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Model 48i High Level

1. gt Bit 8 7 6 5 4 3 PL gt Hex value 80 40 20 10 08 04 02 01 MSB LSB Error status Internal Temperature Alarm 0 0 0 0 0 0 0 1 Optical Chamber Temperature o 0 0 0 0 10 1 10 Alarm AGC Intensity Alarm o 0 0 0 0 1 0 10 Bias Voltage Alarm 0 10 o 0 1 0 0 0 Pressure Alarm 0 0 0 1 0 0 0 0 Sample Flow Alarm 0 0 1 0 o 0 0 10 Motor Speed Alarm 0 1 0 0 o 10 0 10 Not used 1 10 0 0 0 0 0 0 Thermo Electron Corporation Model 48 High Level Instruction Manual D 7
2. Coil Number Status 13 PRESSURE ALARM 14 SAMPLE FLOW ALARM 15 INTENSITY ALARM 16 MOTOR SPEED ALARM 17 BIAS VOLTAGE 18 MB STATUS ALARM 19 INTERFACE BD STATUS ALARM 20 1 0 EXP BD STATUS ALARM 21 CONC ALARM 22 Not Used 23 Not Used Table C 2 Read Registers for 487 High Level Register Number Variable 40001 amp 40002 CO 40003 amp 40004 LOCO 40005840006 HI CO 400078 40008 RANGE STATUS 400098 40010 S R 400118 40022 LO S R 400138 40014 HI S R 40015840016 INT TEMP 40017840018 BENCH TEMP 400198 40020 AUX TEMP 400218 40022 NOT USED 40023840024 NOT USED 40025840026 BENCH PRES 400278 40028 SAMPLE FLOW 400298 40030 INTENSITY 400318 40032 MOTOR SPEED 400338 40034 ANALOG IN 1 40035840036 ANALOG IN 2 40037 amp 40038 ANALOG IN 3 Model 487 High Level Instruction Manual C 9 MODBUS Protocol MODBUS Commands Supported C 10 Model 487 High Level Instruction Manual Register Number Variable 40039 amp 40040 ANALOG IN 4 40041 amp 40042 ANALOG IN 5 40043 amp 40044 ANALOG IN 6 40045 amp 40046 ANALOG IN 7 40047 amp 40048 ANALOG IN 8 40049 amp 40050 NOT USED 40051 amp 40052 NOT USED 40053 amp 40054 NOT USED 40055 amp 40056 BIAS SUPPLY 40057 amp 40058 NOT USED 40059 amp 40060 NOT USED 40061 amp 40062 NOT USED 400638 40064 NOT USED Table C 3 Write Coils for 48 High Level Coil Number Action 101 Z
3. Relay States The Relay States screen displays the state of the 10 digital outputs and allows togeling of the state to either on 1 or off 0 The relays are restored to their original states upon exiting this screen e Inthe Main Menu choose Diagnostics gt Relay States Thermo Electron Corporation Model 48 High Level Instruction Manual 3 57 Operation Diagnostics Menu DH Guided A a E SO EA Test Analog Outputs The Test Analog Outputs menu contains a number of digital to analog converter DAC calibration items Channel choices include all analog outputs 6 voltage channels and 6 current channels if the I O expansion board option is installed e Inthe Main Menu choose Diagnostics gt Test Analog Outputs A AA Set Analog Outputs The Set Analog Outputs screen contains three choices Set to full scale set to zero or reset to normal Full scale sets the analog outputs to the full scale voltage zero sets the analog outputs to 0 volts and normal operation The example below shows the selected output state ALL is set to normal e Inthe Main Menu choose Diagnostics gt Test Analog Outputs gt ALL Voltage Channel 1 6 or Current Channel 1 6 E Pido 3 58 Model 487 High Level Instruction Manual Thermo Electron Corporation Instrument Configuration Contact Information Alarms Menu Thermo Electron Corporation Operation Alarms Menu The Instrument Configuration screen displays inf
4. LCD Signal 6 LFLM_5V LCD Signal 7 NC 8 LLP_5V LCD Signal Model 487 High Level Instruction Manual 6 15 Troubleshooting Connector Pin Descriptions 6 16 Model 48 High Level Instruction Manual Reference Designator Pin gt gt gt gt gt e w N Signal Description LCLK_5V LCD Signal 5V Ground 25V LCD Bias Voltage Ground J3 mo N oOo wo A WO N Keypad Row 1 Input Keypad Row 2 Input Keypad Row 3 Input Keypad Row 4 Input Keypad Col 1 Select Keypad Col 2 Select Keypad Col 3 Select Keypad Col 4 Select J4 Reference Designator J1 EN Pin oOo aoa Y 0 oO 4 WH PD LCD Backlight Voltage 1 NC LCD Backlight Ground Table 6 6 0 Expansion Board Optional Connector Pin Descriptions Signal Description Analog Voltage Input 1 Analog Voltage Input 2 Analog Voltage Input 3 Ground Analog Voltage Input 4 Analog Voltage Input 5 Analog Voltage Input 6 Ground Analog Voltage Input 7 Analog Voltage Input 8 Ground NC Thermo Electron Corporation Troubleshooting Connector Pin Descriptions Connector Reference Pin Signal Description Label Designator NC Ground Current Output 1 Current Output Return Current Output 2 Current Output Return gt gt gt gt gt gt gt co loo N o a Se Current Output 3 20 Current Output Return 21 Current Output 4 22 Current Output Return 23 Current Output 5 24 Current Output Return 25 Cu
5. It is not necessary to recalibrate the Model 487 High Level after replacing the IR source since it is a ratio instrument and replacing the IR source does not affect the calibration Fan Filter Inspection Use the following procedure to inspect and clean the fan filter Figure 5 1 and Cleaning 1 Remove the fan guard from the fan and remove the filter 2 Flush the filter with warm water and let dry a clean oil free purge will help the drying process or blow the filter clean with compressed air 3 Re install the filter and fan guard Thermo Electron Corporation Model 487 High Level Instruction Manual 5 3 Preventive Maintenance Leak Test and Pump Check Out Leak Test and Pump Check Out External Leaks 5 4 Model 487 High Level Instruction Manual Mounting Screws 4 Filter Fan Guard Figure 5 1 Inspecting and Cleaning the Fan There are two major types of leaks external leaks and leaks across the optional zero span solenoid valve seals Use the following procedure to test for external leaks 1 Disconnect the sample input line and plug the SAMPLE fitting 2 Press Cm to display the Main Menu 3 Press to move the cursor to Diagnostics and press to display the Diagnostics menu 4 Press 4 to move the cursor to Flow and press to display the Sample Flow screen The flow reading should indicate zero flow and the pressure reading should be less than 250 mmHg If not check to see that all f
6. Send lrec 5 Receive lrec 100 5 10 15 05 12 03 flags 9c040000 co 7349E 0 loco 5994E 0 intt 33 2 cht 44 7 pres 758 9 smplfl 1 085 speed 100 0 biasv 115 5 intensity 1999940 10 15 05 12 03 flags 9c040000 co 7349E 0 loco 5994E 0 intt 33 2 cht 44 7 pres 758 9 smplfl 1 085 speed 100 0 biasv 115 5 intensity 1999940 10 15 05 12 03 flags 9c040000 co 7349E 0 loco 5994E 0 intt 33 2 cht 44 7 pres 758 9 smplfl 1 085 speed 100 0 biasv 115 5 intensity 1999940 10 15 05 12 03 flags 9c040000 co 7349E 0 loco 5994E 0 intt 33 2 cht 44 7 pres 758 9 smplfl 1 085 speed 100 0 biasv 115 5 intensity 1999940 10 15 05 12 03 flags 9c040000 co 7349E 0 loco 5994E 0 intt 33 2 cht 44 7 pres 758 9 smplfl 1 085 speed 100 0 biasv 115 5 intensity 1999940 erec format lrec format srec format These commands report the output format for long and short records and dynamic data in various formats such as ASCII without text ASCII with text or binary The example below shows the output format for long records is ASCII with text according to Table B 4 Send lrec format Receive lrec format 01 set erec format format set lrec format format set srec format format These commands set the output format for long and short records and dynamic data according to Table B 4 The example below sets the long record output format to ASCII with text Send set lrec format 1 Receive set lrec format 1 ok Thermo Electron Corporation C Li
7. Analog Input Calibrate The Analog Input Calibrate Zero screen allows the user to calibrate the Zero zero state of the selected analog input e Inthe Main Menu choose Service gt Analog Input Calibration gt Select Channel gt Calibrate Zero Hook up a voltage source of 0 V to the analog input channel E Pido Analog Input Calibrate The Analog Input Calibration Full Scale screen allows the user to calibrate Full Scale the full scale state of the selected analog input e Inthe Main Menu choose Service gt Analog Input Calibration gt Select Channel gt Calibrate Full Scale Hook up a voltage source of 10 V to the analog input channel 3 78 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Service Menu Dilution Ratio The Dilution Ratio screen allows the user to view and set the dilution ratio Acceptable values are 1 500 1 The default is 1 1 When this value is set the dilution ratio is applied to all concentration measurements This screen is only accessible if the dilution ratio option is installed e Inthe Main Menu choose Service gt Dilution Ratio Ra mh drs Py Tit a i ie i Display Pixel Test The Display Pixel Test is used to test the LCD display The display pixel test is visible only when the instrument is in service mode For more information on the service mode see Service Mode earlier in the chapter e Inthe Main Menu choose Service gt Display Pixel Tes
8. CO Coefficient Reset User Calibration Default 3 18 Model 487 High Level Instruction Manual The CO span coefficient is usually calculated by the instrument processor during calibration The span coefficients are used to correct the CO readings and normally has a value near 1 000 The CO Coefficient screen enables the CO span coefficient to be manually changed while sampling span gas of known concentration Note The concentration value will show ERROR if the measured concentration is not a valid span value either higher than the selected range or 0 or lower A The display shows the current CO concentration reading The next line of the display shows the CO span coefficient that is stored in memory and is being used to correct the CO concentration Notice that as the span coefficient value is changed the current CO concentration reading above also changes However no real changes are made until is pressed In dual or auto range modes HIGH or LOW is displayed to indicate the calibration of the high or low coefficient The example below shows the coefficient screen in dual auto range mode e Inthe Main Menu choose Calibration Factors gt Hi Coef ep gids PLP The Reset User Calibration Default screen allows the user to reset the calibration configuration values to factory defaults e Inthe Main Menu choose Service gt Calibration Factors gt Reset User Cal Defaults Thermo Electron Corp
9. Contents Logic STAG ina 3 41 Instrument AC 3 42 Analog Output Confiouration nicas 3 42 Select Output Range ia 3 43 Minimum and Maximum Value a ai 3 43 Choose Signal To ips nn Saeki es Ge 3 44 Analog Input a A tesa be sede ca eet 3 45 Descripto rsa recne io i e EEE AE A R Titi 3 46 O Ae A E E A 3 47 D cimal Place lata aaie Ei 3 47 Numberof Table Points nan ala ea ani 3 47 Tabl e Point sien tard s a E E 3 48 OS E E A E A Tea 3 48 User Valle ii A A 3 49 Temperature So mipensatio mantissa ses iesduatanndueseisr ese ccighiniteontss 3 49 Pressure Compensation sisnujarosi lil td 3 49 Sereen CONTA A e i ed iia 3 50 Service A aeee e eo Ga NE 3 50 Datel IM a A a 3 51 Diagnostics Mental 3 51 Prograni VEO ai 3 52 Voltages idee be a is 3 52 Motherboard Y oltases ss Geeks cesar ees Ge 3 53 Interface Board Voltages ire a aan 3 53 T O Bo rd Voltages rinrin hata iaiia 3 54 APIA LATICES adios a daa ei 3 54 lia y OPC POE O E canst Soa EE E e AE E a asta ck and 3 54 POW iia A ti 3 55 sample Referente Ratio dual cese Leo 3 55 ESAS A O custahetuccemtscusstessenee week 3 56 A e E e A a aha S 3 56 Analog Input Read ais 3 56 Analog Input Voltages uan dci 3 57 Digital Ipiales 3 57 Re tae loo 3 57 Test Anal pues it se 3 58 Set Analog Q tputs ae aaa hice ees see tee 3 58 Instrument Configuration indi 3 59 Contact Mora e a 3 59 Alarms Men snssinisinonisnnicsiinaniiai iniaa 3 59 Internal Temperature mrotes nte ee E E eee 3 60 Min and Max Internal
10. The gas filter wheel contains samples of CO and N gas that filter the radiation from the infrared source A chopper disk that rotates along with the wheel periodically interrupts the radiation to create a modulated signal The infrared source is a special wire wound resistor operated at high temperature to create infrared radiation The pre amplifier assembly is mounted on the optical bench along with an infrared detector that detects the energy of the infrared light passing through the optical bench It amplifies the pulsating signal from the infrared detector The sample flow sensor located at the optical bench outlet measures the flow of sample through the optical bench The pressure transducer measures the pressure of the sample gas The capillary and the pump control the sample gas flow The pump draws the sample gas through the optical filter bench The purge flow switch monitors the flow of purge gas when the filter wheel purge gas option is installed The processor software tasks are organized into four areas e Instrument control e Monitoring signals e Measurement calculations e Output communication Model 48 High Level Instruction Manual 8 3 System Description Electronics Instrument Control Monitoring Signals Output Communication Electronics 8 4 Model 487 High Level Instruction Manual Low level embedded processors are used to control the various functions on the boards such as analog and digita
11. Value String Value Source Alarm Information B 42 Model 487 High Level Instruction Manual The value field displays values which are parsed out of the response to a DATA ERec command It also displays though background changes alarm status The button when pressed triggers input from either a dialog box or a selection list There are five kinds of buttons B I L T and N Each line in the layout string corresponds to one line on the display The layout string describes each of the three major fields as well as translation mechanisms and corresponding commands The first field in the layout string is the text It is delimited by a The string up to the first will be read and inserted in the text field of the line This is followed by a possible string enclosed in quotes that is used to place a string into the value field The value source which is the item or word number in the DATA ERec response appears next This is followed by an optional bitfield designator The datum identified by the value source can be printed as a string s hexadecimal x decimal d or floating point f or binary b number Typically bitfield extractions are only done for decimal or hexadecimal numbers Floating point numbers can be followed with an optional precision specifier which will be used as an argument to printf s f format e g a field of 4 would be translated into the printf command of 3f Alternately the special
12. and coef 2 commands report the coefficients of the curve developed from the Hi Multi Point Calibration in single range mode The high coef 0 high coef 1 and high coef 2 commands report the coefficients of the curve developed from the Hi Multi Point Calibration in dual or auto range mode The low coef 0 low coef 1 and low coef 2 commands report the coefficients of the curve developed from the Lo Multi Point Calibration in dual and auto range mode The example below reports the coefficient 0 having a value of 1 005 Send coef 0 Receive coef O 1 005 ok Model 48 High Level Instruction Manual B 23 C Link Protocol Commands Calibration B 24 Model 487 High Level Instruction Manual co bkg This command reports the current CO backgrounds The example below reports that the CO background is 1 4 ppm Send co bkg Receive co bkg 1 4 ppm set co bkg value This command is used to set CO backgrounds to user defined values to value where value is a floating point representation of the background in current selected units The example below sets the CO background to 1 4 Send set co bkg 1 400 Receive set co bkg 1 400 ok init ratio This command reports the initial sample reference ratio The example below reports that the initial ratio was 1 16210 Send initial ratio Receive initial ratio 1 16210 sp conc high sp conc low sp conc These commands report span concentration in single range mode or the
13. e Inthe Main Menu choose Service gt Flow Calibration gt Span ip guided Piet Restore Default Flow The Restore Default Flow Calibration screen allows the user to reset the Calibration flow calibration configuration values to factory defaults e Inthe Main Menu choose Service gt Select Flow Calibration A or B gt Set Defaults 3 72 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Service Menu Initial The Initial Sample Reference S R Ratio screen displays both the initial Sample Reference S R ratio and the current S R ratio The initial S R ratio is determined at Rati the factory and is used to correct for the slight variations found from one ato correlation wheel to another The only time the initial S R ratio should be changed is when the correlation wheel is replaced or sample reference is between 0 90 and 1 20 Note This adjustment should only be performed by an instrument service technician A e Inthe Main Menu choose Service gt Initial S R Ratio premik pruni Ph dm PP PPP L Ea bii i Wi hid Multi Point Up to three gas concentrations cal points for each range may be calibrated Calibration to using the following steps Three cal points will give the most accurate readings over the entire range The calibration process is sequential and will work properly if all steps are followed in order The example below shows the multi point calibration screen in single r
14. later in this chapter e Use t Jand to move the cursor up and down e Press to select a choice e Press M to return to the Main Menu or _ to return to the Run screen Thermo Electron Corporation Model 487 High Level Instruction Manual 3 7 Operation Range Menu Range Menu Ro Ea MATTE The Range menu allows the operator to select the gas units CO ranges and to set the custom ranges The screens below show the range menu in single range mode and dual auto range modes The only difference between the screens are the words HI and LO to indicate which range is displayed For more information about the single dual and auto range modes see Single Range Mode Dual Range Mode and Auto Range Mode below e Inthe Main Menu choose Range DH pirri MAMA Single Range Mode 3 8 Model 487 High Level Instruction Manual In the single range mode there is one range one averaging time and one span coefficient By default the two CO analog outputs are arranged on the rear panel connector as shown in Figure 3 4 See Table 3 2 for channels and pin connections Single range mode may be selected from the Range Mode Select on page 3 68 Thermo Electron Corporation Dual Range Mode Thermo Electron Corporation 0000000000000000 00 O000000000000000000 Operation Range Menu Figure 3 4 Pin Out of Rear Panel Connector in Single R
15. on page 7 34 4 Unplug all connectors from the motherboard Note connector locations to facilitate reconnection Model 48 High Level Instruction Manual 7 35 Servicing Measurement Interface Board Replacement Measurement Interface Board Replacement 7 36 Model 48 High Level Instruction Manual Using the nut driver remove the six standoffs securing the board to the rear panel Pop off the motherboard from motherboard support bracket and remove the motherboard To install the motherboard follow previous steps in reverse Use the following procedure to replace the measurement interface board Figure 7 17 Equipment Required Measurement interface board Philips screwdriver 2 Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A Remove the measurement bench and lower the partition panel to gain access to the measurement interface board connectors and standoffs Refer to Removing the Measurement Bench and Lowering the Partition Panel on page 7 7 Unplug all connectors from the measurement interface board Figure 7 17 Note the locations of the connectors to facilitate reconnection Pop off the measurement interface board from the four mounting studs and remove the board To install the measurement interface board follow the previous steps in reverse Re install t
16. Connector Pin Descriptions 6 16 Table 6 7 Digital Output Board Connector Pin Descriptions 6 17 Table 6 8 Pre amp Board Connector Pin Descriptions 6 19 Table 7 1 Model 48 High Level Replacement Parts ccc cence 7 4 Table 7 2 Model 487 High Level Cables oooconicinoioicnocincncincnccncnninnnncnnooso 7 5 Table 7 3 External Device Connection Component c cccceccseeseeteteeeeees 7 6 Table 7 4 Analog Output Channels and Rear Panel Pin Connections 7 28 Table 7 5 Analog Input Channels and Rear Panel Pin Connections 7 30 Table 8 1 RS 232 DB Connector Pin Configurations ooococncincninincinc 8 10 Table 8 2 RS 485 DB Connector Pin Configuration oocoocinncnininin 8 10 Table 9 1 Cable DPI mr tdo 9 4 Table 9 2 Color Codes for 25 Pin and 37 Pin Cables 9 4 Table 9 3 Mounting Options ociconicinicinnincnnincnnincnncnononorncnornnnnrnrnncnrnncnnnnos 9 5 Table B 1 C Link Protocol Commands oococoococicciccicionoccioniocinonorncononnonorooinooos B 2 Table B 2 Averaging Me a a rd B 8 Table B 3 Alarm Trigger Values ooooocoociccodocicinincnoinononcnrncnnocornnonocornrnooos B 15 Table B 4 Record Output Formats ooociccocincocioconinconcnncnonocnnnconnnocnrnocnrnncnnnoos B 19 Table B 5 Stream Time ValueS ooconoonicicicononocoinnonncnonoroororcnrnnono
17. Model 48 High Level Instruction Manual 8 9 System Description 1 0 Components RS 232 Connection RS 485 Connection 8 10 Model 487 High Level Instruction Manual The Streaming Data protocol transmits user selected measurement data via the serial port in real time for capture by a serial printer data logger or PC A null modem crossed cable is required when connecting the analyzer to an IBM Compatible PC However a straight cable one to one may be required when connecting the analyzer to other remote devices As a general rule when the connector of the host remote device is female a straight cable is required and when the connector is male a null modem cable is required Data Format 1200 2400 4800 9600 19200 38400 57600 or 115200 BAUD 8 data bits 1 stop bit no parity All responses are terminated with a carriage return hex 0D Refer to Table 8 1 for the DB9 connector pin configuration Table 8 1 RS 232 DB Connector Pin Configurations DB9 Pin Function 2 RX 3 TX 7 RTS 8 CTS 5 Ground The instrument uses a four wire RS 485 configuration with automatic flow control SD Refer to Table 8 2 for the DB9 connector pin configuration Table 8 2 RS 485 DB Connector Pin Configuration DB9 Pin Function 2 receive 8 receive 7 transmit 3 transmit 5 ground Thermo Electron Corporation System Description 1 0 Components Ethernet Connection An RJ45 connector is used for
18. Pin Color Pin Color 1 BLACK 20 RED BLACK 2 BROWN 21 ORANGE BLACK 3 RED 22 YELLOW BLACK 4 ORANGE 23 GREEN BLACK 5 YELLOW 24 GRAY BLACK 6 GREEN 25 PINK BLACK 7 BLUE End color codes for 25 pin cables continue for 37 pin cables 8 VIOLET 26 PINK GREEN 9 GRAY 27 PIND RED 19 WHITE 28 PINK VIOLET 11 PINK 29 LIGHT BLUE 12 LIGHT GREEN 30 LIGHT BLUE BROWN 13 BLACK WHITE 31 LIGHT BLUE RED 14 BROWN WHITE 32 LIGHT BLUE VIOLET 15 RED WHITE 33 LIGHT BLUE BLACK 16 ORANGE WHITE 34 GRAY GREEN 17 GREEN WHITE 35 GRAY RED 18 BLUE WHITE 36 GRAY VIOLET 19 VIOLET WHITE 37 LIGHT GREEN BLACK Thermo Electron Corporation Optional Equipment Mounting Options Mounting Options The analyzer can be installed in the configuration described in Table 9 3 and shown in Figure 9 2 through Figure 9 5 Table 9 3 Mounting Options Mounting Type Description Bench Positioned on bench includes mounting feet and front panel side trim handles ElA rack Mounted in an ElA style rack includes mounting slides and front panel ElA rack mounting handles Retrofit rack Mounted in a Thermo non ElA rack includes mounting slides and retrofit front panel rack mounting handles Figure 9 2 Rack Mount Option Assembly Thermo Electron Corporation Model 487 High Level Instruction Manual 9 5 Optional Equipment Mounting Options 16 75 REF Figure 9 3 Bench Mounting 9 6 Model 487 High Level Instruction Manual Thermo Electro
19. corresponds with expected value If not select proper range Check user defined low set point set to zero Alarm Zero Check Alarm Span Check Alarm Zero Autocal Alarm Span Autocal Instrument out of calibration Recalibrate instrument Check gas supply Perform manual calibration Alarm Motherboard Status Alarm Interface Status Alarm 1 0 Exp Status Internal cables not connected properly Board is defective Check that all internal cables are connected properly Recycle AC power to instrument If still alarming change board Thermo Electron Corporation Troubleshooting Board Level Connection Diagrams Board Level Figure 6 1 and Figure 6 2 are board level connection diagrams for the Connection lt P electronics and measurement system These illustrations can be used along with the connector pin descriptions in Table 6 3 through Table Diagrams 6 6 to troubleshoot board level faults EXPANSION I O TOMEASURAVENT SYSTEM DIGITAL OUTPUTS 37 Pin 8 Pin RS232 RS485 LCD DISPLAY RS232 RS485 10 BASE T 8 Pin EXPANSION RS485 topin SPARE DATA 8 Pin ANALOG OUTPUTS DIGITAL INPUTS 37 Pin gt I1PJ8 3 Pin POWER_GOOD 3 Pin 3 Pin REAR PANEL AC INPUT P1 2 Pin AC FRONT PANEL S A POWERSW Panta as 7 PJ6 TRANSFOFVER uo 3 Pin An 4 OVACA 240VAC Nemo a 1 CPTICNS 1 Figure 6 1 Board Level Connection Diagram
20. gt Pressure Calibration gt Span Restore Default The Restore Default Calibration screen allows the user to reset the pressure Calibration calibration configuration values to factory defaults e In the Main Menu choose Service gt Pressure Calibration gt Set Defaults 3 70 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Service Menu Flow Calibration The Flow Calibration submenu is used to calibrate the flow sensor to zero span or restore factory default values The flow calibration is visible only when the instrument is in service mode For more information on the service mode see Service Mode earlier in the chapter Note This adjustment should only be performed by an instrument service technician A e Inthe Main Menu choose Service gt Flow Calibration Roc Parti Calibrate Flow Zero The Calibrate Flow Zero screen calibrates the flow sensor at zero flow Note The pump must be disconnected before performing the zero calibration A e Inthe Main Menu choose Service gt Flow Calibration gt Zero Thermo Electron Corporation Model 48 High Level Instruction Manual 3 71 Operation Service Menu Calibrate Flow Span The Calibrate Flow Span screen allows the user to view and set the flow sensor calibrate span point Note An independent flow sensor is required to read the flow then the operator enters the flow value on this screen to perform the calibration A
21. high and low span concentrations in dual or auto range mode If the mode is incorrect the instrument responds with can t wrong settings The example below reports the span gas concentration in single range mode Send sp conc Receive sp conc 1000 set sp conc value set high sp conc value set low sp conc value These commands set the span concentrations to user defined values to value where value is a floating point representation of the span concentration in current selected units The example below sets the span concentration to 1000 ppb in the single range mode Send set sp conc 1000 Receive set sp conc 1000 ok Thermo Electron Corporation C Link Protocol Commands Keys Display Keys Display Push button o down en enter he help le left me menu ri right ru run button do down en enter he help le left me menu ri right ru run up 1 2 3 4 These commands simulate pressing the front panel pushbuttons The numbers represent the front panel soft keys from left to right Send push enter Receive push enter ok isc iscreen This command retrieves the framebuffer data used for the display on the iSeries instrument It is 19200 bytes in size 2 bits per pixel 4 pixels per byte arranged as 320 by 240 characters The data is sent in RLE encoded form to save time in transmission It is sent as a type 5 binary c_link response with no checksum The RLE encoding consists of a 0
22. 9600 is default Model 48 High Level Instruction Manual D 1 Geysitech Bayern Hessen Protocol TCP Communication Parameters TCP Communication Parameters Instrument Address Abbreviations Used Basic Command Structure D 2 Model 48 High Level Instruction Manual iSeries Instruments support the Geysitech TCP protocol over TCP IP The register definition is the same as for the serial interface TCP connection port for Geysitech 9882 The Geysitech instrument address has a value between 0 and 127 and is represented by 3 digit ASCII number with leading zeros or leading spaces if required e g Instrument address of 1 is represented as 001 or lt SP gt lt SP gt 1 The instrument Address is the same as the Instrument ID used for C Link and MODBUS commands This can be set via the front panel The Instrument Address is represented by lt address gt in the examples throughout this document Note Device IDs 128 through 247 are not supported because of limitations imposed by the C Link protocol A The following is a list of abbreviations used in this document lt CR gt is abbreviation for Carriage Return ASCII code 0x0D lt STX gt is abbreviation for Start of Text ASCII code 0x02 lt ETX gt is abbreviation for End of Text ASCII code 0x03 lt SP gt is abbreviation for space ASCII code 0x20 The following is the basic structure of a Geysitech command lt STX gt Command text lt ETX gt lt BCC gt OR lt STX gt Com
23. Bench Temperature alarm limit screen is used to change the Temperature Limits minimum bench temperature alarm limit The minimum and maximum Bench Temperature screens function the same way e Inthe Main Menu choose Alarms gt Bench Temp gt Min or Max Thermo Electron Corporation Model 48 High Level Instruction Manual 3 61 Operation Alarms Menu EH priori MAPA Pressure The Pressure screen displays the current reaction chamber pressure reading and sets the minimum and maximum alarm limits Acceptable alarm limits range from 250 to 1 000 mmHg If the pressure reading goes beyond either the minimum or maximum limit an alarm is activated The word ALARM appears in the Run screen and in the Main Menu e In the Main Menu choose Alarms gt Pressure Min and Max Pressure The Minimum Pressure alarm limit screen is used to change the minimum Limits temperature alarm limit The minimum and maximum pressure screens function the same way e In the Main Menu choose Alarms gt Pressure gt Min or Max 3 62 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Alarms Menu Sample Flow The Sample Flow screen displays the current sample flow reading and sets the minimum and maximum alarm limits Acceptable alarm limits range from 350 to 1 500 LPM If the sample flow reading goes beyond either the minimum or maximum limit an alarm is activated The word ALARM appears in the Run scr
24. Calibration Thermo Electron Corporation Operation Service Menu The Analog Output Calibrate Zero screen allows the user to calibrate the zero state of the selected analog output The operator must connect a meter to the output and adjust the output until it reads 0 0 V on the meter e Inthe Main Menu choose Service gt Analog Out Calibration gt Select Channel gt Calibrate Zero The Analog Output Calibrate Full Scale screen allows the user to calibrate the full scale state of the selected analog output The operator must connect a meter to the output and adjust output until it reads the value shown in the set output to field e Inthe Main Menu choose Service gt Analog Out Calibration gt Select Channel gt Calibrate Full Scale PR Ea DHAN Era RATE mid La The Analog Input Calibration menu is a selection of 8 analog inputs if the I O expansion board option is installed to calibrate and allows the user to select the calibration action zero or span The analog input calibration is visible only when the instrument is in service mode For more information on the service mode see Service Mode earlier in the chapter Note This adjustment should only be performed by an instrument service technician A Model 487 High Level Instruction Manual 3 77 Operation Service Menu e Inthe Main Menu choose Service gt Analog Input Calibration PERE EEE of mh ir Py Tate ON piiopi mitad LAL A A
25. Calibration Frequency Periodic Zero and Span Checks 4 6 Model 487 High Level Instruction Manual In order to generate data of the highest confidence it is recommended that a multipoint calibration be performed every three months any time any major disassembly of components is performed In order to achieve data of the highest confidence it is suggested that periodic zero and air span checks be performed These checks can be performed by Periodically challenging the instrument with zero air The output of the zero air supply should be greater than the flow demand of the instrument In addition an atmospheric dump bypass should be utilized to ensure that the zero air gas flow is being delivered at atmospheric pressure Record the Model 48 High Level s response in percent of scale as Ao Compute the zero drift from the following equation Zero Drift Ao Z Where Z is the recorder response obtained at the last calibration for zero air scale Periodically challenging the instrument with a CO level of approximately 80 of the URL The 80 URL level may be obtained by dilution of a higher level of CO using a system similar to that of Figure 4 1 or by using a low level cylinder of CO containing CO in air at a concentration of approximately 80 of the URL In either case the cylinder of CO should be checked against an SRM or CRM It should also be true for a cylinder of low level CO The Quality Assurance Handbook sh
26. Carefully remove the detector assembly from the optical bench Install the new detector assembly by following the previous steps in reverse Calibrate the preamp board and then return to Step 7 to set S R Refer to the Preamp Board Calibration procedure that follows Set S R as follows a From the Main Menu press to scroll to Service gt press gt to Initial S R Ratio gt and press Ce The Initial S R Ratio screen appears b At the Initial S R Ratio screen press to select set the initial S R ratio to the value of the current ratio and press to store the value The initial S R ratio should be between 1 14 and 1 18 Note If Service Mode is not displayed refer to Accessing the Service Mode on page 7 3 then return to the beginning of this step A 8 Calibrate the instrument Refer to the Calibration chapter in this manual Calibrate the preamp board after replacing the preamp board Equipment Damage This adjustment should only be performed by an instrument service technician A Let the instrument sample zero air for about 90 minutes 2 From the Main Menu press to scroll to Service gt press gt 4 to scroll to Preamp Board Calibration gt and press Thermo Electron Corporation Pump Replacement Thermo Electron Corporation A Servicing Pump Replacement The Preamp Board Cal screen appears Note If Service Mode is not displayed refer to Accessing th
27. Check gt Next Time Period Hours The Zero Span Period Hours screen defines the period or interval between zero span checks Periods between 0 and 999 hours are acceptable To turn the zero span check off set the period to 0 e Inthe Main Menu choose Calibration gt Zero Span Check gt Period Hours Thermo Electron Corporation Model 48 High Level Instruction Manual 3 21 Operation Calibration Menu DH Guided i aa E SO a EA Zero Span Purge The Zero Duration Minutes screen defines how long zero air is sampled by Duration Minutes the instrument The span and purge duration screens look and function the same way as the zero duration screen and are used to set how long the span gas and sample gas are sampled by the instrument Durations between 0 and 60 minutes are acceptable Each time a zero span check occurs the zero check is done first followed by the span check To perform just a zero check set the span and purge duration screen to 0 off The same applies to perform just a span or purge check e Inthe Main Menu choose Calibration gt Zero Span Check gt Zero Span or Purge Duration Min DH Guided fot PELE EE Zero Span Averaging The Zero Span Averaging Time screen allows the user to adjust the Time zero span averaging time The zero span averaging time is used by the analyzer only when performing an automatic zero or span check The analyzer s averaging time is used for all other functions Th
28. Common Electronics Thermo Electron Corporation Model 487 High Level Instruction Manual 6 5 Troubleshooting Board Level Connection Diagrams 12 Pin TO COMMON ELECTRONICS TF In 3 Pin 4 Pin 5 Pin MEASUREMENT INTERFACE BOARD JUS Pin 2 Pin DATA 3 Pin Perrine 4 Pin 2 Pin 2 Pin 2 Pin 2 Pin 2 Pin 24V 2 Pin possesses 6 Pin AC gt 3 Pin 4 Pin 3 Pin 0d _ IR SOURCE PREAMP BOARD 4 Cond _ IR DETECTOR CHOPPER MOTOR _ OPTICAL PICKUP CHAMBER PRESSURE SAMPLE FLOW FLOW SWITCH AMBIENT TEMP THERM PERM OVEN CONNECTORS Not Used _ ZERO SPAN SOL SAMPLE SOL _ SPAN 1 SOL L SPAN 2 SOL _ FAN 02 CONNECTORS Not Used AC _ BENCH HEATER AND THERM AC _ AC PUMP Figure 6 2 Board Level Connection Diagram Measurement System 6 6 Model 487 High Level Instruction Manual Thermo Electron Corporation Connector Pin Descriptions Thermo Electron Corporation Troubleshooting Connector Pin Descriptions The connector pin descriptions in Table 6 3 through Table 6 8 can be used along with the board level connection diagrams to troubleshoot board level faults Motherboard Connector Pin Descriptions on page 6 7 Measurement Interface Board Connector Pin Descriptions on page 6 12 Front Panel Board Connector Pin Diagram on page 6 14 I O Expansion Board Optional Connector Pin Descriptions on page 6 16 Digital
29. Flow Calibration gt and press The Flow Sensor Cal screen appears Note If Service Mode is not displayed refer to Accessing the Service Mode on page 7 3 then return to the beginning of this step A 4 At the Flow Sensor Cal screen press to select Zero The Calibrate Flow Zero screen appears 5 Wait at least 10 seconds for the zero reading to stabilize and then press to save the zero flow value 6 Reconnect the pump cable to the AC PUMP connector on the measurement interface board Thermo Electron Corporation Servicing Capillary Cleaning or Replacement 7 Connect a calibrated flow sensor at the SAMPLE bulkhead on the rear panel 8 Press to return to the Flow Sensor Cal screen 9 At the Flow Sensor Cal screen press to select Span The Calibrate Flow Span screen appears 10 Wait at least 10 seconds for the reading to stabilize use __ gt and J _4_ to enter the flow sensor reading and press to save the value 11 Install the cover Capillary Cleaning Use the following procedure to clean or replace the capillary Figure 7 13 or Replacement Equipment Required Wrench 5 8 inch Capillary Capillary cleaning wire smaller than 0 015 inch amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A f Equipment Damage Some internal components can be damaged by small 1 Turn instrument OFF unplug the powe
30. Mode is not displayed refer to Accessing the Service Mode on page 7 3 then return to the beginning of this step A 4 At the Pressure Sensor Cal screen press to select Zero The Calibrate Pressure Zero screen appears 5 Wait at least 10 seconds for the zero reading to stabilize and then press to save the zero pressure value 6 Disconnect the pump from the pressure transducer 7 Press _W_ to return to the Pressure Sensor Cal screen 8 At the Pressure Sensor Cal screen press to select Span The Calibrate Pressure Span screen appears 9 Wait at least 10 seconds for the ambient reading to stabilize use e Jand J 4 to enter the known barometric pressure and press __ to save the pressure value 10 Reconnect the instrument tubing to the pressure transducer Thermo Electron Corporation Flow Transducer Replacement Thermo Electron Corporation A Servicing Flow Transducer Replacement 11 Install the cover Use the following procedure to replace the flow transducer Figure 7 12 Equipment Required Flow transducer Philips screwdriver 2 Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Disconnect flow transducer cable from the FLOW connector on the measuremen
