Thermo Scientific 410iQ User manual

410iQ
Instruction Manual
Carbon Dioxide Analyzer
117081-00 • 1Apr2020

Thermo Scientific 410iQ Instruction Manual iii
Contents
Introduction........................................................................................................ 1-1
iQ Series Instrument Platform............................................................. 1-1
410iQ Principle of Operation ............................................................. 1-3
Specifications ...................................................................................... 1-5
Dimensions......................................................................................... 1-7
Installation and Setup...................................................................................... 2-1
Unpacking and Inspection .................................................................. 2-1
Cover Removing and Replacing .......................................................... 2-2
Mounting Options.............................................................................. 2-3
Bench Mount................................................................................... 2-3
Rack Mount..................................................................................... 2-4
Setup Procedure .................................................................................. 2-6
Startup ................................................................................................ 2-8
Operation ............................................................................................................ 3-1
Instrument Display ............................................................................. 3-1
Main Menus and Keypads................................................................ 3-6
Numeric Keypad........................................................................... 3-7
Alphanumeric Keypad................................................................... 3-8
Calibration........................................................................................ 3-10
Calibrate Background..................................................................... 3-12
Calibrate Span Coefficient ............................................................. 3-13
Zero/Span Schedule ....................................................................... 3-15
Calibrate O2Span Coefficient ........................................................ 3-17
Advanced Calibration..................................................................... 3-18
Manual Calibration..................................................................... 3-20
Multipoint Calibration................................................................ 3-25
Manual O2Calibration ............................................................... 3-28
2-Point O2Calibration................................................................ 3-30
Calibration History ..................................................................... 3-32
Data.................................................................................................. 3-33
View Data Log (Last Hour)............................................................ 3-34
View Data Log (Last 24 Hours) ..................................................... 3-35
View Data Log (User Defined Time) ............................................. 3-36
Advanced Data............................................................................... 3-38
Data Logging Setup .................................................................... 3-39
Select Data Logging Variables ..................................................... 3-40
Chapter 1
Chapter 2
Chapter 3

Contents
iv 410iQ Instruction Manual Thermo Scientific
Streaming Data Setup ................................................................. 3-41
Select Streaming Variables........................................................... 3-42
Settings ............................................................................................. 3-43
Health Check................................................................................. 3-44
Status and Alarms........................................................................ 3-45
Concentration............................................................................. 3-46
NDIR Bench............................................................................... 3-48
Flow and Pressure ....................................................................... 3-53
Peripherals Support..................................................................... 3-55
Valve and Pump Resets ............................................................... 3-57
Serial Numbers ........................................................................... 3-62
Predictive Diagnostics ................................................................. 3-63
Maintenance ............................................................................... 3-64
Preventive Maintenance .............................................................. 3-65
Change Part ................................................................................ 3-67
Maintenance History................................................................... 3-68
File Sharing and Support............................................................. 3-69
iQ360 ......................................................................................... 3-70
Measurement Settings .................................................................... 3-73
Averaging Time........................................................................... 3-75
Range Mode Selection................................................................. 3-77
Range Setting.............................................................................. 3-79
Gas Mode ................................................................................... 3-80
Gas Units.................................................................................... 3-81
Advanced Measurement Settings ................................................. 3-82
Communications ........................................................................... 3-90
Wired TCP/DHCP .................................................................... 3-92
Serial RS-232/485....................................................................... 3-94
Analog I/O.................................................................................. 3-95
Digital I/O.................................................................................. 3-96
Email Server (SMTP).................................................................. 3-97
Bayern Hessen Settings ............................................................... 3-98
Ethernet Protocol Selection......................................................... 3-99
Instrument Settings...................................................................... 3-100
Display Setup............................................................................ 3-101
Alarm Setpoints......................................................................... 3-102
Clock ........................................................................................ 3-105
Time Zone................................................................................ 3-109
Configuration .............................................................................. 3-112
Security Access Levels................................................................... 3-113
Change Security to View Only Access ....................................... 3-115
Change Full Access Security Password....................................... 3-116
Change Instrument Password.................................................... 3-118
Reset Instrument Password ....................................................... 3-120
USB Drive ................................................................................... 3-121
Firmware Update Via USB Drive.............................................. 3-122

