Thermo Fisher Scientific 48i User Manual
Model 48i
Instruction Manual
Gas Filter Correlation CO Analyzer
Part Number 101891-00
18Dec2010
© 2007 Thermo Fisher Scientific Inc. All rights reserved.
Specifications, terms and pricing are subject to change. Not all products are available in all countries. Please
consult your local sales representative for details.
Thermo Fisher Scientific
Air Quality Instruments
27 Forge Parkway
Franklin, MA 02038
1-508-520-0430
www.thermo.com/aqi
WEEE Compliance
This product is required to comply with the European Union’s Waste
Electrical & Electronic Equipment (WEEE) Directive 2002/96/EC. It is
marked with the following symbol:
Thermo Fisher Scientific has contracted with one or more
recycling/disposal companies in each EU Member State, and this product
should be disposed of or recycled through them. Further information on
Thermo Fisher Scientific’s compliance with these Directives, the recyclers
in your country, and information on Thermo Fisher Scientific products
which may assist the detection of substances subject to the RoHS Directive
are available at: www.thermo.com/WEEERoHS.
Thermo Fisher Scientific WEEE Compliance
Reference Method Designation
The Thermo Scientific Model 48i is designated by the United States
Environmental Protection Agency (USEPA) as a Reference Method for CO
as set forth in the U.S. Environmental Protection Agency regulations at
Title 40, Part 53 of the U.S. Code of Fereral Regulations.
Designated Reference Method Number: RFCA-0981-054
EPA Designation Date: September 23, 1981 (amended for Model 48i)
The Model 48i CO Analyzer meets EPA reference designation
requirements when operated with the following:
Range 0-1 to 100 ppm
Averaging Time 10 to 300 seconds
Temperature Range 20 to 35 °C
Line Voltage 90 to 110 Vac @50/60 Hertz
105 to 125 Vac @50/60 Hertz
210 to 250 Vac @50/60 Hertz
Pressure Compensation ON or OFF
Temperature Compensation ON or OFF
Flow Rate 0.5 to 2 L/min
RS-232/RS-485 Interface
With or without the following options:
Teflon Particulate Filter
Internal Zero/Span and Sample Valves
Internal Zero Air Scrubber
Rack Mounts
I/O Expansion Board
Thermo Fisher Scientific WEEE Compliance
About This Manual
This manual provides information about installing, operating, maintaining,
and servicing the Model 48i CO gas analyzer. It also contains important
alerts to ensure safe operation and prevent equipment damage. The manual
is organized into the following chapters and appendices to provide direct
access to specific operation and service information.
● Chapter 1 “Introduction” provides an overview of product features,
describes the principles of operation, and lists the specifications.
● Chapter 2 “Installation” describes how to unpack, setup, and startup
the analyzer.
● Chapter 3 “Operation” describes the front panel display, the front
panel pushbuttons, and the menu-driven firmware.
● Chapter 4 “Calibration” provides the procedures for calibrating the
analyzer and describes the required equipment.
● Chapter 5 “Preventive Maintenance” provides maintenance procedures
to ensure reliable and consistent instrument operation.
● Chapter 6 “Troubleshooting” presents guidelines for diagnosing
analyzer failures, isolating faults, and includes recommended actions for
restoring proper operation.
● Chapter 7 “Servicing” presents safety alerts for technicians working on
the analyzer, step-by-step instructions for repairing and replacing
components, and a replacement parts list. It also includes contact
information for product support and technical information.
● Chapter 8 “System Description” describes the function and location of
the system components, provides an overview of the firmware structure,
and includes a description of the system electronics and input/output
connections.
● Chapter 9 “Optional Equipment” describes the optional equipment
that can be used with this analyzer.
● Appendix A “Warranty” is a copy of the warranty statement.
● Appendix B “C-Link Protocol Commands” provides a description of
the C-Link protocol commands that can be used to remotely control an
analyzer using a host device such as a PC or datalogger.
Thermo Fisher Scientific Model 48i Instruction Manual i
About This Manual
Safety
● Appendix C “MODBUS Protocol” provides a description of the
MODBUS Protocol Interface and is supported both over RS-232/485
(RTU protocol) as well as TCP/IP over Ethernet.
● Appendix D “Gesytec (Bayern-Hessen) Protocol” provides a
description of the Gesytec (Bayern-Hessen or BH) Protocol Interface
and is supported both over RS-232/485 as well as TCP/IP over
Ethernet.
Safety
Safety and Equipment
Damage Alerts
Review the following safety information carefully before using the analyzer.
This manual provides specific information on how to operate the analyzer,
however, if the analyzer is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be impaired.
This manual contains important information to alert you to potential safety
hazards and risks of equipment damage. Refer to the following types of
alerts you may see in this manual.
Safety and Equipment Damage Alert Descriptions
Alert Description
DANGER A hazard is present that could result in death or serious
WARNING A hazard or unsafe practice could result in serious
CAUTION A hazard or unsafe practice could result in minor to
personal injury if the warning is ignored.
personal injury if the warning is ignored.
moderate personal injury if the warning is ignored.
▲
▲
▲
Equipment Damage A hazard or unsafe practice could result in property
damage if the warning is ignored.
▲
Safety and Equipment Damage Alerts in this Manual
Alert Description
ii Model 48i Instruction Manual Thermo Fisher Scientific
WARNING The Model 48i is supplied with a three-wire grounded
If the equipment is operated in a manner not specified by
The service procedures in this manual are restricted to
power cord. Under no circumstances should this
grounding system be defeated.
the manufacturer, the protection provided by the
equipment may be impaired.
qualified service personnel only.
