Thermo Scientific 49i User manual

Model 49i
Instruction Manual
UV Photometric O3Analyzer
Part number 102434-00
10Jan2008

© 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

Thermo Fisher Scientific WEEE Compliance
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 Equivalent Method Designation
Equivalent Method Designation
The Thermo Scientific Model 49iis designated by the United States
Environmental Protection Agency (USEPA) as an Equivalent Method for
the measurement of ambient concentrations of ozone pursuant with the
requirements defined in the Code of Federal Regulations, Title 40, Part 53.
Designated Equivalent Method Number: EQOA-0880-047
EPA Designation Date: August 27, 1980 (amended for Model 49i)
The Model 49imeets EPA designation requirements when operated as
follows:
With or without the following options:
Range 50 to 1000 ppb
Averaging Time 10 to 300 seconds
Temperature Range 20 to 30 °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 1 to 3 LPM
RS-232/RS-485 Interface
Teflon Particulate Filter
Rack Mounts
Internal Ozonator with Remote Activation
Internal Zero Air Scrubber
I/O Expansion Board

Thermo Fisher Scientific Model 49iInstruction Manual vii
Contents
Chapter 1 Introduction......................................................................................1-1
Principle of Operation ............................................................1-2
Specifications ..........................................................................1-3
Chapter 2 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
Startup ....................................................................................2-9
Chapter 3 Operation ..........................................................................................3-1
Display....................................................................................3-2
Pushbuttons............................................................................3-3
Soft Keys..............................................................................3-4
Software Overview ..................................................................3-4
Power-Up Screen .................................................................3-6
Run Screen...........................................................................3-6
Main Menu..........................................................................3-7
Range Menu ...........................................................................3-8
Single Range Mode ..............................................................3-8
Dual Range Mode..............................................................3-10
Auto Range Mode..............................................................3-11
Gas Units...........................................................................3-14
O3Range...........................................................................3-14
Set Custom Ranges ............................................................3-16
Averaging Time.....................................................................3-17
Calibration Factors Menu .....................................................3-18
O3Background..................................................................3-18
O3Span Coefficient...........................................................3-20
Calibration Menu .................................................................3-21
Calibrate Zero....................................................................3-22
Calibrate O3Coefficient ....................................................3-22
Zero/Span Check ...............................................................3-23

Contents
viii Model 49iInstruction Manual Thermo Fisher Scientific
Instrument Controls Menu ...................................................3-27
Custom Levels....................................................................3-27
Pump .................................................................................3-28
Ozonator Solenoid .............................................................3-29
Cycle Time ........................................................................3-29
Temperature Compensation...............................................3-30
Pressure Compensation ......................................................3-30
Datalogging Settings ..........................................................3-31
Communication Settings....................................................3-41
I/O Configuration..............................................................3-49
Screen Contrast..................................................................3-62
Service Mode .....................................................................3-63
Date/Time .........................................................................3-63
Diagnostics Menu .................................................................3-64
Program Version ................................................................3-64
Voltages .............................................................................3-65
Temperatures .....................................................................3-67
Pressure..............................................................................3-67
Flows .................................................................................3-67
Cell A/B O3.......................................................................3-68
Intensities...........................................................................3-68
Analog Input Readings.......................................................3-69
Analog Input Voltages........................................................3-69
Digital Inputs.....................................................................3-69
Relay States ........................................................................3-70
Test Analog Outputs..........................................................3-70
Instrument Configuration..................................................3-71
Contact Information..........................................................3-72
Alarms Menu ........................................................................3-72
O3Lamp Temperature.......................................................3-73
Lamp Temperature ............................................................3-74
Bench Temperature............................................................3-75
Pressure..............................................................................3-76
Flow A and B .....................................................................3-77
Intensity A and B ...............................................................3-78
Zero and Span Check.........................................................3-79
Zero and Span Auto Calibration ........................................3-80
Ozonator Level 1-5 Check .................................................3-80
O3Concentration ..............................................................3-81
Service Menu ........................................................................3-83
Pressure Check...................................................................3-83
Lamp Setting......................................................................3-85
Detector Calibration ..........................................................3-86
Intensity Check..................................................................3-86

