Troubleshooting & Repair | Teledyne GFC 7001EM instruction

Troubleshooting & Repair

Model GFC7001E Carbon Dioxide Analyzer

Figure 13-11: GFC 7001E/EM – Internal Pneumatics with O2 Sensor Option 65

Figure 13-12: GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66

Teledyne Analytical Instruments

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Image 281

Teledyne GFC 7001EM operation manual Troubleshooting & Repair

Contents

Teledyne Electronic Technologies Model GFC 7001E Family Carbon Monoxide Analyzers Model GFC7001E Carbon Dioxide Analyzer Safety Messages This page intentionally left blank Coverage WarrantyWarranty Policy 02024D 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 229 217227 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 Maintenance Schedule and Procedures Advanced Features of the GFC 7001E/EM AnalyzerBasic Operation of the GFC 7001E/EM Analyzer GFC 7001E/EM Validation and Verification M 300E/300EM Basic Unit Specifications Specifications and ApprovalsSpecifications EPA Equivalency Designation TUV Designation Safety ComplianceCE Mark Compliance Emissions Compliance This page intentionally left blank GFC 7001E/EM Analyzer Layout Getting Started Exhaust SampleRear Panel Label Function IZS Internal Layout GFC 7001E Internal Layout GFC 7001EM with CO2 and O2 Sensor Option Optical Bench Layout Electrical Shock Hazard General Safety HazardUnpacking the GFC 7001E/EM Analyzer Area Minimum Required Clearance Ventilation ClearanceVentilation Clearance Electrical Connections Power Connection Analog Output Connector Connecting the Status OutputsPIN Analog Output Voltage Signal Current Signal Analog Output Connections Condition Status Output SignalsRear Panel Status Label Definition Control Input Connector Control Input Signals Connecting the Control Inputs Connecting to a LAN or the Internet Connecting the Serial PortsConnecting to a Multidrop Network Pneumatic Connections NIST-SRM Type Nominal Concentration Span Gas Pneumatic Connections to GFC 7001E/EM Basic Configuration Calibration Gas Sources Sample Gas Source Exhaust Outlet Initial OperationInput Gas Venting 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 4. CO2 Sensor Calibration Procedure 3. O2 Sensor Calibration ProcedureGFC 7001E/EM Analyzer is now ready for operation Thank YOU FAQ’S Frequently Asked Questions Term Description/Definition Glossary Data Acquisition System As Teflon Rack Mount Kits OPT 20 to OPT Optional Hardware and SoftwareModel GFC7001E Carbon Dioxide Analyzer Option Description Number Current Loop Analog Outputs Option Carrying STRAP/HANDLE OPT Current Loop Option Installed on the Motherboard Calibration Valves Options 50A, 50B, 50E, 50H Expendables and Spares Kits Options 42AGeneral Information Related to ALL Valve Options ZERO/SPAN Valve Option 50A Internal Pneumatics OPT 50A Mode Valve Condition SampleZero/Span Valve Operating States for Option Zero CAL Sample GAS Source Pneumatic Set Up OPT 50ACalibration GAS Sources Span GAS Zero/Span Valve Operating States for Option 50B ZERO/SPAN/SHUTOFF Valve Option 50BInternal Pneumatics OPT 50B Calibration GAS Sources Span GAS Pneumatic Set Up OPT 50BInput GAS Venting Exhaust Outlet 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 60A Communication Options60B 60C 12 GFC 7001E/EM Ethernet Card Ethernet Option 63A Ethernet + Multidrop OPT 63C Second GAS SensorsOxygen Sensor Option 65A Theory of Operation Paramagnetic measurement of O2 Pneumatic Operation of the O2 Sensor Operation within the GFC 7001E/EM Analyzer Carbon Dioxide Sensor Option 67A 1. CO2 Sensor Ranges and SpecificationsTheory of Operation Ndir measurement of CO2 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 Maintenance Mode Switch Special FeaturesSecond Language Switch Dilution Ratio Option Part Operating Instructions This page intentionally left blank Analyzer Operating Modes Basic OperationOverview of 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 Level Menu Access Allowed Setup  Pass Password FeaturePassword Levels 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 Physical Range Versus Analog Output Reporting Ranges Setup  Rnge Analog Output Reporting Range ConfigurationGFC 7001E Family Physical range by Model Model Range Analog Output Ranges for CO Concentration Analog Output Connector Pin Out Range  Range1 Low Range Range2 High Range Reporting Range ModesSngl Dual Auto 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 Setup  Idas Using the Data Acquisition System Idas Advanced FeaturesFront Panel LED Status Indicators for iDAS Idas Status IDAS Data Channel Properties Idas StructureIDAS Channels Default Idas Channels Teledyne Analytical Instruments 110 Teledyne Analytical Instruments 111 Conc ATIMER, 1 Setup DAS EDIT Accessing the Idas Edit ModeName Conc