Thermo Scientific 48iQ User manual

48iQ
Instruction Manual
Carbon Monoxide Analyzer
117080-00 • 1Sep2019

Thermo Scientific 48iQ Instruction Manual iii
Contents
Introduction........................................................................................................ 1-1
iQ Series Instrument Platform............................................................. 1-1
48iQ 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 ................................................................................................ 2-9
Operation ............................................................................................................ 3-1
Instrument Display ............................................................................. 3-1
Main Menus and Keypads................................................................ 3-5
Numeric Keypad........................................................................... 3-6
Alphanumeric Keypad................................................................... 3-7
Calibration.......................................................................................... 3-9
Calibrate Background..................................................................... 3-11
Calibrate Span Coefficient ............................................................. 3-12
Zero/Span Schedule ....................................................................... 3-14
Calibrate O2Span Coefficient ........................................................ 3-16
Advanced Calibration..................................................................... 3-17
Manual Calibration..................................................................... 3-19
Multipoint Calibration................................................................ 3-24
Manual O2Calibration ............................................................... 3-27
2-Point O2Calibration................................................................ 3-29
Calibration History ..................................................................... 3-31
Data.................................................................................................. 3-32
View Data Log (Last Hour)............................................................ 3-33
View Data Log (Last 24 Hours) ..................................................... 3-34
View Data Log (User Defined Time) ............................................. 3-35
Advanced Data Setup..................................................................... 3-37
Data Logging Setup .................................................................... 3-38
Select Data Logging Variables ..................................................... 3-39
Chapter 1
Chapter 2
Chapter 3

Contents
iv 48iQ Instruction Manual Thermo Scientific
Streaming Data Setup ................................................................. 3-40
Select Streaming Variables........................................................... 3-41
Settings ............................................................................................. 3-42
Health Check................................................................................. 3-43
Status and Alarms........................................................................ 3-44
Concentration............................................................................. 3-45
NDIR Bench............................................................................... 3-47
O2Sensor.................................................................................... 3-50
Flow and Pressure ....................................................................... 3-52
Peripherals Support..................................................................... 3-54
Valve and Pump Resets ............................................................... 3-56
Serial Numbers ........................................................................... 3-61
Predictive Diagnostics ................................................................. 3-62
Maintenance ............................................................................... 3-63
Preventive Maintenance .............................................................. 3-64
Change Part ................................................................................ 3-66
Maintenance History................................................................... 3-67
File Sharing and Support............................................................. 3-68
iQ360 ......................................................................................... 3-69
Measurement Settings .................................................................... 3-72
Averaging Time........................................................................... 3-74
Range Mode Selection................................................................. 3-76
Range Setting.............................................................................. 3-78
Gas Mode ................................................................................... 3-79
Gas Units.................................................................................... 3-80
Advanced Measurement Settings ................................................. 3-81
Communications ........................................................................... 3-89
Wired TCP/DHCP .................................................................... 3-91
Serial RS-232/485....................................................................... 3-93
Analog I/O.................................................................................. 3-94
Digital I/O.................................................................................. 3-95
Email Server (SMTP).................................................................. 3-96
Bayern Hessen Settings ............................................................... 3-97
Instrument Settings........................................................................ 3-99
Display Setup............................................................................ 3-100
Alarm Setpoints......................................................................... 3-101
Clock ........................................................................................ 3-104
Time Zone................................................................................ 3-108
Configuration .............................................................................. 3-111
Security Access Levels................................................................... 3-112
Change Security to View Only Access ....................................... 3-114
Change Full Access Security Password....................................... 3-115
USB Drive ................................................................................... 3-117
Firmware Update Via USB Drive.............................................. 3-118
Download Data To USB Drive................................................. 3-119
Change USB Password.............................................................. 3-122

Contents
Thermo Scientific 48iQ Instruction Manual v
User Contact Information............................................................ 3-124
Update Bootloader....................................................................... 3-125
Calibration.......................................................................................................... 4-1
Equipment Required........................................................................... 4-1
CO Concentration 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
References ......................................................................................... 4-16
Maintenance...................................................................................................... 5-1
Safety Precautions ............................................................................... 5-1
Fan Filter Inspection and Cleaning ..................................................... 5-1
Pump Rebuilding................................................................................ 5-2
Leak Test ............................................................................................ 5-5
Cleaning the Optics ............................................................................ 5-6
IR Source Replacement ....................................................................... 5-8
Troubleshooting ................................................................................................ 6-1
Safety Precautions ............................................................................... 6-1
Troubleshooting Guide....................................................................... 6-1
Chapter 4
Chapter 5
Chapter 6

Contents
vi 48iQ Instruction Manual Thermo Scientific
Servicing.............................................................................................................7-1
Safety Precautions ............................................................................... 7-1
Firmware Updates............................................................................... 7-3
Replacement Parts List ........................................................................ 7-3
Fuse Replacement ............................................................................... 7-5
Filter Replacement .............................................................................. 7-6
Fan Replacement................................................................................. 7-7
Measurement Side Removal ................................................................ 7-9
LCD Module Replacement ............................................................... 7-12
I/O Replacement............................................................................... 7-14
Peripherals Support Board and System Controller Board
Replacement ..................................................................................... 7-16
DMC Pressure and Flow Board ........................................................ 7-17
Pump Replacement ........................................................................... 7-19
Capillary Cleaning and/or Replacement ............................................ 7-22
Capillary O-Ring Replacement ......................................................... 7-24
Power Supply Replacement............................................................... 7-24
Step POL Board Replacement........................................................... 7-26
DMC Optical Bench......................................................................... 7-29
Optical Bench Removal ................................................................. 7-30
Optical Switch Replacement .......................................................... 7-31
Purge Wheel Housing Removal...................................................... 7-34
Filter Wheel Replacement .............................................................. 7-35
Motor Replacement ....................................................................... 7-37
Motor and Filter Wheel Alignment................................................ 7-39
Optical Bench/Heater Removal...................................................... 7-41
Pre-Amp/Detector Assembly Removal ........................................... 7-43
IR Source Replacement .................................................................. 7-45
Optional Manifold Replacement....................................................... 7-48
Optional Zero Air Scrubber Replacement ......................................... 7-50
Optional DMC Oxygen Sensor......................................................... 7-51
Oxygen Sensor Removal................................................................. 7-51
Oxygen Sensor Board Replacement................................................ 7-54
Oxygen Sensor Capillary Replacement ........................................... 7-56
Oxygen Sensor Replacement .......................................................... 7-58
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.............................................................................. 8-3
Infrared Source................................................................................. 8-3
Chapter 7
Chapter 8

