Gow-Mac 5102 Series User manual

Operating Manual
5100 Series Continuous
TC Binary Gas Analyzer
5100 Series: 110 V, 60 Hz
5102 Series: 230 V, 50 Hz
March 2018
Rev. 6
READ INSTRUCTIONS
BEFORE OPERATING
277 Brodhead Road, Bethlehem, PA 18017- 8600 U.S.A. Tel: [phone]

GOW-MAC Instrument Co. 5100 Series Continuous Gas Analyzer
03/18, Rev. 6

5100 Series Continuous Gas Analyzer
03/18, Rev. 6 3
GOW-MAC Instrument Co.
DISCLAIMERS
The information in this document is subject to change without notice. This manual could include technical inaccuracies or typographical
errors. Changes are made periodically to the information herein; these changes will be incorporated in subsequent revisions of the
manual. GOW-MAC®Instrument Co. reserves the right to make improvements and/or changes to the product(s) and/or programs
described in this manual at any time and without notice.
All information referred to and/or included in this report is current as of the original issue date of this manual. GOW-MAC®Instrument
Co. makes no warranty or representation with respect to the accuracy of the information or with respect to the suitability of the use
of such information outside GOW-MAC®Instrument Co., nor does GOW-MAC®Instrument Co. assume responsibility for any injury
or damage which may result, directly or indirectly, from the use of such information.
This document contains proprietary information which is protected by copyright. All rights are reserved. No part of the document may
be photographed, reproduced, or translated into another language without the prior written consent of GOW-MAC®Instrument Co.
The warranties made by GOW-MAC®Instrument Co. with respect to the product are voided if the product is not used and serviced in
accordance with the instructions in this manual.
Please protect yourself and your employees by following these operating instructions. We encourage our customers to write or call
for any additional information relative to the use or repair of this instrument.
TRADEMARK AND PATENT INFORMATION
®GOW-MAC is a registered trademark of GOW-MAC Instrument Co.
in the United States and other countries. (Reg. U.S. Pat. & T. M. o󰀩ce)
Other trademarks used herein are trademarks or registered trademarks of their respective owners.
Copyright© 2015 by GOW-MAC®Instrument Co.

