Thermo 410i User manual

Model 410i
Instruction Manual
Optical Filter CO2 Analyzer
Part number 102011-00
8Apr2005

© 2005 Thermo Electron Corporation. All rights reserved.
“Analyze. Detect. Measure. Control” is a trademark of Thermo Electron Corporation. All other product names and
logos are the property of their respective owner.
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 Electron Corporation Model 410iInstruction Manual iii
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
Startup .................................................................................... 2-5
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 .............................................................. 3-9
Dual Range Mode.............................................................. 3-10
Autorange Mode ................................................................ 3-11
Gas Units........................................................................... 3-14
CO2Range ........................................................................ 3-15
Set Custom Ranges ............................................................ 3-16
Averaging Time..................................................................... 3-17
Calibration Factors Menu ..................................................... 3-18
CO2Background Correction ............................................. 3-19
CO2Span Coefficients....................................................... 3-21
Calibration Menu ................................................................. 3-22
Calibrate CO2Background................................................ 3-23
Calibrate CO2Coefficient.................................................. 3-24
Zero/Span Check Menu..................................................... 3-24

Contents
iv Model 410iInstruction Manual Thermo Electron Corporation
Instrument Controls Menu ................................................... 3-29
Datalogging Settings .......................................................... 3-30
Communication Settings.................................................... 3-40
I/O Configuration.............................................................. 3-52
Temperature Compensation............................................... 3-70
Pressure Compensation ...................................................... 3-71
Screen Contrast.................................................................. 3-72
Service Mode ..................................................................... 3-73
Date/Time ......................................................................... 3-73
Diagnostics Menu ................................................................. 3-74
Program Version ................................................................ 3-75
Voltages ............................................................................. 3-76
Temperatures ..................................................................... 3-78
Pressure.............................................................................. 3-79
Flow................................................................................... 3-79
Sample/Reference Ratio ..................................................... 3-80
AGC Intensity.................................................................... 3-80
Motor Speed ...................................................................... 3-81
Analog Input Readings....................................................... 3-81
Analog Input Voltages........................................................ 3-82
Digital Inputs..................................................................... 3-83
Relay States ........................................................................ 3-83
Test Analog Outputs.......................................................... 3-84
Instrument Configuration.................................................. 3-86
Contact Information.......................................................... 3-87
Alarms Menu ........................................................................ 3-87
Internal Temperature ......................................................... 3-88
Bench Temperature............................................................ 3-90
Pressure.............................................................................. 3-91
Sample Flow ...................................................................... 3-92
Bias Voltage ....................................................................... 3-94
AGC Intensity.................................................................... 3-95
Motor Speed ...................................................................... 3-96
Zero and Span Check......................................................... 3-97
Zero and Span Auto Calibration ........................................ 3-98
Concentration.................................................................... 3-99
Service Menu ...................................................................... 3-101
Single/Dual/Auto Select................................................... 3-102
Pressure Calibration ......................................................... 3-103
Flow Calibration .............................................................. 3-106
Initial S/R Ratio............................................................... 3-108
Multi-point Calibration ................................................... 3-109
Preamp Board Calibration................................................ 3-112
Temperature Calibration.................................................. 3-113
Analog Output Calibration .............................................. 3-113