Contents
Thermo Scientific 48iQ Instruction Manual vii
Optical Bench DMC Board ............................................................. 8-3
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
Fan................................................................................................... 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
Internal Zero Air Scrubber ................................................................ 9-18
PTFE Particulate Filter ..................................................................... 9-18
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
Chapter 9
Appendix A
Appendix B

Contents
viii 48iQ Instruction Manual Thermo Scientific
List of Tables.......................................................................................B-3
GNU Lesser General Public License............................................................ C-1
GNU Lesser General Public License................................................... C-1
Appendix C

Thermo Scientific 48iQ Instruction Manual 1-1
Chapter 1
Introduction
The Thermo Scientific™ 48iQ Carbon Monoxide (CO) Analyzer utilizes
gas filter correlation technology to measure the amount of carbon
monoxide in the air.
The analyzer is based on the principle that carbon monoxide (CO) absorbs
infrared radiation at a wavelength of 4.6 microns. Because infrared
absorption is a nonlinear measurement technique, it is necessary for the
instrument electronics to transform the basic analyzer signal into a linear
output.
The 48iQ Gas Analyzer uses an exact calibration curve to accurately
linearize the instrument output over any range up to a concentration of
10,000 ppm.
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.
iQ Series
Instrument
Platform

Introduction
iQ Series Instrument Platform
1-2 48iQ Instruction Manual Thermo Scientific
●The iQ Series GUI runs on a 7” color touchscreen display. The
GUI is highly flexible and can be customized to enable a tailored
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. 48iQ Front

Introduction
48iQ Principle of Operation
Thermo Scientific 48iQ Instruction Manual 1-3
The 48iQ operates on the principle that carbon monoxide (CO) absorbs
infrared radiation at a wavelength of 4.6 microns. Gas Filter Correlation
(GFC) is a particular infrared technique that selectively measures light
absorption uniquely due to CO by the ratio of sample-absorbed light to a
filtered reference measurement. Light from a broadband infrared source
passes through a gas filter wheel alternating between N2and CO filled cells
and passes through a narrow bandpass interference filter before passing into
the volume containing sample gas. Light that passes through the N2cell is
absorbed by CO in the sample gas normally as the sample signal; light that
passes through the CO cell is already blocked where CO absorbs, and so is
unchanged by sample CO as the reference. The ratio of “sample” to
“reference” (S/R) is acquired at high speeds and corrects for light intensity
and other changes to achieve precision measurement. Because the filtering
is achieved with CO gas itself, the GFC technique is specific for CO.
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 48iQ uses an internally stored calibration curve
to accurately linearize the instrument output over any range up to a
concentration of 10,000 ppm.
Gas sample is drawn into the 48iQ through the rear panel of the analyzer
and through the optical detection system 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 connected 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 to the inlet configuration, options may be added, such as an
oxygen sensor or a “zero scrubber” that catalyzes CO to CO2to provide a
zero reference. Each of these operate within the basic gas intake pathway
described above.
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 48 DMC Bench where CO is 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 there is also
a filter purge that bypasses the sampling but is also drawn by the pump
downstream of the constriction. Figure 1–3 shows the example of a three
inlet configuration with zero span capabilities and a zero air scrubber.
48iQ Principle of
Operation

Introduction
48iQ Principle of Operation
1-4 48iQ Instruction Manual Thermo Scientific
Figure 1–2. 48iQ Flow Schematic
Figure 1–3. 48iQ Flow Schematic with Zero Span and Zero Air Scrubber

Introduction
Specifications
Thermo Scientific 48iQ Instruction Manual 1-5
Table 1–1 lists the specifications for the 48iQ.
Table 1–1. 48iQ Specifications
Range 0-10000 (ppm or mg/m3)
Zero Noise 0.02 ppm RMS (30 second averaging time)
Detection Limit 0.04 ppm (30 second averaging time)
Zero Drift <0.1 ppm (24 hour)
Span Drift ±0.5% reading (24 hour)
Response Time 60 seconds (30 second averaging time)
Linearity ±1% full-scale ≤ 1000 ppm
±2.5% full-scale > 1000 ppm
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 34.3 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, EPA
Specifications

Introduction
Specifications
1-6 48iQ Instruction Manual Thermo Scientific
Table 1–2. 48iQ 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 48iQ Instruction Manual 1-7
Figure 1–4. Bench Mount Assembly (dimensions in inches [mm])
Dimensions

Introduction
Dimensions
1-8 48iQ Instruction Manual Thermo Scientific
Figure 1–5. Rack Mount Assembly (dimensions in inches [mm])

Introduction
Dimensions
Thermo Scientific 48iQ Instruction Manual 1-9
Figure 1–6. Rack Mount Requirements
Figure 1–7. Rack Requirements Part 2

Thermo Scientific 48iQ 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 48iQ 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 48iQ 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