MODEL 48C

GAS FILTER CORRELATION CO ANALYZER

INSTRUCTION MANUAL
P/N 42P255

THERMO ELECTRON CORPORATION

ENVIRONMENTAL INSTRUMENTS
27 FORGE PARKWAY FRANKLIN MASSACHUSETTS 02038

(866) 282-0430 Toll Free

(508) 520-0430 International
(508) 520-1460 Fax

[Link]/eid

3Mar2004

The 220V option complies with 89/336/EEC directive for electromagnetic compatibility.
© 2003 Thermo Electron Corporation. All rights reserved. Thermo Electron Corporation, question
everything, and Analyze. Detect. Measure. Control are trademarks 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.
 REFERENCE METHOD DESIGNATION

The Thermo Environmental Instruments, Inc. Model 48C is designated by the United
States Environmental Protection Agency (USEPA) as a Reference Method for the
measurement of ambient concentrations of Carbon Monoxide pursuant with the
requirements defined in the Code of Federal Regulations, Title 40, Part 53.

Designated Reference Method Number: RFCA-0981-054

EPA Designation Date: September 23, 1981

The Model 48C CO Analyzer meets EPA reference designation requirements when
operated with the following:

Range 0 - 1 to 100 ppm

Averaging Time 10 to 300 seconds
Temperature Range 20 to 30°C
Line Voltage 90 to 110 VAC @ 50/60 Hertz
105 to 125 VAC @ 50/60 Hertz
210 to 250 VAC @ 50/60 Hertz
Pressure Compensation on or off
Temperature Compensation on or off
Flow Rate 0.5 to 2 LPM

RS-232 Interface
With or without the following options:
100 Teflon  Particulate Filter
200 Carrying Handle
210 Rack Mounts
320 Internal Zero/Span and Sample/Calibration Solenoid Valves
330 Internal Zero/Span and Sample/Calibration Solenoid Valves with
Remote I/O Activation
410 Internal Zero Air Scrubber
610 4-20 mA Current Output
725 Remote I/O Board
770 RS-485 Interface
 TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION .........................................................................1-1

Principle of Operation...................................................................................................... 1-1

Specifications................................................................................................................... 1-3

CHAPTER 2 INSTALLATION...........................................................................2-1

Lifting............................................................................................................................... 2-1
Unpacking ........................................................................................................................ 2-1
Setup Procedure ............................................................................................................... 2-2
Analog Output Cover Installation ........................................................................ 2-4
Startup .............................................................................................................................. 2-6

CHAPTER 3 OPERATION ...............................................................................3-1

Display ............................................................................................................................. 3-1

Pushbuttons ...................................................................................................................... 3-1
Run Pushbutton.................................................................................................... 3-1
Menu Pushbutton ................................................................................................. 3-2
Enter Pushbutton.................................................................................................. 3-2
Help Pushbutton................................................................................................... 3-2
↑ ↓ ← → Pushbuttons ......................................................................................... 3-2
Software Overview .......................................................................................................... 3-2
Power-Up Screen ................................................................................................. 3-4
Self Test Screen ................................................................................................... 3-4
Run Screen ........................................................................................................... 3-5
Main Menu........................................................................................................... 3-5
Range Menu ..................................................................................................................... 3-6
Single Range Mode.............................................................................................. 3-7
Dual Range Mode ................................................................................................ 3-7
Autorange Mode .................................................................................................. 3-8
Gas Units............................................................................................................ 3-10
CO Range........................................................................................................... 3-11
Custom Ranges Menu ........................................................................................ 3-13
Custom Range Screen ............................................................................ 3-14
Averaging Time ............................................................................................................. 3-15
Calibration Factors Menu .............................................................................................. 3-16
CO Background Correction ............................................................................... 3-17
CO Background.................................................................................................. 3-18
CO Span Gas...................................................................................................... 3-19
CO Span Coefficient .......................................................................................... 3-20

v
Calibration Menu ........................................................................................................... 3-21
Calibrate Zero .................................................................................................... 3-22
Calibrate Span.................................................................................................... 3-23
Instrument Controls Menu ............................................................................................. 3-24
Temperature Correction ..................................................................................... 3-25
Pressure Correction ............................................................................................ 3-26
Baud Rate........................................................................................................... 3-27
Instrument ID ..................................................................................................... 3-28
Screen Brightness............................................................................................... 3-29
Service Mode ..................................................................................................... 3-30
Time ................................................................................................................... 3-31
Date .................................................................................................................... 3-32
Diagnostics Menu .......................................................................................................... 3-33
Program Number................................................................................................ 3-34
Voltages ............................................................................................................. 3-35
Temperatures...................................................................................................... 3-36
Pressure .............................................................................................................. 3-37
Flow ................................................................................................................... 3-38
Sample/Reference Ratio..................................................................................... 3-39
AGC Intensity .................................................................................................... 3-40
Motor Speed....................................................................................................... 3-41
Test Analog Outputs .......................................................................................... 3-42
Zero ........................................................................................................ 3-43
Fullscale ................................................................................................. 3-44
Ramp ...................................................................................................... 3-45
Option Switches ................................................................................................. 3-46
Alarms............................................................................................................................ 3-47
Internal Temperature.......................................................................................... 3-48
Min and Max Internal Temperature Limits............................................ 3-49
Chamber Temperature........................................................................................ 3-50
Min and Max Chamber Temperature Limits ......................................... 3-51
Pressure .............................................................................................................. 3-52
Min and Max Pressure Limits................................................................ 3-53
Flow ................................................................................................................... 3-54
Min and Max Flow Limits ..................................................................... 3-55
Bias Voltage....................................................................................................... 3-56
Min and Max Bias Voltage Limits......................................................... 3-57
AGC Intensity .................................................................................................... 3-58
Min and Max AGC Intensity Limits ...................................................... 3-59
Motor Speed....................................................................................................... 3-60
CO Concentration .............................................................................................. 3-61
Min and Max CO Concentration Limits ................................................ 3-62

vi
Service Mode Menu ....................................................................................................... 3-63
Pressure .............................................................................................................. 3-64
Flow ................................................................................................................... 3-65
Intensity Check................................................................................................... 3-66
A/D Frequency................................................................................................... 3-67
Temperature Compensation Coefficient ............................................................ 3-69
Initial S/R Ratio ................................................................................................. 3-70
Hi or Lo Multi-Point Calibration ....................................................................... 3-71
Default Coefficients .................................................................................. 3-73
Relay Logic ........................................................................................................ 3-74
Set Test Display ................................................................................................. 3-75
Internal Option Switches................................................................................................ 3-76
Remote ............................................................................................................... 3-77
RS-232 ............................................................................................................... 3-77
Zero/Span and Sample Solenoid Valves............................................................ 3-77
Double Range and Autorange ............................................................................ 3-78
Lock ................................................................................................................... 3-78
Spares................................................................................................................. 3-78

CHAPTER 4 CALIBRATION ............................................................................4-1

Equipment Required ........................................................................................................ 4-1

CO Concentration Standard ................................................................................. 4-1
Zero Air Generator............................................................................................... 4-1
Compression ............................................................................................ 4-2
Drying ...................................................................................................... 4-2
Oxidation ................................................................................................. 4-2
Scrubbing ................................................................................................. 4-2
Flow Meter(s) and Controller(s) .......................................................................... 4-2
Pressure Regulator for CO Standard Cylinder ..................................................... 4-3
Mixing Chamber .................................................................................................. 4-3
Output Manifold................................................................................................... 4-3
Pre-Calibration ................................................................................................................ 4-3
Calibration........................................................................................................................ 4-3
Connect Instrument .............................................................................................. 4-3
Zero Adjust .......................................................................................................... 4-4
Span Adjust.......................................................................................................... 4-4
Additional Concentration Standards .................................................................... 4-6
Calibration Curve................................................................................................. 4-6
Frequency of Calibration...................................................................................... 4-6
Periodic Zero and Span Checks ....................................................................................... 4-6
References........................................................................................................................ 4-7
Hi and Lo Multi-Point Calibration................................................................................... 4-8
Default Coefficients ............................................................................................. 4-9
Cal Point 1, 2, and 3 Adjust ................................................................................. 4-9

vii
CHAPTER 5 PREVENTIVE MAINTENANCE...................................................5-1

Spare Parts ....................................................................................................................... 5-1

Cleaning the Optics.......................................................................................................... 5-1
IR Source Replacement.................................................................................................... 5-2
System Leaks and Pump Check Out ................................................................................ 5-2
External Leaks...................................................................................................... 5-3
Leaks Across the Optional Zero/Span Solenoid Valves ...................................... 5-3

CHAPTER 6 TROUBLESHOOTING ................................................................6-1

Troubleshooting Guide .................................................................................................... 6-1

CHAPTER 7 SERVICING .................................................................................7-1

Safety Precautions............................................................................................................ 7-1

Replacement Parts List..................................................................................................... 7-2
IR Source Replacement.................................................................................................... 7-4
Correlation Wheel Replacement ...................................................................................... 7-4
Chopper Motor Replacement ........................................................................................... 7-6
Optical Bench Replacement............................................................................................. 7-6
Optical Switch Replacement............................................................................................ 7-7
Bench Heater and Bench Heater Power Supply Replacement ......................................... 7-7
Preamplifier/Detector Assembly Replacement ................................................................ 7-8
Pump Rebuilding ............................................................................................................. 7-8
Pump Replacement .......................................................................................................... 7-9
Pressure Transducer Replacement ................................................................................. 7-10
Flow Sensor Replacement.............................................................................................. 7-10
Input Signal Conditioning Board Replacement ............................................................. 7-11
DC and Bias Power Supply Boards Replacement.......................................................... 7-11
Capillary Removal ......................................................................................................... 7-12
Optional Zero/Span and Sample Solenoid Valve Replacement..................................... 7-12
Analog Output Adjustment ............................................................................................ 7-12
Pressure Transducer Adjustment ................................................................................... 7-14
Temperature Sensor Adjustment.................................................................................... 7-15
Fuse Replacement .......................................................................................................... 7-16
Servicing Locations........................................................................................................ 7-17

viii
CHAPTER 8 THEORY OF OPERATION..........................................................8-1

Electronics........................................................................................................................ 8-1
DC Power Supply................................................................................................. 8-1
Bias Power Supply............................................................................................... 8-1
Detector and Preamplifier .................................................................................... 8-2
Input Signal Conditioning Board ......................................................................... 8-2
Temperature Control Board ................................................................................. 8-3
The Microprocessor System................................................................................. 8-3
Display Module........................................................................................ 8-3
Processor Board ....................................................................................... 8-3
Analog to Digital Board........................................................................... 8-4
Digital/Analog Board............................................................................... 8-4
C-Link Board ........................................................................................... 8-4
Software ........................................................................................................................... 8-4
Subassemblies .................................................................................................................. 8-5
Optical Bench....................................................................................................... 8-5
Correlation Wheel and Chopper Motor ............................................................... 8-5
Infrared (IR) Source ............................................................................................. 8-5
Flow Components ................................................................................................ 8-6
Temperature and Pressure Transducer ................................................................. 8-6

CHAPTER 9 OPTIONAL EQUIPMENT ............................................................9-1

Rack Mounts with Slides ................................................................................................. 9-1

Internal Zero/Span and Sample Solenoid Valves............................................................. 9-3
Zero/Span Check.................................................................................................. 9-3
Remote Activation of Zero/Span and Sample Valves ..................................................... 9-6
Input Pins ............................................................................................................. 9-7
Instrument Status Outputs.................................................................................... 9-7
4-20 mA Isolated Current Output .................................................................................... 9-9
Teflon Particulate Filter .............................................................................................. 9-10
Purge Housing ............................................................................................................... 9-10
Instrument Handle.......................................................................................................... 9-12

APPENDIX A WARRANTY.............................................................................. A-1

APPENDIX B RS-232 COMMANDS................................................................ B-1

ix
APPENDIX C SCHEMATICS .......................................................................... C-1

Motherboard.....................................................................................................................C-2
Pushbutton Board 1..........................................................................................................C-3
Pushbutton Board 2..........................................................................................................C-3
Processor Board ...............................................................................................................C-4
Analog/Digital Board.......................................................................................................C-5
Digital/Analog Board.......................................................................................................C-6
Power Supply Board ........................................................................................................C-7
Preamplifier......................................................................................................................C-8
Input Board ......................................................................................................................C-9
Bias Power Supply Board ..............................................................................................C-10
Temperature Control Board ...........................................................................................C-11
C-Link Board .................................................................................................................C-12
4-20 mA Outputs (optional)...........................................................................................C-13
Input/Output Board (optional) .......................................................................................C-14
Rear Connector Interface Board.....................................................................................C-15

APPENDIX D PUMP MAINTENANCE............................................................. D-1

x
 LIST OF ILLUSTRATIONS

FIGURE PAGE

1-1 Model 48C Flow Schematic................................................................................. 1-2

2-1 Model 48C Rear Panel ......................................................................................... 2-3

2-2 Atmospheric Dump Bypass plumbing ................................................................. 2-3
2-3 Shielded Cable with Shielding Pulled Back ........................................................ 2-4
2-4 Exploded View of Analog Output Cover Installation.......................................... 2-5
2-5 Properly Installed Shield Cable............................................................................ 2-6

3-1 Model 48C Front Panel........................................................................................ 3-1

3-2 Flowchart of Menu-Driven Software................................................................... 3-3
3-3 Pin-Out of Rear Panel Terminal Strip in Single Range Mode............................. 3-7
3-4 Pin-Out of Rear Panel Terminal Strip in Dual Range Mode ............................... 3-7
3-5 Pin-Out of Rear Panel Terminal Strip in Autorange Mode ................................. 3-8
3-6 Analog Output in Autorange Mode ..................................................................... 3-9
3-7 Location of Internal Option Switches ................................................................ 3-76

4-1 Calibration Flow schematic ................................................................................. 4-4

7-1 Properly Grounded Antistatic Wrist Strap ........................................................... 7-1

7-2 Model 48C Component Layout............................................................................ 7-3
7-3 Optical Bench (Exploded View) .......................................................................... 7-5
7-4 Optical Bench....................................................................................................... 7-7
7-5 Pump Assembly Diagram .................................................................................. 7-10

9-1 Rack Mount Option Assembly............................................................................. 9-1

9-2 Model 48C Dimensional Outline ......................................................................... 9-2
9-3 Rear Panel I/O Connector .................................................................................... 9-6
9-4 Remote I/O Zero Gas Mode Activation ............................................................... 9-7
9-5 Remote I/O Span Gas Mode Activation .............................................................. 9-7
9-6 Instrument Status Output Relays.......................................................................... 9-8
9-7 Pin-Out of Rear Panel Terminal Strip with Optional Current Output ................. 9-9
9-8 Purge Housing Assembly................................................................................... 9-11
9-9 Instrument Handle Assembly............................................................................. 9-12

xi
 LIST OF TABLES

TABLE PAGE

3-1 Available Operating Ranges .............................................................................. 3-12

3-2 A/D Converters .................................................................................................. 3-67
3-3 Option Switch Functions.................................................................................... 3-77
3-4 Operating Mode Truth Table ............................................................................. 3-78

4-1 Scrubbing Materials ............................................................................................. 4-2

5-1 Recommended Spare Parts .................................................................................. 5-1

7-1 Replacement Parts................................................................................................ 7-2

9-1 Instrument Status Output Truth Table ................................................................. 9-9

9-2 Current Output Channel with Corresponding Concentration .............................. 9-9

xiii
CHAPTER 1
INTRODUCTION
The Model 48C Gas Filter Correlation (GFC) CO Analyzer measures ambient level CO
concentrations. The Model 48C combines proven detection technology, easy to use
menu-driven software, and advanced diagnostics to offer unsurpassed flexibility and
reliability. The Model 48C has the following features:

Multi-line alphanumeric display

Menu-driven software
Field programmable ranges
Dual range mode
Auto range mode
Multiple analog outputs
High sensitivity
Fast response time
Linearity through all ranges
Highly specific to CO
Self-aligning optics
Automatic temperature and pressure correction
EPA approved

Thermo Environmental Instruments is pleased to supply this CO analyzer. We are

committed to the manufacture of instruments exhibiting high standards of quality,
performance, and workmanship. TEI service personnel are available for assistance with
any questions or problems that may arise in the use of this analyzer.

PRINCIPLE OF OPERATION

The Model 48C is based on the principle that carbon monoxide (CO) absorbs infrared
radiation at a wavelength of 4.6 microns. Because infrared absorption is a non-linear
measurement technique, it is necessary for the instrument electronics to transform the
basic analyzer signal into a linear output. The Model 48C uses an exact calibration curve
to accurately linearize the instrument output over any range up to a concentration of
10,000 ppm.

The sample is drawn into the Model 48C 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.

1-1
Chapter 1 Introduction

The CO gas filter acts to produce a reference beam which cannot be further attenuated by
CO in the sample cell. The N2 side of the filter wheel is transparent to the infrared
radiation and therefore produces a measure 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 48C outputs the CO concentration to the front panel display and the analog
outputs.

Figure 1-1. Model 48C Flow Schematic B42P809

1-2
 Chapter 1 Introduction

SPECIFICATIONS

Preset ranges 0-1, 2, 5, 10, 20, 50, 100, 200, 500, 1000, 2000, 5000,
10000 ppm
0-1, 2, 5, 10, 20, 50, 100, 200, 500, 1000, 2000, 5000,
10000 mg/m3

Custom ranges 0-1 to 10000 ppm

0-1 to 10000 mg/m3

Zero noise 0.02 ppm RMS (30 second time setting)

Lower detectable limit 0.04 ppm

Zero drift (24 hour) < 0.1 ppm

Span drift (24 hour) ±1% fullscale

Response time 60 seconds (30 second time setting)

Precision ± 0.1 ppm

Linearity ± 1% fullscale ≤ 1000 ppm

± 2.5% fullscale > 1000 ppm

Sample flow rate 0.5-2 liters/min

Operating temperature 20 - 30°C (may be safely operated over the range of 0 -

45°C)*

Power requirements 105-125 VAC, 60 Hz

220-240 VAC, 50 Hz
100 Watts

Physical dimensions 16.75" (W) X 8.62" (H) X 23" (D)

Weight 45 lbs.