Contents
Thermo Electron Corporation Model 410iInstruction Manual v
Analog Input Calibration .................................................3-116
Display Pixel Test ............................................................3-119
Restore User Defaults.......................................................3-120
Password .............................................................................3-120
Lock Instrument ..............................................................3-121
Change Password .............................................................3-121
Remove Password.............................................................3-122
Enter Password.................................................................3-123
Chapter 4 Calibration........................................................................................4-1
Equipment Required...............................................................4-1
CO2Concentration Standard ..............................................4-1
Zero Air ...............................................................................4-1
Flow Meter(s) and Controller(s)...........................................4-2
Pressure Regulator for CO2 Standard Cylinder....................4-2
Mixing Chamber..................................................................4-2
Output Manifold .................................................................4-3
Pre-Calibration .......................................................................4-3
Calibration..............................................................................4-4
Connect the Instrument.......................................................4-4
Zero Adjust..........................................................................4-4
Span Adjust..........................................................................4-5
Additional Concentration Standards ....................................4-6
Calibration Curve ................................................................4-6
Calibration Frequency..........................................................4-6
Periodic Zero and Span Checks...............................................4-6
References ...............................................................................4-8
HI and LO Multi-Point Calibration .......................................4-8
Default Coefficients .............................................................4-9
Cal Point 1, 2, and 3 Adjust.................................................4-9
Chapter 5 Preventive Maintenance ...............................................................5-1
Replacement Parts...................................................................5-1
Cleaning the Outside Case......................................................5-2
IR Source Replacement ...........................................................5-2
Fan Filter Inspection and Cleaning .........................................5-2
Leak Test and Pump Check Out.............................................5-3
External Leaks......................................................................5-3
Leaks Across the Optional Zero/Span and Sample Solenoid
Valves...................................................................................5-4
Pump Rebuilding....................................................................5-4

Contents
vi Model 410iInstruction Manual Thermo Electron Corporation
Chapter 6 Troubleshooting...............................................................................6-1
Safety Precautions ................................................................... 6-1
Troubleshooting Guides.......................................................... 6-1
Board-Level Connection Diagrams ......................................... 6-5
Connector Pin Descriptions.................................................... 6-7
Service Locations................................................................... 6-20
Chapter 7 Servicing...........................................................................................7-1
Safety Precautions ................................................................... 7-3
Firmware Updates................................................................... 7-3
Replacement Parts List............................................................ 7-4
Cable List................................................................................ 7-5
Lowering the Partition Panel................................................... 7-6
Fuse Replacement ................................................................... 7-8
Fan Replacement..................................................................... 7-9
IR Source Replacement ......................................................... 7-10
Filter Wheel Replacement ..................................................... 7-11
Chopper Motor Replacement................................................ 7-13
Optical Bench Replacement.................................................. 7-14
Optical Switch Replacement ................................................. 7-15
Bench Heater Assembly Replacement.................................... 7-16
Detector/Preamplifier Assembly Replacement....................... 7-17
Pump Replacement............................................................... 7-18
Pressure Transducer Replacement ......................................... 7-19
Pressure Transducer Calibration ........................................... 7-21
Flow Transducer Replacement .............................................. 7-23
Flow Transducer Calibration ................................................ 7-24
Capillary Cleaning or Replacement ....................................... 7-26
Optional Zero/Span and Sample Solenoid
Valve Replacement................................................................ 7-26
Analog Output Testing ......................................................... 7-27
Analog Output Adjustment................................................... 7-29
Ambient Temperature Calibration ........................................ 7-31
I/O Expansion Board (Optional) Replacement ..................... 7-32
Digital Output Board Replacement....................................... 7-34
Motherboard Replacement.................................................... 7-35
Measurement Interface Board Replacement .......................... 7-36
Front Panel Board Replacement............................................7-37
LCD Module Replacement ...................................................7-38
Service Locations...................................................................7-39

