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Teledyne Analytical Instruments

Operation Manual

MODEL GFC 7001E FAMILY

CARBON MONOXIDE ANALYZERS

(Includes GFC 7001E, GFC 7001EM)

TELEDYNE ELECTRONIC TECHNOLOGIES

Analytical Instruments

16830 Chestnut Street

City of Industry, CA 91748

Telephone: (626) 934-1500

Fax: (626) 961-2538

Web: www.teledyne-ai.com

Summary of content (321 pages)

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Operation Manual MODEL GFC 7001E FAMILY CARBON MONOXIDE ANALYZERS (Includes GFC 7001E, GFC 7001EM) TELEDYNE ELECTRONIC TECHNOLOGIES Analytical Instruments 16830 Chestnut Street City of Industry, CA 91748 Telephone: (626) 934-1500 Fax: (626) 961-2538 Web: www.teledyne-ai.
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Safety Messages Model GFC7001E Carbon Dioxide Analyzer SAFETY MESSAGES Warning and cautionary messages are provided for the purpose of avoiding risk of personal injury or instrument damage. These important safety messages and associated safety alert symbols are found throughout this manual; the safety symbols are also located inside the instrument(s).
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Warranty Model GFC7001E Carbon Dioxide Analyzer WARRANTY WARRANTY POLICY (02024D) Prior to shipment, TAI equipment is thoroughly inspected and tested. Should equipment failure occur, TAI assures its customers that prompt service and support will be available. COVERAGE After the warranty period and throughout the equipment lifetime, TAI stands ready to provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the industry.
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Manual Information Model GFC7001E Carbon Dioxide Analyzer ABOUT THIS MANUAL This manual is comprised of multiple documents, in PDF format, as listed below. Part No. Rev Name/Description 04288 D GFC 7001E/EM Manual 04906 H Menu Tree and Software Documentation, L.
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer TABLE OF CONTENTS PART I – GENERAL INFORMATION .................................................................................... 21 1. INTRODUCTION ................................................................................................................ 23 1.1. GFC 7001E FAMILY Overview .....................................................................................................................23 1.2. Additional Documentation .....
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer 5.3. Carrying Strap/Handle (OPT 29) ...................................................................................................................62 5.4. Current Loop Analog Outputs (Option 41) ....................................................................................................62 5.4.1. Converting Current Loop Analog Outputs to Standard Voltage Outputs ...............................................63 5.5.
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer 6.6. SETUP  RNGE: Analog Output Reporting Range Configuration ..............................................................97 6.6.1. Physical Range versus Analog Output Reporting Ranges ....................................................................97 6.6.2. Analog Output Ranges for CO Concentration .......................................................................................98 6.6.3. Reporting Range Modes ..........................
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer 8.1.7. Terminal Operating Modes ..................................................................................................................156 8.1.7.1. Help Commands in Terminal Mode ..............................................................................................156 8.1.7.2. Command Syntax .........................................................................................................................157 8.1.7.3.
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer 9.7. Calibration of Optional Sensors ..................................................................................................................209 9.7.1. O2 Sensor Calibration Procedure.........................................................................................................209 9.7.1.1. O2 Calibration Setup .....................................................................................................................
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer 11.5.4.1. Overview .....................................................................................................................................242 11.5.4.2. Signal Synchronization and Demodulation ................................................................................243 11.5.4.3. Sync/Demod Status LED’s .........................................................................................................244 11.5.4.4.
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer 13.2.2. Typical Sample Gas Flow Problems ..................................................................................................282 13.2.2.1. Flow is Zero ................................................................................................................................282 13.2.2.2. Low Flow ....................................................................................................................................
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Table of Contents Model GFC7001E Carbon Dioxide Analyzer 14.4.2.1. Working at the Instrument Rack .................................................................................................309 14.4.2.2. Working at an Anti-ESD Work Bench .........................................................................................309 14.4.2.3. Transferring Components from Rack to Bench and Back ..........................................................310 14.4.2.4.
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Table of Contents Figure 5-12: Figure 5-13: Figure 5-14: Figure 5-15: Figure 5-16: Figure 5-17: Figure 5-18: Figure 5-19: Figure 6-1: Figure 6-2: Figure 6-3: Figure 6-4: Figure 7-1: Figure 7-2: Figure 7-3: Figure 7-4: Figure 7-5: Figure 7-6: Figure 7-7: Figure 8-1: Figure 8-2: Figure 8-3: Figure 8-4: Figure 8-5: Figure 8-6: Figure 8-7: Figure 8-8: Figure 9-1: Figure 9-2: Figure 9-3: Figure 9-4: Figure 9-5: Figure 9-6: Figure 9-7: Figure 9-8: Figure 11-1: Figure 11-2: Figure 11-3: Figure 11-4: Figure 11-5: F
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Table of Contents Figure 13-4: Figure 13-5: Figure 13-6: Figure 13-7: Figure 13-8: Figure 13-9: Figure 13-10: Figure 13-11: Figure 13-12: Figure 13-13: Figure 13-14: Figure 13-15: Figure 13-16: Figure 13-17: Figure 13-18: Figure 13-19: Figure 13-20: Figure 14-1: Figure 14-2: Model GFC7001E Carbon Dioxide Analyzer Sync/Demod Board Status LED Locations ................................................................................275 Relay Board Status LEDs .................................................
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Table of Contents Table 7-4: Table 7-5: Table 7-6: Table 7-7: Table 7-8: Table 7-9: Table 7-10: Table 7-11: Table 8-1: Table 8-2: Table 8-3: Table 8-4: Table 8-5: Table 8-6: Table 8-7: Table 8-8: Table 9-1: Table 9-2: Table 9-3: Table 9-4: Table 9-5: Table 10-1: Table 10-2: Table 10-3: Table 11-1: Table 11-2: Table 11-3: Table 11-4: Table 11-5: Table 12-1: Table 12-2: Table 12-3: Table 13-1: Table 13-2: Table 13-3: Table 13-4: Table 13-5: Table 13-6: Table 13-7: Table 13-8: Table 13-9: Table 13-10: Table 13
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Part 1 General Information Model GFC7001E Carbon Dioxide Analyzer PART I – GENERAL INFORMATION Teledyne Analytical Instruments 21
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Introduction Model GFC7001E Carbon Dioxide Analyzer 1. INTRODUCTION 1.1. GFC 7001E FAMILY OVERVIEW The family includes the GFC 7001E and the GFC 7001EM Gas Filter Correlation (GFC) Carbon Monoxide Analyzer. The GFC 7001E family of analyzers is a microprocessor-controlled analyzer that determines the concentration of carbon monoxide (CO) in a sample gas drawn through the instrument.
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Introduction Model GFC7001E Carbon Dioxide Analyzer Several options can be purchased for the analyzer that allows the user to more easily supply and manipulate Zero Air and Span Gas. For more information of these options, see Section 5.6. 1.2. ADDITIONAL DOCUMENTATION Additional documentation for the GFC 7001E/EM CO Analyzer is available from Teledyne’s website at http://www.teledyne-ai.com/manuals/.  APICOM software manual, P/N 03945.  DAS Manual, P/N 02837.
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Introduction Model GFC7001E Carbon Dioxide Analyzer 1.2.1. USING THIS MANUAL NOTE This manual explains the operation and use of both the GFC 7001E and the GFC 7001EM Gas Filter Correlation Carbon Monoxide Analyzer. For the most part these two instruments are nearly identical in their features and functions. The examples and illustrations shown in this manual represent the GFC 7001E. Where a significant difference does exist between the different models, each version is shown.
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Introduction Model GFC7001E Carbon Dioxide Analyzer PART II – OPERATING INSTRUCTIONS BASIC OPERATION OF THE GFC 7001E/EM ANALYZER Step-by-Step instructions for using the display/keyboard to set up and operate the GFC 7001E/EM Analyzer. ADVANCED FEATURES OF THE GFC 7001E/EM ANALYZER Step-by-Step instructions for using the GFC 7001E/EM Analyzer’s more advanced features such as the iDAS system, the DIAG and VARS menus and the and the TEST channel analog output.
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Specifications Model GFC7001E Carbon Dioxide Analyzer 2. SPECIFICATIONS AND APPROVALS 2.1. SPECIFICATIONS Table 2-1: M 300E/300EM Basic Unit Specifications Ranges GFC 7001E: Min: 0-1 ppm; Max: 0-1000 ppm of Full Scale (User selectable) GFC 7001EM: Min: 0-5 ppm; Max: 0-5000 ppm of Full Scale (User selectable) Measurement Units GFC 7001E: ppb, ppm, µg/m3, mg/m3 (user selectable) GFC 7001EM: ppm, mg/m3 (user selectable) Zero Noise GFC 7001E: < 0.02 ppm RMS1; Span Noise GFC 7001E:<0.
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Specifications 1 As defined by the USEPA Model GFC7001E Carbon Dioxide Analyzer 2 At constant temperature and pressure 2.2. EPA EQUIVALENCY DESIGNATION Teledyne’s GFC 7001E Carbon Monoxide Analyzer is designated as Reference Method Number EQOA-0992087 as defined in 40 CFR Part 53, when operated under the following conditions:  Range: Any range from 10 ppm to 50 ppm.  Ambient temperature range of 10 to 40C.  Line voltage range of 90 – 127 and 200 – 230 VAC, 50/60 Hz.
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Specifications Model GFC7001E Carbon Dioxide Analyzer 2.3. TUV DESIGNATION On behalf of Teledyne TÜV Rheinland Immissionsschutz und Energiesysteme GmbH has performed the suitability test of the measuring system GFC 7001E for the component carbon monoxide.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3. GETTING STARTED 3.1. GFC 7001E/EM ANALYZER LAYOUT Figure 3-1: Front Panel Layout Table 3-1: Front Panel Nomenclature Name Significance Mode Field Displays the name of the analyzer’s current operating mode. Message Field Displays a variety of informational messages such as warning messages, operational data, test function values and response messages during interactive tasks.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer Figure 3-2: Rear Panel Layout Table 3-2: Inlet / Outlet Connector Nomenclature REAR PANEL LABEL FUNCTION Connect a gas line from the source of sample gas here. SAMPLE Calibration gases are also inlet here on units without zero/span/shutoff valve options installed. Connect an exhaust gas line of not more than 10 meters long here that leads outside EXHAUST the shelter or immediate area surrounding the instrument.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer Figure 3-3: Internal Layout – GFC 7001E Teledyne Analytical Instruments 33
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Getting Started Figure 3-4: Model GFC7001E Carbon Dioxide Analyzer Internal Layout – GFC 7001EM with CO2 and O2 Sensor Option Teledyne Analytical Instruments 34
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Getting Started Model GFC7001E Carbon Dioxide Analyzer Sample Gas Outlet fitting Sample Gas Flow Sensor Sample Chamber Sync/Demod PCA Housing Pressure Sensor(s) Bench Temperature Thermistor Shock Absorbing Mounting Bracket Opto-Pickup PCA Purge Gas Pressure Regulator IR Source GFC Wheel Heat Sync GFC Wheel Motor GFC Temperature Sensor Purge Gas Inlet GFC Heater Figure 3-5: Optical Bench Layout Teledyne Analytical Instruments 35
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Getting Started Model GFC7001E Carbon Dioxide Analyzer Figure 3-6: GFC 7001E/EM Internal Gas Flow (Basic Configuration) NOTE For pneumatic diagrams of GFC 7001E/EM Analyzer with various calibration valve options, see Section 5.6. 3.2. UNPACKING THE GFC 7001E/EM ANALYZER CAUTION GENERAL SAFETY HAZARD To avoid personal injury, always use two persons to lift and carry the GFC 7001E/EM. CAUTION ELECTRICAL SHOCK HAZARD Never disconnect PCAs, wiring harnesses or electronic subassemblies while under power.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer See A Primer on Electro-Static Discharge in this manual for more information on preventing ESD damage. NOTE It is recommended that you store shipping containers/materials for future use if/when the instrument should be returned to the factory for repair and/or calibration serivce. See Warranty section in this manual and shipping procedures on our Website at http://www.teledyne-api.com under Customer Support > Return Authorization. 1.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.3. ELECTRICAL CONNECTIONS NOTE To maintain compliance with EMC standards, it is required that the cable length be no greater than 3 meters for all I/O connections, which include Analog In, Analog Out, Status Out, Control In, Ethernet/LAN, USB, RS-232, and RS-485. 3.3.1.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.3.2. ANALOG OUTPUT CONNECTIONS The GFC 7001E is equipped with several analog output channels accessible through a connector on the back panel of the instrument. The standard configuration for these outputs is mVDC. An optional current loop output is available for each. When the instrument is in its default configuration, channels A1 and A2 output a signal that is proportional to the CO concentration of the sample gas.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer The status outputs are accessed via a 12-pin connector on the analyzer’s rear panel labeled STATUS (see Figure 3-2). Pin-outs for this connector are: Figure 3-8: 6 7 8 D + Optional O2 CAL 5 DIAG MODE 4 SPAN CAL 3 HIGH RANGE 2 CONC VALID SYSTEM OK 1 ZERO CAL STATUS Status Output Connector Table 3-5: Status Output Signals REAR PANEL LABEL 1 STATUS DEFINITION CONDITION SYSTEM OK ON if no faults are present.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.3.4. CONNECTING THE CONTROL INPUTS If you wish to use the analyzer to remotely activate the zero and span calibration modes, several digital control inputs are provided through a 10-pin connector labeled CONTROL IN on the analyzer’s rear panel. There are two methods for energizing the control inputs. The internal +5V available from the pin labeled “+” is the most convenient method.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.3.5. CONNECTING THE SERIAL PORTS If you wish to utilize either of the analyzer’s two serial interface COMM ports, refer to Section 8 for instructions on their configuration and usage. 3.3.6. CONNECTING TO A LAN OR THE INTERNET If your unit has a Teledyne’s Ethernet card, plug one end into the 7’ CAT5 cable supplied with the option into the appropriate place on the back of the analyzer and the other end into any nearby Ethernet access port.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.4.1.2. Span Gas Span gas is a gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired measurement range. In the case of CO measurements made with the GFC 7001E/EM Analyzer, it is recommended that you use a span gas with a CO concentration equal to 80-90% of the measurement range for your application.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.4.2. PNEUMATIC CONNECTIONS TO GFC 7001E/EM BASIC CONFIGURATION NOTE In order to prevent dust from getting into the gas flow channels of your analyzer, it was shipped with small plugs inserted into each of the pneumatic fittings on the back panel. Make sure that all of these dust plugs are removed before attaching exhaust and supply gas lines.