31. PCB assembly included with optional I O Expansion Board Figure 2 5 shows the recommended method for attaching the cable to the terminal board using the included tie down and spacer Table 2 1 identifies the connector pins and associated signals Model 48 High Level Instruction Manual 2 5 Installation Connecting External Devices See Detail A See Detail B Assembled Connector 2 6 Model 487 High Level Instruction Manual Figure 2 5 I O Terminal Board Views Detail A Detail B Table 2 1 I O Terminal Board Pin Descriptions Pin Signal Description Pin Signal Description 1 Analog1 13 Power_Fail_NC 2 Analog ground 14 Power_Fail_COM 3 Analog2 15 Power_Fail_NO 4 Analog ground 16 TTL_Input1 5 Analog3 17 TTL_Input2 6 Analog ground 18 TTL_Input3 7 Analog4 19 TTL_Input4 8 Analog ground 20 Digital ground 9 Analog5 21 TTL_Input 10 Analog ground 22 TTL_Input6 11 Analog6 23 TTL_Input7 12 Analog ground 24 Digital ground Thermo Electron Corporation D O Terminal Board Installation Connecting External Devices identifies the connector pins and associated signals See Detail A Thermo Electron Corporation d Assembled Connector See Detail B Detail A Figure 2 6 D O Terminal Board Views Table 2 2 D O Terminal Board Pin Descriptions Pin Signal Description Relay1_ContactA Pin Figure 2 6 sh
32. POE Samek e Pih EEE F The Service Mode screen is used to turn the service mode on or off The service mode locks out any remote actions and includes parameters and functions that are useful when making adjustments or diagnosing the Model 487 High Level For more information about the service mode see Service Menu later in this chapter Thermo Electron Corporation Operation Diagnostics Menu Note The service mode should be turned off when finished as it prevents remote operation A e Inthe Main Menu choose Instrument Controls gt Service Mode Cp Gobel MIA Date Time The Date Time screen allows the user to view and change the system date and time 24 hour format The internal clock is powered by its own battery when instrument power is off e Inthe Main Menu choose Instrument Controls gt Date Time Diagnostics The Diagnostics menu provides access to diagnostic information and Menu functions This menu is useful when troubleshooting the instrument The analog input readings and analog input voltages are only displayed if the I O expansion board option is installed e Inthe Main Menu choose Diagnostics Thermo Electron Corporation Model 48 High Level Instruction Manual 3 51 Operation Diagnostics Menu Program Version The Program Version screen read only shows the version number of the program installed Prior to contacting the factory with any questions regarding the instrument please no
33. Reports sets current time 24 hour time B 31 up Simulates pressing up pushbutton B 25 zero Sets zero span valves to zero mode B 29 Model 48 High Level Instruction Manual B 7 C Link Protocol Commands Measurements Measurements 28 time high avg time low avg time These commands report the averaging time in seconds when operating in single range or averaging time used with the high and low ranges when operating in dual or auto range mode The example below shows that the averaging time is 300 seconds according to Table B 2 Send avg time Receive avg time 11 300 sec set avg time selection set high avg time selection set low avg time selection These commands set the averaging time high and low averaging times according to Table B 2 The example below sets the low range averaging time to 120 seconds Send set low avg time 8 Receive set low avg time 8 ok Table B 2 Averaging Times Selection Averaging Time seconds 0 1 seconds 1 2 2 5 3 10 4 20 5 30 6 60 7 90 8 120 9 180 10 240 11 300 co high co low co B 8 Model 48 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Measurements These commands report the measured CO concentration when operating in single range or high and low CO when operating in dual or auto range mode The example below shows that the CO concentration is 40 ppm Send co Receive co 0
34. Specifier for Front Panel Layout ooooonnicnicnoncononncnnncnnnonnnnoss B 41 A iasaeevedlgeasanid eagevaavseesanda taanenasanee B 42 Value SNE on ae hace eco cM OS B 42 VE OURCS nania a h catanc Rn acacia anand B 42 Pl A A neney rere orem er B 42 Translation Vabless ii B 43 Selection Table o B 43 B tt n Lest matory c5 id B 43 Examples arias B 44 Appendix C MODBUS Protocol court aaay C 1 Serial Communication Parameters viii tia C 1 TCP Communication Parametros dla C 2 Application Data Unit Denon C 2 Slave Address rennin A C 2 MBAL Header aae a a nce tala ete a sae C 2 Function Code viii cos C 3 A ce ace MBs date ace eae cee tack eh Gen oan Ione ee celia C 3 xii Model 487 High Level Instruction Manual Thermo Electron Corporation Contents Error Ubeda ad C 3 Puncuon Codes iiddn C 3 0x01 0x02 Read Coils Read Inputs cams C 3 0x03 0x04 Read Holding Registers Read Input Registers C 5 MODBUS Commands supported ces C 8 Appendix D Geysitech Bayern Hessen Protocol ocooommemm D 1 Serial Communication Parameters siii D 1 TCP Communication Parameters A ai D 2 Instrument Address A AS AS D 2 Abbreviations Used aaa nda ai iaa D 2 Basic Command o e D 2 Block Checksum BE Esconde aaaaa D 3 Geysitech Command ds D 3 Instrument Control Command ST oonnocccononononccinannnoninnnananinannanos D 3 Data Sampling Data Query Command DA eccononnicninnnnncnnncnninnnnnos D 4 Measurements reported in response to
35. Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Datalogging Send set copy sp to lrec Receive set copy sp to lrec ok set copy lrec to sp set copy srec to sp set copy stream to sp These commands copy the current contents of the long record short record or streaming data list into the scratch pad sp These commands are useful in easy modification of current long record short record or streaming data lists The example below copies the current list of long records into the scratch pad Send set copy lrec to sp Receive set copy lrec to sp ok sp field number This command reports the variable number and name stored at index in the scratch pad list The example below shows that the field 5 in the scratch pad is set to index number 13 which is for the variable pressure Send sp field 5 Receive sp field 5 13 pres set sp field number value number 1 32 is the maximum number of fields in long and short record lists number 1 18 is for streaming data lists This command sets the scratch pad field number item number in scratch pad list to value where value is the index number of a variable in the analog out variable list Available variables and their corresponding index numbers may be obtained using the command list var aout The set sp field command is used to create a list of variables which can then be transferred into the long record short record or streaming data l
36. Zero Span Avy r ging TAME sissa ern 3 22 Zero Spam Ratio A A ARN 3 23 Instrument Controls Mn OI 3 23 Datalogsing A atii eei 3 24 Select SREC ERE C ui 3 24 View Logged Dat Di 3 24 Nimberor Records st lec dni aini 3 25 Dateand messi NOS 3 25 A LOr niiae A A A A ANTE 3 26 Select Contenti ani a 3 26 Goncentratio nsa A tte A tenes 3 27 Other Measutements iii 3 28 A oe a aa ch dal EO 3 28 Commit Content asirai A A Sonatas 3 29 Reset to Default Content ia oda 3 29 Configure Datalo ES ici dad 3 29 Logging Period Minima ias 3 30 Memory Allocation Percetitis ichasss ccnacsvavess easduconcveedeesdssavcwacobecets 3 30 Data Treat ina 3 31 Communication SEIN GS iia ia 3 31 O EN 3 31 UNED a cis coat sunset cums cant a ited oak coda os 3 32 Communication Protocol vaciadas pil 3 32 Streaming Data Configuration ici da 3 33 Streaming Data Intel os 3 33 Goncentrations adds iii i 3 34 Other Measurements AAA oir gta ache ah rea 3 34 Analog A pene er ia E nT Pert nr reer nner Pech neta S 3 35 RS 232 RS 485 Selectos 3 35 AA nean Akis 3 36 A ES 3 36 Ada d 3 37 o II 3 37 Delta cscascsietvianduiniicjawertavelieessupdeaiteayanetesuntarceeeiaenvinss 3 37 H st Name lio 3 38 VO Configuration iia 3 38 QOutp t Relay Settings o o bordo ceo ae 3 39 A aa a a a aai 3 39 Instrument State sisari ireo enaren ii 3 39 A iena e e a aei eia eaei 3 40 Non Alimunmia ia 3 40 Digital Input Ets a OS 3 41 Thermo Electron Corporation Thermo Electron Corporation
37. alarm agc intensity min alarm agc intensity max These commands report the agc intensity alarm minimum and maximum value current settings The example below reports that the agc intensity alarm minimum value is 20 Send alarm agc intensity min Receive alarm agc intensity min 20 set alarm agc intensity min value set alarm agc intensity max value These commands set the agc intensity alarm minimum and maximum values to value where value is a floating point number representing agc intensity alarm limits The example below sets the agc intensity alarm maximum value to 20 Send set alarm agc intensity max 20 Receive set alarm agc intensity max 20 ok alarm bias voltage min alarm bias voltage max These commands report the bias voltage alarm minimum and maximum value current settings The example below reports that the bias voltage alarm minimum value is 20 Model 48 High Level Instruction Manual B 11 C Link Protocol Commands Alarms B 12 Model 487 High Level Instruction Manual Send alarm bias voltage min Receive alarm bias voltage min 20 set alarm bias voltage min value set alarm bias voltage max value These commands set the bias voltage alarm minimum and maximum values to value where value is a floating point number representing bias voltage alarm limits The example below sets the bias voltage alarm maximum value to 20 Send set alarm bias voltage max 20 Receive set alarm bias voltage max 20 ok alarm chamber
38. available and that it matches the voltage and frequency configuration of the instrument Unplug the power cord open the fuse drawer on the back panel and check the fuses visually or with a multimeter Unplug the power cord disconnect the switch and check operation with a multimeter Replace pressure transducer Run output noisy Recorder noise Sample CO concentration varying Foreign material in optical bench Replace or repair recorder Run instrument on a span CO source if quiet there is no malfunction Clean optical bench Analyzer does not calibrate properly System leak Pressure or temperature transducer out of calibration Dirty system Leaky correlation wheel Find and repair leak Recalibrate pressure and temperature transducer Clean cells and flow components Replace with a known good wheel Thermo Electron Corporation Table 6 2 Troubleshooting Alarm Messages Alarm Message Alarm Internal Temp Possible Cause Check fan operation Check fan filter Troubleshooting Troubleshooting Guides Action Replace fan if not operating properly Clean or replace foam filter refer to Preventive Maintenance chapter in this manual Alarm Chamber Temp Chamber temperature below set point of 50 C Check 10K ohm thermistor replace if bad Check temperature control board to insure the LEDs are coming on If not temperature control board coul
39. beginning of this step A 3 At the Analog Output Cal screen press _4_ to scroll to the voltage channel or current channel corresponding to the rear panel terminal pins where the meter is connected then press 4 With the cursor at Calibrate Zero press Ce The Analog Output Cal line displays Zero Note When calibrating the analog output always calibrate zero first and then calibrate full scale A 5 Use until the meter reads the value shown in the Set Output To line then press to save the value 6 Press to return to the previous screen 7 Press 4 to select Calibrate Full Scale 8 Use t until the meter reads the value shown in the Set Output To line then press to save the value Model 48 High Level Instruction Manual 7 29 Servicing Analog Input Calibration Analog Input Calibration Calibrating the Input Channels to Zero Volts 7 30 Model 48 High Level Instruction Manual Use the following procedures to calibrate the analog inputs after replacing the optional I O expansion board These procedures include selecting analog input channels calibrating them to zero volts and then calibrating them to full scale using a known voltage source Table 7 5 Analog Input Channels and Rear Panel Pin Connections Input Channel Pin 1 0 J oO O a oj n o I NIDJI AJ N o Ground 4 8 11 Use the following procedure to calibrate the input channels
40. by spaces and the line is terminated by a n Valid fields are t parse a time specifier 2 bytes D parse a date specifier 3 bytes i ignore one 8 bit character 1 byte e parse a 24 bit floating point number 3 bytes n x E parse a 24 bit floating point number 3 bytes N x f parse a 32 bit floating point number 4 bytes c parse an 8 bit signed number 1 byte C parse an 8 bit unsigned number 1 byte n parse a 16 bit signed number 2 bytes N parse a 16 bit unsigned number 2 bytes m parse a 24 bit signed number 3 bytes M parse a 24 bit unsigned number 3 bytes l parse a 32 bit signed number 4 bytes L parse a 32 bit unsigned number 4 bytes There is an optional single digit d which may follow any of the numeric fields which indicates that after the field has been parsed out the resulting value is to be divided by 104d Thus the 16 bit field OxFFC6 would be interpreted with the format specifier n3 as the number 0 058 The subsequent lines in the ERec Layout response describe the appearance of the full panel The full instrument panel as it appears on the screen has two columns of lines Each line is composed of three major components 1 a text field 2 a value field and 3 a button None of these three components is required The text field contains statically displayed text Model 48 High Level Instruction Manual B 41 C Link Protocol Commands Record Layout Definition Text
41. character can precede the precision specifier this causes an indirection on the precision specifier which now becomes a field number This is useful when formatting for example numbers which have varying precision depending on the mode of the instrument Binary numbers can also have an optional precision specifier which is used to determine how many bits to print For example the specifier b4 will print the lowest four bits of the parsed number There are serious restrictions on where an s field may appear currently sources 1 and 2 must be s and no others may be s The value source is followed by optional alarm information indicated by a commercial at sign with a source indicator and a starting bit indicator All alarm information is presumed to be two bits long low and high The bitfield extraction is performed on the integer part of the source Typical alarm information would appear as 6 4 Thermo Electron Corporation C Link Protocol Commands Record Layout Definition Translation Table Then there appears an optional translation table within braces This is a string of words separated by spaces An example translation table would be Code_0 Code_1 Code_2 Code_3 The value once extracted is used as a zero based index into the translation table to determine the string to display Selection Table Then there appears an optional selection table within parentheses This is a string of numbers
42. filled Read holding input registers reads the measurement data from the instrument Issuing either of these function codes will generate the same response These functions read the contents of one or more contiguous registers These registers are 16 bits each and are organized as shown below All of the values are reported as 32 bit IEEE standard 754 floating point format This uses 2 sequential registers least significant 16 bits first The request specifies the starting register address and the number of registers Registers are addressed starting at zero Therefore registers numbered 1 16 are addressed as 1 15 The register data in the response message are packed as two bytes per register with the binary contents right justified within each byte For each register the first byte contains the high order bits and the second contains the low order bits Model 48i High Level Instruction Manual C 5 MODBUS Protocol Function Codes Request Function code 1 Byte 0x03 or 0x04 Starting Address 2 Bytes 0x0000 to maximum allowed by instrument Quantity of Registers 2 Bytes 1 to maximum allowed by instrument Response Function code 1 Byte 0x03 or 0x04 Byte count 1 Byte 2xN Register value N x 2 Bytes N NorN 1 N Quantity of Registers Error Response Function code 1 Byte Function code 0x80 Exception code 1 Byte 01 IIlegal Function 02 Illegal Address 03 Illegal Data 04 Slave Device Failure Here is an example of a request
43. high sp conc Reports sets high span concentration B 24 host name Reports sets host name string B 34 init ratio Reports initial sample reference ratio B 24 instr name Reports instrument name B 34 instrument id Reports sets instrument id B 35 internal temp Reports current internal instrument temperature B 9 Model 48 High Level Instruction Manual B 5 C Link Protocol Commands Commands B 6 Model 48 High Level Instruction Manual Command Description Page isc iscreen Retrieves framebuffer data used for the display B 25 layout ack Disables stale layout layout changed indicator B 35 le left Simulates pressing left pushbutton B 25 list din Lists current selection for digital input B 1 list dout Lists current selection for digital output 16 list Irec Lists current selection Irec logging data B 16 list sp Lists current selection in the scratchpad list B 16 list srec Lists current selection srec logging data B 16 list stream Lists current selection streaming data output B 1 list var aout Reports list of analog output index numbers and variables B 39 list var din Reports list of digital input index numbers and variables B 39 list var dout Reports list of digital output index numbers and variables B 39 low avg time Reports sets low averaging time B 8 low co Reports CO concentration calculated with low range B 9 coefficients low co coef Reports sets
44. low range CO coefficient B 23 low coef 0 Reports coefficients of the curve developed from lo multi B 23 point calibration low coef 1 Reports coefficients of the curve developed from lo multi B 23 point calibration low coef 2 Reports coefficients of the curve developed from lo multi B 23 point calibration low range Reports sets current CO low range B 27 low ratio Reports sample reference ratio calculated using the low B 10 averaging time low sp conc Reports sets low span concentration B 24 Ir Outputs long records in the format specified in the command B 17 Irec Outputs long records B 17 Irec format Reports sets output format for long records ASCII or binary B 18 Irec layout Reports current layout of Irec data B 19 Irec mem size Reports maximum number of long records that can be stored B 19 Irec per Reports sets long record logging period B 1 malloc Irec Reports sets memory allocation for long records B 20 malloc srec Reports sets memory allocation for short records B 20 me menu Simulates pressing menu pushbutton B 25 Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Commands Command Description Page mode Reports operating mode in local service or remote B 35 motor Reports motor speed B 9 no of Irec Reports sets number of long records stored in memory B 20 no of srec Reports sets number of short records stored in mem
45. n This shows the use of indirect precision specifiers for floating point displays The background value is taken from the 7th element and the precision specifier is taken from the 8th If the asterisk were not present it would indicate instead that 8 digits after the decimal point should be displayed Model 48 High Level Instruction Manual B 45 Serial Communication Parameters Thermo Electron Corporation Appendix C MODBUS Protocol This appendix 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 The MODBUS Commands that are implemented are explained in detail in this document The MODBUS protocol support for the iSeries enables the user to perform the functions of reading the various concentrations and other analog values or variables read the status of the digital outputs of the analyzer and to trigger or simulate the activation of a digital input to the instrument This is achieved by using the supported MODBUS commands listed below For details of the Model 48i High Level MODBUS Protocol specification see the following topics e Serial Communication Parameters on page C 1 e TCP Communication Parameters on page C 2 e Application Data Unit Definition on page C 2 e Function Codes on page C 3 e MODBUS Commands Supported on page C 8 Additional information on the MODBUS protocol can be obtained at htt
46. performance This is produced by feeding a purge gas to the rear panel bulkhead at a constant pressure of 15 psig A 0 000 inch glass capillary green will deliver the required 140cc min purge flow Flows greater than this are not recommended due to unstable cooling effects on the IR source Lower flows are acceptable as long as the purge housing is adequately purged for the application A 5 10 micron pore size two inch diameter Teflon element is available for the Model 487 High Level This filter should be installed just prior to the SAMPLE bulkhead When using a filter all calibrations and span checks must be performed through the filter The I O expansion board provides six analog current output channels 0 20 mA or 4 20 mA and eight analog voltage inputs 0 10V The DB25 connector on the rear panel provides the interface for these inputs and outputs Thermo Electron Corporation 25 Pin Terminal Board Assembly Terminal Block and Cable Kits Cables Thermo Electron Corporation Optional Equipment Terminal Block and Cable Kits The 25 pin terminal board assembly is included with the optional I O expansion board Refer to Terminal Board PCB Assemblies on page 2 5 for information on attaching the cable to the connector board For associated part numbers refer to External Device Connection Components on page 7 5 The optional terminal block and cable kits provide a convenient way to connect devices to the instrume
47. power cord and remove the cover 2 Remove the two cover screws holding the IR source cover to the motor plate and remove the IR source cover Figure 7 5 3 Loosen both clamp screws from the IR source mounting posts and remove IR source 4 Install a new IR source by following the previous steps in reverse Ensure that the IR source element is evenly spaced between the mounting posts 7 10 Model 48i High Level Instruction Manual Thermo Electron Corporation Servicing Filter Wheel Replacement SEMS Nuts 4 gt S LEPE Brass Connectors 2 Washers 2 IR Source Cover Y Ge Cover Screws 2 y EA Clamp Screws 2 a ee IR Source Mounts Motor Plate Filter Wheel ES a e amp Access Hole Figure 7 5 Replacing the IR Source Filter Wheel Use the following procedure to replace the filter wheel Replaceme nt Equipment Required Filter wheel Allen wrenches 5 32 inch and 5 64 inch Philips screwdriver amounts of static electricity A properly ground antistatic wrist strap must f Equipment Damage Some internal components can be damaged by small be worn while handling any internal component A 1 Turn instrument OFF unplug the power cord and remove the cover Thermo Electron Corporation Model 48i High Level Instruction Manual 7 11 Servicing Filter Wheel Replacement 7 12 Model 48 High Level Instruction Manual Motor Plate Screws 3 Remove the chopper mo
48. pressure compensation is off a pressure of 760 mmHg is used Model 48 High Level Instruction Manual B 9 C Link Protocol Commands Measurements B 10 Model 487 High Level Instruction Manual as default pressure even though the actual pressure is 753 4 mmHg The example below shows that the actual reaction chamber pressure is 753 4 mmHg Send pres Receive pres 753 4 mmHg ratio high ratio low ratio The ratio command reports the sample reference ratio in single mode The high ratio commands reports the sample reference ratio using high averaging time and the low ratio command using low averaging time when operating in dual or auto mode The example below shows that the current ratio is 1 16110 Send ratio Receive ratio 1 161100 flags This reports 8 hexadecimal digits or flags that represent the status of the AGC circuit pressure and temperature compensation status gas units gas mode and alarms To decode the flags each hexadecimal digit is converted to binary as shown in the Figure B 1 It is the binary digits that define the status of each parameter In the example below the instrument is reporting that the AGC circuit is on that the instrument is in the span gas mode and that the CO high concentration alarm is activated Send flags Receive flags 80028000 Thermo Electron Corporation Thermo Electron Corporation Alarms C Link Protocol Commands Alarms I Figure B 1 Flags
49. pues Cai o 3 76 Analog Output Calibrate Lerida 3 77 Analog Output Calibrate Full Scale viiioomiiodncicn nicas 3 77 Analog Input CalbratiO basin add diia 3 77 Analog Input Calibrate Pero ies tartas 3 78 Analog Input Calibrate Full ale als 3 78 A ais he Gl ree ede ies fa eat 3 79 Display Pixel Testi ibas 3 79 Restore User Defaults 0 iii 3 79 Ps WO AA A ES 3 80 Set Password A a OS Pe 3 80 Loco LA SER na nana celia 3 81 Change Password ii Ses slo 3 81 Remove Passwoldi m tica 3 81 Unlock Instrument incita dia 3 82 Thermo Electron Corporation Chapter 4 Chapter 5 Chapter 6 Thermo Electron Corporation Contents Calibratio tects esau An ad ntnnautvcadbaanurentdvonsnste ensued iraran ae 4 1 Equipment Required att ti ie std a 4 1 CO Concentration standard pe do ete 4 Zero Air Generator tr da tas 4 1 COMPE i 4 2 Drinos a er tes te vanced eens au aecprapteaul E A E E a ati 4 2 Scrubbing o td 4 2 Flow Meter s and Controller S oooonnnccconnnononcnonananacinananacinanananons 4 2 Pressure Regulator for CO Standard Cylinder cooccocnicnnnnnnnnonmemm 4 3 Mising Chambers o iio 4 3 OQ tput Manttold cti a idea 4 3 Pre Calibration iii at 4 3 Calibration e e o Omni or e 4 3 Connect the struts dit 4 3 A A DT a Tn ERE SEI TRONS oT 4 4 Sa TNR LIS Bas sta bec rere nde acetal nara la E E es hal ea cact R EEA aR 4 4 Calibration Frequency iii esting tienen 4 6 Periodic Zero and Span Checks ostia idad pda 4 6 HI and LO Multi Point C
50. range for the selected analog output channel Possible ranges for the voltage outputs are 0 100 mV 0 1 0 5 0 10 V e In the Main Menu choose Instrument Controls gt I O Configuration gt Analog Output Config gt Select Channel gt Select Range The Minimum Value screen is used to edit the zero 0 to full scale 100 value in percentages for the selected analog output channel See Table 3 6 for a list of choices In dual or auto range mode HI or LO is displayed to indicate high or low concentrations Range Status is visible only in auto range mode The minimum and maximum output value screens function the same way The example below shows the set minimum value screen Model 487 High Level Instruction Manual 3 43 Operation Instrument Controls Menu 3 44 Choose Signal To Output Model 48 High Level Instruction Manual e Inthe Main Menu choose Instrument Controls gt IO Configuration gt Analog Output Config gt Select Channel gt Set Minimum or Maximum Value DH pikari E E Table 3 6 Analog Output Zero to Full Scale Table Output Zero Value Full Scale 100 Value co Zero 0 LOCO Zero 0 HICO Zero 0 Range Status Recommend not to change the setting for this output Sample Reference Ratio 0 0 1 2 LO Sample Reference Ratio 0 0 1 2 HI Sample Reference Ratio 0 0 1 2 Internal Temperature User set alarm min value User se
51. selected output signal that is tied to the selected field item If no changes have been made NO CHANGES TO RECORD LIST will appear For more information about selecting the analog output signal group choices see Select Content above e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Commit Content Reset to Default Content The Reset to Default Content screen is used to reset all of the datalogging field items to default values For more information about selecting the analog output signal group choices see Select Content above e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Reset to Default Content Configure Datalogging Thermo Electron Corporation The Configure Datalogging menu deals with datalogging configuration for the currently selected record type e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Configure Datalogging Model 487 High Level Instruction Manual 3 29 Operation Instrument Controls Menu mehi CRA PATO op Cu EEE A Fosso Le Seol AA AS PEE EE Logging Period Min The Logging Period Min screen is used to select the logging period in minutes for the record format srec or lrec List of choices include off 1 5 15 30 and 60 minutes default e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Configure Datalogging gt Logging Period Min ERED Memory
52. set span Receive set span ok gas unit This command reports the current gas units ppm or mg m The example reports that the gas unit is set to ppm Send gas unit Receive gas unit ppm set gas unit unit ppm mg m This command sets the gas units to ppm or mg m The example below sets the gas units to mg m Send set gas unit mg m3 Receive set gas unit mg m3 ok pres comp This command reports whether pressure compensation is on or off The example below shows that pressure compensation is on Send pres comp Receive pres comp on set pres comp onoff These commands turn the pressure compensation on or off The example below turns pressure compensation off Send set pres comp off Receive set pres comp off ok Model 48 High Level Instruction Manual B 29 C Link Protocol Commands Hardware Configuration temp comp This command reports whether temperature compensation is on or off The example below shows the temperature compensation is off Send temp comp Receive temp comp off set temp comp onoff These commands turn the temperature compensation on or off The example below turns temperature compensation off Send set temp comp off Receive set temp comp off ok Hardwa re contrast This command reports the screen s level of contrast The example below Configuration shows the screen contrast is 50 according to Table B 7 Send contrast Receive contrast 5 50 set contrast level T
53. steps in reverse For additional assistance Thermo Electron has service available from exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information 866 282 0430 Toll Free 508 520 0430 International Model 487 High Level Instruction Manual 7 39 Chapter 8 System Description This chapter 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 and functions as follows e Hardware on page 8 1 e Software on page 8 3 e Electronics on page 8 4 e I O Components on page 8 8 Hardware Model 48 High Level hardware components Figure 8 1 include e Optical bench e Band pass filter e Bench heater board e Chopper motor e Optical pickup e Gas filter wheel e Infrared source e Pre amplifier assembly with IR detector e Sample flow sensor e Pressure transducer e Capillary e Pump e Purge flow switch optional Thermo Electron Corporation Model 487 High Level Instruction Manual 8 1 System Description Hardware Pressure Transducer Pump Motor and Wheel Assy a a A EA s a WA Fan DA Y Flow Transd ZN ow Transducer IN F R n IR Source Cover Shiba pona Detector Assy i and Pre Amp Thermistor o Front Panel gt gt 1 0 Expansion Boar
54. the 10Mbs Ethernet connection supporting TCP IP communications via standard IPV4 addressing The IP address may be configured for static addressing or dynamic addressing set using a DHCP server Any serial port protocols may be accessed over Ethernet in addition to the serial port External Accessory The external accessory connector is not used in the Model 48 High Level Connector analyze This port is used in other models to communicate with smart external devices that may be mounted hundreds of feet from the analyzer using an RS 485 electrical interface Thermo Electron Corporation Model 48 High Level Instruction Manual 8 11 Internal Zero Span Assembly Internal Zero Air Scrubber Filter Wheel Purge Thermo Electron Corporation Chapter 9 Optional Equipment The Model 487 High Level is available with the following options e Internal Zero Span Assembly on page 9 1 e Internal Zero Air Scrubber on page 9 1 e Filter Wheel Purge on page 9 1 e Teflon Particulate Filter on page 9 2 e I O Expansion Board Assembly on page 9 2 e Terminal Block and Cable Kits on page 9 3 e Cables on page 9 3 e Mounting Options on page 9 5 With the internal zero span assembly option a source of span gas is connected to the SPAN port and a source of zero air is connected to the ZERO port Zero and span gas should be supplied at atmospheric pressure It may be necessary to use an atmospheric
55. transducer Figure 7 Replacement Equipment Required Pressure transducer Philips screwdriver 2 amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A f Equipment Damage Some internal components can be damaged by small 1 Turn instrument OFF unplug the power cord and remove the cover 2 Disconnect plumbing from the pressure transducer assembly Figure 7 2 Note the plumbing connections to facilitate reconnection 3 Disconnect the pressure transducer from the PRES connector on the measurement interface board 4 Remove the two pressure transducer assembly retaining screws and remove the pressure transducer assembly Figure 7 11 7 20 Model 48 High Level Instruction Manual Thermo Electron Corporation Retaining Screws 2 Pressure Transducer Calibration Thermo Electron Corporation Servicing Pressure Transducer Calibration Figure 7 11 Replacing the Pressure Transducer 5 To install the pressure transducer assembly follow the previous steps in reverse 6 Calibrate the pressure transducer Refer to the Flow Transducer Calibration procedure that follows Use the following procedure to calibrate the pressure transducer Note An error in the zero setting of the pressure transducer does not introduce a measurable error in the output concentration reading Therefore if only a barometer is available and not a vac
56. zero check offset The maximum zero and span offset screens function the same way e Inthe Main Menu choose Alarms gt Zero or Span Check gt Max Offset ip priori ML EA Zero and Span Auto The Zero Auto Calibration screen read only allow the user to view the Calibration status of the most recent auto background calibration The zero and span auto calibration screens are visible only if the auto calibration option is enabled and function the same way e Inthe Main Menu choose Alarms gt Zero or Span Autocal ETEO fuai 3 66 Model 487 High Level Instruction Manual Thermo Electron Corporation Concentration Min and Max Concentration Limit Thermo Electron Corporation Min Trigger Concentration Operation Alarms Menu The Concentration screen displays the current CO concentration and sets the minimum and maximum alarm limits Acceptable alarm limits range from 0 to 20 000 ppm The minimum alarm may be programmed as a floor trigger alarm is triggered when the concentration falls below the minimum value or a ceiling trigger alarm is triggered when the concentration goes above the minimum value If the CO concentration goes beyond either the minimum or maximum limit an alarm is activated The word ALARM appears in the Run screen and in the Main Menu e Inthe Main Menu choose Alarms gt Concentration The Minimum Concentration alarm limit screens is used to change the minimum concentra
57. 040E 0 ppm flow This command reports the current sample flow The example below reports that the current sample flow is 1 108 liters minute Send flow Receive flow 1 108 1 m chamber temp This command reports the current optical chamber temperature The example below reports that the current optical chamber temperature is 45 2 Es Send chamber temp Receive chamber temp 45 2 deg C internal temp This command reports the current internal instrument temperature The first reading is the temperature being used in instrument calculations The second temperature is the actual temperature being measured If temperature compensation is on then both temperature readings are the same If temperature compensation is off a temperature of 30 C is used as the default temperature even though the actual internal temperature is 27 2 C The example below shows that temperature compensation is on and that the internal temperature is 27 2 C Send internal temp Receive internal temp 27 2 deg C motor This command reports the current motor speed The example below reports that the current motor speed is 100 Send motor Receive motor 100 pres This command reports the current reaction chamber pressure The first pressure reading is the pressure reading being used in instrument calculations The second pressure is the actual pressure reading being measured If pressure compensation is on then both pressure readings are the same If
58. 2 1 0 BD COMM closed 2 2 LOCAL REMOTE open 3 4 UNITS open 4 19 BIAS VOLTAGE closed 7 7 SAMPLE MODE open 8 8 GEN MODE open list Irec list srec list stream list sp These commands report the list of current selections for long record logging data short record logging data streaming data output or the scratch pad sp list The example below shows the list for streaming data output Send Receive list stream list stream field index variable x x time 1 10 auxt 2 13 pres 3 14 smplfl 4 15 intensity Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Datalogging er xy Ir xy st xy x 0 1 Reply termination format see set format format command y 0 1 2 Output format see set erec lrec srec format format command These commands report the last long and short records stored or the dynamic data record In the example below the command requests a long record with no checksum in ASCII format with text For details on how to decode the flag fields within these records see the flags command Send 1ro1 Receive 1ro1 10 15 05 12 03 flags 9C040000 co 7349E 0 loco 5994E 0 intt 33 2 cht 44 7 pres 758 9 smplfl 1 085 speed 100 0 biasv 115 5 intensity 1999940 erec This command returns a brief description of the main operating conditions at the time the command is issued i e dynamic data The example below shows a typical response The format is def
59. 4800 and 9600 19200 38400 57600 and 115200 are available e In the Main Menu choose Instrument Controls gt Communication Settings gt Baud Rate Thermo Electron Corporation Model 48 High Level Instruction Manual 3 31 Operation Instrument Controls Menu Instrument ID The Instrument ID screen allows the operator to edit the instrument ID The ID is used to identify the instrument when using the C Link or MODBUS protocols to control the instrument or collect data It may be necessary to edit the ID number if two or more of the same instrument are connected to one computer Valid Instrument ID numbers are from 0 to 127 The Model 487 High Level has a default Instrument ID of 48 For more information about the Instrument ID see Appendix B C Link Protocol Commands or Appendix C MODBUS Protocol e Inthe Main Menu choose Instrument Controls gt Communication Settings gt Instrument ID Communication Protocol The Communication Protocol screen is used to change the instrument communication protocol for serial communications e Inthe Main Menu choose Instrument Controls gt Communication Settings gt Communication Protocol 3 32 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu Streaming Data The Streaming Data Configuration menu is used to allow for configuration Configuration of the 8 streaming data output items streaming interval current data forma
