relay when the Oxygen concentration rises to the High ICS limit setpoint. It will deactivate
the ICS relay when the Oxygen concentration falls below the Low ICS limit (sections 3.2.3 and
3.2.4).
1.4.5 Fault Relay Output
The Fault relay output is used to indicate that there is at least one system fault active on the Model
Mini-ICS Analyzer (section 4.3.1 –fault codes and definitions). The Fault relay contacts are Form B
(SPST), voltage-free.
Note: The user can configure the ICS relay to activate on certain Fault conditions for process
safety applications (sections 4.1.2.9, and Appendix C).

System Hardware Overview
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page 1-7
1.4.6 Remote Calibration Relay Output
The Remote Calibration relay is used to activate a valve that flows calibration gas to the sensor
during gas calibration. This is a convenience item for applications where the sensor/sampling
system is a long distance from the analyzer. The Calibration relay is mapped to the analyzer
Calibration function. It activates whenever the user initiates a gas calibration routine by entering
CAL mode (section 3.2.1), closing off the flow of process gas and introducing calibration gas to the
Oxygen Sensor. The Remote Calibration relay contacts are Form B (SPST), voltage-free.
1.4.7 Analog Voltage Output
The Analog Voltage output is used to indicate to a remote device (user control system, chart-
recorder, etc.), the displayed Oxygen concentration in dynamic electrical potential. The Analog
voltage can vary from 0 volts for minimum-scale-deflection, to either 1, 5 or 10 volts full-scale. The
Analog voltage output is scaled according to the analyzer’s active range, and must be used in
conjunction with the Range ID voltage when the Analyzer is configured for auto-ranging (section
1.4.9).
1.4.8 Analog Current Output:
The Analog Current output is used to indicate to a remote device (user control system, chart-
recorder, etc.), the displayed 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 according to the analyzer’s active range, and must be used in
conjunction with the Range ID voltage when the Analyzer is configured for auto-ranging (section
1.4.9).
1.4.9 Range ID Output
To remotely detect the present range of Oxygen concentration, the Model Mini-ICS features a 0-
10V 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’ current full-scale. There are four voltage levels are used in the Mini-ICS:
•For a Full Scale of 1%, the Range ID output is 5.63 Volts
•For a Full Scale of 10%, the Range ID output is 6.25 Volts
•For a Full Scale of 25%, the Range ID output is 6.88 Volts
•For a Full Scale of 50%, the Range ID output is 7.50 Volts
•For a Manual Scale, the Range ID output is 9.30 Volts
1.4.10 Service Port
The Service port provides a user-friendly means of digital communications with the Model Mini-ICS
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 Front Panel User Interface
1.5.1 The “UP” Pushbutton
The “UP” pushbutton can be used to program the Mini-ICS Analyzer via the front 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 Mini-ICS Analyzer via the front 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 Mini-ICS Analyzer via the front panel. This
momentary push-button soft key is used to navigate the operational modes available through the
front panel. Its function is menu-driven.
1.5.4 7-Segment Alphanumeric Display
The 7-Segment alphanumeric display feeds back information from the Mini-ICS to the user via the
front panel. The primary purpose of the 7-Segment display is to show the Oxygen concentration
readout. It is also used for feedback information 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 the front panel that the Model
Mini-ICS is measuring the concentration of the sample gas and updating the display and outputs
accordingly, and has not detected any Alarm, or Fault conditions.
1.5.6 O2Alarm Indicator LED
The purpose of the O2Alarm Indicator LED is to inform the user via the front panel that the O2
Alarm and its associated relay are in active mode.
1.5.7 Low Flow Indicator LED
The purpose of the Low Flow Indicator LED is to inform the user via the front panel that the sample
gas flow from the process to the Oxygen sensor is below the mechanical set point of the flow
switch. Since Low Flow is considered a system Fault condition, when the Low Flow LED is active,
the Fault relay will also be active.
1.5.8 Fault Indicator LED
The purpose if the Fault Indicator LED is to inform the user via the front panel that at least one
system fault, other than the Low Flow Fault is active. Note that when the Fault Indicator LED is
active, the Fault relay will also be active.

Installing the Analyzer
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page
2-2
2CHAPTER 2–SYSTEM INSTALLATION AND START-UP
2.1 Installing the Analyzer
STEP 1:
LOCATETHEANALYZER...
PANEL CUTOUT
STEP 2:
INSTALL THE SENSOR…
Sampling Package
STEP 3:
INSTALL THEANALYZER
Figure 6 –Installation outline

Installing the Analyzer
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page
2-3
2.1.1 Step 1 –Locate and Mount the Analyzer unit
The Model Mini-ICS is designed to be mounted flush to the surface of equipment or on a control
panel. Select a suitable location for the Model Mini-ICS 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.
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.
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 analyzer unit into the cutout.
Ensure that a proper seal is made at the gasket on the model Mini-ICS control panel.
Installation of the analyzer chassis requires four clearance holes for the #8-32 threaded studs and
a cutout in the control panel to allow the chassis to slide flush to the panel. Make sure there are no
burrs or sharp edges in the cutout or mounting-holes, which would interfere with the gasket on the
analyzer control panel. The gasket ensures a watertight seal around the control panel. The
control panel, when properly installed is suitable for NEMA Type 4, IP66 environments. The rear
electronics enclosure is suitable for NEMA Type 1, IP 20 environments.
2.91"
6.20"
6.62"
2.75"
PANEL CUTOUT & DRILL PATTERN
.169 DIA. HOLE
4 PLACES
Figure 7 –analyzer
mounting

Installing the Analyzer
Manual Part Number:
5-06-4900-53-0
Revision Level: C
ECO 044952
Revision Date:
May 08, 2018
Page
2-4
2.1.2 Step 2 –Install the Oxygen Sensor
The Model Mini-ICS will be supplied with the Model GP, the Model CAG-250, or the Model IT
Oxygen sensor, depending on the application. In most cases, it will also be supplied with a
Neutronics-specified Sampling system. For sensor installation and pneumatic connections for the
Neutronics Inc. Sampling system, please refer to the Sampling System Manual.
2.1.3 Step 3 –Install the Analyzer
DANGER: Electrical connections on the rear of the Model Mini-ICS Oxygen
analyzer may have hazardous voltages present once power has been applied to the
unit. High voltages may remain present for a short time even after power has been
disconnected from the analyzer. Take care in observing standard electrical practices
when making electrical connections to the Model Mini-ICS Oxygen analyzer.
DANGER: The model Mini-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-ICS housing is not rated waterproof. Do not mount the analyzer
or the sensor in an area where it may contact water or other liquid elements.
WARNING: Be certain that all power is OFF to the analyzer and associated wiring (cables)
before attempting installation. DO NOT WORK WITH LIVE WIRES! Do not leave any exposed
wire at the terminal blocks. Before applying power, ensure terminal blocks are fully inserted into
the mating connector at the analyzer.
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.
Please reference Figures 8 and 9 below, and drawing SP-E-1473, in the rear of this manual,
showing the detail of the electrical interface terminals, and wiring connections.
Figure 8 –analyzer electrical interface
label (Vac version shown)