Outputs CO
selectable voltage
4-20 mA, RS-232, RS-485

* In non-condensing environments

1-3
CHAPTER 2
INSTALLATION
The installation of the Model 48C includes lifting the instrument, unpacking the
instrument, connecting sample and exhaust lines to the instrument, and attaching the
analog outputs to a recording device. For more information about optional equipment,
see Chapter 9, “Optional Equipment.”

LIFTING

A procedure appropriate to lifting a heavy object should be used when lifting the
analyzer. This procedure consists of bending at the knees while keeping your back
straight and upright. The analyzer should be grasped at the bottom, in the front and at the
rear of the unit. Do not attempt to lift the analyzer by the cover or other external fittings.
While one person may lift the unit, it is desirable to have two persons lifting, one by
grasping the bottom in the front and the other by grasping the bottom in the rear.

UNPACKING

The Model 48C is shipped complete in one container. If, upon receipt of the analyzer,
there is obvious damage to the shipping container, notify the carrier immediately and
hold for inspection. The carrier, and not Thermo Environmental Instruments Inc., is
responsible for any damage incurred during shipment. Follow the procedure below to
unpack and inspect the instrument.

1. Remove the instrument from the shipping container and set on a table or bench that
allows easy access to both the front and rear of the instrument.
2. Remove the instrument cover to expose the internal components.
3. Remove any packing material.
4. Check for possible damage during shipment.
5. Check that all connectors and printed circuit boards are firmly attached.
6. Re-install the instrument cover.

SETUP PROCEDURE

1. Connect the sample line to the SAMPLE bulkhead on the rear panel (see Figure 2-1).
Ensure that the sample line is not contaminated by dirty, wet or incompatible
materials. All tubing should be constructed of FEP Teflon, 316 stainless steel,
borosilicate glass, or similar tubing with an OD of 1/4" and a minimum ID of 1/8".
The length of the tubing should be less than 10 feet.

2-1
Chapter 2 Installation

NOTE: All gas must be delivered to the instrument at atmospheric pressure. It may be
necessary to employ an atmospheric bypass plumbing arrangement, as shown in Figure
2-2.

2. Connect the EXHAUST bulkhead to a suitable vent. The exhaust line should be 1/4"
OD with a minimum ID of 1/8". The length of the exhaust line should be less than
10 feet. Verify that there is no restriction in this line.
3. If the optional zero/span solenoid valves are installed, connect a source of CO-free
air to the ZERO bulkhead.
4. If the optional zero/span solenoid valves are installed, connect a source of CO span
gas to the SPAN bulkhead.
5. Connect a suitable recording device to the rear panel terminals. Refer to “Operating
Modes” in Chapter 3 for the pin-out of the rear panel terminals in each operating
mode.
4. Plug the instrument into an outlet of the appropriate voltage and frequency.

CAUTION: The Model 48C is supplied with a three-wire grounding cord. Under no
circumstances should this grounding system be defeated.

2-2
 Chapter 2 Installation

Figure 2-1. Model 48C Rear Panel 42P730

Figure 2-2. Atmospheric Dump Bypass Plumbing 57P7100

2-3
Chapter 2 Installation

Analog Output Cover Installation

This analog output cover must be mounted over the analog outputs to comply with
89/336/EEC Directive. This procedure describes how to install the user-supplied analog
output cable in the instrument’s analog output cover. The following shielded cables or
their equivalent are recommended:

Cable Gauge No. of Conductors

Alpha #1741C 20 2
Alpha #1746C 18 2
Alpha #5320/2C* 20 2
Alpha #51 52C* 20 2
Alpha #5162C* 18 2
Alpha #1743C 20 4
Alpha 1747/4C 18 4
Alpha #5320/4C 20 4
Alpha #5154C 20 4
Alpha #5164C 18 4
Belden #8208 18 2

* Maximum shielding. Under harsh environments, maximum shielding may be required.

The following tools are required:

Small screwdriver
Wire stripper
Electrical tape or heat shrink tubing

The user-supplied shielded analog output cable must be properly grounded by coming
into full contact with the cable clamp (mounted to the analog output cover). To ensure
full contact, the shielding must be exposed and folded back over the cable as shown in
Figure 2-3.

Figure 2-3. Shielded Cable with Shielding Pulled Back

2-4
 Chapter 2 Installation

Follow the procedure below to prepare the shielded cable:

1. Remove about 1.8 cm of insulation from the cable.

2. Fold back the shielding.
3. Use electrical tape or shrink tubing to hold the shielding in place. Be sure at least 1.5
cm of shielding is exposed.
4. Strip each signal wire.

Follow the procedure below to connect the shielded cable to the 8-position header:

1. Pass the shielded cable through the cable clamp on the analog output cover, as
shown in Figure 2-4.

Figure 2-4. Exploded View of Analog Output Cover Installation

2. Insert the bare signal wire into the slot of the header.
3. Tighten down the corresponding set screw.
4. Repeat steps 2 and 3 for each signal wire.
5. Plug the header(s) into the analog output connectors.
6. Install the analog output cover using the four #6 screws with star lockwashers.
7. Position the cable shielding so that it. comes in contact with the cable clamp.
8. Tighten down the cable clamp onto the shielding, as shown in Figure 2-5.

2-5
Chapter 2 Installation

Figure 2-5. Properly Installed Shield Cable

1. Install cable clamp into shield cover and secure. Be sure there is good electrical
conductivity between clamp and shield cover.

The following is a parts list of components in the analog output cover assembly:

Part No. Description Qty.

7592 Analog output cover 1

11519 8-Position header 2
5889 #6 Star lock washers 4
5820 6-32X3/8” screw 4
14549 Cable clamp 1

STARTUP

1. Turn the power on.

2. Set instrument parameters such as operating ranges and averaging times to
appropriate settings. For more information about instrument parameters, see
Chapter 3, “Operation.”
3. Before beginning actual monitoring, perform a multipoint calibration as described in
Chapter 4, “Calibration.”

2-6
CHAPTER 3
OPERATION
This chapter describes the front panel display, front panel pushbuttons, and menu-driven
software.

DISPLAY

The 4 line by 20 character alphanumeric display shows the sample concentrations,

instrument parameters, instrument controls, and help messages. Some menus contain
more items than can be displayed at one time. For these menus, use the ↑ and ↓
pushbuttons to move the cursor up and down to each choice.

PUSHBUTTONS

Run Pushbutton

The RUN pushbutton, shown below, is used to display the Run screen. The Run screen
displays the CO concentration. In addition, the RUN pushbutton is used to switch the
optional zero/span and sample solenoid valves. For more information about the optional
solenoid valves, see Chapter 9, “Optional Equipment.”

Figure 3-1. Model 48C Front Panel 42P730

3-1
Chapter 3 Operation

Menu Pushbutton

The MENU pushbutton is used to display the Main Menu and to display submenus. When
in the Run screen, this pushbutton displays the Main Menu. When in any other screen, a
submenu is displayed. For more information about the Main Menu, see “Main Menu”
later in this chapter.

Enter Pushbutton

The ENTER pushbutton is used to choose a menu item, complete an entry, and toggle
on/off functions.

Help Pushbutton

The HELP pushbutton is context-sensitive, that is, it provides additional information about
the screen that is being displayed. Press the HELP pushbutton for a concise explanation
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, press MENU to
return to the previous screen or RUN to return to the Run screen.

↑ ↓ ← → Pushbuttons

The four arrow pushbuttons (↑, ↓, ←, and →) move the cursor up, down, right, and left.

SOFTWARE OVERVIEW

The Model 48C is based on menu-driven software as illustrated by the flowchart in

Figure 3-2. The Power-Up and Self Test screens, shown at the top of the flowchart, are
displayed each time the instrument is turned on. These screens are 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 is
where the CO concentration is displayed. From the Run screen, the Main Menu can be
displayed by pressing the MENU pushbutton. The Main Menu contains a list of
submenus. Each submenu contains related instrument parameters and/or functions. This
chapter describes each submenu and screen in detail. Refer to the appropriate sections for
more information.

3-2
3-3
Chapter 3 Operation

Figure 3-2. Flowchart of Menu-Driven Software

Chapter 3 Operation

Power-Up Screen

The Power-Up screen, as shown below, is displayed on power up of the Model 48C.

THERMO ENVIRONMENTAL
INSTRUMENTS

MODEL 48C

Power-Up Screen

Self Test Screen

The Self Test Screen, as shown below, is displayed while the internal components are
warming up and a diagnostic check is performed.

MODEL 48C

SELF TEST
12/05/94 11:30

Self Test Screen

3-4
 Chapter 3 Operation

Run Screen

The standard Run screen, as shown below, displays the CO concentration. It also
displays time and the status of the RS-232 interface and optional zero/span and sample
solenoid valves, if installed. 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.” In
dual or auto range mode two simultaneous calculations are performed. One uses the
coefficients associated with the low range producing the low range concentration and the
other uses the coefficients associated with the high range producing the high range
concentration. The “l” preceding “CO PPM” indicates that the low concentration is
displayed. To display the high concentration press the ↑ pushbutton. To display the low
concentration press the ↓ pushbutton.

lCO PPM 25.5

SAMPLE 10:25 REMOTE

Run Screen

Main Menu

The Main Menu contains several submenus as shown below. Instrument parameters and
features are divided into these submenus according to their function. Use the ↑ and ↓
pushbuttons to move the cursor to each submenu. Use the ENTER pushbutton to select a
submenu. The last menu item SERVICE appears only in the service mode.

MAIN MENU: 10:25

>RANGE
AVERAGING TIME
CALIBRATION FACTORS
Main Menu

CALIBRATION
INSTRUMENT CONTROLS
DIAGNOSTICS
ALARM
SERVICE

Main Menu

3-5
Chapter 3 Operation

RANGE MENU

The Range menu contains the gas units, CO ranges, and the custom ranges. In the upper
right-hand corner of the display, the word single, dual, or auto is displayed to indicate the
active mode. The Range menu in the dual and autorange modes appear the same except
for the word dual or auto, displayed in the upper right-hand corner. For more information
about the single, dual, or autorange modes, see “Single Range Mode,” “Dual Range
Mode,” and “Autorange Mode” below. The “AutoRange” screen is the same as the
“Dual” screen below except has AUTO where the “Dual” screen reads DUAL.

To display the Range menu:

From the Main Menu choose Range

To use the Range menu:

Press the ↑ and ↓ pushbuttons to move the cursor to each choice

Press ENTER to select a choice
Press MENU to return to the Main Menu
Press RUN to return to the Run screen

Range Menu in Single and Dual/Autorange Mode

3-6
 Chapter 3 Operation

Single Range Mode

In single range mode, there is one range, one averaging time, and one span coefficient.
The two CO analog outputs are arranged on the rear panel terminal strip as shown in
Figure 3-3. To use the single range mode, set option switches 4 and 5 off. For more
information about setting the internal option switches, see “Internal Option Switches,”
later in this chapter.

42P942-2

Figure 3-3. Pin-Out of Rear Panel Terminal Strip in Single Range Mode

Dual Range Mode

In dual range mode, there are two independent CO analog outputs as shown below.

42P943-3

Figure 3-4. Pin-Out of Rear Panel Terminal Strip in Dual Range Mode

3-7
Chapter 3 Operation

There are two ranges, high CO range and low CO range, that correspond to the high CO
and low CO analog outputs, respectively. There are two span coefficients so that each
range can be calibrated separately. This may be 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 0-1000 ppm. To use the dual range mode, set option switch 4 on and option
switch 5 off. For more information about setting the internal option switches, see
“Internal Option Switches,” later in this chapter. This enables the sample concentration
reading to be sent to the analog outputs at two different ranges.

Autorange Mode

The autorange mode switches the CO analog output between their respective high and
low ranges, depending on the concentration level. The high and low ranges are defined in
the Range menu. The CO analog output has a corresponding status output, as shown in
Figure 3-5. The status outputs are used to indicate which range, high or low, is being
used.

42P943-1

Figure 3-5. Pin-Out of Rear Panel Terminal Strip in Autorange Mode

For example, suppose the low CO range is set to 50 ppm and the high CO range is set to
100 ppm (see Figure 3-6). Sample concentrations below 50 ppb are presented to the CO
analog output using the low CO range. Sample concentration above 50 ppm are
presented to the CO analog output using the high CO range. The CO status output
indicates which range the CO analog output is using. When the low CO range is active,
the CO status output is at 0 volts. When the high CO range is active, the CO status
output is at 50% of full-scale.

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, e.g., if the low NO range is set to
50 ppm and the high range is set to 100 ppm.

3-8
 Chapter 3 Operation

To use the autorange mode, option switches 4 and 5 must be on. For more information
about setting the internal option switches, see “Internal Option Switches,” later in this
chapter

When the high CO range is active, the concentration must drop to 95% of the low CO
range for the low CO range to become active.

To use the autorange mode, set option switch 4 and 5 on. For more information about
setting the internal option switches, see “Internal Option Switches,” later in this chapter.

42P942-5

Figure 3-6. Analog Output in Autorange Mode

3-9
Chapter 3 Operation

Gas Units

The Gas Units screen, shown below, defines how the CO concentration reading is
3
expressed. Gas Units of parts per million (ppm) and milligrams per cubic meter (mg/m )
3
are available. The mg/m gas concentration mode is calculated using a factory standard
pressure of 760 mm Hg and a factory standard temperature of 20°C.
3
When switching from ppm to mg/m , the CO and custom ranges default to the highest
3
range in that mode. For example, when switching from mg/m to ppm, all the ranges
default to 10,000 ppm.

The first line of the display shows the current gas units. The second line of the display is
where the gas units are selected.

To display the Gas Units screen:

From the Main Menu choose Range

From the Range Menu choose Gas Units

To use the Gas Units screen:

Use the ↑ and ↓ pushbuttons to select the gas units

Press ENTER to accept the choice
Press MENU to return to the Range menu
Press RUN to return to the Run screen.

GAS UNITS PPM

SET TO MG/M3
& RANGES TO DEFAULTS?
Gas Units Screen
78 SELECT

Gas Units Screen

3-10
 Chapter 3 Operation

CO Range

The CO range 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 second line of the display shows the current CO range. The third line of the display
is used to change the range. The range screen is similar for the single, dual, and
autorange modes as shown below. The only difference between the screens is the word
HIGH or LOW is displayed in Dual or Auto range on the first line to indicate which range
is displayed. For more information about the single, dual, or autorange modes, see
“Single Range Mode,” “Dual Range Mode,” and “Autorange Mode” earlier in this
chapter.

Table 3-1 lists the available preset ranges.

To display the CO range screen:

From the Main Menu choose Range

If in Dual or Auto Range; from the Range menu choose CO Hi Range or CO Lo
Range

To use the CO ranges:

Use the ↑ and ↓ pushbuttons to scroll through the preset ranges

Press ENTER to accept a range
Press MENU to return to the Range menu
Press RUN to return to the Run screen

RANGE: HIGH RANGE: DUAL

CO PPM 50.0 CO PPM 200.0
SET TO 100.0? SET TO 200.0
78 SELECT 78 SELECT

Range Screens in Single and Dual/Auto Range Modes

3-11
Chapter 3 Operation

3
ppm mg/m
1 1
2 2
5 5
10 10
20 20
50 50
100 100
200 200
500 500
1,000 1,000
2,000 2,000
5,000 5,000
10,000 10,000
C1 C1
C2 C2
C3 C3

Table 3-1. Available Operating Ranges

C1, C2, and C3 are custom ranges. For more information about custom ranges, see
“Custom Ranges Menu” below.

3-12
 Chapter 3 Operation

Custom Ranges Menu

The Custom Ranges Menu, shown below, lists three custom ranges: C1, C2, and C3.
Custom ranges are user-defined ranges. In the ppm mode, any value between 1 and
3
10,000 ppm can be specified as a range. In the mg/m mode, any value between 1 and
3
10,000 mg/m can be specified. See “Custom Range Screen” below for more information
about defining the custom ranges.

To display the Set Custom Ranges screen:

From the Main Menu choose Range

From the Range menu choose Set Custom Ranges

To use the Set Custom Ranges menu:

Use the ↑ and ↓ pushbutton to move the cursor between each custom range
Press ENTER to select the custom range to define
Press MENU to return to the Range menu
Press RUN to return to the Run screen

Set Custom Ranges Menu

3-13
Chapter 3 Operation

Custom Range Screen. The Custom Range screen, shown below, is used to define
the custom range.

The first line of the display shows the current custom range. The second line of the
display is used to set the range. To use the custom fullscale range, be sure to select C1,
C2, or C3 in the CO Range screen. See “CO Range” above for more information.

To display the Custom Range screen:

From the Main Menu choose Range

From the Range menu choose Set Custom Ranges
From the Set Custom Range menu choose C1, C2, or C3

To use the Custom Range screen:

Use the ↑ and ↓ pushbutton to increment and decrement each digit

Use the ← and → pushbutton to move the cursor left and right
Press ENTER to accept the custom range
Press MENU to return to the Set Custom Ranges menu
Press RUN to return to the run screen

Set Custom Range 1 Screen

3-14
 Chapter 3 Operation

AVERAGING TIME

The averaging time defines 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 screens for the single and dual or auto range modes are 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 and auto range modes
have two averaging times (high and low). The Averaging Time screens function the same
way in the single, dual, and autorange modes. The following averaging times are
available: 1, 2, 5, 10, 20, 30, 60, 90, 120, 180, 240, and 300 seconds.

