Maintenance Schedule & Procedures | Teledyne GFC 7001EM guide

Maintenance

Model GFC7001E Carbon Dioxide Analyzer

12.MAINTENANCE SCHEDULE & PROCEDURES

Predictive diagnostic functions, including data acquisition records, failure warnings and test functions built into the analyzer, allow the user to determine when repairs are necessary without performing painstaking preventative maintenance procedures. There are, however, a minimal number of simple procedures that when performed regularly will ensure that the analyzer continues to operate accurately and reliably over its lifetime. Repairs and troubleshooting are covered in Section Error! Reference source not found. of this manual.

12.1.MAINTENANCE SCHEDULE

Table 12-1 shows a typical maintenance schedule for the analyzer. Please note that in certain environments (i.e. dusty, very high ambient pollutant levels) some maintenance procedures may need to be performed more often than shown.

NOTE

A Span and Zero Calibration Check (see CAL CHECK REQ’D Column of Table 12-1) must be performed

following certain of the maintenance procedure listed below. See Sections 9.3 and 9.4 for instructions on performing checks.

CAUTION

GENERAL SAFETY HAZARD

Risk of electrical shock. Disconnect power before performing any of the following

operations that require entry into the interior of the analyzer.

CAUTION

QUALIFIED PERSONNEL

The operations outlined in this section are to be performed by qualified maintenance

personnel only.

Teledyne Analytical Instruments

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Teledyne GFC 7001EM operation manual Maintenance Schedule & Procedures, Qualified Personnel