60. 487 High Level Instruction Manual 3 13 Operation Range Menu Set Custom Ranges 3 14 Model 487 High Level Instruction Manual Table 3 5 lists the available preset ranges e Inthe Main Menu choose Range gt Range O EH OEE Bel POEL PEGG Table 3 5 Available Operating Ranges ppm mgm 50 50 100 100 200 200 500 500 1 000 1 000 2 000 2 000 5 000 5 000 10 000 10 000 20 000 20 000 C1 C1 C2 C2 C3 C3 Cl C2 and C3 are custom ranges For more information about custom ranges see Set Custom Ranges below The Set Custom Ranges menu lists three custom ranges C1 C2 and C3 Custom ranges are user defined ranges In the ppm or mg m mode any value between 50 and 20 000 ppm can be specified as a range e Inthe Main Menu choose Range gt Set Custom Ranges Thermo Electron Corporation Operation Averaging Time ejes AA PP Tite 4 METEEN Lid Wi mpini PS PHP L ri Custom Ranges The Custom Ranges screen is used to define the custom ranges The display shows the current custom range The next line of the display is used to set the range To use the custom full scale range be sure to select it Custom range 1 2 or 3 in the CO Ranges screen For more information about selecting ranges see CO Range above e Inthe Main Menu choose Range gt Set Custom Ranges gt Custom range 1 2 or 3 Wi mid Pin Piet Ave raging Time The Averaging Time d
61. Allocation The Memory Allocation Percent screen is used to select the percentage of Percent each record type for both short records and long records Percentages between 0 and 100 are available in increments of 10 Changing this value results in log erasure for both short records and long records e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Configure Datalogging gt Memory Allocation 3 30 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu Data Treatment The Data Treatment screen is used to select the data type for the selected record whether the data should be averaged over the interval the minimum or maximum used or the current value logged Data treatment doesn t apply to all data just to the concentration measurement All other data points log the current value at the end of the interval e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Configure Datalogging gt Data Treatment EUs EEE E a PUES Fad Bat ad O y HED Eel Communication The Communication Settings menu is used with communications control 8 Settings and configuration e In the Main Menu choose Instrument Controls gt Communication Settings ERED CH o ely mT WH mnt ee ee boose TT Sad het iL P H Ss ir Baud Rate The Baud Rate screen is used to set the RS 232 RS 485 interface baud rate Baud rates of 1200 2400
62. C Ground PERM OVEN J20 1 Perm Oven Gas Thermistor THERM 2 Ground PERM OVEN J21 1 Perm Oven Heater On Off 2 15V_PWR 3 Perm Oven Thermistor 4 Ground FLOW SW J11 1 N C 2 Ground 3 Purge Flow Signal Input MOT DRV J8 1 Motor Drive Voltage 1 2 Motor Drive Voltage 2 3 Motor Drive Voltage 3 4 Motor Drive Voltage 4 OPT J6 1 Optical Pickup Signal Input 2 Ground 3 Optical Pickup Power Table 6 5 Front Panel Board Connector Pin Diagram Connector Label MOTHERBOARD Reference Designator J1 Pin a oOo N OQO wo A WO N Signal Description Ground Ground LCLK LCD Signal Ground Ground LLP LCD Signal LFLM LCD Signal LD4 LCD Signal Thermo Electron Corporation Thermo Electron Corporation Troubleshooting Connector Pin Descriptions Connector Reference Pin Signal Description Label Designator 9 LDO LCD Signal 10 LD5 LCD Signal 11 LD1 LCD Signal 12 LD6 LCD Signal 13 LD2 LCD Signal 14 LD7 LCD Signal 15 LD3 LCD Signal 16 LCD Bias Voltagel 17 5V 18 Ground 19 Ground 20 LCD_ONOFF LCD Signal 21 Keypad Row 2 Input 22 Keypad Row 1 Input 23 Keypad Row 4 Input 24 Keypad Row 3 Input 25 Keypad Col 2 Select 26 Keypad Col 1 Select 27 Keypad Col 4 Select 28 Keypad Col 3 Select 29 Ground 30 Ground 31 Ground 32 Ground 33 24V 34 24V LCD DATA J2 1 LDO_5V LCD Signal 2 LD1_5V LCD Signal 3 LD2_5V LCD Signal 4 LD3_5V LCD Signal 5 LCD_ONOFF_5V
63. Corporation Connector Label Troubleshooting Connector Pin Descriptions Reference Pin Signal Description Designator 31 24V 32 24V 33 24V 34 24V 35 24V 36 24V 37 24V Table 6 8 Pre amp Board Connector Pin Descriptions Connector Signal Description Label OUT Preamp Signal Output SH Ground for Shield BLK Ground GRN SPI Data Out ORG SPI CLK VIO SPI CS BLU 15V BRN 5V RED 18V for IR Source WHT 100V BLK 18V for IR Source YEL IR Source Return YEL IR Detector Return RED IR Detector Cooler BLK IR Detector Cooler WHT IR Detector WHT IR Detector Thermo Electron Corporation Model 487 High Level Instruction Manual 6 19 Troubleshooting Service Locations Service For additional assistance Thermo Electron has service available from Locations exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information 866 282 0430 Toll Free 508 520 0430 International 6 20 Model 48 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation Chapter 7 Servicing This chapter explains how to replace the Model 487 High Level subassemblies It assumes that a subassembly has been identified as defective and needs to be replaced For fault location information refer to the Preventive Maintenance chapter and the Troubleshooting chapter in this manual The s
64. D Signal LD2 LCD Signal Thermo Electron Corporation Troubleshooting Connector Pin Descriptions Connector Reference Pin Signal Description Label Designator 14 LD7 LCD Signal 15 LD3 LCD Signal 16 LCD Bias Voltagel 17 5V 18 Ground 19 Ground 20 LCD_ONOFF LCD Signal 21 Keypad Row 2 Input 22 Keypad Row 1 Input 23 Keypad Row 4 Input 24 Keypad Row 3 Input 25 Keypad Col 2 Select 26 Keypad Col 1 Select 27 Keypad Col 4 Select 28 Keypad Col 3 Select 29 Ground 30 Ground 31 Ground 32 Ground 33 24V 34 24V RS232 RS485 A PTA 1 NC 2 Serial Port 1 RX RS485 IN 3 Serial Port 1 TX RS485 OUT 4 NC 5 Ground 6 NC 7 Serial Port 1 RTS RS485 QUT 8 Serial Port 1 CTS RS485 IN 9 NC RS232 RS485 B P1 B 1 NC 2 Serial Port 2 RX RS485 IN 3 Serial Port 2 TX RS485 OUT 4 NC Thermo Electron Corporation Model 48 High Level Instruction Manual 6 11 Troubleshooting Connector Pin Descriptions 6 12 Model 48 High Level Instruction Manual Connector Label Reference Designator Pin oOo co N wm wo Signal Description Ground NC Serial Port 2 RTS RS485 OUT Serial Port 2 CTS RS485 IN NC AC IN PJ1 w N AC HOT AC NEUT AC Ground AC 24VPWR 0 nN AC HOT AC NEUT AC Ground AC INTF BD PJ3 AC HOT AC NEUT Connector Label DATA PREAMP BD Reference Designator J17 J7 Pin wo N OOO Y on gt WW DN AC Ground Ta
65. DA command D 6 Single Range Modernitas iris D 6 Dual Auto Range Modeiimiciorni cti D 6 Operating and Error Status adidas D 6 Thermo Electron Corporation Model 48 High Level Instruction Manual xiii Thermo Electron Corporation Model 48 High Level Instruction Manual xiv Thermo Electron Corporation Figures Figure 1 1 Model 487 High Level Flow Schematic 0 00 0 cece 1 3 Figure 2 1 Remove the Packing Material 0 00 00 ccccccccsesceceesesceteesesteteseseees 2 2 Figure 2 2 Removing the Shipping SCTeWwS s 2 2 Figure 2 3 Model 487 High Level Rear Panel 2 4 Figure 2 4 Atmospheric Dump Bypass PluMbiNQ o oninococnoninocinnonrnnnooooo 2 4 Figure 2 5 0 Terminal Board Views oooociconcicconiccocinconinccnrnccnrncnnrnccnrnnnooos 2 6 Figure 2 6 D O Terminal Board Views 2 7 Figure 2 7 25 Pin Terminal Board ViQWS ooooociccococciccococcnnnonocncnrnnnnocoronnononoso 2 8 Figure 3 1 Front Panel Display ccc cececescsceeceseseseecesesesesceseseseeteeseseees 3 2 Figure 3 2 Front Panel PUSADUTLONS oooocociconoccnnnncncncnnnnnnccncnrnnnnnororonoonoooso 3 2 Figure 3 3 Flowchart of Menu Driven Software o oococicoocincoinconincnnrnccninncosos 3 5 Figure 3 4 Pin Out of Rear Panel Connector in Single Range Mode 3 9 Figure 3 5 Pin Out of Rear Panel Connector in Dual Range Mode 3 10 Figure 3 6 Analog Output in Auto Range Mode ocoo icoc inicnininicoo oo
66. Damage Some internal components can be damaged by small 1 Turn instrument OFF unplug the power cord and remove the cover 2 Disconnect the chopper motor cable from the MOT DRY connector on the measurement interface board and disconnect the detector cable from the PREAMP cable connector on the measurement interface board 3 Disconnect the plumbing connections from the optical bench 4 Remove the four screws holding the optical bench to the shock mounts and carefully remove the optical bench 5 Replace the optical bench by following the previous steps in reverse 6 Calibrate the instrument Refer to the Calibration chapter in this manual a a t Shock Mounts 4 Q Standoffs 4 U Figure 7 7 Replacing the Optical Bench 7 14 Model 48 High Level Instruction Manual Thermo Electron Corporation Servicing Optical Switch Replacement Optical Switch Use the following procedure to replace the optical switch Figure 7 8 Replaceme Nt Equipment Required Optical switch Flatblade screwdriver 1 4 inch and 3 16 inch Philips screwdriver amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A f Equipment Damage Some internal components can be damaged by small 1 Turn instrument OFF unplug the power cord and remove the cover 2 Remove the optical bench following the Optical Bench Replacement proced
67. ERO MODE 102 SPAN MODE 103 SET BACKGROUND 104 CAL TO LOW SPAN 105 AOUTS TO ZERO 106 AOUTS TO FS 107 CAL TO HIGH SPAN 108 NOT USED Thermo Electron Corporation Serial Communication Parameters Thermo Electron Corporation Appendix D Geysitech Bayern Hessen Protocol This appendix provides a description of the Geysitech Bayern Hessen or BH Protocol Interface and is supported both over RS 232 485 as well as TCP IP over Ethernet The Geysitech Commands that are implemented are explained in detail in this document The Geysitech protocol support for the Series enables the user to perform the functions of reading the various concentrations and to trigger the instrument to be in sample zero span mode if valid for that instrument This is achieved by using the supported Geysitech commands listed below For details of the Model 487 High Level Geysitech Protocol specification see the following topics e Serial Communication Parameters on page D 1 e TCP Communication Parameters on page D 2 e Instrument Address on page D 2 e Abbreviations Used on page D 2 e Basic Command Structure on page D 2 e Block Checksum on page D 3 e Geysitech Commands on page D 3 The following are the communication parameters that are used to configure the serial port of the Series to support Geysitech protocol Number of Data bits 8 Number of Stop bits 1 Parity None Data rate from 1200 115200 Baud
68. F and unplug the power cord Remove fuse drawer located on the AC power connector If either fuse is blown replace both fuses Thermo Electron Corporation Fan Replacement Thermo Electron Corporation Servicing Fan Replacement 4 Insert fuse drawer and reconnect power cord Use the following procedure to replace the fan Figure 7 4 Equipment Required Fan Philips screwdriver Adjustable wrench Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Remove the fan guard from the fan and remove the filter 3 Pull the power connectors off the fan 4 Remove the four fan mounting screws and remove the fan 5 Install a new fan following the previous steps in reverse Mounting Screws 4 Filter Fan Guard A Y Ye Figure 7 4 Replacing the Fan Model 48 High Level Instruction Manual 7 9 Servicing IR Source Replacement IR Source Use the following procedure to replace the IR source Figure 7 5 Replacement Equipment Required IR Source Flatblade screwdriver Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Turn instrument OFF unplug the
69. Model 487 High Level Instruction Manual Gas Filter Correlation CO Analyzer Part Number 102778 00 26May2006 CE Thermo ELECTRON CORPORATION 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 WEEE Compliance This product is required to comply with the European Union s Waste Electrical amp Electronic Equipment WEEE Directive 2002 96 EC It is marked with the following symbol Thermo Electron 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 Electron s compliance with these Directives the recyclers in your country and information on Thermo Electron products which may assist the detection of substances subject to the RoHS Directive are available at www thermo com WEEERoHS WEEE Compliance Thermo Electron Corporation About This Manual This manual provides information about operating maintaining and servicing the Model 487 High Level CO gas analyzer It also contains important alerts to ensure safe operation and prevent eq
70. O acetates 8 3 Pre amplifier Assembly with IR Detector oooonocnocnonoconnconononnnrnnonnoos 8 3 Sample Blow Sensoria eis e e eee 8 3 Pressure ras dadas 8 3 Capillary iii ia 8 3 A poss a aa cates gare eai ar aa ab Ea 8 3 Purge Flow Switch optional dende 8 3 AI e Aa oa nN 8 3 Instrument Control dd Gia core ae ee eee 8 4 Monitoring Sienals cicccd eens a 8 4 Output Communication oWuepra opm cr Meer NOTRE Tro Rory RP Ty Reet ery or 8 4 Electro iii A i it 8 4 Motherboard A chan ead Std eld 8 5 External CONE ctOrs dare rrr eeii a anai assii 8 5 Terma Connectors dan a e aE E S ce 8 5 Measurement Interface Board veis dde 8 6 Measurement Interface Board ConnectOIS ooocccononnoncnnonnannncnnnncnnos 8 6 Flow Sensor ASIN A iia 8 6 Pressure Sensor Assembly a 8 6 Bench Heater Do o On aiii 8 7 Pre amp Board AssemblVeraciaria lacada 8 7 Digital Output Boatd iiioianicaiii ia 8 7 I O Expansion Board Optional cccecccszbesccceseacecataeiceesidsanetadaaeocetonstel 8 7 Front Panel Connector Border it 8 7 VO Component a a a a itis 8 8 Analog Voltage UU ltd id 8 8 Analog Current Outputs Optional ii aid 8 8 Analog Voltage Inputs Oprionalucniin ii 8 9 Digital Relay Outputs isis 8 9 Digit l Inputs niai ial dl di dde 8 9 Semnal PO tases see Caachi es aac rE E Eea aE a Seed as 8 9 RS 232 CORMECHON annann is 8 10 RS 485 Conte coi ita 8 10 Ethernet Connection dc 8 11 External Accessory Connector aii laa 8 11 Optional Equipment cesssssscc
71. Out6 23 GNDD 12 Isolated ground 24 GNDD 2 8 Model 487 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation Installation Startup Sta rtup Use the following procedure when starting the instrument l Turn the power ON Allow 90 minutes for the instrument to stabilize Set instrument parameters such as operating ranges and averaging times to appropriate settings For more information about instrument parameters see the Operation chapter Before beginning the actual monitoring perform a multipoint calibration as described in the Calibration chapter Model 48 High Level Instruction Manual 2 9 Chapter 3 Operation This chapter describes the front panel display front panel pushbuttons and menu driven software For details see the following topics e Display on page 3 1 e Pushbuttons on page 3 2 e Software Overview on page 3 4 e Averaging Time on page 3 15 e Calibration Factors Menu on page 3 16 e Calibration Menu on page 3 19 e Instrument Controls Menu on page 3 23 e Diagnostics Menu on page 3 51 e Alarms Menu on page 3 59 e Service Menu on page 3 68 e Password on page 3 80 Display The 320 x 240 graphics liquid crystal display LCD shows the sample concentrations instrument parameters instrument controls help and error messages Some menus contain more items than can be displayed at one ti
72. Output Board Connector Pin Descriptions on page 6 17 Pre amp Board Connector Pin Descriptions on page 6 19 Table 6 3 Motherboard Connector Pin Descriptions Connector Reference Pin Signal Description Label Designator INTF DATA J1 1 Ground 2 RS485 to Interface Board 3 RS485 to Interface Board 10 BASE T J2 1 Ethernet Output 2 Ethernet Output 3 Ethernet Input 4 NC 5 NC 6 Ethernet Input 7 NC 8 NC INTF DATA J1 1 Ground 2 RS485 to Interface Board 3 RS485 to Interface Board 10 BASE T J2 1 Ethernet Output 2 Ethernet Output 3 Ethernet Input 4 NC 5 NC Model 48 High Level Instruction Manual 6 7 Troubleshooting Connector Pin Descriptions Connector Label Reference Designator Pin co N Om Signal Description Ethernet Input NC NC EXPANSION BD J2 mo N 0O wo A WO N 5V 24V 24V Ground Ground Ground RS485 to Expansion Board RS485 to Expansion Board SPARE DATA gt 0 N OQO wo A WO N 5V 24V 24V Ground Ground Ground RS485 to Spare Board RS485 to Spare Board 1 0 6 8 Model 487 High Level Instruction Manual J5 oOo O N on A WW N gt lt gt gt gt gt gt al gt w N Power Fail Relay N C Contact Ground TTL Input 1 TTL Input 2 Ground TTL Input 5 TTL Input 7 TTL Input 8 TTL Input 10 Ground TTL Input 13 TTL Input 15 Ground Analog Voltage 1 Anal
73. SUPPLIED BY SELLER SHALL Model 48 High Level Instruction Manual A 1 Warranty Warranty A 2 Model 487 High Level Instruction Manual IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED PRODUCTS THE OBLIGATIONS CREATED BY THIS SECTION TO REPAIR OR REPLACE A DEFECTIVE PRODUCT SHALL BE THE SOLE REMEDY OF BUYER IN THE EVENT OF A DEFECTIVE PRODUCT EXCEPT AS EXPRESSLY PROVIDED IN THIS SECTION 8 SELLER DISCLAIMS ALL WARRANTIES WHETHER EXPRESS OR IMPLIED ORAL OR WRITTEN WITH RESPECT TO THE PRODUCTS INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE SELLER DOES NOT WARRANT THAT THE PRODUCTS ARE ERROR FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT Thermo Electron Corporation Instrument Identification Thermo Electron Corporation Number Appendix B C Link Protocol Commands This appendix provides a description of the C Link protocol commands that can be used to remotely control a Model 48i High Level analyzer using a host device such as a PC or a datalogger C Link protocol may be used over RS 232 RS 485 or Ethernet C Link functions can be accessed over Ethernet using TCP IP port 9880 For details see the following topics e Instrument Identification Number on page B 1 e Commands on page B 2 e Measurements on page B 8 e Alarms on page B 11 e Diagnostics on page B 15 e Datalogging on page B 16 e Calib
74. Temperature Limits 3 61 Benchi Temperatutes mimine en en an a a h te ENEN 3 61 Min and Max Bench Temperature Limits n se 3 61 DES A a e a a a aa 3 62 Min and Max Pressure Lia As 3 62 Model 487 High Level Instruction Manual vii Contents viii Model 48 High Level Instruction Manual sample Latidos ii 3 63 Min and Max Sample Flow Limits cc nicinnicnnnaniconionadnn comriccnnnss 3 63 Bias Volare i 3 63 Min and Max Bias Voltage Limits ninia 3 64 AGE ANOETA aceboy Steal enanedeAn ee 3 64 Min and Max AGC Intensity Limits didas 3 65 A A th e Me a 3 65 Zero and Span Checo ita 3 65 Max Zero and Span Oltra io 3 66 Zero and Span Auto Calibration tii td 3 66 Concentrato nim naene n e R A his 3 67 Min and Max Concentration Litio be 3 67 Min Trigger CONCE ito lcd edici 3 67 Service Meira A A AA iaa 3 68 Range Mode Selec td 3 68 Pressure Calibrations secccssivessicnsiuestaeisdecudsinenceediancesen tacriatiiavcestiastes 3 69 Calibrate Press re Zero 3 69 Calibrate Pressure Spansion ne ann 3 70 Restore Default Calibrations civics leva diine hie rae utede ee 3 70 Flow Cabrio dd 3 71 Calibrate Blow Zero ica ibid 3 71 Calibrate Flow paid ios 3 72 Restore Default Flow Calibration sa 3 72 Initial Sample Reference Ratios annie 3 73 Multi Point Cabrio nacos riera ini 3 73 Calibrate Point 1 273 ninia id 3 74 Corn unta ii 3 74 Default Coefficients taa ta 3 75 Preamp Board Calibre te adi 3 75 Temperature Calibrador ia tots 3 75 Analog ut
75. This is an I series Instrument Screen Information not available range high range low range These commands report CO range in single range mode or the high and low ranges in dual or auto range mode If the mode is incorrect the instrument responds with can t wrong settings The example below reports that the CO full scale range is set to 50 ppm according to Table B 6 Send range Receive range 6 5000E 2 ppm set range Selection set high range Selection set low range Selection These commands select the CO full scale ranges according to Table B 6 The example below sets the CO full scale range to 2 000 ppm Send set range 5 Receive set range 5 ok Table B 6 Standard Ranges Selection ppm mg m 0 50 50 1 100 100 2 200 200 3 500 500 4 1 000 1 000 5 2 000 2 000 6 5 000 5 000 7 10 000 10 000 8 20 000 20 000 9 C1 C1 10 C2 C2 11 C3 C3 Model 48 High Level Instruction Manual B 27 C Link Protocol Commands Measurement Configuration B 28 Model 48 High Level Instruction Manual custom range range 1 2 3 This command reports the user defined value of custom range 1 2 or 3 The example below reports that custom range 1 is defined to 5 50 ppm Send custom 1 Receive custom 1 550E 2 ppm set custom range range value set custom 1 range value set custom 2 range value set custom 3 range value These commands are used to set the maximum concentration
76. Time CHS mTOR pH eb E a ale a EE anne Bde Calibration Factors Calibration factors are used to correct the CO concentration readings that Menu the instrument generates using its own internal calibration data The Calibration Factors menu displays the calibration factors The screens below show the calibration factors menu in single mode and dual auto range modes The only difference between the screens are the words LO and HI to indicate which range is displayed Normally the instrument is calibrated automatically using the Calibration menu described in Calibration Menu later in this chapter However the instrument can also be calibrated manually using the Calibration Factors menu To manually calibrate the instrument see CO Background and CO Coefficient below for more information e Inthe Main Menu choose Calibration Factors DH init MAMA 3 16 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Calibration Factors Menu CO Background The CO background correction is determined during zero calibration The CO background is the amount of signal read by the analyzer while sampling zero air The background signal is electrical noise Before the analyzer sets the CO reading to zero it stores these value as the CO background correction The CO Background screen is used to perform a manual zero calibration of the instrument As such the instrument should
77. al m OCH iid CI a E S EA The Calibrate CO Coefficient screen is used to adjust the CO coefficient and enter the span concentration The display shows the current CO concentration reading and the current CO range The next line of the display is where the CO calibration gas concentration is entered The CO span coefficient is calculated stored and used to correct the current CO reading For more information about calibration see Chapter 4 Calibration In dual or auto range modes HIGH or LOW is displayed to indicate the calibration of the high or low coefficient e Inthe Main Menu choose Calibration gt Cal CO Coefficient parara d EEE The Zero Span Check menu is available with the zero span valve option It is used to program the instrument to perform fully automated zero and span check or adjustments Total Duration Hour is the sum of zero span and purge duration minutes Zero and Span Calibration Reset are toggle items that change between yes or no when selected and displayed if auto calibration is installed e Inthe Main Menu choose Calibration gt Zero Span Check Thermo Electron Corporation Operation Calibration Menu Next Time The Next Time screen is used to view and set the next zero span check date and time Once the initial zero span check is performed the date and time of the next zero span check is calculated and displayed e Inthe Main Menu choose Calibration gt Zero Span
78. al object before touching any internal components When the instrument is unplugged the chassis is not at earth ground A Handle all printed circuit boards by the edges A Do not remove the LCD panel or frame from the LCD module A The polarizing plate is very fragile handle it carefully A Do not wipe the polarizing plate with a dry cloth it may easily scratch the plate A Do not use alcohol acetone MEK or other Ketone based or aromatic solvents to clean the LCD module use a soft cloth moistened with a naphtha cleaning solvent A Do not place the LCD module near organic solvents or corrosive gases A Do not shake or jolt the LCD module A E Figure 7 1 Properly Grounded Antistatic Wrist Strap The firmware can be updated by the user in the field via the serial port or over the Ethernet This includes both the main processor firmware and the firmware in all low level processors Refer to the Port manual for the firmware update procedure If the Service Mode is not displayed on the Main Menu use the following procedure to display it 1 At the Main Menu press to scroll to Instrument Controls gt press gt J to scroll to Service Mode gt and press Model 48 High Level Instruction Manual 7 3 Servicing Replacement Parts List Replacement Parts List 7 4 Model 487 High Level Instruction Manual The Service Mode screen appears Press to toggle the Service Mode to ON Press gt to r
79. al Block and Cable Kit DB37 optional 102645 00 Cable DB37M to Open End Cable Six Feet optional 102646 00 Cable DB37F to Open End Six Feet optional 102659 00 Cable DB25M to Open End Six Feet optional 6219 Cable RS 232 optional 102888 00 Terminal Board PCB Assembly DB37F standard with all instruments 102891 00 Terminal Board PCB Assembly DB37M standard with all instruments 103084 00 Terminal Board PCB Assembly DB25M standard with all instruments Pressure Transducer Pump Motor and Wheel Assy IR Source Cover Detector Assy and Pre Amp 1 0 Expansion Board Opt Digital Output Board Measurement Interface Board Motherboard Figure 7 2 Component Layout Thermo Electron Corporation Servicing Removing the Measurement Bench and Lowering the Partition Panel Removing the The partition panel of the measurement bench can be lowered to improve M easurement B en ch access to connectors and components Refer to the following steps when a procedure requires lowering the partition panel see Figure 7 3 and Lowering the Partition Panel REMOVE SCREWS Pass Through Connectors Loosen f Partition Panel Captive SLIDE BENCH OUT Remove Screws gt Remove Hidden Screw Figure 7 3 Removing the Measurement Bench and Lowering the Partition Panel Equipment Required Philips screwdriver Equipment Damage Some internal compon
80. alibrador 4 7 Default Coefficients snra er a ote ee ean aL 4 7 Gal Pointl 2 and 3 AN Ue 4 7 References ui 4 9 Preventive Maintenance sssssesssesssssssssssssesssssssseessesssessseessseesneesneesse 5 1 e 5 1 Replacement Partit td 5 2 Cleaning the Outside Caseiunaionic iii iii 5 2 Cleaning the Opt endci did 5 2 IR Soutce Replacement eater lodos Den nta lo e a a 5 3 Fan Filter Inspection and Clemens 5 3 Leak Test and Pump Check Out cence an akin Gente 5 4 External Lea siii 5 4 Leaks Across the Optional Zero Span and Sample Solenoid Valves 5 5 Pump Rebuild inte dcir iionl 5 5 Troubleshooting opa 6 1 Safety Precautions aia 6 1 Troubleshooting Guides tii ds 6 1 Board Level Connection Diagrams 23 cecstacessstes lts 6 5 Connector Pin Descriptions viii en 6 7 SETVICE LOCA O INS ii A ia 6 20 Model 48 High Level Instruction Manual ix Contents x Model 48 High Level Instruction Manual SOC A A T 7 1 Safety Precautions saaa ae E atts nist ore dete R 7 2 Firmware Updates casita A 7 3 Accessing the Service Mode taste acid 7 3 Replacement Parts Listin itinin nor eiiean inae a R Es 7 4 Cable Lituania 7 5 External Device Connection Component 7 5 Removing the Measurement Bench and Lowering the Partition Panel 7 7 Fuse Replacement A A hini a e E E E 7 8 Fan Replacement iii iio 7 9 IR Source Replacement nan asii 7 10 Filter Wheel Replacement cua dai 7 11 Chopper Motor Replacements auto 7 13 Optical Bench Replicante cti aio 7 13 O
81. and response to read registers 10 13 Request Field Name Hex Function 0x03 Starting Address Hi 0x00 Starting Address Lo 0x09 No of Registers Hi 0x00 No of Registers Lo 0x04 Response Field Name Hex Function 0x03 Byte Count 0x06 Register value Hi 10 0x02 Register value Lo 10 0x2B Register value Hi 11 0x00 C 6 Model 48 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation MODBUS Protocol Function Codes Register value Lo 11 0x00 Register value Hi 12 0x00 Register value Lo 12 0x64 Register value Hi 13 0x00 Register value Lo 13 0x64 The contents of register 10 are shown as the two byte values of 0x02 0x2B Then contents of registers 11 13 are 0x00 0x00 0x00 0x64 and 0x00 0x64 respectively 0x05 Force Write Single Coil The force write single coil function simulates the activation of the digital inputs in the instrument which triggers the respective action This function code is used to set a single action to either ON or OFF The request specifies the address of the action to be forced Actions are addressed starting at zero Therefore action number 1 is addressed as 0 The requested ON OFF state is specified by a constant in the request data field A value of 0xFF00 requests the action to be ON A value of 0x0000 requests it to be OFF All other values are illegal and will not affect the output The normal response is an echo of the request returned after th
82. ands report the pressure alarm minimum and maximum value current settings The example below reports that the pressure alarm minimum value is 205 mmHg Model 48 High Level Instruction Manual B 13 C Link Protocol Commands Alarms B 14 Model 487 High Level Instruction Manual Send pressure alarm min Receive pressure alarm min 205 mmHg set alarm pressure min value set alarm pressure max value These commands set the pressure alarm minimum and maximum values to value where value is a floating point number representing pressure alarm limits in millimeters of mercury The example below sets the pressure alarm maximum value to 215 mmHg Send set alarm pressure max 215 Receive set alarm pressure max 215 ok alarm sample flow min alarm sample flow max These commands report the sample flow alarm minimum and maximum value current settings The example below reports that the sample flow alarm minimum value is 2 LPM Send alarm sample flow min Receive alarm sample flow min 2 1 min set alarm sample flow min value set alarm sample flow max value These commands set the sample flow alarm minimum and maximum values to value where value is a floating point number representing sample flow alarm limits in liters per minute The example below sets the sample flow alarm maximum value to 1 LPM Send set alarm sample flow max 1 Receive set alarm sample flow max 1 ok alarm trig conc This command reports the CO concentration alarm tri
83. ange Mode Table 3 2 Default Analog Outputs in Single Range Mode Channel Pin Description 1 14 CO Analog Output 2 33 CO Analog Output 3 15 None 4 34 None 5 17 None 6 36 None Ground 16 18 19 35 37 Signal Ground Note All channels are user definable If any customization has been made to the analog output configuration the default selections my not apply A In the dual range mode there are two independent analog outputs These are labeled simply as the High Range and the Low Range Each channel has its own analog output range averaging time and span coefficient This enables the sample concentration reading to be sent to the analog outputs at two different ranges For example the low CO analog output can be set to output concentrations from 0 to 50 ppm and the high CO analog output set to output concentrations from 0 to 100 ppm Model 48 High Level Instruction Manual 3 9 Operation Range Menu In addition each CO analog output has a span coefficient There are two span coefficients so that each range can be calibrated separately This is necessary if the two ranges are not close to one another For example the low CO range is set to 0 50 ppm and the high CO range is set to 0 20 000 ppm By default in the dual range mode the analog outputs are arranged on the rear panel connector as shown in Figure 3 5 See Table 3 3 for channels and pin connections Dual range mode may be select
84. ange mode In dual or auto range modes HI or LO is displayed to indicate the calibration of the high or low concentrations and function the same way Note This adjustment should only be performed by an instrument service technician A e Inthe Main Menu choose Service gt Multipoint Calibration Thermo Electron Corporation Model 48 High Level Instruction Manual 3 73 Operation Service Menu Calibrate Point 1 2 3 The Calibrate Point 1 screen allows the user to view and set the selected calibration point The calibrate 2 and calibrate 3 screens function the same way e Inthe Main Menu choose Service gt Multipoint Cal gt Calibrate 1 2 or 3 DH Guided ML PRA Coefficients The Coefficients screen allows the user to view and re calculate the calibration coefficients e Inthe Main Menu choose Service gt Multipoint Cal gt Choose Cal Point gt Coefficients EH Guided Piet 3 74 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Service Menu Default Coefficients The Default Coefficients screen allows the user to view and reset the calibration coefficients to default values e Inthe Main Menu choose Service gt Multipoint Cal gt Choose Cal Point gt Coefficients Preamp Board Calibration The Pre amp Board Calibration screen is used to adjust the preamp board calibration parameters Note This adjustment should only be performed by an instrument servic
85. ard Connectors located on the measurement interface board include Data communication with the motherboard e 24V and 120VAC power supply inputs e Fan and solenoid outputs e 120VAC output and thermistor input from the bench heater board e Flow and pressure sensor inputs e Chopper motor output e Optical pickup input e Pre amp board e Ambient temperature thermistor e Purge flow switch input The flow sensor assembly consists of a board containing an instrumentation amplifier and a flow transducer with input and output gas fittings The flow transducer output is produced by measuring the pressure difference across a precision orifice This unit is used for measuring the flow of sample gas in the measurement system The pressure sensor assembly consists of a board containing an instrumentation amplifier and a pressure transducer with a gas input fitting The pressure transducer output is produced by measuring the pressure difference between the sample gas pressure and ambient air pressure Thermo Electron Corporation Bench Heater Board Pre amp Board Assembly Digital Output Board 1 0 Expansion Board Optional Front Panel Connector Board Thermo Electron Corporation System Description Electronics The bench heater board provides connections for the optical bench heater resistors and optical bench temperature thermistor The optical bench temperature is measured with a thermistor The voltage across the thermistor is app
86. aters and install the new heaters and heater board assembly 5 Calibrate the instrument Refer to the Calibration chapter in this manual Detector Preampl ifier Use the following procedure to replace the detector preamplifier assembly Assembly Figure 7 9 Replacement Fsupmen Required detector preamplifier assembly Allen wrenches 3 32 inch and 7 64 inch amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A f Equipment Damage Some internal components can be damaged by small 1 Turn instrument OFF unplug the power cord and remove the cover 2 Disconnect the cable from the PREAMP connector on the measurement interface board and disconnect the two wires from the top of the chopper motor plate Preamp Cover gt To Motor Plate Detector Assy Optical Bench To PREAMP on Measurement Interface Board Figure 7 9 Replacing the Detector Preamplifier Assembly Thermo Electron Corporation Model 48 High Level Instruction Manual 7 17 Servicing Preamp Board Calibration Preamp Board Calibration A 7 18 Model 48i High Level Instruction Manual Remove the two screws holding the preamplifier cover to the preamplifier assembly and remove the cover Insert an Allen wrench through the access holes in the preamplifier printed circuit board and remove the screws holding the detector assembly to the optical bench
87. atus and I O Expansion board status if installed indicate that the power supplies are working and connections are successful There are no setting screens for these alarms e Inthe Main Menu choose Alarms The Internal Temperature screen displays the current internal temperature and sets the minimum and maximum alarm limits Acceptable alarm limits range from 8 to 47 C If the internal temperature reading goes beyond either the minimum or maximum alarm limit an alarm is activated The word ALARM appears in the Run screen and in the Main Menu e Inthe Main Menu choose Alarms gt Internal Temp Thermo Electron Corporation Operation Alarms Menu Min and Max Internal The Minimum Internal Temperature alarm limit screen is used to change Temperature Limits the minimum internal temperature alarm limit The minimum and maximum internal temperature screens function the same way e Inthe Main Menu choose Alarms gt Internal Temp gt Min or Max ty Wi bid Bench Temperature The Bench Temperature screen displays the current bench temperature and sets the minimum and maximum alarm limits Acceptable alarm limits range from 40 to 59 C If the bench temperature reading goes beyond either the minimum or maximum limit an alarm is activated The word ALARM appears in the Run screen and in the Main Menu e Inthe Main Menu choose Alarms gt Bench Temp i mid Min and Max Bench The Minimum
88. atus Internal Temperature Analog Input 4 Bench Temperature Analog Input 5 Bench Pressure Analog Input 6 Sample Flow Analog Input 7 Intensity Analog Input 8 Motor Speed Bias Supply Analog Input The Analog Input Configuration menu displays a list of the 8 analog input Configuration channels available for configuration This screen is only displayed if the I O expansion board option is installed Configuration includes entering Thermo Electron Corporation Model 48 High Level Instruction Manual 3 45 Operation Instrument Controls Menu descriptor units decimal places choice of 1 10 points in the table and corresponding number of points selected e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config ip gies PLP Descriptor The Descriptor screen allows the user to enter the descriptor for the selected analog input channel The descriptor is used in datalogging and streaming data to report what data is being sent out The descriptor may be from 1 to 3 characters in length and defaults to IN1 to IN8 user input channel number e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config gt Select Channel gt Descriptor my Ba POT hal fat ip priri ML a EA 3 46 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu Units The Units screen allows the user to enter the unit
89. ax 215 ok alarm internal temp min alarm internal temp max These commands report the internal temperature alarm minimum and maximum value current settings The example below reports that the internal temperature alarm minimum value is 15 0 C Send internal temp alarm min Receive internal temp alarm min 15 0 deg C set internal temp alarm min value set internal temp alarm max value These commands set the internal temperature alarm minimum and maximum values to value where value is a floating point number representing internal temperature alarm limits in degrees C The example below sets the internal temperature alarm maximum value to 45 0 C Send set internal temp alarm max 45 Receive set internal temp alarm max 45 ok alarm motor speed min alarm motor speed max These commands report the motor speed alarm minimum and maximum value current settings The example below reports that the motor speed alarm minimum value is 20 minutes Send alarm motor speed min Receive alarm motor speed min 20 set alarm motor speed min value set alarm motor speed max value These commands set the motor speed alarm minimum and maximum values to value where value is a floating point number representing motor speed alarm limits in minutes The example below sets the motor speed alarm maximum value to 20 minutes Send set alarm motor speed max 20 Receive set alarm motor speed max 20 ok alarm pressure min alarm pressure max These comm