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5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.
TERMS AND CONDITIONS OF SALE
WARRANTIES THE 5100 SERIES ANALYZERS SOLD BY GOW-MAC®INSTRUMENT CO. ARE WARRANTED FOR A PERIOD OF
ONE YEAR AGAINST DEFECTS IN MATERIALS AND WORKMANSHIP. THE TERMS OF THIS WARRANTY ARE AS FOLLOWS:
1. The warranty period begins with the shipping date of the equipment to the original purchaser.
2. Certain parts such as batteries, fuses, laments, etc., are expendable in normal use, and their service life is unpredictable. Such items are
not covered by this warranty.
3. All requests for service or repair under this warranty must be received within the warranty period by GOW-MAC®or its authorized
representative. All repairs are made at GOW-MAC plants or at the o󰀩ce of authorized representatives.
4. All repairs, adjustments, and other service under this warranty shall be performed free of charge to the purchaser. However,
warranty service and repairs shall be limited to equipment malfunctions which, in the opinion of GOW-MAC®, are due or
traceable to defects in original materials or workmanship. Instrument malfunctions caused by abuse or neglect of the equipment
are expressly not covered by this warranty.
5. Instrument parts which have been repaired or replaced during the warranty period are themselves warranted only for the
remaining unexpired portion of the original one year warranty.
6. Repairs, adjustments, and service performed after expiration of the one year warranty period shall be charged to the purchaser
at the then current prices for parts, labor, and transportation.
7. This warranty attaches to the equipment itself and is not limited to the original purchaser. Unexpired portions of the warranty
are thus transferable to subsequent owners.
8. GOW-MAC® expressly disclaims any liability to users of its products for consequential damages of any kind arising out of or
connected with the use of its products.
9. Except as stated in Sections 1 through 8 above, GOW-MAC® makes no warranty, expressed or implied (either in fact or by
operation of law), statutory or otherwise; and, except as stated in Sections 1 through 8 above, GOW-MAC®shall have no
liability under any warranty, expressed or implied (either in fact or by operation of law), statutory or otherwise.
10. Statements made by any person, including representatives of GOW-MAC® which are inconsistent or in conict with the terms
of this warranty shall not be binding upon GOW-MAC® unless reduced to writing and approved by an o󰀩cer of the Company.
11. This warranty shall be governed by the laws of the Commonwealth of Pennsylvania.
LIABILITY Buyer assumes all responsibility for warning and protecting its employees and independent contractors with respect to all
hazards to persons and property in any way connected with the Equipment and the use thereof. Seller’s liability for any claim of any kind
hereunder, whether or not based on contract, tort (including negligence), strict liability, warranty, or any other grounds, shall not exceed the
purchase price of the Equipment or the portion of the purchase price attributable to any part or parts of the Equipment in respect to which
such claim is made. Seller shall not be liable for any special, indirect, incidental, or consequential damages. Without limiting the generality of
the foregoing, Seller shall have no liability with respect to the results obtained by use of the Equipment, whether in terms of product condition,
operating cost, general e󰀨ectiveness, success or failure, or regardless of any statement made in any written proposal submitted by Seller.
It is expressly understood that any technical advice furnished by Seller with reference to the Equipment is given gratis and Seller assumes
no obligation or liability for the advice given or results obtained, all such advice being given and accepted at Buyer’s risk. Each party hereby
agrees to indemnify and hold the other party harmless from any actions, lawsuits, demands, claims, losses, expenses, costs, including but
not limited to legal fees, and damages arising from the injury, illness or death of the indemnifying party’s employees in any way related to the
Equipment, whether or not such injury, illness, or death is claimed to have been caused by, resulted from, or was in any way connected with
the negligence of the party to be indemnied.
PROPRIETARY INFORMATION Buyer agrees to maintain all proprietary information disclosed by Seller, including such proprietary
information obtainable upon examination of the Equipment, in condence and to refrain from any disclosure thereof to any third party (including
any a󰀩liate of Buyer), for any purpose, without the prior written consent of Seller. Buyer agrees to use said proprietary information solely
for purposes of maintaining and operating the Equipment, and to refrain from any use thereof to design, construct, have constructed and/or
operate any duplication or modication of the Equipment, or from any other use thereof, without the prior written consent of Seller.

5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.
IMPORTANT INFORMATION
These instructions are written for personnel operating the GOW-MAC®5100 Series Continuous TC Binary
Gas Analyzer. Read and understand the safety precautions in this manual to become familiar with the safe
practices for operating this equipment.
Dangers, Warnings, Cautions, and Notes
Dangers, Warnings, Cautions, and Notes appear throughout this manual. A sample of each statement
appears below. Within each sample, a denition of the statement type and its purpose is given.
DANGER
!
DANGERS alert you to an immediate hazard that causes serious injury or
death and requires special precautions to be taken.
WARNING
!
WARNINGS alert you to a potential hazard that causes serious injury or death
under certain conditions.
CAUTION
CAUTIONS alert you to a non-immediate or potential hazard or an unsafe
practice that presents a minor threat of personal injury or damage to
equipment, data, or processes.
NOTE

NOTES emphasize or remind you of an important piece of information.

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GOW-MAC Instrument Co.

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GOW-MAC Instrument Co.
Table of Contents
Section 1 Safety .......................................................................................................................11
Section 2 Principle of Operation ........................................................................................... 15
Section 3 Specications .........................................................................................................17
Section 4 Installation.............................................................................................................. 19
Section 5 Operating Controls ................................................................................................ 29
Section 6 Operation of Manually Operated 5100 Series...................................................... 33
Section C: Quick Start-Up........................................................................................................... 42
Section D: Detailed Start-Up....................................................................................................... 49
Section 7 Electrical Accessories .......................................................................................... 57
Section 8 Maintenance & Service.......................................................................................... 59
Section 9 Troubleshooting..................................................................................................... 63
Section 10 Repair/Replacement Parts List ............................................................................ 65
Appendix A: 5100 Series Quick Start Reference Flow Chart .................................................. 67

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5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.

