Teledyne GFC7001T

Troubleshooting and ServiceTeledyne API – Model T300/T300M CO Analyzer

Teledyne Analytical Instruments 283

7. Carefully remove the opto-pickup printed circuit assembly.

Opto-Pickup

Figure 12-16: Removing the Opto-Pickup Assembly

8. Remove the three (3) screws holding the GFC Wheel motor/heat sink assembly to

the GFC Wheel housing.

9. Carefully remove the GFC Wheel motor/heat sink assembly from the GFC Wheel

housing.

GFC WHEEL HOUSING

Figure 12-17: Removing the GFC Wheel Housing

Contents

Main Operation Manual Model GFC7001T Carbon Monoxide Analyzer Model GFC7001T Carbon Monoxide Analyzer Teledyne Analytical Instruments ii Copyright 2013 Teledyne Analytical Instruments Teledyne Analytical Instruments iii Teledyne Analytical Instruments iv Selected Options for the Model GFC 7001T Teledyne Analytical Instruments v ABOUT THIS MANUAL ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY IMPORTANT IMPACT ON READINGS OR DATA Page Teledyne Analytical Instruments IMPORTANT SAFETY INFORMATION CAUTION - General Safety Hazard Teledyne Analytical Instruments viii CONSIGNES DE SCURIT MISE EN GARDE Teledyne Analytical Instruments TABLE OF CONTENTS Teledyne Analytical Instruments x 5. SETUP MENU 93 Teledyne Analytical Instruments xi Teledyne Analytical Instruments xii Teledyne Analytical Instruments xiii Teledyne Analytical Instruments xiv Teledyne Analytical Instruments xv LIST OF APPENDICES Teledyne Analytical Instruments xvi LIST OF FIGURES Teledyne Analytical Instruments xvii LIST OF TABLES Teledyne Analytical Instruments xviii Teledyne Analytical Instruments xix Page Page Page 1. INTRODUCTION, FEATURES AND OPTIONS 1.1. GFC7001T FAMILY OVERVIEW 1.2. FEATURES 1.3. GFC7001T/GFC7001TM DOCUMENTATION 1.4. OPTIONS IntroductionTeledyne API Model T300/T300M CO Analyzer Teledyne Analytical Instruments 25 Table 1-1: Analyzer Options Option Option Number Description/Notes Reference CAUTION - GENERAL SAFETY HAZARD Page Page Page SpecificationsTeledyne API Model T300/T300M CO Analyzer 2. SPECIFICATIONS AND APPROVALS 2.1. SPECIFICATIONS Table 2-1: GFC7001T/GFC7001TM Basic Unit Specifications Parameter Specification SpecificationsTeledyne API Model T300/T300M CO Analyzer Parameter Specification Table 2-2: O2 Sensor Option Specifications Parameter Description Table 2-3: CO2 Sensor Option Specifications Parameter Description 2.2. EPA EQUIVALENCY DESIGNATION 2.3. APPROVALS AND CERTIFICATIONS Page 3. GETTING STARTED 3.1. UNPACKING THE GFC7001T/GFC7001TM ANALYZER 3.1.1. VENTILATION CLEARANCE 3.2. INSTRUMENT LAYOUT 3.2.1. FRONT PANEL Page Getting StartedTeledyne API Model T300/T300M CO Analyzer Table 3-2: Display Screen and Touch Control Description Field Description/Function Page Page 3.2.3. GFC7001T/GFC7001TM ANALYZER LAYOUT Figure 3-5 shows the GFC7001T internal layout. Page Page Getting StartedTeledyne API Model T300/T300M CO Analyzer Figure 3-7: Optical Bench Layout (shorter bench, GFC7001TM, shown) 3.3. CONNECTIONS AND SETUP Teledyne Analytical Instruments 44 3.3.1. ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD CAUTION GENERAL SAFETY HAZARD Page Teledyne Analytical Instruments 46 CAUTION AVOID INVALIDATING WARRANTY Page Page Getting StartedTeledyne API Model T300/T300M CO Analyzer Table 3-6: Status Output Signals Getting StartedTeledyne API Model T300/T300M CO Analyzer Teledyne Analytical Instruments 50 - Figure 3-12: Control Input Connector Table 3-7: Control Input Signals Page Page Page Page Page Page Page Teledyne Analytical Instruments 58 3.3.2. PNEUMATIC CONNECTIONS Teledyne Analytical Instruments 60 ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY IMPORTANT Leak Check Page Page Page Page Page Page Page Page Page Page Page 3.4. STARTUP, FUNCTIONAL CHECKS, AND INITIAL CALIBRATION 3.4.1. STARTUP 3.4.2. WARNING MESSAGES Getting StartedTeledyne API Model T300/T300M CO Analyzer Table 3-13 lists brief descriptions of the warning messages that may occur during start up. Table 3-13: Possible Warning Messages at Start-Up 3.4.3. FUNCTIONAL CHECKS 3.4.4. INITIAL CALIBRATION Page Page Page Page Page Page Page Page Page 4. OVERVIEW OF OPERATING MODES 4.1. SAMPLE MODE 4.1.1. TEST FUNCTIONS OverviewTeledyne API Model T300/T300M CO AnalyzerTeledyne API Model T300/T300M CO Analyzer Teledyne Analytical Instruments 87 Figure 4-2: Viewing GFC7001T/GFC7001TM Test Functions IMPORTANT IMPACT ON READING OR DATA Table 4-2: Test Functions Defined OverviewTeledyne API Model T300/T300M CO AnalyzerTeledyne API Model T300/T300M CO Analyzer 4.1.2. WARNING MESSAGES Table 4-3: List of Warning Messages OverviewTeledyne API Model T300/T300M CO AnalyzerTeledyne API Model T300/T300M CO Analyzer To view and clear warning messages: 4.2. CALIBRATION MODE 4.3. SETUP MODE 4.3.1. PASSWORD SECURITY 4.3.2. PRIMARY SETUP MENU OverviewTeledyne API Model T300/T300M CO AnalyzerTeledyne API Model T300/T300M CO Analyzer 4.3.3. SECONDARY SETUP MENU (SETUP>MORE) Table 4-5: Secondary Setup Mode (SETUP>MORE) Features and Functions 5. SETUP MENU 5.1. SETUP CFG: CONFIGURATION INFORMATION Page 5.4.2. PHYSICAL RANGE VS ANALOG OUTPUT REPORTING RANGES 5.4.3. REPORTING RANGE MODES: SINGLE, DUAL, AUTO RANGES Page Page Page Page Page Page 5.4.4. RANGE UNITS 5.4.5. DILUTION RATIO (OPTION) 5.5. SETUP PASS: PASSWORD PROTECTION Page Page 5.6. SETUP CLK: SETTING THE INTERNAL TIME-OF-DAY CLOCK AND ADJUSTING SPEED Page 5.7. SETUP COMM: COMMUNICATIONS PORTS 5.7.1. ID (MACHINE IDENTIFICATION) 5.7.2. INET (ETHERNET) 5.7.3. COM1 AND COM2 (MODE, BAUD RATE AND TEST PORT) SetupTeledyne API Model T300/T300M CO Analyzer 5.8. SETUP VARS: VARIABLES SETUP AND DEFINITION 4 3 2 1 5.9. SETUP DIAG: DIAGNOSTICS FUNCTIONS Page Page 5.9.1. SIGNAL I/O 5.9.2. ANALOG OUTPUT 5.9.3. ANALOG I/O CONFIGURATION Teledyne Analytical Instruments 117 Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page SetupTeledyne API Model T300/T300M CO Analyzer To access and adjust settings for the external Analog Inputs option channels press: Figure 5-7. DIAG Analog Inputs (Option) Configuration Menu 5.9.4. ELECTRICAL TEST Page SetupTeledyne API Model T300/T300M CO Analyzer To activate the TEST Channel and select the CO MEASURE function, press: setting. ENTR accepts the new setting. 