Contents
Thermo Electron Corporation Model 410iInstruction Manual vii
Chapter 8 System Description.........................................................................8-1
Hardware ................................................................................8-1
Optical Bench ......................................................................8-2
Band-pass Filter ...................................................................8-2
Bench Heater Board.............................................................8-2
Chopper Motor....................................................................8-2
Optical Pickup.....................................................................8-3
Infrared Source ....................................................................8-3
Pre-amplifier Assembly with IR Detector .............................8-3
Sample Flow Sensor .............................................................8-3
Pressure Transducer .............................................................8-3
Capillary ..............................................................................8-3
Pump ...................................................................................8-3
Software..................................................................................8-4
Instrument Control..............................................................8-4
Monitoring Signals...............................................................8-4
Output Communication......................................................8-4
Electronics ..............................................................................8-5
Motherboard........................................................................8-5
Measurement Interface Board ..............................................8-6
Flow Sensor Assembly..........................................................8-6
Pressure Sensor Assembly .....................................................8-7
Bench Heater Board.............................................................8-7
Pre-amp Board Assembly .....................................................8-7
Digital Output Board...........................................................8-7
I/O Expansion Board (Optional) .........................................8-7
Front Panel Connector Board ..............................................8-7
I/O Components ....................................................................8-8
Analog Voltage Outputs.......................................................8-8
Analog Current Outputs (Optional) ....................................8-8
Analog Voltage Inputs (Optional)........................................8-9
Digital Relay Outputs ..........................................................8-9
Digital Inputs.......................................................................8-9
Serial Ports.........................................................................8-10
RS-232 Connection ...........................................................8-10
RS-485 Connection ...........................................................8-11
Ethernet Connection..........................................................8-11
External Accessory Connector ............................................8-11
Chapter 9 Optional Equipment ........................................................................9-1
Internal Zero/Span and Sample Valves....................................9-1
Teflon Particulate Filter ..........................................................9-1
I/O Expansion Board Assembly...............................................9-1
Terminal Block and Cable Kits ...............................................9-1
Mounting Options..................................................................9-2

Contents
viii Model 410iInstruction Manual Thermo Electron Corporation
Appendix A Warranty............................................................................................A-1
Appendix B C-Link Protocol Commands............................................................ B-1
Instrument Identification Number..........................................B-2
Commands .............................................................................B-2
Measurements.........................................................................B-8
Alarms...................................................................................B-11
Diagnostics ...........................................................................B-15
Datalogging ..........................................................................B-16
Calibration............................................................................B-22
Keys/Display.........................................................................B-25
Measurement Configuration .................................................B-27
Hardware Configuration.......................................................B-30
Communications Configuration ...........................................B-32
I/O Configuration.................................................................B-36
Record Layout Definition .....................................................B-40
Format Specifier for ASCII Responses................................B-41
Format Specifier for Binary Responses ...............................B-41
Format Specifier for Front-Panel Layout ...........................B-41
Appendix C MODBUS Protocol ........................................................................... C-1
Serial Communication Parameters ..........................................C-2
TCP Communication Parameters ...........................................C-2
Application Data Unit Definition ...........................................C-2
Function Codes.......................................................................C-3
MODBUS Commands Supported..........................................C-8

Thermo Electron Corporation Model 48iInstruction Manual iii
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
iv Model 48iInstruction Manual Thermo Electron Corporation
• 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.
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. 

Preface
Thermo Electron Corporation Model 48iInstruction Manual v
Where to Get Help Service is available from exclusive distributors worldwide. Contact one of
the phone numbers below for product support and technical information.
866-282-0430
508-520-0430
Safety and Equipment Damage Alerts in this Manual
Alert Description
WARNING If the equipment is operated in a manner not specified by
the manufacturer, the protection provided by the
equipment may be impaired. 
The service procedures in this manual are restricted to
qualified service personnel only. 
The Model 410iis supplied with a three-wire grounding
cord. Under no circumstances should this grounding
system be defeated. 
CAUTION If the LCD panel breaks, do not to let the liquid crystal
contact your skin or clothes. If the liquid crystal contacts
your skin or clothes, wash it off immediately using soap
and water. 
Equipment Damage Do not attempt to lift the analyzer by the cover or other
external fittings. 
Some internal components can be damaged by small
amounts of static electricity. A properly grounded
antistatic wrist strap must be worn while handling any
internal component. 
Handle all printed circuit boards by the edges only. 
Do not remove the panel or frame from the LCD module.

The LCD module polarizing plate is very fragile, handle it
carefully. 
Do not wipe the LCD module polarizing plate with a dry
cloth, it may easily scratch the plate. 
Do not use Ketonics solvent or aromatic solvent to clean
the LCD module, use a soft cloth moistened with a
naphtha cleaning solvent. 
Do not place the LCD module near organic solvents or
corrosive gases. 
Do not shake or jolt the LCD module. 