90. ble 6 4 Measurement Interface Board Connector Pin Descriptions Signal Description Ground RS485 from Motherboard RS485 from Motherboard Preamp Signal Input Ground for Shield Ground SPI Data Out SPI CLK SPI CS 15V 5V 18V for IR Source Ground 100V 100V Return Thermo Electron Corporation Thermo Electron Corporation Connector Label Reference Designator Pin Troubleshooting Connector Pin Descriptions Signal Description PRES J9 FP Ww N Pressure Sensor Input Ground 15V 15V FLOW on A WO N Flow Sensor Input Ground 15V 15V Ground AMB TEMP J5 Ambient Temperature Thermistor Ground 02 SENS J2 o oO A WO N Sensor Signal Input Ground Temperature Signal Input Ground 15V 15V AC BENCH 24V IN FAN J4 FPF WO N BENCH THERMISTOR Ground AC HOT AC BENCH HEATER 24V Ground 24V Ground AC PUMP AC HOT AC NEUT AC Ground Z S SOL 24V Zero Span Solenoid Control SAMPLE SOL 24V Sample Solenoid Control SPAN1 SOL 24V Converter Solenoid Control Model 487 High Level Instruction Manual 6 13 Troubleshooting Connector Pin Descriptions 6 14 Model 48 High Level Instruction Manual Connector Reference Pin Signal Description Label Designator SPANZ SOL J16 1 24V 2 Span 2 Solenoid Control AC 02 J3 1 AC HOT 2 AC NEUT 3 A
91. ble materials All tubing should be constructed of 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 free of particulates It may be necessary to use the Teflon particulate filter as described in Teflon Particulate Filter on page 9 2 A Note Gas must be delivered to the instrument at atmospheric pressure It may be necessary to use an atmospheric bypass plumbing arrangement as shown in Figure 2 4 if gas pressure is greater than atmospheric pressure A 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 Ifthe optional zero span solenoid valves are installed connect a source of CO free air to the ZERO bulkhead and connect a source of CO span gas to the SPAN bulkhead 4 Connect a suitable recording device to the rear panel connector For detailed information about connecting to the instrument refer to Connecting External Devices on page 2 5 External Device Connection Components on page 7 5 Terminal Block and Cable Kits on page 9 3 Instrument Controls Menu on page 3 23 For detailed information about troubleshooting a connection refer to Analog Output Test
92. changed for the change to take effect A e Inthe Main Menu choose Instrument Controls gt Communication Settings gt TCP IP Settings CHA y Pla Pi Use DHCP The Use DHCP screen is used to specify whether to use DHCP or not e Inthe Main Menu choose Instrument Controls gt Communication Settings gt TCP IP Settings gt Use DCHP 3 36 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu IP Address The IP Address screen is used to edit the IP address The IP address can only be changed when DHCP is on For more information on DHCP see Use DHCP above e Inthe Main Menu choose Instrument Controls gt Communication Settings gt TCP IP Settings gt IP Address Netmask The Netmask screen is used to edit the netmask e Inthe Main Menu choose Instrument Controls gt Communication Settings gt TCP IP Settings gt Netmask Default Gateway The Default Gateway screen is used to edit the gateway address e Inthe Main Menu choose Instrument Controls gt Communication Settings gt TCP IP Settings gt Gateway Thermo Electron Corporation Model 48 High Level Instruction Manual 3 37 Operation Instrument Controls Menu Host Name The host name screen is used to edit the host name When DHCP is enabled this name is reported to the DHCP server e In the Main Menu choose Instrument Controls gt Communication Settings gt TCP IP Setting
93. command reports the current time 24 hour time The example below reports that the internal time is 2 15 30 pm Send time Receive time 14 15 30 set time hh mm ss hh hours mm minutes ss seconds Model 48 High Level Instruction Manual B 31 C Link Protocol Commands Communications Configuration Communications Configuration B 32 Model 487 High Level Instruction Manual This command sets the internal clock 24 hour time The example below sets the internal time to 2 15 pm Note If seconds are omitted the seconds default to 00 A Send set time 14 15 Receive set time 14 15 ok addr dns This command reports the TCP IP address for the domain name server Send addr dns Receive addr dns 192 168 1 1 set addr dns address This command sets the dns address where address consists of four numbers gt ranging from 0 255 inclusive separated by Send set addr dns 192 168 1 1 Receive set addr dns 192 168 1 1 ok addr gw This command reports the default TCP IP gateway address Send addr gw Receive addr gw 192 168 1 1 set addr gw address This command sets the default gateway address where address consists of gt four numbers ranging from 0 255 inclusive separated by Send set addr gw 192 168 1 1 Receive set addr gw 192 168 1 1 ok addr ip This command reports the IP address of the analyzer Send addr ip Receive addr ip 192 168 1 200 set addr ip address This
94. command sets the analyzer s IP address where address consists of four 9 numbers ranging from 0 255 inclusive separated by Send set addr ip 192 168 1 200 Receive set addr ip 192 168 1 200 ok Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Communications Configuration addr nm This command reports the IP netmask Send addr nm Receive addr nm 255 255 255 0 set addr nm address This command sets the nm address where address consists of four numbers gt ranging from 0 255 inclusive separated by Send set addr nm 255 255 255 0 Receive set addr nm 255 255 255 0 ok baud This command reports the current baud rate for the serial port RS232 RS485 The example below reports that the current baud rate is 9600 baud Send baud Receive baud 9600 set baud rate rate 1200 2400 4800 9600 19200 38400 57600 115200 This command sets the instrument baud rate The example below sets the instrument s baud rate to 9600 Note After the command is sent the baud rate of the sending device must be changed to agree with the instrument A Send set baud 9600 Receive set baud 9600 ok dhcp This command reports the current state of use of DHCP on or off DHCP is used to assign an IP address to the analyzer automatically The example below shows that DHCP is on Send dhcp Receive dhcp on set dhcp onoff These commands enables and disab
95. d Opt y e e p igi i fi S N Digital Output Board Front Panel Board f a A E was Bist IL f N Measurement Interface Board Motherboard Power Supply Optical Bench Band pass Filter Bench Heater Board Chopper Motor 8 2 Model 487 High Level Instruction Manual Figure 8 1 Hardware Components The optical bench is an airtight chamber that contains the sample gas The bench includes mirrors that cause the infrared light from the infrared source to pass through the sample gas multiple times before reaching the infrared detector The band pass filter limits the light entering the optical bench to a narrow band of the infrared portion of the spectrum The bench heater board applies power to the bench heater resistors and transmits the bench temperature monitored by a thermistor This assembly is used for maintaining the optical bench at a constant temperature The chopper motor spins the gas filter wheel and chopper disk at a uniform speed Thermo Electron Corporation Optical Pickup Gas Filter Wheel Infrared Source Pre amplifier Assembly with IR Detector Sample Flow Sensor Pressure Transducer Capillary Pump Purge Flow Switch optional Software Thermo Electron Corporation System Description Software The optical pickup detects the position of the gas filter wheel provides synchronizing signals for the signal demodulation and provides a method for checking the chopper motor speed
96. d be defective Alarm Pressure High pressure indication Check the pump for a tear in the diaphragm replace with pump repair kit if necessary Refer to Preventive Maintenance chapter in this manual Check that capillaries are properly installed and O rings are in good shape Replace if necessary Check flow system for leaks Alarm Flow Alarm Bias voltage Flow low Defective measurement interface board Defective pre amp board Check sample capillary 0 015 inch ID for blockage Replace as necessary If using sample particulate filter make sure It is not blocked Disconnect sample particulate filter from the sample bulkhead if flow increases replace the filter Replace measurement interface board Replace pre amp board Alarm AGC intensity Thermo Electron Corporation Pre amp Gain not set properly Defective measurement interface board Check Gain adjustment Replace measurement interface board Model 48 High Level Instruction Manual 6 3 Troubleshooting Troubleshooting Guides 6 4 Model 487 High Level Instruction Manual Alarm Message Alarm Motor Speed Possible Cause Defective measurement interface board Defective chopper motor or cable Action Replace measurement interface board Check chopper motor cable Replace chopper motor Alarm CO Conc Concentration has exceeded range limit Concentration low Check to insure range
97. d 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 3 Remove the packing material Figure 2 1 Model 48 High Level Instruction Manual 2 1 Installation Unpacking and Inspection Remove Packing a pienes D Remove Packing A 2 pieces Units without Optional 1 0 Board Units with Optional 1 0 Board Figure 2 1 Remove the Packing Material 4 Remove the three shipping screws Figure 2 2 Shipping Screws 3 Figure 2 2 Removing the Shipping Screws 5 Check for possible damage during shipment 2 2 Model 487 High Level Instruction Manual Thermo Electron Corporation Setup Procedure Thermo Electron Corporation Installation Setup Procedure 6 Check that all connectors and circuit boards are firmly attached 7 Re install the cover 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 incompati
98. d instrument responds with measurement data which depends on the range DA mode and is listed in Measurement reported in response to DA commands below The command structure for a data query command is as follows lt STX gt DA lt address gt lt ETX gt lt BCC gt The lt address gt is optional which means it can be left out completely The lt address gt if present must match the Instrument Address Additional space can be present after the lt address gt If the lt address gt is left out then no space is allowed in the query string A command with no address is also a valid command The following are the different acceptable formats of the DA command with Instrument Address 5 lt STX gt DA lt CR gt lt STX gt DA005 lt CR gt lt STX gt DA lt SP gt lt SP gt 5 lt ETX gt lt BCC gt lt STX gt DA lt ETX gt lt BCC gt The data query string is valid and will be answered with data transmission only if the command starts with lt STX gt which is followed by the characters DA and the lt address gt if present matches the Instrument Address and the command is terminated with either lt CR gt with no checksum or lt ETX gt followed by the correct checksum lt BCC gt D 4 Model 48 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation Geysitech Bayern Hessen Protocol Geysitech Commands Sample Data Reply String in response to Data Query Command DA In response to a valid data
99. d item is shown by lt after it In dual or auto range mode HI or LO is displayed to indicate high or low concentrations e Inthe Main Menu choose Instrument Controls gt Communication Settings gt Streaming Data Config gt Select Item gt Other Measurements 3 34 Model 487 High Level Instruction Manual Thermo Electron Corporation Analog Inputs RS 232 RS 485 Selection Thermo Electron Corporation Operation Instrument Controls Menu O OEH pikari The Analog Inputs screen allows the user to select the analog input signal none or analog inputs 1 8 that is tied to the selected streaming data item The selected item is shown by lt after it e Inthe Main Menu choose Instrument Controls gt Communication Settings gt Streaming Data Config gt Select Item gt Analog Inputs O OEH pikari The RS 232 RS 485 Selection screen allows the user to choose between the RS 232 or RS 485 specification for serial communication Note Disconnect the serial cable before changing RS 232 and RS 485 selection to prevent damage to the connected equipment A e In the Main Menu choose Instrument Controls gt Communication Settings gt RS 232 RS 485 Selection Model 487 High Level Instruction Manual 3 35 Operation Instrument Controls Menu TCP IP Settings The TCP IP Settings menu is used for defining TCP IP settings Note The instrument power must be cycled after this parameter has been
100. d milligrams per cubic meter mg m are available The mg m gas concentration mode is calculated using a standard pressure of 760 mmHg and a standard temperature of 20 C When switching from ppm to mg m the analog ranges all default to the highest range in that mode For example when switching from mg m to ppm all the ranges default to 20 000 ppm Therefore whenever you change units you should also check the range settings e Inthe Main Menu choose Range gt Gas Units Note If the units change from ppm to mg m or vice versa the instrument should be re calibrated particularly if the user s standard temperature is different from 20 C A display warning will appear that ranges will be defaulted and calibration parameters reset A The CO Range screen defines the concentration range of the analog outputs For example a CO range of 0 50 ppm restricts the analog output to concentrations between 0 and 50 ppm The display shows the current CO range The next line of the display is used to change the range The range screen is similar for the single dual and auto range modes The only difference between the screens are the words High or Low displayed to indicate which range is displayed The example below shows the CO range screen in single mode For more information about the dual and auto range modes see Single Range Mode Dual Range Mode and Auto Range Mode earlier in this chapter Model
101. de a diluted CO concentration of approximately 80 of the upper range limit URL of the analyzer The total air flow must exceed the total demand of the analyzer connected to the output manifold to ensure that no ambient air is pulled into the manifold vent The exact CO concentration is calculated from A CO stp X Fco SKT Fp Foo Aa OU 7 CO Where CO our diluted CO concentration at the output manifold ppm CO srp concentration of the undiluted CO standard ppm Eco flow rate of CO standard corrected to 25 C and 760 mmHg LPM Fp flow rate of dilution air corrected to 25 C and 760 mmHg LPM Allow the instrument to sample this CO concentration standard until a stable response is obtained From the Main Menu choose Calibration gt Calibrate Span The first line of the display shows the current CO concentration reading The second line of the display shows the CO range and the third line is where the CO concentration is entered Enter the CO calibration gas concentration using the pushbuttons and then press to calibrate the CO reading to the CO calibration gas recorder response percent scale CO our x 100 URL Zco Where URL nominal upper range limit of the instrument operating range Zco instrument response to zero air scale Record the CO concentration and the instrument s response Model 48 High Level Instruction Manual 4 5 Calibration Periodic Zero and Span Checks
102. death or serious personal injury if the warning is ignored 4 WARNING A hazard is present or an unsafe practice can result in serious personal injury if the warning is ignored 4 CAUTION The hazard or unsafe practice could result in minor to moderate personal injury if the warning is ignored A Equipment Damage The hazard or unsafe practice could result in property damage if the warning is ignored A Thermo Electron Corporation About This Manual Safety and Equipment Damage Alerts 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 4 The service procedures in this manual are restricted to qualified service personnel only A The Model 487 High Level is supplied with a three wire grounding cord Under no circumstances should this grounding system be defeated 4 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 A Equipment Damage Do not attempt to lift the analyzer by the cover or other external fittings A 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 4 This adjustment should only be performed b
103. dump bypass plumbing arrangement to accomplish this For more information refer to the Installation chapter and the Operation chapter The internal zero air scrubber is mounted inside the instrument and provides a source of zero air The filter wheel purge option includes a housing attached between the optical bench and the motor plate Figure 9 1 It surrounds the gas correlation wheel and allows purging the area around the gas correlation wheel with a gas other than that present in the local atmosphere This option increases reliability in the presence of contaminants that could interfere with the analytical process Model 48 High Level Instruction Manual 9 1 Optional Equipment Teflon Particulate Filter Calibration Note Teflon Particulate Filter 1 0 Expansion Board Assembly 9 2 Model 487 High Level Instruction Manual Motor Plate Purge Wheel Housing Figure 9 1 Purge Housing Assembly The stability of the purge gas is very important Since this gas is in the same optical path as the sample changes in the composition of the purge gas can change the calibration of the instrument Therefore either zero air or a non toxic dry inert gas such as nitrogen is recommended for use in this option Other than the effect of the purge gas operation and calibration of the instrument is not affected by the addition of the purge housing A constant purge flow of approximately 140cc min is recommended for optimum
104. e state has been written Request Function code 1 Byte 0x05 Starting Address 2 Bytes 0x0000 to maximum allowed by instrument Output Value 2 Bytes 0x0000 or OxFFOO Response Function code 1 Byte 0x05 Starting Address 2 Bytes 0x0000 to maximum allowed by instrument Output Value 2 Bytes 0x0000 or OxFFOO Error Response Function code 1 Byte Function code 0x80 Exception code 1 Byte 01 IIlegal Function 02 lllegal Address 03 Illegal Data 04 Slave Device Failure Model 48i High Level Instruction Manual C 7 MODBUS Protocol MODBUS Commands Supported MODBUS Commands Supported C 8 Model 48 High Level Instruction Manual Here is an example of a request to write Coil 5 ON Request Field Name Hex Function 05 Output Address Hi 00 Output Address Lo 05 Output Value Hi FF Output Value Lo 00 Response Field Name Hex Function 05 Output Address Hi 00 Output Address Lo 05 Output Value Hi FF Output Value Lo 00 The following Table C 1 through Table C 3 lists the MODBUS commands supported for the Model 487 High Level Table C 1 Read Coils for 487 High Level Coil Number Status 1 AUTO RANGE 2 LOCAL REMOTE 3 SERVICE 4 UNITS 5 ZERO MODE 6 SPAN MODE 7 SAMPLE MODE 8 GEN ALARM 9 CONC MAX ALARM 10 CONC MIN ALARM 11 INTERNAL TEMP ALARM 12 BENCH TEMP ALARM Thermo Electron Corporation Thermo Electron Corporation MODBUS Protocol MODBUS Commands Supported
105. e technician A e Inthe Main Menu choose Service gt Preamp Calibration Temperature The Temperature calibration screen allows the user to view and set the Calibration ambient temperature sensor calibration The temperature calibration is visible only when the instrument is in service mode For more information on the service mode see Service Mode earlier in the chapter Note This adjustment should only be performed by an instrument service technician A Thermo Electron Corporation Model 48 High Level Instruction Manual 3 75 Operation Service Menu e Inthe Main Menu choose Service gt Temperature Calibration Analog Output The Analog Output Calibration menu is a selection of 6 voltage channels Calibration and 6 current channels if I O expansion board option is installed to calibrate and allows the user to select the calibration action zero or span The analog output calibration is visible only when the instrument is in service mode For more information on the service mode see Service Mode earlier in the chapter Note This adjustment should only be performed by an instrument service technician A e Inthe Main Menu choose Service gt Analog Out Calibration Wa proi mh ie Tints El mir de rv ir A CHS mTOR gH eb nv AS Fl ana i 3 76 Model 48i High Level Instruction Manual Thermo Electron Corporation Analog Output Calibrate Zero Analog Output Calibrate Full Scale Analog Input
106. e 7 5 identifies the associated channels 2 From the Main Menu press to scroll to Service press gt to scroll to Analog Input Calibration and press Ce The Analog Input Cal screen displays input channels 1 8 3 At the Analog Input Cal screen press to scroll to the channel selected in Step 1 and press Ce 4 Press to scroll to Calibrate Full Scale and press The screen displays the current input voltage for the selected channel 5 Use Jand _ J 4 to enter the source voltage and press _ to calibrate the input voltage for the selected channel to the source voltage 6 Press gt to return to the input channels display and repeat Steps 3 5 to calibrate other input channels to the source voltage as necessary Model 487 High Level Instruction Manual 7 31 Servicing Ambient Temperature Calibration Ambient Temperature Calibration 7 32 Model 48 High Level Instruction Manual Use the following procedure to calibrate the ambient internal temperature for the instrument Equipment Required Calibrated thermometer or 10K ohm 1 resistor WARNING The service procedures in this manual are restricted to qualified service representatives 4 If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A Equipment Damage Some internal components can be damaged by small amounts of static electric
107. e Service Mode on page 7 3 then return to the beginning of this step A 3 At the Preamp Board Cal screen use until either the Sample or Reference value reads more than 150 000 then press to save the value Use the following procedure to rebuild the pump Figure 7 10 Equipment Required Pump Nut driver Philips screwdriver 2 Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Disconnect the pump power cable from the AC PUMP connector on the measurement interface board 3 Remove both lines from the pump 4 Loosen the four captive screws holding the pump bracket to the shock mounts and remove the pump assembly and the shock mounts 5 Invert the pump assembly remove the two pump mounting screws located on the bottom side of the pump bracket and remove the bracket from the pump 6 Install the new pump by following the previous steps in reverse 7 Perform a leak test as described in the Preventive Maintenance chapter Model 487 High Level Instruction Manual 7 19 Servicing Pressure Transducer Replacement Pump Bracket Floor Plate Pump Mounting Screws 2 Bottom Figure 7 10 Replacing the Pump Pressure Transducer Use the following procedure to replace the pressure
108. e following averaging times are available 1 2 5 10 20 30 60 90 120 180 240 and 300 seconds e Inthe Main Menu choose Calibration gt Zero Span Check gt Zero Span Avg Sec 3 22 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu Zero Span Ratio The Zero Span Ratio screen is used to adjust the ratio of zeros to spans For example if this value is set to 1 a span check will follow every zero check If this value is set to 3 there will be two zero checks between each zero span check This value may be set from 1 to 10 with 1 as default e Inthe Main Menu choose Calibration gt Zero Span Check gt Zero Span Ratio Pra Hp popii Bai PET PLP PRE Instrument Co ntrols The Instrument Controls menu contains a number of items The software M enu controls listed in this menu enable control of the listed instrument functions e Inthe Main Menu choose Instrument Controls Thermo Electron Corporation Model 48 High Level Instruction Manual 3 23 Operation Instrument Controls Menu Datalogging Settings Select SREC LREC View Logged Data 3 24 Model 487 High Level Instruction Manual The Datalogging Settings menu deals with datalogging In the Main Menu choose Instrument Controls gt Datalogging Settings moyga CH gupi hat h POES a Pi EE EE The Select SREC LREC is used to select short record or long record format for oth
109. ed from the Range Mode Select on page 3 68 o000000000000000000 c000000000000000000 O Figure 3 5 Pin Out of Rear Panel Connector in Dual Range Mode Table 3 3 Default Analog Outputs in Dual Range Mode Channel Pin Description 1 14 CO High Range 2 33 CO Low Range 3 15 None 4 34 None 5 17 None 6 36 None Ground 16 18 19 35 37 Signal Ground Note All channels are user definable If any customization has been made to the analog output configuration the default selections my not apply A 3 10 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Range Menu Auto Range Mode The auto range mode switches the CO analog outputs between a high and low ranges depending on the concentration level The high and low ranges are defined in the Range menu For example suppose the low range is set to 50 ppm and the high range is set to 100 ppm Figure 3 6 Sample concentrations below 50 ppm are presented to the low ranges analog outputs and sample concentrations above 50 ppm are presented to the high ranges analog outputs When the low range is active the status output is at 0 volts When the high range is active the status output is at half of full scale When the high range is active the concentration must drop to 95 of the low CO range for the low range to become active In addition each CO analog output has a span coefficient There are tw
110. een and in the Main Menu e Inthe Main Menu choose Alarms gt Sample Flow CH Cir Min and Max Sample The Minimum Sample Flow alarm limit screen is used to change the Flow Limits minimum sample flow alarm limit The minimum and maximum sample flow screens function the same way e Inthe Main Menu choose Alarms gt Sample Flow gt Min or Max Cu Cir Bias Voltage The Bias Voltage screen displays the current bias voltage reading and sets the minimum and maximum alarm limits Acceptable alarm limits range from 130 to 100 volts If the bias voltage reading goes beyond either the minimum or maximum limit an alarm is activated The word ALARM appears in the Run screen and in the Main Menu e Inthe Main Menu choose Alarms gt Bias Voltage Thermo Electron Corporation Model 48 High Level Instruction Manual 3 63 Operation Alarms Menu amg nn PEN Saad fat Min and Max Bias The Minimum Bias Voltage alarm limit screen is used to change the Voltage Limits minimum bias voltage alarm limit The minimum and maximum bias voltage screens function the same way e Inthe Main Menu choose Alarms gt Bias Voltage gt Min or Max ip priori PLP AGC Intensity The AGC Intensity screen displays the current AGC Intensity reading and sets the minimum and maximum alarm limits Acceptable alarm limits range from 150 000 to 300 000 Hz If the AGC intensity reading goes beyond either the minimum or maxim
111. efines a time period 1 to 300 seconds during which CO measurements are taken The average concentration of the readings are calculated for that time period The front panel display and analog outputs are updated every 10 seconds for averaging times between 10 and 300 seconds For averaging times of 1 2 and 5 seconds the front panel display and analog outputs are updated every second An averaging time of 10 seconds for example means that the average concentration of the last 10 seconds will be output at each update An averaging time of 300 seconds means that the moving average concentration of the last 300 seconds will be output at each update Therefore the lower the averaging time the faster the front panel display and analog outputs respond to concentration changes Longer averaging times are typically used to smooth output data The Averaging Time screen for the single range mode is shown below In the dual and auto range modes an Averaging Time Menu is displayed before the averaging time screens This menu is needed because the dual Thermo Electron Corporation Model 48 High Level Instruction Manual 3 15 Operation Calibration Factors Menu and auto range modes have two averaging times high and low The Averaging Time screens function the same way in the single dual and auto range modes The following averaging times are available 1 2 5 10 20 30 60 90 120 180 240 and 300 seconds e Inthe Main Menu choose Averaging
112. eive analog vin 1 75 325 2 796 analog vout range channel This command reports the analog voltage output channel range where channel is between 1 and 6 inclusive according to Table B 10 Send analog vout range 2 Receive analog vout range 2 3 Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands 1 0 Configuration set analog vout range channel range This command sets analog voltage output channel to the range where channel is between 1 and 6 inclusive and range is set according to Table B 10 The example below sets channel 2 to the 0 10 V range Send set analog vout range 2 3 Receive set analog vout range 2 3 ok Table B 10 Analog Voltage Output Range Values Range Output Range 1 0 1V 2 0 100 mV 3 0 10 V 4 0 5 V 0 cannot be set to this but may report Undefined dig in This command reports the status of the digital inputs as a 4 digit hexadecimal string with the most significant bit MSB being input 16 Send dig in Receive dig in oxff7f din channel This command reports the action assigned to input channel and the corresponding active state The example below reports the input 1 to be assigned an index number 3 corresponding to action of set background mode with the active state being high Send din 1 Receive din 1 3 SET BACKGROUND high set din channel index state This command assigns digital input channel 1 16 to activate the action indicated b
113. ent ambient air from entering the manifold Prior to calibration be sure the instrument is operating properly Turn on the instrument and allow it to stabilize for one hour Perform the service checks of the Preventive Maintenance chapter Select the operating range and the averaging time of the Model 487 High Level Note The averaging time should be less than the zero duration and less than the span duration A The calibration and calibration check duration times should be long enough to account for the transition purge process when switching from sample to zero and from zero to span This transition time is the time required to purge the existing air A Depending on the plumbing configuration and the instrument data from approximately the first minute of a zero calibration or check should be disregarded because of residual sample air Also data from approximately the first minute of a span calibration or check should be disregarded because the span is mixing with the residual zero air A Use the following procedure to calibrate the instrument Connect the instrument and the calibration equipment as shown in Figure 4 1 If an optional sample line filter is used the calibration must be performed through this filter Ensure that the flow rate into the output manifold is greater than the total flow required by the analyzer and any other flow demand connected to the manifold Model 48 High Level Instruction Manual 4 3 Calibrati
114. ents can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Turn instrument OFF and unplug the power cord 2 Ifthe instrument is mounted in a rack remove it from the rack Thermo Electron Corporation Model 487 High Level Instruction Manual 7 7 Servicing Fuse Replacement Fuse Replacement 7 8 Model 487 High Level Instruction Manual 10 11 Remove the cover Disconnect the plumbing connections at the rear of the measurement bench Disconnect the connectors that pass through the center of the partition panel Remove two screws from the left side of the case Remove one screw from the bottom front of the case Remove one screw from the top front of the partition panel While holding the case securely loosen the captive screw at the rear of the measurement bench and pull the measurement bench from the rear of the case Remove the screw at the top rear of the partition panel securing the top of partition panel to the measurement bench and lower the panel being careful not to put excessive tension on the cables Replace the measurement bench by following the previous steps in reverse Use the following procedure to replace the fuse Equipment Required l Le 3 Replacement fuses 250VAC 3 Amp SlowBlow for 100VAC and 110VAC models 250VAC 1 60 Amp SlowBlow for 220 240VAC models Turn instrument OF
115. er operations in this menu In the Main Menu choose Instrument Controls gt Datalogging Settings gt Select SREC LREC E PT ON alba mita bri AA The View Logged Data screen is used to select the start point to view the logged data by number of records or date and time In the Main Menu choose Instrument Controls gt Datalogging Settings gt Select SREC or LREC gt View Logged Data Thermo Electron Corporation Operation Instrument Controls Menu Number of Records The Number of Records screen is used to select the starting point to display the number of records back to view prek prup PELIR E bil pes EP bee Bs EEE TE Sanat oa EY anal i iNi i The Record Display screen read only displays the selected records ERE FHE HEH PrP L a Ea bed PIRRO Pihet PRE Date and Time The Date and Time screen is used to set a start date and time for which to view logged data For example if 20 JUN 2005 10 00 is entered then the first logged data record that is displayed is the first record after this time If set to one minute logging this would be at 20 JUN 2005 10 01 Thermo Electron Corporation Model 48 High Level Instruction Manual 3 25 Operation Instrument Controls Menu Pike EE EE The Record Display screen read only displays the selected records Erase Log The Erase Log is used to erase all saved data for the selected record type not all short records a
116. ermistor on the Interface board When temperature compensation is off the display shows the factory standard temperature of 30 C e Inthe Main Menu choose Instrument Controls gt Temperature Compensation NOE Bei PERT PE Pressure Pressure compensation provides compensation for any changes to the Compensation instrument s output signal due to reaction chamber pressure variations The Thermo Electron Corporation Model 48 High Level Instruction Manual 3 49 Operation Instrument Controls Menu Screen Contrast Service Mode 3 50 Model 487 High Level Instruction Manual effects of reaction chamber pressure changes on the analyzer s subsystems and output have been empirically determined This empirical data is used to compensate for any change in reaction chamber pressure When pressure compensation is on the first line of the display represents the current pressure in the reaction chamber When pressure compensation is off the first line of the display shows the factory standard pressure of 750 mmHg e In the Main Menu choose Instrument Controls gt Pressure Compensation The Screen Contrast screen is used to change the contrast of the display Intensities between 0 and 100 in increments of 10 are available Changing the screen contrast may be necessary if the instrument is operated at extreme temperatures e Inthe Main Menu choose Instrument Controls gt Screen Contrast CHS mTOR gH eb Ey er
117. ervice mode described in the Operation chapter also includes parameters and functions that are useful when making adjustments or diagnosing problems For additional service assistance see Service Locations on page 7 39 This chapter includes the following parts information and component replacement procedures e Safety Precautions on page 7 2 e Firmware Updates on page 7 3 e Accessing the Service Mode on page 7 3 e Replacement Parts List on page 5 2 e Cable List on page 7 5 e External Device Connection Components on page 7 5 e Removing the Measurement Bench and Lowering the Partition Panel on page 7 7 e Fuse Replacement on page 7 8 e Fan Replacement on page 7 9 e IR Source Replacement on page 7 10 e Filter Wheel Replacement on page 7 11 e Chopper Motor Replacement on page 7 13 e Optical Bench Replacement on page 7 13 e Optical Switch Replacement on page 7 15 e Bench Heater Assembly Replacement on page 7 16 Model 487 High Level Instruction Manual 7 1 Servicing Safety Precautions Safety Precautions A A 7 2 Model 48 High Level Instruction Manual e Detector Preamplifier Assembly Replacement on page 7 17 e Preamp Board Calibration on page 7 18 e Pump Replacement on page 7 19 e Pressure Transducer Replacement on page 7 20 e Flow Transducer Replacement on page 7 24 e Capillary Clea
118. es to trigger the digital input action If nothing is connected to the digital input pin the state should be left at open to prevent the action from being triggered e Press to toggle and set the logic state open or closed Thermo Electron Corporation Model 48 High Level Instruction Manual 3 41 Operation Instrument Controls Menu EOT Saad fat Instrument Action The Instrument Action screen allows the user to choose the instrument action that is tied to the selected digital input e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Digital Input Settings gt Select Relay gt Instrument Action DH pikari ML r EA Analog Output The Analog Output Configuration menu displays a list of the analog Configuration output channels available for configuration Channel choices include all voltage channels all current channels voltage channels 1 6 and current channels 1 6 if the I O expansion board option is installed Configuration choices include selecting range setting minimum maximum values and choosing signal to output e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Output Config 3 42 Model 487 High Level Instruction Manual Thermo Electron Corporation Select Output Range Minimum and Maximum Thermo Electron Corporation Value Operation Instrument Controls Menu POE DN EUH E aa The Select Output Range screen is used to select the hardware
119. eturn to the Main Menu Return to the procedure Table 7 1 lists the replacement parts for the Model 487 High Level major subassemblies Refer to Table 7 2 to identify the component location Table 7 1 Model 48i High Level Replacement Parts Part Number Description 100480 00 Front Panel Pushbutton Board 101491 11 Processor Board 100533 00 Motherboard 100539 00 Digital Output Board 100542 00 1 0 Expansion Board Optional 102340 00 Front Panel Connector Board 100480 00 Front Panel Display 100399 00 Transformer 220 240VAC Optional 101863 00 Transformer 100VAC Optional 100868 00 Measurement Interface Board 101780 00 Detector Assembly 101686 00 Heater Board Assembly 101023 00 Pressure Transducer 102055 00 Flow Transducer Sample 101390 00 Solenoid Valve 101426 00 Pump 110 VAC w Plate and Fittings 8606 Pump Repair Kit for 101426 00 101055 00 AC Receptacle Assembly 101681 00 Power Supply Assembly 24VDC w Base Plate and Screws 100907 00 Fan 24VDC 4510 Fuse 250VAC 3 0 Amp SlowBlow for 100VAC and 110VAC models 14007 Fuse 250VAC 1 60 Amp SlowBlow for 220 240VAC models 4109 Capillary Flow Transducer Thermo Electron Corporation Servicing Cable List Part Number Description 7336 Capillary 0 018 inch ID 8630 Filter Guard Assembly w foam 7361 I R Source 101424 00 Optical Switch 7412 Field Mirror 7413 E
