Subsystem Checkout, AC Mains Configuration | Teledyne GFC 7001EM

Troubleshooting & Repair

Model GFC7001E Carbon Dioxide Analyzer

13.5.SUBSYSTEM CHECKOUT

The preceding of this manual discussed a variety of methods for identifying possible sources of failures or performance problems within the analyzer. In most cases this included a list of possible causes. This describes how to determine individually determine if a certain component or subsystem is actually the cause of the problem being investigated.

13.5.1.AC MAINS CONFIGURATION

The analyzer is correctly configured for the AC mains voltage in use if:

1.The Sample Pump is running.

2.The GFC Wheel motor is spinning. LED’s D1 & D2 (located on the sync/demod PCA) should be flashing.

3.If incorrect power is suspected, check that the correct voltage and frequency is present at the line input on the rear panel.

If the unit is set for 230 VAC and is plugged into 115VAC, or 100VAC the sample pump will not start, and the heaters will not come up to temperature.

If the unit is set for 115 or 100 VAC and is plugged into a 230 VAC circuit, the circuit breaker built into the ON/OFF Switch on the Front Panel will trip to the OFF position immediately after power is switched on.

13.5.2.DC POWER SUPPLY

If you have determined that the analyzer’s AC mains power is working, but the unit is still not operating properly, there may be a problem with one of the instrument’s switching power supplies. The supplies can have two faults, namely no DC output, and noisy output.

To assist tracing DC Power Supply problems, the wiring used to connect the various printed circuit assemblies and DC Powered components and the associated test points on the relay board follow a standard color-coding scheme as defined in the following table.

Table 13-6:	DC Power Test Point and Wiring Color Codes

NAME		TEST POINT#	TP AND WIRE COLOR
Dgnd		1	Black
+5V		2	Red

Agnd		3	Green

+15V		4	Blue
-15V		5	Yellow
+12R		6	Purple
+12V		7	Orange

Teledyne Analytical Instruments

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Image 288

Teledyne GFC 7001EM Subsystem Checkout, AC Mains Configuration, DC Power Supply, Name Test POINT# TP and Wire Color

