Teledyne GFC7000E User Manual

INSTRUCTION MANUAL

MODEL GFC7000E

CARBON DIOXIDE ANALYZER

© TELEDYNE ANALYTICAL INSTRUMENTS

16830 Chestnut St.

City of Industry, Ca. 91748

USA

Phone: [phone]

Phone: [phone]

Fax: [phone]

Fax: [phone]

	04584
	REV. A1
Copyright 2003 Teledyne Instruments Incorporated	02-August-2004

Model GFC7000E Instruction Manual

GFC7000E Documentation

SAFETY MESSAGES

Your safety and the safety of others is very important. We have provided many important safety messages in this manual. Please read these messages carefully.

A safety message alerts you to potential hazards that could hurt you or others. Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the instrument. The definition of these symbols is described below:

GENERAL SAFETY HAZARD: Refer to the instructions for details on the specific hazard.

CAUTION: Hot Surface Warning

CAUTION: Electrical Shock Hazard

TECHNICIAN SYMBOL: All operations marked with this symbol are to be performed by qualified maintenance personnel only.

CAUTION

The analyzer should only be used for the purpose and in the manner described in this manual. If you use the analyzer in a manner other than that for which it was intended, unpredictable behavior could ensue with possible hazardous consequences.

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Model GFC7000E Instruction Manual		GFC7000E Documentation
TABLE OF CONTENTS
SAFETY MESSAGES	I
TABLE OF CONTENTS ......................................................................................................................		II
LIST OF APPENDICES....................................................................................................................		VII
LIST OF FIGURES	VII
LIST OF TABLES	VIII
1. MGFC7000E DOCUMENTATION.....................................................................................................		1
1.1. Using This Manual ...................................................................................................................		1
2. SPECIFICATIONS, APPROVALS AND WARRANTY..........................................................................		5
2.1. Specifications..........................................................................................................................		5
2.2. CE Mark Compliance ................................................................................................................		6
2.3. Warranty................................................................................................................................		6
3. GETTING STARTED.......................................................................................................................		9
3.1. Unpacking and Initial Set Up .....................................................................................................		9
3.1.1. Electrical Connections ......................................................................................................		11
3.1.2. Pneumatic Connections:...................................................................................................		15
3.1.2.1. Basic Pneumatic Connections......................................................................................		15
3.1.2.2. Connections with Internal Valve Options Installed..........................................................		19
3.2. Initial Operation ....................................................................................................................		21
3.2.1. Startup..........................................................................................................................		22
3.2.2. Warm Up .......................................................................................................................		23
3.2.3. Warning Messages ..........................................................................................................		24
3.2.4. Functional Check.............................................................................................................		25
3.3. Initial Calibration Procedure ....................................................................................................		26
4. FREQUENTLY ASKED QUESTIONS...............................................................................................		33
4.1. FAQ’s...................................................................................................................................		33
4.2. Glossary...............................................................................................................................		34
5. OPTIONAL HARDWARE AND SOFTWARE ....................................................................................		37
5.1. Rack Mount Kits (Options 20a, 20b & 21)..................................................................................		37
5.2. Current Loop Analog Outputs (Option 41) .................................................................................		37
5.3. Expendable Kits (Options 42C, 42D and 43) ..............................................................................		38
5.4. Calibration Valves Options ......................................................................................................		38
5.4.1. Zero/Span/Shutoff Valve (Option 50) .................................................................................		38
5.4.2. Zero/Span/Shutoff with External CO2 Scrubber (Option 51)..................................................		40
5.4.3. Zero/Span Valve (Option 52) ............................................................................................		40
5.4.4. Zero/Span Valve with External CO2 Scrubber (Option 53)......................................................		41
5.5. Communication Options..........................................................................................................		41
5.5.1. RS232 Modem Cable (Option 60).......................................................................................		41
5.5.2. RS-232 Multidrop (Option 62) ...........................................................................................		42
5.5.3. Ethernet (Option 63) .......................................................................................................		42
5.6. Additional Manuals.................................................................................................................		42
5.6.1. Printed Manuals (Option 70) .............................................................................................		42
5.6.2. Manual on CD (Part number 045840200)............................................................................		43
5.7. Extended Warranty (Options 92 & 93) ......................................................................................		43
5.8. Dilution Ratio Option (Option ??) .............................................................................................		43
5.9. Maintenance Mode Switch (Option ??) ......................................................................................		43
5.10. Second Language Switch (Option ??)......................................................................................		44
6. OPERATING INSTRUCTIONS ......................................................................................................		45
6.1. Overview of Operating modes .................................................................................................		45
6.2. Sample Mode........................................................................................................................		46
6.2.1. Test Functions ................................................................................................................		46