Contents

Teledyne Electronic Technologies Model GFC 7001E Family Carbon Monoxide Analyzers Model GFC7001E Carbon Dioxide Analyzer Safety Messages This page intentionally left blank Warranty Policy 02024D WarrantyCoverage Warranty Model GFC7001E Carbon Dioxide Analyzer Rev Name/Description About this Manual Manual Information Model GFC7001E Carbon Dioxide Analyzer Table of Contents Part II Operating Instructions Basic Operation 149 107 185 Calibration Procedures 227 217229 Maintenance Schedule & Procedures 305 Primer on ELECTRO-STATIC Discharge List of Figures List of Appendices 110 List of Tables Teledyne’s Serial I/O Command Types 157 This page intentionally left blank Part General Information Teledyne Analytical Instruments GFC 7001E Family Overview Introduction Additional Documentation Table of Contents Using this Manual GFC 7001E/EM Validation and Verification Advanced Features of the GFC 7001E/EM AnalyzerMaintenance Schedule and Procedures Basic Operation of the GFC 7001E/EM Analyzer Specifications Specifications and ApprovalsM 300E/300EM Basic Unit Specifications EPA Equivalency Designation Emissions Compliance Safety ComplianceTUV Designation CE Mark Compliance This page intentionally left blank GFC 7001E/EM Analyzer Layout Getting Started IZS SampleExhaust Rear Panel Label Function Internal Layout GFC 7001E Internal Layout GFC 7001EM with CO2 and O2 Sensor Option Optical Bench Layout Unpacking the GFC 7001E/EM Analyzer General Safety HazardElectrical Shock Hazard Ventilation Clearance Ventilation ClearanceArea Minimum Required Clearance Electrical Connections Power Connection Analog Output Connections Connecting the Status OutputsAnalog Output Connector PIN Analog Output Voltage Signal Current Signal Rear Panel Status Label Definition Status Output SignalsCondition Control Input Connector Control Input Signals Connecting the Control Inputs Pneumatic Connections Connecting the Serial PortsConnecting to a LAN or the Internet Connecting to a Multidrop Network NIST-SRM Type Nominal Concentration Span Gas Pneumatic Connections to GFC 7001E/EM Basic Configuration Calibration Gas Sources Sample Gas Source Input Gas Venting Initial OperationExhaust Outlet Startup Name Color Behavior Significance Front Panel Display during System Warm-Up Possible Warning Messages at Start-Up Functional Check Interferents for CO2 Measurements Initial Calibration of the GFC 7001E/EM Singl Entr Verifying the GFC 7001E/EM Reporting Range Settings Dilution Ratio Set Up Set CO Span Gas Concentration Zero/Span Calibration To perform the zero/span calibration procedure, press Thank YOU 3. O2 Sensor Calibration Procedure4. CO2 Sensor Calibration Procedure GFC 7001E/EM Analyzer is now ready for operation FAQ’S Frequently Asked Questions Term Description/Definition Glossary Data Acquisition System As Teflon Option Description Number Optional Hardware and SoftwareRack Mount Kits OPT 20 to OPT Model GFC7001E Carbon Dioxide Analyzer Current Loop Analog Outputs Option Carrying STRAP/HANDLE OPT Current Loop Option Installed on the Motherboard ZERO/SPAN Valve Option 50A Expendables and Spares Kits Options 42ACalibration Valves Options 50A, 50B, 50E, 50H General Information Related to ALL Valve Options Zero CAL Mode Valve Condition SampleInternal Pneumatics OPT 50A Zero/Span Valve Operating States for Option Span GAS Pneumatic Set Up OPT 50ASample GAS Source Calibration GAS Sources Internal Pneumatics OPT 50B ZERO/SPAN/SHUTOFF Valve Option 50BZero/Span Valve Operating States for Option 50B Exhaust Outlet Pneumatic Set Up OPT 50BCalibration GAS Sources Span GAS Input GAS Venting Internal Pneumatics OPT 50H ZERO/SPAN Valve with Internal CO Scrubber Option 50H Exhaust Ouitlet Pneumatic Set Up OPT 50H Internal Pneumatics OPT 50E ZERO/SPAN/SHUTOFF with Internal Zero AIR Scrubber Option 50E Pneumatic Set Up OPT 50E 60C Communication Options60A 60B 12 GFC 7001E/EM Ethernet Card Ethernet Option 63A Theory of Operation Paramagnetic measurement of O2 Second GAS SensorsEthernet + Multidrop OPT 63C Oxygen Sensor Option 65A Pneumatic Operation of the O2 Sensor Operation within the GFC 7001E/EM Analyzer Ndir measurement of CO2 1. CO2 Sensor Ranges and SpecificationsCarbon Dioxide Sensor Option 67A Theory of Operation 16 CO2 sensor Theory of Operation Pneumatic Operation of the CO2 Sensor 17 GFC 7001E/EM Internal Pneumatics with CO2 Sensor Option Electronic Operation of the CO2 Sensor 19 Concentration Alarm Relay Concentration Alarm Relay Option Optional Hardware and Software Dilution Ratio Option Special FeaturesMaintenance Mode Switch Second Language Switch Part Operating Instructions This page intentionally left blank Overview of Operating Modes Basic OperationAnalyzer Operating Modes Sample Mode Test Functions Defined List of