5.10. SETUP MORE ALRM (OPTION): USING THE GAS CONCENTRATION ALARMS 5.10.1. SETTING THE GFC7001T CONCENTRATION ALARM LIMITS Page 6. COMMUNICATIONS SETUP AND OPERATION 6.1. DATA TERMINAL/COMMUNICATION EQUIPMENT (DTE DCE) 6.2. COMMU NICATIO N MODES, BAUD RATE AND PORT TESTING 6.2.1. COMMUNICATION MODES Page CommunicationsTeledyne API Model T300/T300M CO Analyzer Figure 6-1: COM1[2] Communication Modes Setup 6.2.2. COM PORT BAUD RATE CommunicationsTeledyne API Model T300/T300M CO Analyzer Figure 6-2: COMM Port Baud Rate Figure 6-3: COMM COM1 Test Port 6.2.3. COM PORT TESTING 6.3. RS-232 6.4. RS-485 (OPTION) 6.5. ETHERNET 6.5.1. CONFIGURING ETHERNET COMMUNICATION MANUALLY (STATIC IP ADDRESS) CommunicationsTeledyne API Model T300/T300M CO Analyzer Figure 6-4: COMM LAN / Internet Manual Configuration PROPERTY DEFAULT STATE DESCRIPTION HOST NAME [initially blank] Contact your IT Network Administrator Page 6.5.3. CHANGING THE ANALYZERS HOSTNAME 6.6. USB PORT (OPTION) FOR REMOTE ACCESS Page 6.7. COMMUNICATIONS PROTOCOLS 6.7.1. MODBUS Example Read/Write Definition window: Example Connection Setup window: Example MODBUS Poll window: 6.7.2. HESSEN Page Page Page Page Teledyne Analytical Instruments 157 6.7.3. HESSEN PROTOCOL GAS LIST ENTRIES [GAS TYPE],[RANGE],[GAS ID],[REPORTED] CO, 0, 310, REPORTED CO2, 0, 311, REPORTED O2, 0, 312, REPORTED CO, 2, 310, REPORTED Page Page CommunicationsTeledyne API Model T300/T300M CO Analyzer OPERATIONAL FLAGS1 SPARE/UNUSED BITS UNASSIGNED FLAGS (0000) To assign or reset the status flag bit assignments, press: Page 7. DATA ACQUISITION SYSTEM (DAS) AND APICOM 7.1. DAS STRUCTURE 7.1.1. DAS DATA CHANNELS 7.1.2. DEFAULT DAS CHANNELS Page DAC and APICONTeledyne API Model T300/T300M CO Analyzer Triggering Events and Data Parameters/Functions for these default channels are: Parameters: 1 Parameters: 2 List of ParametersList of Channels Figure 7-1: Default DAS Channel Setup 7.1.3. VIEWING DAS CHANNELS AND INDIVIDUAL RECORDS PREV <PRM PRM> PV10 NEXT NX10 7.1.4. EDITING DAS CHANNELS Page 7.1.5. EDITING DAS TRIGGERING EVENTS 7.1.6. EDITING DAS PARAMETERS Page Page 7.1.7. SAMPLE PERIOD AND REPORT PERIOD Page 7.1.8. NUMBER OF RECORDS 7.1.9. RS-232 REPORT FUNCTION 7.1.10. DISABLING/ENABLING DATA CHANNELS 7.1.11. HOLDOFF FEATURE 7.2. REMOTE DAS CONFIGURATION 7.2.1. DAS CONFIGURATION VIA APICOM Page 7.2.2. DAS CONFIGURATION USING TERMINAL EMULATION PROGRAMS Page 8. REMOTE OPERATION 8.1. COMPUTER MODE 8.1.1. REMOTE CONTROL VIA APICOM 8.2. INTERACTIVE MODE 8.2.1. REMOTE CONTROL VIA A TERMINAL EMULATION PROGRAM Page 8.3. REMOTE ACCESS BY MODEM Page Page 8.4. PASSWORD SECURITY FOR SERIAL REMOTE COMMUNICATIONS Page 9. CALIBRATION PROCEDURES 9.1. CALIBRATION PREPARATIONS 9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES Page 9.1.2. DATA RECORDING DEVICES 9.2. MANUAL CALIBRATION 9.