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Getting Started Figure 3-11: Model GFC7001E Carbon Dioxide Analyzer Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator 3.4.2.1. Sample Gas Source Attach a sample inlet line to the SAMPLE inlet port. The sample input line should not be more than 2 meters long.  Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure and ideally should equal ambient atmospheric pressure.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.4.2.3. Input Gas Venting The span gas, zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These vents should be:  At least 0.2m long;  No more than 2m long and;  Vented outside the shelter or immediate area surrounding the instrument. 3.4.2.4.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.5.1. STARTUP After the electrical and pneumatic connections are made, turn on the instrument. The pump and exhaust fan should start immediately. The display should immediately display a single, horizontal dash in the upper left corner of the display. This will last approximately 30 seconds while the CPU loads the operating system. Once the CPU has completed this activity it will begin loading the analyzer firmware and configuration data.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.5.2. WARM UP The GFC 7001E/EM requires about 60 minutes warm-up time before reliable CO measurements can be taken. During that time, various portions of the instrument’s front panel will behave as shown in Table 3-8. See Figure 3-1 for the layout. Table 3-8: NAME COLOR Front Panel Display during System Warm-Up BEHAVIOR SIGNIFICANCE Concentration Field N/A Displays current, compensated CO Concentration This is normal operation.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer Table 3-9: Possible Warning Messages at Start-Up Message ANALOG CAL WARNING The instrument's A/D circuitry or one of its analog outputs is not calibrated. BENCH TEMP WARNING Optical bench temperature is outside the specified limits. BOX TEMP WARNING The temperature inside the GFC 7001E/EM chassis is outside the specified limits. CANNOT DYN SPAN2 Remote span calibration failed while the dynamic span feature was set to turned on.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.5.4. FUNCTIONAL CHECK After the analyzer’s components have warmed up for at least 60 minutes, verify that the software properly supports any hardware options that were installed. For information on navigating through the analyzer’s software menus, see the menu trees described in Appendix A.1.  Check to make sure that the analyzer is functioning within allowable operating parameters.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.6. INITIAL CALIBRATION OF THE GFC 7001E/EM To perform the following calibration you must have sources for zero air and span gas available for input into the sample port on the back of the analyzer. See Section 3.4 for instructions for connecting these gas sources. The initial calibration should be carried out using the same reporting range set up as used during the analyzer’s factory calibration.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.6.2.1.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.6.2.2.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.6.2.3. Set CO Span Gas Concentration Set the expected CO pan gas concentration. This should be 80-90% of range of concentration range for which the analyzer’s analog output range is set.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.6.2.4. Zero/Span Calibration To perform the zero/span calibration procedure, press: SAMPLE RANGE=0.0 PPm < TST TST > CAL CO= XX.XX SETUP Set the Display to show the STABIL test function. This function calculates the stability of the CO measurement. Toggle TST> button until ... SAMPLE STABIL= XXXX PPM < TST TST > CO=XX.XX CAL SETUP Allow zero gas to enter the sample port at the rear of the analyzer. Wait until STABIL falls below 0.
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Getting Started Model GFC7001E Carbon Dioxide Analyzer 3.6.3. O2 SENSOR CALIBRATION PROCEDURE If your GFC 7001E/EM is equipped with the optional O2 sensor, this sensor should be calibrated during installation of the instrument. See Section 9.7.1 for instructions. 3.6.4. CO2 SENSOR CALIBRATION PROCEDURE If your GFC 7001E/EM is equipped with the optional CO2 sensor, this sensor should be calibrated during installation of the instrument. See Section 9.7.2 for instructions.
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FAQs Model GFC7001E Carbon Dioxide Analyzer 4. FREQUENTLY ASKED QUESTIONS 4.1. FAQ’S The following is a list from the Teledyne’s Customer Service Department of the most commonly asked questions relating to the GFC 7001E/EM CO Analyzer.
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FAQs Model GFC7001E Carbon Dioxide Analyzer Q: How do I measure the sample flow? A: Sample flow is measured by attaching a calibrated rotameter, wet test meter, or other flow-measuring device to the sample inlet port when the instrument is operating. The sample flow should be 800 cm3/min 10%. See Section 12.3.4. Q: How long does the IR source last? A: Typical lifetime is about 2-3 years.
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FAQs Model GFC7001E Carbon Dioxide Analyzer Term NOX NOy Description/Definition NH3 O2 O3 SO2 nitrogen oxides, here defined as the sum of NO and NO2 nitrogen oxides, often called odd nitrogen. The sum of NO, NO2 (NOX) plus other compounds such as HNO3 Definitions vary widely and may include nitrate (NO3), PAN, N2O and other compounds. ammonia molecular oxygen ozone sulfur dioxide DAS Data Acquisition System DIAG Diagnostics, the diagnostic settings of the analyzer.
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FAQs Model GFC7001E Carbon Dioxide Analyzer Term Description/Definition PCB Printed Circuit Board, the bare board without electronic component. PLC Programmable Logic Controller, a device that is used to control instruments based on a logic level signal coming from the analyzer PFA Per-Fluoro-Alkoxy, an inert polymer.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5. OPTIONAL HARDWARE AND SOFTWARE This includes a brief description of the hardware and software options available for the GFC 7001E/EM Gas Filter Correlation Carbon Monoxide Analyzer.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.3. CARRYING STRAP/HANDLE (OPT 29) The chassis of the GFC 7001E/EM Analyzer allows the user to attach a strap handle for carrying the instrument. The handle is located on the right side and pulls out to accommodate a hand for transport. When pushed in, the handle is nearly flush with the chassis, only protruding out about 9 mm (3/8”).
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Optional Hardware and Software Figure 5-2: Model GFC7001E Carbon Dioxide Analyzer Current Loop Option Installed on the Motherboard 5.4.1. CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD VOLTAGE OUTPUTS NOTE Servicing or handling of circuit components requires electrostatic discharge protection, i.e. ESD grounding straps, mats and containers. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5. Disconnect the current loop option PCA from the appropriate connector on the motherboard (see Figure 5-2). 6. Each connector, J19 and J23, requires two shunts. Place one shunt on the two left most pins and the second shunt on the two pins next to it (see Figure 5-2).  6 spare shunts (P/N CN0000132) were shipped with the instrument attached to JP1 on the back of the instruments keyboard and display PCA. 7.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.2.1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.2.2. Pneumatic Set Up (OPT 50A)  See Figure 3-2 for the location of gas inlets and Figure 5-4: Pneumatic Connections – Option 50A: Zero/Span Calibration Valves SAMPLE GAS SOURCE: Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters long.  Maximum pressure of any gas at the sample inlet should not exceed 1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.3. ZERO/SPAN/SHUTOFF VALVE (OPTION 50B) This option requires that both zero air and span gas be supplied from external sources.  Span gas will be supplied from a pressurized bottle of calibrated CO gas.  A critical flow control orifice, internal to the instrument ensures that the proper flow rate is maintained.  An internal vent line ensures that the gas pressure of the span gas is reduced to ambient atmospheric pressure.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.3.2. Pneumatic Set Up (OPT 50B) See Figure 3-2 for the location of gas inlets and outlets. Figure 5-6: Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves SAMPLE GAS SOURCE: Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters long.  Maximum pressure of any gas at the sample inlet should not exceed 1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.4. ZERO/SPAN VALVE WITH INTERNAL CO SCRUBBER (OPTION 50H) Option 50H is operationally and pneumatically similar to Option 50A above, except that the zero air is generated by an internal zero air scrubber. This means that the IZS inlet can simply be left open to ambient air.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.4.2. Pneumatic Set Up (OPT 50H) See Figure 3-2 for the location of gas inlets and outlets and span gas no shutoff valves are required. Figure 5-8: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves SAMPLE GAS SOURCE: Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters long.  Maximum pressure of any gas at the sample inlet should not exceed 1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.5. ZERO/SPAN/SHUTOFF WITH INTERNAL ZERO AIR SCRUBBER (OPTION 50E) 5.6.5.1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.6.5.2. Pneumatic Set Up (OPT 50E) See Figure 3-2 for the location of gas inlets and outlets. Figure 5-10: Pneumatic Connections – Option 50E: Zero/Span Calibration Valves SAMPLE GAS SOURCE: Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters long.  Maximum pressure of any gas at the sample inlet should not exceed 1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.7. COMMUNICATION OPTIONS 5.7.1. RS-232 MODEM CABLE (OPTION 60A) Table 5-5: OPTION NO. GFC 7001E/EM Modem Cable Options DESCRIPTION 60A Shielded, straight-through DB-9F to DB-25M cable of about 1.8 m length.  This cable is used to interface with older computers or code activated switches with a DB-25 serial connectors. 60B Shielded, straight-through DB-9F to DB-9F cable of about 1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.7.3. ETHERNET (OPTION 63A) The ETHERNET option allows the analyzer to be connected to any Ethernet Local Area Network (LAN) running TCP/IP. The local area network must have routers capable of operating at 10BaseT. If internet access is available through the LAN, this option also allows communication with the instrument over the public internet. Maximum communication speed is limited by the RS-232 port to 115.2 kBaud.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.7.4. ETHERNET + MULTIDROP (OPT 63C) This option allows the instrument to communicate on both RS-232 and ETHERNET networks simultaneously. It includes the following:  RS-232 MULTIDROP (OPT 62)  ETHERNET (OPT 63A) 5.8. SECOND GAS SENSORS 5.8.1. OXYGEN SENSOR (OPTION 65A) 5.8.1.1.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.8.1.2. Operation within the GFC 7001E/EM Analyzer The oxygen sensor option is transparently integrated into the core analyzer operation. All functions can be viewed or accessed through the front panel, just like the functions for CO.  The O2 concentration is displayed in the upper right-hand corner, alternating with CO concentration.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.9. CARBON DIOXIDE SENSOR (OPTION 67A) The optional CO2 sensor allows the GFC 7001E/EM to measure both CO and CO2 simultaneously. This option includes a CO2 sensor probe, a Logic PCA that conditions the probe output and issues a 0-5 VDC signal to the analyzer’s CPU that is used to compute the CO2 concentration.
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Optional Hardware and Software Figure 5-16: Model GFC7001E Carbon Dioxide Analyzer CO2 sensor Theory of Operation The sensor computes the ratio between the reference signal and the measurement signal to determine the degree of light absorbed by CO2 present in the sensor chamber. This dual wavelength method the CO2 measurement allows the instrument to compensate for ancillary effects like sensor aging and contamination. 5.9.2.2.
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Optional Hardware and Software Figure 5-17: Model GFC7001E Carbon Dioxide Analyzer GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66 5.9.2.4. Electronic Operation of the CO2 Sensor The CO2 PCA which is mounted to the rear side of the Relay Board Mounting Bracket controls the CO2 Sensor.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.10. CONCENTRATION ALARM RELAY (OPTION 61) The Teledyne “E” series analyzers have an option for four (4) “dry contact” relays on the rear panel of the instrument. This relay option is different from and in addition to the “Contact Closures” that come standard on all TAI instruments. The relays have 3 pins that have connections on the rear panel (see Figure 5-19).