Warning Messages IR source may be faulty Examples Calibration Mode Setup Mode Setup  Acal Automatic Calibration Setup  CFG Configuration Information Password Levels Setup  Pass Password FeaturePassword Level Menu Access Allowed Basic Operation Model GFC7001E Carbon Dioxide Analyzer Basic Operation Model GFC7001E Carbon Dioxide Analyzer Setting the internal Clock’s Time and Day Adjusting the Internal Clock’s Speed Model Range Setup  Rnge Analog Output Reporting Range ConfigurationPhysical Range Versus Analog Output Reporting Ranges GFC 7001E Family Physical range by Model Analog Output Ranges for CO Concentration Analog Output Connector Pin Out Sngl Dual Auto Reporting Range ModesRange  Range1 Low Range Range2 High Range This is the default reporting range mode for the analyzer Teledyne Analytical Instruments 101 Teledyne Analytical Instruments 102 Teledyne Analytical Instruments 103 Teledyne Analytical Instruments 104 Teledyne Analytical Instruments 105 Setup RNGE  DIL Using the Optional Dilution Ratio Feature Idas Status Advanced FeaturesSetup  Idas Using the Data Acquisition System Idas Front Panel LED Status Indicators for iDAS IDAS Channels Idas StructureIDAS Data Channel Properties Default Idas Channels Teledyne Analytical Instruments 110 Teledyne Analytical Instruments 111 Channel No Setup DAS EDIT Accessing the Idas Edit ModeConc ATIMER, 1 Name Conc Trigger Event Atimer Editing iDAS Data Channel Names Editing iDAS Triggering Events IDAS Data Parameter Functions Editing iDAS Parameters Teledyne Analytical Instruments 116 Editing Sample Period and Report Period Report Periods in Progress When Instrument Is Powered Off Editing the Number of Records RS-232 Report Function Enabling/Disabling the Holdoff Feature Starting Date Feature Compact Report FeatureDISABLING/ENABLING Data Channels IDAS Configuration Using Apicom Remote Idas Configuration IDAS Configuration Through a Terminal Emulation Program IDAS Configuration Using Terminal Emulation Programs Allowed Vars Variable Description Default Values Setup  More  Vars Internal Variables VarsOFF Teledyne Analytical Instruments 126 Setup  More  Diag Using the Diagnostics Functions Accessing the Diagnostic Features Accessing the Analog Output Signal Configuration Submenu Using the GFC 7001E/EM ANALYZER’S Analog Outputs Teledyne Analytical Instruments 130 Curr Analog Output Voltage / Current Range SelectionAnalog Output Voltage Range Min/Max Range Name Range Span Minimum Output Maximum Output Teledyne Analytical Instruments 132 Calibration of the Analog Outputs Automatic Calibration of the Analog Outputs Teledyne Analytical Instruments 135 Individual Calibration of the Analog Outputs Teledyne Analytical Instruments 137 Teledyne Analytical Instruments 138 Manual Adjustment of Current Loop Output Span and Offset Teledyne Analytical Instruments 140 Current Loop Output Check Voltage across Resistor for 2-20 mA Resistor for 4-20 mAMVDC 100 MVDC Turning AN Analog Output OVER-RANGE Feature ON/OFF Adding a Recorder Offset to AN Analog Output Test Channel Description Zero Full Scale None Selecting a Test Channel Function for Output A4 Teledyne Analytical Instruments 145 AIN Calibration Setting the GFC 7001E Concentration Alarm Limits Setup MORE  Alrm Using the GAS Concentration Alarms11 CO Concentration Alarm Default Settings Teledyne Analytical Instruments 148 RS-232 DTE and DCE Communication Setup  MORE Comm Using the ANALYSER’S Communication PortsComm Port Default Settings Remote Operation Teledyne Analytical Instruments 150 Comm Port Baud Rate Comm Port Communication Modes Teledyne Analytical Instruments 153 Comm Port Testing Machine ID ESC Help Commands in Terminal ModeTerminal Mode Software Commands Terminal Operating Modes Command Command Type Command SyntaxID Command CR Teledyne’s Serial I/O Command Types Dddhhmm Id Messagecrlf Status Reporting Logon Is the default password Comm Port Password SecurityRS-232PASS=NNNNNN Location of JP2 on RS-232-Multidrop PCA Option Multidrop RS-232 SET UP Last Make Sure Jumper between JP2 pins 21  Is installedHost Tapi Analyzer CPU RS-485 Setup RS-485 Configuration of COM2 RX/TX RX/TX+ GND Back Panel Connector Pin-Outs for COM2 in RS-485 Mode LED Function Remote Access VIA the EthernetEthernet Status Indicators Ethernet Card COM2 Communication Modes and Baud Rate Configuring the Ethernet Interface Option Using Dhcp Teledyne Analytical Instruments 166 Manually Configuring the Network IP Addresses ON/OFF Teledyne Analytical Instruments 169 Changing the ANALYZER’S Hostname Minimum Requirements Modbus SetupActions Remote Access by Modem AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 Teledyne Analytical Instruments 174 RS-232 Communication Parameters for Hessen Protocol Using the GFC 7001E/EM with a