Contents
Thermo Fisher Scientific Model 49iInstruction Manual ix
Range Mode Select................................................................3-87
Pressure Calibration ...........................................................3-88
Flow A and B Calibration ..................................................3-90
Temperature Calibration....................................................3-92
Analog Output Calibration ................................................3-93
Analog Input Calibration ...................................................3-94
Dilution Ratio....................................................................3-96
Display Pixel Test ..............................................................3-96
Restore User Defaults.........................................................3-97
Password Menu.....................................................................3-97
Set Password ......................................................................3-98
Lock Instrument ................................................................3-98
Change Password ...............................................................3-99
Remove Password...............................................................3-99
Unlock Instrument ..........................................................3-100
Chapter 4 Calibration........................................................................................4-1
Equipment Required...............................................................4-1
Zero Air Generator ..............................................................4-1
Calibration Photometer System............................................4-2
Instrument Preparation ...........................................................4-3
Calibration Photometer System Preparation............................4-3
System Check.......................................................................4-3
Ozone Loss Test...................................................................4-4
Linearity Check....................................................................4-5
Intercomparability Test........................................................4-7
Calibration Procedure .............................................................4-8
Connect Instrument.............................................................4-9
Zero Adjust..........................................................................4-9
Span Adjust........................................................................4-10
Additional Concentration Standards ..................................4-10
Calibration Curve ..............................................................4-11
Periodic Zero and Span Checks.............................................4-11
Internal Ozonator Adjustment (Option) ...............................4-13
Chapter 5 Preventive Maintenance ...............................................................5-1
Safety Precautions ...................................................................5-2
Replacement Parts...................................................................5-2
Outside Case Cleaning............................................................5-2
Optical Bench Cleaning ..........................................................5-2
Lamp Replacement .................................................................5-3
Monitoring Detector Frequencies and Noise...........................5-4
Increasing Lamp Output......................................................5-4
Monitoring Lamp Noise ......................................................5-4

Contents
xModel 49iInstruction Manual Thermo Fisher Scientific
Capillary Service......................................................................5-5
Pump Rebuilding....................................................................5-6
Leak Test and Pump Checkout ...............................................5-7
External Leaks......................................................................5-7
Solenoid Leaks ....................................................................5-8
Solenoid Leak Test...............................................................5-9
Ozone Scrubber Test.............................................................5-10
Chapter 6 Troubleshooting.............................................................................. 6-1
Safety Precautions ...................................................................6-1
Troubleshooting Guides..........................................................6-2
Board-Level Connection Diagrams .........................................6-6
Connector Pin Descriptions....................................................6-8
Service Locations...................................................................6-21
Chapter 7 Servicing.......................................................................................... 7-1
Safety Precautions ...................................................................7-3
Firmware Updates...................................................................7-4
Accessing the Service Mode.....................................................7-4
Replacement Parts List............................................................7-4
Cable List................................................................................7-6
External Device Connection Components ..............................7-6
Removing the Measurement Bench and
Lowering the Partition Panel...................................................7-8
Fuse Replacement ...................................................................7-9
Pump Replacement...............................................................7-10
Fan Replacement...................................................................7-11
Analog Output Testing .........................................................7-12
Analog Output Calibration ...................................................7-14
Analog Input Calibration ......................................................7-15
Calibrating the Input Channels to Zero Volts ....................7-15
Calibrating the Input Channels to Full Scale......................7-16
I/O Expansion Board Replacement (Optional) .....................7-17
Digital Output Board Replacement.......................................7-19
Motherboard Replacement....................................................7-20
Measurement Interface Board Replacement ..........................7-21
Front Panel Board Replacement............................................7-22
LCD Module Replacement ...................................................7-23
Optical Bench Replacement..................................................7-24
Optical Bench Temperature Calibration ...............................7-26
Photometer Lamp Replacement ............................................7-27
Photometer Lamp Voltage Adjustment .................................7-28
Photometer Board Replacement............................................7-29
Detector Replacement...........................................................7-30

Contents
Thermo Fisher Scientific Model 49iInstruction Manual xi
Ozone Scrubber Replacement ...............................................7-31
Sample/Reference Solenoid Replacement ..............................7-32
Zero/Span Solenoid Replacement (Optional)........................7-33
Pressure Transducer Replacement .........................................7-33
Pressure Transducer Calibration ...........................................7-34
Flow Transducer Replacement ..............................................7-36
Flow Transducer Calibration ................................................7-37
Ozonator Lamp Replacement (Optional)..............................7-38
Ozonator Lamp Heater Replacement (Optional) ..................7-40
Ozonator Replacement (Optional)........................................7-41
Ozonator Board Replacement (Optional)..............................7-41
Service Locations...................................................................7-42
Chapter 8 System Description.........................................................................8-1
Hardware ................................................................................8-1
Optical Bench with Photometer Lamp.................................8-2
Detector System...................................................................8-2
Flow Transducers.................................................................8-2
Pressure Transducer .............................................................8-2
Ozonator Assembly ..............................................................8-3
Ozonator Lamp Power Supply .............................................8-3
Photometer Lamp Power Supply..........................................8-3
Optical Bench Temperature Thermistor ..............................8-3
Pump ...................................................................................8-3
Sample/Reference Solenoid Valves .......................................8-3
Software..................................................................................8-3
Instrument Control..............................................................8-4
Monitoring Signals...............................................................8-4
Measurement Calculations ...................................................8-4
Output Communication......................................................8-5
Electronics ..............................................................................8-5
Motherboard........................................................................8-5
Measurement Interface Board ..............................................8-6
Digital Output Board...........................................................8-7
I/O Expansion Board (Optional) .........................................8-7
Front Panel Connector Board ..............................................8-8
I/O Components ....................................................................8-8
Analog Voltage Outputs.......................................................8-8
Analog Current Outputs (Optional) ....................................8-9
Analog Voltage Inputs (Optional)........................................8-9
Digital Relay Outputs ..........................................................8-9
Digital Inputs.......................................................................8-9