Contents
Thermo Scientific 410iQ Instruction Manual v
Download Data To USB Drive................................................. 3-126
Change USB Password.............................................................. 3-129
Reset USB Password.................................................................. 3-131
User Contact Information............................................................ 3-132
Update Bootloader....................................................................... 3-133
Calibration.......................................................................................................... 4-1
Equipment Required........................................................................... 4-1
CO2Concentration Standard........................................................... 4-1
Zero Air Generator........................................................................... 4-1
External Flow Meter(s) and Controller(s)......................................... 4-2
Pre-Calibration ................................................................................... 4-2
Calibration.......................................................................................... 4-3
Connect the Instrument................................................................... 4-3
Detector Gain .................................................................................. 4-4
Initial S/R ........................................................................................ 4-5
Multipoint Calibration..................................................................... 4-6
High and Low Multipoint Calibration............................................. 4-8
Calibration Frequency...................................................................... 4-8
Calibrate Background....................................................................... 4-9
Calibrate Span Coefficient ............................................................. 4-10
Periodic Zero and Span Checks......................................................... 4-12
Manual Calibration........................................................................... 4-13
Adjust Background......................................................................... 4-13
Adjust Span Coefficient.................................................................. 4-14
Reset Bkg to 0.000 and Span Coef to 1.000................................... 4-14
Zero/Span Schedule .......................................................................... 4-15
Next Time ..................................................................................... 4-15
Period ............................................................................................ 4-15
Zero/Span/Purge Duration Minutes .............................................. 4-15
Schedule Averaging Time............................................................... 4-16
Background Calibration and Span Calibration............................... 4-16
Zero Calibration and Span Calibration .......................................... 4-16
Zero/Span Ratio............................................................................. 4-16
Maintenance...................................................................................................... 5-1
Safety Precautions ............................................................................... 5-1
Fan Filter Inspection and Cleaning ..................................................... 5-1
Pump Rebuilding................................................................................ 5-2
Leak Test ............................................................................................ 5-5
IR Source Replacement ....................................................................... 5-6
Troubleshooting ................................................................................................ 6-1
Safety Precautions ............................................................................... 6-1
Troubleshooting Guide....................................................................... 6-1
Chapter 4
Chapter 5
Chapter 6

Contents
vi 410iQ Instruction Manual Thermo Scientific
Servicing.............................................................................................................7-1
Safety Precautions ............................................................................... 7-1
Firmware Updates............................................................................... 7-3
Replacement Parts List ........................................................................ 7-3
Fuse Replacement ............................................................................... 7-6
Filter Replacement .............................................................................. 7-7
Fan Replacement................................................................................. 7-8
Measurement Side Removal .............................................................. 7-10
LCD Module Replacement ............................................................... 7-14
I/O Replacement............................................................................... 7-16
Peripherals Support Board and System Controller Board
Replacement ..................................................................................... 7-18
DMC Pressure and Flow Board ........................................................ 7-19
Pump Replacement ........................................................................... 7-21
Capillary Cleaning and/or Replacement ............................................ 7-24
Capillary O-Ring Replacement ......................................................... 7-26
Power Supply Replacement............................................................... 7-26
Step POL Board Replacement........................................................... 7-28
DMC Optical Bench......................................................................... 7-31
Optical Bench Removal ................................................................. 7-33
Optical Switch Replacement .......................................................... 7-35
Purge Wheel Housing Removal...................................................... 7-40
Filter Wheel Replacement .............................................................. 7-42
Motor Replacement ....................................................................... 7-44
Motor and Filter Wheel Alignment................................................ 7-46
Optical Bench Heater Removal...................................................... 7-48
Pre-Amp/Detector Assembly Removal ........................................... 7-51
IR Source Replacement .................................................................. 7-54
Optional Manifold Replacement....................................................... 7-57
Optional DMC Oxygen Sensor......................................................... 7-59
Oxygen Sensor Removal................................................................. 7-59
Oxygen Sensor Board Replacement................................................ 7-62
Oxygen Sensor Capillary Replacement ........................................... 7-64
Oxygen Sensor Replacement .......................................................... 7-66
System Description...........................................................................................8-1
Optical Bench DMC........................................................................... 8-2
Optical Bench Hardware.................................................................. 8-2
Filter Wheel Motor .......................................................................... 8-2
Filter Wheel Purge ........................................................................ 8-2
Detector Preamp.............................................................................. 8-4
Infrared Source................................................................................. 8-4
Optical Bench DMC Board ............................................................. 8-4
Chapter 7
Chapter 8