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer CO2 gas. The software is flexible enough to allow you to configure the alarms so that you can have 2 alarm levels for each gas. CO Alarm 1 = 20 PPM CO Alarm 2 = 100 PPM CO2 Alarm 1 = 20 PPM CO2 Alarm 2 = 100 PPM In this example, CO Alarm 1 & CO2 Alarm 1 will both be associated with the “Alarm 2” relay on the rear panel. This allows you do have multiple alarm levels for individual gasses.
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Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer 5.11. SPECIAL FEATURES 5.11.1. DILUTION RATIO OPTION The Dilution Ratio Option is a software option that is designed for applications where the Sample gas is diluted before being analyzed by the GFC 7001E. Typically this occurs in Continuous Emission Monitoring (CEM) applications where the quality of gas in a smoke stack is being tested and the sampling method used to remove the gas from the stack dilutes the gas.
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Part II Operating Instructions Model GFC7001E Carbon Dioxide Analyzer PART II – OPERATING INSTRUCTIONS Teledyne Analytical Instruments 83
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6. BASIC OPERATION The GFC 7001E/EM Analyzer is a computer-controlled analyzer with a dynamic menu interface that allows all major operations to be controlled from the front panel display and keyboard through user-friendly menus (a complete set of menu trees is located in Appendix A of this manual).
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.2. SAMPLE MODE This is the analyzer’s standard operating mode. In this mode the instrument is analyzing the gas in the sample chamber, calculating CO concentration and reporting this information to the user via the front panel display, the analog outputs and, if set up properly, the RS-232/RS-485/Ethernet ports.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer Table 6-2: PARAMETER Test Functions Defined DISPLAY TITLE UNITS Stability STABIL 3 PPB , PPM 3 UGM , MGM Standard deviation of CO concentration readings. Data points are recorded every ten seconds using the last 25 data points. This function can be reset to show O2 or CO2 stability in instruments with those sensor options installed.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.3. WARNING MESSAGES The most common instrument failures will be reported as a warning on the analyzer’s front panel and through the COMM ports. Section 13.1.1 explains how to use these messages to troubleshoot problems. Section 6.3 shows how to view and clear warning messages. Table 6-3: List of Warning Messages MEANING MESSAGE ANALOG CAL WARNING The instrument’s A/D circuitry or one of its analog outputs is not calibrated.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer To view and clear warning messages: Figure 6-3: Viewing and Clearing GFC 7001E/EM WARNING Messages 6.4. CALIBRATION MODE Press the CAL key to switch the GFC 7001E/EM into calibration mode. In this mode the user can, in conjunction with introducing zero or span gases of known concentrations into the analyzer, cause it to adjust and recalculate the slope (gain) and offset of the its measurement range.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.5. SETUP MODE The SETUP mode contains a variety of choices that are used to configure the analyzer’s hardware and software features, perform diagnostic procedures, gather information on the instruments performance and configure or access data from the internal data acquisition system (iDAS). NOTE Any changes made to a variable during one of the following procedures is not acknowledged by the instrument until the ENTR Key is pressed.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.5.1. SETUP  CFG: CONFIGURATION INFORMATION Pressing the CFG key displays the instrument’s configuration information. This display lists the analyzer model, serial number, firmware revision, software library revision, CPU type and other information.  Special instrument or software features or installed options may also be listed here.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.5.3. SETUP  PASS: PASSWORD FEATURE The GFC 7001E/EM provides password protection of the calibration and setup functions to prevent unauthorized adjustments. When the passwords have been enabled in the PASS menu item, the system will prompt the user for a password anytime a password-protected function (e.g., SETUP) is requested. This allows normal operation of the instrument, but requires the password (101) to access to the menus under SETUP.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer Teledyne Analytical Instruments 93
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer Example: If all passwords are enabled, the following keypad sequence would be required to enter the SETUP menu: NOTE The instrument still prompts for a password when entering the VARS and DIAG menus, even if passwords are disabled. It will display the default password (818) upon entering these menus. The user only has to press ENTR to access the password-protected menus but does not have to enter the required number code.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.5.4. SETUP  CLK: SETTING THE GFC 7001E/EM ANALYZER’S INTERNAL CLOCK 6.5.4.1. Setting the internal Clock’s Time and Day The GFC 7001E/EM has a time of day clock that supports the DURATION step of the automatic calibration (ACAL) sequence feature, time of day TEST function, and time stamps on for the iDAS feature and most COMM port messages.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.5.4.2. Adjusting the Internal Clock’s Speed In order to compensate for CPU clocks which run faster or slower, you can adjust a variable called CLOCK_ADJ to speed up or slow down the clock by a fixed amount every day.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6. SETUP  RNGE: ANALOG OUTPUT REPORTING RANGE CONFIGURATION 6.6.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING RANGES Functionally, the GFC 7001E Family of CO Analyzers have one hardware PHYSICAL RANGE that is capable of determining CO concentrations between across a very wide array of values.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6.2. ANALOG OUTPUT RANGES FOR CO CONCENTRATION The analyzer has several active analog output signals related accessible through a connector on the rear panel (see Figure 3-2).
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6.3. REPORTING RANGE MODES The GFC 7001E/EM provides three analog output range modes to choose from.  Single range (SNGL) mode sets a single maximum range for the analog output. If single range is selected both outputs are slaved together and will represent the same measurement span (e.g. 0-50 ppm), however their electronic signal levels may be configured for different ranges (e.g. 0-10 VDC vs. 0-.1 VDC).
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6.3.1. RNGE  MODE  SNGL: Configuring the GFC 7001E/EM Analyzer for SINGLE Range Mode NOTE This is the default reporting range mode for the analyzer. When the single range mode is selected (SNGL), all analog CO concentration outputs (A1 and A2) are slaved together and set to the same reporting range limits (e.g. 500.0 ppb). The span limit of this reporting range can be set to any value within the physical range of the analyzer.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6.3.2. RNGE  MODE  DUAL: Configuring the GFC 7001E/EM Analyzer for DUAL Range Mode Selecting the DUAL range mode allows the A1 and A2 outputs to be configured with different reporting ranges. The analyzer software calls these two ranges low and high.  The LOW range setting corresponds with the analog output labeled A1 on the rear panel of the instrument.  The HIGH range setting corresponds with the A2 output.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer To set the upper range limit for each independent reporting range, press: .
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6.3.3. RNGE  MODE  AUTO: Configuring the GFC 7001E/EM Analyzer for AUTO Range Mode In AUTO range mode, the analyzer automatically switches the reporting range between two user-defined ranges (low and high).  The unit will switch from low range to high range when the CO2 concentration exceeds 98% of the low range span.  The unit will return from high range back to low range once both the CO2 concentration falls below 75% of the low range span.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer SETUP X.X Avoid accidentally setting the range ( ) of the instrument with a higher span limit than the range ( ). This will cause the unit to stay in the low reporting range perpetually and defeat the function of the range mode. CFG DAS CLK MORE EXIT SETUP X.X SET UNIT DIL EXIT DIL ENTR EXIT SETUP X.X SNGL DUAL SETUP X.X The and ranges have separate slopes and offsets for computing the CO concentration.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6.4. SETUP  RNGE  UNIT: SETTING THE REPORTING RANGE UNITS OF MEASURE The GFC 7001E/EM can display concentrations in parts per million (106 mols per mol, PPM) or milligrams per cubic meter (mg/m3, MG). Changing units affects all of the display, COMM port and iDAS values for all reporting ranges regardless of the analyzer’s range mode.
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Basic Operation Model GFC7001E Carbon Dioxide Analyzer 6.6.5. SETUP RNGE  DIL: USING THE OPTIONAL DILUTION RATIO FEATURE This feature is a optional software utility that allows the user to compensate for any dilution of the sample gas that may occur before it enters the sample inlet. Typically this occurs in continuous emission monitoring (CEM) applications where the sampling method used to remove the gas from the stack dilutes it. Using the dilution ratio option is a 4-step process: 1.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7. ADVANCED FEATURES 7.1. SETUP  IDAS: USING THE DATA ACQUISITION SYSTEM (IDAS) The GFC 7001E/EM Analyzer contains a flexible and powerful, Internal Data Acquisition System (iDAS) that enables the analyzer to store concentration and calibration data as well as a host of diagnostic parameters.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer The iDAS can be disabled, as opposed to suspended, only by disabling or deleting its individual data channels. 7.1.2. IDAS STRUCTURE The iDAS is designed around the feature of a “record”. A record is a single data point. The type of data recorded in a record is defined by two properties: PARAMETER type that defines the kind of data to be stored (e.g. the average of gas concentrations measured with three digits of precision). See Section 7.1.5.3.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.3. DEFAULT IDAS CHANNELS A set of default Data Channels has been included in the analyzer’s software for logging CO concentration and certain predictive diagnostic data. These default channels include but are not limited to:  CONC: Samples CO concentration at one minute intervals and stores an average every hour with a time and date stamp. Readings during calibration and calibration hold off are not included in the data.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer Triggering Events and Data Parameters/Functions for these default channels are: Figure 7-1: Default iDAS Channel Setup Teledyne Analytical Instruments 110
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.4. SETUP DAS VIEW: VIEWING IDAS CHANNELS AND INDIVIDUAL RECORDS iDAS data and settings can be viewed on the front panel through the following keystroke sequence. Moves the VIEW backward 10 record SETUP X.X CFG RNGE PASS CLK MORE Moves the VIEW backward 1 records or channel EXIT Moves the VIEW forward 1 record or channel Moves the VIEW forward 10 records SETUP X.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5. SETUP DAS EDIT: ACCESSING THE IDAS EDIT MODE iDAS configuration is most conveniently done through the APICOM remote control program. The following list of key strokes shows how to edit the iDAS using the front panel. When editing the data channels, the top line of the display indicates some of the configuration parameters. For example, the display line: 0) CONC: ATIMER, 1, 800 Translates to the following configuration: Channel No.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5.1. Editing iDAS Data Channel Names To edit the name of an iDAS data channel, follow the instruction shown in Section 7.1.5.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5.2. Editing iDAS Triggering Events Triggering events define when and how the iDAS records a measurement of any given data channel. The most commonly used triggering events are: ATIMER: Sampling at regular intervals specified by an automatic timer. Most trending information is usually stored at such regular intervals, which can be instantaneous or averaged.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer Triggering events are firmware-specific and a complete list of Triggers for this model analyzer can be found in Appendix A-5. 7.1.5.3. Editing iDAS Parameters Data parameters are types of data that may be measured and stored by the iDAS. For each analyzer model, the list of available data parameters is different, fully defined and not customizable. Appendix A-5 lists firmware specific data parameters for the GFC 7001E/EM.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer To modify, add or delete a parameter, follow the instruction shown in Section 7.1.5 then press: NOTE When the STORE NUM SAMPLES feature is turned on, the instrument will store how many measurements were used to compute the AVG, SDEV, MIN or MAX value but not the actual measurements themselves.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5.4. Editing Sample Period and Report Period The iDAS defines two principal time periods by which sample readings are taken and permanently recorded: SAMPLE PERIOD: Determines how often iDAS temporarily records a sample reading of the parameter in volatile memory. SAMPLE PERIOD is only used when the iDAS parameter’s sample mode is set for AVG, SDEV, MIN or MAX.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer The SAMPLE PERIOD and REPORT PERIOD intervals are synchronized to the beginning and end of the appropriate interval of the instruments internal clock. If SAMPLE PERIOD were set for one minute the first reading would occur at the beginning of the next full minute according to the instrument’s internal clock.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5.6. Editing the Number of Records The number of data records in the iDAS is limited to about a cumulative one million data points in all channels (one megabyte of space on the Disk-on-Chip). However, the actual number of records is also limited by the total number of parameters and channels and other settings in the iDAS configuration. Every additional data channel, parameter, number of samples setting, etc.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5.7. RS-232 Report Function The iDAS can automatically report data to the communications ports, where they can be captured with a terminal emulation program or simply viewed by the user using the APICOM software. To enable automatic COMM port reporting, follow the instruction shown in Section 7.1.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5.8. Enabling/Disabling the HOLDOFF Feature The iDAS HOLDOFF feature prevents data collection during calibration operations and at certain times when the quality of the analyzer’s CO measurements may not be certain (e.g. while the instrument is warming up). In this case, the length of time that the HOLDOFF feature is active is determined by the value of the internal variable (VARS), DAS_HOLDOFF.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.5.9. The Compact Report Feature When enabled, this option avoids unnecessary line breaks on all RS-232 reports. Instead of reporting each parameter in one channel on a separate line, up to five parameters are reported in one line. The COMPACT DATA REPORT generally cannot be accessed from the standard iDAS front panel menu, but is available via the instruments communication ports by using APICOM or the analyzer’s standard serial data protocol.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.7. REMOTE IDAS CONFIGURATION 7.1.7.1. iDAS Configuration Using APICOM Editing channels, parameters and triggering events as described in this can be performed via the APICOM remote control program using the graphic interface shown below. Refer to Section 8 for details on remote access to the GFC 7001E/EM Analyzer.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.1.7.2. iDAS Configuration Using Terminal Emulation Programs Although Teledyne recommends the use of APICOM, the iDAS can also be accessed and configured through a terminal emulation program such as HyperTerminal (see example in Figure 7-3). To do this:  All configuration commands must be created and edited off line (e.g. cut & pasted in from a text file or word processor) following a strict syntax (see below for example).
