Thermo Scientific 48iQTL User manual

48iQTL
Instruction Manual
Trace Level Carbon Monoxide Analyzer
119014-00 • 27Sep2018

Thermo Scientific 48iQTL Instruction Manual iii
Contents
Introduction........................................................................................................ 1-1
iQ Series Instrument Platform............................................................. 1-1
48iQTL Principle of Operation .......................................................... 1-3
Specifications ...................................................................................... 1-5
Dimensions......................................................................................... 1-6
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................................................................ 3-5
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
Advanced Calibration..................................................................... 3-16
Manual Calibration..................................................................... 3-18
Multipoint Calibration................................................................ 3-23
Calibration History ..................................................................... 3-26
Data.................................................................................................. 3-27
View Data Log (Last Hour)............................................................ 3-28
View Data Log (Last 24 Hours) ..................................................... 3-29
View Data Log (User Defined Time) ............................................. 3-30
Advanced Data Setup..................................................................... 3-32
Data Logging Setup .................................................................... 3-33
Select Data Logging Variables ..................................................... 3-34
Streaming Data Setup ................................................................. 3-35
Select Streaming Variables........................................................... 3-36
Settings ............................................................................................. 3-37
Chapter 1
Chapter 2
Chapter 3

Contents
iv 48iQTL Instruction Manual Thermo Scientific
Health Check................................................................................. 3-38
Status and Alarms........................................................................ 3-39
Concentration............................................................................. 3-40
NDIR Bench............................................................................... 3-42
Flow and Pressure ....................................................................... 3-45
Peripherals Support..................................................................... 3-47
Valve and Pump Resets ............................................................... 3-49
Serial Numbers ........................................................................... 3-54
Predictive Diagnostics ................................................................. 3-55
Maintenance ............................................................................... 3-56
Preventive Maintenance .............................................................. 3-57
Change Part ................................................................................ 3-59
Maintenance History................................................................... 3-60
File Sharing and Support............................................................. 3-61
iQ360 ......................................................................................... 3-62
Measurement Settings .................................................................... 3-65
Averaging Time........................................................................... 3-67
Range Mode Selection................................................................. 3-69
Range Setting.............................................................................. 3-71
Gas Mode ................................................................................... 3-72
Gas Units.................................................................................... 3-73
Advanced Measurement Settings ................................................. 3-74
Communications ........................................................................... 3-83
Wired TCP/DHCP .................................................................... 3-85
Serial RS-232/485....................................................................... 3-87
Analog I/O.................................................................................. 3-88
Digital I/O.................................................................................. 3-89
Email Server (SMTP).................................................................. 3-90
Bayern Hessen Settings ............................................................... 3-91
Instrument Settings........................................................................ 3-93
Display Setup.............................................................................. 3-94
Alarm Setpoints........................................................................... 3-95
Clock .......................................................................................... 3-97
Date / Time Parameters .............................................................. 3-98
Time Zone.................................................................................. 3-99
Time Server............................................................................... 3-101
Date Format.............................................................................. 3-102
Configuration .............................................................................. 3-103
Security Access Levels................................................................... 3-104
Change Security to View Only Access ....................................... 3-106
Change Full Access Security Password....................................... 3-107
USB Drive ................................................................................... 3-109
Firmware Update Via USB Drive.............................................. 3-110
Download Data To USB Drive................................................. 3-111
Change USB Password.............................................................. 3-114
User Contact Information............................................................ 3-116

Contents
Thermo Scientific 48iQTL Instruction Manual v
Update Bootloader....................................................................... 3-117
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
Servicing............................................................................................................. 7-1
Chapter 4
Chapter 5
Chapter 6
Chapter 7

Contents
vi 48iQTL Instruction Manual Thermo Scientific
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
Heater Assembly ............................................................................... 7-47
Heater Assembly Removal.............................................................. 7-47
Heater Assembly Install.................................................................. 7-50
Sample/Zero Valve Replacement....................................................... 7-52
Optional Manifold Replacement....................................................... 7-55
Zero Air Scrubber Replacement ........................................................ 7-57
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
CO Scrubber.................................................................................... 8-3
Optical Bench DMC Board ............................................................. 8-4
Instrument Temperature Control..................................................... 8-4
Fan (rear panel)............................................................................. 8-4
Case Heater Assembly ................................................................... 8-4
Chapter 8

Contents
Thermo Scientific 48iQTL 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
Fan................................................................................................... 8-8
Step POL Board............................................................................... 8-8
Sample Pump................................................................................... 8-8
Solenoid Valve Panel (optional) ....................................................... 8-8
Sample/Zero Valve........................................................................... 8-8
Flow/Pressure DMC ........................................................................... 8-8
Firmware............................................................................................. 8-9
Permeation Dryer................................................................................ 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
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
List of Tables.......................................................................................B-3
Chapter 9
Appendix A
Appendix B