5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.
5100 SERIES CONTINUOUS THERMAL CONDUCTIVITY GAS ANALYZER
OPERATION & MAINTENANCE MANUAL
This manual provides operating instructions and maintenance requirements for the 5100 Series
Continuous TC Gas Analyzer to permit safe and e󰀩cient use of your instrument. It is important that you
thoroughly read this manual BEFORE operating your instrument. Failure to do so could result in damaging
the instrument and/or yourself. Certain sections of this manual pertain to specic options you may or may
not have chosen for your instrument. Please read them carefully and check the enclosed schematics to
ensure proper operation. Operate the 5100 Series Continuous TC Gas Analyzer according to the operating
procedures stated herein. Any questions concerning the safe and proper use of your instrument should be
addressed to:
Mail: GOW-MAC Instrument Co.
277 Brodhead Road
Bethlehem, PA 18017
Tel: [phone]
Fax: [phone]
E-mail: [email protected]

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5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.

5100 Series Continuous Gas Analyzer
03/18, Rev. 6 11
GOW-MAC Instrument Co.
Section 1
Safety
NOTE

This chapter contains information to promote safety in the operation
and maintenance of this equipment. It is not intended to supersede,
replicate, or replace any safety documentation or procedures
provided from or established by ocial safety sources.
WARNING
!
Do NOT operate the GOW-MAC®5100 Series Continuous TC
Binary Gas Analyzer until you read and understand the operating,
maintenance, and safety instructions included in this manual.
All persons involved with the operation of this equipment including plant engineering, operations, and
management-must understand the potential hazards involved, and know and observe all required
safety precautions.
Your safety and the safety of equipment, nearby facilities, and personnel require a proper safety
attitude and emphasis on safe work procedures. This is the essence of any good safety program. If at
any time you identify safety deciencies, immediately correct them and bring them to the attention of
management.
Before an accident can be prevented, it must be anticipated. Use pre-job discussions with your
coworkers and supervisors to identify hazards and the means to avoid them. At your facility, various
gases may exist in liquid and/or gaseous states. Familiarize yourself with the hazards associated with
each gas found at your facility.
NOTE

Read and understand the Safety Data Sheets (SDS) for the materials
used with this equipment. All personnel who work in the vicinity
of this equipment should read, understand, and follow all safety
information contained in the SDS, in addition to following all
government and facility safety regulations.

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5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.
A. Emergency Procedures
The 5100 Series Analyzer is designed to operate safely, e󰀩ciently, and reliably. However, as with any
analytical equipment involving gases, an emergency can occur at any time. The emergency response
could involve calling for medical assistance, management notication, re assistance, or evacuation
from the vicinity of the analyzer. Obtain the following phone numbers and post them at the site
telephone locations. Periodically review the numbers and update them as required.
EMERGENCY PHONE NUMBERS
Ambulance ( ) ________________________
Fire Department ( ) ________________________
Sheri󰀨 or Police Department ( ) ________________________
On-Site Operations Representative ( ) ________________________
Training and education are the most important parts of any safety program. For every possible
emergency, establish an Emergency Response Plan and maintain it for immediate use.
B. Basic Safety Requirements
The following safety guidelines apply at all times when working with the 5100 Series:
• Prevent electrical shock — Unplug and remove the AC power cord from the rear panel before
opening and working on the analyzer. Use tools designed for work on electrical equipment.
• Prevent injury — Always wear safety glasses and appropriate safety protection. Ensure that all
tools and instruments used during installation and maintenance are in good condition. Be aware
that high-velocity gas may be released at vents and safety relief valves.
• Follow posted precautions — Read all precautionary labels attached to the equipment. Be
sure to read all cylinder labels and warnings. Comply with all precautions before handling the
equipment.
Situations may develop for which no written procedures exist. Think carefully before acting.
Know the function of each valve and switch, and its e󰀨ect on the equipment. Carefully review all
operating procedures before starting up this equipment to ensure knowledge and understanding.
C. Precautionary Labels
To avoid serious injury, read all precautionary labels attached to equipment, cylinders, containers, and
boxes prior to start up.
Labels attached in appropriate areas of the analyzer warn you of inherent hazards associated with the
system. For personal safety, read the labels and perform directed precautions before handling the
equipment.