To display the Averaging Time menu/screen:

From the Main Menu Choose Averaging Time

To use the Averaging Time screen:

In Dual or Auto range select Hi or Lo average in single range proceed to next step
Use the ↑ and ↓ pushbuttons to select the averaging time
Press ENTER to accept the averaging time
Press MENU to return to the Main Menu
Press RUN to return to the Run screen

AVG TIME 10 SEC AVERAGING TIME:

SET TO 10 SEC >HI AVG TIME 300 SEC
LO AVG TIME 300 SEC
78 SELECT

HI AVG TIME 30 SEC

SET TO 30 SEC

78 SELECT

Single and Dual/Auto Mode Averaging Time Screens

3-15
Chapter 3 Operation

CALIBRATION FACTORS MENU

Calibration factors are determined during automatic and manual calibration and are used
to correct the CO concentration readings. The Calibration Factors menu displays the
calibration factors as shown below. Normally the instrument is calibrated automatically,
that is, introduce the span gas and use the Calibration Screen. However, the instrument
can be calibrated manually using this menu by changing the factors.

To display the Calibration Factors menu:

From the Main Menu choose Calibration Factors:

To use the Calibration Factors menu:

Use the ↑ and ↓ pushbuttons to move the cursor up and down

Press ENTER to go to the Calibration Factor screen
Press MENU to return to the Main Menu
Press RUN to return to the Run Screen

CALIBRATION FACTORS: CALIBRATION FACTORS:

>BKG PPM 0.000 >BKG PPM 0.000
SPAN GAS 1.000 HI SPAN GAS 1.000
CO COEF 1.000 HI CO COEF 1.000

LO SPAN GAS 1.000

LO CO COEF 1.000

Calibration Factors Menu in Single and Dual/Autorange Modes

3-16
 Chapter 3 Operation

CO Background Correction

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 the 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 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 ppb.

To set the CO reading in the example below to zero, use the ↑ pushbutton to increment
the CO background correction to 1.4 ppm. As the CO background correction reading is
increased, the CO reading is decreased. At this point however, no real changes have been
made. The analog outputs have not been affected and the stored CO background
correction of 0.0 ppm is still being used. Press the ENTER pushbutton to set the CO
reading to 0 ppm and store the background correction of 1.4 ppm. To escape without
making any changes, press the MENU pushbutton to return to the Calibration Factors
menu or the RUN pushbutton to return to the Run screen.

3-17
Chapter 3 Operation

CO Background

To display the CO Background screen:

From the Main Menu choose Calibration Factors

From the Calibration Factors menu choose CO Background

To use the CO Background screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the CO background

Press ENTER to accept a change in the background
Press MENU to return to the Calibration Factors menu
Press RUN to return to the Run screen

CO Background Screen

3-18
 Chapter 3 Operation

CO Span Gas

The CO span gas is set prior to calibration. The span gas is used to calibrate the CO
level.

To display the CO Span Gas screen:

From the Main Menu choose Calibration Factors

From the Calibration Factors menu choose Span Gas

To use the CO Span Gas screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the gas value

Use the ← and →pushbuttons to change the gas value
Press ENTER to accept a change
Press MENU to return to the Calibration Factors menu
Press RUN to return to the Run screen

SPAN GAS: HI SPAN GAS:

PPM 00000.250 PPM 00000.250
SET TO 00000.500 SET TO 01000.000
78 INC/DEC 78 INC/DEC

Single and Dual/Auto range CO Span Gas Screen

3-19
Chapter 3 Operation

CO Span Coefficient

The CO span coefficient is calculated during calibration. The span coefficient is used to
correct the CO readings and normally has a value near 1.000.

The CO Span Coefficient screen enables the CO span coefficient to be manually changed
while sampling span gas of known concentration. The first line of the display shows the
current CO concentration reading. The second 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 using the ↑ and ↓ pushbuttons, the
current CO concentration reading on the first line also changes.

To display the CO Span Coefficient screen:

From the Main Menu choose Calibration Factors

From the Calibration Factors menu choose CO Coef

To use the CO Span Coefficient screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the span coefficient

Press ENTER to accept a change
Press MENU to return to the Calibration Factors menu
Press RUN to return to the Run screen

CO PPM 51.4 HI CO -0.100

CO COEF 1.000? HI CO COEF 1.000

78 INC/DEC 78 INC/DEC

Single and Dual/Auto range CO Span Coefficient Screen

3-20
 Chapter 3 Operation

CALIBRATION MENU

The Calibration menu is used to calibrate zero and span. The calibration menu is similar
for the single, dual, and autorange mode as shown below. The dual and autorange modes
have two CO span factors (hi and lo). This allows each range to be calibrated separately.
This may be 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 1000 ppm. For more information about
calibration, see Chapter 4, “Calibration.”

To display the Calibration menu:

From the Main Menu choose Calibration

To use the Calibration menu:

Use the ↑ and ↓ pushbuttons to move the cursor up and down

Press ENTER to accept the choice
Press MENU to return to the Main Menu
Press the RUN to return to the Run screen

Calibration Menu in Single and Dual/Autorange Modes

3-21
Chapter 3 Operation

Calibrate Zero

The Calibrate Zero screen, shown below, is used to perform a zero calibration. Be
sure the analyzer samples zero air until stable readings are obtained. The first line
of the display shows the current CO reading. For more information about the CO
background, see “CO Background Correction,” earlier in this chapter.

To display the Calibrate Zero screen:

From the Main Menu choose Calibration

From the Calibration menu choose Calibrate Zero

To use the Calibrate Zero screen:

Press ENTER to set the CO reading to zero

Press MENU to return to the Calibration menu
Press RUN to return to the Run screen

Zero Calibration Screen

3-22
 Chapter 3 Operation

Calibrate CO

The Calibrate CO screen is used to adjust the CO span concentration while

sampling span gas of known concentration. The first line of the display shows the
current CO concentration reading. The second line of the display shows the
current CO range. The third 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.”

To display the Calibrate CO screen:

From the Main Menu choose Calibration

From the Calibration menu choose Calibrate CO

To use the Calibrate CO screen:

Use the ↑ and ↓ pushbuttons to increment/decrement each digit

Use the ← and → pushbuttons to move the cursor left and right
Press ENTER to calibrate the CO reading to the CO calibration gas
Press MENU to return to the Calibration menu
Press RUN to return to the Run screen

CO PPM 79.1 HI CO -0.092

RANGE 100.0 HI RANGE 200.0
SET TO 00080.0 SET TO 01000.000
78 INC/DEC 78 INC/DEC

Single and Dual/Auto range CO Calibration Screen

3-23
Chapter 3 Operation

INSTRUMENT CONTROLS MENU

The Instrument Controls menu is shown below. This menu contains items that
control general instrument operations.

To display the Instrument Controls Menu:

From the Main Menu choose Instrument Controls

To use the Instrument Controls Menu:

Use the ↑ and ↓ pushbuttons to scroll through the choices

Press ENTER to select a choice

Instrument Controls Menu

3-24
 Chapter 3 Operation

Temperature Correction

Temperature correction provides compensation for any changes to the 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. Changes in temperature are corrected by this
empirical data.
The temperature correction screen is shown below. When temperature correction
is on, the first line of the display shows the current internal instrument
temperature. When temperature correction is off, the first line of the display
o
shows the standard temperature of 25 C.

To display the Temperature Correction screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Temperature Correction

To use the Temperature Correction screen:

Use the ↑ and ↓ pushbuttons to toggle temperature correction on and off

Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

Temperature Correction Screen

3-25
Chapter 3 Operation

Pressure Correction

Pressure correction provides compensation for any changes to the instrument's

output signal due to optical chamber pressure variations. The effects of chamber
pressure variations on the analyzer's subsystems and output has been empirically
determined. Changes in optical chamber pressure are corrected by this empirical
data. The pressure correction screen is shown below. When pressure correction is
on, the first line of the display represents the current pressure in the reaction
chamber. When pressure correction is off, the first line of the display shows the
standard pressure of 750 mm Hg.

To display the Pressure Correction screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Pressure Correction

To use the Pressure Correction screen:

Use the ↑ and ↓ pushbuttons to toggle pressure correction on and off

Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

Pressure Correction Screen

3-26
 Chapter 3 Operation

Baud Rate

The Baud Rate screen, shown below, is used to set the RS-232 interface baud rate.
Baud rates of 1200, 2400, 4800, and 9600 are available.

To display the Baud Rate screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Baud Rate

To use the Baud Rate screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the baud rate

Press ENTER to accept a change
Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

BAUD RATE 9600

SET TO 2400?

78 INC/DEC

Baud Rate Screen

3-27
Chapter 3 Operation

Instrument ID

The Instrument ID screen, shown below, enables the Instrument ID to be user-

defined. This is useful if two or more of the same instrument are connected to one
computer. Valid Instrument ID numbers are from 0 to 99. The Model 48C has a
default Instrument ID of 48. For more information about the Instrument ID, see
Appendix B, “RS-232 Commands.”

To display the Instrument ID screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Instrument ID

To use the Instrument ID screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the ID number

Press ENTER to accept a change
Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

Instrument ID Screen

3-28
 Chapter 3 Operation

Screen Brightness

The Screen Brightness screen, shown below, is used to change the screen
brightness. Intensities of 25%, 50%, 75%, and 100% are available. Changing the
screen brightness to a lower intensity will extend the life of the display.

To display the Screen Brightness screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Screen Brightness

To use the Screen Brightness screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the screen brightness

Press ENTER to accept a change

Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

Screen Brightness Screen

3-29
Chapter 3 Operation

Service Mode

The Service Mode screen, shown below, is used to turn the service mode on and
off. The service mode includes parameters and functions that are useful when
making adjustments or diagnosing the Model 48C. For more information about
the service mode, see “Service Mode Menu,” later in this chapter.

To display the Service Mode screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Service Mode

To use the Service Mode screen:

Press ENTER to toggle service mode on and off

Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

Service Mode Screen

3-30
 Chapter 3 Operation

Time

The internal clock is set by the Time screen as shown below. The first line of the
display shows the current time (military). The second line of the display is used to
change the time. The internal clock is powered by its own battery when
instrument power is off.

To display the Time screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Time

To use the Time screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the hours and

minutes
Use the ← and → pushbuttons to move the cursor left and right
Press ENTER to accept a change
Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

TIME 03:28
SET TO 03:28

78 INC/DEC 65CURSOR

Time Screen

3-31
Chapter 3 Operation

Date

The date is set by the Date screen as shown below. The first line of the display
shows the current date. The second line of the display is used to change the date.
The date is updated by the internal clock.

To display the Date screen:

From the Main Menu choose Instrument Controls

From the Instrument Controls menu choose Date

To use the Date screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the month, day, and

year
Use the ← and → pushbutton to move the cursor left and right
Press ENTER to accept a change
Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

DATE 11/26/02
SET TO 12/25/02

78 INC/DEC 65CURSOR

Date Screen

3-32
 Chapter 3 Operation

DIAGNOSTICS MENU

The Diagnostics menu, shown below, provides access to diagnostic information

and functions. This menu is useful when troubleshooting the instrument.

To display the Diagnostics menu:

From the Main Menu choose Diagnostics

To use the Diagnostics menu:

Use the ↑ and ↓ pushbuttons move the cursor up and down

Press MENU to return to the Main Menu
Press RUN to return to the Run screen

Diagnostics Menu

3-33
Chapter 3 Operation

Program Number

The Program Number screen, shown below, shows the version numbers of the
programs installed. Prior to contacting the factory with any questions regarding
the instrument, please note the program numbers.

To display the Program Number screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Program Number

To use the Program Number screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

INSTRUMENT PROGRAM:
48C000100P
COMMUNICATIONS:
48C000100L

Program Number Screen

3-34
 Chapter 3 Operation

Voltages

The Voltages screen as shown below, displays the current dc power supply
voltages. This enables the power supply to be quickly tested for low or
fluctuating voltages without having to use a voltage meter.

To display the Voltages screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Voltages

To use the Voltages screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

Voltages Screen

3-35
Chapter 3 Operation

Temperatures

The Temperatures screen, as shown below, displays the current internal

instrument temperature and chamber temperature.

To display the Temperatures screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Temperatures

To use the Temperatures screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

Temperatures Screen

3-36
 Chapter 3 Operation

Pressure

The Pressure screen, shown below, displays the current optical chamber pressure.
The pressure is measured by an internal pressure transducer.

To display the Pressure screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Pressure

To use the Pressure screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

Pressure Screen

3-37
Chapter 3 Operation

Flow

The Flow screen, shown below, displays the current sample flow rate. The flow is
measured by an internal flow sensor.

To display the Flow Screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Flow

To use the Flow screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

Flow Screen

3-38
 Chapter 3 Operation

Sample/Reference Ratio

The Sample/Reference Ratio screen, shown below, displays the ratio of the
intensities of the light source through the sample (CO) side and reference (N2)
side of the correlation wheel. Normally, when zero air is being sampled, the
sample/reference ratio is between 1.14 and 1.18. A ratio outside of this range may
indicate that the correlation wheel is dirty or leaking gas.

To display the Sample/Reference Ratio screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Sample/Ref Ratio

To use the Sample/Reference Ratio screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

Sample/Reference Ratio Screen

3-39
Chapter 3 Operation

AGC Intensity

The AGC Intensity screen, shown below, displays the intensity (in Hertz) of the
reference channel Automatic Gain Control (AGC) circuit. The AGC circuit
optimizes the noise and resolution levels of the Model 48C. The AGC intensity
reading should be about 250,000 Hertz.

To display the AGC Intensity screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose AGC Intensity

To use the AGC Intensity screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

AGC Intensity Screen

3-40
 Chapter 3 Operation

Motor Speed

The Motor Speed screen, shown below, 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.

To display the Motor Speed screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Motor Speed

To use the Motor Speed screen:

This is a view only screen

Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

Motor Speed Screen

3-41
Chapter 3 Operation

Test Analog Outputs

The Test Analog Outputs menu contains three choices as shown below. These
functions enable the analog outputs to be set to zero and fullscale in order to
adjust the analog outputs to agree with the front panel display. In addition, a
digital to analog (DAC) ramp can be generated to fully test the analog outputs.

To display the Test Analog Outputs menu:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Test Analog Outputs

To use the Test Analog Output menu:

Use the ↑ and ↓ pushbuttons to move the cursor up and down

Press ENTER to select a choice
Press MENU to return to the Instrument Controls menu
Press RUN to return to the Run screen

Test Analog Outputs Menu

3-42
 Chapter 3 Operation

Zero. The Zero screen, as shown below, sets the analog outputs to zero volts.
Use the ↑ and ↓ pushbuttons to increment/decrement the output level. For
example, to set the analog outputs to 5%, use the ↑ pushbutton to increment the
0.0 to 5.0%.

To display the Zero screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Test Analog Outputs
From the Test Analog Outputs menu choose Zero

To use the Zero screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the output level

Press MENU to return to the Diagnostics menu and cancel the zero output
Press RUN to return to the Run screen and cancel the zero output

Zero Analog Outputs Screen

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Chapter 3 Operation

Fullscale. The Fullscale screen, as shown below, sets the analog outputs to
fullscale. Use the ↑ and ↓ pushbuttons to increment/decrement the output level.
For example, to set the analog outputs to 95%, use the ↓ pushbutton to decrement
the 100.0 to 95.0%.

To display the Fullscale screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Test Analog Outputs
From the Test Analog Outputs menu choose Fullscale

To use the Fullscale screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the output level

Press MENU to return to the Diagnostics menu and cancel the fullscale
output
Press RUN to return to the Run screen and cancel the fullscale output

Fullscale Analog Outputs Screen

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 Chapter 3 Operation

Ramp. The digital to analog (DAC) ramp is used to fully test the analog outputs.
The analog outputs start at -2.3% and then increments by 0.1% every second until
it reaches 100.0%. A linear output indicates that the analog outputs are operating
correctly.

To display the Ramp screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Test Analog Outputs
From the Test Analog Outputs menu choose Ramp

To use the Ramp screen:

This is a view only screen

Press MENU to return to the Diagnostics menu and cancel the ramp output
Press RUN to return to the Run screen and cancel the ramp output

Ramp Analog Outputs Screen

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Chapter 3 Operation

Option Switches

The Option Switches screen, shown below, enables the settings of the internal option
switches to be viewed. Use the ↑ and ↓ pushbuttons to view entire list. Option switch
settings can not be changed through the software. For more information about the
internal option switches, see “Internal Option Switches” later in this chapter.

To display the Option Switches screen:

From the Main Menu choose Diagnostics

From the Diagnostics menu choose Option Switches

To use the Option Switches screen:

This is a view only screen

Use the ↑ and ↓ pushbuttons to move up and down
Press MENU to return to the Diagnostics menu
Press RUN to return to the Run screen

OPTION SWITCHES:
>#1 REMOTE ON
#2 RS-232 ON
#3 Z/SPAN VALVE OFF

#4 DOUBLE RANGE OFF

#5 AUTORANGE OFF
#6 LOCK OFF
#7 SPARE OFF
#8 FACTORY SET OFF

Option Switch Status Screen

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 Chapter 3 Operation

ALARMS

The Alarms menu, shown below, 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. The number in the
upper right-hand corner of the display indicates how many alarms have occurred. If no
alarms have occurred, 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 ENTER.

To display the Alarm menu:

From the Main Menu choose Alarm

To use the Alarm menu:

Use the ↑ and ↓ pushbuttons to move the cursor up and down

Press ENTER to select a choice
Press MENU to return to the Main Menu
Press RUN to return to the Run screen

Alarm Menu

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Chapter 3 Operation

Internal Temperature

The Internal Temperature screen, shown below, displays the current internal temperature
and factory-set min and max limits. The min and max alarm limits can be changed when
o
the instrument is in the service mode. Acceptable alarm limits range from 8 to 47 C. If
the internal temperature goes beyond either the min or max limit, an alarm is activated.
The word “Alarm” appears in the Run screen and in the Main Menu.