Preface
vi Model 48iInstruction Manual Thermo Electron Corporation

Thermo Electron Corporation 410iInstruction Manual 1-1
Chapter 1 Introduction
The Model 410iAnalyzer measures CO2concentration using advanced
NDIR technology. The Model 410icombines proven detection technology,
easy to use menu-driven software, and advanced diagnostics to offer
unsurpassed flexibility and reliability. The Model 410ihas the following
features:
• 320 x 240 graphics display
• Menu-driven software
• Field programmable ranges
• User-selectable single/dual/auto range modes
• Multiple user-defined analog outputs
• Analog input options
• High sensitivity
• Fast response time
• Linearity through all ranges
• Highly specific to CO2
• Self-aligning optics
• Automatic temperature and pressure compensation
• User-selectable digital input/output capabilities
• Standard communications features include RS232/485 and Ethernet
• C-Link, MODBUS, and streaming data protocols
For details of the analyzer’s principle of operation and product
specifications, see the following topics:

Introduction
Principle of Operation
1-2 410iInstruction Manual Thermo Electron Corporation
•“Principle of Operation” on page 1-2 describes the principles by which
your analyzer operates.
•“Specifications” on page 1-3 is a list of the analyzer’s performance
specifications.
Thermo Electron is pleased to supply this CO2analyzer. We are committed
to the manufacture of instruments exhibiting high standards of quality,
performance, and workmanship. Service personnel are available for
assistance with any questions or problems that may arise in the use of this
analyzer. For more information on servicing, see Chapter 7 “Servicing”.
Principle of Operation The Model 410ioperates on the principle that carbon dioxide (CO2)
absorbs infrared radiation at a wavelength of 4.26 microns.
The sample is drawn into the Model 410ithrough the sample bulkhead, as
shown in Figure 1-1. The sample flows through the optical bench.
Radiation from an infrared source is chopped and then passed through a
rotating optical wheel alternating between sample and reference filters. The
radiation then enters the optical bench where absorption by the sample gas
occurs. The infrared radiation then exits the optical bench and falls on an
infrared detector. The chopped detector signal is modulated by the
alternation between the filters with an amplitude related to the
concentration of CO2in the sample cell. Because infrared absorption is a
non-linear measurement, it is necessary to transform the basic analyzer
signal into a linear output. The Model 410iuses an internally stored
calibration curve to accurately linearize the instrument output over any
range up to a concentration of 10,000 ppm.
The Model 410ioutputs the CO2concentration to the front panel display,
the analog outputs, and also makes the data available over the serial or
ethernet connection.

Introduction
Specifications
Thermo Electron Corporation 410iInstruction Manual 1-3
Figure 1-1. Model 410iFlow Schematic
Specifications Table 1-1. Model 410iSpecifications
Preset ranges 0-200, 500, 1000, 2000, 5000, and 10000 ppm
0-500, 1000, 2000, 5000, 10000, 20000 mg/m3
Custom ranges 0-200 to 10000 ppm ppm
0-500 to 20000 mg/m3
Zero roise 0.5 ppm RMS (60 second averaging time)
Minimum detectable
limit
1 ppm
Zero drift (24 hour) ±1.0 ppm
Span drift (24 hour) ±2% span concentration
Response time 90 seconds (30 second averaging time)
Linearity ±1.5% of span (at concentrations of 10 to 100% of span)
Sample flow rate 1.0 LPM
Operating temperature 5–45 °C

