CO Meas, MR Ratio, Pres, PHT Drive, Slope | Teledyne GFC 7001EM

Maintenance

Model GFC7001E Carbon Dioxide Analyzer

Table 12-2: GFC 7001E/EM Test Function Record

DATE RECORDED

FUNCTION

OPERATING

MODE*

STABILITY

ZERO CAL

CO MEAS

ZERO CAL

ZERO CAL

MR RATIO

SPAN CAL

PRES

SAMPLE

PHT DRIVE

SAMPLE

AFTER WARM-

UP

SLOPE

SPAN CAL

OFFSET

ZERO CAL

Teledyne Analytical Instruments

262

Image 262

Teledyne GFC 7001EM Date Recorded Function Operating Mode Stability, CO Meas, MR Ratio, Pres, PHT Drive, Slope, Offset

Contents

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