To display the Internal Temperature screen:

From the Main Menu choose Alarm

From the Alarm menu choose Internal Temperature

To use the Internal Temperature screen:

Use the ↑ and ↓ pushbuttons to move up and down (service mode on)
Press ENTER to select a choice (service mode on)
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

Internal Temperature Screen

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 Chapter 3 Operation

Min and Max Internal Temperature Limits. The Min Internal Temperature
limit screen, shown below, is accessible only when the instrument is in the service mode.
It is used to change the min internal temperature alarm limit. The min and max Internal
Temperature screens function the same way.

To display the Min or Max Internal Temperature limit screen (service mode):

From the Main Menu choose Alarm

From the Alarm menu choose Internal Temperature
From the Internal Temperature menu choose Min or Max

To use the Min or Max Internal Temperature limit screen (service mode on):

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Press ENTER to accept the change
Press MENU to return to the Internal Temperature menu
Press RUN to return to the Run screen

CHAMBER TEMP:
ACTUAL 49.4dC
>MIN 40.0dC
MAX 52.0dC

Set Min Internal Temperature Screen

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Chapter 3 Operation

Chamber Temperature

The Chamber Temperature screen, shown below, displays the current chamber
temperature and the factory-set min and max alarm limits. The min and max alarm limits
can be changed when the instrument is in the service mode. Acceptable alarm limits
o
range from 40 to 52 C. If the chamber temperature reading goes beyond either the min or
max alarm limit, an alarm is activated. The word “Alarm” appears in the Run screen and
in the Main Menu.

To display the Chamber Temperature screen:

From the Main Menu choose Alarm

From the Alarm menu choose Chamber Temperature

To use the Chamber Temperature screen:

Use the ↑ and ↓ pushbuttons to move up and down (service mode on)
Press ENTER to select a choice (service mode on)
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

Chamber Temperature Screen

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 Chapter 3 Operation

Min and Max Chamber Temperature Limits. The Min Chamber

Temperature limit screen, shown below, is accessible only when the instrument is in the
service mode. It is used to change the min chamber temperature alarm limit. The min
and max Chamber Temperature screens function the same way.

To display the Min or Max Chamber Temperature limit screen (service mode on):

From the Main Menu choose Alarm

From the Alarm menu choose Chamber Temperature
From the Chamber Temperature menu choose Min or Max

To use the Min or Max Chamber Temperature limit screen (service mode on):

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Press ENTER to accept the change
Press MENU to return to the Chamber Temperature menu
Press RUN to return to the Run screen

Set Min Chamber Temperature Screen

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Chapter 3 Operation

Pressure

The Pressure screen, shown below, displays the current optical chamber pressure reading
and the factory-set min and max alarm limits. The min and max alarm limits can be
changed when the instrument is in the service mode. Acceptable alarm limits range from
250 to 1,000 mm Hg. If the pressure reading goes beyond either the min or max alarm
limit, an alarm is activated. The word “Alarm” appears in the Run screen and in the Main
Menu.

To display the Pressure screen:

From the Main Menu choose Alarm

From the Alarm menu choose Pressure

To use the Pressure screen:

Use the ↑ and ↓ pushbuttons to move up and down (service mode on)
Press the ENTER pushbutton to select a choice (service mode on)
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

Pressure Flow Screen

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 Chapter 3 Operation

Min and Max Pressure Limits. The Min Pressure limit screen, shown below, is
accessible only when the instrument is in the service mode. It is used to change the min
pressure alarm limit. The min and max Pressure screens function the same way.

To display the Min or Max Pressure limit screen (service mode on):

From the Main Menu choose Alarm

From the Alarm menu choose Pressure
From the Pressure menu choose Min or Max

To use the Min or Max Pressure limit screen (service mode on):

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Press ENTER to accept the change
Press MENU to return to the Pressure menu
Press RUN to return to the Run screen

Set Min Pressure Screen

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Chapter 3 Operation

Flow

The Flow screen, shown below, displays the current sample flow reading and the factory-
set min and max alarm limits. The min and max alarm limits can be changed when the
instrument is in the service mode. Acceptable alarm limits range from 0 to 1 LPM. If the
flow reading goes beyond either the min or max alarm limit, an alarm is activated. The
word “Alarm” appears in the Run screen and in the Main Menu.

To display the Flow screen:

From the Main Menu choose Alarm

From the Alarm menu choose Flow

To use the Flow screen:

Use the ↑ and ↓ pushbuttons to move the up and down (service mode on)
Press the ENTER pushbutton to select a choice (service mode on)
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

Flow Screen

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 Chapter 3 Operation

Min and Max Flow Limits. The Min Flow limit screen, shown below, is
accessible only when the instrument is in the service mode. It is used to change the min
flow alarm limit. The min and max Flow screens function the same way.

To display the Min or Max Flow limit screen (service mode on):

From the Main Menu choose Alarm

From the Alarm menu choose Sample Flow
From the Sample Flow menu choose Min or Max

To use the Min or Max Flow limit screen (service mode on):

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Press ENTER to accept the change
Press MENU to return to the Sample Flow menu
Press RUN to return to the Run screen

Set Min Sample Flow Screen

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Chapter 3 Operation

Bias Voltage

The Bias Voltage screen, shown below, displays the current bias voltage and the factory-
set min and max alarm limits. The min and max alarm limits can be changed when the
instrument is in the service mode. Acceptable limits range from -130 to -100 volts. If the
bias voltage reading goes beyond either the min or max alarm limit, an alarm is activated.
The word “Alarm” appears in the Run screen and in the Main Menu.

To display the Bias Voltage screen:

From the Main Menu choose Alarm

From the Alarm menu choose Bias Voltage

To use the Bias Voltage screen:

Use the ↑ and ↓ pushbuttons to move up and down (service mode on)
Press ENTER to select a choice (service mode on)
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

Bias Voltage Screen

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 Chapter 3 Operation

Min and Max Bias Voltage Limits. The Min Bias Voltage limit screen, shown
below, is accessible only when the instrument is in the service mode. It is used to change
the min bias voltage alarm limit. The min and max Bias Voltage screens function the
same way.

To display the Min or Max Bias Voltage limit screen (service mode on):

From the Main Menu choose Alarm

From the Alarm menu choose Bias Voltage
From the Bias Voltage menu choose Min or Max

To use the Min or Max Bias Voltage limit screen (service mode on):

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Press ENTER to accept the change
Press MENU to return to the Bias Voltage menu
Press RUN to return to the Run screen

Set Min Bias Voltage Screen

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Chapter 3 Operation

AGC Intensity

The AGC Intensity screen, shown below, displays the current AGC Intensity reading and
the factory-set min and max alarm limits. The min and max alarm limits can be changed
when the instrument is in the service mode. Acceptable alarm limits range from 150,000
to 300,000 Hertz. If the AGC intensity reading goes beyond either the min or max alarm
limit, an alarm is activated. The word “Alarm” appears in the Run screen and in the Main
Menu.

To display the AGC Intensity screen:

From the Main Menu choose Alarm

From the Alarm menu choose AGC Intensity

To use the AGC Intensity screen:

Use the ↑ and ↓ pushbuttons to move up and down (service mode on)
Press ENTER to select a choice (service mode on)
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

Set Min AGC Intensity Screen

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 Chapter 3 Operation

Min and Max AGC Intensity Limits. The Min AGC Intensity limit screen,
shown below, is accessible only when the instrument is in the service mode. It is used to
change the min AGC intensity alarm limit. The min and max AGC Intensity screens
function the same way.

To display the Min or Max AGC Intensity limit screen (service mode on):

From the Main Menu choose Alarm

From the Alarm menu choose AGC Intensity
From the AGC Intensity menu choose Min or Max

To use the Min or Max AGC Intensity limit screen (service mode on):

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Press ENTER to accept the change
Press MENU to return to the AGC Intensity menu
Press RUN to return to the Run screen

Set Min Intensity Screen

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Chapter 3 Operation

Motor Speed

The Motor Speed screen, shown below, displays the current motor speed. A reading
other 100.0% indicates a problem with either the motor or the power supply board.

To display the Motor Speed screen:

From the Main Menu choose Alarm

From the Alarm menu choose Motor Speed

To use the Motor Speed screen:

Use the ↑ and ↓ pushbuttons to move up and down

Press ENTER to select a choice
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

Motor Speed Screen

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 Chapter 3 Operation

CO Concentration

The CO Concentration screen, shown below, displays the current CO concentration and
the factory-set max alarm limit. The max alarm limit can be changed when the
instrument is in the service mode. Acceptable alarm limits range from 0 to 10,000 ppm.
If the CO concentration in single mode or low CO concentration in dual or auto range
mode exceeds the max alarm limit, an alarm is activated. The word “Alarm” appears in
the Run screen and in the Main Menu.

To display the CO Concentration screen:

From the Main Menu choose Alarm

From the Alarm menu choose CO Concentration

To use the CO Concentration screen:

Use the ↑ and ↓ pushbuttons to move up and down (service mode on)
Press ENTER to select a choice (service mode on)
Press MENU to return to the Alarm menu
Press RUN to return to the Run screen

CO CONCENTRATION:
ACTUAL PPM 58.3

>MAX 10000

CO Concentration Screen

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Chapter 3 Operation

Max CO Concentration Limits. The Max CO Concentration limit screen, shown

below, is accessible only when the instrument is in the service mode. It is used to change
the maximum CO concentration alarm limit. Setting the maximum alarm level to 00000.0
disables the alarm.

To display the Max CO Concentration limit screen (service mode on):

From the Main Menu choose Alarm

From the Alarm menu choose CO Concentration
From the CO Concentration menu choose Max

To use the Max CO Concentration limit screen (service mode on):

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Use the ← and → pushbuttons to move the cursor left and right
Press ENTER to accept the change
Press MENU to return to the CO Concentration menu
Press RUN to return to the Run screen

MAX PPM 00000.0

SET TO 00050.0

78 INC/DEC

Set Max CO Concentration Screen

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 Chapter 3 Operation

SERVICE MODE MENU

The Service Mode menu, shown below, appears only when the instrument is in the
service mode. To put the instrument into the service mode, select Instrument Controls
from the Main Menu, from the Instrument Controls menu select Service Mode. When the
instrument is in the service mode, the Main Menu extends to include the Service Mode
menu. The service mode includes some of the same information found in the Diagnostic
menu. However, items such as Pressure and Flow are updated every second as opposed
to every 10 seconds. The rapid update time enables the readings on the display to
respond faster to adjustment. In addition, advanced diagnostic functions are included in
the service mode. Meaningful data should not be collected when the instrument is in the
service mode. The “Hi Multi-Point Cal” and “Lo Multi-Point Cal” screens appear when
the analyzer is in dual or auto range only.

To display the Service Mode menu:

From the Main Menu choose Service Mode

To use the Service Mode menu:

Use the ↑ and ↓ pushbuttons to move the cursor up and down

Press ENTER to select a choice
Press MENU to return to the Main Menu
Press RUN to return to the Run screen

SERVICE:
>PRESSURE
FLOW
INTENSITY CHECK

A/D FREQUENCY
TEMP COMP COEF
INITIAL S/R RATIO
HI MULTI-POINT CAL
LO MULTI-POINT CAL
RELAY LOGIC
SET TEST DISPLAY

Service Mode Menu

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Chapter 3 Operation

Pressure

The Pressure screen, shown below, shows the fluorescence chamber pressure. The
fluorescence chamber pressure is updated every second. This screen is used while
adjusting the pressure transducer potentiometers.

CAUTION: 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. For more information about appropriate safety precautions, see
Chapter 7, “Servicing.”

To display the Pressure screen:

From the Main Menu choose Service Mode

From the Service Mode menu choose Pressure

To use the Pressure screen:

This is a view only screen

Press MENU to return to the Service Mode menu
Press RUN to return to the Run screen

Pressure Screen

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 Chapter 3 Operation

Flow

The Flow screen, shown below, shows the flow reading. The flow reading is updated
every second. This screen is used while the flow sensor potentiometers are adjusted. The
potentiometer closest to the floor plate is the zero adjust potentiometer and the
potentiometer farthest from the floor plate is the span potentiometer.

CAUTION: 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. For more information about appropriate safety precautions, see
Chapter 7, “Servicing.”

To display the Flow screen:

From the Main Menu choose Service Mode

From the Service Mode menu choose Flow

To use the Flow screen:

This is a view only screen

Press MENU to return to the Service Mode menu
Press RUN to return to the Run screen

Flow Screen

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Chapter 3 Operation

Intensity Check

The Intensity Check screen, shown below, is used to turn the automatic gain control
(AGC) circuit on and off.

To display the Intensity Check screen:

From the Main Menu choose Service Mode

From the Service Mode menu choose Intensity Check

To use the Intensity Check screen:

Press ENTER to turn the AGC circuit on and off

Press MENU to return to the Service Mode menu
Press RUN to return to the Run screen

Intensity Check Screen

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 Chapter 3 Operation

A/D Frequency

The A/D Frequency screen, shown below, displays the frequency of each of the 12 analog
to digital (A/D) converters located on the A/D Board. Each A/D has a frequency range
between 0 and 100,000 Hertz. This frequency range corresponds to a voltage range of 0
to -10 volts dc. See Appendix C, “Schematics” for the A/D Board schematic. The A/D
converters are assigned as follows:

A/D Converter Function

AN0 Flow
AN1 Spare
AN2 Spare
AN3 Spare
AN4 Spare
AN5 Spare
AN6 Pressure
AN7 Spare
AN8 Bias Voltage
AN9 Spare
AN10 Internal Temperature
AN11 Optical Chamber Temperature

Table 3-2. A/D Converters

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Chapter 3 Operation

To display the A/D Frequency screen:

From the Main Menu choose Service Mode

From the Service Mode menu choose A/D Frequency

To use the A/D Frequency screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the A to D number

Press MENU to return to the Service Mode menu
Press RUN to return to the Run screen

A/D Frequency Screen

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 Chapter 3 Operation

Temperature Compensation Coefficient

The Temperature Compensation Coefficient is used to compensate for the effects of

ambient temperatures on the zero stream. The temperature compensation coefficient can
be set by to different means, “Auto Set” which, is automatically calculated based on a
span gas reading at a previously stored temperature and the current temperature, and
“Adjust” which, is a manual adjustment made by adjusting the displayed temperature
compensation coefficient to reach the expected concentration value.

To display the Temperature Compensation Coefficient Screen:

From the Main Menu choose Service Mode

From the Service Mode choose Temp Comp Coef

TEMP COMP COEF 0.0

>AUTO SET
ADJUST

Temperature Compensation Coefficient Screen

To use the Temp Comp Coef Screen:

Select either Auto Set or Adjust

If using Auto Set press ENTER. Note: The current temperature must be different
than the previous temperature.
If using Adjust use the ↑ and ↓ pushbuttons to match the displayed concentration
to the desired concentration.

PREV TEMP 33.1dC CO PPM -0.108

CRNT TEMP 30.1dC T. COMP COEF 0.0
TEMP COEF 0.0
CALC TEMP COEF? 78 INC/DEC

Auto Set Screen Adjust Screen

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Chapter 3 Operation

Initial S/R Ratio

The Initial S/R Ratio screen, shown below, displays both the initial S/R ratio and the
current S/R ratio. The initial S/R ratio is determined at the factory, and is used to correct
for the slight variations found from one correlation wheel to another. The only time the
initial S/R ratio should be changed is when the correlation wheel is replaced or after
factory consultation. Normally, when zero air is being sampled, the sample/reference
ratio is between 1.14 and 1.18.

To display the Initial S/R Ratio:

From the Main Menu choose Service Mode

From the Service Mode menu choose Initial S/R Ratio

To use the Initial S/R Ratio screen:

Use the ↑ and ↓ pushbuttons to increment/decrement the value

Use the ← and → pushbuttons to move the cursor left and right
Press ENTER to accept the change
Press MENU to return to the Service Mode menu
Press RUN to return to the Run screen

Initial S/R Ratio

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 Chapter 3 Operation

Hi or Lo Multi-Point Calibration

Up to three gas concentrations (cal-points) for each range may be calibrated 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 only work properly if all steps are
followed in order. The examples below use the Lo Multi-Point Cal screens, but the
procedure is the same for the Hi Multi-Point Cal screens.

To view the Hi or Lo Multi-Point Cal Screen:

From the Main Menu choose Service Mode

From Service Mode choose Hi or Lo Multi-Point Cal

LO MULTI-POINT CAL:
>CAL POINT 1
CAL POINT 2
CAL POINT 3

COEFFICIENTS
DEFAULT COEF

Lo Multi-Point Cal Screen

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Chapter 3 Operation

To use the Hi or Lo Multi-Point Cal Screen. NOTE: If only using one span gas, simply
skip setting Cal points 2 and 3 below.

Select Cal point 1

While running span gas 1 (typically 80% of the range) through the instrument, use
the ← and → to move the cursor and the ↑ and ↓ pushbuttons to increment or
decrement the value of the digits until the desired concentration is displayed. Press
ENTER.
Select Cal Point 2
While running span gas 2 (typically 50% of the range) through the instrument, use
the ← and → to move the cursor and the ↑ and ↓ pushbuttons to increment or
decrement the value of the digits until the desired concentration is displayed. Press
ENTER.
Select Cal Point 3
While running span gas 3 (typically 20% of the range) through the instrument, use
the ← and → to move the cursor and the ↑ and ↓ pushbuttons to increment or
decrement the value of the digits until the desired concentration is displayed. Press
ENTER.

CO PPM 20.1
CAL FACTOR 1 1.0000
CAL GAS 1 00020.000
78 INC/DEC

Cal Point 1 Screen

Select Coefficients
Press ENTER to recalculate the coefficients.
The Analyzer will automatically recalculate and then save the new parameters.

COEF 0 1.000000
1 0.000000
2 0.000000
RECALCULATE?

Coefficients Screen

Repeat the above procedure if performing a Hi Multi-Point Calibration.