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION Page Page 9.2.3. PERFORMING A BASIC MANUAL CALIBRATION Page Page 9.3. MANUAL CALIBRATION WITH ZERO/SPAN VALVES 9.3.1. SETUP FOR CALIBRATION USING VALVE OPTIONS Page Page Page 9.3.3. MANUAL CALIBRATION USING VALVE OPTIONS Page Page 9.4. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL) Page Page 9.4.1. SETUP ACAL: PROGRAMMING AND AUTO CAL SEQUENCE Page Page 9.5. CO CALIBRATION QUALITY 9.6. CALIBRATION OF THE GFC7001T/GFC7001TM ELECTRONIC SUBSYSTEMS 9.6.1. DARK CALIBRATION TEST 9.6.2. PRESSURE CALIBRATION 9.6.3. FLOW CALIBRATION 9.7. CALIBRATION OF OPTIONAL SENSORS 9.7.1. O2 SENSOR CALIBRATION Page Page Page 9.7.2. CO2 SENSOR CALIBRATION PROCEDURE Page Page Page 10. EPA CALIBRATION PROTOCOL 10.1. CALIBRATION REQUIREMENTS 10.1.1. CALIBRATION OF EQUIPMENT - GENERAL GUIDELINES 10.1.2. CALIBRATION EQUIPMENT, SUPPLIES, AND EXPENDABLES EPA Calibration Protocol Teledyne API Model T300/T300M CO Analyzer Table 10-1: Matrix for Calibration Equipment & Supplies 10.1.3. RECOMMENDED STANDARDS FOR ESTABLISHING TRACEABILITY 10.1.4. CALIBRATION FREQUENCY 10.1.5. LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS EPA Calibration Protocol Teledyne API Model T300/T300M CO Analyzer 10.2. ZERO AND SPAN CHECKS 10.2.1. ZERO/SPAN CHECK PROCEDURES 10.2.2. PRECISION CHECK 10.3. PRECISION CALIBRATION 10.3.1. PRECISION CALIBRATION PROCEDURES 10.4. AUDITING PROCEDURE 10.4.1. CALIBRATION AUDIT 10.4.2. DATA REDUCTION AUDIT 10.5. DYNAMIC MULTIPOINT CALIBRATION PROCEDURE 10.5.1. LINEARITY TEST Page Failed IR detector, GFC Wheel or Sync/Demod Board Contaminated optical bench or sample lines 10.6. REFERENCES Page Page Page Page Page Teledyne Analytical Instruments 11. MAINTENANCE SCHEDULE & PROCEDURES 11.1. MAINTENANCE SCHEDULE CAUTION GENERAL SAFETY HAZARD CAUTION QUALIFIED PERSONNEL Page ITEM ACTION FREQ CAL CHECK REQD MANUAL DATE PERFORMED Page MaintenanceTeledyne API Model T300/T300M CO Analyzer 11.2. PREDICTING FAILURES USING THE TEST FUNCTIONS Table 11-3: Predictive uses for Test Functions FUNCTION CONDITION BEHAVIOR INTERPRETATION 11.3. MAINTENANCE PROCEDURES 11.3.1. REPLACING THE SAMPLE PARTICULATE FILTER 11.3.2. PERFORMING LEAK CHECKS 11.3.3. PERFORMING A SAMPLE FLOW CHECK Page Teledyne Analytical Instruments 12. TROUBLESHOOTING AND SERVICE NOTE QUALIFIED PERSONNEL CAUTION GENERAL SAFETY HAZARD 12.1. GENERAL TROUBLESHOOTING 12.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES Page Troubleshooting and ServiceTeledyne API Model T300/T300M CO Analyzer Troubleshooting and ServiceTeledyne API Model T300/T300M CO Analyzer Table 13-1: Warning Messages Indicated Failures (cont.) 12.