▲
▲
▲
Alert Description
About This Manual
FCC Compliance
CAUTION If the LCD panel breaks, do not let the liquid crystal
Equipment Damage Do not attempt to lift the analyzer by the cover or other
Disconnect the serial cable before changing RS-232 and
Some internal components can be damaged by small
Do not use solvents or other cleaning products to clean
Do not remove the LCD panel or frame from the LCD
The LCD polarizing plate is very fragile, handle it
Do not wipe the LCD polarizing plate with a dry cloth, as
contact your skin or clothes. If the liquid crystal contacts
your skin or clothes, wash it off immediately using soap
and water.
external fittings.
RS-485 selection to prevent damage to any equipment
currently connected to the analyzer.
amounts of static electricity. A properly grounded
antistatic wrist strap must be worn while handling any
internal component.
the outside case.
module.
carefully.
it may easily scratch the plate.
▲
▲
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FCC Compliance
Do not use alcohol, acetone, MEK or other ketone based
or aromatic solvent to clean the LCD module, but rather
use a soft cloth moistened with a naphtha cleaning
solvent.
Do not place the LCD module near organic solvents or
corrosive gases.
Do not shake or jolt the LCD module.
▲
▲
▲
Changes or modifications to this unit not expressly approved by the party
responsible for compliance could void the user’s authority to operate the
equipment.
Note This equipment has been tested and found to comply within the
limits for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the instruction manual,
may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference, in
Thermo Fisher Scientific Model 48i Instruction Manual iii
About This Manual
W
W
WEEE Symbol
which case the user will be required to correct the interference at his or her
own expense. ▲
EEE Symbol
here to Get Help
The following symbol and description identify the WEEE marking used on
the instrument and in the associated documentation.
Symbol Description
Marking of electrical and electronic equipment which applies to waste
electrical and electronic equipment falling under the Directive 2002/96/EC
(WEEE) and the equipment that has been put on the market after 13 August
2005.
▲
Service is available from exclusive distributors worldwide. Contact one of
the phone numbers below for product support and technical information
or visit us on the web at www.thermo.com/aqi.
1-866-282-0430 Toll Free
1-508-520-0430 International
iv Model 48i Instruction Manual Thermo Fisher Scientific
Contents
Contents
Chapter 1
Chapter 2
Chapter 3
Introduction........................................................................................................ 1-1
Principle of Operation ........................................................................ 1-2
Specifications ...................................................................................... 1-3
Installation ......................................................................................................... 2-1
Lifting................................................................................................. 2-1
Unpacking and Inspection .................................................................. 2-1
Setup Procedure.................................................................................. 2-3
Connecting External Devices .............................................................. 2-5
Terminal Board PCB Assemblies...................................................... 2-5
I/O Terminal Board...................................................................... 2-5
D/O Terminal Board.................................................................... 2-7
25-Pin Terminal Board ................................................................. 2-8
Startup................................................................................................ 2-9
Operation............................................................................................................ 3-1
Display................................................................................................ 3-1
Pushbuttons........................................................................................ 3-2
Soft Keys.......................................................................................... 3-3
Alphanumeric Entry Screen ............................................................. 3-4
Firmware Overview............................................................................. 3-4
Power-Up Screen ............................................................................. 3-6
Run Screen....................................................................................... 3-6
Custom Run Screens..................................................................... 3-7
Main Menu...................................................................................... 3-8
Range Menu ....................................................................................... 3-8
Single Range Mode .......................................................................... 3-9
Dual Range Mode.......................................................................... 3-10
Auto Range Mode.......................................................................... 3-11
Gas Units....................................................................................... 3-13
CO Range...................................................................................... 3-14
Set Custom Ranges ........................................................................ 3-15
Custom Ranges........................................................................... 3-15
Averaging Time................................................................................. 3-16
Calibration Factors Menu ................................................................. 3-16
CO Background............................................................................. 3-17
CO Coefficient .............................................................................. 3-18
Background .............................................................................. 3-18
O
2
O
Coefficient................................................................................ 3-19
2
Thermo Fisher Scientific Model 48i Instruction Manual v
Contents
Reset User Calibration Defaults ..................................................... 3-20
Calibration Menu ............................................................................. 3-20
Calibrate CO Background.............................................................. 3-21
Calibrate CO Coefficient ............................................................... 3-21
Zero/Span Check ........................................................................... 3-22
Next Time .................................................................................. 3-22
Period Hours............................................................................... 3-23
Total Duration Hour .................................................................. 3-23
Zero/Span/Purge Duration Minutes ........................................... 3-23
Zero/Span Averaging Time ......................................................... 3-24
Zero/Span Calibration Reset ....................................................... 3-24
Zero/Span Ratio.......................................................................... 3-24
Calibrate O
Calibrate O
Background ............................................................... 3-25
2
Coefficient................................................................. 3-25
2
Instrument Controls Menu ............................................................... 3-25
Datalogging Settings ...................................................................... 3-26
Select Srec/Lrec ........................................................................... 3-27
View Logged Data....................................................................... 3-27
Number of Records..................................................................... 3-27
Date and Time............................................................................ 3-28
Erase Log .................................................................................... 3-29
Select Content............................................................................. 3-29
Choose Field Data....................................................................... 3-29
Concentrations............................................................................ 3-30
Corrected Concentrations ........................................................... 3-30
Other Measurements................................................................... 3-31
Analog Inputs.............................................................................. 3-31
Commit Content ........................................................................ 3-32
Reset to Default Content ............................................................ 3-32