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 Chapter 3 Operation

Default Coefficients The Default Coefficient Screen is used prior to a calibration

when there has been a bad calibration or new ranges have been set up.

To view the Default Coef Screen

From the Main Menu Select Service Mode

From the Service Mode Menu select Hi or Lo Multi Point Cal
From Hi or Lo Multi-Point Cal select Default Coef

COEF 0 1.000000
1 0.009000
2 0.000000
SET TO DEFAULT?

Default Coef Screen

To use the Default Coef Screen

Press ENTER to set coefficients to their default values

The Analyzer will automatically reset the default values and save the default
parameters COEF 0= 1.000000, COEF 1= 0.000000, COEF 2= 0.000000.

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Chapter 3 Operation

Relay Logic

The Relay Logic Screen allows the user to change the I/O relays to either normally open
or normally closed.

To view the Rely Logic Screen:

From the Main Menu select Service Mode

From the Service Mode select Relay Logic

RELAY LOGIC
NORMALLY OPEN

SET TO CLOSED?

Relay Logic Screen

To use the Relay Logic Screen:

From the Main Menu Screen select Service Mode

From the Service Mode select Relay Logic
To change the logic of the relay press the ENTER pushbutton

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 Chapter 3 Operation

Set Test Display

The Set Test Display screen, shown below, displays the contents of a given memory
location. This screen is useful to TEI service personnel only.

To display the Set Test Display screen:

From the Main Menu choose Service Mode

From the Service Mode menu choose Set Test Display

To use the Set Test Display screen:

Use the ↑ and ↓ pushbuttons to change the display mode

Press MENU to return to the Service Mode menu
Press RUN to return to the Run screen

Set Test Display

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Chapter 3 Operation

INTERNAL OPTION SWITCHES

The internal option switches are located on the motherboard (near front panel), as shown
in Figure 3-7 below. The function of each option switch is given in Table 3-3. These
switches are used to activate hardware and software options.

CAUTION: 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. For more information about appropriate safety precautions, see
Chapter 7, “Servicing.”

Figure 3-7. Location of Internal Option Switches 64P7192

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 Chapter 3 Operation

Option Switch Function

1 Remote
2 RS-232
3 Zero/Span and Sample Solenoid Valves
4 Double Range
5 Autorange
6 Lock
7 Spare
8 Factory Set

Table 3-3. Option Switch Functions

Remote

Option switch 1 is on when a remote interface is installed, such as RS-232 or I/O

activation.

RS-232

Option switch 2 is used to select between RS-232 and I/O activation. When option
switch 2 is on, RS-232 is selected. When it is off, I/O activation is selected.

Zero/Span and Sample Solenoid Valves

Option switch 3 is on when the optional zero/span and sample solenoid valves are
installed. For more information about the solenoid valves, see Chapter 9, “Optional
Equipment.”

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Chapter 3 Operation

Double Range and Autorange

The double range (option switch 4) and autorange (option switch 5) switches are used to
activate the dual and autorange modes. Table 3-3 shows how each mode is activated.
For more information about the single, dual, and autorange modes, see “Operating
Modes,” earlier in this chapter.

Operating Mode Option Switch 4 Option Switch 5

Single Range Mode Off Off
Dual Range Mode On Off
Autorange Mode On On

Table 3-4. Operating Mode Truth Table

Lock

When option switch 6 is on, instrument parameters are “locked” and cannot be changed.
This prevents any erroneous entry of instrument parameters. When option switch 2 is off,
instrument parameters can be changed.

Spare

This option switch is currently not used.

Factory Set

The factory set option switch is put in the on position when the dual three point
calibration is used. Other available functions are “Sample Zero Temperature
compensation”, “Set initial S/R zero”, Execute linear adjustment”, and “Test display”.

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CHAPTER 4
CALIBRATION
This chapter describes the procedures for performing a standard zero/span calibration and
Multi-Point calibrations of the Model 48C. The information described here is more than
adequate to perform the calibration. However, if greater detail is needed, please refer to
1
the Quality Assurance Handbook for Air Pollution Measurement Systems .

EQUIPMENT REQUIRED

CO Concentration Standard

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
1
Assurance Handbook . The CO gas cylinder should be recertified on a regular basis
determined by the local quality control program.

Zero Air Generator

Zero air, free of contaminants which will cause a detectable response on the CO analyzer
is required. The zero air should contain <0.01 ppm CO. Since the Model 48C 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 contain
CO concentrations in the 0.1 - 0.3 ppm range. Thus cylinder zero air should be scrubbed
of the residual CO prior to its use in the Model 48C as a dilution gas or a zero standard.
Room air which has been scrubbed of CO can be used as the zero air source. It is not
necessary to remove SO2, NO, NO2, CO2, water vapor, or hydrocarbons, since the Model
48C 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 (see below).
o
A platinum on alumina catalyst, operated at 250 C, has been found to be a convenient
oxidizer to convert CO to CO2.

If a zero air source is required, the following interferant removal methods are
recommended.

4-1
Chapter 4 Calibration

Compression. 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.

Drying. 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.

Oxidation. NO is usually oxidized to NO2 in order to ease its scrubbing. Oxidation can
be accomplished by either ozonation or chemical contact. During ozonation, the air is
passed through an ozone generator. The O3 that is produced reacts with the NO to form
NO2. Care must be taken to allow sufficient residence time for the ozonation reaction to
go to completion.

Chemical oxidation is accomplished by passing the air stream through a reacting bed.
Such agents as CrO3 on a alumina support or Purafil are very efficient at oxidizing NO
to NO2. The chemical contact approach has the advantage of needing no electrical power
input for its application.

Scrubbing. The last step in the generation of the zero air is the removal of the
remaining contaminants by either further reaction or absorption. Fixed bed reactors are
usually employed. Table 4-1 shows effective scrubbing materials.

To Remove Use
NO2 Soda-Lime (6-12 mesh), Purafil
Hydrocarbons Molecular Sieve (4A), Activated Charcoal
O3 and SO2 Activated Charcoal

Table 4-1. Scrubbing Materials

Flow Meter(s) and Controller(s)

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
1 o
Handbook . It should be noted that all flows should be corrected to 25 C and 760 mm
Hg, and that care should be exercised in correcting for water vapor content.

4-2
 Chapter 4 Calibration

Pressure Regulator for CO Standard Cylinder

The regulator used must have a nonreactive diaphragm and internal parts, as well as a
suitable delivery pressure.

Mixing Chamber

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.

Output Manifold

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 prevent ambient air from entering the manifold.

PRE-CALIBRATION

Prior to calibration, be sure the Model 48C is operating properly. The Model 48C's
internal diagnostics makes this a quick and simple process. Turn on the instrument and
allow it to stabilize for one hour. Perform the service checks of Chapter 5 “Preventive
Maintenance.” Select the operating range and the averaging time of the Model 48C.

CALIBRATION

Connect Instrument

Connect the Model 48C to be calibrated, 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.

4-3
Chapter 4 Calibration

Figure 4-1. Calibration Flow Schematic B42P807

Zero Adjust

1. Allow sufficient time for the Model 48C 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. Allow the Model 48C to
sample zero air until a stable reading is obtained. From the Main Menu choose
Calibration. From the Calibration menu choose Calibrate Zero. In the Calibrate
Zero screen, press ENTER 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.

Span Adjust

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 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:

4-4
 Chapter 4 Calibration

( [CO ] STD x FCO )

[CO ]OUT = (1)
( FD + FCO )

Where:
[CO]OUT = diluted CO concentration at the output manifold, ppm
[CO]STD = concentration of the undiluted CO standard, ppm
FCO = flow rate of CO standard corrected to 25°C and 760 mm Hg, LPM
FD = flow rate of dilution air corrected to 25°C and 750 mm Hg, LPM

Allow the Model 48C to sample this CO concentration standard until a stable response is
obtained.

2. From the Main Menu choose Calibration. From the Calibration menu choose
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 ↑, ↓, ←, and → pushbuttons. Press ENTER to calibrate the CO reading to
the CO calibration gas.

recorder response (percent scale) = (([CO]OUT x 100)/URL) + ZCO (2)

Where:

URL = nominal upper range limit of the Model 48C's operating range
ZCO = Model 48C's response to zero air, %scale

3. Record the CO concentration and the Model 48C's response.

4-5
Chapter 4 Calibration

Additional Concentration Standards

Generate several additional concentrations (at least five others are suggested) by
decreasing FCO or increasing FD. Be sure the total flow exceeds the Model 48C's total
flow demand. For each concentration generated, calculate the exact CO concentration
using Equation (1). Record the concentration and the Model 48C's response for each
concentration.

Calibration Curve

Plot the Model 48C's response versus the corresponding CO concentrations. Connect the
experimental points using a straight line, preferably determined by linear regression
techniques. The calibration curve is used to reduce subsequent ambient data.

Frequency of Calibration

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, or any time the zero or span checks give results outside the
limits described in “Periodic Zero and Span Checks” below.

PERIODIC ZERO AND SPAN CHECKS

In order to achieve data of the highest confidence, it is suggest that periodic zero and air
span checks be performed. These checks can be performed by:

1. Periodically challenging the Model 48C with zero air. The output of the zero air
supply should be greater than the flow demand of the Model 48C. 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 48C'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.

4-6
 Chapter 4 Calibration

2. Periodically challenging the Model 48C 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 SMR or CRM. It should also
1
be true for a cylinder of low level CO. The Quality Assurance Handbook should be
referred to for the procedure of checking the cylinders. Record the Model 48C's
response in % of scale as A80. Compute the span error from the following equation:

Span Error, % = ([A80 - Z)URL/100] - [CO]) X 100/[CO]

Where:

Z = Recorder response obtained at the last calibration for zero air, % scale.
[CO] = Span concentration

3. Latest copy of the Quality Assurance Handbook for Air Pollution Measurement
1
Systems should be consulted to determine the level of acceptance of zero and span
errors.

4. For detailed guidance in setting up a quality assurance program, refer to the Code of
3 1
Federal Regulations and the EPA Handbook on Quality Assurance .

REFERENCES

1. QUALITY ASSURANCE HANDBOOK FOR AIR POLLUTION

MEASUREMENT SYSTEMS, Volume II - Ambient Air Specific Methods EPA
600/4-77-027a, May 1977 and 40 CFR 50, Appendix C.

2. Available from Purafil, Inc., POB 80434, Atlanta, GA 30366.

3. 40 CFR 58, Appendix A, B.

4-7
Chapter 4 Calibration

HI AND LO MULTI-POINT CALIBRATION

The Model 48C CO Analyzer can 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 Cal Point 1, Cal Point 2, and Cal Point 3. The customer decides the ranges
and TEI recommends calibrations points of 80% (Cal Point 1), 50% (Cal Point 2), and
20% (Cal Point 3) of the range selected.

To use the Multi-Point calibration program dipswitch 8 must be in the on position and a
zero adjust needs to have been done (see page 4-4).

The equipment used, pre-calibration and Calibration-Connect Instrument are the same for
the Multi-Point calibration as they are for a standard calibration (see pages 4-1 to 4-4).

Default Coefficients

NOTE: If performing a Multi-Point calibration after changing ranges or a “bad”

calibration it is recommended to start off with default values for the Cal point
coefficients.

To set default values from the “Main Menu” select “Service Mode”. From “Service
Mode” select “Hi Multi-Point Cal” or “Lo Multi-Point Cal”. From “Hi or Lo Multi-Point
Cal” select Default Coef”. Press ENTER. The analyzer will automatically reset the default
values.

Cal Point 1, 2, and 3 Adjust

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
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:

( [CO ] STD x FCO )

[CO ]OUT =
( FD + FCO )

4-8
 Chapter 4 Calibration

Where:
[CO]OUT = diluted CO concentration at the output manifold, ppm
[CO]STD = concentration of the undiluted CO standard, ppm
FCO = flow rate of CO standard corrected to 25°C and 760 mm Hg, LPM
FD = flow rate of dilution air corrected to 25°C and 750 mm Hg, LPM

Allow the Model 48C to sample this CO concentration standard until a stable response is
obtained.

2. From the Main Menu select “Service Mode”. From “Service Mode” select “Lo
Multi-Point Cal”. From “Lo Multi-Point Cal” Select “Cal Point 1”. Use ← and
→ pushbuttons to move the cursor and the ↑ and ↓ pushbuttons to increment or
decrement the digit values until they match the concentration being introduced to
the analyzer. Press ENTER. The analyzer will perform a series of calculations and
save the new parameters.
3. Press MENU to back up a step in the Service Mode menu.
4. Repeat step 1 for a 50% concentration of the upper range.
5. Select “Cal Point 2”
6. Use ← and → pushbuttons to move the cursor and the ↑ and ↓ pushbuttons to
increment or decrement the digit values until they match the concentration being
introduced to the analyzer. Press ENTER. The analyzer will perform a series of
calculations and save the new parameters.
7. Press MENU to back up a step in the Service Mode menu.
8. Repeat step 1 for a 20% concentration of the upper range.
9. Select “Cal Point3”
10. Use ← and → pushbuttons to move the cursor and the ↑ and ↓ pushbuttons to
increment or decrement the digit values until they match the concentration being
introduced to the analyzer. Press ENTER. The analyzer will perform a series of
calculations and save the new parameters.
11. Press MENU to back up a step in the Service Mode menu.
12. Select “Coefficients”.
13. Press ENTER. The analyzer will automatically calculate the new coefficients and
save the new parameters.
14. Repeat steps 1 through 13 for “Hi Multi-Point Cal”

4-9
CHAPTER 5
PREVENTIVE MAINTENANCE
This chapter describes the periodic maintenance procedures that should be performed on
the Model 48C to ensure proper, uninterrupted operation. Certain components such as
the sample pump, solenoid valves, and IR source have a limited life and should be
checked on a regular calendar basis and replaced if necessary. Other operations, such as
cleaning the optics and checking the calibration of the pressure and temperature
transducers should also be performed on a regular basis. What follows is a check and/or
cleaning procedure for these elements. Replacement procedures for components found to
be defective by these checks are given in Chapter 7, “Servicing.”

SPARE PARTS

Table 5-1 lists the recommended spare parts.

Part Number Description

7361 IR Source
7336 Capillary
4510 Fuse – T, 3A, 250V (115V)
14009 Fuse – T, 1.25A, 250V (220V)
8606 Pump Rebuild Kit (KNF)
8907 Pump Rebuild Kit (ASF)
7368 Solenoid

Table 5-1. Recommended Spare Parts

CLEANING THE OPTICS

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.

To clean the mirrors, follow the procedure below:

5-1
Chapter 5 Preventive Maintenance

CAUTION: 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. For more information about appropriate safety precautions,
see Chapter 7, “Servicing.”

1. Turn off power and disconnect power line.

2. Remove the field mirror (see Figure 7-2) by removing the four Allen head screws
holding it to the main bench (use a 9/64 Allen wrench). Remove the relay mirror, by
removing the three Allen head screws holding it to the main bench (use a 9/64 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.
4. Reassemble following the above procedure in reverse. It is not necessary to realign
any mirror following cleaning.
5. Re-install the instrument cover.
6. Calibrate following the procedure of Chapter 4, “Calibration.”

IR SOURCE REPLACEMENT

The IR source control system has been designed to operate the wire wound resistor IR
source conservatively in order to increase its life. Nevertheless, 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
prevents 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:

There is no light output.

After cleaning the optics, the IR light intensities remain below 100,000 Hz.

Since the Model 48C is a ratio instrument, and since replacing the IR source does not
affect the calibration, it is not necessary to recalibrate the Model 48C after replacing the
IR source.

SYSTEM LEAKS AND PUMP CHECK OUT

There are two major types of leaks: external leaks and leaks across the optional zero/span
solenoid valve seals.

5-2
 Chapter 5 Preventive Maintenance

External leaks

To test for the presence of leaks around the fittings, disconnect the sample input line and
plug the SAMPLE fitting. The flow as read in the Flow screen (Diagnostics menu) should
slowly decrease to zero. The pressure as read in the Pressure screen (Diagnostics menu)
should drop to below 250 mm Hg. 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 mm Hg is obtained.

Leaks Across the Optional Zero/Span and Sample Solenoid Valves

In order to check for leaks across the optional valves, plug the SPAN inlet line, press the
RUN pushbutton and follow the procedure above. If the pressure drops below 250 mm
Hg the valve associated with the span line is okay. Repeat for the valve associated with
the zero line by plugging the zero inlet, press the RUN pushbutton and follow the
procedure above. If the pressure drops below 250 mm Hg. the valve associated with the
zero line is okay.

5-3
CHAPTER 6
TROUBLESHOOTING
The Model 48C has been designed to achieve a high level of reliability. Only premium
components are used, thus complete failure is rare. In the event of problems or failure,
the troubleshooting guidelines presented in this chapter should be helpful in isolating the
fault(s). The Service Department at Thermo Environmental can be consulted in the event
of problems at (508) 520-0430. In any correspondence with the factory please note the
serial number of the instrument.

CAUTION: 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. For more information about appropriate safety precautions, see
Chapter 7, “Servicing.”