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS Troubleshooting and ServiceTeledyne API Model T300/T300M CO Analyzer Table 12-2: Test Functions - Indicated Failures PRES SAMPLE FL SAMP TEMP BENCH TEMP WHEEL TEMP 12.1.3. THE DIAGNOSTIC SIGNAL I/O FUNCTION 12.1.4. STATUS LEDS Motherboard Troubleshooting and ServiceTeledyne API Model T300/T300M CO Analyzer Table 12-3: Sync/Demod Board Status Failure Indications D2 Segment Sensor Status JP4 Connector to Opto-Pickup Board Figure 12-4: Sync/Demod Board Status LED Locations STATUS LEDs DC VOLTAGE TEST POINTS RELAY PCA PN 04135 Troubleshooting and ServiceTeledyne API Model T300/T300M CO Analyzer Table 12-5: Relay Board Status LED Failure Indications 12.2. GAS FLOW PROBLEMS Page Page Page 12.2.2. TYPICAL SAMPLE GAS FLOW PROBLEMS 12.3. CALIBRATION PROBLEMS 12.3.1. MISCALIBRATED 12.3.2. NON-REPEATABLE ZERO AND SPAN 12.3.3. INABILITY TO SPAN NO SPAN BUTTON (CALS) 12.3.4. INABILITY TO ZERO NO ZERO BUTTON (CALZ) 12.4. OTHER PERFORMANCE PROBLEMS 12.4.1. TEMPERATURE PROBLEMS Page 12.4.2. EXCESSIVE NOISE 12.5. SUBSYSTEM CHECKOUT 12.5.1. AC MAINS CONFIGURATION 12.5.2. DC POWER SUPPLY 12.5.3. I2C BUS 12.5.4. TOUCHSCREEN INTERFACE 12.5.5. LCD DISPLAY MODULE 12.5.6. RELAY BOARD 12.5.7. SENSOR ASSEMBLY Page Page 12.5.8. MOTHERBOARD Page Page 12.5.9. CPU 12.5.10. RS-232 COMMUNICATIONS 12.5.11. THE OPTIONAL CO2 SENSOR 12.6. REPAIR PROCEDURES 12.6.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 12.6.2. REMOVING/REPLACING THE GFC WHEEL Page 12.6.3. CHECKING AND ADJUSTING THE SYNC/DEMODULATOR, CIRCUIT GAIN (CO MEAS) VR1 Adjustment Made He re 12.6.4. DISK-ON-MODULE REPLACEMENT 12.7. FREQUENTLY ASKED QUESTIONS 12.8. TECHNICAL ASSISTANCE 13. THEORY OF OPERATION 13.1. MEASUREMENT METHOD 13.1.1. BEERS LAW I = Io e-Lc I I L C 13.2. MEASUREMENT FUNDAMENTALS 13.2.1. GAS FILTER CORRELATION Page Page Teledyne Analytical Instruments 294 CAUTION GENERAL SAFETY HAZARD 13.3. FLOW RATE CONTROL 13.3.2. PARTICULATE FILTER 13.3.3. PNEUMATIC SENSORS 13.4. ELECTRONIC OPERATION Page 13.4.1. CPU 13.4.2. OPTICAL BENCH & GFC WHEEL Page 13.4.3. SYNCHRONOUS DEMODULATOR (SYNC/DEMOD) ASSEMBLY Theory of Operation Teledyne API Model T300/T300M CO Analyzer Sample & Hold Circuits (x4) CO Reference Phase Lock Loop Compact Programmable Logic Device Page 13.4.4. RELAY BOARD Page STATUS LEDs DC VOLTAGE TEST POINTS RELAY PCA PN 04135 13.4.5. MOTHERBOARD Page 13.4.6. I2C DATA BUS 13.4.7. POWER SUPPLY/ CIRCUIT BREAKER Page 13.4.8. FRONT PANEL TOUCHSCREEN/DISPLAY INTERFACE 13.5. SOFTWARE OPERATION 13.5.1. ADAPTIVE FILTER 13.5.2. CALIBRATION - SLOPE AND OFFSET 13.5.3. MEASUREMENT ALGORITHM 13.5.4. TEMPERATURE AND PRESSURE COMPENSATION 13.5.5. INTERNAL DATA ACQUISITION SYSTEM (DAS) 14. A PRIMER ON ELECTRO-STATIC DISCHARGE 14.1. HOW STATIC CHARGES ARE CREATED 14.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE 14.3. COMMON MYTHS ABOUT ESD DAMAGE 14.4. BASIC PRINCIPLES OF STATIC CONTROL 14.4.1. GENERAL RULES 14.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE Page Page CAUTION GLOSSARY