Model GFC 7001E Family Carbon Monoxide Analyzers
Teledyne Electronic Technologies
Model GFC7001E Carbon Dioxide Analyzer
Safety Messages
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Coverage
Warranty
Warranty Policy 02024D
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
229
217
227
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
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Part General Information
Teledyne Analytical Instruments
Introduction
GFC 7001E Family Overview
Additional Documentation
Using this Manual
Table of Contents
Advanced Features of the GFC 7001E/EM Analyzer
Maintenance Schedule and Procedures
Basic Operation of the GFC 7001E/EM Analyzer
GFC 7001E/EM Validation and Verification
M 300E/300EM Basic Unit Specifications
Specifications and Approvals
Specifications
EPA Equivalency Designation
Safety Compliance
TUV Designation
CE Mark Compliance
Emissions Compliance
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Getting Started
GFC 7001E/EM Analyzer Layout
Sample
Exhaust
Rear 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 Hazard
Unpacking the GFC 7001E/EM Analyzer
Area Minimum Required Clearance
Ventilation Clearance
Ventilation Clearance
Power Connection
Electrical Connections
Connecting the Status Outputs
Analog Output Connector
PIN Analog Output Voltage Signal Current Signal
Analog Output Connections
Condition
Status Output Signals
Rear Panel Status Label Definition
Connecting the Control Inputs
Control Input Connector Control Input Signals
Connecting the Serial Ports
Connecting to a LAN or the Internet
Connecting to a Multidrop Network
Pneumatic Connections
Span Gas
NIST-SRM Type Nominal Concentration
Pneumatic Connections to GFC 7001E/EM Basic Configuration
Sample Gas Source
Calibration Gas Sources
Exhaust Outlet
Initial Operation
Input Gas Venting
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
3. O2 Sensor Calibration Procedure
4. CO2 Sensor Calibration Procedure
GFC 7001E/EM Analyzer is now ready for operation
Thank YOU
Frequently Asked Questions
FAQ’S
Glossary
Term Description/Definition
Data Acquisition System
As Teflon
Optional Hardware and Software
Rack Mount Kits OPT 20 to OPT
Model GFC7001E Carbon Dioxide Analyzer
Option Description Number
Carrying STRAP/HANDLE OPT
Current Loop Analog Outputs Option
Current Loop Option Installed on the Motherboard
Expendables and Spares Kits Options 42A
Calibration Valves Options 50A, 50B, 50E, 50H
General Information Related to ALL Valve Options
ZERO/SPAN Valve Option 50A
Mode Valve Condition Sample
Internal Pneumatics OPT 50A
Zero/Span Valve Operating States for Option
Zero CAL
Pneumatic Set Up OPT 50A
Sample GAS Source
Calibration GAS Sources
Span GAS
Zero/Span Valve Operating States for Option 50B
ZERO/SPAN/SHUTOFF Valve Option 50B
Internal Pneumatics OPT 50B
Pneumatic Set Up OPT 50B
Calibration GAS Sources Span GAS
Input GAS Venting
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
Communication Options
60A
60B
60C
Ethernet Option 63A
12 GFC 7001E/EM Ethernet Card
Second GAS Sensors
Ethernet + Multidrop OPT 63C
Oxygen Sensor Option 65A
Theory of Operation Paramagnetic measurement of O2
Operation within the GFC 7001E/EM Analyzer
Pneumatic Operation of the O2 Sensor
1. CO2 Sensor Ranges and Specifications
Carbon Dioxide Sensor Option 67A
Theory of Operation
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
Special Features
Maintenance Mode Switch
Second Language Switch
Dilution Ratio Option
Part Operating Instructions
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Analyzer Operating Modes
Basic Operation
Overview of 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 Level Menu Access Allowed
Setup Pass Password Feature
Password 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
Setup Rnge Analog Output Reporting Range Configuration
Physical Range Versus Analog Output Reporting Ranges
GFC 7001E Family Physical range by Model
Model Range
Analog Output Connector Pin Out
Analog Output Ranges for CO Concentration
Range Range1 Low Range Range2 High Range
Reporting Range Modes