TROUBLESHOOTING GUIDE

MALFUNCTION POSSIBLE CAUSE ACTION

Does not start up No power Check that the instrument is

plugged into the proper source
(115 or 220 volts)

Check instrument fuse

Power supply Check voltages from power

supply

Digital electronics Check that all boards are

defective seated properly

Replace boards one at a time

with spare boards to isolate
the faulty board

6-1
Chapter 6 Troubleshooting

MALFUNCTION POSSIBLE CAUSE ACTION

Pressure transducer does Pressure transducer Replace pressure transducer

not hold calibration defective
or is noisy

Digital electronics Replace boards one at a time

defective with a spare boards to isolate
the faulty board

Run output noisy Recorder noise Replace or repair recorder

Sample CO concentration Run Model 48C on a span CO

varying source - if quiet, there is no
malfunction

Foreign material in Clean optical bench

optical bench

Digital electronics Replace one board at a time

defective with a spare board to isolate
defective board

Analyzer does not System leak Find and repair leak

calibrate properly
Pressure or temperature Recalibrate pressure and
transducer out of temperature transducer
calibration

Dirty system Clean cells and flow

components

Leaky correlation wheel Replace with a known good

wheel

Digital electronics Replace one board at a time

defective with a spare board to isolate
the defective board

6-2
 Chapter 6 Troubleshooting

MALFUNCTION POSSIBLE CAUSE ACTION

Analog test ramp Faulty recorder Replace recorder

D/A calibration off Recalibrate the D/A with a

DMV known to be in
calibration

Digital electronics Replace one board at a time

defective with a spare board to isolate
the defective board

6-3
CHAPTER 7
SERVICING
This chapter explains how to replace the Model 48C subassemblies. Fault location is
accomplished in the preceding chapters of “Preventive Maintenance” and
“Troubleshooting.” This chapter assumes that a subassembly has been identified as
defective and needs to be replaced. For additional service assistance, see “Servicing
Locations” later in this chapter.

SAFETY PRECAUTIONS

Some internal components can be damaged by the discharge of static electricity. To

avoid damaging internal components, follow these precautions when performing any
service procedure:

Wear an antistatic wrist strap that is properly connected to earth ground (note that
when the analyzer is unplugged, the chassis is not at earth ground)
If an antistatic wrist strap is not available, be sure to touch a grounded metal object
before touching any internal components
Handle all printed circuit boards by the edges
Carefully observe the instructions in each procedure

64P263/42P744

Figure 7-1. Properly Grounded Antistatic Wrist Strap

7-1
Chapter 7 Servicing

REPLACEMENT PARTS LIST

Table 7-1 lists the part numbers of the major subassemblies in the Model 48C. Refer to
Figure 7-2 to identify their location.

Part Number Description

9831 Motherboard
9837 Processor Board
9849 Analog/Digital Board
9839 Digital/Analog Board
8931 Power Supply Board
8938 Detector Assembly (Preamplifier Board 7363)
9989 Input Board
8933 Bias Power Supply Board
8935 Temperature Control Board
9835 Clock Board
9936 Pressure Transducer
9934 Flow Sensor
4735 Chopper Motor
7336 Capillary - 18 mil
8606 Pump Rebuild Kit
8550 Pump 110V
8551 Pump 220V

Table 7-1. Replacement Parts

7-2
7-3
48P737
Figure 7-2. Model 48C Component Layout
Chapter 7 Servicing
Chapter 7 Servicing

NOTE: Power should be removed from the instrument before any servicing is
performed.

IR SOURCE REPLACEMENT

Equipment required:
New IR Source (Part No. 7361)
Screwdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Disconnect IR Source cable from IR Source cover (see Figure 7-3).
4. Remove the two screws holding the IR Source cover to the motor plate. Remove the
IR Source cover.
5. Loosen both clamp screws from brass standoff, remove IR Source.
6. Install new IR Source by following the above procedure in reverse.
7. Re-install the instrument cover.

CORRELATION WHEEL REPLACEMENT

Equipment required:
New Correlation Filter Wheel (Part No. 7358)
Allen Wrench - 5/32" and 5/64"

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Remove the chopper assembly by removing the three Allen head screws holding the
motor mount to the optical bench (see Figure 7-3).
4. Loosen the set screw holding the correlation wheel to the motor shaft. Note that
there is an access hole in the bottom of the motor plate.
5. Carefully pry the correlation wheel off of the motor shaft.
6. Install new correlation wheel by following the above procedure in reverse. Make
sure that the set screw seats on the flat of the motor shaft.
7. Re-install the instrument cover.
8. Let the Model 48C sample zero air for about 90 minutes.
9. From the Service Mode menu, select Initial S/R Ratio, which should be between 1.14
and 1.18. Set the Init Zero ratio to match the Current ratio and press ENTER.
10. Calibrate the instrument.

7-4
7-5
Figure 7-3. Optical Bench (Exploded View 42P761
Chapter 7 Servicing
Chapter 7 Servicing

Figure 7-4. Optical Bench 48OPT

CHOPPER MOTOR REPLACEMENT

Equipment required:
New Chopper Motor (Part No. 4735)
Allen Wrenches - 5/32" and 5/64"
Screwdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Follow the directions for correlation wheel replacement above, up to and including
Step 4.
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 above directions in reverse.
5. Re-install the instrument cover.
6. Calibrate the instrument.

OPTICAL BENCH REPLACEMENT

Equipment required:
Screwdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.

7-6
 Chapter 7 Servicing

2. Disconnect power and remove cover.

3. Disconnect all connections between the optical bench and the electronics.
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 above directions in reverse.
6. Re-install the instrument cover.

OPTICAL SWITCH REPLACEMENT

Equipment required:
New Optical Switch (Part No. 7360)
Screwdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Remove optical bench following the directions of above.
3. Remove screw holding optical switch to optical switch mount block, and remove
optical switch.
4. Install new optical switch by following the above directions in reverse.
5. Re-install the instrument cover.

BENCH HEATER AND BENCH HEATER POWER SUPPLY REPLACEMENT

Equipment required:
Bench Heater (Part No. 5924 110V) (Part No. 5925 220V)
Bench Heater Power Supply (Part No. 7362)
Heat Conductive Compound
Screwdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Remove the optical bench following the optical bench replacement directions above.
3. Remove the screws holding the heater and heater power supply to the optical bench
bottom. Remove the heater and power supply.
4. Install the new heater and heater power supply.
5. Re-install the instrument cover.

7-7
Chapter 7 Servicing

PREAMPLIFIER/DETECTOR ASSEMBLY REPLACEMENT

Equipment required:
Detector Assembly (Part No. 8938), (Preamplifier Board - Part No. 7363)
Screwdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Disconnect the cables between the preamplifier and IR Source, Bias Power Supply
Board, and Input Signal Conditioning Board.
4. Remove the four screws holding the preamplifier cover to the preamplifier assembly
and remove the cover.
5. Remove the screws holding the preamplifier/detector assembly to the optical bench.
Note access holes through the preamplifier printed circuit board. Carefully remove
the preamplifier/detector assembly from the optical bench.
6. Install the new preamplifier/detector assembly by following the above directions in
reverse.
7. Re-install the instrument cover.

PUMP REBUILDING

Equipment required:
Screwdriver
Pump Rebuild Kit (Flapper Valve and Diaphragm) (Part No. 8606 KNF)

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Loosen the fittings and remove both lines going to the pump.
4. Remove the four screws from the top plate, remove top plate, flapper valve, and the
bottom plate.
5. Remove the screw holding diaphragm onto piston, remove diaphragm.
6. Assemble the pump by following the above procedure 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.
7. Re-install the instrument cover.
8. Perform a leak test as described in Chapter 5, “Preventive Maintenance.”

7-8
 Chapter 7 Servicing

Figure 7-5. Pump Assembly Diagram 93P737

PUMP REPLACEMENT

Equipment required:
Pump (Part No. 8550 (110V) or 8551 (220V))
Nut Driver
Screwdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Disconnect the power line of the pump from Motherboard.
4. Remove both lines from pump.
5. Remove the four screws holding the pump bracket to the shock mounts.
6. Remove the two screws holding the pump to the pump bracket.

7-9
Chapter 7 Servicing

7. Install the new pump by following the above procedure in reverse.

8. Re-install the instrument cover.
9. Perform a leak test as described in Chapter 5, “Preventive Maintenance.”

PRESSURE TRANSDUCER REPLACEMENT

Equipment required:
Pressure Transducer (Part No. 9877)
Nut Driver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Disconnect the pressure transducer from the Motherboard.
4. Remove the two screws holding the pressure transducer to the floor plate.
5. Install the new pressure transducer following the above procedure in reverse.
6. Re-install the instrument cover.
7. Check calibration of pressure transducer.

FLOW SENSOR REPLACEMENT

Equipment Required:
Flow Sensor (Part No. 9934)
Nutdriver

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Disconnect flow sensor from the Motherboard.
4. Remove the silastic tubing on both inlet and outlet of the flow sensor.
5. Remove the two screws holding the flow sensor to the floor plate.
6. Install the new flow sensor following the above procedure in reverse.
7. Re-install the instrument cover.
8. Check calibration of flow sensor.

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 Chapter 7 Servicing

INPUT SIGNAL CONDITIONING BOARD REPLACEMENT

Equipment required:
Nut Driver
Input Signal Conditioning Board (Part No. 9989)

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Disconnect all plug-in connections from the Input Signal Conditioning Board.
4. Remove all screws holding the board to the bracket, and remove the board.
5. Install the new board by following the above directions in reverse.
6. Re-install the instrument cover.

DC AND BIAS POWER SUPPLY BOARDS REPLACEMENT

Equipment required:
Nut Driver
Screwdriver
DC Power Supply Board (Part No. 8931)
Bias Supply Board (Part No. 8933)

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Disconnect all plug-in connections from the Input Signal Conditioning Board.
4. Remove the four screws holding the Input Signal Conditioning Board bracket from
the Main Power Supply Board bracket, and remove the Input Signal Conditioning
Board assembly.
5. Disconnect all plug-in connections from the Main Power Supply Board being
replaced.
6. Remove the screws holding the board to the chassis and remove the board.
7. Install the new board by following the above directions in reverse. Care should be
exercised to ensure that voltage regulators fit into the plug on the bottom of the
board.
8. Re-install the instrument cover.

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Chapter 7 Servicing

CAPILLARY REMOVAL

Equipment required:
Capillary (Part No 7336)
Wire to clean old capillary

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Remove the capillary from the inlet elbow fitting on the pump head.
4. Clean with less than 0.015" diameter wire or replace.
5. Install the capillary by following the above directions in reverse.
6. Re-install the instrument cover.

OPTIONAL ZERO/SPAN AND SAMPLE SOLENOID VALVE REPLACEMENT

Equipment required:
Solenoid Valve (Part No. 7368)
Screwdriver
Wrench - 9/16"

1. Wear an antistatic wrist strap, see “Safety Precautions,” earlier in this chapter for
more information.
2. Disconnect power and remove cover.
3. Unplug the solenoid from Main Power Supply Board.
4. Remove Teflon® lines from solenoid.
5. Remove both screws holding the solenoid to the rear panel.
6. Install the solenoid by following the above directions in reverse.
7. Re-install the instrument cover.
8. Perform a leak test as described in Chapter 5, “Preventive Maintenance.”

ANALOG OUTPUT ADJUSTMENT

The analog outputs need only be adjusted if the concentration value on the front panel
display disagrees with the analog outputs. To see if the analog outputs need to be
adjusted, compare the front panel display to the analog output voltage. If they differ by
more than 1%, then the analog outputs should be adjusted. This procedure should only be
performed by an instrument service technician.

1. Wear an antistatic wrist strap that is properly connected to earth ground, see “Safety
Precautions,” earlier in this chapter for more information.
2. Remove the instrument cover.

7-12
 Chapter 7 Servicing

3. From the Run screen, press the MENU pushbutton to display the Main Menu. Use the
↓ pushbutton to move the cursor to Diagnostics, and press ENTER to display the
Diagnostics menu. Use the ↓ pushbutton to move the cursor to Test Analog Outputs, and
press ENTER. The Test Analog Output screen appears as shown below.

Test Analog Outputs Menu

4. Press ENTER to select Zero. The zero screen appears as shown below. Using a small
screwdriver, adjust potentiometer R1 and R3 on the D/A Board until the analog
outputs read 0 volts. Press the MENU pushbutton to return to the Test Analog
Outputs menu.

Zero Analog Outputs Screen

5. Press the ↓ pushbutton to move the cursor to Fullscale and press ENTER. The
fullscale screen appears as shown below. Using a small screwdriver, adjust
potentiometer R2 and R4 on the D/A Board until the analog outputs read 10 volts
(standard instrument). Press the MENU pushbutton to return to the Test Analog
Outputs menu.

7-13
Chapter 7 Servicing

Fullscale Analog Outputs Screen

6. Repeat the above steps to ensure the adjustments are accurate.

7. Re-install the instrument cover.

PRESSURE TRANSDUCER ADJUSTMENT

This procedure should only be performed by an instrument service technician.

Equipment Required:
Vacuum Pump
Screwdriver

CAUTION: 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.

1. Wear an antistatic wrist strap that is properly connected to earth ground, see “Safety
Precautions,” earlier in this chapter for more information.
2. Remove the instrument cover.
3. Disconnect the tubing from the pressure transducer and connect a vacuum pump
known to produce a vacuum less than 1 mm Hg.
4. From the Run screen, press MENU to display the Main Menu. Use the ↓ pushbutton
to move the cursor to Service menu. Press ENTER to display the Service menu. Use
the ↓ pushbutton to move the cursor to Pressure. Press ENTER to display the
pressure reading.
5. Adjust the zero potentiometer on the pressure transducer for a reading of zero mm
Hg.
6. Disconnect the vacuum pump. The display should read the current local barometric
pressure. If this value does not agree with a known accurate barometer, adjust the
span potentiometer.
7. Reconnect the tubing to the pressure transducer.
8. Re-install the instrument cover.

7-14
 Chapter 7 Servicing

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 vacuum pump, only adjust the span setting. 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 mm Hg per foot of altitude. Do not try to calibrate the pressure
transducer unless the pressure is known accurately.

TEMPERATURE SENSOR ADJUSTMENT

This procedure should only be performed by an instrument service technician.

Equipment Required:
Calibrated Thermometer or 10KΩ ± 1% Resistor
Screwdriver

CAUTION: 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.

1. Wear an antistatic wrist strap that is properly connected to earth ground, see “Safety
Precautions,” earlier in this chapter for more information.
2. Remove the instrument cover.
3. Tape the thermistor plugged into the Motherboard to a calibrated thermometer.
4. Adjust the GAIN potentiometer on the Analog to Digital Board until the internal
temperature reading agrees with the value on the calibrated thermometer. Since the
thermistors used in the Model 48C 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 on the Motherboard, and
adjust the GAIN potentiometer for an internal temperature reading of 25°C. Note that
a 1°C change corresponds to a ± 5% change in resistance, thus this alternative
procedure can be quite accurate as a check; however, it clearly is not NIST traceable.
5. Re-install the instrument cover.

7-15
Chapter 7 Servicing

FUSE REPLACEMENT

Equipment Required:
115V T, 3A, 250V (Part No. 4510)
220V T, 1.25A, 250V (Part No. 14009)

1. Disconnect power to instrument.

2. Remove fuse drawer, located on the AC power connector.
3. Replace both fuses, if either is blown.
4. Insert fuse drawer and reconnect power cord.

7-16
 Chapter 7 Servicing

SERVICE LOCATIONS

For additional assistance, Environmental Instruments Division 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

7-17
CHAPTER 8
THEORY OF OPERATION
In order to fully understand the operation of the Model 48C, a general knowledge of the
electronics, software, and subassemblies is necessary.

ELECTRONICS

The electronics can be broken down into the following subassemblies:

DC Power Supply
Bias Power Supply
Detector and Preamplifier
Input Signal Conditioning Board
Temperature controller
Microprocessor System

A brief description of each follows. Note that all the electrical schematics are given in
Chapter 11 “Schematics.”

DC Power Supply

The DC Power Supply outputs the regulated and unregulated dc voltages necessary to
operate the digital electronics, the Bias Power Supply, the detector and preamplifier, the
Input Signal Conditioning Board, and the Temperature Control Board. It outputs +24
volts unregulated and ±15 volts and +5 volts regulated. The main transformer can be
configured for use with either 110 or 220 volts ac. The power supply board also contains
the circuitry for driving the optional zero/span and sample solenoid valves and an
additional circuit for driving the chopper motor.

Bias Power Supply

The Bias Power Supply Board provides the necessary bias voltages for the solid-state
detector, its internal thermoelectric cooler, and the IR Source. The high current 18 volt
regulator provides power to the IR Source and thermoelectric cooler. In addition, the 18
volt source also powers an oscillator. The output of the oscillator goes to step-up
transformer T1. The step-up transformer generates the high bias voltage required by the
detector. A voltage sensing circuit is included and sent to the microcomputer for
diagnostic display.

8-1
Chapter 8 Theory of Operation

Detector and Preamplifier

The detector used on the Model 48C is a Photo Conductive, Lead-Selenide (PbSe)
device, with an internal thermoelectric cooler. The PbSe detector operates through use of
the internal photoelectric effect.

That is, its conductivity is proportional to the high intensity hitting it. One characteristic
of this device is that it has a high conductivity even with no light. The background
conductivity increases with increasing temperature. Thus in order to reduce the
background conductivity, the detector is cooled. In order to distinguish the signal from
background, the source is chopped. Thus the output of the detector includes an ac
component due to the light signal, superimposed upon a dc component due to the
background conductivity. It should be noted that the ac component is very small
compared to the dc component.

The output of the detector passes through a coupling capacitor C2 and C3 of the
preamplifier board, which only passes the ac component. The ac component is then
amplified by the op-amp IC-1. The output signal is an ac signal, with a low frequency
component and a high frequency component. The low frequency component is at 30 Hz,
and is due to the 30 Hz rotation of the correlation wheel. The high frequency component
is at 360 Hz and is due to the mask on the correlation wheel which divides the wheel into
12 sectors. The output of the preamplifier is fed through a shielded cable to the input
signal conditioning board.

Input Signal Conditioning Board

The Input Signal Conditioning Board contains the circuitry necessary to operate the AGC
(automatic gain control), the rectifier, and the demodulation circuitry. In addition, it
includes the necessary components to digitize the signal output.

The output of the detector is fed to U1, which acts as a control gain amplifier. The
control sensing element for the AGC feedback is the resistor RAY1, acting with U1 to
feedback the gain information to the control gain amplifier.

The output of the control gain amplifier passes through a buffer. This information is then
fed to D4, D5, and U4 for demodulation. This signal is digitized by use of the V-F's U12,
U13, and U14.