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GOW-MAC Instrument Co.
D. Summary of Known Hazards
This equipment is designed to minimize your exposure to the process gases and other known
hazards. Read and thoroughly understand all safety aspects of this system and its operation before
operating or maintaining the equipment.
1. Electrocution
DANGER
!
DO NOT OPERATE THE ANALYZER WITHOUT THE CHASSIS
SECURED IN PLACE. TO GUARD AGAINST ELECTRICAL SHOCK
AND POSSIBLE ELECTROCUTION, THE ANALYZER SHOULD BE
SERVICED ONLY BY A GOW-MAC SERVICE TECHNICIAN.
Adherence to the following guidelines helps guard against electrical shock:
• For safety and proper performance, this analyzer must be connected to a properly
grounded three-wire source of electrical power.
• Tampering or unauthorized substitution of components may adversely a󰀨ect the safety of
this instrument. Use only factory-approved components for repair.
• Before checking or replacing any chassis component, turn o󰀨 the power and remove the
AC power cord from the rear panel.
2. Pressure
DANGER
!
MISHANDLING OF GAS CYLINDERS COULD RESULT IN DEATH,
SERIOUS INJURY, OR PROPERTY DAMAGE. HANDLE AND STORE
GAS CYLINDERS WITH EXTREME CARE AND IN ACCORDANCE
WITH MANUFACTURER’S INSTRUCTIONS.
Sudden or uncontrolled release of pressurized gas can cause serious injury. The hazards
of high pressure can be avoided through careful inspection and handling of cylinders and
equipment with proper regulation. Read and understand the MSDS for the process gases
used before operating this analyzer. For more detailed information on the precautions and safe
practices to follow when handling cylinders, obtain and read CGA pamphlet P-1, Safe Handling
of Compressed Gases in Cylinders.
E. General Precautions for Handling and Storing High Pressure Gas Cylinders
Compressed gases have properties that can cause serious accidents, injuries, and even death if
proper precautions and safety practices are not followed. Therefore, during handling and use of
these gases, be certain to use applicable safety precautions described by your local compressed gas
supplier, the Compressed Gas Association, and/or O.S.H.A. regulations.

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GOW-MAC Instrument Co.
1. Read the label on all cylinders BEFORE using to identify the cylinder contents. If the label is
illegible, return the cylinder to the supplier. DO NOT ASSUME THE CONTENTS.
2. Secure cylinders in storage and in use to an immovable structure to prevent accidental falling or
movement. Read the relevant safety codes.
3. Store or move cylinders ONLY in the vertical position. DO NOT move or transport cylinders with
regulators attached.
4. Store cylinders in a well ventilated area away from heat or ignition sources.
5. When installing tubing, provide ONLY approved, adequate pressure reducing regulators and
pressure relief devices to prevent over-pressurizing of tubing and equipment.
6. Never drop cylinders or permit them to strike each other violently.
7. Cylinders may be stored in the open but, in such cases, should be protected against extremes
of weather and from damp ground (to prevent rusting). In areas where extreme temperatures
are prevalent, store cylinders in the shade.
8. The valve protection cap should be left on each cylinder until cylinder has been secured against
a wall or bench, or placed in a cylinder stand and is ready for use.
9. Avoid dragging, rolling or sliding cylinders even for a short distance. Move cylinders by using a
suitable hand truck.
10. Never tamper with safety devices in valves or cylinders.
11. Do not store full and empty cylinders together. Serious suck-back can occur when an empty
cylinder is attached to a pressurized system.
12. No part of a cylinder should be subjected to a temperature higher than 52 °C (125 °F). Do not
permit ame to come in contact with any part of a compressed gas cylinder.
F. Safe Repair Procedures
Any repair work must be performed by a GOW-MAC service technician.
Analyzer manifold purging must be performed by experienced personnel.
Ventilate working area to prevent any leaking supply gas from accumulating.
Vent all gases to the outside.
Vent all pressure relief valves out of enclosed areas. Piping must be properly sized to allow safety
devices to operate according to specications.
De-pressurize supply gas piping before working on it.