Trigger Event Atimer Channel No 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 DISABLING/ENABLING Data Channels Compact Report FeatureStarting Date Feature IDAS Configuration Using Apicom Remote Idas Configuration IDAS Configuration Through a Terminal Emulation Program IDAS Configuration Using Terminal Emulation Programs OFF Setup  More  Vars Internal Variables VarsAllowed Vars Variable Description Default Values 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 Analog Output Voltage Range Min/Max Analog Output Voltage / Current Range SelectionRange Name Range Span Minimum Output Maximum Output 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 MVDC Voltage across Resistor for 2-20 mA Resistor for 4-20 mA100 MVDC Current Loop Output Check 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 11 CO Concentration Alarm Default Settings Setup MORE  Alrm Using the GAS Concentration AlarmsSetting the GFC 7001E Concentration Alarm Limits Teledyne Analytical Instruments 148 Comm Port Default Settings Setup  MORE Comm Using the ANALYSER’S Communication PortsRemote Operation 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 Mode Software Commands Help Commands in Terminal ModeTerminal Operating Modes ESC ID Command CR Command SyntaxTeledyne’s Serial I/O Command Types Command Command Type Dddhhmm Id Messagecrlf Status Reporting RS-232PASS=NNNNNN Comm Port Password SecurityLogon Is the default password Location of JP2 on RS-232-Multidrop PCA Option Multidrop RS-232 SET UP Host Make Sure Jumper between JP2 pins 21  Is installedTapi Analyzer Last 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 Ethernet Status Indicators Remote Access VIA the EthernetEthernet Card COM2 Communication Modes and Baud Rate 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 Actions Modbus SetupMinimum Requirements Remote Access by Modem AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 Teledyne Analytical Instruments 174 Hessen Comm Port Configuration Using the GFC 7001E/EM with a Hessen Protocol NetworkGeneral Overview of Hessen Protocol RS-232 Communication Parameters for Hessen Protocol Activating Hessen Protocol Selecting a Hessen Protocol Type Mode ID Mode Description CMD Setting the Hessen Protocol Response ModeTeledyne’s Hessen Protocol Response Modes BCC Gas List Entry Format and Definitions Hessen Protocol GAS List Entries Editing or Adding Hessen Gas List Entries Deleting Hessen Gas List Entries Status Flag Name Default BIT Assignment Setting Hessen Protocol Status FlagsOperational FLAGS1 SPARE/UNUSED Bits Instrument ID Code To assign or reset the status flag bit assignments, press Apicom Remote Control Program Before Calibration Calibration ProceduresAutomatic ZERO/SPAN CAL/CHECK Autocal CO Calibration Quality Analysis 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 Automatic ZERO/SPAN CAL/CHECK Autocal Mode Name ActionUse of Zero/Span Valve with Remote Contact Closure Autocal Modes Attribute Action AutoCal Attribute Setup Parameters Example AutoCal Sequence 14150030 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 Calibration Data Quality Evaluation CO Calibration QualityFunction Minimum Value Optimum Value Maximum Value Dark Calibration Test Calibration of the GFC 7001E/EM’S Electronic Subsystems Pressure Calibration Flow Calibration Electrical Test Calibration Calibration of Optional Sensors 1. O2 Sensor Calibration Procedure1.1. O2 Calibration Setup Set O2 Span Gas Concentration Activate O2 Sensor Stability Function Teledyne Analytical Instruments 212 Set CO2 Span Gas Concentration 2. CO2 Sensor Calibration Procedure2.1. CO2 Calibration Setup Activate CO2 Sensor Stability Function 2.4. CO2 Zero/Span Calibration Teledyne Analytical Instruments 216 Calibration of Equipment General Guidelines EPA Calibration ProtocolCalibration Requirements Spare Parts and Expendable Supplies Calibration EQUIPMENT, SUPPLIES, and ExpendablesData Recording Device Matrix for Calibration Equipment & Supplies Recommended Standards for Establishing Traceability Activity Matrix for Quality Assurance Checks Calibration FrequencyLevel 1 Calibrations Versus Level 2 Checks Level 2 Zero and Span Check Zero and Span ChecksLevel 1 Zero and Span Calibration Precision Check ZERO/SPAN Check ProceduresPrecisions Calibration Precision Calibration Procedures Auditing ProcedureCalibration Audit Data Reduction Audit Linearity Test Dynamic Multipoint Calibration ProcedureSystem AUDIT/VALIDATION Teledyne Analytical Instruments 225 References Part Technical Information Teledyne Analytical Instruments 228 Measurement Fundamentals Theory of OperationMeasurement Method 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 Critical Flow Orifice Flow Rate ControlCritical Flow Orifice Area High LOW Pressure Spring Rings Filter