Contents
viii 48iQTL Instruction Manual Thermo Scientific
GNU Lesser General Public License............................................................ C-1
GNU Lesser General Public License................................................... C-1
Appendix C

Thermo Scientific 48iQTL Instruction Manual 1-1
Chapter 1
Introduction
The Thermo Scientific™ 48iQ Trace Level Carbon Monoxide (CO)
Analyzer utilizes gas filter correlation technology to measure the amount of
carbon monoxide in the air.
The 48iQTL Analyzer is based on the principle that carbon monoxide
(CO) absorbs infrared radiation at a wavelength of 4.6 microns. The
instrument employs pressure compensation and maintains constant
temperature over the operating temperature range for stability.
Dual range and auto range are standard features in the 48iQTL. Standard
features also include an intelligent zero reference to optimize drift
performance and dynamic filtering to maintain data stability and integrity
in changing environmental conditions.
User settable alarm levels for concentration and a wide variety of internal
diagnostics are available from an easy to follow touch screen display.
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.
iQ Series
Instrument
Platform

Introduction
iQ Series Instrument Platform
1-2 48iQTL Instruction Manual Thermo Scientific
●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
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. 48iQTL Front

Introduction
48iQTL Principle of Operation
Thermo Scientific 48iQTL Instruction Manual 1-3
The 48iQTL 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 48iQTL uses an internally stored calibration
curve to accurately linearize the instrument output over any range up to a
concentration of 1000 ppm.
Gas sample is drawn into the 48iQTL 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.
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 0.5 SLPM while monitoring and
maintaining ambient pressure on the optical bench side. Note that the
sample is drawn through a permeation dryer that selectively removes water
from it prior to being drawn though the 48 DMC bench. Figure 1–3 shows
the example of a three inlet configuration with zero span capabilities.
48iQTL Principle
of Operation

Introduction
48iQTL Principle of Operation
1-4 48iQTL Instruction Manual Thermo Scientific
Figure 1–2. 48iQTL Flow Schematic
Figure 1–3. 48iQTL Flow Schematic with Zero Span Manifold

Introduction
Specifications
Thermo Scientific 48iQTL Instruction Manual 1-5
Table 1–1 lists the specifications for the 48iQTL.
Table 1–1. 48iQTL Specifications
Range 0-1000 (ppm or mg/m3)
Zero Noise 0.01 ppm RMS1
Span Noise 0.5% of reading above 2.5 ppm1
Detection Limit 0.02 ppm1
Zero Drift <0.025 ppm (24 hour)1,2
Span Drift ±0.5% reading (24 hour)1,2
Precision 0.5% of reading1,2
Response Time 60 seconds1
Linearity ±1% full-scale or 0.04 ppm, whichever is greater
Flow Rate 0.5 SLPM (1 atm inlet pressure)
Operating Temperature Range 5–40 °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 40 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
1Dynamic filtering ON (default)
2Intelligent zero reference ON (default)
Specifications

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

Introduction
Dimensions
Thermo Scientific 48iQTL Instruction Manual 1-7
Figure 1–5. Rack Mount Assembly (dimensions in inches [mm])

Introduction
Dimensions
1-8 48iQTL Instruction Manual Thermo Scientific
Figure 1–6. Rack Mount Requirements
Figure 1–7. Rack Requirements Part 2

Thermo Scientific 48iQTL 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 48iQTL 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 48iQTL 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

Installation and Setup
Mounting Options
Thermo Scientific 48iQTL Instruction Manual 2-3
The instrument can be installed in the following configurations:
●Bench Mount
●Rack Mount
Positioned on bench, includes installing feet. See Figure 2–2.
Equipment required:
Slot drive, 5/16-inch
1. Fasten feet in position 1 or 2 to fit to the desired depth.
Figure 2–2. Installing Feet
Mounting
Options
Bench Mount

Installation and Setup
Mounting Options
2-4 48iQTL Instruction Manual Thermo Scientific
Mounting in a rack includes removing the front panel and installing ears
and handles.
Equipment required:
Phillips drive, #2
1. Start by gripping from the top corners of the front panel and pull
outwards. See Figure 2–3.
Figure 2–3. Removing the Front Panel
2. Unfasten the four 8-32 pan head screws.
3. Slide ears outwards.
4. Use the same four 8-32 pan head screws to secure it.
5. Install the handles with the four 8-32 flat head screws that came with
the handle kit on the backside. See Figure 2–4.
Rack Mount