Configure Datalogging................................................................ 3-33
Logging Period Min.................................................................... 3-33
Memory Allocation Percent......................................................... 3-33
Data Treatment .......................................................................... 3-34
Flag Status Data .......................................................................... 3-34
Communication Settings................................................................ 3-35
Serial Settings.............................................................................. 3-35
Baud Rate ................................................................................... 3-35
Data Bits..................................................................................... 3-36
Parity .......................................................................................... 3-36
Stop Bits ..................................................................................... 3-36
RS-232/RS-485 Selection............................................................ 3-37
Instrument ID............................................................................. 3-37
Gesytec Serial No........................................................................ 3-38
Communication Protocol............................................................ 3-38
Streaming Data Configuration .................................................... 3-39
Streaming Data Interval .............................................................. 3-40
vi Model 48i Instruction Manual Thermo Fisher Scientific
Contents
Add Labels .................................................................................. 3-40
Prepend Timestamp.................................................................... 3-40
Add Flags.................................................................................... 3-40
Choose Stream Data Item ........................................................... 3-41
Concentrations............................................................................ 3-41
Corrected Concentrations ........................................................... 3-41
Other Measurements................................................................... 3-42
Analog Inputs ............................................................................. 3-42
TCP/IP Settings.......................................................................... 3-43
Use DHCP ................................................................................. 3-43
IP Address................................................................................... 3-44
Netmask ..................................................................................... 3-44
Default Gateway ......................................................................... 3-44
Host Name ................................................................................. 3-45
Network Time Protocol Server.................................................... 3-45
I/O Configuration ......................................................................... 3-45
Output Relay Settings................................................................. 3-46
Logic State .................................................................................. 3-46
Instrument State ......................................................................... 3-47
Alarms......................................................................................... 3-47
Non-Alarm ................................................................................. 3-48
Digital Input Settings.................................................................. 3-48
Logic State .................................................................................. 3-49
Instrument Action....................................................................... 3-49
Analog Output Configuration (Select Channel).......................... 3-49
Allow Over/Under Range............................................................ 3-50
Analog Output Configuration (Select Action)............................. 3-50
Select Range................................................................................ 3-51
Minimum and Maximum Value ................................................. 3-51
Choose Signal to Output ............................................................ 3-52
Analog Input Configuration........................................................ 3-54
Descriptor................................................................................... 3-54
Units........................................................................................... 3-55
Decimal Places ............................................................................ 3-55
Number of Table Points ............................................................. 3-55
Table Point ................................................................................. 3-56
Volts ........................................................................................... 3-56
User Value .................................................................................. 3-57
Temperature Compensation .......................................................... 3-57
Pressure Compensation.................................................................. 3-58
O
Compensation .......................................................................... 3-58
2
Screen Contrast.............................................................................. 3-59
Service Mode ................................................................................. 3-59
Date/Time ..................................................................................... 3-60
Timezone....................................................................................... 3-60
Diagnostics Menu............................................................................. 3-61
Thermo Fisher Scientific Model 48i Instruction Manual vii
Contents
Program Versions........................................................................... 3-61
Voltages ......................................................................................... 3-62
Motherboard Voltages................................................................. 3-62
Interface Board Voltages ............................................................. 3-62
I/O Board Voltages ..................................................................... 3-63
Temperatures ................................................................................. 3-63
Pressure.......................................................................................... 3-63
Flow............................................................................................... 3-64
Sample/Reference Ratio ................................................................. 3-64
AGC Intensity................................................................................ 3-64
Motor Speed .................................................................................. 3-65
O
Sensor Readings........................................................................ 3-65
2
Analog Input Readings................................................................... 3-65
Analog Input Voltages.................................................................... 3-66
Digital Inputs................................................................................. 3-66
Relay States .................................................................................... 3-66
Test Analog Outputs...................................................................... 3-67
Set Analog Outputs..................................................................... 3-67
Instrument Configuration.............................................................. 3-67
Contact Information ...................................................................... 3-68
Alarms Menu .................................................................................... 3-68
Internal Temperature ..................................................................... 3-69
Min and Max Internal Temperature Limits................................. 3-69
Bench Temperature........................................................................ 3-70
Min and Max Bench Temperature Limits ................................... 3-70
Pressure.......................................................................................... 3-70
Min and Max Pressure Limits ..................................................... 3-71
Sample Flow .................................................................................. 3-71
Min and Max Sample Flow Limits .............................................. 3-72
Bias Voltage ................................................................................... 3-72
Min and Max Bias Voltage Limits............................................... 3-72
AGC Intensity................................................................................ 3-73