Contents
xii Model 49iInstruction Manual Thermo Fisher Scientific
Serial Ports............................................................................8-10
RS-232 Connection ...........................................................8-11
RS-485 Connection ...........................................................8-11
Ethernet Connection..........................................................8-12
External Accessory Connector ............................................8-12
Chapter 9 Optional Equipment........................................................................ 9-1
Internal Sample/Calibration....................................................9-1
Ozonator.................................................................................9-1
Zero Air Source.......................................................................9-1
Teflon Particulate Filter ..........................................................9-2
I/O Expansion Board Assembly...............................................9-2
Terminal Block and Cable Kits ...............................................9-2
Cables .....................................................................................9-2
25-Pin Terminal Board Assembly............................................9-4
Mounting Options..................................................................9-4
Appendix A Warranty .........................................................................................A-1
Appendix B C-Link Protocol Commands .........................................................B-1
Instrument Identification Number......................................... B-2
Entering Units in PPB ........................................................... B-2
Accessing Streaming Data ...................................................... B-2
Commands ............................................................................ B-2
Measurements........................................................................ B-8
Alarms.................................................................................. B-11
Diagnostics .......................................................................... B-16
Datalogging ......................................................................... B-17
Calibration........................................................................... B-24
Keys/Display........................................................................ B-26
Measurement Configuration ................................................ B-29
Hardware Configuration...................................................... B-33
Communications Configuration .......................................... B-35
I/O Configuration................................................................ B-39
Record Layout Definition .................................................... B-43
Format Specifier for ASCII Responses............................... B-44
Format Specifier for Binary Responses .............................. B-44
Format Specifier for Front-Panel Layout .......................... B-45
Appendix C MODBUS Protocol.........................................................................C-1
Serial Communication Parameters .........................................C-2
TCP Communication Parameters ..........................................C-2

Contents
Thermo Fisher Scientific Model 49iInstruction Manual xiii
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 RegistersC-5
(0x05) Force (Write) Single Coil......................................... C-7
MODBUS Commands Supported.........................................C-8
Appendix D Geysitech (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 <BCC> .......................................................D-3
Geysitech Commands ............................................................D-3
Instrument Control Command (ST)...................................D-3
Data Sampling/Data Query Command (DA) .....................D-4
Measurements Reported in Response to
DA Command for 49i and 49i PS.......................................D-7
Operating and Error Status .................................................D-7

Contents
xiv Model 49iInstruction Manual Thermo Fisher Scientific

Figures
Thermo Fisher Scientific Model 49iInstruction Manual xv
Figures
Model 49i Flow Schematic ......................................................1-3
Remove the Packing Material ..................................................2-2
Remove the Shipping Screws ...................................................2-2
Model 49i Rear Panel ..............................................................2-4
Atmospheric Dump Bypass Plumbing .....................................2-4
I/O Terminal Board Views ......................................................2-6
D/O Terminal Board Views ....................................................2-7
25-Pin Terminal Board Views .................................................2-8
49i Front Panel Display ...........................................................3-2
Front Panel Pushbuttons .........................................................3-3
Flowchart of Menu-Driven Software .......................................3-5
Pin-Out of Rear Panel Connector in Single Range Mode ........3-9
Pin-Out of Rear Panel Connector in Dual Range Mode ........3-10
Analog Output in Auto Range Mode ....................................3-12
Pin-Out of Rear Panel Connector in Auto Range Mode ........3-13
Model 49i Connected as Calibrator .........................................4-3
Model 49i Connected to Calibration Photometer
and External Ozonator ............................................................4-9
Ozonator Flow Scheme .........................................................4-13
Capillary Location ...................................................................5-6
Rebuilding the Pump ..............................................................5-7
Board-Level Connection Diagram - Common Electronics .......6-6
Board-Level Connection Diagram - Measurement System ......6-7
Properly Grounded Antistatic Wrist Strap ...............................7-4
Component Layout .................................................................7-7
Removing the Measurement Bench and
Lowering the Partition Panel ...................................................7-8
Replacing the Pump ..............................................................7-10
Replacing a Fan .....................................................................7-12
Rear Panel Analog Input and Output Pins ............................7-13
Replacing the I/O Expansion Board (Optional) ....................7-18
Rear Panel Board Connectors ................................................7-19
Replacing the Measurement Interface Board .........................7-22
Replacing the Front Panel Board and the LCD Module ........7-23
Replacing the Optical Bench .................................................7-25
Replacing the Detectors .........................................................7-30
Ozonator Board Location ......................................................7-39
Hardware Components ...........................................................8-2
Rack Mount Option Assembly ................................................9-5
Bench Mounting .....................................................................9-6
EIA Rack Mounting ................................................................9-7
Retrofit Rack Mounting ..........................................................9-8