120. etween 1 14 and 1 18 10 Calibrate the instrument Refer to the Calibration chapter in this manual Use the following procedure to replace the chopper motor Figure 7 6 Equipment Required Chopper motor Allen wrenches 5 32 inch and 5 64 inch Flatblade screwdriver Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Disconnect the chopper motor power cable from the MOT DRV connector on the measurement interface board 2 Follow the directions for Filter Wheel Replacement procedure up to and including Step 3 3 Remove the chopper motor from the motor plate by removing the two screws that hold it to the motor plate 4 Install the new chopper motor by following the previous steps in reverse 5 Install the filter wheel on the motor shaft make sure that the set screw seats on the flat of the motor shaft and tighten the set screw 6 Calibrate the instrument Refer to the Calibration chapter in this manual Use the following procedure to replace the optical bench Figure 7 7 Equipment Required Model 48 High Level Instruction Manual 7 13 Servicing Optical Bench Replacement Optical bench Philips screwdriver amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A f Equipment
121. followed by an 8 bit count of consecutive OxFF bytes The following c code will expand the incoming data Thermo Electron Corporation Model 487 High Level Instruction Manual B 25 C Link Protocol Commands Keys Display B 26 Model 48 High Level Instruction Manual void unpackDisplay void far tdib unsigned char far rlescreen int ijk unsigned char far sc4bpp sc2bpp screen ptr ptr screen unsigned char far malloc 19200 RLE decode the screen for i 0 i lt 19200 amp amp ptr screen lt 19200 i ptr rlescreen i if rlescreen i 0 unsigned char rlecount unsigned char rlescreen i while rlecount ptr 0 rlecount else if rlescreen i Oxff unsigned char rlecount unsigned char rlescreen i while rlecount ptr Oxff rlecount To convert this data into a BMP for use with windows it needs to be turned into a 4BPP as that is the smallest windows can display Also note that BMP files are upside down relative to this data i e the top display line is the last line in the BMP sec screen This command is meant for backward compatibility on the C series Screen information is reported using the iscreen command above Thermo Electron Corporation Measurement Configuration Thermo Electron Corporation C Link Protocol Commands Measurement Configuration Send screen Receive screen
122. for any of the three custom ranges 1 2 or 3 to range value where value is a floating point number representing concentration in ppm or mg m3 The example below sets the custom 1 range to 55 5 ppm Send set custom 1 range 55 5 Receive set custom 1 range 55 5 ok range mode This command reports the current range mode Send range mode Receive range mode single set range mode mode This command sets the current range mode to single dual or auto The example below sets the range mode to single Send set range mode single Receive set range mode single ok gas mode This command reports the current mode of sample zero or span The example below reports that the gas mode is sample Send gas mode Receive gas mode sample set sample This command sets the zero span valves to the sample mode The example below sets the instrument to sample mode that is the instrument is reading the sample gas Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Measurement Configuration Send set sample Receive set sample ok set zero This command sets the zero span valves to the zero mode The example below sets the instrument to zero mode that is the instrument is reading the sample gas Send set zero Receive set zero ok set span This command sets the zero span valves to the span mode The example below sets the instrument to span mode that is the instrument is sampling span gas Send
123. g converters per B 38 channel en enter Simulates pressing enter pushbutton B 25 er Returns a brief description of the main operating conditions B 17 in the format specified in the commands erec Returns a brief description of the main operating conditions B 17 in the format specified in the command erec format Reports sets erec format ASCII or binary B 18 erec layout Reports current layout of erec data B 19 flags Reports 8 hexadecimal digits or flags that represent the B 10 status of the AGC circuit pressure and temperature compensation status gas units gas mode and alarms flow Reports current measured sample flow in LPM B 9 format Reports sets current reply termination format B 34 gas mode Reports current mode of sample zero or span B 28 gas unit Reports sets current gas units B 29 he help Simulates pressing help pushbutton B 25 high avg time Reports sets high range averaging time B 8 high co Reports CO concentration calculated with high range B 9 coefficients high co coef Reports sets high range CO coefficients B 23 high coef 0 Reports coefficients of the curve developed from hi multi B 23 point calibration high coef 1 Reports coefficients of the curve developed from hi multi B 23 point calibration high coef 2 Reports coefficients of the curve developed from hi multi B 23 point calibration high range Reports selects current CO high range B 27 high ratio Reports sample reference ratio calculated using the high B 10 averaging time
124. gger action for minimum alarm current setting to either floor or ceiling The example below shows the CO concentration minimum alarm trigger to ceiling according to Table B 3 Send alarm trig conc Receive alarm trig conc 1 set alarm trig conc value These commands set the CO concentration alarm minimum value where value is set to either floor or ceiling according to Table B 3 The example below sets the CO concentration minimum alarm trigger to ceiling Send set alarm trig conc 1 Receive set alarm trig conc 1 ok Thermo Electron Corporation Diagnostics Thermo Electron Corporation C Link Protocol Commands Diagnostics Table B 3 Alarm Trigger Values Value Alarm Trigger 00 Floor 01 Ceiling agc int This command reports the current intensity of the reference channel AGC circuit The example below reports that the current AGC intensity is 200 000 Hz Send agc int Receive agc int 250000 Hz bias voltage This command reports the current IR bias supply voltage The example below reports that the bias voltage is 102 3 volts Send bias voltage Receive bias voltage 102 3 V diag volt mb This command reports the diagnostic voltage measurements on the motherboard The sequence of voltages is Positive 24 positive 15 positive 5 positive 3 3 and negative 3 3 Each voltage value is separated by a space Send diag volt mb Receive diag volt mb 24 1 14 9 4 9 3 2 3 2 diag volt mib This command report
125. gh Level has the following features e 320 x 240 graphics display e Menu driven software e Field programmable ranges e User selectable single dual auto range modes e Multiple user defined analog outputs e Analog input options e High sensitivity e Fast response time e Linearity through all ranges e Highly specific to CO e Self aligning optics e Automatic temperature and pressure compensation e User selectable digital input output capabilities e Standard communications features include RS232 485 and Ethernet e C Link MODBUS Geysitech Bayern Hessen and streaming data protocols For details of the analyzer s principle of operation and product specifications see the following topics e Principle of Operation on page 1 2 e Specifications on page 1 3 Model 48 High Level Instruction Manual 1 1 Introduction Principle of Operation Principle of Operation 1 2 Model 48i High Level Instruction Manual Thermo Electron is pleased to supply this CO analyzer 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 the Servicing chapter starting on page 7 1 The Model 482 High Level operates on the principle that carbon monoxide CO absorbs infrared radiation at a wavelength of 4 6
126. h an input voltage range of OV tol0VDC Six current outputs are provided with a normal operating range of 0 to 20 mA The front panel connector board interfaces between the motherboard and the front panel mounted function key panel and Graphics display It serves as central location to tie the three connectors required for the function key panel the graphics display control lines and the graphics display backlight to a single ribbon cable extending back to the motherboard This board also includes signal buffers for the graphics display control signals and a high voltage power supply for the graphics display backlight Model 48 High Level Instruction Manual 8 7 System Description 1 0 Components 1 0 Components Analog Voltage Outputs Analog Current Outputs Optional 8 8 Model 487 High Level Instruction Manual External I O is driven from a generic bus that is capable of controlling the following devices e Analog output voltage and current e Analog input voltage e Digital output TTL levels e Digital input TTL levels Note The instrument has spare solenoid valve drivers and I O support for future expansion A The instrument provides six analog voltage outputs Each may be software configured for any one of the following ranges while maintaining a minimum resolution of 12 bits e 0 100mV e 0 1V e 0 5V e 0 10V The user can calibrate each analog output zero and span point through firmware At least 5 of fu
127. han one percent the analog outputs should be adjusted Refer to the Analog Output Calibration procedure that follows Press Ce to reset the analog outputs to normal peo o Ex 10 e os Current Outputs Analog Voltage Inputs Figure 7 14 Rear Panel Analog Input and Output Pins Table 7 4 Analog Output Channels and Rear Panel Pin Connections Voltage Channel Pin Current Channel Pin 1 14 1 15 2 33 2 17 3 15 3 19 4 34 4 21 5 17 5 23 6 36 6 25 Ground 16 18 19 35 37 Current Output 16 18 20 22 24 Return 7 28 Model 48 High Level Instruction Manual Thermo Electron Corporation Analog Output Calibration Thermo Electron Corporation Servicing Analog Output Calibration Use the following procedure to calibrate the analog outputs if a meter reading in the Analog Output Testing procedure differed by more than one percent or after replacing the optional I O expansion board Equipment Required Multimeter 1 Connect a meter to the channel to be adjusted and set to voltage or current as appropriate Figure 7 14 shows the analog output pins and Table 7 4 identifies the associated channels 2 From the Main Menu press to scroll to Service press gt to scroll to Analog Out Calibration and press Ce The Analog Output Cal screen displays Note If Service Mode is not displayed refer to Accessing the Service Mode on page 7 3 then return to the
128. he Pressure Transducer 7 21 Figure 7 12 Replacing the Flow Transducer 7 23 Figure 7 13 Cleaning or Replacing the Capillary 7 26 Figure 7 14 Rear Panel Analog Input and Output PinS o o 7 28 Figure 7 15 Replacing the I O Expansion Board Optional 7 34 Model 48 High Level Instruction Manual xv Figures xvi Model 48 High Level Instruction Manual Figure 7 16 Rear Panel Board Connectors onoococoocincocinconinccninccnincnrncnnrnononos 7 34 Figure 7 17 Replacing the Measurement Interface Board 1 31 Figure 7 18 Replacing the Front Panel Board and the LCD Module 7 38 Figure 8 1 Hardware Components c ccccccscscscesestesestesesteseseseeeseeseseeseees 8 2 Figure 9 1 Purge Housing Assembly ooococoococicccoccconncocoonocornnonnncnrnnnonororonooos 9 2 Figure 9 2 Rack Mount Option Assembly o oonococninccninccnnocininocnnonininncnnoooo 9 5 Figure 9 3 Bench Mossos aia 9 6 Figure 9 4 EIA Rack Mounting ooconoconoccononocccnnnononncnononenccnrnonennnnrnononoonrnnnooos 9 7 Figure 9 5 Retrofit Rack MOUNTING ccc cececescscecesesestetesesesteteseseeteenees 9 8 Figure B Flags ests ot Fae ln a i va ee vee AnA nse B 11 Thermo Electron Corporation Thermo Electron Corporation Tables Table 1 1 Model 487 High Level Specifications o ooc
129. he functions of the instrument and to collect measurement and diagnostic information The motherboard outputs instrument status and measurement data to the front panel mounted graphics display and to the rear panel I O The motherboard also contains I O circuitry and the associated connector to monitor external digital status lines and to output analog voltages that represent the measurement data Connectors located on the motherboard include External Connectors External connectors include e External Accessory e RS 232 485 Communications two connectors e Ethernet Communications e I O connector with Power Fail Relay 16 Digital Inputs and 6 Analog Voltage Outputs Internal Connectors Internal connectors include e Function key panel and Display e Measurement Interface Board Data e I O Expansion Board Data e Digital Output Board e AC distribution Thermo Electron Corporation Model 487 High Level Instruction Manual 8 5 System Description Electronics Measurement Interface Board Measurement Interface Board Connectors Flow Sensor Assembly Pressure Sensor Assembly 8 6 Model 487 High Level Instruction Manual The measurement interface board serves as a central connection area for all measurement electronics in the instrument It contains power supplies and interface circuitry for sensors and control devices in the measurement system It sends status data to the motherboard and receives control signals from the motherbo
130. he instrument name Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Communications Configuration Send instr name Receive instr name CO Analyzer CO Analyzer instrument id This command reports the instrument id Send instrument id Receive instrument id 12 set instrument id value This command sets the instrument id to value where value is a decimal number between 0 and 127 inclusive Note sending this command via RS 232 or RS 485 will require the host to use the new id for subsequent commands 5 Send set instrument id 12 Receive set instrument id 12 ok mode This command reports what operating mode the instrument is in local service or remote The example below shows that the instrument is in the remote mode Send mode Receive mode remote set mode local set mode remote These commands set the instrument to local or remote mode The example below sets the instrument to the local mode Send set mode local Receive set mode local ok program no This command reports the analyzer s model information and program version number which will be dependant on the current version Send program no Receive program no iSeries 48iHL 01 02 12 095 set layout ack This command disables the stale layout layout change indicator that is attached to each response if the layout has changed Model 48 High Level Instruction Manual B 35 C Link Protocol Commands 1 0 Configu
131. he instrument upon successful completion of the button command to update the value field This is not currently used Thermo Electron Corporation Model 48 High Level Instruction Manual B 43 C Link Protocol Commands Record Layout Definition Examples B 44 Model 487 High Level Instruction Manual Some examples n is the C syntax for an end of line character Concentrations n This is a single text only line An This is a single blank line NO 3s n This is a line which appears slightly indented The text field is NO the value is taken from the third element of the data response and interpreted as a string NO 18sBd ddd set no coef s n This is a line which also appears slightly indented The next field is also NO but the value is taken from the eighteenth element of the data response again interpreted as a string A button appears on this line which when pressed pops up an input dialog which will state Please enter a new value for NO using a d ddd format The string entered by the user is used to construct the output command If the user enters for example 1 234 the constructed command will be set no coef 1 234 NO 21f Code_0 Code 1 Code 2 Code 3 Code 4 Code 5 Code 6 Code_7 Code _8 Code_9 Code_10 Code 11 Lset range no d n This is a line which appears slightly indented the title is again NO and the value the twenty first element of the data response interpreted as a floating point
132. he measurement bench Refer to Removing the Measurement Bench and Lowering the Partition Panel on page 7 7 in this chapter Thermo Electron Corporation Servicing Front Panel Board Replacement SS a gt Measurement Interface Board UE Figure 7 17 Replacing the Measurement Interface Board Front Panel Board Use the following procedure to replace the front panel board Figure 7 Replacement Equipment Required Eront panel board amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A f Equipment Damage Some internal components can be damaged by small 1 Turn instrument OFF unplug the power cord and remove the cover 2 Remove the three ribbon cables and the two wire connector from the front panel board 3 Pop off the board from the two top mounting studs and remove the board by lifting it up and off the slotted bottom support 4 Replace the front panel board by following previous steps in reverse Thermo Electron Corporation Model 48 High Level Instruction Manual 7 37 Servicing LCD Module Replacement Mounting Studs 2 Ribbon Cables 3 LCD Module Replacement A A 7 38 Model 48 High Level Instruction Manual LCD Module LCD Module Screws 2 Retaining Screws 2 Front Panel Board Bottom Support Figure 7 18 Replacing the Front Panel Board and the LCD Module Use the following procedure to replace
133. he serial number and program number of the instrument This chapter provides the following troubleshooting and service support information e Safety Precautions on page 6 1 e Troubleshooting Guides on page 6 1 e Board Level Connection Diagrams on page 6 5 e Connector Pin Descriptions on page 6 7 e Service Locations on page 6 20 Read the safety precautions in the Preface and Servicing chapter before performing any actions listed in this chapter The troubleshooting guides presented in this chapter are designed to help isolate and identify instrument problems Table 6 1 provides general troubleshooting information and indicates the checks that you should perform if you experience an instrument problem Table 6 2 lists all the alarm messages you may see on the graphics display and provides recommendations about how to resolve the alarm condition Model 48 High Level Instruction Manual 6 1 Troubleshooting Troubleshooting Guides 6 2 Model 487 High Level Instruction Manual Malfunction Does not start The light on display does not come on and the pump motor is not running Pressure transducer does not hold calibration or is noisy Table 6 1 Troubleshooting General Guide Possible Cause No power or wrong power configuration Main fuse is blown or missing Bad switch or wiring connection Pressure transducer defective Action Check the line to confirm that power is
134. his command sets the screen s level of contrast according to Table B 7 The example below sets the contrast level to 50 Send set contrast 5 Receive set contrast 5 ok Table B 7 Contrast Levels Level Contrast Level 0 0 10 20 30 40 50 60 70 80 90 100 OoO ao r ws oi oy amp I wt rp o B 30 Model 48 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Hardware Configuration date This command reports the current date The example below reports the date as December 1 2004 Send date Receive date 12 01 04 set date mm dd yy mm month dd day yy year This command sets the date of the analyzer s internal clock The example below sets the date to December 1 2004 Send set date 12 01 04 Receive set date 12 01 04 ok set default params This command sets all the parameters to their default values This does not affect the factory calibrated parameters Send set default params Receive set default params ok save set save params This command stores all current parameters in FLASH memory It is important that each time instrument parameters are changed that this command be sent If changes are not saved they will be lost in the event of a power failure The example below saves the parameters to FLASH memoty Send set save params Receive set save params ok time This
135. ined by the current settings of format and erec format commands For details on how to decode the flag fields within these records see the flags command Send erec Receive erec 09 48 04 06 05 flags 9C040510 co 0 000 4 loco 0 002 4 s r 0 000 los r 0 902 biasv 112 668 agci 96 500 intt 34 023 cht 47 995 smpfl 0 000 pres 0 000 avgt1 10 avgt2 10 cobkg 0 000 cocoef 1 000 lococoef 1 000 corange 10000000 000 locorange 10000000 000 motor 100 000 lrec srec lrec xxxx yy SIeC XXXX YY lrec aa bb 00 pp qq yy srec aa bb 00 pp qq yy xxxx the number of past records yy the number of records to return 1 to 10 aa hours 01 to 24 bb minutes 01 to 59 oo month 01 to 12 pp day 01 to 31 qq year Model 48 High Level Instruction Manual B 17 C Link Protocol Commands Datalogging B 18 Model 487 High Level Instruction Manual These commands output long or short records The output format is determined by the set lrec format and set srec format commands The logging time is determined by the set lrec per and set srec per commands In the following example there are 740 long records currently stored in memory When the command lrec 100 5 is sent the instrument counts back 100 records from the last record collected record 740 and then returns 5 records 640 641 642 643 and 644 For details on how to decode the flag fields within these records see the flags command
136. ing on page 7 27 Model 48 High Level Instruction Manual 2 3 Installation Setup Procedure 5 Plug the instrument into an outlet of the appropriate voltage and frequency AN WARNING The Model 48 High Level is supplied with a three wire grounding cord Under no circumstances should this grounding system be defeated A Figure 2 3 Model 487 High Level Rear Panel Vent to Exhaust Line at Instrument Bulkhead Atmospheric Pressure ay We a w So lt Input Gas Line Figure 2 4 Atmospheric Dump Bypass Plumbing 2 4 Model 487 High Level Instruction Manual Thermo Electron Corporation Connecting External Devices Terminal Board PCB Assemblies 1 0 Terminal Board Thermo Electron Corporation Installation Connecting External Devices Several components are available for connecting external devices to Series instruments These connection options include e Individual terminal board PCB assemblies e Terminal block and cable kits optional e Individual cables optional For detailed information on the optional connection components refer to the Optional Equipment chapter For associated part numbers refer to External Device Connection Components on page 7 5 The following terminal board PCB assemblies are available for Series instruments e I O terminal board PCB assembly 37 pin standard e D O terminal board PCB assembly 37 pin standard e 25 pin terminal board
137. ing any procedures in this chapter WARNING If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A Model 48 High Level Instruction Manual 5 1 Preventive Maintenance Replacement Parts Replacement Parts Cleaning the Outside Case Cleaning the Optics 5 2 Model 487 High Level Instruction Manual Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component For more information about appropriate safety precautions see the Servicing chapter A See the Servicing chapter for a list of replacement parts and the associated replacement procedures WARNING If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A Clean the outside case using a damp cloth being careful not to damage the labels on the case Equipment Damage Do not use solvents or other cleaning products to clean the outside case A Best results are obtained when the optics are cleaned prior to calibration The cleanliness of the mirrors should be checked any time the AGC intensity is below 200 000 Hz since one cause of low output is light attenuation due to dirt on the mirrors Equipment Damage Some internal components can be damaged by small amounts of static electrici
138. ists using the set copy sp to lrec set copy sp to srec or set copy sp to stream commands Send set sp field 1 34 Receive set sp field 1 34 ok stream per This command reports the currently set time interval in seconds for streaming data Send stream per Receive stream per 10 Model 48 High Level Instruction Manual B 21 C Link Protocol Commands Calibration Calibration B 22 Model 487 High Level Instruction Manual set stream per number value number value 1 2 5 10 20 30 60 90 120 180 240 300 This command sets the time interval between two consecutive streaming data strings to number value in seconds The example below sets the number value to 10 seconds Send set stream per 10 Receive set stream per 10 ok stream time This command reports if the streaming data string will have a time stamp attached to it or not according to Table B 5 Send stream time Receive stream time O set stream time value This command enables value where value is to attach or disable time stamp to streaming data string according to Table B 5 The example below attaches a time stamp to streaming data Send set stream time O Receive set stream time O ok Table B 5 Stream Time Values Value Stream Time 00 Attaches time stamp to streaming data string 01 Disables time stamp to streaming data string set cal co bkg This command will auto calibrate the CO background The examp
139. ittings are tight and that none of the input lines are cracked or broken For detailed information about this screen refer to the Operation chapter If the pump diaphragm is in good condition and the capillary not blocked it should take less than one minute from the time the inlet is plugged to the time the reading below 250 mmHg is obtained Thermo Electron Corporation Preventive Maintenance Pump Rebuilding Leaks Across the Optional In order to check for leaks across the optional valves plug the SPAN inlet Zero Span and Sample line press gt until span appears in the status line and follow the Solenoid Valves External Leaks procedure If the pressure drops below 250 mmHg the valve associated with the span line is functioning normally Repeat for the valve associated with the zero line by plugging the zero inlet press Cr until zero appears in the status line and follow the External Leaks procedure If the pressure drops below 250 mmHg the valve associated with the zero line is functioning normally Pump Rebuilding Use the following procedure to rebuild the pump Figure 5 2 To replace the pump see Pump Replacement on page 7 19 Equipment Required Flatblade screwdriver Pump rebuild kit flapper valve and diaphragm f Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal co
140. ity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Remove the instrument cover 2 Tape the thermistor Figure 7 3 to a calibrated thermometer Note Since the thermistors are interchangeable to an accuracy of 0 2 C and have a value of 10K ohms at 25 C an alternate procedure is to connect an accurately known 10K resistor to the thermistor input AMB TEMP on the measurement interface board and enter the temperature reading A A 1 C change corresponds to a 5 change in resistance thus this g P g alternative procedure can be quite accurate as a check however it clearly is not NIST traceable A 3 From the Main Menu press to scroll to Service gt press gt to scroll to Temperature Calibration gt and press The Calibrate Ambient Temperature screen appears Note If Service Mode is not displayed refer to Accessing the Service Mode on page 7 3 then return to the beginning of this step A Thermo Electron Corporation Servicing 1 0 Expansion Board Optional Replacement 4 Waitat least 10 seconds for the ambient reading to stabilize use e Jand to enter the known temperature and press to save the temperature value 5 Install the cover 1 0 Expa nsion Board Usethe following procedure to replace the optional I O expansion board Optional Figure 7 15 Replacement Note After replacing the optional I O expansion boa
141. jeuy ise sajels Aejay syndy jey6iq sebeyoA Indu Hojeuy synejag 189 19sn josay JUO ABuey ony Jo eng 104 1e9 duel 49849 UedS sGuipeoy Indul Bojeuy 4209 IH sefuey unisny Jos 189 paeog due 91d 19949 019Z paadg 103014 aware J209 07 189 1909 07 auey IH eo UCA IH peeds 1040 ysuayu 99V apoy 3911S 209 1H 129 Bxg awit Say 07 buey 07 L 189 jurod ni 07 ysuaju DOV oney joy a dues Se 1JUOg U3319S 6yg 189 aw SAY IH spun sey 189 quodn in abeyon serg moj uopesu dwog Sold oney Y S elu Moly ajduies ainssaiq uopesu dwog dula y 189 mold S9INSSIId sdw 6yuo9 O I 19949 UBdg o19z S nejag 129 19sn 19soy sofuey uoJsng 18S 189 ainssaid dua y9ueg sabeyon sBunjes wwog 4909 189 ja09 obuey wales apo ebuey dw 4 jeusayuy suolsiej weibolg sburyjag BurbBojejeg 5x8 189 6yg aun Gay SHUN sey s o1juo 0108 oul 3D1AIS suuely sonsoubeig oun a uoneiquyes Segoe sa obuey nue uen u 4195 uny u 19S 1591 419S u9aJ9s dn 13M0d Figure 3 3 Flowchart of Menu Driven Software 3 5 Model 48 High Level Instruction Manual Thermo Electron Corporation Operation Software Overview Power Up Screen The Power Up screen is displayed on power up of the Model 48 The Self Test is displayed while the internal components are warming up and diagnostic checks are performed Thermo ELECTRON CORPORATION iSeries Run Screen The Ru
142. l I O These processors are controlled over a serial interface with a single high level processor that also controls the front panel user interface The low level processors all run a common piece of firmware that is bundled with the high level firmware and loaded on power up if a different version is detected Each board has a specific address that is used to identify to the firmware what functions are supported on that board This address is also used for the communications between the low level processors and the high level processor Every tenth of a second the frequency counters analog I O and digital I O are read and written to by the low level processor The counters are accumulated over the past second and the analog inputs are averaged over that second The high level processor polls the low level processors once per second to exchange the measurement and control data Signals are gathered from the low level processors once per second and then processed by the high level processor to produce the final measurement values The one second accumulated counts are accumulated and reported for the user specified averaging time If this averaging time is greater than ten seconds the measurement is reported every 10 seconds The one second average of the other analog inputs are reported directly no additional signal conditioning is performed by the high level processor The front panel display serial and Ethernet data ports and analog outp
143. le below shows a successful auto calibration of the CO background Send set cal co bkg Receive set cal co bkg ok set cal co coef set cal high co coef set cal low co coef These commands will auto calibrate CO coefficients based on CO span gas concentrations The high and low commands are only available in dual and auto range mode If the mode is incorrect the instrument responds with can t wrong settings The example below shows a successful auto calibration of the low CO coefficient Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Calibration Send set cal low co coef Receive set cal low co coef ok co coef high co coef low co coef These commands report CO coefficients in single range mode or the high and low range coefficients in dual or auto range mode If the mode is incorrect the instrument responds with can t wrong settings The example below reports that the CO coefficient is 1 200 Send co coef Receive co coef 1 200 set co coef value set high co coef value set low co coef value These commands set the CO coefficients to user defined values to value where value is a floating point representation of the coefficient The example below sets the CO coefficient to 1 200 Send set co coef 1 200 Receive set co coef 1 200 ok coef 0 coef 1 coef 2 high coef 0 high coef 1 high coef 2 low coef 0 low coef 1 low coef 2 The coef 0 coef 1
144. ler by third party suppliers shall be limited to the assignment by Seller to Buyer of any such third party supplier s warranty to the extent the same is assignable In no event shall Seller have any obligation to make repairs replacements or corrections required in whole or in part as the result of i normal wear and tear ii accident disaster or event of force majeure iii misuse fault or negligence of or by Buyer iv use of the Products in a manner for which they were not designed v causes external to the Products such as but not limited to power failure or electrical power surges vi improper storage of the Products or vii use of the Products in combination with equipment or software not supplied by Seller If Seller determines that Products for which Buyer has requested warranty services are not covered by the warranty hereunder Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller s then prevailing time and materials rates If Seller provides repair services or replacement parts that are not covered by the warranty provided in this Section 8 Buyer shall pay Seller therefore at Seller s then prevailing time and materials rates ANY INSTALLATION MAINTENANCE REPAIR SERVICE RELOCATION OR ALTERATION TO OR OF OR OTHER TAMPERING WITH THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER S PRIOR WRITTEN APPROVAL OR ANY USE OF REPLACEMENT PARTS NOT
145. les the DHCP service by either on or off Changes to this parameter will only take effect when the analyzer is powered up The example below sets the DHCP service on Model 48 High Level Instruction Manual B 33 C Link Protocol Commands Communications Configuration B 34 Model 487 High Level Instruction Manual Note When DHCP is set to on the user supplied addr gw addr dns addr ip and addr nm parameters are not used A Send set dhcp on Receive set dhcp on ok format This command reports the current reply termination format The example below shows that the reply format is 00 which means reply with no checksum according to Table B 8 Send format Receive format 00 set format format This command sets the reply termination format where format is set according to Table B 8 The example below sets the reply termination format to checksum Send set format 01 Receive set format 01 ok Table B 8 Reply Termination Formats Format Reply Termination 00 lt CR gt 01 lt NL gt sum xxxx lt CR gt where xxxx 4 hexadecimal digits that represent the sum of all the characters bytes in the message host name This command reports the host name string Send host name Receive host name analyzero1 set host name string This command sets the host name string where string is 1 13 alphanumeric characters Send set host name analyzero1 Receive set host name analyzer01 ok instr name This command reports t
146. lied to the main processor and used to display and control the temperature of the optical bench The main processor compares the voltage to a set point and controls the 120VAC power to the bench heater resistors to maintain a constant bench temperature The pre amp board assembly amplifies the signal from an infrared sensor that receives light passing through the sample gas The preamplifier gain is adjusted by the main processor to bring the signal amplitude within a normal operating range The output of the pre amp board is fed to the measurement interface board Wires from the pre amp board apply power to the infrared source resistor The pre amp board assembly is mounted on top of the optical bench The digital output board connects to the motherboard and provides solenoid driver outputs and relay contact outputs to a connector located on the rear panel of the instrument Ten relay contacts normally open with power off are provided which are electrically isolated from each other Eight solenoid driver outputs open collector are provided along with a corresponding 24VDC supply pin on the connector The I O expansion board connects to the motherboard and adds the capability to input external analog voltage inputs and to output analog currents via a connector located on the rear panel of the instrument It contains local power supplies a DC DC isolator supply a sub processor and analog circuits Eight analog voltage inputs are provided wit
147. ll scale over and under range are also supported The analog outputs may be assigned to any measurement or diagnostic channel with a user defined range in the units of the selected parameter The voltage outputs are independent of the current outputs The optional I O Expansion board includes six isolated current outputs These are software configured for any one of the following ranges while maintaining a minimum resolution of 11 bits e 0 20 mA e 420 mA The user can calibrate each analog output zero and span point through firmware At least 5 of full scale over and under range are also supported The analog outputs may be assigned to any measurement or diagnostic channel with a user defined range in the units of the selected parameter The current outputs are independent of the voltage outputs The current Thermo Electron Corporation Analog Voltage Inputs Optional Digital Relay Outputs Digital Inputs Serial Ports Thermo Electron Corporation System Description 1 0 Components outputs are isolated from the instrument power and ground but they share a common return line Isolated GND The optional I O expansion board includes eight analog voltage inputs These inputs are used to gather measurement data from third party devices such as meteorological equipment The user may assign a label unit and a voltage to user defined unit conversion table up to 16 points All voltage inputs have a resolution of 12 bits ove
148. m allowed by instrument Unit Identifier 1 Byte 0x00 to OxFF Passed back in response Response Function code 1 Byte 0x01 or 0x02 Byte count 1 Byte N Output Status n Byte N N or N 1 N Quantity of Outputs 8 if the remainder not equal to zero then N N 1 Error Response Function code 1 Byte 0x01 or 0x02 Exception code 1 Byte 01 IIlegal Function 02 Illegal Address 03 Illegal Data 04 Slave Device Failure Here is an example of a request and response to read outputs 2 15 Thermo Electron Corporation 0x03 0x04 Read Holding Registers Read Input Thermo Electron Corporation Registers MODBUS Protocol Function Codes Request Field Name Hex Function 0x01 Starting Address Hi 0x00 Starting Address Lo 0x02 Quantity of Outputs Hi 0x00 Quantity of Outputs Lo 0x0D Response Field Name Hex Function 0x01 Byte Count 0x03 Output Status 2 10 OxCD Output Status 11 15 Ox0A The status of outputs 2 10 is shown as the byte value 0xCD or binary 1100 1101 Output 10 is the MSB of this byte and output 2 is the LSB By convention bits within a byte are shown with the MSB to the left and the LSB to the right Thus the outputs in the first byte are 10 through 2 from left to right In the last data byte the status of outputs 15 11 is shown as the byte value 0x0A or binary 0000 1010 Output 15 is in the fifth bit position from the left and output 11 is the LSB of this byte The four remaining high order bits are zero
149. mand text lt CR gt Each Command is framed by control characters lt STX gt at the start and terminated with either lt ETX gt or lt CR gt If a command is terminated with lt ETX gt then additional two characters lt BCC gt is attached after lt ETX gt this is the block checksum Thermo Electron Corporation Block Checksum lt BCC gt Geysitech Commands Instrument Control Command Thermo Electron Corporation ST Geysitech Bayern Hessen Protocol Block Checksum lt BCC gt The block checksum is calculated beginning with a seed value of 00000000 binary 0x00 and bitwise exclusive ORing with each of the characters of the command string or response including the framing characters lt STX gt and lt ETX gt The checksum works as an error check The command terminator determines the presence or absence of lt BCC gt If a command is terminated by lt ETX gt then the next two characters are the checksum if the command is terminated with lt CR gt no checksum is attached The block checksum is represented by two characters which represent a 2 digit hex number 1byte e g 1 byte 0xAB hex checksum will be represented by the two characters A amp B The checksum is referred to as lt BCC gt throughout this document The following commands are supported by the Geysitech protocol e Instrument Control Command ST e Data Sampling Data Query Command DA There are three control commands