Min and Max AGC Intensity Limits ........................................... 3-73
Motor Speed .................................................................................. 3-73
Zero and Span Check..................................................................... 3-74
Max Zero and Span Offset .......................................................... 3-74
Zero and Span Auto Calibration ....................................................3-74
Concentration................................................................................ 3-75
Min and Max Concentration Limits ........................................... 3-75
Min Trigger Concentration......................................................... 3-76
O
Concentration........................................................................... 3-76
2
Min and Max O
Concentration Limits ...................................... 3-76
2
Min Trigger ................................................................................ 3-77
External Alarms.............................................................................. 3-77
Service Menu .................................................................................... 3-78
Range Mode Select......................................................................... 3-78
viii Model 48i Instruction Manual Thermo Fisher Scientific
Contents
Pressure Calibration ....................................................................... 3-79
Calibrate Pressure Zero ............................................................... 3-79
Calibrate Pressure Span............................................................... 3-80
Restore Default Pressure Calibration........................................... 3-80
Flow Calibration ............................................................................ 3-81
Calibrate Flow Zero .................................................................... 3-81
Calibrate Flow Span.................................................................... 3-81
Restore Default Flow Calibration................................................ 3-82
Initial Sample/Reference Ratio....................................................... 3-82
Multi-Point Calibration ................................................................. 3-83
Calibrate Point 1/2/3 .................................................................. 3-83
Coefficients................................................................................. 3-84
Default Coefficients .................................................................... 3-84
Preamp Board Calibration ............................................................. 3-84
Temperature Calibration................................................................ 3-85
Analog Output Calibration ............................................................ 3-85
Analog Output Calibrate Zero .................................................... 3-86
Analog Output Calibrate Full-Scale ............................................ 3-86
Analog Input Calibration ............................................................... 3-87
Analog Input Calibrate Zero ....................................................... 3-87
Analog Input Calibrate Full-Scale ............................................... 3-88
O
Correction Concentration......................................................... 3-88
2
Dilution Ratio................................................................................ 3-89
Setup Run Screens ......................................................................... 3-89
Edit Run Screen.......................................................................... 3-90
Edit Title .................................................................................... 3-90
Enabled....................................................................................... 3-90
Number of Items ........................................................................ 3-91
Select Run Screen Item ............................................................... 3-91
Concentrations............................................................................ 3-92
Corrected Concentrations ........................................................... 3-92
Other Measurements................................................................... 3-93
Analog Inputs ............................................................................. 3-93
Display Pixel Test .......................................................................... 3-93
Restore User Defaults..................................................................... 3-94
Password ........................................................................................... 3-94
Set Password .................................................................................. 3-95
Lock Instrument ............................................................................ 3-95
Lock/Unlock and Local/Remote Operation ................................ 3-95
Change Password ........................................................................... 3-96
Remove Password .......................................................................... 3-96
Unlock Instrument ........................................................................ 3-96
Chapter 4
Calibration.......................................................................................................... 4-1
Equipment Required........................................................................... 4-1
CO Concentration Standard............................................................ 4-1
Thermo Fisher Scientific Model 48i Instruction Manual ix
Contents
Zero Air Generator........................................................................... 4-1
Compression ................................................................................. 4-2
Drying .......................................................................................... 4-2
Scrubbing...................................................................................... 4-2
Flow Meter(s) and Controller(s)....................................................... 4-2
Pressure Regulator for CO Standard Cylinder.................................. 4-2
Mixing Chamber.............................................................................. 4-3
Output Manifold ............................................................................. 4-3
Pre-Calibration ................................................................................... 4-3
Calibration.......................................................................................... 4-3
Connect the Instrument................................................................... 4-3
Zero Adjust...................................................................................... 4-4
Span Adjust...................................................................................... 4-5
Calibration Frequency...................................................................... 4-6
Periodic Zero and Span Checks........................................................... 4-6
HI and LO Multi-Point Calibration ................................................... 4-7
Default Coefficients ......................................................................... 4-7
Cal Point 1, 2, and 3 Adjust............................................................. 4-7
References ........................................................................................... 4-9
Chapter 5
Chapter 6
Preventive Maintenance .................................................................................5-1
Safety Precautions ............................................................................... 5-1
Replacement Parts............................................................................... 5-2
Cleaning the Outside Case.................................................................. 5-2
Cleaning the Optics ............................................................................ 5-2
IR Source Replacement ....................................................................... 5-3
Fan Filter Inspection and Cleaning ..................................................... 5-3
Leak Test and Pump Check Out......................................................... 5-4
External Leaks.................................................................................. 5-4
Leaks Across the Optional Zero/Span and Sample Solenoid Valves.. 5-5
Pump Rebuilding................................................................................ 5-5
Disassembly .................................................................................. 5-5
Assembly with New Diaphragm and Valve.................................... 5-8
Troubleshooting.................................................................................................6-1
Safety Precautions ............................................................................... 6-1
Troubleshooting Guides...................................................................... 6-1