8-2
 Chapter 8 Theory of Operation

Temperature Control Board

Two 50 watt 100 ohm resistors (400 ohm for 220 V) mounted on the optical bench are
used to heat the optical bench above the dew point, to avoid moisture condensation on the
mirrors. A thermistor is used to determine the bench temperature, with op-amp U1 and
the solid state relay K1 used as the control elements to control the current into the
heaters.

The Microprocessor System

The microprocessor system consists of P.C. boards which plug into a motherboard,
connecting them to each other and to the rest of the instrument. These boards are as
follows:

Display Module
Processor Board
Analog to Digital Board
Digital to Analog Board
C-Link Board

Display Module. The vacuum fluorescent display module shows CO concentrations,

instrument parameters, and help messages. The single board display module consists of
80 characters (4 line by 20 column), refresh memory, character generator, dc/dc converter
and all necessary control logic. The display module is powered by +5 volts dc.

Processor Board. The Processor Board contains a Motorola M68HC11F1

microprocessor (U14), RAM (U5), and EEPROM (U2). In addition, this high-
performance, nonmultiplexed 68-pin microprocessor, contains 512 bytes of EEPROM
and 1K of RAM. It is operated at a frequency of 1 MHz, which is generated by crystal
X1.

During each instruction cycle, the processor fetches an instruction from memory and
executes it, reading or writing data to or from the data bus, or performing a calculation on
some internal register or registers. The reset signal is generated by U7. This signal
resets the M68HC11F1 every tenth of a second, and is used by the microprocessor to
keep track of time. Each time the microprocessor is reset, it reads the counters,
increments the clock, checks the status of the pushbuttons, and updates the D/A
converters and display. The MC6840 counter chip (U1) acts as the interface between the
Input Signal Conditioning Board and the microprocessor. A pulse train from the Input
Signal Conditioning Board is directly fed into one of three counters on the MC6840
counter chip.

8-3
Chapter 8 Theory of Operation

Analog to Digital Board. The Analog to Digital Board acts as an interface

between all the signals monitored by the processor system and the microprocessor itself.
The internal ambient temperature, internal ambient pressure, and power supply voltages
are converted to digital signals used by the microprocessor.

Digital/Analog Board. The Digital to Analog Board contains four D/A converters,
one for each analog output. Each is addressed by the processor via signals from PA0-PA7
and PG0 and PG1. The D/A converters are zeroed using potentiometers R2, R4, R6, and
R8. The fullscale output of the four D/A converters is set by jumpers on switches SW1-
SW4 on the D/A board. Fullscale voltages of 10, 5, 1, and 0.1 volts are available.

C-Link Board. The C-Link Board contains the RS-232 circuitry, clock, and memory
for the datalogger. Incoming RS-232 signals are converted to TTL levels by U3, an RS-
232 driver/receiver. The TTL signals are then interpreted by U5, a 68HC11
microprocessor, which is dedicated to remote communications. Data records from the
internal datalogger are stored in U2, a 128K RAM, and the link program is stored in U6,
a 64K EPROM. U10 is the internal clock. A battery supplies +5 volts to the clock and
the data logger memory when instrument power off.

SOFTWARE

The program is stored on U2 of the Processor Board. Ten times a second the
microprocessor receives a reset pulse. This forces the program into the reset mode,
during which time the status of all pushbuttons are checked, the counters are read, the
timer incremented, etc. If for any reason this does not occur, e.g., if the source burns out,
the chopper motor stops, the optical switch fails, etc., the program will hang up. If this
were to occur, there would be no new update of data. It is important to understand this
for troubleshooting.

Ten pulses equal one second. The Model 48C operates on a ten second cycle. Thus 100
reset pulses corresponds to one full cycle. Every five seconds a signal is sent to the input
signal conditioning board changing which V-F receives the sample signal and which one
the reference signal. After ten seconds, the program determines the running count for the
last forms a ratio of these two signals. Using this information, as well as the pressure and
temperature information determined from the pressure and temperature transducers, and
the calibration information, the Model 48C program determines a linearized, temperature
and pressure corrected CO concentration. Every ten seconds this new information is
presented to the digital display and analog outputs, if a time constant of 10 seconds is set.
Note, the past 30 measurements are stored in memory, thus the values for the past 300
seconds are available.

8-4
 Chapter 8 Theory of Operation

If a time constant other than 10 seconds is set, the program takes the average over the
proper number of values. Thus if a time constant of 60 seconds is set, the program will
retrieve the past six measurements, take the average, and output this information to the
display and analog outputs.

Note, however, that a new update still occurs every ten seconds, with the latest computed
concentration being added to the average, and the earliest one being dropped. Thus every
ten seconds, there will be an updated average of the past six current computed
concentrations.

SUBASSEMBLIES

Optical Bench

The optical bench is of the White Cell design. The use of the White Cell multipass
optical bench allows one to achieve a long path length, with a large acceptance angle, in a
small physical package. The bench has been designed for easy disassembly for cleaning.
The source, detector, correlation wheel, and chopper motor mount rigidly to the bench.
No realignment should be necessary after routine cleaning.

Correlation Wheel and Chopper Motor

The correlation wheel consists of two hemispherical cells, one filled with CO and the
other with N2. Integral with the correlation wheel is the chopper pattern necessary to
produce the high frequency (360 Hz) chop necessary for the infrared detector. The
correlation wheel is rotated by a synchronous motor.

Infrared (IR) Source

The infrared source is a special wire wound resistor. It is heated by passing a highly
regulated dc voltage through the resistor. Replacement, when necessary, is
straightforward.

8-5
Chapter 8 Theory of Operation

Flow Components

The Model 48C operates at normal atmospheric pressure. Figure 1-1 summarizes the
flow schematic. A downstream pump and capillary control the sample flow through the
optical bench, which is monitored by a flow sensor. The nominal flow is 1 liter per
minute, with values between 1/2 - 2 liters per minute acceptable.

The optional zero/span and sample valves are operated by successive engagements of the
RUN pushbutton on the front panel. The control signals for the valves go through the
microcomputer.

Temperature and Pressure Transducer

Temperature and pressure must be measured if one wants to compensate for changes in
ambient values. The pressure is measured by a pressure transducer. The temperature is
measured by a thermistor.

8-6
CHAPTER 9
OPTIONAL EQUIPMENT
This chapter describes the Model 48C optional equipment.

RACK MOUNTS WITH SLIDES

Rack mounts with slides for standard 19-inch relay racks are available. Figure 9-1
illustrates the installation of the rack mount option. The mounting hardware is installed
on the analyzer at the factory. For installation on an existing instrument, detailed
instructions will be provided when the rack mounting hardware is shipped. Also
available, as Option 209, are the handle mounting brackets and handles without the rack
mounts.

Figure 9-1. Rack Mount Option Assembly 93P726

9-1
 Chapter 9 Optional Equipment

9-2
D42P725
Figure 9-2. Model 48C Dimensional Outline
 Chapter 9 Optional Equipment

INTERNAL ZERO/SPAN AND SAMPLE VALVES

With the zero/span and sample valve option, a source of span gas is connected to the
SPAN port and a source of zero air is connected to the ZERO port (see Figure 2-1). Zero
and span gas should be supplied at atmospheric pressure. It may be necessary to use an
atmospheric dump bypass plumbing arrangement to accomplish this (see Figure 2-2). If
this option is installed, option switch 3 must be on (see Figure 3-7).

Use the RUN pushbutton while in the Run screen to manually switch the valves between
sample, zero, and span. The active mode is shown in the lower left-hand corner of the
display as shown below.

Run Screen in Sample Mode

Zero/Span Check

Automatic zero/span checking is available in the local mode (option switch 1 off) with
the zero/span valve option. Zero/Span Check appears in the Calibration screen as shown
below. Use the 9 pushbutton to move the cursor to Zero/Span Check and press ENTER.

Calibration Screen with Zero/Span Check

The Zero/Span Check menu appears as shown below.

9-3
Chapter 9 Optional Equipment

Zero/Span Check Menu

To set zero/span check, follow the procedure below:

1. Set the date of the first zero/span check. The Next Date screen, shown below, is
used to set the initial or start date of the zero/span check. Once the initial zero/span
check is performed, the date of the next zero/span check is calculated and displayed.

Next Date Screen

2. Set the time of the first zero/span check. The Next Time screen, shown below, is
used to set the initial time of the zero/span check. Once the initial zero/span check is
performed, the time of the next zero/span check is calculated and displayed.

9-4
 Chapter 9 Optional Equipment

Next Time Screen

3. Set the period between zero/span checks. The Period screen, shown below, defines
the period or interval between zero/span checks. Periods between 2 and 1,000 hours
are acceptable. To turn the zero/span check off, set the period to 0.

Period Screen

4. Set the zero check and the span check duration. The Z (zero) Duration screen,
shown below, defines how long zero air is sampled by the instrument. The S (span)
Duration screen looks and functions the same way as the Z Duration screen, and is
used to set how long the span gas is sampled by the instrument. Durations between
1 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 S
Duration screen to 0. To perform just a span check, set the Z duration screen to 0.

Z Duration Screen

9-5
Chapter 9 Optional Equipment

REMOTE ACTIVATION OF ZERO/SPAN AND SAMPLE VALVES

The rear panel I/O (DB25) connector, shown in Figure 9-3, enables the zero/span and
sample valves to be remotely controlled via contact closure. In addition, the connector
has several instrument status outputs. Option switch 1 must be on and option switch 2 off
in order to enable the remote I/O connector.

Pin Out

(1) Ground (13) NC

(2) NC (14) Ground
(3) NC (15) NC
(4) NC (16) NC
(5) INPUT - Zero Gas (17) NC
(6) Ground (18) INPUT - Span Gas
(7) Relay Common (19) Ground
(8) STATUS - Concentration Alarm (20) Relay Common
(9) STATUS - Local or Remote Mode (21) STATUS - Zero Mode
(10) STATUS - ppm or mg/m3 mode (22) STATUS - Span Mode
(11) STATUS - General Alarm (23) NC
(12) Relay Common (24) STATUS - NC
(25) Relay Common

Figure 9-3. Rear Panel I/O Connector 64P947-5

9-6
 Chapter 9 Optional Equipment

Input Pins

To activate the zero gas mode, connect pin 1, 6, 14, or 19 (ground) to pin 5 (zero gas
mode), as shown in Figure 9-4. To deactivate the zero gas mode, disconnect ground from
the zero gas mode input.

12

Figure 9-4. Remote I/O Zero Gas Mode Activation 64P947-6

To activate the span gas mode, connect pin 1, 6, 14, or 19 (ground) to pin 18 (span gas
mode), as shown in Figure 9-5. To deactivate the span gas mode, disconnect ground
from the span gas mode input.

Figure 9-5. Remote I/O Span Gas Mode Activation 64P947-7

9-7
Chapter 9 Optional Equipment

Instrument Status Outputs

Several instrument status outputs are available on the rear panel I/O connector via reed
relays on the I/O Board. The reed relays are arranged as shown in Figure 9-6. In the
instrument status output truth table, each pin is referred to as open or closed (based on the
physical position of the corresponding relay). The Relay Common line is common to
each of the relays. The relays can be set to either normally open or normally closed. The
following tables and figures are with the relays set to normally open. If the relays are set
to normally closed, reverse the logic of the tables (i.e. open becomes closed and closed
becomes open).

Figure 9-6. Instrument Status Output Relays

9-8
 Chapter 9 Optional Equipment

The following table is for when the relays are set to normally open.

Status Pin Relay Closed Relay Open

Concentration Alarm 8 Alarm No Alarm
Local or Remote Mode 9 Local or Service Mode Remote Mode
3 3
MG/M or PPM Mode 10 mg/m mode ppm mode
General Alarm 11 Alarm No Alarm
Zero Gas Mode 21 Zero Mode On Zero Mode OFF
Span Gas Mode 22 Span Mode On Span Mode Off

Table 9-1. Instrument Status Output Truth Table

4-20 mA ISOLATED CURRENT OUTPUT

A 4-20 mA Isolated Current Output enables the CO concentration to be output at 4-20

mA as shown in Table 9-2 and Figure 9-7.

Current Output Output #1 Output #2 Output #3 Output #4

Channel
Range Mode
Single CO CO Unused Unused
Dual Low CO Hi CO Unused Unused
Auto CO Status High = 12 Unused Unused
mA
Status Low = 4 mA

Table 9-2 Current Output Channel with Corresponding Concentartion

Figure 9-7. Pin-Out of Rear Panel Terminal Strip for Optional Current Output

9-9
Chapter 9 Optional Equipment

TEFLON PARTICULATE FILTER

A 5-10 micron pore size, 2 inch diameter Teflon→ element is available for the Model
43C. 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.

PURGE HOUSING

This housing is attached between the optical bench and Bodine8 motor faceplate
(Figure 9-8). 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. It should be noted that this setup is standard on the Models 41C and
41CHL.

Calibration note: 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 nontoxic 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 140 cc/minute is recommended for optimum

performance. This is produced by feeding a purge gas to the rear panel bulkhead at a
constant pressure of 15 psig. A 0.006" glass capillary (green, TEI Part No. 4115),
mounted inside the capillary housing on the rear panel of the instrument will deliver the
required 140 cc/minute 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.

9-10
9-11
Figure 9-8. Purge Housing Assembly
Chapter 9 Optional Equipment
Chapter 9 Optional Equipment

INSTRUMENT HANDLE

An instrument handle is available to aid in carrying the instrument. It also enables the
instrument to be slightly elevated, while resting on a table or bench, to increase visibility
of the display. Figure 9-9 shows the installation of the instrument handle.

Figure 9-9. Instrument Handle Assembly 93P727

9-12
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 13 months from date of installation or 12 months from
date of shipment, whichever is less (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 Seller 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 SUPPLIED BY SELLER, SHALL 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.

A-1
APPENDIX B
RS-232/485 COMMANDS
RS-232/485 COMMANDS

The RS-232/485 interface enables the analyzer to be remotely controlled by a host remote
device such as, a PC, PLC, datalogger, etc. On the rear panel of the analyzer there are
two male DB9 connectors. Both connectors are identical, so either can be connected to
the remote device. The remaining connector can be used to connect a second analyzer.
Using a daisy-chain configuration, several analyzers can be connected to one remote
device.

RS-232 CONNECTION

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 host 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, or 9600 BAUD

8 data bits
1 stop bit
no parity
All responses are terminated with a carriage return (hex 0D)

RS-485 CONNECTION
The instrument uses a four wire RS-485 configuration with automatic flow control (SD).
The pin configuration for DB9 connector on the rear of the instrument follows:

Pin# (DB9) Function

4 + receive
8 - receive
2 + transmit
7 - transmit
5 ground

INSTRUMENT IDENTIFICATION NUMBER

Each command sent to the analyzer must begin with the instrument's identification
number plus 128. For example, if the instrument ID is set to 25, then decimal 153
precedes each command. The analyzer ignores any command that does no begin with its
instrument identification number.

B-1
Appendix B RS-232 Commands

COMMANDS

The analyzer must be in the remote mode in order to change instrument parameters via
RS-232. However, the command "set mode remote" can be sent to the Model 48C to put
it in the remote mode. Report commands can be issued either in the remote or local
mode.

The RS-232 commands can be sent in either uppercase or lowercase characters. In the
examples below, only the characters between the quotation marks (" ") are sent and
received. If an incorrect command is sent, a "bad cmd" message will be received. The
example below sends the incorrect command "set time avg" instead of the correct
command "set avg time".

Send: "set time avg"

Receive: "set time avg bad cmd"

co
low co

The “co” command reports the current CO concentration reading in single mode or the
high CO reading in dual or auto range. The “low co” command reports the low CO
reading when in dual or auto range. The example below reports that the current CO
reading is 40 ppm.

Send: "co"
Receive: "co 0040E+0 ppm"

gas mode

This 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 optional valves to the sample mode. The example sets the
instrument in the sample mode, that is, the instrument is sampling zero air.

Send: "set sample"

Receive: "set sample ok"

B-2
 Appendix B RS-232 Commands

set zero

This command sets the optional valves to the zero mode. The example sets the
instrument in the zero mode, that is, the instrument is sampling zero air.

Send: "set zero"

Receive: "set zero ok"

set span

This command sets the optional valves to the span mode. The example below sets the
instrument to the span mode, that is, the instrument is sampling span gas.

Send: "set span"

Receive: "set span ok"

sp conc
low sp conc

The “sp conc” command reports the span concentration in single range mode or the high
span concentration in the dual or auto range mode. The “low sp conc” command reports
the low span concentration level in the dual or auto range mode. The example below
reports the span gas concentration in single range mode.

Send: "sp conc"

Receive: "sp conc 1000"

set sp conc xxxx

set low sp conc xxxx

The “set sp conc” command sets the span concentration level in the single range mode or
the high span concentration level in the dual or auto range mode. The “set low sp conc”
command sets the low span concentration in the dual or auto range mode. The example
below sets the span concentration to 1000 ppm in the single range mode.

Send: "set sp conc 1000"

Receive: "set sp conc 1000 ok"

B-3
Appendix B RS-232 Commands

co bkg

This command reports the current CO background. The example below reports that the
CO background is 1.4 ppm.

Send: "co bkg"

Receive: "co bkg 1.400 ppm"

set co bkg [Link]

This command is used to set the CO background to a user-defined value. The example
below sets the CO background to 1.4 ppb.

Send: "set co bkg 1.400"

Receive: "set co bkg 1.400 ok"

set cal co bkg

This command performs the automatic calibration of the CO background. The example
below shows a successful automatic calibration.

Send: "set cal co bkg"

Receive: "set cal co bkg ok"

co coef
low co coef

The “co coef” command reports the co coefficient in single range mode and the high co
coefficient in dual range or auto range mode when using a zero/span calibration. The
example below reports a co coefficient of 1.005.