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GOW-MAC Instrument Co.
Section 2
Principle of Operation
A. Detectors
1. Thermal Conductivity Detector (TCD)
The thermal conductivity detector (TCD) consists of a relatively large mass of metal to provide a
stable heat sink. Stainless steel is generally used because of its compatibility with most sample
gases and its high thermal conductivity. Through the metal block ow passages and recessed
cavities are drilled for the detector elements, such as a hot wire lament.
Detector elements used in the 5100 Series Gas Analyzer are fabricated from either rhenium-
tungsten (WX) or tungsten (W2). The laments are connected to form a Wheatstone Bridge,
then powered by a high-quality constant current source. The output of the bridge is then
electrically zeroed. When a sample with a lower thermal conductivity than the balance (or zero
standard) gas is introduced, an unbalance in the Wheatstone Bridge occurs. This unbalance is
displayed on the readout and can be calibrated in terms of the composition (Figure 2-1).
GOW-MAC uses reference laments in the “opposite” legs of the bridge in all its 5100 Series
Gas Analyzers in order to provide better stability due to variations in temperature and barometric
pressure. Small temperature changes in the detector will a󰀨ect both elements equally and
cancel out. Therefore, a “sealed reference” gas can be provided (Single Pass Unit). A “owing
reference” Dual Pass Unit) provides the additional cancellation e󰀨ects for slight variations.
The sealed/owing reference gas is usually a single-component gas representing the major
component in the sample gas.
B-
B+
G- G+
DC
Milliammeter
Adjustable
Current
Supply
Zero
Potentiometer
20 K Ω
Calibration
Recorder
Output
2 K Ω
Figure 2-1: Thermal Conductivity Cell

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GOW-MAC Instrument Co.
2. Detector Selection
The detector in your 5100 Series Continuous TC Gas Analyzer is one of the following (check
Section 3 - Specications for more details):
a. Our di󰀨usion type TCDs are relatively insensitive to ow changes and are suitable for
sample ows of approximately 200-250 cm3/min. Response time is less than 2 seconds.
Either a 4 or an 8 element detector is available. Check Section 3 - Specications for more
details.
b. The ow-through TCD has a low internal volume and a response time of less than one
second. It is suitable for sample ows of approximately 50-100 cm3/min.
c. Our nanokatharometer TCD is of ow-through design and has a response time of less than
one second. It is suitable for sample ow rates of 50-100 cm3/min. and is slightly more
sensitive than the ow-through TCD.
d. The Model TE II semi-di󰀨usion TCD has a lower volume than the di󰀨usion TCD, therefore,
response time is slightly faster and the sample ow rate is slower, 100-200 cm3/min.
B. Flow System
The ow system in a single pass unit has a owing sample and either a static air reference or
hermetically sealed reference gas. A dual pass unit has a owing sample and a owing reference gas.
The reference, sample, and calibration gas connections are made at the rear of the instrument. One-
eighth inch (1/8”) tube connectors are provided at the rear of the instrument to enable the customer
to make tubing connections. The metering valves located on the front panel are used to regulate the
sample, reference, or calibration gas ows through the detector.
C. Electronics
All electrical controls for the detector are on the front panel. A digital display is provided for the
analysis readout. Amplication of the signal increases the sensitivity of the instrument and allows the
operator to run the detector at a lower lament current which greatly increases the life of the laments.
A solid state constant current power supply is used for increased stability. All detectors are enclosed
in an insulated enclosure which is controlled at 100 °C by a proportional temperature controller, which
is located on the front panel.

5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.
Section 3
Specications
Customer:
Job #:
Instrument Part Number:
Instrument Serial Number:
Power Requirements: 5100 Series: 600 W at 115 V, 60 Hz
5102 Series: 600 W at 230 V, 50 Hz
Gas Connections: 1/8 inch compression
Detector:
Type:
Filaments:
Bridge Current:
Zero Gas:
Operating Temp:
Normal Flow Rate:
Response Time: <15 seconds @ 200 ccpm owrate
Readout Meter: Vacuum uorescent display
Calibrated Range:
Recorder: 4-20 mA
Dimensions (inches): W 17.12 without panel-mount bracket
W 19.0 with panel-mount bracket
H 15.75
D 23.0 with ttings
Weight: Net: approx. 75 lbs.
Shipping: approx. 80 lbs.
Schematics Drawing #_______________ Flow Diagram
Drawing #_______________ Wiring Schematic

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GOW-MAC Instrument Co.