Board-Level Connection Diagrams ..................................................... 6-5
Connector Pin Descriptions................................................................ 6-7
Service Locations............................................................................... 6-20
Chapter 7
Servicing.............................................................................................................7-1
Safety Precautions ............................................................................... 7-3
Firmware Updates............................................................................... 7-4
Accessing the Service Mode................................................................. 7-4
x Model 48i Instruction Manual Thermo Fisher Scientific
Contents
Replacement Parts List........................................................................ 7-4
Cable List............................................................................................ 7-6
External Device Connection Components .......................................... 7-6
Removing the Measurement Case Assembly and Lowering the Partition
Panel................................................................................................... 7-8
Fuse Replacement ............................................................................... 7-9
Fan/Filter Replacement..................................................................... 7-10
IR Source Replacement..................................................................... 7-11
Filter Wheel Replacement ................................................................. 7-12
Chopper Motor Replacement............................................................ 7-14
Optical Bench Replacement.............................................................. 7-15
Optical Switch Replacement ............................................................. 7-16
Bench Heater Assembly Replacement ............................................... 7-17
Detector/Preamplifier Assembly Replacement................................... 7-18
Preamp Board Calibration ................................................................ 7-20
Pump Replacement........................................................................... 7-20
Pressure Transducer Replacement ..................................................... 7-21
Pressure Transducer Calibration........................................................ 7-22
Flow Transducer Replacement .......................................................... 7-24
Flow Transducer Calibration ............................................................ 7-25
Capillary Cleaning or Replacement................................................... 7-26
Optional Zero/Span and Sample Solenoid Valve Replacement.......... 7-27
Analog Output Testing ..................................................................... 7-28
Analog Output Calibration ............................................................... 7-30
Analog Input Calibration .................................................................. 7-31
Calibrating the Input Channels to Zero Volts ................................ 7-31
Calibrating the Input Channels to Full-Scale ................................. 7-32
Ambient Temperature Calibration .................................................... 7-33
I/O Expansion Board (Optional) Replacement ................................. 7-34
Internal O
Sensor (Optional) Replacement...................................... 7-36
2
Digital Output Board Replacement .................................................. 7-36
Motherboard Replacement................................................................ 7-37
Measurement Interface Board Replacement ...................................... 7-38
Front Panel Board Replacement........................................................ 7-39
LCD Module Replacement............................................................... 7-40
Service Locations............................................................................... 7-41
Chapter 8
System Description ..........................................................................................8-1
Hardware ............................................................................................ 8-1
Optical Bench.................................................................................. 8-2
Band-pass Filter ............................................................................... 8-2
Bench Heater Board......................................................................... 8-2
Chopper Motor................................................................................ 8-2
Optical Pickup................................................................................. 8-3
Gas Filter Wheel .............................................................................. 8-3
Infrared Source ................................................................................ 8-3
Thermo Fisher Scientific Model 48i Instruction Manual xi
Contents
Pre-amplifier Assembly with IR Detector ......................................... 8-3
Sample Flow Sensor ......................................................................... 8-3
Pressure Transducer ......................................................................... 8-3
Capillary .......................................................................................... 8-3
Pump ............................................................................................... 8-3
Purge Flow Switch (optional)........................................................... 8-3
Firmware............................................................................................. 8-3
Instrument Control.......................................................................... 8-4
Monitoring Signals........................................................................... 8-4
Output Communication .................................................................. 8-4
Electronics .......................................................................................... 8-5
Motherboard.................................................................................... 8-5
Measurement Interface Board .......................................................... 8-6
Measurement Interface Board Connectors..................................... 8-6
Flow Sensor Assembly ...................................................................... 8-6
Pressure Sensor Assembly ................................................................. 8-6
Bench Heater Board......................................................................... 8-7
Pre-amp Board Assembly ................................................................. 8-7
Digital Output Board....................................................................... 8-7
I/O Expansion Board (Optional) ..................................................... 8-7
Front Panel Connector Board .......................................................... 8-7
I/O Components................................................................................. 8-8
Analog Voltage Outputs................................................................... 8-8
Analog Current Outputs (Optional) ................................................ 8-8
Analog Voltage Inputs (Optional) .................................................... 8-9
Digital Relay Outputs ...................................................................... 8-9
Digital Inputs................................................................................... 8-9
Serial Ports ..................................................................................... 8-10
RS-232 Connection ....................................................................... 8-10
RS-485 Connection ....................................................................... 8-11
Ethernet Connection...................................................................... 8-11
External Accessory Connector ........................................................ 8-11
Chapter 9
Optional Equipment...........................................................................................9-1
Internal Zero/Span Assembly .............................................................. 9-1
Internal Oxygen (O
Internal O
Sensor Calibration ......................................................... 9-2
2
) Sensor............................................................... 9-1
2
Alternate Sensor Calibration ............................................................ 9-3
Internal Zero Air Scrubber .................................................................. 9-4
Filter Wheel Purge .............................................................................. 9-4
Calibration Note.............................................................................. 9-5
Teflon Particulate Filter ...................................................................... 9-5
I/O Expansion Board Assembly........................................................... 9-5