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.2. SETUP  MORE  VARS: INTERNAL VARIABLES (VARS) The GFC 7001E/EM has several user-adjustable software variables, which define certain operational parameters. Usually, these variables are automatically set by the instrument’s firmware, but can be manually redefined using the VARS menu. The following table lists all variables that are available within the 818 password protected level.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer To access and navigate the VARS menu, use the following key sequence. Concentration display continuously cycles through all gasses. SETUP X.X CFG DAS RNGE PASS CLK EXIT SETUP X.X COMM DIAG In all cases: discards the new setting. EXIT accepts the new setting. SETUP X.X EXIT Toggle these keys to enter the correct SETUP X.X PREV JUMP PRNT EXIT SETUP X.X Toggle these keys to set the iDAS HOLDOFF time period in minutes (MAX = 20 minutes).
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.3. SETUP  MORE  DIAG: USING THE DIAGNOSTICS FUNCTIONS A series of diagnostic tools is grouped together under the SETUPMOREDIAG menu, as these parameters are dependent on firmware revision (see Appendix A). These tools can be used in a variety of troubleshooting and diagnostic procedures and are referred to in many places of the maintenance and trouble-shooting sections of this manual.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.3.1.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4. USING THE GFC 7001E/EM ANALYZER’S ANALOG OUTPUTS. The GFC 7001E/EM Analyzer comes equipped with four analog outputs.  The first two outputs (A1 & A2) carry analog signals that represent the currently measured concentration of CO (see Section 6.6.2).  The third output (A3) is only active if the analyzer is equipped with one of the optional 2nd gas sensors (e.g. O2 or CO2).
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer To access the ANALOG I/O CONFIGURATION sub menu, press: Figure 7-4: Accessing the Analog I/O Configuration Submenus Teledyne Analytical Instruments 130
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.2. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION In its standard configuration, each of the analog outputs is set to output a 0–5 VDC signals. Several other output ranges are available. Each range has is usable from -5% to + 5% of the rated span. Table 7-7: Analog Output Voltage Range Min/Max RANGE NAME RANGE SPAN MINIMUM OUTPUT MAXIMUM OUTPUT 0.1V 0-100 mVDC -5 mVDC 105 mVDC 1V 0-1 VDC -0.05 VDC 1.05 VDC 5V 0-5 VDC -0.25 VDC 5.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer To change the output type and range, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: Teledyne Analytical Instruments 132
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.3. CALIBRATION OF THE ANALOG OUTPUTS Analog output calibration should to be carried out on first startup of the analyzer (performed in the factory as part of the configuration process) or whenever recalibration is required. The analog outputs can be calibrated automatically or adjusted manually.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.3.2. Automatic Calibration of the Analog Outputs To calibrate the outputs as a group with the AOUTS CALIBRATION command, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: NOTE Before performing this procedure, make sure that the AUTO CAL for each analog output is enabled. (See Section 7.4.3.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer NOTE: Manual calibration should be used for any analog output set for a 0.1V output range or in cases where the outputs must be closely matched to the characteristics of the recording device.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.3.3.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.3.4. Manual Calibration of the Analog Outputs Configured for Voltage Ranges For highest accuracy, the voltages of the analog outputs can be manually calibrated. NOTE: The menu for manually adjusting the analog output signal level will only appear if the AUTO-CAL feature is turned off for the channel being adjusted (see Section 7.4.3.1).
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer To adjust the signal levels of an analog output channel manually, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: Teledyne Analytical Instruments 138
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.3.5. Manual Adjustment of Current Loop Output Span and Offset A current loop option may be purchased for the A1, A2 and A3 analog outputs of the analyzer. This option places circuitry in series with the output of the D-to-A converter on the motherboard that changes the normal DC voltage output to a 0-20 milliamp signal (see Section 5.4).
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer To adjust the zero and span signal levels of the current outputs, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: Teledyne Analytical Instruments 140
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer An alternative method for measuring the output of the Current Loop converter is to connect a 250 ohm 1% resistor across the current loop output in lieu of the current meter (see Figure 3-7 for pin assignments and diagram of the analog output connector). This allows the use of a voltmeter connected across the resistor to measure converter output as VDC or mVDC.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.4. TURNING AN ANALOG OUTPUT OVER-RANGE FEATURE ON/OFF In its default configuration, a ± 5% over-range is available on each of the GFC 7001E/EM Analyzer’s analog outputs. This over-range can be disabled if your recording device is sensitive to excess voltage or current.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT Some analog signal recorders require that the zero signal is significantly different from the baseline of the recorder in order to record slightly negative readings from noise around the zero point. This can be achieved in the GFC 7001E/EM by defining a zero offset, a small voltage (e.g., 10% of span).
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4 The test functions available to be reported are listed in Table 7-10: Table 7-10: Test Channels Functions available on the GFC 7001E/EM’s Analog Output ZERO FULL SCALE * The demodulated, peak IR detector output during the measure portion of the GFC Wheel cycle. 0 mV 5000 mV CO REFERENCE The demodulated, peak IR detector output during the reference portion of the GFC Wheel cycle.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer To activate the TEST Channel and select CO MEASURE a function, press: SETUP X.X CFG DAS RNGE PASS CLK EXIT SETUP X.X COMM VARS EXIT SETUP X.X EXIT Toggle these keys to enter the correct DIAG PREV ENTR Continue pressing EXIT until ... DIAG PREV NEXT EXIT DIAG EXIT Toggle these keys to choose a mass flow controller TEST channel parameter. DIAG PREV NEXT EXIT discards the new setting. accepts the new setting.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.4.7. AIN CALIBRATION This is the submenu to conduct a calibration of the GFC 7001E/EM Analyzer’s analog inputs. This calibration should only be necessary after major repair such as a replacement of CPU, motherboard or power supplies.
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Advanced Features Model GFC7001E Carbon Dioxide Analyzer 7.5. SETUP MORE  ALRM: USING THE GAS CONCENTRATION ALARMS The GFC 7001E/EM includes two CO concentration alarms if OPT 61 is installed on your instrument. Each alarm has a user settable limit, and is associated with a Single Pole Double Throw relay output accessible via the alarm output connector on the instrument’s back panel (See Section 3.3.3).
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8. REMOTE OPERATION 8.1. SETUP  MORE COMM: USING THE ANALYSER’S COMMUNICATION PORTS The GFC 7001E/EM is equipped with two serial communication ports located on the rear panel (see Figure 3-2). Both ports operate similarly and give the user the ability to communicate with, issue commands to, and receive data from the analyzer through an external computer system or terminal. By default, both ports operate on the RS-232 protocol.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer Female DB-9 (COM2) Male DB-9 (RS-232) (As seen from outside analyzer) (As seen from outside analyzer) TXD TXD GND RXD 1 2 6 3 7 4 8 GND RXD 5 1 9 6 CTS RTS 2 3 7 4 8 5 9 CTS RTS (DTE mode) (DTE mode) RXD GND TXD 1 2 6 3 7 4 8 5 9 RTS CTS (DCE mode) Figure 8-1: Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE) The signals from these two connectors are routed from the motherboard via a wiring
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.1.3.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.1.4. COMM PORT COMMUNICATION MODES Each of the analyzer’s serial ports can be configured to operate in a number of different modes, listed in Table 8-1. As modes are selected, the analyzer sums the mode ID numbers and displays this combined number on the front panel display. For example, if quiet mode (01), computer mode (02) and Multi-Drop-Enabled mode (32) are selected, the analyzer would display a combined MODE ID of 35.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer Press the following keys to select communication modes for a one of the COMM ports, such as the following example where RS-485 mode is enabled: Teledyne Analytical Instruments 153
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.1.5. COMM PORT TESTING The serial ports can be tested for correct connection and output in the COMM menu. This test sends a string of 256 ‘w’ characters to the selected COMM port. While the test is running, the red LED on the rear panel of the analyzer should flicker.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.1.6. MACHINE ID Each type of Teledyne’s analyzer is configured with a default ID code.  The default ID code for the GFC 7001E/EM Analyzers is 300. The ID number is only important if more than one analyzer is connected to the same communications channel such as when several analyzers are:  On the same Ethernet LAN (see Section 8.4);  in a RS-232 multidrop chain (see Section 8.2) or;  operating over a RS-485 network (See Section 8.3).
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.1.7. TERMINAL OPERATING MODES The GFC 7001E/EM can be remotely configured, calibrated or queried for stored data through the serial ports. As terminals and computers use different communication schemes, the analyzer supports two communicate modes specifically designed to interface with these two types of devices.  The COMPUTER MODE is used when the analyzer is connected to a computer with a dedicated interface program.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.1.7.2. Command Syntax Commands are not case-sensitive and all arguments within one command (i.e. ID numbers, keywords, data values, etc.) must be separated with a space character. All Commands follow the syntax: X [ID] COMMAND Where X is the command type (one letter) that defines the type of command. Allowed designators are listed in Appendix A-6. [ID] is the machine identification number (Section 8.1.6).