Send “co coef”

Receive “co coef 1.005”

B-4
 Appendix B RS-232 Commands

set co coef [Link]

set low co coef [Link]

The “set co coef” command sets the CO coefficient to a user-defined value in the single
range and sets the high coefficient in the dual or auto range. The “set low co coefficient”
sets the low coefficient in the dual or auto range. The example below sets the CO
coefficient to 1.005.

Send: "set co coef 1.005"

Receive: "set co coef 1.005 ok"

set cal co coef

This command performs the automatic calculation of the co coefficient. The example
below shows a successful automatic calculation.

Send: "set cal co coef"

Receive: "set cal co coef ok"

set cal low co coef

This command performs the automatic calculation of the low CO coefficient. The
example below shows a successful automatic calculation.

Send: "set cal low co coef"

Receive: "set cal low co coef ok"

coef 0
coef 1
coef 2
low coef 0
low coef 1
low coef 2

The “coef 0”, “coef 1”, and “coef 2” commands report the coefficients of the curve
developed for the Hi Multi-Point Calibration and the “low coef 0”, “low coef 1”, and the
“low coef 2” commands report the coefficients of the curve developed from the Lo Multi-
Point Calibration. The example below reports the coefficient 0 having a value of 1.005
Send: "coef 0"
Receive: "coef 0 1.005"

B-5
Appendix B RS-232 Commands

relay status

The “relay status” command reports the relay status (normally open or normally closed)
of the input/output relays.

Send: "relay status"

Receive: "relay status open"

set relay open

The “set relay (open or closed)” command sets the logic state of the output relays to open
or closed. The example below sets the logic state of the relays to normally open.

Send: "set relay open"

Receive: "set relay open ok"

instr name

The “instr name” command reports the name of the instrument.

Send: "instr name"

Receive: "instr name CO Analyzer"

mode

This reports what operating mode the instrument is in: local 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"

B-6
 Appendix B RS-232 Commands

gas unit
3
This 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

unit = | ppm | mg/m3 |

3
This command sets the gas units to ppm or mg/m . The example below sets the gas units
3
mg/m .

Send: "set gas unit mg/m3"

Receive: "set gas unit mg/m3 ok"

range
low range

The “range” command reports the current CO range in single mode or the high range in
dual or auto mode. “low” range reports the low range in dual or auto mode. The example
below reports that the CO range is set to 50 ppm.

Send: "range"
Receive: "range 5: 5000E-2 ppm"

B-7
Appendix B RS-232 Commands

set range d
set low range d
d = Code in table below

The “set range” command selects the CO fullscale range according to the table below for
single mode and sets the high range for dual and auto range. The “set low range”
command sets the low range in dual or auto range. The example below sets the CO
fullscale range to 50 ppm.

Send: "set range 5"

Receive: "set range 5 ok"

3
Code ppm mg/m

0 1 1

1 2 2

2 5 5

3 10 10

4 20 20

5 50 50

6 100 100

7 200 200

8 500 500

9 1,000 1,000

10 2,000 2,000

11 5,000 5,000

12 10,000 10,000

13 C1 C1

14 C2 C2

15 C3 C3

B-8
 Appendix B RS-232 Commands

custom d

d=|1|2|3|

This reports the user-defined value of custom range 1, 2, or 3. The example below
reports that custom range 1 is defined to 55.0 ppm.

Send: "custom 1"

Receive: "custom 1 5500E-2 ppm"

set custom 1 range ddddd.d

set custom 2 range ddddd.d
set custom 3 range ddddd.d

These commands are used to define the custom ranges. To use the custom range select it
using the set range command. The example below defines custom range 1 to 55.5 ppm.

Send: "set custom 1 range 55.5"

Receive: "set custom 1 range 55.5 ok"

avg time
low avg time

The “avg time” command reports the averaging time setting in single mode or the high
averaging time in dual or auto range. The “low avg time” command reports the low
averaging time in dual or auto range. The example below reports that the averaging time
is set to 60 seconds.

Send: "avg time"

Receive: "avg time 060 sec"

B-9
Appendix B RS-232 Commands

set avg time d

set low avg time d

d = Code in table below

The “set avg time” command sets the averaging time according to the Table below for
single mode and sets the high averaging time in dual or auto mode. The “set low avg
time” sets the averaging time for the low CO in dual or auto range. The example below
sets the averaging time to 60 seconds.

Send: "set avg time 3"

Receive: "set avg time 3 ok"

Code Averaging time (seconds)

0 1
1 2
2 5
3 10
4 20
5 30
6 60
7 90
8 120
9 180
10 240
11 300

B-10
 Appendix B RS-232 Commands

internal temp

This reports the current internal instrument temperature. The first temperature 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, actual 27.2"

temp comp

This reports whether temperature compensation is on or off. The example below shows a
typical response to this command.

Send: "temp comp"

Receive: "temp comp off"

set temp comp on

set temp comp off

This command turns the temperature compensation on and off. The example below turns
temperature compensation off.

Send: "set temp comp off"

Receive: "set temp comp off ok"

chamber temp

This reports the current optical chamber temperature. The example below reports that the
current optical chamber temperature is 45.2°C.

Send: "chamber temp"

Receive: "chamber temp 45.2 deg C"

B-11
Appendix B RS-232 Commands

pres

This 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 pressure compensation is off, a pressure of 750 mm Hg is used
as the default pressure even though the actual pressure is 753.4 mm Hg. The example
below shows that actual reaction chamber pressure is 753.4 mm Hg.

Send: "pres"
Receive: "pres 750.0 mm Hg, actual 753.4"

pres comp

This 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 on

set pres comp off

These commands turn the pressure compensation on and off. The example below turns
pressure compensation off.

Send: "set pres comp off"

Receive: "set pres comp off ok"

time

This reports the current time (military time). The example below reports that the internal
time is [Link] pm.

Send: "time"
Receive: "time [Link]"

B-12
 Appendix B RS-232 Commands

set time hh:mm:ss

hh = hours
mm = minutes
ss = seconds

Sets the internal clock (military time). The example below sets the internal time to 2:15
pm. Note that if seconds are omitted, the seconds default to 00.

Send: "set time 14:15"

Receive: "set time 14:15 ok"

date

This reports the current date. The example below reports the date as December 1, 1994.

Send: "date"
Receive: "date 12-01-94"

set date mm-dd-yy

mm = month
dd = day
yy = year

Sets the internal date. The example below sets the internal date to December 1, 1994.

Send: "set date 12-01-94"

Receive: "set date 12-01-94 ok"

agc int

This reports the current intensity of the reference channel AGC circuit. The example
below reports that the current AGC intensity is 250,000 Hz.

Send: "agc int"

Receive: "agc int 250000 Hz"

B-13
Appendix B RS-232 Commands

ratio

The “ratio” command reports the current sample/reference ratio. When operating in dual
or auto range this command reports the sample/reference ratio calculated using the high
averaging time. The example below shows that the current ratio is 1.16110.

Send: "ratio"
Receive: "ratio 1.161100"

low ratio

The “low ratio” command reports the sample/reference ratio calculated using the low
averaging time. The example below shows that the current ratio is 1.14110.

Send: "low ratio"

Receive: "low ratio 1.141100"

Init ratio

This command reports the initial sample/reference ratio. The example below reports that
the initial ratio was 1.16210.

Send: "init ratio"

Receive: "init ratio 1.16210"

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"

B-14
 Appendix B RS-232 Commands

flow

This 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 l/m"

dtoa d

d = DTOA in table below

This reports the outputs of the 7 Digital to Analog converters (0000 = 0.0% FS, 1000 =
100.0% fullscale). The example below shows that the D/A for the CO voltage Out is
97.7% fullscale.

Send: "dtoa 1"

Receive: "dtoa 1 0977"

D to A Function Single Range Dual Range Auto Range

1 Voltage Output CO Low CO CO
2 Voltage Output CO High CO Range Status
3 Not Used
4 Not Used
5 Current Output CO Low CO CO
6 Current Output CO High CO Range Status
7 Not Used
8 Not Used

option switches

This reports the status (on/off) of the 8 option switches. For example, a return of
11100000, means that option switches 1, 2, and 3 are on and the others are off (see
“Internal Option Switches” in Chapter 3 “Operation,” for more information about option
switches). The example below shows that option switches 1, 2, and 3 are on.

Send: "option sw"

Receive: "option switches 11100000"

B-15
Appendix B RS-232 Commands

program no

This reports the analyzer's program number and the Link (communications) program
number. The example below shows that the installed processor program is 48 00000100
and the installed communication program (link) is 48L 00000100.

Send: "program no"

Receive: "program no processor 48 00000100 link 48L 00000100"

set default params

This command sets the instrument’s parameters to their default values. The example
below shows a typical response. NOTE: It is important to send the “set save params”
command after issuing this command.

Send: "set default params"

Receive: "set default params ok"

set save params

This command stores parameters in the EEPROM. 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 EEPROM.

Send: "set save params"

Receive: "set save params ok"

screen

This reports the information currently being displayed on the instrument's front panel
display. The example below shows a typical response to this command.

Send: "sc"
Receive: " "
"CO PPM 29.5"
" "
"SAMPLE 14:25 REMOTE"

B-16
 Appendix B RS-232 Commands

push button

button = | run | menu | enter | help | up | down | left | right |

This command is used to simulate pressing the Model 48C front panel pushbuttons. In
the example below, the push command is used in conjunction with the screen command
to view the Main Menu. Note that the instrument is in the Run screen initially. Also note
that sending just the button command receives the same response.

Send: "push menu" or Send: "menu"

Receive: "push menu ok" Receive: "menu ok"

Send: "screen"
Receive: "MAIN MENU: 10:25"
">RANGE "
" AVERAGING TIME "
" CALIBRATION FACTORS "

motor

This command reports the motor speed. The example below shows that the motor speed
is 100%.

Send: "motor"
Receive: "motor 100%"

bright

This command reports the display’s level of brightness. The example below shows that
the level of brightness is 75%.

Send: "bright"
Receive: "bright 75%"

B-17
Appendix B RS-232 Commands

set bright d

This command sets the display’s brightness level.

d= 0, 1, 2, or 3.

0 = 25%
1 = 50%
2 = 75%
3 = 100%

The example below sets the display’s level of brightness to 50%

Send: "set bright 2"

Receive: "set ok"

baud

This command reports current baud rate of the connection. The example below shows
that the current baud rate is 9600.

Send: "baud"
Receive: "baud = 9600"

set baud rate

rate = 1200, 2400, 4800, or 9600

This command sets the baud rate. After the command is sent, the baud rate of the sending
device must be changed to agree with the instrument. The example below sets the baud
rate to 9600.

Send: "set baud 9600"

Receive: "set baud 9600 ok"

B-18
 Appendix B RS-232 Commands

format

This command reports the current reply termination format as shown below:

Send: "format"
Receive: "format 00"

Code Reply Termination

00 <CR>
01 0x80 xxxx <CR>

where xxxx = the sum of all characters in the message

set format dd

dd = | 00 | 01 |

This command sets the reply termination format. The example below sets the reply
termination format to checksum.

Send: "format 01"

Receive: "format 01 ok"
"sum 0570"

Code Reply Termination

00 <CR>

01 <nl>sum xxxx<CR>

where xxxx = 4 hexadecimal digits that represent the sum of all the characters in the
message

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
below. 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"

B-19
Appendix B RS-232 Commands

B-20
 Appendix B RS-232 Commands

Records

There are two types of records that can be stored: long records (lrec) and short (srec)
records. In addition, there is dynamic data (erec) that is constantly updated during the
operation of the instrument.

Both long and short records contain the time, date, flags, and concentrations; long records
also contain internal temperature, chamber temperature, pressure, sample flow, motor
speed, bias voltage, and agc intensity. The memory used to store data is organized in 15
blocks.

Each block contains 8192 bytes. Typically, a long record equals 40 bytes and a short
record equals 20 bytes. Therefore, the number of long records per block is approximately
8192/40=204 whereas the number of short records per block is approximately
8192/20=409.

The maximum number of records stored in the clink memory is equal to (the number of
long records per block multiplied by the number of blocks reserved) minus two.

set lrec blocks dd

dd = 0 to 15

This command sets the number of blocks to be used for saving long records. 15 minus dd
equals the number of blocks to be used to save short records.

Send: "set lrec blocks 10"

Receive: "set lrec blocks 10 ok"

lrec mem size

These commands report the maximum number of long records that can be stored with the
current settings and the number of blocks reserved for long records. The example below
is for a long record.

Send: "lrec mem size"

Receive: "lrec mem size 2038 recs, 10 blocks"

B-21
Appendix B RS-232 Commands

srec mem size

This command reports the maximum number of short records that can be stored with the
current settings and the number of blocks reserved for short records. The example below
is for a short record.

Send: "srec mem size"

Receive: "srec mem size 2038 recs, 10 blocks"

no of lrec

This command reports the number of long records collected. The following example shows a
typical response to this command.

Send: "no of lrec"

Receive: "no of lrec 852 recs"

no of srec

This command reports the number of short records collected. The following example
shows a typical response to this command.

Send: "no of srec"

Receive: "no of srec 1265 recs"

set clr records

This command clears all short and long records stored.

Send: "set clr records"

Receive: "set clr records ok"

srec per

This command reports the srec logging period.

Send: "srec per"

Receive: "srec per 5 min"

B-22
 Appendix B RS-232 Commands

set srec per dd

dd =  1  5  15  30  60 

This command sets the srec logging period to every dd minutes.

Send: "set srec per 15"

Receive: "set srec per 15 ok"

lrec per

This command reports the lrec logging period.

Send: "lrec per"

Receive: "lrec per 5 min"

set lrec per dd

dd =  1  5  15  30  60 

This command sets the lrec logging period to every dd minutes.

Send: "set lrec per 15"

Receive: "set lrec per 15 ok"

B-23
Appendix B RS-232 Commands

Record Formats

Long and short records, and dynamic data can be output in various formats such as ASCII
without text, ASCII with text, or binary (see Table B-1 for codes). The following
commands report and set the current output format for long (lrec) and short records (srec),
and dynamic data (erec).

lrec format
srec format
erec format

These commands report the output format for long and short records, and dynamic data.
The following example shows that the output format for long records is ASCII with text.

Format Code Format output

0 ASCII no text
1 ASCII with text
2 Binary
Table B-1 Format Codes

Send: "lrec format"

Receive: "lrec format 01"

set lrec format f

set srec format f
set erec format f

f = format code from Table B-1 shown above.

These commands set the output format. The following example sets the lrec output
format to ASCII with text.

Send: "set lrec format 1"

Receive: "set lrec format 01 ok"

B-24
 Appendix B RS-232 Commands

lrxy, srxy, erxy

These commands report the last long or short record stored, or the current dynamic data
record. The x can be a 0 or 1, 0=no check sum returned, 1= check sum returned. The y is
the format code, which can be 1, 2, or 3 their functions are located in Table B-1 “Format
Codes”.

Send: “lr01”
Receive: “10:15 12-28-02 flags 9C040000 co 7349E+0 loco 5994E+0 innt 33.2 cht
44.7 pres 758.9 smplfl 1.085 speed 100.0 biasv –115.5 intensity 199940”
lrec
srec
lrec xxxx yy
srec xxxx yy
lrec aa:bb oo-pp-qq yy
srec aa:bb oo-pp-qq yy

xxxx = the number of past records

yy = the number of records to return (1 to 10)
aa = hours (01 to 24, military time)
bb = minutes (00 to 59)
oo = month (01 to 12)
pp = day (01 to 31)
qq = year (enter "00" for the year 2000)

These commands output long or short records. The output format is determined by the
set lrec format and set srec format commands. The logging period 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.

Send: "lrec 100 5"

Receive:

Record 640: “10:15 12-28-02 flags 9C040000 co 7349E+0 loco 5994E+0 innt 33.2 cht 44.7 pres 758.9
smplfl 1.085 speed 100.0 biasv –115.5 intensity 199940
Record 641: 10:20 12-28 flags 9C040000 co 7349E+0 loco 5994E+0 innt 33.2 cht 44.7 pres 758.9 smplfl
1.085 speed 100.0 biasv –115.5 intensity 199940
Record 642: 10:25 12-28 flags 9C040000 co 7349E+0 loco 5994E+0 innt 33.2 cht 44.7 pres 758.9 smplfl
1.085 speed 100.0 biasv –115.5 intensity 199940
Record 643: 10:30 12-28 flags 9C040000 co 7349E+0 loco 5994E+0 innt 33.2 cht 44.7 pres 758.9 smplfl
1.085 speed 100.0 biasv –115.5 intensity 199940
Record 644: 10:35 12-28 flags 9C040000 co 7349E+0 loco 5994E+0 innt 33.2 cht 44.7 pres 758.9 smplfl
1.085 speed 100.0 biasv –115.5 intensity 199940”

B-25
APPENDIX C
SCHEMATICS
This appendix contains the schematics for the standard and optional printed circuit
boards contained in the Model 48C. Always turn off the instrument and unplug the
power cord before removing any printed circuit board. For more information about
appropriate safety precautions, see Chapter 7, “Servicing.” A description of each
board can be found in Chapter 8, “Theory of Operation.”

PC Board Schematic No. Part No. Page

Motherboard 42P939 9831 C-2
Pushbutton Board 1 93P906 9950 C-3
Pushbutton Board 2 93P906 9952 C-3
Processor Board 93P907 9837 C-4
Analog/Digital Board 42P941 8331 C-5
Digital/Analog Board 93P908 9839 C-6
Power Supply Board 42P940 8931 C-7
Preamplifier 42P948 8938 C-8
Input Board 42P936 9989 C-9
Bias Power Supply Board 42P938 8933 C-10
Temperature Control Board 42P937 8935 C-11
C-Link Board 93P914 9843 C-12
4-20 mA Outputs (optional) 93P912 9954 C-13
Input/Output Board (optional) 93P913 9956 C-14
Rear Connector Interface Board 93P915 9903 C-15

C-1
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11
C-12
C-13
C-14
C-15
 APPENDIX D

PUMP MAINTENANCE