6.2.2. Warning Messages ..........................................................................................................		48
6.3. Calibration Mode ...................................................................................................................		50
6.3.1. SETUP – PASS: Calibration Password Security .....................................................................		50
6.4. SETUP Mode .........................................................................................................................		52
6.4.1. SETUP Mode Password Security.........................................................................................		53
6.5. SETUP – CFG: Viewing the Analyzer’s Configuration Information ..................................................		53
6.6. SETUP – CLK: Setting the Internal Time-of-Day Clock.................................................................		54
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6.7. SETUP – RNGE: Analog Output Reporting Range Configuration.....................................................	56
6.7.1. Physical Range versus Analog Output Reporting Ranges........................................................	56
6.7.2. Reporting Range Modes ...................................................................................................	57
6.7.3. Single Range mode (SNGL) ..............................................................................................	58
6.7.4. Dual Range Mode (DUAL) .................................................................................................	60
6.7.5. Auto Range Mode (AUTO).................................................................................................	61
6.7.6. Range Units ...................................................................................................................	62
6.7.7. Dilution Ratio .................................................................................................................	63
6.8. SETUP – VARS: Using the Internal Variables..............................................................................	64
6.9. SETUP – DIAG: Using the Diagnostics Functions.........................................................................	66
6.9.1. Accessing the Diagnostic Features .....................................................................................	67
6.9.2. Signal I/O ......................................................................................................................	67
6.9.3. Analog Output Step Test ..................................................................................................	68
6.9.4. Analog I/O Configuration..................................................................................................	69
6.9.4.1. Analog Output Signal Type and Range Span Selection ....................................................	71
6.9.4.2. Analog Output Calibration Mode..................................................................................	71
6.9.4.3. Manual Analog Output Calibration and Voltage Adjustment .............................................	73
6.9.4.4. Current Loop Output Adjustment.................................................................................	75
6.9.4.5. AIN Calibration.........................................................................................................	77
6.9.5. Electric Test ...................................................................................................................	77
6.9.6. Dark Calibration Test .......................................................................................................	78
6.9.7. Pressure Calibration ........................................................................................................	78
6.9.8. Flow Calibration ..............................................................................................................	80
6.9.9. Test Channel Output........................................................................................................	81
6.10. SETUP – COMM: Using the Analyser’s Communication Ports .......................................................	82
6.10.1. Analyzer ID Code ..........................................................................................................	82
6.10.2. COMM Port Default Settings ............................................................................................	83
6.10.3. COMM Port Cable Connections.........................................................................................	84
6.10.4. RS-485 Configuration of COM2 ........................................................................................	84
6.10.5. DTE and DCE Communication..........................................................................................	85
6.10.6. COMM Port Communication Modes ...................................................................................	85
6.10.7. COM Port Baud Rate ......................................................................................................	88
6.10.8. COM Port Testing ..........................................................................................................	89
6.10.9. Ethernet Card Configuration............................................................................................	89
6.10.9.1. Ethernet Card COM2 Communication Modes and Baud Rate...........................................	90
6.10.9.2. Configuring the Ethernet Interface Option using DHCP..................................................	90
6.10.9.3. Manually Configuring the Network IP Addresses...........................................................	92
6.10.9.4. Changing the Analyzer’s HOSTNAME ..........................................................................	94
6.11. SETUP – ALRM: Using the Gas Concentration Alarms.................................................................	95
6.12. SETUP – DAS: Using the Data Acquisition System (iDAS)...........................................................	96
6.12.1. iDAS Structure..............................................................................................................	96
6.12.1.1. iDAS Channels........................................................................................................	97
6.12.1.2. iDAS Parameters.....................................................................................................	98
6.12.1.3. iDAS Triggering Events ............................................................................................	98
6.12.2. Default iDAS Channels ...................................................................................................	99
6.12.2.1. Viewing iDAS Data and Settings ..............................................................................	103
6.12.2.2. Editing iDAS Data Channels ....................................................................................	104
6.12.2.3. Trigger Events ......................................................................................................	105
6.12.2.4. Editing iDAS Parameters ........................................................................................	106
6.12.2.5. Sample Period and Report Period.............................................................................	107
6.12.2.6. Number of Records ...............................................................................................	109
6.12.2.7. RS-232 Report Function .........................................................................................	110
6.12.2.8. Compact Report....................................................................................................	111