Contents
Thermo Scientific 410iQ Instruction Manual vii
Common Electronics .......................................................................... 8-4
Power Supply ................................................................................... 8-7
Front Panel ...................................................................................... 8-7
I/O and Communication Components ............................................ 8-7
System Controller Board .................................................................. 8-7
Backplane Board .............................................................................. 8-7
Peripherals Support System................................................................. 8-8
Step POL Board............................................................................... 8-8
Sample Pump................................................................................... 8-8
Solenoid Valve Panel (optional) ....................................................... 8-8
Flow/Pressure DMC ........................................................................... 8-8
Firmware............................................................................................. 8-8
Oxygen Sensor (optional).................................................................... 8-9
Optional Equipment .......................................................................................... 9-1
Connecting External Devices .............................................................. 9-1
Communication Board .................................................................... 9-2
RS-232/RS-485 Port..................................................................... 9-2
RS-485 External Accessory Port .................................................... 9-3
Analog I/O Board ............................................................................ 9-4
Analog Voltage Inputs................................................................... 9-4
Analog Voltage Outputs................................................................ 9-5
Analog Output Calibration .............................................................. 9-6
Analog Output Zero Calibration................................................... 9-7
Analog Output Full Scale Calibration ........................................... 9-9
Digital I/O Board........................................................................... 9-11
Digital Inputs.............................................................................. 9-11
Digital Relay Switches................................................................. 9-13
Valve Driver Outputs.................................................................. 9-15
Internal Zero/Span Assembly ............................................................ 9-17
Internal Oxygen (O2) Sensor............................................................. 9-18
PTFE Particulate Filter ..................................................................... 9-19
Safety, Warranty, and WEEE.......................................................................... A-1
Safety ..................................................................................................A-1
Safety and Equipment Damage Alerts ..............................................A-1
Warranty.............................................................................................A-2
WEEE Compliance.............................................................................A-4
WEEE Symbol.................................................................................A-4
Quick Reference .............................................................................................. B-1
List of Figures .....................................................................................B-1
List of Tables.......................................................................................B-4
Chapter 9
Appendix A
Appendix B

Contents
viii 410iQ Instruction Manual Thermo Scientific
GNU Lesser General Public License............................................................ C-1
GNU Lesser General Public License................................................... C-1
Appendix C

Thermo Scientific 410iQ Instruction Manual 1-1
Chapter 1
Introduction
The Thermo Scientific™ 410iQ Carbon Dioxide (CO2) Analyzer utilizes
advanced Non-Dispersive Infrared (NDIR) optical filter technology to
measure concentration of CO2. The 410iQ is available in Standard or High
Level.
The 410iQ Standard Analyzer uses an internally stored calibration curve to
accurately linearize the instrument output over any range up to a
concentration of 10,000 ppm.
The 410iQ High Level Analyzer uses an internally stored calibration curve
to accurately linearize the instrument output over any range up to a
concentration of 25% by volume.
The iQ Series Instrument Platform is a smart environmental monitoring
solution for ambient and source gas analysis that affords greater control
over instrument performance and data availability.
●Distributed Measurement and Control (DMC) module design
simplifies serviceability. Each DMC module contains its own
microprocessor control enabling functional performance validation
at the module level.
●Built-in predictive diagnostics and preventive maintenance
schedules identify problems before they occur. The iQ Series
platform sends email notifications directly to Thermo Fisher
Scientific’s world class service support team or locally identified
addressees in order to proactively communicate analyzer
performance conditions and identify spare parts needs before an
operational concern arises.
●The iQ Series platform supports Modbus, streaming and VNC
protocols over serial and Ethernet as well as analog and digital I/O
for easy integration into most data management systems.
●Three standard USB ports afford convenient data download
capability as well as the ability to connect additional hardware, such
as a computer keyboard or mouse.
●The iQ Series GUI runs on a 7” color touchscreen display. The
GUI is highly flexible and can be customized to enable a tailored
iQ Series
Instrument
Platform