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer  For example, +1.0, 1234.5678, -0.1, 1 are all valid floating-point numbers. Boolean expressions: Used to specify the value of variables or I/O signals that may assume only two values.  They are denoted by the keywords ON and OFF. Text strings: Used to represent data that cannot be easily represented by other data types, such as data channel names, which may contain letters and numbers.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.1.7.5. COMM Port Password Security In order to provide security for remote access of the GFC 7001E/EM, a LOGON feature can be enabled to require a password before the instrument will accept commands. This is done by turning on the SECURITY MODE (Mode 4, Table 8-1. Once the SECURITY MODE is enabled, the following items apply.  A password is required before the port will respond or pass on commands.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.2. MULTIDROP RS-232 SET UP The RS-232 multidrop consists of a printed circuit assembly that is seated on the CPU card and is connected by a Y-ribbon cable from its J3 connector to the CPU’s COM1 and COM2 connectors. This PCA includes all circuitry required to enable your analyzer for multidrop operation.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer Note: If you are adding an instrument to the end of a previously configured chain, remove the shunt between Pins 21  22 of JP2 on the multidrop PCA in the instrument that was previously the last instrument in the chain. 3. Close the instrument. 4. Using straight-through, DB9 male  DB9 Female cable, interconnect the host and the analyzers as shown in Figure 8-4. 5.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.3. RS-485 CONFIGURATION OF COM2 As delivered from the factory, COM2 is configured for RS-232 communications. This port can be reconfigured for operation as a non-isolated, half-duplex RS-485 port capable of supporting up to 32 instruments with a maximum distance between the host and the furthest instrument being 4000 feet. If you require full duplex or isolated operation, please contact Teledyne’s Customer Service.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer Female DB-9 (COM2) (As seen from outside analyzer) RX/TXGND RX/TX+ 1 2 6 3 7 4 8 5 9 (RS-485) Figure 8-6: Back Panel Connector Pin-Outs for COM2 in RS-485 Mode. The signal from this connector is routed from the motherboard via a wiring harness to a 3-pin connector on the CPU card, J15. Figure 8-7: CPU Connector Pin-Outs for COM2 in RS-485 Mode NOTE The DCE/DTE switch has no effect on COM2.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.4. REMOTE ACCESS VIA THE ETHERNET When equipped with the optional Ethernet interface, the analyzer can be connected to any standard 10BaseT Ethernet network via low-cost network hubs, switches or routers. The interface operates as a standard TCP/IP device on port 3000. This allows a remote computer to connect through the internet to the analyzer using APICOM, terminal emulators or other programs.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.4.2. CONFIGURING THE ETHERNET INTERFACE OPTION USING DHCP The Ethernet option for you GFC 7001E/EM uses Dynamic Host Configuration Protocol (DHCP) to configure its interface with your LAN automatically. This requires your network servers also be running DHCP. The analyzer will do this the first time you turn the instrument on after it has been physically connected to your network.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer To view the above properties listed in Table 8-5, press: Teledyne Analytical Instruments 166
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.4.3. MANUALLY CONFIGURING THE NETWORK IP ADDRESSES There are several circumstances when you may need to configure the interface settings of the analyzer’s Ethernet card manually. The INET submenu may also be used to edit the Ethernet card’s configuration properties.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X ID ADDR 1 SETUP X.X INET SETUP X.X 8 ENTR EXIT DHCP:ON ENTR accepts the new setting EXIT ignores the new setting EXIT DHCP:ON ON SETUP X.X EXIT ENTER PASSWORD:818 EDIT Toggle this key to turn DHCP ON/OFF EXIT COMMUNICATIONS MENU SETUP X.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer STEP 2: Configure the INSTRUMENT IP, GATEWAY IP and SUBNET MASK addresses by pressing: KEY FUNCTION [0] Press this key to cycle through the range of numerals and available characters (“0 – 9” & “ . ”) Moves the cursor one character to the left or right. INS Inserts a character before the cursor location. DEL Deletes a character at the cursor location. Some keys only appear as needed.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.4.4. CHANGING THE ANALYZER’S HOSTNAME The HOSTNAME is the name by which the analyzer appears on your network.  The default name for all Teledyne’s GFC 7001E Analyzers is GFC 7001E.  The default name for all Teledyne’s GFC 7001EM Analyzers is GFC 7001EM. To change this name (particularly if you have more than one GFC 7001E/EM Analyzer on your network), press: KEY
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.5. MODBUS SETUP The following set of instructions assumes that the user is familiar with MODBUS communications, and provides minimal information to get started. For additional instruction, please refer to the Teledyne MODBUS manual, PN 06276. Also refer to www.modbus.org for MODBUS communication protocols. Minimum Requirements  Instrument firmware with MODBUS capabilities installed.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer Example Read/Write Definition window: Example Connection Setup window: Example MODBUS Poll window: 8.5.1. REMOTE ACCESS BY MODEM The GFC 7001E/EM can be connected to a modem for remote access. This requires a cable between the analyzer’s COMM port and the modem, typically a DB-9F to DB-25M cable (available from Teledyne with P/N WR0000024). Once the cable has been connected, check to make sure:  The DTE-DCE is in the DCE position.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer Once this is completed, the appropriate setup command line for your modem can be entered into the analyzer. The default setting for this feature is: AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 This string can be altered to match your modem’s initialization and can be up to 100 characters long.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer To initialize the modem press: Teledyne Analytical Instruments 174
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6. USING THE GFC 7001E/EM WITH A HESSEN PROTOCOL NETWORK 8.6.1. GENERAL OVERVIEW OF HESSEN PROTOCOL The Hessen protocol is a multidrop protocol, in which several remote instruments are connected via a common communications channel to a host computer. The remote instruments are regarded as slaves of the host computer. The remote instruments are unaware that they are connected to a multidrop bus and never initiate Hessen protocol messages.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6.3. ACTIVATING HESSEN PROTOCOL Once the COMM port has been properly configured, the next step in configuring the GFC 7001E/EM to operate over a Hessen protocol network is to activate the Hessen mode for COMM ports and configure the communication parameters for the port(s) appropriately.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6.4. SELECTING A HESSEN PROTOCOL TYPE Currently there are two versions of Hessen Protocol in use. The original implementation, referred to as TYPE 1, and a more recently released version, TYPE 2 that has more flexibility when operating with instruments that can measure more than one type of gas.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6.5. SETTING THE HESSEN PROTOCOL RESPONSE MODE The Teledyne’s implementation of Hessen Protocol allows the user to choose one of several different modes of response for the analyzer. Table 8-7: Teledyne’s Hessen Protocol Response Modes MODE ID MODE DESCRIPTION CMD This is the Default Setting. Reponses from the instrument are encoded as the traditional command format.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6.6. HESSEN PROTOCOL GAS LIST ENTRIES 8.6.6.1. Gas List Entry Format and Definitions The GFC 7001E/EM Analyzer keeps a list of available gas types. Each entry in this list is of the following format. [GAS TYPE],[RANGE],[GAS ID],[REPORTED] WHERE: GAS TYPE = The type of gas to be reported (e.g. CO, CO2, O2, etc.). RANGE = The concentration range for this entry in the gas list.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6.6.2.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6.6.3.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.6.7. SETTING HESSEN PROTOCOL STATUS FLAGS Teledyne’s implementation of Hessen protocols includes a set of status bits that the instrument includes in responses to inform the host computer of its condition. Each bit can be assigned to one operational and warning message flag.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer To assign or reset the status flag bit assignments, press: CAL SETUP X.X CFG DAS RNGE PASS CLK EXIT SETUP X.X VARS DIAG EXIT SETUP X.X ID COM1 COM2 EXIT SETUP X.X EDIT PRNT EXIT Continue pressing until ... Continue pressing until desired flag message is displayed SETUP X.X PREV NEXT PRNT EXIT SETUP X.X discards the new setting. The and keys move the cursor brackets “ left and right along the bit string.
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Remote Operation Model GFC7001E Carbon Dioxide Analyzer 8.7. APICOM REMOTE CONTROL PROGRAM APICOM is an easy-to-use, yet powerful interface program that allows the user to access and control any of Teledyne’s main line of ambient and stack-gas instruments from a remote connection through direct cable, modem or Ethernet. Running APICOM, a user can:  Establish a link from a remote location to the GFC 7001E/EM through direct cable connection via RS232 modem or Ethernet.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9. CALIBRATION PROCEDURES This section contains a variety of information regarding the various methods for calibrating a GFC 7001E/EM as well as other supporting information. For information on EPA protocol calibration, please refer to Section 10. This section is organized as follows: SECTION 9.1 – BEFORE CALIBRATION This section contains general information you should know before about calibrating the analyzer. SECTION 9.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer Contact your regional EPA or other appropriate governing agency for more detailed recommendations. 9.1. BEFORE CALIBRATION The calibration procedures in this section assume that the range mode, analog range and units of measure have already been selected for the analyzer. If this has not been done, please do so before continuing (see Section 6.6 for instructions).
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.1.2.2. Span Gas Span Gas is a gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired measurement range. It is recommended that the span gas used have a concentration equal to 80-90% of the full measurement range. If Span Gas is sourced directly from a calibrated, pressurized tank, the gas mixture should be CO mixed with Zero Air or N2 at the required ratio.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.2. MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE GFC 7001E/EM ANALYZER IN ITS BASE CONFIGURATION ZERO/SPAN CALIBRATION CHECKS VS. ZERO/SPAN CALIBRATION Pressing the ENTR key during the following procedure resets the stored values for OFFSET and SLOPE and alters the instrument’s Calibration. This should ONLY BE DONE during an actual calibration of the GFC 7001E/EM. NEVER press the ENTR key if you are only checking calibration. 9.2.1.
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Calibration Procedures Figure 9-2: Model GFC7001E Carbon Dioxide Analyzer Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator Teledyne Analytical Instruments 189
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.2.2. PERFORMING A BASIC MANUAL CALIBRATION CHECK NOTE If the ZERO or SPAN keys are not displayed, the measurement made during is out of the allowable range allowed for a reliable calibration. See Section 12 for troubleshooting tips.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.2.3. PERFORMING A BASIC MANUAL CALIBRATION The following section describes the basic method for manually calibrating the GFC 7001E/EM. If the analyzer’s reporting range is set for the AUTO range mode, a step will appear for selecting which range is to be calibrated (LOW or HIGH). Each of these two ranges MUST be calibrated separately. 9.2.3.1.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.2.3.2.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.3. MANUAL CALIBRATION WITH ZERO/SPAN VALVES There are a variety of valve options available on the GFC 7001E/EM for handling calibration gases (see Section 5.6 for descriptions of each). Generally performing calibration checks and zero/span point calibrations on analyzers with these options installed is similar to the methods discussed in the previous sections of this section.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer Figure 9-5: Pneumatic Connections – Option 51B: Zero/Span Calibration Valves Figure 9-6: Pneumatic Connections – Option 51C: Zero/Span Calibration Valves Teledyne Analytical Instruments 194
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.3.2.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.3.3. MANUAL CALIBRATION USING VALVE OPTIONS The following section describes the basic method for manually calibrating the GFC 7001E/EM Analyzer. If the analyzer’s reporting range is set for the DUAL or AUTO range modes, a step will appear for selecting which range is to be calibrated (LOW or HIGH). Each of these two ranges MUST be calibrated separately. 9.3.3.1.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.3.3.2. Zero/Span Point Calibration Procedure The zero and cal operations are initiated directly and independently with dedicated keys (CALZ & CALS).
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure Contact closures for controlling calibration and calibration checks are located on the rear panel CONTROL IN connector. Instructions for setup and use of these contacts can be found in Section 3.3.4.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer For each mode, there are seven parameters that control operational details of the SEQUENCE (see Table 9-3). Table 9-3: AutoCal Attribute Setup Parameters ATTRIBUTE TIMER ENABLED ACTION Turns on the Sequence timer. STARTING DATE Sequence will operate after Starting Date. STARTING TIME Time of day sequence will run. DELTA DAYS Number of days to skip between each Sequence execution.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer The following example sets sequence #2 to do a zero-span calibration every other day starting at 2:15 PM on September 4, 2008, lasting 15 minutes, without calibration. This will start ½ hour later each iteration. Table 9-4: Example AutoCal Sequence MODE AND ATTRIBUTE VALUE COMMENT SEQUENCE 2 Define Sequence #2 MODE ZERO-SPAN Select Zero and Span Mode TIMER ENABLE ON Enable the timer STARTING DATE Sept.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.4.1. SETUP  ACAL: PROGRAMMING AND AUTO CAL SEQUENCE NOTE If at any time an illegal entry is selected, (for example: Delta Days > 366) the ENTR key will disappear from the display. To program the example sequence shown in Table 9-4, press: SAMPLE RANGE = 50.0 PPM CO=XX.XX < TST TST > CAL CALZ CZLS SETUP SETUP X.X CFG ACAL DAS RNGE PASS CLK MORE EXIT SETUP X.X SEQ 1) DISABLED NEXT MODE SETUP X.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer CONTINUED FROM PREVIOUS PAGE STARTING DATE SETUP X.X STARTING DATE: 04–SEP–08 EDIT SETUP X.X EXIT STARTING TIME:00:00 EDIT Toggle keys to set time: Format : HH:MM This is a 24 hr clock . PM hours are 13 – 24. Example 2:15 PM = 14:15 SETUP X.X 1 EXIT STARTING TIME:00:00 4 :1 SETUP X.X 5 ENTR STARTING TIME:14:15 EDIT SETUP X.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer CONTINUED FROM PREVIOUS PAGE DELTA TIME SETUP X.X DURATION:15.0 MINUTES EDIT Toggle keys to set duration for each iteration of the sequence: Set in Decimal minutes from 0.1 – 60.0. SETUP X.X 3 0 SETUP X.X EXIT DURATION 15.0MINUTES .0 ENTR DURATION:30.0 MINUTES EDIT SETUP X.X EXIT CALIBRATE: OFF EDIT SETUP X.X Toggle key Between Off and ON. EXIT CALIBRATE: OFF ON SETUP X.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.5. CO CALIBRATION QUALITY After completing one of the calibration procedures described above, it is important to evaluate the analyzer’s calibration SLOPE and OFFSET parameters. These values describe the linear response curve of the analyzer. The values for these terms, both individually and relative to each other, indicate the quality of the calibration.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.6. CALIBRATION OF THE GFC 7001E/EM’S ELECTRONIC SUBSYSTEMS 9.6.1. DARK CALIBRATION TEST The dark calibration test interrupts the signal path between the IR photo-detector and the remainder of the sync/demod board circuitry. This allows the instrument to compensate for any voltage levels inherent in the sync/demod circuitry that might effect the calculation of CO concentration.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.6.2. PRESSURE CALIBRATION A sensor at the exit of the sample chamber continuously measures the pressure of the sample gas. This data is used to compensate the final CO concentration calculation for changes in atmospheric pressure and is stored in the CPU’s memory as the test function PRES (also viewable via the front panel). NOTE This calibration must be performed when the pressure of the sample gas is equal to ambient atmospheric pressure.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.6.3. FLOW CALIBRATION The flow calibration allows the user to adjust the values of the sample flow rates as they are displayed on the front panel and reported through COMM ports to match the actual flow rate measured at the sample inlet. This does not change the hardware measurement of the flow sensors, only the software-calculated values.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.6.4. ELECTRICAL TEST CALIBRATION To run the Electrical Test, see Section 13.5.6.2.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.7. CALIBRATION OF OPTIONAL SENSORS 9.7.1. O2 SENSOR CALIBRATION PROCEDURE 9.7.1.1. O2 Calibration Setup The pneumatic connections for calibrating are as follows: Figure 9-7: O2 Sensor Calibration Set Up O2 SENSOR ZERO GAS: Teledyne recommends using pure N2 when calibration the zero point of your O2 sensor option. O2 SENSOR SPAN GAS: Teledyne recommends using 20.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.7.1.2. Set O2 Span Gas Concentration Set the expected O2 span gas concentration. This should be equal to the percent concentration of the O2 span gas of the selected reporting range (default factory setting = 20.8%; the approximate O2 content of ambient air).