Sngl Dual Auto
This is the default reporting range mode for the analyzer
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Setup RNGE DIL Using the Optional Dilution Ratio Feature
Advanced Features
Setup Idas Using the Data Acquisition System Idas
Front Panel LED Status Indicators for iDAS
Idas Status
IDAS Data Channel Properties
Idas Structure
IDAS Channels
Default Idas Channels
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Setup DAS EDIT Accessing the Idas Edit Mode
Conc ATIMER, 1
Name Conc Trigger Event Atimer
Channel No
Editing iDAS Data Channel Names
Editing iDAS Triggering Events
Editing iDAS Parameters
IDAS Data Parameter Functions
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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 Feature
Starting Date Feature
Remote Idas Configuration
IDAS Configuration Using Apicom
IDAS Configuration Using Terminal Emulation Programs
IDAS Configuration Through a Terminal Emulation Program
OFF
Setup More Vars Internal Variables Vars
Allowed Vars Variable Description Default Values
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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
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Analog Output Voltage / Current Range Selection
Analog Output Voltage Range Min/Max
Range Name Range Span Minimum Output Maximum Output
Curr
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Calibration of the Analog Outputs
Automatic Calibration of the Analog Outputs
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Individual Calibration of the Analog Outputs
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Manual Adjustment of Current Loop Output Span and Offset
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Voltage across Resistor for 2-20 mA Resistor for 4-20 mA
MVDC
100 MVDC
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
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AIN Calibration
11 CO Concentration Alarm Default Settings
Setup MORE Alrm Using the GAS Concentration Alarms
Setting the GFC 7001E Concentration Alarm Limits
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Setup MORE Comm Using the ANALYSER’S Communication Ports
Comm Port Default Settings
Remote Operation
RS-232 DTE and DCE Communication
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Comm Port Baud Rate
Comm Port Communication Modes
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Comm Port Testing
Machine ID
Help Commands in Terminal Mode
Terminal Mode Software Commands
Terminal Operating Modes
ESC
Command Syntax
ID Command CR
Teledyne’s Serial I/O Command Types
Command Command Type
Status Reporting
Dddhhmm Id Messagecrlf
RS-232PASS=NNNNNN
Comm Port Password Security
Logon Is the default password
Multidrop RS-232 SET UP
Location of JP2 on RS-232-Multidrop PCA Option
Make Sure Jumper between JP2 pins 21 Is installed
Host
Tapi Analyzer
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
Remote Access VIA the Ethernet
Ethernet Status Indicators
Ethernet Card COM2 Communication Modes and Baud Rate
LED Function
Configuring the Ethernet Interface Option Using Dhcp
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Manually Configuring the Network IP Addresses
ON/OFF
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Changing the ANALYZER’S Hostname
Actions
Modbus Setup
Minimum Requirements
Remote Access by Modem
AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0
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Using the GFC 7001E/EM with a Hessen Protocol Network
Hessen Comm Port Configuration
General Overview of Hessen Protocol
RS-232 Communication Parameters for Hessen Protocol
Activating Hessen Protocol
Selecting a Hessen Protocol Type
Setting the Hessen Protocol Response Mode
Mode ID Mode Description CMD
Teledyne’s Hessen Protocol Response Modes
BCC
Hessen Protocol GAS List Entries
Gas List Entry Format and Definitions
Editing or Adding Hessen Gas List Entries
Deleting Hessen Gas List Entries
Setting Hessen Protocol Status Flags
Status Flag Name Default BIT Assignment