25-Pin Terminal Board Assembly..................................................... 9-5
Terminal Block and Cable Kits ........................................................... 9-5
Cables ................................................................................................. 9-6
xii Model 48i Instruction Manual Thermo Fisher Scientific
Contents
Mounting Options.............................................................................. 9-7
Appendix A
Appendix B
Warranty.............................................................................................................A-1
C-Link Protocol Commands ............................................................................B-1
Instrument Identification Number......................................................B-1
Commands .........................................................................................B-2
Entering Units in PPB .....................................................................B-3
Convert Concentration Formats ......................................................B-3
Commands List................................................................................B-3
Measurements...................................................................................B-10
Alarms...............................................................................................B-14
Diagnostics .......................................................................................B-18
Datalogging ......................................................................................B-19
Calibration........................................................................................B-26
Keys/Display.....................................................................................B-33
Measurement Configuration .............................................................B-35
Hardware Configuration...................................................................B-38
Communications Configuration .......................................................B-40
I/O Configuration ............................................................................B-48
Record Layout Definition .................................................................B-53
Format Specifier for ASCII Responses............................................B-54
Format Specifier for Binary Responses ...........................................B-54
Format Specifier for Erec Layout.................................................... B-54
Text ............................................................................................B-55
Value String ................................................................................ B-55
Value Source............................................................................... B-55
Alarm Information......................................................................B-55
Translation Table........................................................................ B-56
Selection Table............................................................................B-56
Button Designator ......................................................................B-56
Examples..................................................................................... B-57
Appendix C
MODBUS Protocol ............................................................................................C-1
Serial Communication Parameters ......................................................C-1
TCP Communication Parameters .......................................................C-2
Application Data Unit Definition .......................................................C-2
Slave Address ...................................................................................C-2
MBAP Header .................................................................................C-2
Function Code.................................................................................C-3
Data.................................................................................................C-3
Error Check .....................................................................................C-3
Function Codes...................................................................................C-3
(0x01/0x02) Read Coils/Read Inputs ...............................................C-3
(0x03/0x04) Read Holding Registers/Read Input Registers..............C-5
Thermo Fisher Scientific Model 48i Instruction Manual xiii
Contents
(0x05) Force (Write) Single Coil..................................................... C-7
MODBUS Parameters Supported ...................................................... C-8
Reading a Write Coil .................................................................... C-12
Appendix D
Gesytec (Bayern-Hessen) Protocol ..............................................................D-1
Serial Communication Parameters .....................................................D-1
TCP Communication Parameters ...................................................... D-2
Instrument Address ............................................................................ D-2
Abbreviations Used ............................................................................ D-2
Basic Command Structure ................................................................. D-2
Block Checksum Characters <BCC>..................................................D-3
Gesytec Commands ...........................................................................D-3
Instrument Control Command (ST)............................................... D-3
Data Sampling/Data Query Command (DA).................................. D-4
Measurements reported in response to DA command .....................D-7
Single Range Mode ...................................................................... D-7
Dual/Auto Range Mode............................................................... D-7
Operating and Error Status ............................................................. D-7
xiv Model 48i Instruction Manual Thermo Fisher Scientific
Figures
Figure 1–1. Model 48i Flow Schematic ............................................................. 1-3
Figure 2–1. Remove the Packing Material ......................................................... 2-2
Figure 2–2. Removing the Shipping Screws ...................................................... 2-2
Figure 2–3. Model 48i Rear Panel...................................................................... 2-4
Figure 2–4. Atmospheric Dump Bypass Plumbing ............................................. 2-4
Figure 2–5. I/O Terminal Board Views ............................................................... 2-6
Figure 2–6. D/O Terminal Board Views.............................................................. 2-7
Figure 2–7. 25-Pin Terminal Board Views.......................................................... 2-8
Figure 3–1. Front Panel Display.......................................................................... 3-2
Figure 3–2. Front Panel Pushbuttons.................................................................. 3-2
Figure 3–3. Flowchart of Menu-Driven Firmware.............................................. 3-5
Figure 3–4. Pin-Out of Rear Panel Connector in Single Range Mode ............... 3-9
Figure 3–5. Pin-Out of Rear Panel Connector in Dual Range Mode................ 3-10
Figure 3–6. Analog Output in Auto Range Mode............................................. 3-12
Figure 3–7. Pin-Out of Rear Connector in Auto Range Mode.......................... 3-12
Figure 4–1. Calibration Flow Schematic ............................................................ 4-4
Figure 5–1. Inspecting and Cleaning the Fan..................................................... 5-4
Figure 5–2. Rebuilding the Pump (New Technology)......................................... 5-7
Figure 5–3. Rebuilding the Pump........................................................................ 5-9
Figure 6–1. Board-Level Connection Diagram - Common Electronics............... 6-5
Figure 6–2. Board-Level Connection Diagram - Measurement System ............ 6-6
Figure 7–1. Properly Grounded Antistatic Wrist Strap ...................................... 7-4
Figure 7–2. Component Layout........................................................................... 7-7
Figure 7–3. Removing the Measurement Case Assembly and Lowering the
Partition Panel ...................................................................................................... 7-8
Figure 7–4. Replacing the Fan .......................................................................... 7-11
Figure 7–5. Replacing the IR Source ................................................................ 7-12
Figure 7–6. Removing the Motor...................................................................... 7-13
Figure 7–7. Replacing the Optical Bench ......................................................... 7-16
Figure 7–8. Replacing the Optical Switch (Inverted View) .............................. 7-17