150. me For these menus use _ Jand to move the cursor up and down to each item Thermo Electron Corporation Model 487 High Level Instruction Manual 3 1 Operation Pushbuttons Figure 3 1 Front Panel Display your skin or clothes If the liquid crystal contacts your skin or clothes wash it off immediately using soap and water A i CAUTION If the LCD panel breaks do not to let the liquid crystal contact Pushbuttons The Pushbuttons allow the user to traverse the various screens menus Figure 3 2 Front Panel Pushbuttons 3 2 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Pushbuttons Table 3 1 lists the front panel pushbuttons and their functions Table 3 1 Front Panel Pushbuttons Key Name E Soft Keys Function The E soft keys are used to provide shortcuts that allow the user to jump to user selectable menu screens For more information on processing soft keys see Soft Keys below Cr Run The Cr is used to display the Run screen The Run screen normally displays the CO concentration Cm Menu The Cm is used to display the Main Menu when in the Run screen or back up one level in the menu system For more information about the Main Menu see Main Menu later in this chapter 2 Help The 2 is context sensitive that is it provides additional information about the screen that is being displayed Press 2 for a brief explanati
151. microns Because infrared absorption is a non linear measurement technique it is necessary to transform the basic analyzer signal into a linear output The Model 487 High Level uses an internally stored calibration curve to accurately linearize the instrument output over any range up to a concentration of 20 000 The sample is drawn into the Model 487 High Level through 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 gas filter alternating between CO and N2 The radiation then passes through a narrow bandpass interference filter and 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 CO gas filter acts to produce a reference beam which cannot be further attenuated by CO in the sample cell The N side of the filter wheel is transparent to the infrared radiation and therefore produces a measurement beam which can be absorbed by CO in the cell The chopped detector signal is modulated by the alternation between the two gas filters with an amplitude related to the concentration of CO in the sample cell Other gases do not cause modulation of the detector signal since they absorb the reference and measure beams equally Thus the GFC system responds specifically to CO The Model 487 High Level outputs the CO concentration to the front
152. mponent A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Loosen the fittings and remove both lines going to the pump 3 Remove the four screws from the top plate remove top plate flapper valve and the bottom plate Thermo Electron Corporation Model 487 High Level Instruction Manual 5 5 Preventive Maintenance Pump Rebuilding Figure 5 2 Rebuilding the Pump 4 Remove the screw securing the diaphragm to piston and remove diaphragm 5 Assemble the pump by following the previous steps in reverse make sure the Teflon white side of the diaphragm is facing up and that the flapper valves cover the holes of the top and bottom plate 6 Perform the Leak Test and Pump Check Out on page 5 4 5 6 Model 487 High Level Instruction Manual Thermo Electron Corporation Safety Precautions Troubleshooting Thermo Electron Corporation Guides Chapter 6 Troubleshooting This instrument has been designed to achieve a high level of reliability In the event of problems or failure the troubleshooting guidelines board level connection diagrams connector pin descriptions and testing procedures presented in this chapter should be helpful in isolating and identifying problems The Technical Support Department at Thermo Electron can also be consulted in the event of problems See Service Locations on page 6 20 for contact information In any correspondence with the factory please note both t
153. n Corporation Optional Equipment Mounting Options 16 75 Figure 9 4 EIA Rack Mounting Thermo Electron Corporation Model 487 High Level Instruction Manual 9 7 Optional Equipment Mounting Options 16 75 Figure 9 5 Retrofit Rack Mounting 9 8 Model 487 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation Appendix A Warranty Seller warrants that the Products will operate substantially in conformance with Seller s published specifications when subjected to normal proper and intended usage by properly trained personnel for 12 months from date of shipment the Warranty Period Seller agrees during the Warranty Period provided it is promptly notified in writing upon the discovery of any defect and further provided that all costs of returning the defective Products to Seller are pre paid by Buyer to repair or replace at Seller s option defective Products so as to cause the same to operate in substantial conformance with said specifications Replacement parts may be new or refurbished at the election of Seller All replaced parts shall become the property of Seller Shipment to Buyer of repaired or replacement Products shall be made in accordance with the provisions of Section 5 above Lamps fuses bulbs and other expendable items are expressly excluded from the warranty under this Section 8 Seller s sole liability with respect to equipment materials parts or software furnished to Sel
154. n Manual Note Not all menu items may be assigned to soft keys If a particular menu or screen item cannot be assigned the key assignment screen will not come up upon entering right arrow soft key combinations All items under the Service menu including the menu itself cannot be assigned soft keys A The Model 487 High Level utilizes the menu driven software as illustrated by the flowchart in Figure 3 3 The Power Up screen shown at the top of the flowchart is displayed each time the instrument is turned on This screen is displayed while the instrument is warming up and performing self checks After the warm up period the Run screen is automatically displayed The Run screen is the normal operating screen It displays the CO concentration depending on operating mode From the Run screen the Main Menu can be displayed by pressing mu The Main Menu contains a list of submenus Each submenu contains related instrument settings This chapter describes each submenu and screen in detail Refer to the appropriate sections for more information Thermo Electron Corporation Operation Software Overview yuawinjsuy q90Jun puomssed aAoway piomssed abueyD quawinsjsu 4907 P4JOMSSed 18S 19Sf ynejaq a101soy 1591 19x1d Aejdsiq oney uonniq 1e9 Indu Bojeuy 19 indino Bojeuy snjejs Pa O I snje1s pg 1ul snes a 32u09 e901ny ueds e90my 0197 psomssed oJuj j9ejuog 5yuoy juauna su sindino Bo
155. n screen displays the CO concentration The status bar displays optional zero span solenoid valves if installed time and alarm status The word SAMPLE on the bottom left of the display indicates the analyzer has the span zero valve option and is in SAMPLE mode Other modes appear in the same area of the display as ZERO or SPAN For more information about the optional solenoid valves see Chapter 9 Optional Equipment When operating in dual or auto range mode two sets of coefficients are used to calculate the CO High and Low concentrations Also two averaging times are used one for each range The title bar indicates which range concentrations are displayed The words LOW RANGE CONCENTRATION on the top of the display indicates that the low concentration is displayed In dual range mode pressing the 4 Jand arrows will toggle between high and low concentrations The example below shows the Run screen in single range mode 3 6 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Software Overview Main Menu The Main Menu contains a number of submenus Instrument parameters and settings can be read and modified within the submenus according to their function The concentration appears above the main menu and submenus in every screen The Service menu is visible only when the instrument is in service mode For more information on the service mode see Service Mode
156. nd relay stat Receive relay stat open Note If individual relays have been assigned different logic then the response would be a 4 digit hexadecimal string with the least significant byte LSB being relay no 1 A Thermo Electron Corporation Model 48 High Level Instruction Manual B 39 C Link Protocol Commands Record Layout Definition Record Layout Definition Format Specifier for ASCII Responses B 40 Model 487 High Level Instruction Manual For example Receive relay stat 0x0001 indicates relay no 1 is set to normally open logic all others are normally closed Receive relay stat 0x0005 indicates relay no 1 and 3 are set to be normally open logic all others are normally closed set relay open set relay open value set relay closed set relay closed value These commands set the relay logic to normally open or closed for relay number value where value is the relay between 1 and 16 The example below sets the relay no 1 logic to normally open Note If the command is sent without an appended relay number then all the relays are assigned the set logic of normally open closed 5 Send set relay open 1 Receive set relay open 1 ok The Erec Lrec Srec layouts contain the following e A format specifier for parsing ASCII responses e A format specifier for parsing binary responses In addition to these the Erec Layout contains e A format specifier for producing the front panel displays Values are read in using ei
157. nd long records e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Erase Log Select Content The Select Content submenu displays a list of 32 record fields to use and a submenu list of the analog output signal group choices to choose from Choices are Concentrations Other Measurements and Analog Inputs if the I O expansion board is installed This is a temporary list of items for 3 26 Model 487 High Level Instruction Manual Thermo Electron Corporation Concentrations Thermo Electron Corporation Operation Instrument Controls Menu the selected record type that must be committed via the datalogging menu before the changes will apply Note that committing any changes to this list will erase all currently logged data as the format of the stored data is changed In the Main Menu choose Instrument Controls gt Datalogging Settings gt Select Content The Concentrations screen allows the user to select the output signal that is tied to the selected field item The selected item is shown by lt after it Note that at this point pressing indicates that these are proposed changes as opposed to implemented changes To change the selected record format and erase record log file data see Commit Content below Range status is visible only in auto range mode In the Main Menu choose Instrument Controls gt Datalogging Settings gt Select Content gt Select Field gt Concentration
158. nds Commands Command Description Page addr nm Reports sets netmask address B 33 agc int Reports current AGC intensity B 15 alarm agc intensity Reports sets AGC intensity alarm maximum value B 11 max alarm agc intensity Reports sets AGC intensity alarm minimum value B 11 min alarm bias voltage Reports sets bias voltage alarm maximum value B 11 max alarm bias voltage Reports sets bias voltage alarm minimum value B 11 min alarm chamber Reports sets chamber temperature alarm maximum value B 12 temp max alarm chamber Reports sets chamber temperature alarm minimum value B 12 temp min alarm conc max Reports sets current CO concentration alarm maximum value B 12 alarm conc min Reports sets current CO concentration alarm minimum value B 12 alarm internal temp Reports sets internal temperature alarm maximum value B 13 max alarm internal temp Reports sets internal temperature alarm minimum value B 13 min alarm motor speed Reports sets motor speed alarm maximum value B 13 max alarm motor speed Reports sets motor speed alarm minimum value B 13 min alarm pressure max Reports sets pressure alarm maximum value B 13 alarm pressure min Reports sets pressure alarm minimum value B 13 alarm sample flow Reports sets sample flow alarm maximum value B 14 max alarm sample flow Reports sets sample flow alarm minimum value B 14 min alarm trig conc Reports sets current CO concent
159. ning or Replacement on page 7 25 e Optional Zero Span and Sample Solenoid Valve Replacement on page 7 26 e Analog Output Testing on page 7 27 e Analog Output Calibration on page 7 29 e Analog Input Calibration on page 7 30 e Ambient Temperature Calibration on page 7 32 e I O Expansion Board Optional Replacement on page 7 33 e Digital Output Board Replacement on page 7 34 e Motherboard Replacement on page 7 35 e Measurement Interface Board Replacement on page 7 36 e Front Panel Board Replacement on page 7 37 e LCD Module Replacement on page 7 38 e Service Locations on page 7 39 Read the safety precautions before beginning any procedures in this chapter WARNING The service procedures in this manual are restricted to qualified representatives A If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A CAUTION Carefully observe the instructions in each procedure A Thermo Electron Corporation Firmware Updates Accessing the Service Mode Thermo Electron Corporation Servicing Firmware Updates Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component Figure 7 1 If an antistatic wrist strap is not available be sure to touch a grounded met
160. nk Protocol Commands Datalogging Table B 4 Record Output Formats Format Output Format 0 ASCII no text 1 ASCII with text 2 Binary data erec layout lrec layout srec layout These commands report the layout string indicating the data formats for data that is sent out in response to the erec lrec srec and related commands For details on how to interpret the strings see Record Layout Definition later in this appendix Send lrec layout Receive lrec layout s s 1x f f f f EDI s r pres intensity motor lrec mem size srec mem size These commands report the long and short records that can be stored with the current settings and the number of blocks reserved for long and short records To calculate the number of short records per block add 2 to the number of records and then divide by the number of blocks The example below shows that 10 blocks were reserved for long records and the maximum number of long records that can be stored in memory is 2038 Send lrec mem size Receive lrec mem size 2038 recs 10 blocks lrec per srec per These commands report the long and short records logging period The example below shows that the short record logging period is 5 minutes Send srec per Receive srec per 5 min set srec per value set srec per value value 1 5 15 30 60 Thermo Electron Corporation Model 48 High Level Instruction Manual B 19 C Link Protocol Commands Datalogging B 20 M
161. nt These kits break out the signals on the rear panel connector to individual numbered terminals Two types of terminal block and cable kits are available One kit is for the DB37 connectors and can be used for either the analog output connector or the relay output connector The other kit is for the DB25 connector and can be used for the optional I O expansion board For associated part numbers refer External Device Connection Components on page 7 5 Each kit consists of e one six foot cable e one terminal block e one snap track Note Supporting all of the connections on units with the optional I O expansion board requires e two DB37 kits e one DB25 kit Table 9 1 identifies the optional individual cables that are available for the instrument and Table 9 2 provides the cable color codes For associated part numbers refer to External Device Connection Components on page 7 3 Note Table 9 2 provides the color coding for both 25 pin cables and 37 pin cables Color codes for pins 1 25 are for 25 pin cables color codes for pins 1 37 are for 37 pin cables A Model 48 High Level Instruction Manual 9 3 Optional Equipment 9 4 Model 487 High Level Instruction Manual Table 9 1 Cable Options Description Cable Length DB37M to open end Six feet DB37F to open end Six feet DB25M to open end Six feet RS 232 Table 9 2 Color Codes for 25 Pin and 37 Pin Cables
162. ntrance Mirror 7414 Exit Mirror 7358 Filter Wheel Assembly 101427 00 Chopper Motor Cable List Table 7 2 describes the Model 48i High Level cables See the Troubleshooting chapter for associated connection diagrams and board connector pin descriptions Table 7 2 Model 48i High Level Cables Part Number 101 036 00 Description DC Power Supply 24V Output 1037 00 1048 00 1038 00 115VAC Supply to Measurement Interface Board RS 485 Data Power Switch to Motherboard 1364 00 DC Power Supply Status Monitor 1054 00 Motherboard to Front Panel Board 035 00 DC Power Supply AC Input 1033 00 AC from Receptacle 1377 00 AC to Power Switch 1055 00 Main AC Receptacle Assembly 0 0 0 0 0 101 0 0 0 0 1267 00 Fan Power Cable External Device Table 7 3 lists the standard and optional cables and components used for P P Connection Components Thermo Electron Corporation connecting external devices such as PCs and data loggers to an iSeries instrument Model 48 High Level Instruction Manual 7 5 Servicing External Device Connection Components Flow Transducer Optical Bench Thermistor Front Panel Front Panel Board 7 6 Model 487 High Level Instruction Manual Table 7 3 External Device Connection Components Part Number Description 101562 00 Terminal Block and Cable Kit DB25 optional 101556 00 Termin
163. number There is a no translation button which creates a selection list of twelve Code nn options The number of the user selection is used to create the output command Mode 6 12 13xflocal remote service service 0 1 Tset mode s n This is a line which has a title of Mode and value taken from the sixth field of the data response There is a bitfield extraction of bits 12 through 13 from the source the value type is not important here because the value is being translated to an output string Once the bits have been extracted Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Record Layout Definition they are shifted down to the bit zero position Thus the possible values of this example will be 0 through 3 The translation list shows the words which correspond to each input value the zeroth value appearing first 0 gt local 1 gt remote etc The selection list shows that only the first two values in this case are to be shown to the user when the button is pressed The T button indicates full translation input code to string and user selection number to output string xC This is a line that starts a new column the xC or L Comp 6 11x off on Tset temp comp s n This shows that the bitfield end the second part of a bitfield specification is optional The bitfield will be one bit long starting in this case at the eleventh bit Background 7f 8Bd ddd set 03 bkg s
164. o 3 11 Figure 3 7 Pin Out of Rear Connector in Auto Range Mode 3 12 Figure 4 1 Calibration Flow Schematic ococoocicociccccinconinconcnccnrnccnrnccnrnocanonos 4 4 Figure 5 1 Inspecting and Cleaning the FaN cooociconciciccccinconinccninccnrnccnrnnnnoos 5 4 Figure 5 2 Rebuilding the PUMP o oooociooncconnnncnocnnnnnocncnrnnnocorornnnonocoronnonoroso 5 6 Figure 6 1 Board Level Connection Diagram Common Electronics 6 5 Figure 6 2 Board Level Connection Diagram Measurement System 6 6 Figure 7 1 Properly Grounded Antistatic Wrist Strap ocooc io o 7 3 Figure 7 2 Component Layout 2s sce e e o ae 7 6 Figure 7 3 Removing the Measurement Bench and Lowering the Partition 7 7 Figure 7 4 Replacing the Fan cc cceccscecesesesescecesescseeceseseseeceeseseeceeseseaes 7 9 Figure 7 5 Replacing the IR Source oooooccicicocncociniccnncononocnrnncnrnccnrnnnnrnnnonos 7 11 Figure 7 6 Removing the Motor ccc cccesesessesesesestetesesesteteseseeteteseseaes 7 12 Figure 7 7 Replacing the Optical Bench oo cece cece cetesteeeteeeeseees 7 14 Figure 7 8 Replacing the Optical Switch Inverted View 7 16 Figure 7 9 Replacing the Detector Preamplifier Assembly 1 17 Figure 7 10 Replacing the PuUMP oocioococococcccnnnicocononononocorononnocornnnonororannonoooso 7 20 Figure 7 11 Replacing t
165. o span coefficients so that each range can be calibrated separately This is necessary if the two ranges are not close to one another For example the low CO range is set to 0 50 ppm and the high CO range is set to 0 20 000 ppm Figure 3 6 Analog Output in Auto Range Mode Thermo Electron Corporation Model 48 High Level Instruction Manual 3 11 Operation Range Menu By default in the auto range mode the analog outputs are arranged on the rear panel connector as shown in Figure 3 7 See Table 3 4 for channels and pin connections Auto range mode may be selected from the Range Mode Select on page 3 68 000000000000000000 c000000000000000000 O Figure 3 7 Pin Out of Rear Connector in Auto Range Mode Table 3 4 Default Analog Outputs in Auto Range Mode Channel Pin Description 1 14 CO Analog Output 2 33 Range Status half scale high range zero scale low range 3 15 None 4 34 None 5 17 None 6 36 None Ground 16 18 19 35 37 Signal Ground Note All channels are user definable If any customization has been made to the analog output configuration the default selections my not apply A 3 12 Model 487 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation Gas Units CO Range Operation Range Menu The Gas Units screen defines how the CO concentration readings is expressed Gas units of parts per million ppm an
166. occinicinincininninicccnnoss 1 3 Table 2 1 O Terminal Board Pin DescriptiONS oococicocoinocincnnnnnincnncninncnnosoo 2 6 Table 2 2 D O Terminal Board Pin DescriptiONS oconcininoininninicncnnoss 2 7 Table 2 3 25 Pin Terminal Board Pin DescriptiONS o oooocicinonocococnincncnncnrnnnnos 2 8 Table 3 1 Front Panel Pushbuttons ooococnicccicciccconicocoononnononnonorncnocnooss 3 3 Table 3 2 Default Analog Outputs in Single Range Mode 3 9 Table 3 3 Default Analog Outputs in Dual Range Mode 3 10 Table 3 4 Default Analog Outputs in Auto Range Mode 3 12 Table 3 5 Available Operating Ranges ooocincicionininninnnconinncncnncninncninonoso 3 14 Table 3 6 Analog Output Zero to Full Scale Table 3 44 Table 3 7 Signal Type Group ChOICES o ocoonicoocicciciocininccnnocinonocnrnncnnnncnnnoos 3 45 Table 6 1 Troubleshooting General Guide ooooicinoicincicncincnincnccnncncnnosso 6 2 Table 6 2 Troubleshooting Alarm Messages oocococooonicinonccncnnnonncncnonrnnnooos 6 3 Table 6 3 Motherboard Connector Pin Descripti0NS ocooninio o 6 7 Table 6 4 Measurement Interface Board Connector Pin Descriptions 6 12 Table 6 5 Front Panel Board Connector Pin DiagraM ooooococinicinciccco 6 14 Table 6 6 0 Expansion Board Optional
167. odel 48 High Level Instruction Manual These commands set the long and short records logging period to value in minutes The example below sets the long record logging period to 15 minutes Send set lrec per 15 Receive set lrec per 15 ok no of lrec no of srec These commands report the number of long and short records stored in the long and short records memory The example below shows that 50 long records have been stored in the memory Send no of lrec Receive no of lrec 50 recs malloc lrec malloc srec These commands report the currently set memory allocation for long and short records in percent of total memory Send malloc lrec Receive malloc lrec 10 set malloc lrec value set malloc srec value value 0 to 100 These commands set the percent of memory space allocated for long and short records to value where value is a floating point number representing percent The example below sets the memory allocation for long records to 10 Note Issuing these commands will clear all the logging data memory All the existing records should be retrieved using appropriate commands if required A Send set malloc lrec 10 Receive set malloc lrec 10 ok set copy sp to lrec set copy sp to srec set copy sp to stream These commands copy the current selections in scratch pad sp into the long record short record or streaming data list The example below copies the current list in scratch pad into the long records list
168. og Voltage 3 Thermo Electron Corporation Thermo Electron Corporation Troubleshooting Connector Pin Descriptions Connector Reference Pin Signal Description Label Designator 16 Ground 17 Analog Voltage 5 18 Ground 19 Ground 20 Power Fail Relay COM 21 Power Fail Relay N O Contact 22 Ground 23 TTL Input 3 24 TTL Input 4 25 TTL Input 6 26 Ground 27 TTL Input 9 28 TTL Input 11 29 TTL Input 12 30 TTL Input 14 31 TTL Input 16 32 Ground 33 Analog Voltage 2 34 Analog Voltage 4 35 Ground 36 Analog Voltage 6 37 Ground SER EN J7 Serial Enable Jumper 2 3 3V 24V IN J10 24V 2 Ground DIGITAL 1 0 J14 5V 2 24V 3 24V 4 Ground 5 Ground 6 Ground 7 SPI Reset 8 SPI Input Model 48 High Level Instruction Manual 6 9 Troubleshooting Connector Pin Descriptions 6 10 Model 487 High Level Instruction Manual Connector Label Reference Designator Pin Signal Description SPI Output SPI Board Select SPI Clock EXT RS485 oOo a N on A WW N gt imd gt gt gt gt al w N RS485 to Rear Panel RS485 to Rear Panel 5V 5V 5V Ground Ground Ground NC NC 24 24 24 24 24 24 MONITOR J17 24V Power Monitor Ground FRONT PANEL BD J18 oOo 0 N Ooo A W N Ground Ground LCLK LCD Signal Ground Ground LLP LCD Signal LFLM LCD Signal LD4 LCD Signal LDO LCD Signal LD5 LCD Signal LD1 LCD Signal LD6 LC
169. on Calibration Zero Adjust Span Adjust 4 4 Model 487 High Level Instruction Manual F OFFI cogftom CONTROLLER FLOWMETER ZERO MIXING AIR CHAMBER PRESSURE co REGULATOR SS Q FLOW DK CONTROLLER FLOWMETER OUTPUT co MANIFOLD EXTRA OUTLETS CAPPED WHEN NOT IN USE TO INLET OF ANALYZER UNDER CALIBRATION Figure 4 1 Calibration Flow Schematic Use the following procedure to set the CO reading to zero 1 Allow sufficient time for the Model 487 High Level to warm up and stabilize 2 Adjust the dilution system of Figure 4 1 so that zero air alone is present in the manifold Since not all flow controllers have a positive shut off it might be necessary to disconnect the CO input line and cap it 3 Allow the instrument to sample zero air until a stable reading is obtained 4 Press M and choose Calibration gt Calibrate Zero 5 In the Calibrate Zero screen press to set the CO reading to zero If a strip chart recorder is used to obtain a record of the analog output it is recommended that the system be adjusted to obtain a zero trace at 5 of scale This is to allow observation of zero drift and or zero noise Record the stable zero air response as Z Use the following procedure to adjust the span Thermo Electron Corporation Thermo Electron Corporation l Calibration Calibration Adjust the zero air flow and the CO flow from the standard CO cylinder to provi
170. on Instrument Controls Menu Alarms The Alarms status screen allows the user to select the alarm status for the selected relay output The selected item is shown by lt after it e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Output Relay Settings gt Select Relay gt Instrument State gt Alarms Non Alarm The Non Alarm status screen allows the user to select the non alarm status for the selected relay output The selected item is shown by lt after it e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Output Relay Settings gt Select Relay gt Instrument State gt Non Alarm 3 40 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu my Ptr d dh Digital Input Settings The Digital Input Settings menu displays a list of the 16 digital inputs available and allows the user to select the logic state and instrument parameter for the relay selected Note The digital inputs must be asserted for at least one second for the action to be activated A e In the Main Menu choose Instrument Controls gt I O Configuration gt Digital Input Settings pHo mid Logic State The Logic State screen is used to change the I O relay to either normally open or normally closed The default state is open which indicates that a relay connected between the digital input pin and ground is normally open and clos
171. on about the current screen or menu Help messages are displayed using lower case letters to easily distinguish them from the operating screens To exit a help screen pressl_ Jor to return to the previous screen or to return to the Run screen e Up Down Ce gt Left Right The four arrow pushbuttons t J e and move the cursor up down left and right or change values and states in specific screens Enter The is used to select a menu item accept set save a change and or toggle on off functions Soft Keys The Soft Keys are multi functional keys that use part of the display to identify their function at any moment The function of the soft keys allows immediate access to the menu structure and most often used menus and screens They are located directly underneath the display and as the keys functions change this is indicated by user defined labels in the lower part of the display so that the user knows what the keys are to be used for To change a soft key place the menu cursor gt on the item of the selected menu or screen you wish to set Press gt followed by the selected soft key within 1 second of pressing the right arrow key The edit soft key prompt will be displayed for configuration for the new label Thermo Electron Corporation Model 48 High Level Instruction Manual 3 3 Operation Software Overview Software Overview 3 4 Model 487 High Level Instructio
172. on of Primary and Secondary Standards for Flow Measurements Specific information on certification of concentration standards is given in EPA 600 R93 224 EPA Traceability Protocol for Assay and Certification of Gaseous Calibration Standards 1993 Available from www NTIS gov PB94130424 Model 48 High Level Instruction Manual 4 9 Safety Precautions Thermo Electron Corporation A Chapter 5 Preventive Maintenance This chapter describes the periodic maintenance procedures that should be pP P P performed on the instrument to ensure proper operation Since usage and environmental conditions vary greatly you should inspect the components frequently until an appropriate maintenance schedule is determined This includes the sample pump solenoid valves and IR source which have a limited life Other operations such as cleaning the optics and checking the calibration of the pressure and temperature transducers should be performed on a regular basis This chapter includes the following maintenance information and replacement procedures e Safety Precautions on page 5 1 e Replacement Parts on page 5 2 e Cleaning the Outside Case on page 5 2 e Cleaning the Optics on page 5 2 e IR Source Replacement on page 5 3 e Fan Filter Inspection and Cleaning on page 5 3 e Leak Test and Pump Check Out on page 5 4 e Pump Rebuilding on page 5 5 Read the safety precautions before beginn
173. ons and save the new parameters Press WM to back up a step in the Service Mode menu Repeat Step 1 for a 50 concentration of the upper range Select Cal Point 2 Use Ce to move the cursor and to increment or decrement the digit values until they match the concentration being introduced to the instrument Press The instrument will perform a series of calculations and save the new parameters Press to back up a step in the Service Mode menu 10 Repeat Step 1 for a 20 concentration of the upper range 11 Select Cal Point 3 Thermo Electron Corporation References Thermo Electron Corporation 12 13 14 15 1 Calibration References Use e J to move the cursor and J 4 to increment or decrement the digit values until they match the concentration being introduced to the instrument Press The instrument will perform a series of calculations and save the new parameters Press _ J to back up a step in the Service Mode menu Select Coefficients and press Ce The instrument will automatically calculate the new coefficients and save the new parameters Repeat Steps 1 through 12 for Hi Multi Point Cal Section 12 of EPA 454 R 98 004 Quality Assurance Handbook for Air Pollution Measurement Systems Volume II Part 1 August 1998 available at www epa gov ttn amtic qabook html and 40 CFR 50 Appendix C Section 12 also provides information on Calibrati
174. oped from hi multi B 23 point calibration contrast Reports sets current screen contrast B 30 copy Irec to sp Sets copies current Irec selection into the scratch pad B 21 copy sp to Irec Sets copies current selections in scratch pad into Irec list B 20 copy sp to srec Sets copies current selections in scratch pad into srec list B 20 copy sp to stream Sets copies current selections in scratch pad into stream list B 20 copy srec to sp Sets copies current srec selection into the scratch pad B 21 copy stream to sp Sets copies current streaming data selection into the scratch B 21 pad custom Reports sets defined custom range concentration B 28 date Reports sets current date B 31 default params Sets parameters to default values B 31 dhcp Reports sets state of use of DHCP B 33 diag volt iob Reports diagnostic voltage level for I O expansion board B 15 diag volt mb Reports diagnostic voltage level for motherboard B 15 diag volt mib Reports diagnostic voltage level for measurement interface B 15 board dig in Reports status of the digital inputs B 37 din Reports sets digital input channel and active state B 37 do down Simulates pressing down pushbutton B 25 Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Commands Command Description Page dout Reports sets digital output channel and active state B 37 dtoa Reports outputs of the digital to analo
175. or a zero standard Room air which has been scrubbed of CO can also be used as the zero air source Model 48 High Level Instruction Manual 4 1 Calibration Equipment Required Compression Drying Scrubbing Flow Meter s and Controller s 4 2 Model 487 High Level Instruction Manual It is not necessary to remove SO2 NO NO2 CO water vapor or hydrocarbons since the Model 487 High Level does not respond to these molecules If water vapor is not removed it might be necessary to correct the flow measurement data when calculating the dilution ratio of the span CO reference A platinum on alumina catalyst operated at 250 C has been found to be a convenient oxidizer to convert CO to CO If a zero air source is required the following interferant removal methods are recommended e Compression e Drying e Oxidation e Scrubbing The zero air source should be at an elevated pressure to allow accurate and reproducible flow control and to aid in subsequent operations such as drying oxidation and scrubbing An air compressor that gives an output of 10 psig is usually sufficient for most applications Several drying methods are available Passing the compressed air through a bed of silica gel using a heatless air dryer or removing water vapor with a permeation dryer are three possible approaches The last step in the generation of the zero air is the removal of the remaining contaminants by either further reaction o
176. oration Operation Calibration Menu Calibration Menu The Calibration menu is used to calibrate zero and span The calibration menu is similar for the single dual and auto range mode as shown below The only difference between the screens are the words HI and LO to indicate which range is displayed The dual and auto range modes have two CO span factors high and low This allows each range to be calibrated separately This is necessary if the two ranges used are not close to one another For example a low CO range of 50 ppm and a high CO range of 1 000 ppm For more information about calibration see Chapter 4 Calibration e Inthe Main Menu choose Calibration Calibrate CO Background Thermo Electron Corporation The Calibrate CO Background screen is used to adjust the CO background or perform a zero calibration Before performing a zero calibration ensure the analyzer samples zero air for at least 5 minutes It is important to note the averaging time when calibrating The longer the averaging time the more accurate the calibration will be To be most accurate use the 300 second averaging time For more information about calibration see Chapter 4 Calibration e Inthe Main Menu choose Calibration gt Cal CO Background Model 487 High Level Instruction Manual 3 19 Operation Calibration Menu Calibrate CO Coefficient Zero Span Check 3 20 Model 487 High Level Instruction Manu
177. ormation on the hardware configuration of the instrument Note If the analyzer is in service mode pressing on the item will toggle it yes or no with the exception of purchased options such as dilution and auto calibration A e Inthe Main Menu choose Diagnostics gt Instrument Configuration Wi mpini The Contact Information screen displays the customer service information e Inthe Main Menu choose Diagnostics gt Contact Information Ea rae LF es ESTA i ia nd La Wi mid The alarms menu displays a list of items that are monitored by the analyzer If the item being monitored goes outside the lower or upper limit the status of that item will go from OK to either LOW or HIGH respectively If the alarm is not a level alarm the status will go from OK to FAIL The number of alarms detected is displayed to indicate how many alarms have occurred If no alarms are detected the number zero is displayed To see the actual reading of an item and its minimum and maximum limits move the cursor to the item and press Model 487 High Level Instruction Manual 3 59 Operation Alarms Menu Internal Temperature 3 60 Model 487 High Level Instruction Manual Items displayed are determined by the options installed The zero span check and auto calibration screens are visible only if the zero span check or auto calibration options are enabled The motherboard status interface board st
178. ory B 20 pres Reports current reaction chamber pressure B 9 pres comp Reports sets pressure compensation on or off B 29 program no Reports analyzer program number B 35 push Simulates pressing a key on the front panel B 25 range Reports sets current CO range B 27 range mode Reports sets current range mode B 28 ratio Reports sample reference ratio B 10 relay stat Reports sets relay logic status to for the designated relay s B 39 ri right Simulates pressing right pushbutton B 25 ru run Simulates pressing run pushbutton B 25 sample Sets zero span valves to sample mode B 28 save Stores parameters in FLASH B 31 save params Stores parameters in FLASH B 31 sc screen C series legacy command that reports a generic response B 26 Use iscreen instead sp conc Reports sets span concentration B 24 sp field Reports sets item number and name in scratch pad list B 21 span Sets zero span valves to span mode B 29 sr Reports last short record stored B 17 srec Reports maximum number of short records B 17 srec format Reports sets output format for short records ASCII or binary B 18 srec layout Reports current layout of short record data B 19 srec mem size Reports maximum number of short records B 19 srec per Reports sets short record logging period B 19 stream per Reports sets current set time interval for streaming data B 21 stream time Reports sets a time stamp to streaming data or not B 22 temp comp Reports sets temperature compensation on or off B 30 time