Hessen Protocol NetworkHessen Comm Port Configuration General Overview of Hessen Protocol Activating Hessen Protocol Selecting a Hessen Protocol Type BCC Setting the Hessen Protocol Response ModeMode ID Mode Description CMD Teledyne’s Hessen Protocol Response Modes Gas List Entry Format and Definitions Hessen Protocol GAS List Entries Editing or Adding Hessen Gas List Entries Deleting Hessen Gas List Entries SPARE/UNUSED Bits Setting Hessen Protocol Status FlagsStatus Flag Name Default BIT Assignment Operational FLAGS1 Instrument ID Code To assign or reset the status flag bit assignments, press Apicom Remote Control Program CO Calibration Quality Analysis Calibration ProceduresBefore Calibration Automatic ZERO/SPAN CAL/CHECK Autocal Required EQUIPMENT, SUPPLIES, and Expendables Before Calibration Traceability Data Recording Devices ZERO/SPAN Calibration Checks VS. ZERO/SPAN Calibration Setup for Basic Calibration Checks and Calibration Teledyne Analytical Instruments 189 Performing a Basic Manual Calibration Check Performing a Basic Manual Calibration Setting the Expected Span Gas Concentration Zero/Span Point Calibration Procedure Manual Calibration with ZERO/SPAN Valves Setup for Calibration Using Valve Options Teledyne Analytical Instruments 194 Manual Calibration Checks with Valve Options Installed Manual Calibration Using Valve Options Teledyne Analytical Instruments 197 Autocal Modes Mode Name ActionAutomatic ZERO/SPAN CAL/CHECK Autocal Use of Zero/Span Valve with Remote Contact Closure Attribute Action AutoCal Attribute Setup Parameters 0030 1415Example AutoCal Sequence To program the example sequence shown in -4, press Setup  Acal Programming and Auto CAL Sequence Teledyne Analytical Instruments 202 DURATION30.0 Minutes AutoCal with Auto or Dual Reporting Ranges Modes Selected Maximum Value CO Calibration QualityCalibration Data Quality Evaluation Function Minimum Value Optimum Value Dark Calibration Test Calibration of the GFC 7001E/EM’S Electronic Subsystems Pressure Calibration Flow Calibration Electrical Test Calibration 1.1. O2 Calibration Setup 1. O2 Sensor Calibration ProcedureCalibration of Optional Sensors Set O2 Span Gas Concentration Activate O2 Sensor Stability Function Teledyne Analytical Instruments 212 2.1. CO2 Calibration Setup 2. CO2 Sensor Calibration ProcedureSet CO2 Span Gas Concentration Activate CO2 Sensor Stability Function 2.4. CO2 Zero/Span Calibration Teledyne Analytical Instruments 216 Calibration Requirements EPA Calibration ProtocolCalibration of Equipment General Guidelines Data Recording Device Calibration EQUIPMENT, SUPPLIES, and ExpendablesSpare Parts and Expendable Supplies Matrix for Calibration Equipment & Supplies Recommended Standards for Establishing Traceability Level 1 Calibrations Versus Level 2 Checks Calibration FrequencyActivity Matrix for Quality Assurance Checks Level 1 Zero and Span Calibration Zero and Span ChecksLevel 2 Zero and Span Check Precisions Calibration ZERO/SPAN Check ProceduresPrecision Check Data Reduction Audit Auditing ProcedurePrecision Calibration Procedures Calibration Audit System AUDIT/VALIDATION Dynamic Multipoint Calibration ProcedureLinearity Test Teledyne Analytical Instruments 225 References Part Technical Information Teledyne Analytical Instruments 228 Measurement Method Theory of OperationMeasurement Fundamentals Absorption Path Lengths for GFC 7001E and GFC 7001EM GAS Filter Correlation Measurement Fundamentals with GFC Wheel GFC Wheel Effect of CO in the Sample on CO Meas & CO REF Measure Reference Ratio Effects of Interfering Gas on CO Meas & CO REF Summary Interference Rejection Pneumatic Operation Internal Pneumatic Flow Basic Configuration Spring Rings Filter Flow Rate ControlCritical Flow Orifice Critical Flow Orifice Area High LOW Pressure Sample Flow Sensor Particulate FilterPneumatic Sensors Sample Pressure Sensor Overview Electronic Operation Sync Demod PC 104 BusMother Board DISK-ON-MODULE DOM Central Processing Unit CPUFlash Chip Optical Bench & GFC Wheel Temperature ControlIR Source Segment Sensor SensorSchmidt Triggers IR Photo-Detector Synchronous Demodulator SYNC/DEMOD AssemblyOverview IR Beam Passing Through Signal Synchronization and DemodulationGFC 7001E/EM Sync/Demod Block Diagram Sync Demod Sample and Hold Circuits Sync/Demod Status LED Activity Photo-Detector Temperature ControlDark Calibration Switch Sync/Demod Status LED’s GFC Wheel Motor Control Electric Test SwitchRelay Board Heater Control Relay Board Status LED’s LED Color Function Status When LIT Status When UnlitStatus LED’s 11.5.5.6. I2C Watch Dog Circuitry Thermistor Interface MotherboardTo D Conversion Sensor Inputs Internal Digital I/O Analog OutputsExternal Digital I/O Power UP Circuit Power SUPPLY/ Circuit Breaker