Introduction
iQ Series Instrument Platform
1-2 410iQ Instruction Manual Thermo Scientific
experience to simplify daily operations. Custom designed ePort
software allows remote access to the analyzer with a PC. The ePort
control mirrors the same GUI look and feel as the instrument
touchscreen providing a speedy and familiar operational experience.
Figure 1–1. 410iQ Front

Introduction
410iQ Principle of Operation
Thermo Scientific 410iQ Instruction Manual 1-3
The 410iQ operates on the principle that carbon dioxide (CO2) absorbs
infrared radiation at a wavelength of 4.2 microns. Interference filters are
selected to measure specifically: 1) the 4.2 micron region where CO2
strongly absorbs (the sample measurement); and 2) a nearby non-absorbing
wavelength where there is no absorbance by CO2or other interfering gases
(the reference measurement). Coupled with a broadband light source, the
filters are arranged within a rotating filter wheel assembly so that sample
and reference filtered light passes through a sampling volume (the “optical
bench”) and are then detected. Where CO2is present in the sample
volume, the sample light will be absorbed and attenuated, while the
reference light is unchanged. The ratio of sample light to reference light
(“S/R”) is acquired at high speeds and corrects for light intensity and other
changes to achieve a precision measurement.
The so-called “spectral resolution” of the technique is such that the
measured ratio is partly but not strictly linear as predicted by the well-
known “Beer’s Law.” The 410iQ uses an internally stored calibration curve
to accurately linearize the instrument output over any range up to a
concentration of 10,000 ppm (Standard) or 25% (High Level).
Gas sample is drawn into the 410iQ through the rear panel of the analyzer
and through the optical bench using an embedded intake pump, as shown
in Figure 1–2. Gas may be ambient, or it may be delivered from a more
distant location using standard tubing delivered to the rear panel. The rear
panel may be a simple inlet bulkhead, or it could utilize three inlets
controlled with solenoid valves: Conventionally, the three inlet
configuration is used to conduct independent zero and span reference
measurements.
In addition, the 410iQ also has a bulkhead port for introducing CO2free
air or N2to purge the housing that contains the light source and filter
wheel – this filter wheel purge feature is necessary to remove interfering
CO2absorption due to ambient air, which carries CO2concentration close
to 400 ppm.
Figure 1–2 shows the simplest case fluid schematic. Gas is introduced into
the “SAMPLE” port at near ambient pressures (we describe a flow bypass
later on that assures ambient pressure sampling). It is pulled by a single
stage pump through the 410iQ Bench DMC where CO2is detected and
then through a constriction (a capillary in the “Flow Pressure DMC”)
which regulates the flow intake to approximately 1 SLPM while
monitoring and maintaining ambient pressure on the optical bench side.
Note also the filter purge for CO2-free gas to be also introduced from the
rear panel. Figure 1–3 shows the example of a three inlet configuration
associated with the zero span valve option.
410iQ Principle
of Operation

Introduction
410iQ Principle of Operation
1-4 410iQ Instruction Manual Thermo Scientific
Figure 1–2. 410iQ Flow Schematic
Figure 1–3. 410iQ Flow Schematic with Zero Span