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.7.1.3. Activate O2 Sensor Stability Function To change the stability test function from CO concentration to the O2 sensor output, press: NOTE Use the same procedure to reset the STB test function to CO when the O2 calibration procedure is complete.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.7.1.4.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.7.2. CO2 SENSOR CALIBRATION PROCEDURE 9.7.2.1. CO2 Calibration Setup The pneumatic connections for calibrating are as follows Figure 9-8: CO2 Sensor Calibration Set Up CO2 SENSOR ZERO GAS: Teledyne recommends using pure N2 when calibration the zero point of your CO2 sensor option. CO2 SENSOR SPAN GAS: Teledyne recommends using 16% CO2 in N2 when calibration the span point of your CO2 sensor option (Table 3-7) is 20%. 9.7.2.2.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.7.2.3. Activate CO2 Sensor Stability Function To change the stability test function from CO concentration to the CO2 sensor output, press: NOTE Use the same procedure to reset the STB test function to CO when the CO2 calibration procedure is complete.
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Calibration Procedures Model GFC7001E Carbon Dioxide Analyzer 9.7.2.4.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer 10. EPA CALIBRATION PROTOCOL 10.1. CALIBRATION REQUIREMENTS If the GFC 7001E is to be used for EPA SLAMS monitoring, it must be calibrated in accordance with the instructions in this section. The USEPA strongly recommends that you obtain a copy of the publication Quality Assurance Handbook for Air Pollution Measurement Systems Volume 2: Part 1, Ambient (abbreviated, Q.A. Handbook Volume II).
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer 5. If the instrument will be used on more than one range, it should be calibrated separately on each applicable range. 6. Calibration documentation should be maintained with each analyzer and also in a central backup file. 7. The true values of the calibration gases used must be traceable to NIST-SRMs See Table 3-7. 10.1.2.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer Table 10-1: Matrix for Calibration Equipment & Supplies EQUIPMENT & SUPPLIES SPECIFICATION Recorder Compatible with output signal of analyzer; min. chart width of 150 mm (6 in) is recommended Sample line and manifold Constructed of PTFE or glass Calibration equipment REFERENCE ACTION IF REQUIREMENTS ARE NOT MET Return equipment to supplier Check upon receipt Q.A. Handbook1 Vol II Part 1 , App 15, Sec. 4.4 & 5.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer 10.1.4. CALIBRATION FREQUENCY To ensure accurate measurements of the CO concentrations, calibrate the analyzer at the time of installation, and recalibrate it:  No later than three months after the most recent calibration or performance audit which indicate the analyzer’s calibration to be acceptable.  When there is an interruption of more than a few days in analyzer operation.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer Table 10-3: Definition of Level 1 and Level 2 Zero and Span Checks (Q.A. Handbook1 Vol II, Part1, Section 12.3 & 12.4) LEVEL 1 ZERO AND SPAN CALIBRATION LEVEL 2 ZERO AND SPAN CHECK A Level 1 zero and span calibration is a simplified, twopoint analyzer calibration used when analyzer linearity does not need to be checked or verified.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer Refer to the Troubleshooting and Repair (see Section 13) of this manual if the instrument is not within the allowed variations. 10.2.1. ZERO/SPAN CHECK PROCEDURES The Zero and Span calibration can be checked in a variety of different ways. They include:  Manual Zero/Span Check - Zero and Span can be checked from the front panel keyboard. The procedure is in Section 9.3 of this manual.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer  Alternate units, make sure ppm units are selected for EPA monitoring. See Section 6.6.4. The analyzer should be calibrated on the same range used for monitoring. 10.3.1. PRECISION CALIBRATION PROCEDURES To perform a precision calibration during the instrument set up, the input sources of zero air and sample gas and procedures should conform to those described in Section Error! Reference source not found.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer 10.4.3. SYSTEM AUDIT/VALIDATION A system audit is an on-site inspection and review of the quality assurance activities used for the total measurement system (sample collection, sample analysis, data processing, etc.); it is an appraisal of system quality. Conduct a system audit at the startup of a new monitoring system and periodically (as appropriate) as significant changes in system operations occur. 10.5.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer SAMPLE A1:CONC1=50 PPM < TST TST > CAL SAMPLE CO STB=XXXX PPB < TST TST > CAL CO = XXXX SETUP Set the Display to show the COSTB test function. This function calculates the stability of the CO measurement. CO=XXXX SETUP ACTION: Allow calibration gas diluted to proper concentration for Midpoint N to enter the sample port SAMPLE Wait until STABIL falls below 0.2 PPM (for M300E). This may take several minutes.
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EPA Calibration Protocol Model GFC7001E Carbon Dioxide Analyzer 10.6. REFERENCES 1 Quality Assurance Handbook for Air Pollution Measurement Systems Volume II: Part 1 - Ambient Air Quality Monitoring Program Quality System Development - EPA-454/R-98-004 - August 1998. United States Environmental Protection Agency - Office of Air Quality Planning and Standards 2 CFR Title 40: Protection of Environment - PART 53—AMBIENT AIR MONITORING REFERENCE AND EQUIVALENT METHODS: - 53.20 General provisions. - 53.
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Part III Technical Information Model GFC7001E Carbon Dioxide Analyzer PART III – TECHNICAL INFORMATION Teledyne Analytical Instruments 227
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11. THEORY OF OPERATION The GFC 7001E/EM Gas Filter Correlation Carbon monoxide Analyzer is a microprocessor-controlled analyzer that determines the concentration of carbon monoxide (CO) in a sample gas drawn through the instrument.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer Lengthening the absorption path is accomplished partly by making the physical dimension of the reaction cell longer, but primarily by adding extra passes back and forth along the length of the chamber. Table 11-1: Absorption Path Lengths for GFC 7001E and GFC 7001EM MODEL TOTAL NUMBER OF REFLECTIVE PASSES DISTANCE BETWEEN MIRRORS TOTAL ABSORPTION LIGHT PATH GFC 7001E 32 437.5 mm 14 Meters GFC 7001EM 8 312.5 mm 2.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.2.1.1. The GFC Wheel A GFC Wheel is a metallic wheel into which two chambers are carved. The chambers are sealed on both sides with material transparent to 4.7 µm IR radiation creating two airtight cavities. Each cavity is mainly filled with composed gases. One cell is filled with pure N2 (the measurement cell). The other is filled with a combination of N2 and a high concentration of CO (the reference cell).
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.2.1.2. The Measure Reference Ratio The GFC 7001E/EM determines the amount of CO in the sample chamber by computing the ratio between the peak of the measurement pulse (CO MEAS) and the peak of the reference pulse (CO REF). If no gases exist in the sample chamber that absorb light at 4.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer Interference and Signal to Noise Rejection: If an interfering gas, such as H2O vapor is introduced into the sample chamber, the spectrum of the IR beam is changed in a way that is identical for both the reference and the measurement cells, but without changing the ratio between the peak heights of CO MEAS and CO REF. In effect, the difference between the peak heights remains the same.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.3. PNEUMATIC OPERATION CAUTION GENERAL SAFETY HAZARD It is important that the sample airflow system is both leak tight and not pressurized over ambient pressure. Regular leak checks should be performed on the analyzer as described in the maintenance schedule, Table 12-1. Procedures for correctly performing leak checks can be found in Section 12.3.3.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.4. FLOW RATE CONTROL To maintain a constant flow rate of the sample gas through the instrument, the GFC 7001E/EM uses a special flow control assembly located in the exhaust gas line just before the pump. In instruments with the O2 sensor installed, a second flow control assembly is located between the O2 sensor assembly and the pump. These assemblies consist of:  A critical flow orifice.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer The actual flow rate of gas through the orifice (volume of gas per unit of time), depends on the size and shape of the aperture in the orifice. The larger the hole, the more the gas molecules move at the speed of sound and pass through the orifice.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5. ELECTRONIC OPERATION 11.5.1. OVERVIEW Figure 11-9 shows a block diagram of the major electronic components of the GFC 7001E/EM. At the heart of the analyzer is a microcomputer/CPU that controls various internal processes, interprets data, makes calculations, and reports results using specialized firmware developed by Teledyne.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer Analog Outputs A1 Back Panel Connectors Optional 4-20 mA A2 Control Inputs: 1–8 A3 A4 COM1 COM2 Status Outputs: 1–6 Analog Outputs (D/A) Power-Up Circuit Optional Ethernet Interface External Digital I/O) A/D Converter( V/F) MOTHER BOARD Flash Chip PC 104 Bus WHEEL TEMP Zero/Span Valve Options 2 Internal Digital I/O Sensor Status & Control Thermistor Interface BENCH TEMP Disk On Chip RS – 232 Box Temp SAMPLE TEMP PC 104 C
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.2. CENTRAL PROCESSING UNIT (CPU) The CPU for the E-Series instruments is a low power (5 VDC, 360mA MAX), high performance, Vortex86SXbased microcomputer running MS-DOS; its operation and assembly are compliant with the PC/104 Standard. The CPU is installed on the motherboard located inside the rear panel. It supports both RS-232 and RS-485 serial I/O.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.3. OPTICAL BENCH & GFC WHEEL Electronically, in the case of the optical bench for the GFC 7001E Analyzer, GFC Wheel and associated components do more than simply measure the amount of CO present in the sample chamber. A variety of other critical functions are performed here as well. 11.5.3.1.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer KEY: Detection Beam shining through MEASUREMENT side of GFC Wheel Detection Beam shining through REFERENCE side of GFC Wheel IR Detection Ring Segment Sensor Ring M/R Sensor Ring Figure 11-10: GFC Light Mask M/R SENSOR This emitter/detector assembly produces a signal that shines through a portion of the mask that allows light to pass for half of a full revolution of the wheel.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.3.4. IR Photo-Detector The IR beam is converted into an electrical signal by a cooled solid-state photo-conductive detector. The detector is composed of a narrow-band optical filter, a piece of lead-salt crystal whose electrical resistance changes with temperature, and a two-stage thermo-electric cooler. When the analyzer is on, a constant electrical current is directed through the detector.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 56V Bias CO MEAS Sample & Hold Circuits Variable Gain Amp Dark Switch Pre Amp Photodetector Signal Conditioner TEC Control PHT DRIVE E-Test Generator CO Reference Signal Amplifiers Conditioner (x4) Thermo-Electric Cooler Control Circuit E Test A Gate E Test B Gate Dark Test Gate Compact Programmable Logic Device Measure Gate Measure Dark Gate Reference Gate Reference Dark Gate Phase Lock Warning M/R Sensor From GFC Wheel Segment Sen
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer Timing for activating the Sample and Hold Circuits is provided by a Phase Lock Loop (PLL) circuit. Using the segment sensor output as a reference signal the PLL generates clock signal at ten times that frequency. This faster clock signal is used by the PLD to make the Sample and Hold Circuits capture the signal during the center portions of the detected waveform, ignore the rising and falling edges of the detector signal.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.4.6. Electric Test Switch When active, this circuit generates a specific waveform intended to simulate the function of the IR photo-detector but with a known set of value which is substituted for the detector’s actual signal via the dark switch. It may also be initiated by the user (See Section 7.4 for more details). 11.5.5.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.5.5. Status LED’s Eight LED’s are located on the analyzer’s relay board to show the current status on the various control functions performed by the relay board. They are listed on Table 11-4. Table 11-4: Relay Board Status LED’s LED COLOR FUNCTION STATUS WHEN LIT STATUS WHEN UNLIT Cycles On/Off Every 3 Seconds under direct control of the analyzer’s CPU.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.6. MOTHERBOARD This printed circuit assembly provides a multitude of functions including, A/D conversion, digital input/output, PC104 to I2C translation, temperature sensor signal processing and is a pass through for the RS-232 and RS-485 signals. 11.5.6.1.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer BENCH TEMPERATURE SENSOR This thermistor is attached to the sample chamber housing. It reports the current temperature of the chamber housing to the CPU as part of the bench heater control loop. WHEEL TEMPERATURE SENSOR This thermistor is attached to the heatsink on the GFC Wheel motor assembly. It reports the current temperature of the wheel/motor assembly to the CPU as part of the Wheel Heater control loop.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.7. I2C DATA BUS An I2C data bus is used to communicate data and commands between the CPU and the keyboard/display interface and the relay board. I2C is a two-wire, clocked, digital serial I/O bus that is used widely in commercial and consumer electronic systems. A transceiver on the motherboard converts data and control signals from the PC-104 bus to I2C. The data is then fed to the keyboard/display interface and finally onto the relay board.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer Figure 11-15: Power Distribution Block Diagram Teledyne Analytical Instruments 250
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.9. COMMUNICATION INTERFACE The analyzer has several ways to communicate to the outside world. Users can input data and receive information directly via the front panel keypad and display. Direct communication with the CPU is also available by way of the analyzer’s RS-232 & RS-485 I/O ports or an optional Ethernet port.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.10. FRONT PANEL INTERFACE The most commonly used method for communicating with the GFC 7001E/EM Analyzer is via the instrument’s front panel which includes a set of three status LED’s, a vacuum florescent display and a keyboard with 8 context sensitive keys. Figure 11-17: GFC 7001E/EM Front Panel Layout 11.5.10.1. Analyzer Status LED’s Three LED’s are used to inform the user of the instrument’s basic operating status.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.10.3. Display The main display of the analyzer is a vacuum florescent display with two lines of 40 text characters each. Information is organized in the following manner (see Figure 11-17):  Mode Field: Displays the name of the analyzer’s current operating mode.  Message Field: Displays a variety of informational messages such as warning messages, operation data and response messages during interactive tasks.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer KEYPAD DECODER Each key on the front panel communicates with a decoder IC via a separate analog line. When a key is depressed the decoder chip notices the change of state of the associated signal; latches and holds the state of all eight lines (in effect creating an 8-bit data word); alerts the key-depress-detect circuit (a flip-flop IC); translates the 8-bit word into serial data and; sends this to the I2C interface chip.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer I2C INTERFACE CHIP This IC performs several functions:  Using a dedicated digital status bit, it sends an interrupt signal alerting the CPU that new data from the keyboard is ready to send.  Upon acknowledgement by the CPU that it has received the new keyboard data the I2C interface chip resets the key-depress-detect flip-flop.  In response to commands from the CPU, it turns the front panel status LEDs on and off and activates the beeper.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.11. SOFTWARE OPERATION The GFC 7001E/EM Gas Filter Correlation Carbon Monoxide Analyzer has at its heart a high performance, 386based microcomputer running MS-DOS. Inside the DOS shell, special software developed by Teledyne interprets user commands via the various interfaces, performs procedures and tasks, stores data in the CPU’s various memory devices and calculates the concentration of the sample gas.