Figure 7–9. Replacing the Detector/Preamplifier Assembly ........................... 7-19
Figure 7–10. Replacing the Pump..................................................................... 7-21
Figure 7–11. Replacing the Pressure Transducer............................................. 7-22
Figure 7–12. Replacing the Flow Transducer................................................... 7-25
Figure 7–13. Cleaning or Replacing the Capillary............................................ 7-27
Figure 7–14. Rear Panel Analog Input and Output Pins................................... 7-29
Thermo Fisher Scientific Model 48i Instruction Manual xv
Figures
Figure 7–15. Replacing the I/O Expansion Board (Optional)............................ 7-35
Figure 7–16. Rear Panel Board Connectors...................................................... 7-35
Figure 7–17. Replacing the Measurement Interface Board.............................7-39
Figure 7–18. Replacing the Front Panel Board and the LCD Module............... 7-40
Figure 8–1. Hardware Components .................................................................... 8-2
Figure 9–1. Flow Diagram, Internal O
Sensor ...................................................9-2
2
Figure 9–2. Purge Housing Assembly ................................................................. 9-4
Figure 9–3. Rack Mount Option Assembly .........................................................9-8
Figure 9–4. Bench Mounting............................................................................... 9-9
Figure 9–5. EIA Rack Mounting ........................................................................9-10
Figure 9–6. Retrofit Rack Mounting..................................................................9-11
Figure B–1. Flags Field......................................................................................B-13
xvi Model 48i Instruction Manual Thermo Fisher Scientific
Tables
Table 1–1. Model 48i Specifications ................................................................. 1-3
Table 1–2. Model 48i Optional Internal Oxygen Sensor Specifications ........... 1-4
Table 2–1. I/O Terminal Board Pin Descriptions ................................................ 2-6
Table 2–2. D/O Terminal Board Pin Descriptions............................................... 2-7
Table 2–3. 25-Pin Terminal Board Pin Descriptions........................................... 2-8
Table 3–1. Front Panel Pushbuttons................................................................... 3-3
Table 3–2. Default Analog Outputs in Single Range Mode............................... 3-9
Table 3–3. Default Analog Outputs in Dual Range Mode ............................... 3-11
Table 3–4. Default Analog Outputs in Auto Range Mode ............................... 3-13
Table 3–5. Available Operating Ranges........................................................... 3-14
Table 3–6. Analog Output Zero to Full-Scale Table......................................... 3-52
Table 3–7. Signal Type Group Choices............................................................. 3-53
Table 6–1. Troubleshooting - General Guide ..................................................... 6-2
Table 6–2. Troubleshooting - Alarm Messages ................................................. 6-3
Table 6–3. Motherboard Connector Pin Descriptions........................................ 6-7
Table 6–4. Measurement Interface Board Connector Pin Descriptions .......... 6-12
Table 6–5. Front Panel Board Connector Pin Diagram..................................... 6-14
Table 6–6. I/O Expansion Board (Optional) Connector Pin Descriptions ......... 6-16
Table 6–7. Digital Output Board Connector Pin Descriptions.......................... 6-17
Table 6–8. Pre-amp Board Connector Pin Descriptions ................................... 6-19
Table 7–1. Model 48i Replacement Parts.......................................................... 7-4
Table 7–2. Model 48i Cables.............................................................................. 7-6
Table 7–3. External Device Connection Components ........................................ 7-6
Table 7–4. Analog Output Channels and Rear Panel Pin Connections............ 7-30
Table 7–5. Analog Input Channels and Rear Panel Pin Connections............... 7-30
Table 8–1. RS-232 DB9 Connector Pin Configuration...................................... 8-10
Table 8–2. RS-485 DB9 Connector Pin Configuration...................................... 8-11
Table 9–1. Cable Options.................................................................................... 9-6
Table 9–2. Color Codes for 25-Pin and 37-Pin Cables ....................................... 9-6
Table 9–3. Mounting Options ............................................................................. 9-7
Table B–1. Command Response Error Descriptions ..........................................B-3
Table B–2. C-Link Protocol Commands ..............................................................B-3
Table B–3. Averaging Times ............................................................................B-10
Table B–4. Alarm Trigger Values .....................................................................B-18
Table B–5. Record Output Formats ..................................................................B-23
Thermo Fisher Scientific Model 48i Instruction Manual xvii
Tables
Table B–6. Stream Time Values .......................................................................B-26
Table B–7. Standard Ranges ............................................................................B-35
Table B–8. Contrast Levels...............................................................................B-39
Table B–9. Reply Termination Formats ............................................................B-44
Table B–10. Allow Mode Command Values ....................................................B-46
Table B–11. Power Up Mode Values................................................................B-47
Table B–12. Set Layout Ack Values..................................................................B-47
Table B–13. Analog Current Output Range Values..........................................B-48
Table B–14. Analog Voltage Output Range Values .........................................B-49
Table B–15. Default Analog Output Channel Assignments.............................B-51
Table C–1. Read Coils for 48i.............................................................................C-8
Table C–2. Read Registers for 48i....................................................................C-10
Table C–3. Write Coils for 48i..........................................................................C-12
Table D–1. Operating Status for Model 48i...................................................... D-7
Table D–2. Error Status for Model 48i .............................................................. D-8
xviii Model 48i Instruction Manual Thermo Fisher Scientific
Chapter 1
Introduction
The Model 48i CO Analyzer measures CO concentration using Gas Filter
Correlation (GFC). The Model 48i combines proven detection technology,
easy to use menu-driven firmware, and advanced diagnostics to offer
unsurpassed flexibility and reliability. The Model 48i has the following
features:
● 320 x 240 graphics display
● Menu-driven firmware
● Field programmable ranges
● User-selectable single/dual/auto range modes
● Multiple user-defined analog outputs
● Analog input options
● High sensitivity
● Fast response time
● Linearity through all ranges
● Highly specific to CO
● Self-aligning optics
● Automatic temperature and pressure compensation
● User-selectable digital input/output capabilities
● Standard communications features include RS232/485 and Ethernet
● C-Link, MODBUS, Gesytec (Bayern-Hessen), streaming data, and
NTP (Network Time Protocol) protocols. Simultaneous connections
from different locations over Ethernet.
For details of the analyzer’s principle of operation and product
specifications, see the following topics:
● “Principle of Operation” on page 1-2
● “Specifications” on page 1-3
Thermo Fisher Scientific Model 48i Instruction Manual 1-1
Introduction
Principle of Operation
Thermo Fisher Scientific is pleased to supply this CO analyzer. We are
committed to the manufacture of instruments exhibiting high standards of
quality, performance, and workmanship. Service personnel are available for
assistance with any questions or problems that may arise in the use of this
analyzer. For more information on servicing, see the “Servicing” chapter
starting on page 7-1.
Principle of
Operation
The Model 48i operates on the principle that carbon monoxide (CO)
absorbs infrared radiation at a wavelength of 4.6 microns. Because infrared
absorption is a non-linear measurement technique, it is necessary to
transform the basic analyzer signal into a linear output. The Model 48i uses
an internally stored calibration curve to accurately linearize the instrument
output over any range up to a concentration of 10,000 ppm.
The sample is drawn into the Model 48i through the sample bulkhead, as
shown in Figure 1–1. The sample flows through the optical bench.