179. ot Used Not Used Not Used 4 Voltage Output Not Used Not Used Not Used 5 Voltage Output Not Used Not Used Not Used 6 Voltage Output Not Used Not Used Not Used J Current Output CO Low CO CO 8 Current Output CO High CO Range Status 9 Current Output Not Used Not Used Not Used 10 Current Output Not Used Not Used Not Used 11 Current Output Not Used Not Used Not Used 12 Current Output Not Used Not Used Not Used B 38 Model 487 High Level Instruction Manual Thermo Electron Corporation C Link Protocol Commands 1 0 Configuration list var aout list var dout list var din These commands report the list of index numbers and the variables associated with that index number available for selection in the current mode determined by single dual auto gas mode for analog output digital output and digital inputs The index number is used to insert the variable in a field location in a list using set sp field index The example below reports the list of analog output index numbers and variables Send list var aout Receive list var aout index variable none co sr intt cht O auxt 13 pres 14 smplfl 15 intensity 16 speed 28 biasv e WO ouvre oO relay stat This command reports the current relay logic normally open or normally closed if all the relays are set to same state that is all open or all closed The example below shows that the status when all the relays logic is set to normally open Se
180. ould be referred to for the cylinder checking procedure Compute the span error from the following equation gt CO Concentration Actual CO a 100 in tac eth i acca ast A an E Actual CO Concentration Thermo Electron Corporation HI and LO Multi Point Calibration Default Coefficients Cal Point 1 2 and 3 Thermo Electron Corporation Adjust Calibration HI and LO Multi Point Calibration 3 Latest copy of the Quality Assurance Handbook for Air Pollution Measurement Systems should be consulted to determine the level of acceptance of zero and span errors For detailed guidance in setting up a quality assurance program refer to the Code of Federal Regulations and the EPA Handbook on Quality Assurance The instrument can also be calibrated using a dual three point calibration The calibration points are divided into a low range and a high range consisting of three points each e Cal point 1 e Cal point 2 e Cal point 3 The customer defines the ranges and Thermo Electron recommends the following calibration points for each range e Cal point 1 80 of range e Cal point 2 50 of range e Cal point 3 20 or range Note If performing a multi point calibration after a bad calibration or changing ranges it is recommended to start off with default values for the Cal point coefficients A To set default values from the Main Menu select Service Mode gt Hi Multi Point Cal or Lo Multi Point Cal F
181. ows the recommended method for attaching the cable to the terminal board using the included tie down and spacer Table 2 2 Detail B Signal Description Relay7_ContactA Relay1_ContactB Relay7_ContactB Relay2_ContactA Relay8_ContactA Relay2_ContactB Relay8_ContactB Relay3_ContactA Relay9_ContactA Relay3_ContactB Relay9_ContactB Relay4_ContactA gt gt gt gt gt gt gt co co N m a A a Relay10_ContactA Relay4_ContactB Relay10_ContactB O Jo INIo anys Si wt pr Relay5_ContactA Relay5_ContactB Relay6_ContactA 21 22 23 Solenoid_Drive_Outputl 24V Solenoid_Drive_Output2 Relay6_ContactB 24 24V Model 48 High Level Instruction Manual 2 7 Installation Connecting External Devices 25 Pin Terminal Board The 25 pin terminal board is included with the optional I O Expansion Board See Detail A NE See Detail B Assembled Connector Figure 2 7 25 Pin Terminal Board Views Detail A Detail B Table 2 3 25 Pin Terminal Board Pin Descriptions Pin Signal Description Pin Signal Description 1 lOut1 13 Analog_In1 2 Isolated ground 14 Analog_In2 3 lOut2 15 Analog_In3 4 Isolated ground 16 GNDD 5 lOut3 17 Analog_In4 6 Isolated ground 18 Analog_In5 7 lOut4 19 Analog_In6 8 Isolated ground 20 GNDD 9 lOut5 21 Analog_In7 10 Isolated ground 22 Analog_In8 11 l
182. p www modbus org References are from MODBUS Application Protocol Specification V1 1a MODBUS IDA June 4 2004 The following are the communication parameters that are used to configure the serial port of the iSeries to support MODBUS RTU protocol Number of Data bits 8 Number of Stop bits 1 Parity None Date rate from 1200 115200 Baud 9600 is default Model 487 High Level Instruction Manual C 1 MODBUS Protocol TCP Communication Parameters TCP Communication Parameters Application Data Unit Definition Slave Address MBAP Header C 2 Model 48 High Level Instruction Manual iSeries Instruments support the MODBUS TCP protocol The register definition is the same as for the serial interface TCP connection port for MODBUS 502 Here are the MODBUS ADU Application Data Unit formats over serial and TCP IP Serial Slave Address Function Code Data Error Check TCP IP MBAP Header Function Code Data The MODBUS save address is a single byte in length This is the same as the instrument ID used for C Link commands and can be between 1 and 127 decimal i e 0x01 hex to 0x7F hex This address is only used for MODBUS RTU over serial connections Note Device ID 0 used for broadcast MODBUS commands is not supported Device Ds 128 through 247 i e 0x80 hex to OxF7 hex are not supported because of limitations imposed by C Link A In MODBUS over TCP IP a MODBUS Applica
183. panel display the analog outputs and also makes the data available over the serial or Ethernet connection Thermo Electron Corporation Introduction Specifications Il Al Figure 1 1 Model 487 High Level Flow Schematic S ecifications Table 1 1 lists the specifications for the Model 48 High Level P 8 Table 1 1 Model 48i High Level Specifications Thermo Electron Corporation Preset ranges 0 50 100 200 500 1000 2000 5000 10000 20000 ppm or mg m Custom ranges 0 50 to 20000 ppm or mg m Zero roise 2 ppm RMS 10 second averaging time Lower detectable limit 4 ppm Zero drift 24 hour lt 4 ppm Span drift 2 full scale Response time 60 seconds 30 second averaging time Linearity 2 full scale Sample flow rate 0 5 2 LPM Operating temperature 0 45 C Model 48 High Level Instruction Manual 1 3 Introduction Specifications 1 4 Model 48 High Level Instruction Manual Power requirements 100 VAC 50 60 Hz 115 VAC 50 60 Hz 220 240 VAC O 50 60 Hz 275 watts Physical dimensions 16 75 W X 8 62 H X 23 D Weight Approximately 49 Ibs 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 programmable Digital outputs 1 power fail rela
184. ptical Switch Rep acen o ad 7 15 Bench Heater Assembly Replace iiaci is 7 16 Detector Preamplifier Assembly Replacement ooonicninnnnnnnonononinnnnss 7 17 Preamp Board CalibratiOiid oi iia 7 18 O 7 19 Pressure Transducer Replacement asa 7 20 Pressure Transducer Colbie 7 21 Flow Transducer Replacement incio ibas 7 23 Flow Transducer Cabra its dol cti 7 24 Capillary Cleaning or Replacementiviiimion nciiosinpsaimantias 7 25 Optional Zero Span and Sample Solenoid Valve Replacement 7 26 Analog Output Testa a nani 7 27 Analog Output Calibration y odas 7 29 Analog Input Calibration sasstasiarlcidocia lia lacus 7 30 Calibrating the Input Channels to Zero Volts sssr 7 30 Calibrating the Input Channels to Full Scale wo eee eeseeeeeereeee 7 31 Ambient Temperature Calibracion 7 32 I O Expansion Board Optional Replacement cocoocnconinnnnconnnnonoss 7 33 Digital Output Board Replace tics 7 34 Motherboard Replacementi iio comida 7 35 Measurement Interface Board Replacement oocooccncnonncnnonnccnnanannnnons 7 36 Front Panel Board Replacement indiana 7 37 Le DiModule Replacement a oa TUE 7 38 Service LOCAS diia A is 7 39 System DescrpiiON asada 8 1 EA AE E Aa 8 1 Optical A O E ee ne 8 2 Bandpass Bite initial see 8 2 Thermo Electron Corporation Chapter 9 Thermo Electron Corporation Contents Bench Heater Board sustrato 8 2 Chopper Motorissuridatinia td oa 8 2 Optical Pick Upa ii dd 8 3 Gas Filter Wheel aaa ads 8 3 o A
185. query command DA the instrument responds in the following format lt STX gt MD02 lt SP gt lt address gt lt SP gt lt measured valuel gt lt SP gt lt status gt lt SP gt lt SFKT gt lt SP gt lt address 1 gt lt SP gt lt measured value2 gt lt SP gt lt status gt lt SP gt lt SFKT gt lt ETX gt lt BCC gt The response uses the same command terminators as used by the received command i e if the received command was terminated with a lt CR gt the response is terminated with lt CR gt and if the command was terminated with a lt ETX gt lt BCC gt the response is terminated with lt ETX gt and the computed checksum lt BCC gt The 02 after the MD indicates that two measurements are present in the reply string a 03 for three measurements and so on this will also determine the length of the reply string lt address gt is the Instrument Address Each subsequent measurement attached to the response will have the lt address X gt where X keeps incrementing by 1 for each measurement included lt measured value gt is the concentration value in currently selected gas units represented as exponential representation with 4 characters mantissa and 2 characters exponent each with sign Mantissa sign and 4 digits The decimal point is assumed to be after the first digit and is not transmitted Exponent sign and 2 digits Example 5384000 0 is represented as 5384 06 0 04567 is represented as 4567 02 lt status gt i
186. r if greater detail is needed please refer to the Quality Assurance Handbook for Air Pollution Measurement Systems The following sections discuss the required apparatus and procedure for calibrating the instrument The following equipment is required to calibrate the instrument A cylinder of CO in air containing an appropriate concentration of CO suitable for the selected operating range of the analyzer under calibration is necessary The assay of the cylinder must be traceable either to a National Institute of Standards and Technology NIST CO in Air Standard Reference Material SRM or an NIST EPA approved gas manufacturer s Certified Reference Material CRM A recommended protocol for certifying CO gas cylinders against a CO SRM or CRM is given in the Quality Assurance Handbook The CO gas cylinder should be recertified on a regular basis determined by the local quality control program Calibration requires zero air that is free of contaminants which will cause a detectable response on the CO analyzer The zero air should contain lt 0 01 ppm CO Since the Model 487 High Level is virtually interference free it is only necessary to ensure that CO has been removed It should be noted that zero air as supplied in cylinders from commercial suppliers typically contains CO concentrations in the 0 1 0 3 ppm range So cylinder zero air should be scrubbed of the residual CO prior to its use in the Model 487 High Level as a dilution gas
187. r absorption Fixed bed reactors are usually employed In order to obtain an accurate dilution ratio in the dilution method used for calibration the flow rates must be regulated to 1 and be measured to an accuracy of at least 2 The meter and controller can be two separate devices or combined in one device The user s manual for the meter should be consulted for calibration information Additional information on the calibration of flow devices can be found in the Quality Assurance Handbook It should be noted that all flows should be corrected to 25 C and 760 mmHg and that care should be exercised in correcting for water vapor content Thermo Electron Corporation Pressure Regulator for CO Standard Cylinder Mixing Chamber Output Manifold Pre Calibration Calibration Connect the Instrument Thermo Electron Corporation Calibration Pre Calibration The regulator used must have a nonreactive diaphragm and internal parts as well as a suitable delivery pressure A chamber constructed of glass Teflon or other nonreactive material and designed to provide thorough mixing of CO and diluent air for the dilution method is required The output manifold should be constructed of glass Teflon or other nonreactive material and should be of sufficient diameter to ensure an insignificant pressure drop at the analyzer connection The system must have a vent designed to ensure atmospheric pressure at the manifold and to prev
188. r cord and remove the cover 2 Remove the capillary from the inlet elbow fitting on the pump head Thermo Electron Corporation Model 48 High Level Instruction Manual 7 25 Servicing Optional Zero Span and Sample Solenoid Valve Replacement Capillary Figure 7 13 Cleaning or Replacing the Capillary 3 Clean with less than 0 015 inch diameter wire or replace 4 Install the capillary by following the previous steps in reverse Optional Zero Span Use the following procedure to replace the solenoid and Sample Solenoid Equipment Required Valve Replacement Solenoid Philips screwdriver 2 Wrench 9 16 inch f Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Unplug the solenoid electrical connector from the measurement interface board 3 Remove the Teflon lines from the solenoid 4 Remove both screws holding the solenoid to the rear panel and remove the solenoid 7 26 Model 48 High Level Instruction Manual Thermo Electron Corporation Analog Output Thermo Electron Corporation Testing Servicing Analog Output Testing 5 Install the solenoid by following the previous steps in reverse 6 Perform a leak test as described in the Preventive Maintenance chapter The analog outputs
189. r the range of 0 to 10 volts The instrument includes one power fail relay on motherboard and ten digital output relays on the digital output board These are reed relays rated for at least 500 mA 200VDC The power fail relay is Form C both normally opened and normally closed contacts All other relays are Form A normally opened contacts and are used to provide alarm status and mode information from the analyzer as well as remote control to other devices such as for controlling valves during calibration The user may select what information is sent out each relay and whether the active state is opened or closed Sixteen digital inputs are available which may be programmed to signal instrument modes and special conditions including e Zero Gas Mode e Span Gas Mode The actual use of these inputs will vary based on analyzer configuration The digital inputs are TTL level compatible and are pulled up within the analyzer The active state can be user defined in firmware Two serial ports allow daisy chaining so that multiple analyzers may be linked using one PC serial port The standard bi directional serial interface can be configured for either RS 232 or RS 485 The serial baud rate is user selectable in firmware for standard speeds from 1200 to 19 200 baud The user can also set the data bits parity and stop bits The following protocols are supported e C Link e MODBUS Slave e Geysitech Bayern Hessen e Streaming Data
190. ration 1 0 Configuration B 36 Model 487 High Level Instruction Manual Send set layout ack Receive set layout ack ok analog iout range channel This command reports the analog current output range setting for channels where channel must be between 1 and 6 inclusive The example below reports current output channel 4 to the 4 20 mA range according to Table B 9 This command responds with feature not enabled if the I O expansion board is not detected Send analog iout range 4 Receive analog iout range 4 2 set analog iout range channel range This command sets analog current output channel to the channel range where channel is between 1 and 6 inclusive and range is set according to Table B 9 The example below sets current output channel 4 to the 0 20 mA range This command responds with feature not enabled if the I O expansion board is not detected Send set analog iout range 4 1 Receive set analog iout range 4 1 ok Table B 9 Analog Current Output Range Values Range Output Range 1 0 20 mA 2 4 20 mA 0 cannot be set to this but may report Undefined analog vin channel This command retrieves the analog voltage input channel data both the calculated value and the actual voltage In the example below the calculated value of channel 1 is 75 325 degrees F volts are 2 796 This command responds with feature not enabled if the I O expansion board is not detected Send analog vin 1 Rec
191. ration on page B 22 e Keys Display on page B 25 e Measurement Configuration on page B 27 e Hardware Configuration on page B 30 e Communications Configuration on page B 32 e I O Configuration on page B 36 e Record Layout Definition on page B 40 Each command sent to the analyzer over the serial port must begin with the American Standard Code for Information Interchange ASCII symbol or byte value equivalent of the instrument s identification number plus 128 For example if the instrument ID is set to 25 then each command must begin with the ACSI character code 153 decimal The analyzer ignores any command that does not begin with its instrument identification number If the instrument ID is set to 0 then this byte is not required For more information on changing Instrument ID see Chapter 3 Operation Model 48 High Level Instruction Manual B 1 C Link Protocol Commands Commands Commands The analyzer must be in the remote mode in order to change instrument parameters via remote However the command set mode remote can be sent to the analyzer to put it in the remote mode Report commands commands that don t begin with set can be issued either in the remote or local mode For information on changing modes see Chapter 3 Operation The commands can be sent in either uppercase or lowercase characters Each command must begin with the proper instrument identification n
192. ration alarm warning value B 14 analog out range Reports analog current output range per channel B 36 analog vin Retrieves analog voltage input data per channel B 36 analog vout range Reports analog voltage output range per channel B 36 avg time Reports sets averaging time B 8 baud Reports sets current baud rate B 33 bias voltage Reports current IR bias supply voltage B 15 cal co bkg Sets auto calibrates CO background B 22 Model 48 High Level Instruction Manual B 3 C Link Protocol Commands Commands B 4 Model 487 High Level Instruction Manual Command Description Page cal co coef Sets auto calibrates CO coefficient B 22 cal high co coef Sets auto calibrates high range CO coefficient B 22 cal low co coef Sets auto calibrates low range CO coefficient B 22 chamber temp Reports optical chamber temperature B 9 clr lrecs Clears away only long records that have been saved B 16 clr records Clears away all logging records that have been saved B 16 clr srecs Clears away only short records that have been saved B 16 co Reports current CO concentration B 9 co bkg Reports sets current CO background B 24 co coef Reports sets current CO coefficient B 23 coef 0 Reports coefficients of the curve developed from hi multi B 23 point calibration coef 1 Reports coefficients of the curve developed from hi multi B 23 point calibration coef 2 Reports coefficients of the curve devel
193. rd calibrate the current outputs and the analog voltage inputs See Analog Output Calibration on page 7 29 and Analog Input Calibration on page 7 30 in this chapter A Equipment Required I O expansion board Nut driver 3 16 inch amounts of static electricity A properly ground antistatic wrist strap must f Equipment Damage Some internal components can be damaged by small be worn while handling any internal component A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Unplug the I O expansion board cable from the EXPANSION BD connector on the motherboard 3 Remove the two standoffs holding the I O expansion board connector to the rear panel Figure 7 16 4 Pop off the board from the mounting studs and remove the board 5 To install the I O expansion board follow previous steps in reverse Thermo Electron Corporation Model 48 High Level Instruction Manual 7 33 Servicing Digital Output Board Replacement Motherboard Support Bracket Mounting Studs Motherboard Digital Output Board 1 0 Expansion Board Opt Standoffs 2 1 0 Expansion Board Motherboard Digital Output Board Figure 7 16 Rear Panel Board Connectors Dig ital Outp ut Board Use the following procedure to replace the digital output board Figure 7 Replacement Equipment Required Digital output board Nut driver 3 16 inch amounts of static electricity A properly ground an
194. reen allows the user to set the input voltage for the selected table point in the conversion table from 0 00 to 10 50 The default table is a two point table with point 1 0 00 V 000 0 U and point 2 10 00 V 10 0 U e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config gt Select Channel gt Select Point gt Volts Ph my Py PTET pH piopi Piva OA ae A a E 3 48 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu User Value The User Value screen allows the user to set the output value for the corresponding input voltage for the selected table point in the conversion table from 9999999 to 99999999 The default table is a two point table with point 1 0 00 V 000 0 U and point 2 10 00 V 10 0 U e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config gt Select Table Point gt User Value Wi mid Temperature Temperature compensation provides compensation for any changes to the Compensation instrument s output signal due to internal instrument temperature variations The effects of internal instrument temperature changes on the analyzer s subsystems and output have been empirically determined This empirical data is used to compensate for any changes in temperature When temperature compensation is on the display shows the current internal instrument temperature measured by a th
195. rent internal instrument temperature and bench temperature The internal temperature is the air temperature measured by a sensor located on the interface board e Inthe Main Menu choose Diagnostics gt Temperatures ip gules Piet Pressure The Pressure screen read only displays the current optical bench pressure The pressure is measured by a pressure transducer e Inthe Main Menu choose Diagnostics gt Pressure 3 54 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Diagnostics Menu RO Ea Rri Taic Flow The Flow screen read only displays the flow rate The flow is measured by internal flow sensors For more information see Figure 1 1 e Inthe Main Menu choose Diagnostics gt Flow Sample Reference The Sample Reference Ratio screen read only displays the ratio of the Ratio intensities of the light source through the sample wavelength and reference wavelength of the bandpass filter wheel Normally when zero air is being sampled the sample reference ratio is between 1 00 and 1 18 A ratio outside may indicate that the filter wheel is dirty or the infrared source is degraded e Inthe Main Menu choose Diagnostics gt Sample Ref Ratio POE E EUs EEE TE a ETET Aad Le PTE i ae Thermo Electron Corporation Model 48 High Level Instruction Manual 3 55 Operation Diagnostics Menu AGC Intensity The AGC Intensity screen read only displays the intensit
196. ribes the optional equipment that can be used with this analyzer Appendix A Warranty is a copy of the warranty statement 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 datalogger Model 48 High Level Instruction Manual i About This Manual Safety Safety Safety and Equipment Damage Alerts Model 48 High Level Instruction Manual e 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 e Appendix D Geysitech Bayern Hessen Protocol provides a description of the Geysitech Bayern Hessen or BH Protocol Interface and is supported both over RS 232 485 as well as TCP IP over Ethernet Review the following safety information carefully before using the analyzer This manual provides specific information on how to operate the analyzer however if the calibrator is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired 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
197. rnoooonos B 22 Table B 6 Standard Ranges oocooociciciocinincincncononncnnnncnonncncnncnonornnnnnocnnnoos B 27 Model 48 High Level Instruction Manual xvii Tables xviii Model 487 High Level Instruction Manual Table B 7 Contrast Levels naaa natos B 30 Table B 8 Reply Termination Formats ooocococicicocononnnncncononononncornnnnnocornnnonos B 34 Table B 9 Analog Current Output Range Values oooononicoinincininciniconnoo B 36 Table B 10 Analog Voltage Output Range Values ooooononoinincininccnicncooo B 37 Table B 11 Default Output AssignMeNt oonooicincicioninincincncnncncnncnnnncncnncnnnnoo B 38 Table C 1 Read Coils for 487 High Level oooooocicoocicconinconincinoncnccnrnccnroncnnos C 8 Table C 2 Read Registers for 487 High Level C 9 Table C 3 Write Coils for 48i High Level o ocococcciciocicincinincinincinnncnonncnnnoso C 10 Table D 1 Operating Status for Model 487 High Level D 7 Table D 2 Error Status for Model 487 High Level o ooooicon iconniccninicoicoo D 7 Thermo Electron Corporation Thermo Electron Corporation Chapter 1 Introduction The Model 487 CO High Level Analyzer measures CO concentration using Gas Filter Correlation GFC The Model 487 High Level combines proven detection technology easy to use menu driven software and advanced diagnostics to offer unsurpassed flexibility and reliability The Model 487 Hi
198. rom Hi or Lo Multi Point Cal select Default Coef and press The instrument will automatically reset the default values Use the following procedure to adjust cal points 1 2 and 3 1 Adjust the zero air flow and the CO flow from the standard CO cylinder to provide a diluted CO concentration of approximately 80 of the upper range limit URL of the instrument The total air flow must exceed the total demand of the analyzer connected to the output manifold to ensure that no ambient air is pulled into the manifold vent The exact CO concentration is calculated from Model 48 High Level Instruction Manual 4 7 Calibration HI and LO Multi Point Calibration 4 8 Model 487 High Level Instruction Manual CO grp X Fco CO low e CO Jour Fo Es NA 2 UU Where CO our diluted CO concentration at the output manifold ppm CO srp concentration of the undiluted CO standard ppm Eco flow rate of CO standard corrected to 25 C and 760 mmHg LPM Fp flow rate of dilution air corrected to 25 C and 760 mmHg LPM Allow the Model 1487 High Level to sample this CO concentration standard until a stable response is obtained From the Main Menu select Service Mode gt Lo Multi Point Cal gt Cal Point 1 Use e f to move the cursor and t to increment or decrement the digit values until they match the concentration being introduced to the instrument Press The instrument will perform a series of calculati
199. rporation Operation Service Menu Pressure Calibration The Pressure Calibration submenu is used to calibrate the pressure sensor to zero span or restore factory default values The pressure calibration is visible only when the instrument is in service mode For more information on the service mode see Service Mode earlier in this chapter The pressure sensor s zero counts and span slope are displayed on the menu Note This adjustment should only be performed by an instrument service technician A e Inthe Main Menu choose Service gt Pressure Calibration a RATE Calibrate Pressure Zero The Calibrate Pressure Zero screen calibrates the pressure sensor at zero pressure Note A vacuum pump must be connected to the pressure sensor before pump P performing the zero calibration A e In the Main Menu choose Service gt Pressure Calibration gt Zero Thermo Electron Corporation Model 48 High Level Instruction Manual 3 69 Operation Service Menu Calibrate Pressure Span The Calibrate Pressure Span screen allows the user to view and set the pressure sensor calibration span point Note The plumbing going to the pressure sensor should be disconnected so the sensor is reading ambient pressure before performing the span calibration The operator should use an independent barometer to measure the ambient pressure and enter the value on this screen before calibrating A e Inthe Main Menu choose Service
200. rrent Output 6 5V 24V 24V MOTHER BD J2 Ground Ground Ground RS485 to Motherboard RS485 to Motherboard oOo N oon A O N Table 6 7 Digital Output Board Connector Pin Descriptions Connector Reference Pin Signal Description Label Designator MOTHER BD J1 5V 24V 24V Ground Ground Ground SPI Reset SPI Input oOo N oon A O N Thermo Electron Corporation Model 48i High Level Instruction Manual 6 17 Troubleshooting Connector Pin Descriptions 6 18 Model 48 High Level Instruction Manual Connector Reference Label Designator Pin Signal Description SPI Output SPI Board Select SPI Clock DIGITAL J2 OUTPUTS oOo aoa N on A WW N gt gt o gt gt gt gt gt gt gt gt co loo N o a ow N wo N N N N N N N N N NH O O N O Oo FP WO N gt gt Q Relay 1 Contact a Relay 2 Contact a Relay 3 Contact a Relay 4 Contact a Relay 5 Contact a Relay 6 Contact a Relay 7 Contact a Relay 8 Contact a Relay 9 Contact a Relay 10 Contact a NC Solenoid Drive Output 1 Solenoid Drive Output 2 Solenoid Drive Output 3 Solenoid Drive Output 4 Solenoid Drive Output 5 Solenoid Drive Output 6 Solenoid Drive Output 7 Solenoid Drive Output 8 Relay 1 Contact b Relay 2 Contact b Relay 3 Contact b Relay 4 Contact b Relay 5 Contact b Relay 6 Contact b Relay 7 Contact b Relay 8 Contact b Relay 9 Contact b Relay 10 Contact b 24V Thermo Electron
201. rument is shown if the instrument is unlocked and the password is set e Inthe Main Menu choose Password gt Lock Instrument ERED CH MT H EHO primii PLF IE Pi AG eae i Change Password The Change Password is used to change the password used to unlock the instrument s front panel The change password is shown if the instrument is unlocked e Inthe Main Menu choose Password gt Change Password Remove Password The Remove Password screen is used to erase the current password and disable password protection The remove password is shown if the instrument is unlocked and the password set Thermo Electron Corporation Model 48 High Level Instruction Manual 3 81 Operation Unlock Instrument e Inthe Main Menu choose Password gt Remove Password Pi EE EE Unlock Instrument The Unlock Instrument screen is used to enter the password to unlock the front panel The unlock instrument is shown if the instrument is locked e Inthe Main Menu choose Password gt Unlock Instrument 3 82 Model 487 High Level Instruction Manual Thermo Electron Corporation Equipment Required CO Concentration Standard Zero Air Generator Thermo Electron Corporation Chapter 4 Calibration This chapter describes the procedures for performing a standard zero span calibration and a multipoint calibration of the Model 487 High Level The information described here is more than adequate to perform the calibration Howeve
202. s Pa E dra MT U E Haat i Wi mpini PS PHP L ri Model 487 High Level Instruction Manual 3 27 Operation Instrument Controls Menu Other Measurements The Other Measurements screen allows the user to select the output signal that is tied to the selected field item The selected item is shown by lt after it Items displayed are determined by the options installed Note that at this point pressing indicates that these are proposed changes as opposed to implemented changes To change the selected record format and erase record log file data see Commit Content below e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Select Content gt Select Field gt Other Measurements Analog Inputs The Analog Inputs screen allows the user to select the output signal none or analog inputs 1 8 that is tied to the selected field item The selected item is shown by lt after it Note that at this point pressing indicates that these are proposed changes as opposed to implemented changes To change the selected record format and erase record log file data see Commit Content below e Inthe Main Menu choose Instrument Controls gt Datalogging Settings gt Select Content gt Select Field gt Analog Inputs 3 28 Model 487 High Level Instruction Manual Thermo Electron Corporation Commit Content Operation Instrument Controls Menu The Commit Content screen is used to save the
203. s gt Host Name DH Guided Piet I O Configuration The I O Configuration menu deals with configuration of the analyzer s I O system The analog input configuration is displayed only if the I O expansion board option is installed e Inthe Main Menu choose Instrument Controls gt I O Configuration Note The digital outputs may take up to one second after the assigned state occurs to show up on the outputs A 3 38 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Instrument Controls Menu Output Relay Settings The Output Relay Settings menu displays a list of the 10 analog output relays available and allows the user to select the logic state or instrument parameter for the relay selected e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Output Relay Settings Logic State The Logic State screen is used to change the I O relay to either normally open or normally closed e Press to toggle and set the logic state open or closed Instrument State The Instrument State submenu allows the user to select the instrument state that is tied to the selected relay output A submenu lists signal types of either alarm and non alarm to choose from e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Output Relay Settings gt Select Relay gt Instrument State Thermo Electron Corporation Model 48 High Level Instruction Manual 3 39 Operati
204. s for the selected analog input channel The units are displayed on the diagnostic screen and in datalogging and streaming data The units may be from 1 to 3 characters in length and defaults to V volts e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config gt Select Channel gt Units CH mtb Decimal Places The Decimal Places screen allows the user to select how many digits are displayed to the right of the decimal from 0 to 6 with a default of 2 e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config gt Select Channel gt Decimal Places eer PE dra Ta dl Ea bAi i CH mt Number of Table Points The Number of Table Points screen allows the user to select how many points are used in the conversion table The points range from 2 to 10 with a default of 2 e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config gt Select Channel gt Table Points Thermo Electron Corporation Model 48 High Level Instruction Manual 3 47 Operation Instrument Controls Menu Table Point The Table Point submenu allows the user to set up an individual table point e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Input Config gt Select Channel gt Point 1 10 meki CRA PATO gy cuir BEE EE ad Booe PME TY Saad Haat ake ME aei owe AS EE EE Volts The Volts sc
205. s formed by lt operating status gt and lt error status gt and separated by a space i e lt operating status gt lt SP gt lt error status gt Each of the two lt operating status gt and lt error status gt are formed by two characters each representing a 2 digit hex number which is one byte 8 Bits operation status and one byte 8 Bits error status These two bytes contain the information about the main operating conditions of the instrument at that instant For details on how to interpret the status bytes refer to Table D 1 and Table D 2 below lt SFKT gt is the space provided for future use for special function it currently contains a string of ten 0 s i e lt 0000000000 gt Model 48 High Level Instruction Manual D 5 Geysitech Bayern Hessen Protocol Geysitech Commands Measurements reported in response to DA command Single Range Mode Dual Auto Range Mode Operating and Error Status D 6 Model 48 High Level Instruction Manual Example Geysitech Protocol with transmission of three concentrations Instrument ID is 1 Operation Status is 03 Error Status is 04 Data Query String lt STX gt DA lt CR gt Reply String lt STX gt MDO3 lt SP gt 001 lt SP gt 2578 01 lt SP gt 03 lt SP gt 04 lt SP gt 0000000000 lt SP gt 002 lt SP gt t T t Address First Concentration E format 25 78 Address 1 5681 00 lt SP gt 03 lt SP gt 04 lt SP gt 0000000000 lt SP gt 003 lt SP gt 1175 01 lt SP gt 03 lt SP g
206. s the diagnostic voltage measurements on the measurement interface board The sequence of voltages is Positive 24 positive 15 negative 15 positive 5 positive 3 3 positive 18 IR positive 18 MOT and VBIAS Each voltage value is separated by a space Send diag volt mib Receive diag volt mib 24 1 14 9 14 9 4 9 3 2 17 9 17 9 diag volt iob This command reports the diagnostic voltage measurements on the I O expansion board The sequence of voltages is Positive 24 positive 5 positive 3 3 and negative 3 3 Each voltage value is separated by a space Send diag volt iob Receive diag volt iob 24 1 4 9 3 2 3 2 Model 48 High Level Instruction Manual B 15 C Link Protocol Commands Datalogging Datalogging B 16 Model 487 High Level Instruction Manual clr records This command will clear all long and short records that have been saved Send Receive clear records clear records ok set clr lrecs set clr srecs These commands will clear only the long records or only the short records that have been saved The example below clears short records Send set clr srecs Receive set clr srecs ok list din list dout These commands report the current selection for the digital outputs in the format Output no Index number variable name active state The active state for digital outputs is open or closed The active state for digital inputs is high or low Send list dout Receive list dout output index variable state 1 2
207. sample zero air until stable readings are obtained The first line of the display shows the current CO reading This reading is the CO background signal The second line of the display shows the CO background correction that is stored in memory and is being used to correct the CO reading That is the CO background correction is subtracted from the CO reading In the example below the analyzer is reading 1 4 ppm of CO while sampling zero air The CO background correction is 0 0 ppm That is the analyzer is not applying a zero background correction The question mark is used as a prompt to change the background correction In this case the background correction must be increased to 1 4 ppm in order for the CO reading to be at 0 ppm To set the CO reading in the example below to zero use Cr to increment the CO background correction to 1 4 ppm As the CO background correction is increased the CO concentration is decreased At this point however no real changes have been made To escape this screen without making any changes press to return to the Calibration Factors menu or to return to the Run screen Press to actually set the CO reading to 0 ppm and store the background correction of 1 4 ppm e Inthe Main Menu choose Calibration Factors gt CO Bkg ERED CH ee PPP LES Ea bii i runo pH TE vd Sneek ee PE EE E Thermo Electron Corporation Model 48i High Level Instruction Manual 3 17 Operation Calibration Factors Menu
208. sea ties tered em aeee E 1 3 Chapter 2 Installation 2 1 Eea ge Re a ce PRN PATS E L A EDL EO Pat ES 2 1 Unpacking and Inspection iia 2 1 Setup Proceder iaa 2 3 Connecting External Devices variar 2 5 Terminal Board PCB Assent bl GS 4c 20 cater sce aves testa ec baieteeneueeocasty 2 5 VO Terminal Bear taco vectate foe tee deat tele ES 2 5 D O Terminal Board sles o Mem oa otal 2 7 25 Pin Terminal Bard ss it takes 2 8 SEP A ode hang secemuniateiss 2 9 Chapter 3 Opera cunasrcastns ra 3 1 Displayen hanna ea E AAT A RENER REN 3 1 P shbuttonssisnsanninitir dee 3 2 Soft Keys ani 3 3 Software OVervViEW o eee sre E oO As 3 4 PO Werte PSC asias 3 6 R n Scr ee tis ses caged A A sedan R 3 6 Mam Ment od 3 7 Range Menu did da 3 8 Single Range Moderna acid 3 8 Dual Range Mode de Met aa A ARR 3 9 Auto Ranse Mode tds 3 11 Gas Uni io ines 3 13 CORA ed 3 13 o AA A 3 14 Custom Ranges iaa dia 3 15 Ay ragine TING ia o di 3 15 Calibration Factors Menu pd il dis 3 16 COB o SO 3 17 CCC Ge PRICIER ti 3 18 Reset User Calibration Debaultiuua anna ida 3 18 Calibracion Menta biie di da 3 19 Calibrate CO Dacksrotmd nani oia 3 19 Calibrate CO Coefficient ia ira bs 3 20 Thermo Electron Corporation Model 487 High Level Instruction Manual v Contents vi Model 48 High Level Instruction Manual A dest eacaance ANEN 3 20 Next TIME ct A da 3 21 Period HOUtS esna a re nidos 3 21 Zero Span Purge Duration Minutes ssssesseseserseeeresrrersrrerserseees 3 22