Introduction
Specifications
Thermo Scientific 410iQ Instruction Manual 1-5
Table 1–1 lists the specifications for the 410iQ.
Table 1–1. 410iQ Specifications
Range Standard: 0—10,000 ppm
High Level: 0—250,000 ppm or 25%
Zero Noise Standard: 0.5 ppm RMS (60 second averaging time)
High Level: .20 ppm RMS (60 second averaging time)
Detection Limit Standard: 1 ppm (60 second averaging time)
High Level: 40 ppm (60 second averaging time)
Zero Drift (24 hours) Standard: ±1 ppm
High Level: ±40 ppm
Span Drift ±2% of reading (24 hours)
Response Time 90 seconds (30 second averaging time)
Linearity ±1.5% of span (at concentrations of 10 to 100% of span)
Flow Rate 1.0 SLPM (1 atm inlet pressure)
Operating Temperature Range 5–45 °C (may be safely operated over the range of 0–45 °C)
Power Requirements
100–240 VAC 50/60 Hz
275 Watts
Physical Dimensions 24 in (D) x 16.75 in (W) x 8.72 in (H) [609 mm (D) 425.45 mm
(W) x 221.48 mm (H)]
Weight Standard: 31.3 lbs
High Level: 30.1 lbs
Analog I/O 4 Isolated Voltage Inputs 0–10 V
6 Isolated Analog Voltages Outputs, with 4 selectable
ranges
6 Isolated Analog Current Outputs, with 2 selectable ranges
Digital I/O 16 Digital Inputs (TTL)
8 Solenoid Driver Outputs
10 Digital Reed Relay Contact Outputs
Serial Ports 1 RS-232/485 port
1 RS-485 External Accessory port
Other Ports 3 Full Speed USB ports (one in front, two in rear)
1 Gigabit Ethernet port
Communication Protocols MODBUS, Streaming, Bayern Hessen
Approvals and Certifications CE, TUV-SUD Safety
Specifications

Introduction
Specifications
1-6 410iQ Instruction Manual Thermo Scientific
Table 1–2. 410iQ Optional Internal Oxygen Sensor Specifications
Technology Paramagnetic
Range 0-100% O2
Accuracy (Intrinsic error) <±0.1% O2
Linearity <±0.1% O2
Repeatability <±0.1% O2
Zero Drift <±0.2% O2per month (excludes up to 0.1% O2in the first 24
hours of operation)
Response Time (T10-T90) <2.5 seconds
Weight Approximately 2 lbs. (in addition to standard instrument)

Introduction
Dimensions
Thermo Scientific 410iQ Instruction Manual 1-7
Figure 1–4. Bench Mount Assembly (dimensions in inches [mm])
Dimensions

Introduction
Dimensions
1-8 410iQ Instruction Manual Thermo Scientific
Figure 1–5. Rack Mount Assembly (dimensions in inches [mm])

Introduction
Dimensions
Thermo Scientific 410iQ Instruction Manual 1-9
Figure 1–6. Rack Mount Requirements
Figure 1–7. Rack Requirements Part 2

Thermo Scientific 410iQ Instruction Manual 2-1
Chapter 2
Installation and Setup
Installation and Setup describes how to unpack, setup, and start-up the
instrument. The installation should always be followed by instrument
calibration as described in the “Calibration” chapter of this manual.
Equipment Damage Do not attempt to lift the instrument by the cover or
other external fittings. ▲
The 410iQ 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.
2. Remove the cover to expose the internal components. (See “Figure 2–
1” on page 2-2.)
3. Check for possible damage during shipment.
4. Check that all connectors and circuit boards are firmly attached.
5. Re-install the cover.
6. Remove any protective plastic material from the case exterior.
Unpacking and
Inspection

Installation and Setup
Cover Removing and Replacing
2-2 410iQ Instruction Manual Thermo Scientific
Use the following procedure to remove and replace the cover.
Equipment required:
Phillips screwdriver, #2
1. Unfasten the four 8-32 screws securing the cover (shipping screws).
2. Press in both latches located on top cover and hold while pulling up to
remove. Set upright.
Figure 2–1. Removing the Cover
3. To replace, align cover and drop in. Latches will automatically snap in
place.
Cover Removing
and Replacing