Operational FLAGS1
SPARE/UNUSED Bits
To assign or reset the status flag bit assignments, press
Instrument ID Code
Apicom Remote Control Program
Calibration Procedures
Before Calibration
Automatic ZERO/SPAN CAL/CHECK Autocal
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
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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
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Manual Calibration Checks with Valve Options Installed
Manual Calibration Using Valve Options
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Mode Name Action
Automatic ZERO/SPAN CAL/CHECK Autocal
Use of Zero/Span Valve with Remote Contact Closure
Autocal Modes
AutoCal Attribute Setup Parameters
Attribute Action
Example AutoCal Sequence
1415
0030
Setup Acal Programming and Auto CAL Sequence
To program the example sequence shown in -4, press
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AutoCal with Auto or Dual Reporting Ranges Modes Selected
DURATION30.0 Minutes
CO Calibration Quality
Calibration Data Quality Evaluation
Function Minimum Value Optimum Value
Maximum Value
Calibration of the GFC 7001E/EM’S Electronic Subsystems
Dark Calibration Test
Pressure Calibration
Flow Calibration
Electrical Test Calibration
Calibration of Optional Sensors
1. O2 Sensor Calibration Procedure
1.1. O2 Calibration Setup
Set O2 Span Gas Concentration
Activate O2 Sensor Stability Function
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Set CO2 Span Gas Concentration
2. CO2 Sensor Calibration Procedure
2.1. CO2 Calibration Setup
Activate CO2 Sensor Stability Function
2.4. CO2 Zero/Span Calibration
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Calibration of Equipment General Guidelines
EPA Calibration Protocol
Calibration Requirements
Spare Parts and Expendable Supplies
Calibration EQUIPMENT, SUPPLIES, and Expendables
Data Recording Device
Recommended Standards for Establishing Traceability
Matrix for Calibration Equipment & Supplies
Activity Matrix for Quality Assurance Checks
Calibration Frequency
Level 1 Calibrations Versus Level 2 Checks
Level 2 Zero and Span Check
Zero and Span Checks
Level 1 Zero and Span Calibration
Precision Check
ZERO/SPAN Check Procedures
Precisions Calibration
Auditing Procedure
Precision Calibration Procedures
Calibration Audit
Data Reduction Audit
Linearity Test
Dynamic Multipoint Calibration Procedure
System AUDIT/VALIDATION
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References
Part Technical Information
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Measurement Fundamentals
Theory of Operation
Measurement Method
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
Flow Rate Control
Critical Flow Orifice
Critical Flow Orifice Area High LOW Pressure
Spring Rings Filter
Particulate Filter
Pneumatic Sensors
Sample Pressure Sensor
Sample Flow Sensor
Electronic Operation
Overview
PC 104 Bus
Mother
Board
Sync Demod
Flash Chip
Central Processing Unit CPU
DISK-ON-MODULE DOM
IR Source
Temperature Control
Optical Bench & GFC Wheel
Schmidt Triggers
Sensor
Segment Sensor
Overview
Synchronous Demodulator SYNC/DEMOD Assembly
IR Photo-Detector
Signal Synchronization and Demodulation
GFC 7001E/EM Sync/Demod Block Diagram
Sync Demod Sample and Hold Circuits
IR Beam Passing Through
Photo-Detector Temperature Control
Dark Calibration Switch
Sync/Demod Status LED’s
Sync/Demod Status LED Activity
Electric Test Switch
Relay Board
Heater Control
GFC Wheel Motor Control
LED Color Function Status When LIT Status When Unlit
Status LED’s
11.5.5.6. I2C Watch Dog Circuitry
Relay Board Status LED’s
Motherboard
To D Conversion
Sensor Inputs
Thermistor Interface
External Digital I/O
Analog Outputs
Internal Digital I/O
Power SUPPLY/ Circuit Breaker
Power UP Circuit
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Communication Interface
Mother
Keyboard
Relay Board
Front Panel Interface
Analyzer Status LED’s
Keyboard
Front Panel Status LED’s
Display
Keyboard/Display Interface Electronics
Keypad Decoder
Front Panel