5100 Series Continuous Gas Analyzer
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GOW-MAC Instrument Co.
Section 4
Installation
A. Additional Equipment Required
1. AC power source: 5100 Series Analyzer: 600 W at 115 V, 60 Hz
5102 Series Analyzer: 600 W at 230 V, 50 Hz
WARNING
!
OPERATING INSTRUCTIONS FOR BOTH MODELS ARE THE
SAME, EXCEPT FOR LINE VOLTAGE REQUIREMENTS. TO
PREVENT DAMAGE TO THE INSTRUMENT, MAKE SURE THAT AC
ELECTRICAL OUTLET IS THE CORRECT VOLTAGE FOR YOUR
INSTRUMENT BEFORE PLUGGING IT INTO THE OUTLET.
2. Clean 1/8-inch tubing;
• Refrigerant-grade copper tubing is acceptable for percent % level analysis.
• Stainless steel must be used if performing low ppm level detection.
See Section 4.E.2 for cleaning procedure.
Tubing MUST be cleaned and hydrocarbon free. The selection of tubing may vary
depending upon the intended application.
3. Cylinders: (1) Zero Gas
(2) Calibration Gas (also referred to as Span Gas)
(3) Sample Gas
4. Data Recorder with 4-20 mA, <1 second response.
B. Unpacking & Inspection
1. When unpacking the instrument, check it carefully for evidence of shipping damage or rough
handling. Check to ensure that all components ordered have either been supplied or back
ordered. Notify the company of any discrepancies. The packing box should be retained for
use should the instrument ever need to be returned to the factory for repair or modication.
GOW-MAC does not supply eld repair service. All repairs are made at Bethlehem, PA or by an
authorized representative.
2. Remove all plastic shipping caps from gas INLET and OUTLET PORTS.
C. Location
1. The 5100 Series Continuous TC Gas Analyzer should be placed in a location that is secure,
vibration-free, and protected from abrupt temperature changes and drafts (ambient operating
temperature range: 20-30 °C). Irregular changes in the instruments’ environment may upset the
temperature stability in the course of an analysis or preparation.
2. Enough adjacent table-top space should be allowed for the installation of recorders and any
other equipment necessary.

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GOW-MAC Instrument Co.
3. Allow adequate space for the installation of the necessary gas cylinders. Cylinders should be
securely fastened to the wall or table.
CAUTION READ “SECTION 1-SAFETY” AND CONTACT YOUR LOCAL GAS
SUPPLIER TO ENSURE PROPER HANDLING OF CYLINDERS.
4. An (AC) electrical outlet should be near the location where the analyzer is to be installed. If the
outlet is not a 3-pin type, make sure that a good ground connection is available, since a good
ground is necessary for proper operation. The ac outlet should be connected to a circuit that
is not heavily loaded with other electrical equipment. Input voltage to the instrument should
be steady for optimum operating stability. If the line voltage varies more than ±10%, a voltage
regulating transformer is recommended.
NOTE

If a recorder or other data acquisition system/device is being used with
the instrument, it is recommended that it be connected to the same circuit
as the analyzer. This may prevent ground loops.
D. Mounting (if applicable)
Space and materials required:
•19-inch rack space or bench top
•Service access space behind and in front of the analyzer.
•Metal bracket to support the rear side of the cabinet if the analyzer is installed in a cabinet without side support brackets.
E. Gas Connections
External Lines: The use of refrigerant-grade, cleaned, copper tubing is ne for percent level analysis.
Stainless steel tubing must be used for low ppm analysis. Stainless steel tubing may contain
hydrocarbon contaminants, therefore it is imperative that the tubing be cleaned and hydrocarbon
free. The selection of tubing used may vary depending upon the intended application.
NOTE

Plastic tubing is NOT recommended, since all plastics are permeable to
air.
All gas connections to the cylinder regulators and inlet ports should be made as follows:
1. Remove all plastic shipping caps from gas INLET and OUTLET PORTS if not already done.
NOTE

When using your own supply lines, rst purge lines to ensure they
are clean, then select the union or reducing union that will make the
line compatible with the ttings on the analyzer. Torque the unions as
specied by the manufacturer. Go on to Step 5.