Contents

Model GFC 7001E Family Carbon Monoxide Analyzers Teledyne Electronic Technologies Model GFC7001E Carbon Dioxide Analyzer Safety Messages This page intentionally left blank Warranty Warranty Policy 02024DCoverage 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 185 217 227229 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 Advanced Features of the GFC 7001E/EM Analyzer Maintenance Schedule and ProceduresBasic Operation of the GFC 7001E/EM Analyzer GFC 7001E/EM Validation and Verification Specifications and Approvals SpecificationsM 300E/300EM Basic Unit Specifications EPA Equivalency Designation Safety Compliance TUV DesignationCE Mark Compliance Emissions Compliance This page intentionally left blank Getting Started GFC 7001E/EM Analyzer Layout Sample ExhaustRear Panel Label Function IZS Internal Layout GFC 7001E Internal Layout GFC 7001EM with CO2 and O2 Sensor Option Optical Bench Layout General Safety Hazard Unpacking the GFC 7001E/EM AnalyzerElectrical Shock Hazard Ventilation Clearance Ventilation ClearanceArea Minimum Required Clearance Power Connection Electrical Connections Connecting the Status Outputs Analog Output ConnectorPIN Analog Output Voltage Signal Current Signal Analog Output Connections Status Output Signals Rear Panel Status Label DefinitionCondition Connecting the Control Inputs Control Input Connector Control Input Signals Connecting the Serial Ports Connecting to a LAN or the InternetConnecting 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 Initial Operation Input Gas VentingExhaust 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 3. O2 Sensor Calibration Procedure 4. CO2 Sensor Calibration ProcedureGFC 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 OPTModel 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, 50HGeneral Information Related to ALL Valve Options ZERO/SPAN Valve Option 50A Mode Valve Condition Sample Internal Pneumatics OPT 50AZero/Span Valve Operating States for Option Zero CAL Pneumatic Set Up OPT 50A Sample GAS SourceCalibration GAS Sources Span GAS ZERO/SPAN/SHUTOFF Valve Option 50B Internal Pneumatics OPT 50BZero/Span Valve Operating States for Option 50B Pneumatic Set Up OPT 50B Calibration GAS Sources Span GASInput 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 60A60B 60C Ethernet Option 63A 12 GFC 7001E/EM Ethernet Card Second GAS Sensors Ethernet + Multidrop OPT 63COxygen 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 67ATheory 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 SwitchSecond Language Switch Dilution Ratio Option Part Operating Instructions This page intentionally left blank Basic Operation Overview of Operating ModesAnalyzer 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 Setup  Pass Password Feature Password LevelsPassword 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 Setup  Rnge Analog Output Reporting Range Configuration Physical Range Versus Analog Output Reporting RangesGFC 7001E Family Physical range by Model Model Range Analog Output Connector Pin Out Analog Output Ranges for CO Concentration Reporting Range Modes Sngl Dual AutoRange  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 Advanced Features Setup  Idas Using the Data Acquisition System IdasFront Panel LED Status Indicators for iDAS Idas Status Idas Structure IDAS ChannelsIDAS Data Channel Properties Default Idas Channels Teledyne Analytical Instruments 110 Teledyne Analytical Instruments 111 Setup DAS EDIT Accessing the Idas Edit Mode Conc ATIMER, 1Name Conc Trigger Event Atimer 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 Compact Report Feature Starting Date FeatureDISABLING/ENABLING Data Channels Remote Idas Configuration IDAS Configuration Using Apicom IDAS Configuration Using Terminal Emulation Programs IDAS Configuration Through a Terminal Emulation Program Setup  More  Vars Internal Variables Vars Allowed Vars Variable Description Default ValuesOFF 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 Analog Output Voltage / Current Range Selection Analog Output Voltage Range Min/MaxRange 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 Voltage across Resistor for 2-20 mA Resistor for 4-20 mA MVDC100 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 Teledyne Analytical Instruments 145 AIN Calibration Setup MORE  Alrm Using the GAS Concentration Alarms Setting the GFC 7001E Concentration Alarm Limits11 CO Concentration Alarm Default Settings Teledyne Analytical Instruments 148 Setup  MORE Comm Using the ANALYSER’S Communication Ports Comm Port Default SettingsRemote 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 Help Commands in Terminal Mode Terminal Mode Software CommandsTerminal Operating Modes ESC Command Syntax ID Command CRTeledyne’s Serial I/O Command Types Command Command Type Status Reporting Dddhhmm Id Messagecrlf Comm Port Password Security Logon Is the default passwordRS-232PASS=NNNNNN Multidrop RS-232 SET UP Location of JP2 on RS-232-Multidrop PCA Option Make Sure Jumper between JP2 pins 21  Is installed HostTapi 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 IndicatorsEthernet 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 Modbus Setup Minimum RequirementsActions Remote Access by Modem AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 Teledyne Analytical Instruments 174 Using the GFC 7001E/EM with a Hessen Protocol Network Hessen Comm Port ConfigurationGeneral 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 CMDTeledyne’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 AssignmentOperational FLAGS1 SPARE/UNUSED Bits To assign or reset the status flag bit assignments, press Instrument ID Code Apicom Remote Control Program Calibration Procedures Before CalibrationAutomatic 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 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 Mode Name Action Automatic ZERO/SPAN CAL/CHECK AutocalUse of Zero/Span Valve with Remote Contact Closure Autocal Modes AutoCal Attribute Setup Parameters Attribute Action 1415 0030Example 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 CO Calibration Quality Calibration Data Quality