Radiation from an infrared source is chopped and then passed through a
gas filter alternating between CO and N2. The radiation then passes
through a narrow bandpass interference filter and enters the optical bench
where absorption by the sample gas occurs. The infrared radiation then
exits the optical bench and falls on an infrared detector.
The CO gas filter acts to produce a reference beam, which cannot be
further attenuated by CO in the sample cell. The N2 side of the filter wheel
is transparent to the infrared radiation and therefore produces a
measurement beam, which can be absorbed by CO in the cell. The
chopped detector signal is modulated by the alternation between the two
gas filters with an amplitude related to the concentration of CO in the
sample cell. Other gases do not cause modulation of the detector signal
since they absorb the reference and measure beams equally. Thus, the GFC
system responds specifically to CO.
The Model 48i outputs the CO concentration to the front panel display,
the analog outputs, and also makes the data available over the serial or
Ethernet connection.
1-2 Model 48i Instruction Manual Thermo Fisher Scientific
Introduction
Specifications
Specifications
Figure 1–1. Model 48i Flow Schematic
Table 1–1 lists the specifications for the Model 48i.
Table 1–1. Model 48i Specifications
Preset ranges 0-1, 2, 5, 10, 20, 50, 100, 200, 500, 1000, 2000, 5000, 10000
(ppm or mg/m
Custom ranges 0-1 to 10000 (ppm or mg/m
Zero noise 0.02 ppm RMS (30 second averaging time)
Lower detectable limit 0.04 ppm
Zero drift (24 hour) <0.1 ppm
Span drift ±1% full-scale
Response time 60 seconds (30 second averaging time)
Linearity ±1% full-scale ≤ 1000 ppm
±2.5% full-scale > 1000 ppm
3
)
3
)
Sample flow rate 1.0 L/min
Thermo Fisher Scientific Model 48i Instruction Manual 1-3
Introduction
Specifications
Operating temperature 20–
Power requirements
30 °C (may be safely operated over the range of 0–45 °C)*
100 VAC @ 50/60 Hz
115 VAC @ 50/60 Hz
220–240 VAC @ 50/60 Hz
275 watts
Physical dimensions 16.75” (W) X 8.62” (H) X 23” (D)
Weight Approximately 49 lbs.
Analog outputs 6 voltage outputs; 0–100 mV, 1, 5, 10 V (user selectable), 5% of
full-scale over/under range (user selectable), 12 bit resolution,
measurement output user selectable per channel
Digital outputs 1 power fail relay Form C, 10 digital relays Form A, user
selectable alarm output, relay logic, 100 mA @ 200 VDC
Digital inputs 16 digital inputs, user select programmable, TTL level, pulled
high
Serial Ports 1 RS-232 or RS-485 with two connectors, baud rate 1200–
115200, data bits, parity, and stop bits, protocols: C-Link,
MODBUS, Gesytec (Bayern-Hessen), and streaming data (all
user selectable)
Ethernet connection RJ45 connector for 10Mbs Ethernet connection, static or
dynamic TCP/IP addressing
*In non-condensing environments. Performance specifications based on operation with 20–30 °C range.
Table 1–2. Model 48i Optional Internal Oxygen Sensor Specifications
Technology Paramagnetic (Pm)
Range 0-100% O
2
Accuracy (Intrinsic error) <±0.1% O2
Linearity <±0.1% O2
Repeatability <±0.1% O2
Zero Drift <±0.2% O2 per month (excludes up to 0.1% O2 in the first 24
hours of operation)
Response Time (T10-T90) <2.5 seconds
Weight Approximately 2 lbs. (in addition to standard instrument)
1-4 Model 48i Instruction Manual Thermo Fisher Scientific
Chapter 2
Installation
Installation of the Model 48i includes lifting the instrument, unpacking
and inspection, connecting sample, zero, span, and exhaust lines, and
attaching the analog and/or digital outputs to a recording device. The
installation should always be followed by instrument calibration as
described in the “Calibration” chapter of this manual.
Installing the Model 48i includes the following recommendations and
procedures:
● “Lifting” on page 2-1
Lifting
Unpacking and
Inspection
● “Unpacking and Inspection” on page 2-1
● “Setup Procedure” on page 2-3
● “Connecting External Devices” on page 2-5
● “Startup” on page 2-9
When lifting the instrument, use procedure appropriate to lifting a heavy
object, such as bending at the knees while keeping your back straight and
upright. Grasp the instrument at the bottom in the front and at the rear of
the unit. Although one person can lift the unit, it is desirable to have two
persons lifting, one by grasping the bottom in the front and the other by
grasping the bottom in the rear.
Equipment Damage Do not attempt to lift the instrument by the cover or
other external fittings.
The Model 48i is shipped complete in one container. If there is obvious
damage to the shipping container when you receive the instrument, notify
the carrier immediately and hold for inspection. The carrier is responsible
for any damage incurred during shipment.
▲
Use the following procedure to unpack and inspect the instrument.
1. Remove the instrument from the shipping container and set it on a
table or bench that allows easy access to both the front and rear.
Thermo Fisher Scientific Model 48i Instruction Manual 2-1
Installation
Unpacking and Inspection
2. Remove the cover to expose the internal components.
3. Remove the packing material (Figure 2–1).
Remove Packing
(2 pieces)
Remove Packing
(2 pieces)
Units without Optional I/O Board Units with Optional I/O Board
Figure 2–1. Remove the Packing Material
4. Remove the three shipping screws (Figure 2–2).
Shipping Screws (3)
Figure 2–2. Removing the Shipping Screws
2-2 Model 48i Instruction Manual Thermo Fisher Scientific
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