Pneumatic Sensors Particulate FilterSample Pressure Sensor Sample Flow Sensor Overview Electronic Operation Mother PC 104 BusBoard Sync Demod Flash Chip Central Processing Unit CPUDISK-ON-MODULE DOM IR Source Temperature ControlOptical Bench & GFC Wheel Schmidt Triggers SensorSegment Sensor Overview Synchronous Demodulator SYNC/DEMOD AssemblyIR Photo-Detector GFC 7001E/EM Sync/Demod Block Diagram Signal Synchronization and DemodulationSync Demod Sample and Hold Circuits IR Beam Passing Through Dark Calibration Switch Photo-Detector Temperature ControlSync/Demod Status LED’s Sync/Demod Status LED Activity Relay Board Electric Test SwitchHeater Control GFC Wheel Motor Control Status LED’s LED Color Function Status When LIT Status When Unlit11.5.5.6. I2C Watch Dog Circuitry Relay Board Status LED’s To D Conversion MotherboardSensor Inputs Thermistor Interface External Digital I/O Analog OutputsInternal Digital I/O Power UP Circuit Power SUPPLY/ Circuit Breaker Teledyne Analytical Instruments 250 Mother Communication InterfaceKeyboard Relay Board Analyzer Status LED’s Front Panel InterfaceKeyboard Front Panel Status LED’s Keyboard/Display Interface Electronics DisplayKeypad Decoder Front Panel KEY-DEPRESS-DETECT Circuit Keypad Decoder I2C Interface Chip Display Power Watch DOGDisplay Data Decoder Display Controller Adaptive Filter Software Operation Calibration Slope and Offset Temperature and Pressure CompensationMeasurement Algorithm Internal Data Acquisition System Idas Teledyne Analytical Instruments 258 Qualified Personnel Maintenance Schedule & ProceduresMaintenance Schedule Teledyne Analytical Instruments 260 Action GFC 7001E/EM Maintenance Schedule CO Meas Date Recorded Function Operating Mode StabilityMR Ratio Pres Predictive uses for Test Functions Predicting Failures Using the Test FunctionsFunction Condition Behavior Interpretation Rebuilding the Sample Pump Maintenance ProceduresReplacing the Sample Particulate Filter Pressure Leak Check Performing Leak ChecksVacuum Leak Check and Pump Check Performing a Sample Flow Check Cleaning the Optical BenchCleaning Exterior Surfaces of the GFC 7001E/EM Suspect a Leak First Troubleshooting & RepairGeneral Troubleshooting Viewing and Clearing Warning Messages Fault Diagnosis with Warning Messages Config Fault Condition Possible Causes MessageCannot DYN Initialized Fault Diagnosis with Test Functions Test Functions Indicated Failures Pres Sample FL Samp Temp Bench Wheel BOX TempTest Functions Time Range Stabil CO Meas CO REF PHT Drive Slope Offset Diag  Signal I/O Using the Diagnostic Signal I/O Function CPU Status LED CPU Status IndicatorInternal Electronic Status LED’S Sync/Demod Board Status Failure Indications LED Function Fault Status Indicated FailuresSync Demodulator Status LED’s I2C Status LED Failure Indications Relay PCARelay Board Status LED’s 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 Flow is Zero Typical Sample GAS Flow ProblemsLow Flow High Flow Miscalibrated Calibration ProblemsDisplayed Flow = Warnings Actual Flow Does Not Match Displayed Flow Inability to Zero no Zero KEY NON-REPEATABLE Zero and SpanInability to Span no Span KEY Temperature Problems Other Performance ProblemsBox or Sample Temperature Bench Temperature IR Photo-Detector TEC Temperature GFC Wheel Temperature Excessive Noise DC Power Supply AC Mains ConfigurationDC Power Test Point and Wiring Color Codes Name Test POINT# TP and Wire Color KEYBOARD/DISPLAY Interface DC Power Supply Acceptable Levels Socket Relay Board Control DevicesFunction Control Device Electrical Test Sensor AssemblySync/Demodulator Assembly GFC Wheel Drive Opto Pickup AssemblyOpto Pickup Board Nominal Output Frequencies TP2 TP4 Pressure/Flow Sensor Assembly Test Channel / Analog Outputs Voltage 13.5.7.1. A/D FunctionsFull Scale Output of Voltage Range Step Nominal Output Voltage Output Range Nominal Output Values Step Current Analog Outputs Current Loop PIN Left to Right Status Status Outputs12 Status Outputs Check Control Inputs Remote Zero, Span General RS-232 TroubleshootingRS-232 Communications 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 HOW Static Charges are Created Primer on ELECTRO-STATIC DischargeStatic Generation Voltages for Typical Activities Means of Generation Sensitivity of Electronic Devices to Damage by ESD HOW ELECTRO-STATIC Charges Cause DamageDamage Susceptibility Voltage Device Range General Rules Common Myths about ESD DamageBasic Principles of Static Control 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 Rear Board not DET, 49, 88, 182 Pressure Span InletRelay Board WARN, 49, 88, 269 relay PCA Calibration Source WARNING, 49, 88 Span2 Inlet, 32 Specifications, 25Interactive Mode Vent Outlet Teledyne Analytical Instruments 320 Teledyne Analytical Instruments 321