EvaluationFunction 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 1. O2 Sensor Calibration Procedure 1.1. O2 Calibration SetupCalibration of Optional Sensors Set O2 Span Gas Concentration Activate O2 Sensor Stability Function Teledyne Analytical Instruments 212 2. CO2 Sensor Calibration Procedure 2.1. CO2 Calibration SetupSet CO2 Span Gas Concentration Activate CO2 Sensor Stability Function 2.4. CO2 Zero/Span Calibration Teledyne Analytical Instruments 216 EPA Calibration Protocol Calibration RequirementsCalibration of Equipment General Guidelines Calibration EQUIPMENT, SUPPLIES, and Expendables Data Recording DeviceSpare Parts and Expendable Supplies Recommended Standards for Establishing Traceability Matrix for Calibration Equipment & Supplies Calibration Frequency Level 1 Calibrations Versus Level 2 ChecksActivity Matrix for Quality Assurance Checks Zero and Span Checks Level 1 Zero and Span CalibrationLevel 2 Zero and Span Check ZERO/SPAN Check Procedures Precisions CalibrationPrecision Check Auditing Procedure Precision Calibration ProceduresCalibration Audit Data Reduction Audit Dynamic Multipoint Calibration Procedure System AUDIT/VALIDATIONLinearity Test Teledyne Analytical Instruments 225 References Part Technical Information Teledyne Analytical Instruments 228 Theory of Operation Measurement MethodMeasurement 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 Flow Rate Control Critical Flow OrificeCritical Flow Orifice Area High LOW Pressure Spring Rings Filter Particulate Filter Pneumatic SensorsSample Pressure Sensor Sample Flow Sensor Electronic Operation Overview PC 104 Bus MotherBoard Sync Demod Central Processing Unit CPU DISK-ON-MODULE DOMFlash Chip Temperature Control Optical Bench & GFC WheelIR Source Sensor Segment SensorSchmidt Triggers Synchronous Demodulator SYNC/DEMOD Assembly IR Photo-DetectorOverview Signal Synchronization and Demodulation GFC 7001E/EM Sync/Demod Block DiagramSync Demod Sample and Hold Circuits IR Beam Passing Through Photo-Detector Temperature Control Dark Calibration SwitchSync/Demod Status LED’s Sync/Demod Status LED Activity Electric Test Switch Relay BoardHeater Control GFC Wheel Motor Control LED Color Function Status When LIT Status When Unlit Status LED’s11.5.5.6. I2C Watch Dog Circuitry Relay Board Status LED’s Motherboard To D ConversionSensor Inputs Thermistor Interface Analog Outputs Internal Digital I/OExternal Digital I/O Power SUPPLY/ Circuit Breaker Power UP Circuit Teledyne Analytical Instruments 250 Communication Interface MotherKeyboard Relay Board Front Panel Interface Analyzer Status LED’sKeyboard Front Panel Status LED’s Display Keyboard/Display Interface ElectronicsKeypad Decoder Front Panel Keypad Decoder KEY-DEPRESS-DETECT Circuit Display Power Watch DOG I2C Interface ChipDisplay Data Decoder Display Controller Software Operation Adaptive Filter Temperature and Pressure Compensation Calibration Slope and OffsetMeasurement Algorithm Internal Data Acquisition System Idas Teledyne Analytical Instruments 258 Maintenance Schedule & Procedures Maintenance ScheduleQualified Personnel Teledyne Analytical Instruments 260 GFC 7001E/EM Maintenance Schedule Action Date Recorded Function Operating Mode Stability CO MeasMR Ratio Pres Predicting Failures Using the Test Functions Predictive uses for Test FunctionsFunction Condition Behavior Interpretation Maintenance Procedures Replacing the Sample Particulate FilterRebuilding the Sample Pump Performing Leak Checks Vacuum Leak Check and Pump CheckPressure Leak Check Cleaning the Optical Bench Cleaning Exterior Surfaces of the GFC 7001E/EMPerforming a Sample Flow Check Troubleshooting & Repair General TroubleshootingSuspect a Leak First Fault Diagnosis with Warning Messages Viewing and Clearing Warning Messages Fault Condition Possible Causes Message ConfigCannot DYN Initialized Fault Diagnosis with Test Functions Pres Sample FL Samp Temp Bench Wheel BOX Temp Test Functions Indicated FailuresTest 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 Indicator Internal Electronic Status LED’SCPU Status LED LED Function Fault Status Indicated Failures Sync Demodulator Status LED’sSync/Demod Board Status Failure Indications Relay PCA Relay Board Status LED’sI2C 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 Typical Sample GAS Flow Problems Flow is ZeroLow Flow High Flow Calibration Problems MiscalibratedDisplayed Flow = Warnings Actual Flow Does Not Match Displayed Flow NON-REPEATABLE Zero and Span Inability to Span no Span KEYInability to Zero no Zero KEY Other Performance Problems Temperature ProblemsBox or Sample Temperature Bench Temperature GFC Wheel Temperature IR Photo-Detector TEC Temperature Excessive Noise AC Mains Configuration DC Power SupplyDC Power Test Point and Wiring Color Codes Name Test POINT# TP and Wire Color DC Power Supply Acceptable Levels KEYBOARD/DISPLAY Interface Relay Board Control Devices Function Control DeviceSocket Sensor Assembly Sync/Demodulator AssemblyElectrical Test Opto Pickup Assembly GFC Wheel DriveOpto Pickup Board Nominal Output Frequencies TP2 TP4 Pressure/Flow Sensor Assembly 13.5.7.1. A/D Functions Test Channel / Analog Outputs VoltageFull Scale Output of Voltage Range Step Nominal Output Voltage Analog Outputs Current Loop Output Range Nominal Output Values Step Current Status Outputs 12 Status Outputs CheckPIN Left to Right Status General RS-232 Troubleshooting RS-232 CommunicationsControl 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 Primer on ELECTRO-STATIC Discharge HOW Static Charges are CreatedStatic Generation Voltages for Typical Activities Means of Generation HOW ELECTRO-STATIC Charges Cause Damage Sensitivity of Electronic Devices to Damage by ESDDamage Susceptibility Voltage Device Range Common Myths about ESD Damage Basic Principles of Static ControlGeneral 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 Pressure Span Inlet Rear Board not DET, 49, 88, 182Relay Board WARN, 49, 88, 269 relay PCA Calibration Span2 Inlet, 32 Specifications, 25 Interactive ModeSource WARNING, 49, 88 Vent Outlet Teledyne Analytical Instruments 320 Teledyne Analytical Instruments 321