209. separated by spaces 0 1 The selection table lists the translation table entries which the user may select from when setting the parameter This is not necessarily the same as the entries which may be displayed Button Designator Then there appears an optional button designator This will be one of B T L bd Kia or N B Indicates a button which pops up an input dialog prompting the user for a new value using the designated input format The input format is specified from the B through the subsequent semicolon I Indicates a button which pops up a selection list with input translation That is the values read are translated before they are compared to the selection list options L Indicates a button which pops up a selection list without any translation The output value is number of the selected option T Indicates a button which pops up a selection list with output translation The number of the option selected is used as an index into the translation table to generate an output string N Indicates a button which only sends the subsequent command to the instrument No user prompting happens The following string through an optional or the end of the line is the command which is to be sent to the instrument upon the completion of the button selection The command string should normally contain print style formatting to include the user input Ifa is present it indicates a command which is sent to t
210. should be tested if the concentration value on the front panel display disagrees with the analog outputs To check the analog outputs you connect a meter to an analog output channel voltage or current and compare the meter reading with the output value displayed on the Test Analog Outputs screen Equipment Required Multimeter Use the following procedure to test the analog outputs 1 Connect a meter to the channel to be tested Figure 7 14 shows the analog output pins and Table 7 4 identifies the associated channels 2 From the Main Menu press to scroll to Diagnostics press gt _ J to scroll to Test Analog Outputs and press 2 The Test Analog Outputs screen displays 3 Press _ to scroll to the channel corresponding to the rear panel terminal pins where the meter is connected and press e The Set Analog Outputs screen displays 4 Press 4 to set the output to zero The Output Set To line displays Zero 5 Check that the meter is displaying a zero value If the meter reading differs by more than one percent the analog outputs should be adjusted Refer to the Analog Output Calibration procedure that follows 6 Press Cr to set the output to full scale The Output Set To line displays Full Scale Model 487 High Level Instruction Manual 7 27 Servicing Analog Output Testing Analog Voltage Outputs Check that the meter is displaying the full scale value If the meter reading differs by more t
211. ssessessesssssesseeseeseeseessesseeaesasestesseeeeateaseatens 9 1 Internal Zero Span Assembly as riot 9 1 Internal Zero Air Serubber ingiiaciin a 9 1 Filter Wheel Purge usina asarei rieien 9 1 Calibration Note ng lea 9 2 Teflon Partie ate Elia 9 2 Model 48 High Level Instruction Manual xi Contents I O Expansion Board Assist pS 9 2 25 Pin Terminal Board Assembly scescascessessdsseavexssovedsaiavascvtecsceseedoses 9 3 Terminal Block and Cable Misirrad aaa tdi 9 3 A oi dag SORE eaaeanvanedavundaa ean I E 9 3 Mounting prions Si sechauiedeeds Hietenisetene odeadies 9 5 Appendix A Warranty ti A 1 A od cas er aa etc one each ea 2s es EE dtl E ia A 1 Appendix B C Link Protocol Commands s ssssssscssssssseesessessseeseeeseestessesseenesteaeeases B 1 Instrument Identification Number ac ii B 1 Comas iii iascnadeyecnrtlaesi keep tiaceeetieeeie B 2 Entering Units in PPB eis dass tii os jad B 2 Commands VISE oe oad eco sine bes Soa st mettre uae aa B 2 Measurements a A A Ai o B 8 A A AEA A S B 11 DINOS A A ASA B 15 Dat a cane csah ots tend B 16 A O OWT ATS B 22 Keys IDS A E ore R B 25 Measurement Configuration ti ici B 27 Hardware Configuration cirio tii B 30 Communications Configuration mein ide B 32 TO Configuration hae atta ici a aai B 36 Record Layout Dehinitions aise a cetensres B 40 Format Specifier for ASCI Responses iii ds B 40 Format Specifier for Binary Responses s secserssseseerereereecenense B 41 Format
212. supported by the Geysitech protocol This lt control commands is a single letter which triggers an action in the instrument These commands are active only when service mode is inactive and the zero span option is present Command N switches the instrument gas mode to Zero mode Command K switches the instrument gas mode to Span mode Command M switches the instrument gas mode to Sample mode The following are the different acceptable formats of the ST command lt STX gt ST lt address gt lt control command gt lt ETX gt lt BCC gt OR lt STX gt ST lt address gt lt control command gt lt CR gt OR lt STX gt ST lt address gt lt SP gt lt control command gt lt CR gt OR lt STX gt ST lt address gt lt SP gt lt control command gt lt ETX gt lt BCC gt Model 48 High Level Instruction Manual D 3 Geysitech Bayern Hessen Protocol Geysitech Commands The lt address gt is optional which means it can be left out completely The lt address gt if present must match the Instrument Address Additional space can be present after the lt address gt If the received command does not satisfy the above formats or if the lt address gt does not match the Instrument Address the command is ignored This is a sample command to switch the instrument to zero mode instrument id 5 lt STX gt STO05 lt SP gt N lt CR gt Data Sampling Data This command DA initiates a data transfer from the instrument The Query Comman
213. t RRS E CHS try Bs EEE TE aa nr tt aks Restore User The Restore User Defaults screen is used to reset the user calibration and Defaults configuration values to factory defaults The restore default user is visible Thermo Electron Corporation Model 48 High Level Instruction Manual 3 79 Operation Password only when the instrument is in service mode For more information on the service mode see Service Mode earlier in the chapter e Inthe Main Menu choose Service gt Restore User Defaults Yad eae E a eS PTE MATTE Fu d EH es bet bm EH iid MAMA Password The Password menu allows the user to configure password protection If the instrument is locked none of the settings may be changed via the front panel user interface The items visible under the password menu are determined by the instrument s password status e In the Main Menu choose Password pri 4 Set Password The Set Password screen is used to set the password to unlock the front panel The set password is shown if the instrument is unlocked and the password is set e Inthe Main Menu choose Password gt Set Password 3 80 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Lock Instrument m Ea mob Lock Instrument The Lock Instrument screen is used to lock the instruments front panel so users can not change any settings from the front panel The lock inst
214. t and current timestamp setting The Choose Item Signal submenu displays a list of the analog output signal group choices to choose from Choices are Concentrations Other Measurements and Analog Inputs if the I O expansion board option is installed e In the Main Menu choose Instrument Controls gt Communication Settings gt Streaming Data Config Wi mpini Streaming Data Interval The Streaming Data Interval screen is used to adjust the streaming data interval The following interval times are available 1 2 5 10 20 30 60 90 120 180 240 and 300 seconds e Inthe Main Menu choose Instrument Controls gt Communication Settings gt Streaming Data Config gt Streaming Data Interval Thermo Electron Corporation Model 48 High Level Instruction Manual 3 33 Operation Instrument Controls Menu Concentrations The Concentrations screen allows the user to select the output signal that is tied to the selected streaming data item The selected item is shown by lt after it In dual or auto range mode HI or LO is displayed to indicate high or low concentrations Range Status is visible only in auto range mode e Inthe Main Menu choose Instrument Controls gt Communication Settings gt Streaming Data Config gt Select Item gt Concentrations Other Measurements The Other Measurements screen allows the user to select the output signal that is tied to the selected streaming data item The selecte
215. t 04 lt SP T t t Second Concentration 5 681 Address 2 Third Concentration 11 75 0000000000 lt SP gt lt CR gt The attached concentrations are in the selected gas units The measurements that are attached to the response if not valid in a particular mode then a value of 0 0 will be reported The following measurements reported in response to DA command are for the Model 487 High Level The 1 measurement reported in single range mode for the Model 487 High Level includes e CO The 2 measurements reported in dual or auto range modes for the Model 48i High Level include e low CO e high CO See Table D 1 for operating status and Table D 2 for error status for the Model 487 High Level Thermo Electron Corporation Geysitech Bayern Hessen Protocol Geysitech Commands Table D 1 Operating Status for Model 487 High Level D7 D6 D5 D4 D3 D2 D1 DO gt Bit 8 7 6 5 4 3 2 1 gt Hex value 80 40 20 10 08 04 02 01 MSB LSB Operating status Service Mode On 0 0 0 0 0 0 0 1 Maintenance Local 0 0 0 0 0 0 1 0 Zero gas On 0 10 0 10 0 1 0 0 Span gas On 0 10 0 10 1 0 0 10 Gas Unit Indication ppm OR ppb 10 0 0 1 0 0 0 0 Ozonator Off 0 0 1 10 0 0 0 0 PMT Off 0 J1 0 J0 0 10 0 0 Not used 1 10 0 0 0 0 0 10 Table D 2 Error Status for Model 487 High Level D7 D6 D5 D4 D3 D2 D1 DO
216. t alarm max value Bench Temperature User set alarm min value User set alarm max value Bench Pressure User set alarm min value User set alarm max value Intensity User set alarm min value User set alarm max value Motor Speed User set alarm min value User set alarm max value Bias Voltage User set alarm min value User set alarm max value Everything Else 0 Units 10 Units The Choose Signal Type To Output screen displays a submenu list of the analog output signal group choices Group choices are Concentrations Other Measurements and Analog Inputs if the I O expansion board option is installed This allows the user to select the output signal to the selected output channel In dual or auto range mode HI or LO is displayed to indicate high or low concentrations Range Status is visible only in auto range mode The Concentrations screen is shown below See Table 3 7 below for a list of items for each signal group choice Thermo Electron Corporation Operation Instrument Controls Menu e Inthe Main Menu choose Instrument Controls gt I O Configuration gt Analog Output Config gt Select Channel gt Choose Signal To Output PPP L Ea bi O OEH pikari Table 3 7 Signal Type Group Choices Concentrations Other Measurements Analog Inputs None None None CO Sample Reference Analog Input 1 LO CO LO Sample Reference Analog Input 2 HI CO HI Sample Reference Analog Input 3 Range St
217. t interface board Figure 7 2 3 Disconnect the plumbing connections from the flow transducer Note the plumbing connections to facilitate reconnection 4 Remove the two retaining screws holding the flow transducer to the floor plate and remove the flow transducer Figure 7 12 Retaining Screws 2 Figure 7 12 Replacing the Flow Transducer 5 Install the new flow transducer following the previous steps in reverse 6 Calibrate the flow transducer Refer to the Flow Transducer Calibration procedure that follows Model 487 High Level Instruction Manual 7 23 Servicing Flow Transducer Calibration 7 24 Flow Transducer Calibration Model 48 High Level Instruction Manual Use the following procedure to calibrate the flow transducer Equipment Required Calibrated flow sensor WARNING The service procedures in this manual are restricted to qualified service representatives A If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Remove the instrument cover 2 Disconnect the pump cable from AC PUMP connector on the measurement interface board 3 From the Main Menu press _ to scroll to Service gt press gt to scroll to
218. te the product model name and program version number e Inthe Main Menu choose Diagnostics gt Program Version Voltages The Voltages menu displays the current diagnostic voltage readings This screen enables the power supply to be quickly read for low or fluctuating voltages without having to use a voltage meter The I O board is only displayed if the I O expansion board option is installed e Inthe Main Menu choose Diagnostics gt Voltages 3 52 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Diagnostics Menu Motherboard Voltages The Motherboard screen read only is used to display the current voltage readings on the motherboard e Inthe Main Menu choose Diagnostics gt Voltages gt Motherboard Voltages Interface Board Voltages The Interface Board screen read only is used to display the current voltage readings on the interface board e Inthe Main Menu choose Diagnostics gt Voltages gt Interface Board Voltages Thermo Electron Corporation Model 48 High Level Instruction Manual 3 53 Operation Diagnostics Menu 1 0 Board Voltages The I O Board screen read only is used to display the current voltage readings on the I O expansion board This menu is only displayed if the I O expansion board option is installed e Inthe Main Menu choose Diagnostics gt Voltages gt I O Board Voltages Temperatures The Temperatures screen read only displays the cur
219. temp min alarm chamber temp max These commands report the chamber temperature alarm minimum and maximum value current settings The example below reports that the chamber temperature alarm minimum value is 35 0 C Send alarm chamber temp min Receive alarm chamber temp min 35 0 deg C set alarm chamber temp min value set alarm chamber temp max value These commands set the chamber temperature alarm minimum and maximum values to value where value is a floating point number representing chamber temperature alarm limits in degrees C The example below sets the chamber temperature alarm maximum value to 55 0 C Send set alarm chamber temp max 55 0 Receive set alarm chamber temp max 55 0 ok alarm conc min alarm conc max These commands report the CO concentration alarm minimum and maximum values current setting The example below reports that the CO concentration minimum is 5 2 ppm Send alarm conc min Receive alarm conc min 5 2 ppm set alarm conc min value set alarm conc max value These commands set the CO concentration alarm minimum and maximum values to value where value is a floating point representation of the concentration alarm limits Values must be in the units that are currently set for use The example below sets the CO concentration alarm maximum value to 215 Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Commands Alarms Send set alarm conc max 215 Receive set alarm conc m
220. the LCD module Figure 7 18 Equipment Required LCD module Philips screwdriver 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 A Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A Do not remove the panel or frame from the module A The polarizing plate is very fragile handle it carefully A Do not wipe the polarizing plate with a dry cloth it may easily scratch the plate A Do not use alcohol acetone MEK or other Ketone based or aromatic solvents to clean the module use a soft cloth moistened with a naphtha cleaning solvent A Thermo Electron Corporation Service Locations Thermo Electron Corporation Servicing Service Locations Do not place the module near organic solvents or corrosive gases A Do not shake or jolt the module A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Remove the two screws from right side of LCD module viewed front 3 Disconnect the ribbon cable and the two wire connector from the front panel board 4 Loosen left side retaining screws viewed from front and slide the LCD module out towards the right and rear of the instrument 5 Replace the LCD module by following previous
221. ther the ASCII or binary format specifiers and converted to uniform internal representations 32 bit floats or 32 bit integers These values are converted into text for display on the screen using the format specifier for the front panel display Normally the specifier used to parse a particular datum from the input stream will be strongly related to the specifier used to display it such as all of the floating point inputs will be displayed with an f output specifier and all of the integer inputs will be displayed with a d specifier The first line of the Layout response is the scanf like parameter list for parsing the fields from an ASCII ERec response Parameters are separated by spaces and the line is terminated by a n the normal line separator character Valid fields are Thermo Electron Corporation Format Specifier for Binary Responses Format Specifier for Front Panel Layout Thermo Electron Corporation C Link Protocol Commands Record Layout Definition s parse a string d parse a decimal number ld parse a long 32 bit decimal number f parse a floating point number x parse a hexadecimal number lx parse a long 32 bit hex number ignore the field Note Signed versus unsigned for the integer values does not matter it is handled automatically A The second line of the Layout response is the binary parameter list for parsing the fields from a binary response Parameters MUST be separated
222. tion Protocol Header MBAP is used to identify the message This header consists of the following components Transaction Identifier 2 Bytes 0x0000 to OxFFFF Passed back in response Protocol Identifier 2 Bytes 0x00 MODBUS protocol Length 2 Bytes 0x0000 to OxFFFF Number of following bytes Unit Identifier 1 Byte 0x00 to OxFF Passed back in response Thermo Electron Corporation Function Code Data Error Check Function Codes 0x01 0x02 Read Coils Thermo Electron Corporation Read Inputs MODBUS Protocol Function Codes A Slave address is not required in MODBUS over TCP IP because the higher level protocols include device addressing The unit identifier is not used by the instrument The function code is a single byte in length The following function codes are supported by the instrument Read Coils 0x01 Read Inputs 0x02 Read Holding Registers 0x03 Read Input Registers 0x04 Force Write Single Coil 0x05 0x06 Read Exception Status If a function code is received that is not in this list an invalid function exception is returned The data field varies depending on the function For more description of these data fields see Function Codes below In MODBUS over Serial an error check is included in the message This is not necessary in MODBUS over TCP IP because the higher level protocols ensure error free transmission The error check is a two byte 16 bit CRC value This section describes the
223. tion alarm limits The minimum and maximum concentration alarm limit screens function the same way e Inthe Main Menu choose Alarms gt Concentration gt Min or Max The Minimum Trigger screen allows the user to view and set the concentration alarm trigger type to either floor or ceiling The minimum alarm may be programmed as a floor trigger alarm is triggered when the concentration falls below the minimum value or a ceiling trigger alarm is triggered when the concentration goes above the minimum value Model 487 High Level Instruction Manual 3 67 Operation Service Menu e Inthe Main Menu choose Alarms gt Select Concentration gt MinTrigger Service Menu The Service menu appears only when the instrument is in the service mode To put the instrument into the service mode e Inthe Main Menu choose Instrument Controls gt Service Mode Advanced diagnostic functions are included in the service mode Meaningful data should not be collected when the instrument is in the service mode In dual or auto range modes HI or LO multi point calibration is displayed to indicate the calibration of the high or low concentrations e Inthe Main Menu choose Service Range Mode Select The Range Mode Select screen is used to switch between the various range modes single dual and auto range e Inthe Main Menu choose Service gt Range Mode Select 3 68 Model 487 High Level Instruction Manual Thermo Electron Co
224. tistatic wrist strap must be worn while handling any internal component A Equipment Damage Some internal components can be damaged by small 7 34 Model 48 High Level Instruction Manual Thermo Electron Corporation Motherboard Replacement Thermo Electron Corporation A Servicing Motherboard Replacement 1 Turn instrument OFF unplug the power cord and remove the cover 2 Remove the I O expansion board optional if used See I O Expansion Board Optional Replacement on page 7 33 3 Disconnect the digital output board ribbon cable from the motherboard 4 Using the nut driver remove the two standoffs securing the board to the rear panel Figure 7 16 5 Pop off the digital output board from the mounting studs and remove the board 6 To install the digital output board follow previous steps in reverse Use the following procedure to replace the motherboard Figure 7 15 Equipment Required Motherboard Philips screwdriver Nut driver 3 16 inch Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Turn instrument OFF unplug the power cord and remove the cover 2 Remove the I O expansion board optional if used See I O Expansion Board Optional Replacement on page 7 33 3 Remove the digital output board See Digital Output Board Replacement
225. to zero volts 1 From the Main Menu press _4_ to scroll to Service press gt to scroll to Analog Input Calibration and press The Analog Input Cal screen displays Note If Service Mode is not displayed refer to Accessing the Service Mode on page 7 3 then return to the beginning of this step A 2 At the Analog Input Cal screen press _ 4 to scroll to a channel and press 3 With the cursor at Calibrate Zero press e The screen displays the input voltage for the selected channel Thermo Electron Corporation Calibrating the Input Channels to Full Scale Thermo Electron Corporation Servicing Analog Input Calibration 4 Make sure that nothing is connected to the channel input pins and press to calibrate the input voltage on the selected channel to zero volts The screen displays 0 00 V as the voltage setting 5 Press Cm gt Cm to return to the Analog Input Cal screen and repeat Steps 2 through 4 to calibrate other input channels to zero as necessary 6 Continue with the Calibrating the Input Channels to Full Scale procedure that follows Use the following procedure to calibrate the input channels to full scale by applying a known voltage to the channels Equipment Required DC voltage source greater than 0 volts and less than 10 volts 1 Connect the known DC voltage source to the input channel 1 8 to be calibrated Figure 7 14 shows the analog input pins and Tabl
226. tor and wheel assembly by removing the three motor plate Allen screws holding the motor plate to the optical bench Figure 7 6 as Motor Mount Screws 4 E A Motor Motor Plate Figure 7 6 Removing the Motor Remove the cross recessed screw on the bottom or the motor plate Insert the 5 64 inch Allen wrench through the access hole in the bottom of the motor plate loosen the set screw holding the filter wheel to the motor shaft and carefully pry the filter wheel off the motor shaft Figure 7 5 Install new filter wheel by following the previous steps in reverse Make sure that the set screw seats on the flat of the motor shaft After the filter wheel is installed spin the wheel and observe that it runs true on the motor shaft Let the instrument sample zero air for about 90 minutes From the Main Menu press _ _ to scroll to Service gt press gt to scroll to Initial S R Ratio gt and press The Initial S R Ratio screen appears Note If Service Mode is not displayed refer to Accessing the Service Mode on page 7 3 then return to the beginning of this step A Thermo Electron Corporation Chopper Motor Replacement A Optical Bench Replacement Thermo Electron Corporation Servicing Chopper Motor Replacement 9 At the Initial S R Ratio screen press to select set the initial S R ratio to the value of the current ratio and press to store the value The initial S R ratio should be b
227. ty A properly ground antistatic wrist strap must be worn while handling any internal component For more information about appropriate safety precautions see the Servicing chapter A Use the following procedure to clean the mirrors 1 Turn off power and disconnect power line 2 Remove the field mirror by removing the four Allen head screws holding it to the main bench use a 9 64 inch Allen wrench 3 Carefully clean each mirror using a cotton swab and methanol Rinse with distilled or deionized water Dry by blowing clean dry air over the mirror Thermo Electron Corporation Preventive Maintenance IR Source Replacement 4 Reassemble following the above procedure in reverse It is not necessary to realign any mirror following cleaning 5 Calibrate the instrument See the Calibration chapter in this manual IR Source The IR source control system has been designed to operate the wire wound R t resistor IR source conservatively in order to increase its life Nevertheless ep acemen a q i the IR source does have a finite life Since the IR source is relatively inexpensive and easily replaced it is recommended that the IR source be replaced after one year of continuous use This will prevent loss of data due to IR source failure If an IR source is to be replaced on an as needed basis it should be replaced when e There is no light output e After cleaning the optics the IR light intensities remain below 100 000 Hz
228. uipment damage The manual is organized into the following chapters and appendixes 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 desc
229. um limit an alarm is activated The word ALARM appears in the Run screen and in the Main Menu e Inthe Main Menu choose Alarms gt AGC Intensity ae fyl ETEO hel i 3 64 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Alarms Menu Min and Max AGC The Minimum AGC Intensity alarm limit screen is used to change the Intensity Limits minimum sample flow alarm limit The minimum and maximum AGC Intensity screens function the same way e Inthe Main Menu choose Alarms gt AGC Intensity gt Min or Max ty PS E dra emma EEA EUs EEE TE aaa PME Fad Boat abe a EE bee EE SEE Motor Speed The Motor Speed screen read only displays the current motor speed A reading other than 100 0 indicates a problem with either the motor or the power supply e Inthe Main Menu choose Alarms gt Motor Speed pirk prii usr morr RATE nd La Po La mmohe Zero and Span The Zero Span Check screen allows the user to view the status of the most Check recent zero check and set the maximum zero check offset The zero and span check screens are visible only if the zero span check option is enabled and function the same way e Inthe Main Menu choose Alarms gt Zero or Span Check Thermo Electron Corporation Model 48 High Level Instruction Manual 3 65 Operation Alarms Menu gum Ty nv fat Max Zero and Span Offset The Max Zero Check Offset screen is used to change the maximum
230. umber ASCII character The command in the example below begins with the ASCII character code 176 decimal which directs the command to the Model 48i High Level and is terminated by a carriage return CR ASCII character code 13 decimal If an incorrect command is sent a bad command message will be received The example below sends the incorrect command set unit ppm instead of the correct command set gas unit ppm Send set unit ppm Receive set unit ppm bad cmd The save and set save params commands stores parameters in FLASH It is important that each time instrument parameters are changed that this command be sent If changes are not saved they will be lost in the event of a power failure Entering Units in When interfacing to an instrument via C link commands always enter the PPB concentration values in ppb or g m units For example to set a background value to 20 ppm enter 20000 ppb as the value for the set background command Commands List Table B 1 lists the 48i High Level C Link protocol commands The interface will respond to the command strings outlined below Table B 1 C Link Protocol Commands Command Description Page addr dns Reports sets dns address B 32 addr gw Reports sets default gateway address B 32 addr ip Reports sets IP address B 32 B 2 Model 48 High Level Instruction Manual Thermo Electron Corporation Thermo Electron Corporation C Link Protocol Comma
231. ure in this chapter 3 Turn the optical bench over remove the two screws securing the optical switch assembly to the case and remove the optical switch 4 Install the new optical switch by following the previous steps in reverse 5 Calibrate the instrument Refer to the Calibration chapter in this manual Thermo Electron Corporation Model 48 High Level Instruction Manual 7 15 Servicing Bench Heater Assembly Replacement Optical Switch Heater Heater Figure 7 8 Replacing the Optical Switch Inverted View Bench Heater Use the following procedure to replace the bench heater assembly Figure 8 Assembly gt Replacement Fueron Required Bench heater Heat conductive compound Flatblade screwdriver 1 4 inch amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A f Equipment Damage Some internal components can be damaged by small 1 Turn instrument OFF unplug the power cord and remove the cover 2 Remove the optical bench following the Optical Bench Replacement procedure in this chapter 3 Remove the two screws holding each heater to the bottom of the optical bench and remove both heaters and the heater board assembly 7 16 Model 48 High Level Instruction Manual Thermo Electron Corporation Servicing Detector Preamplifier Assembly Replacement 4 Apply heat conductive compound to the bottom of the he
232. uts are the means of communicating the results of the above calculations The front panel display presents the concentrations simultaneously The display is updated every 1 10 seconds depending on the averaging time The analog output ranges are user selectable via software The analog outputs are defaulted based on the measurement range The defaults are calculated by dividing the data values by the full scale range for each of the three parameters and then multiplying each result by the user selected output range Negative concentrations can be represented as long as they are within 5 of full scale The zero and span values may be set by the user to any desired value All electronics operate from a universal switching supply which is capable of auto sensing the input voltage and working over the entire operating range Thermo Electron Corporation System Description Electronics Internal pumps and heaters all operate on 110VAC An optional transformer is required if operating on the 210 250VAC or 90 110VAC ranges An on off switch controls all power to the instrument and is accessible on the front panel Motherboard The motherboard contains the main processor power supplies a sub processor and serves as the communication hub for the instrument The motherboard receives operator inputs from the front panel mounted function key panel and or over I O connections on the rear panel and sends commands to the other boards to control t
233. uum pump only adjust the span setting A A rough check of the pressure accuracy can be made by obtaining the current barometric pressure from the local weather station or airport and comparing it to the pressure reading However since these pressures are usually corrected to sea level it may be necessary to correct the reading to local pressure by subtracting 0 027 mmHg per foot of altitude A Do not attempt to calibrate the pressure transducer unless the pressure is known accurately A Equipment Required Vacuum pump WARNING The service procedures in this manual are restricted to qualified service representatives 4 Model 487 High Level Instruction Manual 7 21 Servicing Pressure Transducer Calibration 7 22 Model 48 High Level Instruction Manual If the equipment is operated in a manner not specified by the manufacturer the protection provided by the equipment may be impaired A Equipment Damage Some internal components can be damaged by small amounts of static electricity A properly ground antistatic wrist strap must be worn while handling any internal component A 1 Remove the instrument cover 2 Disconnect the tubing from the pressure transducer and connect a vacuum pump known to produce a vacuum less than 1 mmHg 3 From the Main Menu press to scroll to Service gt press gt to scroll to Pressure Calibration gt and press The Pressure Sensor Cal screen appears Note If Service
234. various function codes that are supported by the Model 48i High Level Read Coils Inputs read the status of the digital outputs relays in the instrument Issuing either of these function codes will generate the same response These requests specify the starting address i e the address of the first output specified and the number of outputs The outputs are addressed starting at zero Therefore outputs numbered 1 16 are addressed as 0 15 Model 48i High Level Instruction Manual C 3 MODBUS Protocol Function Codes C 4 Model 48 High Level Instruction Manual The outputs in the response message are packed as one per bit of the data field Status is indicated as 1 Active on and 0 Inactive off The LSB of the first data byte contains the output addressed in the query The other outputs follow toward the high end of this byte and from low order to high order in subsequent bytes If the returned output quantity is not a multiple of eight the remaining bits in the final data byte will be padded with zeros toward the high order end of the byte The Byte Count field specifies the quantity of complete bytes of data Note The values reported may not reflect the state of the actual relays in the instrument as the user may program these outputs for either active closed or open A Request Function code 1 Byte 0x01 or 0x02 Starting Address 2 Bytes 0x0000 to maximum allowed by instrument Quantity of outputs 2 Bytes 1 to maximu
235. y in Hertz of the reference channel Automatic Gain Control AGC circuit The AGC circuit optimizes the noise and resolution levels of the Model 487 High Level The AGC intensity reading should be about 200 000 Hertz e Inthe Main Menu choose Diagnostics gt AGC Intensity Motor Speed The Motor Speed screen read only displays the status of the chopper motor A reading of 100 0 means that the motor speed is correct A reading other than 100 0 indicates that there is a problem with the chopper motor or power supply e Inthe Main Menu choose Diagnostics gt Motor Speed Analog Input The Analog Input Readings screen read only displays the 8 current user 8 np 8 y aisptay Readings scaled analog readings if the I O expansion board option is installed e In the Main Menu choose Diagnostics gt Analog Input Readings 3 56 Model 487 High Level Instruction Manual Thermo Electron Corporation Operation Diagnostics Menu EIR pruni Poh dm prepr pH mid PPP L E be do Analog Input The Analog Input Voltages screen read only displays the 8 raw analog Voltages voltage readings if the I O expansion board option is installed e Inthe Main Menu choose Diagnostics gt Analog Input Voltages EUs EEE Eet Bene PME Fad Digital Inputs The Digital Inputs screen read only displays the state of the 16 digital inputs e Inthe Main Menu choose Diagnostics gt Digital Inputs ER Ea Mn Py tit CH bo bet MATTE mid
236. y 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 Protocols C Link MODBUS Geysitech Bayern Hessen and streaming data all user selectable Ethernet connection In non condensing environments RJ45 connector for 10Mbs Ethernet connection static or dynamic TCP IP addressing Thermo Electron Corporation Lifting A Unpacking and Inspection Thermo Electron Corporation Chapter 2 Installation Installing the Model 482 High Level includes the following recommendations and procedures e Lifting on page 2 1 e Unpacking and Inspection on page 2 1 e Setup Procedure on page 2 3 e Connecting External Devices on page 2 5 e Startup on page 2 9 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 Equipment Damage Do not attempt to lift the instrument by the cover or other external fittings A The Model 48i High Level is shippe
237. y an instrument service technician A Handle all printed circuit boards by the edges only amp Do not remove the panel or frame from the LCD module A The LCD module polarizing plate is very fragile handle it carefully 4 Do not wipe the LCD module polarizing plate with a dry cloth it may easily scratch the plate 4 Do not use Ketonics solvent or aromatic solvent to clean the LCD module use a soft cloth moistened with a naphtha cleaning solvent A Do not place the LCD module near organic solvents or corrosive gases amp Do not shake or jolt the LCD module A Thermo Electron Corporation Model 48 High Level Instruction Manual iii About This Manual WEEE Symbol WEEE Symbol The following symbol and description identify the WEEE marking used on the instrument and in the associated documentation Symbol Description Marking of electrical and electronic equipment which applies to electrical and electronic equipment falling under the Directive 2002 96 EC WEEE and the equipment that has been put on the market after 13 August 2005 4 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 Toll Free 508 520 0430 International iv Model 487 High Level Instruction Manual Thermo Electron Corporation Contents Chapter 1 Introduction otitis 1 1 Principle ot Operation arsos nan cn de le 1 2 A
238. y index 1 35 when the input transitions to the designated state high or low Use list din var command to obtain the list of supported index values and corresponding actions Send set din 5 9 high Receive set din 1 9 high ok dout channel Model 48 High Level Instruction Manual B 37 C Link Protocol Commands 1 0 Configuration This command reports the index number and output variable and the active state assigned to output channel The example below reports the input 2 to be assigned an index number 2 corresponding to local remote with the active state being open Send dout 2 Receive dout 2 2 LOCAL REMOTE open set dout channel index state This command assigns digital output channel to be assigned to the action associated with index and assigns it an active state of state open or closed Send set dout 2 2 open Receive set dout 2 2 open ok dtoa channel This reports the outputs of the 6 or 12 Digital to Analog converters according to Table B 11 The example below shows that the D A 1 is 97 7 full scale Send dtoa 1 Receive dtoa 1 97 7 Note All channel ranges are user definable If any customization has been made to the analog output configuration the default selections may not apply A Table B 11 Default Output Assignment DtoA Function Single Range Dual Range Auto Range 1 Voltage Output CO Low CO CO 2 Voltage Output CO High CO Range Status 3 Voltage Output N

Model 48i High Level

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