Introduction
Specifications
1-4 410iInstruction Manual Thermo Electron Corporation
Power requirements 100 VAC @ 50/60 Hz
115 VAC @ 50/60 Hz
220–240 VAC @ 50/60 Hz
275 watts
Physical dimensions 16.75” (W) X 8.62” (H) X 23” (D)
Weight Approximately 39 lbs.
Analog outputs 6 voltage outputs; 0–100 mV, 1, 5, 10 V (User selectable), 5% of
full-scale over/under range, 12 bit resolution, user selectable for
measurement input
Digital outputs 1 power fail relay Form C, 10 digital relays Form A, user selectable
alarm output, relay logic, 100 mA @ 200 VDC
Digital inputs 16 digital inputs, user select programmable, TTL level, pulled high
Serial Ports 1 RS-232 or RS-485 with two connectors, baud rate 1200–115200,
data bits, parity, and stop bits, protocols: C-Link, MODBUS, and
streaming data (all user selectable)
Ethernet connection RJ45 connector for 10Mbs Ethernet connection, static or dynamic
TCP/IP addressing

Thermo Electron Corporation Model 410iInstruction Manual 2-1
Chapter 2 Installation
Installing the Model 410iincludes the following recommendations and
procedures:
•“Lifting” on page 2-1
•“Unpacking and Inspection” on page 2-1
•“Setup Procedure” on page 2-3
•“Startup” on page 2-5
Lifting When lifting the instrument, use procedure appropriate to lifting a heavy
object, such as, bending at the knees while keeping your back straight and
upright. Grasp the instrument at the bottom in the front and at the rear of
the unit. Although one person can lift the unit, it is desirable to have two
persons lifting, one by grasping the bottom in the front and the other by
grasping the bottom in the rear.
Unpacking and
Inspection
The Model 410iis 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.
Equipment Damage Do not attempt to lift the instrument by the cover or
other external fittings. 

Installation
Unpacking and Inspection
2-2 Model 410iInstruction Manual Thermo Electron Corporation
3. Remove the packing material (Figure 2-1).
Figure 2-1. Remove the Packing Material
4. Remove the three shipping screws (Figure 2-2).
Figure 2-2. Remove the Shipping Screws
5. Check for possible damage during shipment.
Units without Optional I/O Board Units with Optional I/O Board
Remove Packing
Remove Packing
(2 pieces)
(2 pieces)
Shipping Screws (3)

Installation
Setup Procedure
Thermo Electron Corporation Model 410iInstruction Manual 2-3
6. Check that all connectors and circuit boards are firmly attached.
7. Re-install the cover.
Setup Procedure Use the following procedure to setup the instrument.
1. Connect the sample line to the SAMPLE bulkhead on the rear panel
(Figure 2-3). Ensure that the sample line is not contaminated by dirty,
wet, or incompatible materials. All tubing should be constructed of FEP
Teflon®, 316 stainless steel, borosilicate glass, or similar tubing with an
OD of 1/4-inch and a minimum ID of 1/8-inch. The length of the
tubing should be less than 10 feet.
Note Gas must be delivered to the instrument at atmospheric pressure. If
sample is supplied under pressure, it may be necessary to use an atmospheric
bypass plumbing arrangement as shown in Figure 2-4. 
2. Connect the EXHAUST bulkhead to a suitable vent. The exhaust line
should be 1/4-inch OD with a minimum ID of 1/8-inch. The length of
the exhaust line should be less than 10 feet. Verify that there is no
restriction in this line.
3. If the optional zero/span solenoid valves are installed, connect a source
of CO2-free air to the ZERO bulkhead, and connect a source of CO2
span gas to the SPAN bulkhead.
4. Connect a suitable recording device to the rear panel connector. See the
“Operation” chapter for more information about the rear panel
pin-outs.
5. Plug the instrument into an outlet of the appropriate voltage and
frequency.
6. Connect a source of CO2-free air or nitrogen to the PURGE port.
WARNING The Model 410iis supplied with a three-wire grounding cord.
Under no circumstances should this grounding system be defeated. 

Installation
Setup Procedure
2-4 Model 410iInstruction Manual Thermo Electron Corporation
Figure 2-3. Model 410iRear Panel
Figure 2-4. Atmospheric Dump Bypass Plumbing
Instrument Bulkhead
Vent to Exhaust Line
at Atmospheric Pressure
Input Gas Line