Keypad Decoder
KEY-DEPRESS-DETECT Circuit
Display Power Watch DOG
I2C Interface Chip
Display Data Decoder
Display Controller
Software Operation
Adaptive Filter
Temperature and Pressure Compensation
Calibration Slope and Offset
Measurement Algorithm
Internal Data Acquisition System Idas
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Qualified Personnel
Maintenance Schedule & Procedures
Maintenance Schedule
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GFC 7001E/EM Maintenance Schedule
Action
Date Recorded Function Operating Mode Stability
CO Meas
MR Ratio
Pres
Predicting Failures Using the Test Functions
Predictive uses for Test Functions
Function Condition Behavior
Interpretation
Rebuilding the Sample Pump
Maintenance Procedures
Replacing the Sample Particulate Filter
Pressure Leak Check
Performing Leak Checks
Vacuum Leak Check and Pump Check
Performing a Sample Flow Check
Cleaning the Optical Bench
Cleaning Exterior Surfaces of the GFC 7001E/EM
Suspect a Leak First
Troubleshooting & Repair
General Troubleshooting
Fault Diagnosis with Warning Messages
Viewing and Clearing Warning Messages
Fault Condition Possible Causes Message
Config
Cannot DYN
Initialized
Fault Diagnosis with Test Functions
Pres Sample FL Samp Temp Bench Wheel BOX Temp
Test Functions Indicated Failures
Test 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 Indicator
Internal Electronic Status LED’S
Sync/Demod Board Status Failure Indications
LED Function Fault Status Indicated Failures
Sync Demodulator Status LED’s
I2C Status LED Failure Indications
Relay PCA
Relay Board Status LED’s
Relay Board Status LED Failure Indications
GAS Flow Problems
GFC 7001E/EM Internal GAS Flow Diagrams
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Troubleshooting & Repair
Typical Sample GAS Flow Problems
Flow is Zero
Low Flow
High Flow
Calibration Problems
Miscalibrated
Displayed Flow = Warnings
Actual Flow Does Not Match Displayed Flow
Inability to Zero no Zero KEY
NON-REPEATABLE Zero and Span
Inability to Span no Span KEY
Other Performance Problems
Temperature Problems
Box or Sample Temperature
Bench Temperature
GFC Wheel Temperature
IR Photo-Detector TEC Temperature
Excessive Noise
AC Mains Configuration
DC Power Supply
DC Power Test Point and Wiring Color Codes
Name Test POINT# TP and Wire Color
DC Power Supply Acceptable Levels
KEYBOARD/DISPLAY Interface
Socket
Relay Board Control Devices
Function Control Device
Electrical Test
Sensor Assembly
Sync/Demodulator Assembly
Opto Pickup Assembly
GFC Wheel Drive
Opto Pickup Board Nominal Output Frequencies
TP2 TP4
Pressure/Flow Sensor Assembly
13.5.7.1. A/D Functions
Test Channel / Analog Outputs Voltage
Full Scale Output of Voltage Range
Step Nominal Output Voltage
Analog Outputs Current Loop
Output Range Nominal Output Values Step Current
PIN Left to Right Status
Status Outputs
12 Status Outputs Check
Control Inputs Remote Zero, Span
General RS-232 Troubleshooting
RS-232 Communications
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
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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
Primer on ELECTRO-STATIC Discharge
HOW Static Charges are Created
Static Generation Voltages for Typical Activities
Means of Generation
HOW ELECTRO-STATIC Charges Cause Damage
Sensitivity of Electronic Devices to Damage by ESD
Damage Susceptibility Voltage
Device Range
General Rules
Common Myths about ESD Damage
Basic Principles of Static Control
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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
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Bench Temp WARNING, 49, 88, 182, 269 Bench Temperature
Analog CAL WARNING, 49, 88 Analog Inputs
Index
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Internal Span Gas Generator
Pnuntc
Pressure Span Inlet
Rear Board not DET, 49, 88, 182
Relay Board WARN, 49, 88, 269 relay PCA
Calibration
Source WARNING, 49, 88
Span2 Inlet, 32 Specifications, 25
Interactive Mode
Vent Outlet
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