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Theory of Operation Model GFC7001E Carbon Dioxide Analyzer 11.5.13. CALIBRATION - SLOPE AND OFFSET Calibration of the analyzer is performed exclusively in software. During instrument calibration (see Section 9) the user enters expected values for zero and span via the front panel keypad and commands the instrument to make readings of calibrated sample gases for both levels. The readings taken are adjusted, linearized, and compared to the expected values.
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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.
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Maintenance Model GFC7001E Carbon Dioxide Analyzer Table 12-1: GFC 7001E/EM Maintenance Schedule ITEM ACTION FREQ CAL CHECK REQ’D Particulate Filter Replace Weekly or As Needed No Verify Test Functions Record and Analyze Weekly or after any Maintenance or Repair No Pump Diaphragm Replace Annually Yes Perform Flow Check Check Flow Annually No Perform Leak Check Verify Leak Tight Annually or after any Maintenance or Repair No Pneumatic lines Examine and Clean As Needed Yes if cle
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Maintenance Model GFC7001E Carbon Dioxide Analyzer Table 12-2: GFC 7001E/EM Test Function Record FUNCTION OPERATING MODE* STABILITY ZERO CAL CO MEAS ZERO CAL DATE RECORDED ZERO CAL MR RATIO SPAN CAL PRES SAMPLE PHT DRIVE AFTER WARMUP SLOPE SPAN CAL OFFSET ZERO CAL SAMPLE Teledyne Analytical Instruments 262
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Maintenance Model GFC7001E Carbon Dioxide Analyzer 12.2. PREDICTING FAILURES USING THE TEST FUNCTIONS The Test Functions can be used to predict failures by looking at how their values change over time. Initially it may be useful to compare the state of these Test Functions to the values recorded on the printed record of the final calibration performed on your instrument at the factory, P/N 04307. Table 12-3 can be used as a basis for taking action as these values change with time.
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Maintenance Model GFC7001E Carbon Dioxide Analyzer 12.3. MAINTENANCE PROCEDURES The following procedures are to be performed periodically as part of the standard maintenance of the GFC 7001E. 12.3.1. REPLACING THE SAMPLE PARTICULATE FILTER The particulate filter should be inspected often for signs of plugging or contamination. We recommend that the filter and the wetted surfaces of the filter housing are handled as little as possible when you change the filter.
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Maintenance Model GFC7001E Carbon Dioxide Analyzer 12.3.3. PERFORMING LEAK CHECKS Leaks are the most common cause of analyzer malfunction; Section 12.3.3.1 presents a simple leak check procedure. Section 12.3.3.2 details a more thorough procedure. 12.3.3.1. Vacuum Leak Check and Pump Check This method is easy and fast. It detects, but does not locate most leaks. It also verifies that the sample pump is in good condition. 1. Turn the analyzer ON, and allow enough time for flows to stabilize. 2.
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Maintenance Model GFC7001E Carbon Dioxide Analyzer 12.3.4. PERFORMING A SAMPLE FLOW CHECK CAUTION GENERAL SAFETY HAZARD Always use a separate calibrated flow meter capable of measuring flows in the 0 – 1000 cm3/min range to measure the gas flow rate though the analyzer. DO NOT use the built in flow measurement viewable from the Front Panel of the instrument. This measurement is only for detecting major flow interruptions such as clogged or plugged gas lines. See Figure 3-2 for sample port location. 1.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13. TROUBLESHOOTING & REPAIR This contains a variety of methods for identifying the source of performance problems with the analyzer. Also included in this are procedures that are used in repairing the instrument. NOTE QUALIFIED PERSONNEL The operations outlined in this section must be performed by qualified maintenance personnel only. CAUTION GENERAL SAFETY HAZARD Risk of electrical shock.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES The most common and/or serious instrument failures will result in a warning message being displayed on the front panel. Table 13-1 lists warning messages, along with their meaning and recommended corrective action.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer Table 13-1: Warning Messages - Indicated Failures WARNING MESSAGE FAULT CONDITION BENCH TEMP WARNING The optical bench temp is controlled at 48  2 °C. BOX TEMP WARNING Box Temp is < 5 °C or > 48 °C. CANNOT DYN SPAN Dynamic Span operation failed Measured concentration value is too high or low. Concentration slope value to high or too low CANNOT DYN ZERO Dynamic Zero operation failed Measured concentration value is too high.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer Table 13-1: Warning Messages – Indicated Failures (cont.) WARNING MESSAGE SAMPLE TEMP WARN FAULT CONDITION POSSIBLE CAUSES Sample temperature is < 10oC or > 100oC. Occurs when CO Ref is <1250 mVDC or >4950 mVDC. SOURCE WARNING Either of these conditions will result in an invalid M/R ratio. SYSTEM RESET WHEEL TEMP WARNING The computer has rebooted.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer The following table contains some of the more common causes for these values to be out of range. Table 13-2: Test Functions - Indicated Failures TEST FUNCTIONS (As Displayed) TIME INDICATED FAILURE(S) Time of day clock is too fast or slow. To adjust, see Section 6.5.4. Battery in clock chip on CPU board may be dead.
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Troubleshooting & Repair Table 13-2: TEST FUNCTIONS (As Displayed) PHT DRIVE SLOPE OFFSET Model GFC7001E Carbon Dioxide Analyzer Test Functions - Indicated Failures (cont.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.1.3. DIAG  SIGNAL I/O: USING THE DIAGNOSTIC SIGNAL I/O FUNCTION The signal I/O diagnostic mode allows access to the digital and analog I/O in the analyzer. Some of the digital signals can be controlled through the keyboard. These signals, combined with a thorough understanding of the instruments Theory of Operation (found in Section Error! Reference source not found.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer See Appendix A-4 for a complete list of the parameters available for review under this menu 13.1.4. INTERNAL ELECTRONIC STATUS LED’S Several LED’s are located inside the instrument to assist in determining if the analyzer’s CPU, I2C bus and relay board, GFC Wheel and the sync/demodulator board are functioning properly. 13.1.4.1.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.1.4.2.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.1.4.3. Relay Board Status LED’s There are eight LED’s located on the Relay Board. The most important of which is D1, which indicates the health of the I2C bus. If D1 is blinking the other faults following LED’s can be used in conjunction with DIAG menu signal I/O to identify hardware failures of the relays and switches on the relay (see Section 13.1.3 and Appendix D).
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer Table 13-5: LED D2 Yellow FUNCTION Wheel Heater Relay Board Status LED Failure Indications SIGNAL I/O PARAMETER ACTIVATED BY WHEEL_HEATER D3 Yellow Bench Heater BENCH_HEATER D4 Yellow Spare N/A D5 Green D6 Green D7 Green D8 Green Sample/Cal Gas Valve Option Zero/Span Gas Valve Option Shutoff Valve Option IR SOURCE CAL_VALVE SPAN_VALVE SHUTOFF_VALVE IR_SOURCE DIAGNOSTIC TECHNIQUE VIEW RESULT WHEEL_TEMP Voltage displ
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.2. GAS FLOW PROBLEMS When troubleshooting flow problems, it is a good idea to first confirm that the actual flow and not the analyzer’s flow sensor and software are in error, or the flow meter is in error. Use an independent flow meter to perform a flow check as described in Section 12.3.4. If this test shows the flow to be correct, check the pressure sensors as described in Section 13.5.6.6. The GFC 7001E/EM has one main gas flow path.
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Troubleshooting & Repair Figure 13-7: Model GFC7001E Carbon Dioxide Analyzer Internal Pneumatic Flow OPT 50A – Zero/Span Valves (OPT 50A & 50B) Figure 13-8: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves Teledyne Analytical Instruments 279
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Troubleshooting & Repair Figure 13-9: Model GFC7001E Carbon Dioxide Analyzer Internal Pneumatic Flow OPT 51B – Zero/Span Valves with Internal Zero Air Scrubber Figure 13-10: Internal Pneumatic Flow OPT 51C – Zero/Span/Shutoff w/ Internal Zero Air Scrubber Teledyne Analytical Instruments 280
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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 281
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.2.2. TYPICAL SAMPLE GAS FLOW PROBLEMS 13.2.2.1. Flow is Zero The unit displays a SAMPLE FLOW warning message on the front panel display or the SAMPLE FLOW test function reports a zero or very low flow rate. Confirm that the sample pump is operating (turning). If not, use an AC voltmeter to make sure that power is being supplied to the pump if no power is present at the electrical leads of the pump. 1.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.2.2.4. Displayed Flow = “Warnings” This warning means that there is inadequate gas flow. There are four conditions that might cause this: 1. A leak upstream or downstream of the flow sensor 2. A flow obstruction upstream or downstream of the flow sensor 3. Bad Flow Sensor Board 4. Bad pump To determine which case is causing the flow problem, view the sample pressure and sample flow functions on the front panel.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.3.2. NON-REPEATABLE ZERO AND SPAN As stated earlier, leaks both in the GFC 7001E/EM and in the external system are a common source of unstable and non-repeatable readings. 1. Check for leaks in the pneumatic systems as described in Section 12.3.3.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.4. OTHER PERFORMANCE PROBLEMS Dynamic problems (i.e. problems which only manifest themselves when the analyzer is monitoring sample gas) can be the most difficult and time consuming to isolate and resolve. The following provides an itemized list of the most common dynamic problems with recommended troubleshooting checks and corrective actions. 13.4.1.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer  At room temperature it should have approximately 30K Ohms resistance; near the 48oC set point it should have ~12K ohms. 13.4.1.3. GFC Wheel Temperature Like the bench heater above there are three possible causes for the GFC Wheel temperature to have failed. 1. The wheel heater has failed.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.4.2. EXCESSIVE NOISE Noise is continuously monitored in the TEST functions as the STABIL reading and only becomes meaningful after sampling a constant gas concentration for at least 10 minutes. Compare the current STABIL reading with that recorded at the time of manufacture (included in the GFC 7001E/EM Final Test and Validation Data Sheet,P/N 04271 shipped with the unit from Teledyne). 1. The most common cause of excessive noise is leaks.