Figures
xvi Model 49iInstruction Manual Thermo Fisher Scientific
Flag Status ............................................................................ B-11

Tables
Thermo Fisher Scientific Model 49iInstruction Manual xvii
Tables
Model 49i Specifications .......................................................................... 1-3
I/O Terminal Board Pin Descriptions ...................................................... 2-6
D/O Terminal Board Pin Descriptions .................................................... 2-7
25-Pin Terminal Board Pin Descriptions ................................................. 2-8
Front Panel Pushbuttons .......................................................................... 3-3
Default Analog Outputs in Single Range Mode ....................................... 3-9
Default Analog Outputs in Dual Range Mode ....................................... 3-11
Default Analog Outputs in Auto Range Mode ....................................... 3-13
Operating Ranges ................................................................................... 3-15
Analog Output Zero to Full-Scale Table ................................................ 3-56
Signal Type Group Choices ................................................................... 3-58
Troubleshooting - General Guide ............................................................ 6-2
Troubleshooting - Alarm Messages ........................................................... 6-4
Motherboard Connector Pin Descriptions ............................................... 6-8
Front Panel Board Connector Pin Diagram ........................................... 6-13
I/O Expansion Board (Optional) Connector Pin Descriptions ............... 6-15
Digital Output Board Connector Pin Descriptions ................................ 6-16
Measurement Interface Board Connector Pin Descriptions .................... 6-17
Ozonator Power Supply Connector Pin Descriptions ............................. 6-19
Photometer Power Supply Connector Pin Descriptions ......................... 6-20
Model 49i Replacement Parts ................................................................... 7-4
Model 49i Cables ..................................................................................... 7-6
External Device Connection Components ............................................... 7-6
Analog Output Channels and Rear Panel Pin Connections .................... 7-14
Analog Input Channels and Rear Panel Pin Connections ....................... 7-14
RS-232 DB Connector Pin Configurations ............................................ 8-11
RS-485 DB Connector Pin Configuration ............................................. 8-11
Cable Options .......................................................................................... 9-3
Color Codes for 25-Pin and 37-Pin Cables .............................................. 9-3
Mounting Options ................................................................................... 9-4
C-Link Protocol Commands ....................................................................B-3
Averaging Times ......................................................................................B-9
Alarm Trigger Values .............................................................................B-16
Record Output Formats .........................................................................B-20
Stream Time Values ...............................................................................B-24
Range Settings ........................................................................................B-29
Contrast Levels .......................................................................................B-33
Reply Termination Formats ...................................................................B-38
Analog Current Output Range Values ...................................................B-40
Analog Voltage Output Range Values ....................................................B-40
Default Output Assignment ...................................................................B-42
Read Coils for 49i ....................................................................................C-8

Tables
xviii Model 49iInstruction Manual Thermo Fisher Scientific
Read Registers for 49i ..............................................................................C-9
Write Coils for 49i .................................................................................C-10
Operating Status for Model 49i and 49i Primary Standard ..................... D-7
Error Status for Model 49i and 49i Primary Standard ............................. D-8

Thermo Fisher Scientific Model 49iInstruction Manual xix
About This Manual
This manual provides information about operating, maintaining, and
servicing the 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 software.
• 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 software 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.

Preface
xx Model 49iInstruction Manual Thermo Fisher Scientific
• 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 a datalogger.
• 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 “Geysitech (Bayern-Hessen) Protocol” provides a
description of the Geysitech (Bayern-Hessen) Protocol Interface and is
supported over RS-232/485 and TCP/IP over Ethernet.
Safety 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.
Safety and Equipment
Damage Alerts
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 will result in death or serious
personal injury if the warning is ignored. 
WARNING A hazard is present or an unsafe practice can result in
serious personal injury if the warning is ignored. 
CAUTION The hazard or unsafe practice could result in minor to
moderate personal injury if the warning is ignored. 
Equipment Damage The hazard or unsafe practice could result in property
damage if the warning is ignored. 