Teledyne Analytical Instruments 250 Relay Board Communication InterfaceMother Keyboard Front Panel Status LED’s Front Panel InterfaceAnalyzer Status LED’s Keyboard Front Panel DisplayKeyboard/Display Interface Electronics Keypad Decoder KEY-DEPRESS-DETECT Circuit Keypad Decoder Display Controller Display Power Watch DOGI2C Interface Chip Display Data Decoder Adaptive Filter Software Operation Internal Data Acquisition System Idas Temperature and Pressure CompensationCalibration Slope and Offset Measurement Algorithm Teledyne Analytical Instruments 258 Maintenance Schedule Maintenance Schedule & ProceduresQualified Personnel Teledyne Analytical Instruments 260 Action GFC 7001E/EM Maintenance Schedule Pres Date Recorded Function Operating Mode StabilityCO Meas MR Ratio Interpretation Predicting Failures Using the Test FunctionsPredictive uses for Test Functions Function Condition Behavior Replacing the Sample Particulate Filter Maintenance ProceduresRebuilding the Sample Pump Vacuum Leak Check and Pump Check Performing Leak ChecksPressure Leak Check Cleaning Exterior Surfaces of the GFC 7001E/EM Cleaning the Optical BenchPerforming a Sample Flow Check General Troubleshooting Troubleshooting & RepairSuspect a Leak First Viewing and Clearing Warning Messages Fault Diagnosis with Warning Messages Initialized Fault Condition Possible Causes MessageConfig Cannot DYN Fault Diagnosis with Test Functions Time Range Stabil CO Meas CO REF Pres Sample FL Samp Temp Bench Wheel BOX TempTest Functions Indicated Failures Test Functions PHT Drive Slope Offset Diag  Signal I/O Using the Diagnostic Signal I/O Function Internal Electronic Status LED’S CPU Status IndicatorCPU Status LED Sync Demodulator Status LED’s LED Function Fault Status Indicated FailuresSync/Demod Board Status Failure Indications Relay Board Status LED’s Relay PCAI2C Status LED Failure Indications Relay Board Status LED Failure Indications GFC 7001E/EM Internal GAS Flow Diagrams GAS Flow Problems Teledyne Analytical Instruments 279 Teledyne Analytical Instruments 280 Troubleshooting & Repair High Flow Typical Sample GAS Flow ProblemsFlow is Zero Low Flow Actual Flow Does Not Match Displayed Flow Calibration ProblemsMiscalibrated Displayed Flow = Warnings Inability to Span no Span KEY NON-REPEATABLE Zero and SpanInability to Zero no Zero KEY Bench Temperature Other Performance ProblemsTemperature Problems Box or Sample Temperature IR Photo-Detector TEC Temperature GFC Wheel Temperature Excessive Noise Name Test POINT# TP and Wire Color AC Mains ConfigurationDC Power Supply DC Power Test Point and Wiring Color Codes KEYBOARD/DISPLAY Interface DC Power Supply Acceptable Levels Function Control Device Relay Board Control DevicesSocket Sync/Demodulator Assembly Sensor AssemblyElectrical Test TP2 TP4 Opto Pickup AssemblyGFC Wheel Drive Opto Pickup Board Nominal Output Frequencies Pressure/Flow Sensor Assembly Step Nominal Output Voltage 13.5.7.1. A/D FunctionsTest Channel / Analog Outputs Voltage Full Scale Output of Voltage Range Output Range Nominal Output Values Step Current Analog Outputs Current Loop 12 Status Outputs Check Status OutputsPIN Left to Right Status RS-232 Communications General RS-232 TroubleshootingControl Inputs Remote Zero, Span Optional CO2 Sensor Troubleshooting Analyzer/Modem or Terminal Operation Repairing Sample Flow Control Assembly Repair Procedures REMOVING/REPLACING the GFC Wheel 15 Opening the GFC Wheel Housing Teledyne Analytical Instruments 301 18 Removing the GFC Wheel Checking the Sync/Demodulator Circuit Gain Adjustment Made Here Adjusting the Sync/Demodulator, Circuit Gain Technical Assistance DISK-ON-MODULE Replacement Procedure Means of Generation Primer on ELECTRO-STATIC DischargeHOW Static Charges are Created Static Generation Voltages for Typical Activities Device Range HOW ELECTRO-STATIC Charges Cause DamageSensitivity of Electronic Devices to Damage by ESD Damage Susceptibility Voltage Basic Principles of Static Control Common Myths about ESD DamageGeneral Rules Teledyne Analytical Instruments 308 Working at an Anti-ESD Work Bench Working at the Instrument Rack Transferring Components from Rack to Bench and Back Opening Shipments from Teledyne’ Customer Service ESD Hazard Packing Components for Return to Teledyne’s Customer Service Teledyne Analytical Instruments 312 Analog CAL WARNING, 49, 88 Analog Inputs Bench Temp WARNING, 49, 88, 182, 269 Bench Temperature Index Teledyne Analytical Instruments 315 Pnuntc Internal Span Gas Generator Calibration Pressure Span InletRear Board not DET, 49, 88, 182 Relay Board WARN, 49, 88, 269 relay PCA Interactive Mode Span2 Inlet, 32 Specifications, 25Source WARNING, 49, 88 Vent Outlet Teledyne Analytical Instruments 320 Teledyne Analytical Instruments 321