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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.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer A voltmeter should be used to verify that the DC voltages are correct per the values in the table below, and an oscilloscope, in AC mode, with band limiting turned on, can be used to evaluate if the supplies are producing excessive noise (> 100 mV p-p). Table 13-7: DC Power Supply Acceptable Levels CHECK RELAY BOARD TEST POINTS POWER SUPPLY ASSY VOLTAGE PS1 +5 PS1 +15 Agnd 3 +15 4 13.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.5. RELAY BOARD The relay board PCA (P/N 04135) can be most easily checked by observing the condition of the its status LED’s on the relay board, as described in Section 13.1.4.3, and the associated output when toggled on and off through signal I/O function in the diagnostic menu, see Section 13.1.3. 1.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.6. SENSOR ASSEMBLY 13.5.6.1. Sync/Demodulator Assembly To verify that the Sync/Demodulator Assembly is working, follow the procedure below: 1. Verify that D1 and D2 are flashing.  If not check the opto pickup assembly, Section 13.5.6.3 and the GFC Wheel drive, Section 13.5.6.4.  If the wheel drive and opto pickup are working properly then verify that there is 2.4 ±0.1 VAC and 2.5 ±0.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.6.3. Opto Pickup Assembly Operation of the opto pickup PCA (P/N 04088) can be verified with a voltmeter. Measure the AC and DC voltage between digital ground on the relay board, or keyboard and TP2 and TP4 on the sync pickup PCA. For a working board, with the GFC motor spinning, they should read 2.4 ±0.1 VAC and 2.5 ±0.15 VDC.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.6.6. Pressure/Flow Sensor Assembly The pressure/flow sensor PCA, located on the top of the absorption bench, can be checked with a voltmeter using the following procedure which, assumes that the wiring is intact, and that the motherboard and the power supplies are operating properly: 1. For Pressure related problems:  Measure the voltage across C1 it should be 5 ± 0.25 VDC. If not then the board is bad.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.7. MOTHERBOARD 13.5.7.1. A/D Functions The simplest method to check the operation of the A-to-D converter on the motherboard is to use the Signal I/O function under the DIAG menu to check the two A/D reference voltages and input signals that can be easily measured with a voltmeter. 3. Use the Signal I/O function (see Section 13.1.3 and Appendix A) to view the value of REF_4096_MV and REF_GND.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.7.3. Analog Outputs: Current Loop To verify that the analog outputs with the optional current mode output are working properly, connect a 250 ohm resistor across the outputs and use a voltmeter to measure the output as described in Section 7.4.3.4 and then perform an analog output step test as described in Section 13.5.7.2. For each step the output should be within 1% of the nominal value listed in the table below.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.7.4. Status Outputs The procedure below can be used to test the Status outputs: 1. Connect a jumper between the “D“ pin and the “” pin on the status output connector. 2. Connect a 1000 ohm resistor between the “+” pin and the pin for the status output that is being tested. 3. Connect a voltmeter between the “” pin and the pin of the output being tested (see table below). Under the DIAG SIGNAL I/O menu (see Section 13.1.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.7.5. Control Inputs – Remote Zero, Span The control input bits can be tested by the following procedure: 1. Connect a jumper from the +5 pin on the Status connector to the U on the Control In connector. pin on the Status connector to the A pin on the Control In 2. Connect a second jumper from the connector. The instrument should switch from Sample Mode to ZERO CAL R mode. pin on the Status connector to the B pin on the Control In 3.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.5.9.2. Troubleshooting Analyzer/Modem or Terminal Operation These are the general steps for troubleshooting problems with a modem connected to a Teledyne analyzer. 1. Check cables for proper connection to the modem, terminal or computer. 2. Check to make sure the DTE-DCE is in the correct position as described in Section 8.1.1. 3. Check to make sure the set up command is correct. See Section 8.2. 4.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.6. REPAIR PROCEDURES This contains procedures that might need to be performed on rare occasions when a major component of the analyzer requires repair or replacement. 13.6.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY The critical flow orifice is housed in the flow control assembly (Teledyne P/N 001760400) located on the top of the optical bench.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.6.2. REMOVING/REPLACING THE GFC WHEEL When removing or replacing the GFC Wheel it is important to perform the disassembly in the following order to avoid damaging the components: 1. Turn off the analyzer. 2. Remove the top cover. 3. Open the instrument’s hinged front panel. 4. Locate the GFC Wheel/motor assembly. See Figure 3-4. 5.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 7. Carefully remove the opto-pickup printed circuit assembly. Opto-Pickup Figure 13-16: Removing the Opto-Pickup Assembly 8. Remove the four (4) screws holding the GFC Wheel motor/heat sink assembly to the GFC Wheel housing. 9. Carefully remove the GFC Wheel motor/heat sink assembly from the GFC Wheel housing.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 10. Remove the one (1) screw fastening the GFC Wheel/mask assembly to the GFC motor hub. 11 12 Figure 13-18: Removing the GFC Wheel 11. Remove the GFC Wheel/mask assembly. 12. Follow the previous steps in reverse order to put the GFC Wheel/motor assembly back together. 13.6.3. CHECKING AND ADJUSTING THE SYNC/DEMODULATOR, CIRCUIT GAIN (CO MEAS) 13.6.3.1.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain To adjust the sync/demodulator circuit gain: 1. Make sure that the analyzer is turned on and warmed up. 2. Set the analyzer display to show the STABIL or CO STB test function. 3. Apply Zero Air to Sample Inlet of the analyzer. 4. Wait until the stability reading falls below 1.0 ppm. 5. Change the analyzer display to show the CO MEAS. 6.
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Troubleshooting & Repair Model GFC7001E Carbon Dioxide Analyzer 13.6.4. DISK-ON-MODULE REPLACEMENT PROCEDURE Replacing the Disk-on-Module (DOM) will cause loss of all DAS data; it also may cause loss of some instrument configuration parameters unless the replacement DOM carries the exact same firmware version. Whenever changing the version of installed software, the memory must be reset. Failure to ensure that memory is reset can cause the analyzer to malfunction, and invalidate measurements.
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ESD Model GFC7001E Carbon Dioxide Analyzer 14. A PRIMER ON ELECTRO-STATIC DISCHARGE Teledyne considers the prevention of damage caused by the discharge of static electricity to be extremely important part of making sure that your analyzer continues to provide reliable service for a long time. This section describes how static electricity occurs, why it is so dangerous to electronic components and assemblies as well as how to prevent that damage from occurring. 14.1.
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ESD Model GFC7001E Carbon Dioxide Analyzer 14.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE Damage to components occurs when these static charges come into contact with an electronic device. Current flows as the charge moves along the conductive circuitry of the device and the typically very high voltage levels of the charge overheat the delicate traces of the integrated circuits, melting them or even vaporizing parts of them.
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ESD Model GFC7001E Carbon Dioxide Analyzer 14.3. COMMON MYTHS ABOUT ESD DAMAGE I didn’t feel a shock so there was no electro-static discharge: The human nervous system isn’t able to feel a static discharge of less than 3500 volts. Most devices are damaged by discharge levels much lower than that. I didn’t touch it so there was no electro-static discharge: Electro Static charges are fields whose lines of force can extend several inches or sometimes even feet away from the surface bearing the charge.
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ESD Model GFC7001E Carbon Dioxide Analyzer For technicians that work in the field, special lightweight and portable anti-ESD kits are available from most suppliers of ESD protection gear. These include everything needed to create a temporary anti-ESD work area anywhere. Always wear an Anti-ESD wrist strap when working on the electronic assemblies of your analyzer.
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ESD Model GFC7001E Carbon Dioxide Analyzer 14.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE 14.4.2.1. Working at the Instrument Rack When working on the analyzer while it is in the instrument rack and plugged into a properly grounded power supply: 1. Attach you anti-ESD wrist strap to ground before doing anything else. Use a wrist strap terminated with an alligator clip and attach it to a bare metal portion of the instrument chassis.
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ESD Model GFC7001E Carbon Dioxide Analyzer 14.4.2.3. Transferring Components from Rack to Bench and Back When transferring a sensitive device from an installed Teledyne analyzer to an anti-ESD workbench or back: 1. Follow the instructions listed above for working at the instrument rack and workstation. 2. Never carry the component or assembly without placing it in an anti-ESD bag or bin. 3.
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ESD Model GFC7001E Carbon Dioxide Analyzer 14.4.2.5. Packing Components for Return to Teledyne’s Customer Service CAUTION – Avoid Warranty Invalidation Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing instructions and Return Merchandise Authorization (RMA) procedures when returning parts for repair or calibration may void your warranty.
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Index Model GFC7001E Carbon Dioxide Analyzer Index AZERO, 182 6 B 60 Hz, 38 A Absorption Path Lengths, 230 AC Power 60 Hz, 38 address.
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Index Model GFC7001E Carbon Dioxide Analyzer CO2 Sensor, 40, 42, 43, 56, 77, 78, 87, 182, 187, 213, 214 Calibration Procedure, 215 Setup, 213 Span Gas Concentration, 213 Troubleshoting, 298 CO2 Sensor Option Pneumatic Set Up for Calibration, 213 CO2 SLOPE, 87 COMM Ports, 42, 150, 152, 159, 175 and iDAS System, 120 Baud Rate, 151 COM1, 177 COM2, 73, 74, 149, 152, 160, 163, 164, 177 Communication Modes, 152, 164 DCE & DTE, 149 Machine ID, 155, 161 Parity, 152, 175 RS232, 73, 160 RS-485, 153 testing, 154
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Index Model GFC7001E Carbon Dioxide Analyzer Analog Outputs, 39, 98 Current Loop, 139 Voltage Ranges, 137 Control InputS, 41 Ethernet, 42, 50, 74, 75, 160, 164 Ethernet, 23, 26 Modem, 172 Multidrop, 42 Serial/COMM Ports, 42, 150 Status Outputs, 39 GFC Wheel, 46, 230, 231, 240, 241, 243, 244, 245, 263, 270, 271, 272, 274, 275, 291, 292, 300, 301, 302 Heater, 245, 249 Light Mask, 233, 241, 242 Motor, 245, 246, 248, 288, 292, 300, 301 Temperature, 49, 87, 88, 144, 286 GFC Wheel Troubleshooting, 300 Schmidt
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Index Model GFC7001E Carbon Dioxide Analyzer Channels, 108, 110, 124 CALDAT, 109 CONC, 109 PNUNTC, 109 Compact Data Report, 122 HOLD OFF, 48, 108, 121, 125 Holdoff Period, 57 Number of Records, 108, 119 Parameters, 108, 115, 124 CONC, 112 NXCNC1, 112 PMTDET, 108 Precision, 115 Report Period, 108, 118, 122 Sample Mode AVG, 115, 116, 117, 118 INST, 115, 116, 117, 118 MAX, 115 MIN, 115, 116, 117, 118 SDEV, 115, 116, 117, 118 Sample Period, 118 Starting Date, 122 Store Number of Samples, 115, 116, 118 Trigger
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Index Model GFC7001E Carbon Dioxide Analyzer O O2, 27, 39, 40, 43, 56, 75, 76, 85, 87, 88, 98, 125, 129, 144, 179, 182, 185, 187, 204, 209, 210, 211, 235, 278 O2 CELL TEMP, 87 O2 CELL TEMP WARNING, 88 O2 OFFSET, 87 O2 sensor, 39, 40, 43, 56, 76, 87, 88, 98, 144, 182, 187, 209, 211, 235, 278 O2 SENSOR, 211 CALIBRATION Procedure, 212 SETUP, 209 Span Gas Concentration, 210 M300E/EM with Zero/Span Valves with Internal Scrubber, 70, 194 M300E/EM with Zero/Span/Shutoff and Internal Scrubber Option, 72, 194 M30
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Index Model GFC7001E Carbon Dioxide Analyzer Qualiified Personnel, 267 SAMPLE A1, 85 SAMPLE FL, 87, 271 Sample Flow Sensor, 236 SAMPLE FLOW WARN, 49, 88, 182, 269 Sample Gas Line, 45, 66, 68, 70, 72 SAMPLE INLET, 32 Sample Mode, 31, 47, 85, 125, 198, 220, 297 SAMPLE PRESS WARN, 49, 88, 182, 269 Sample Pressure Sensor, 236 SAMPLE TEMP, 87, 88, 182, 271, 285 SAMPLE TEMP WARN, 49, 88, 182 Schmidt Triggers, 241 Scubber Zero Air, 186 Standard Temperature and Pressure, 105 Status LED's, 246 CO2 Sensor, 298 CP
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Index Model GFC7001E Carbon Dioxide Analyzer PHT DRIVE, 87, 262, 263, 272 PRES, 87, 262, 263, 265, 271 RANGE, 87, 179, 271 RANGE1, 87, 179 AUTO, 103 RANGE2, 87, 179 AUTO, 103 SAMPLE FL, 87, 271 SAMPLE TEMP, 87, 88, 182, 271, 285 SLOPE, 87, 188, 262, 263, 272 STABIL, 87, 262, 263, 271, 287, 302, 303 TIME, 87, 200, 271 WHEEL TEMP, 87, 271 W Warm-up Period, 48 Warnings, 48 ANALOG CAL WARNING, 49, 88 AZERO, 182 BENCH TEMP WARNING, 182 BENCH TEMP WARNING, 49, 88, 269 BOX TEMP WARNING, 49, 88, 182, 269 CANNOT
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Index Model GFC7001E Carbon Dioxide Analyzer Teledyne Analytical Instruments 320
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