6.12.2.9. Starting Date .......................................................................................................	111
6.12.2.10. Disabling/Enabling Data Channels..........................................................................	111
6.12.2.11. HOLDOFF Feature................................................................................................	112
6.12.3. Remote iDAS Configuration...........................................................................................	113
6.13. Remote Operation of the Analyzer........................................................................................	115
6.13.1. Remote Operation Using the External Digital I/O..............................................................	115
6.13.1.1. Status Outputs .....................................................................................................	115
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6.13.1.2. Control Inputs ......................................................................................................	116
6.13.2. Remote Operation Using the External Serial I/O...............................................................	117
6.13.2.1. Terminal Operating Modes......................................................................................	117
6.13.2.2. Help Commands in Terminal Mode...........................................................................	118
6.13.2.3. Command Syntax .................................................................................................	118
6.13.2.4. Data Types ..........................................................................................................	119
6.13.2.5. Status Reporting...................................................................................................	120
6.13.2.6. Remote Access by Modem ......................................................................................	120
6.13.2.7. COM Port Password Security ...................................................................................	122
6.13.2.8. APICOM Remote Control Program............................................................................	122
6.13.3. Additional Communications Documentation .....................................................................	123
6.13.4. Using the MGFC7000E with a Hessen Protocol Network .....................................................	123
6.13.4.1. General Overview of Hessen Protocol .......................................................................	123
6.13.4.2. Hessen COMM Port Configuration ............................................................................	124
6.13.4.3. Activating Hessen Protocol .....................................................................................	124
6.13.4.4. Selecting a Hessen Protocol Type ............................................................................	125
6.13.4.5. Setting The Hessen Protocol Response Mode .............................................................	126
6.13.4.6. Hessen Protocol Gas ID..........................................................................................	126
6.13.4.7. Setting Hessen Protocol Status Flags .......................................................................	127
6.13.4.8. Instrument ID Code ..............................................................................................	128
7. CALIBRATION PROCEDURES ....................................................................................................	129
7.1. Before Calibration................................................................................................................	129
7.1.1. Zero Air and Span Gas...................................................................................................	129
7.1.2. Calibration Gas Traceability ............................................................................................	130
7.1.3. Data Recording Devices .................................................................................................	130
7.2. Manual Calibration without Zero/Span Valves ..........................................................................	130
7.3. Manual Calibration Checks ....................................................................................................	133
7.4. Manual Calibration with Zero/Span Valves...............................................................................	133
7.5. Manual Calibration Checks with Zero/Span Valves ....................................................................	137
7.5.1. Zero/Span Calibration on Auto Range or Dual Ranges.........................................................	137
7.5.2. Use of Zero/Span Valves with Remote Contact Closure .......................................................	138
7.6. Automatic Zero/Span Cal/Check (AutoCal) ..............................................................................	139
7.6.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected...............................................	142
7.7. Calibration Quality...............................................................................................................	142
8. EPA PROTOCOL CALIBRATION .................................................................................................	143
9. MAINTENANCE SCHEDULE & PROCEDURES ..............................................................................	145
9.1. Maintenance Schedule..........................................................................................................	145
9.2. Predicting Failures Using the Test Functions ............................................................................	148
9.3. Maintenance Procedures .......................................................................................................	148
9.3.1. Replacing the Sample Particulate Filter.............................................................................	149
9.3.2. Rebuilding the Sample Pump ..........................................................................................	150
9.3.3. Performing Leak Checks.................................................................................................	150
9.3.3.1. Vacuum Leak Check and Pump Check ........................................................................	150
9.3.3.2. Pressure Leak Check ...............................................................................................	150
9.3.4. Performing a Sample Flow Check.....................................................................................	151
9.3.5. Cleaning the Optical Bench .............................................................................................	151
9.3.6. Cleaning Exterior Surfaces of the MGFC7000E ...................................................................	151
10. THEORY OF OPERATION.........................................................................................................	153
10.1. Measurement Method .........................................................................................................	153
10.1.1. Beer’s Law .................................................................................................................	153
10.1.2. Measurement Fundamentals .........................................................................................	154
10.1.3. Gas Filter Correlation ...................................................................................................	154
10.1.4. Ambient CO2 Interference Rejection ...............................................................................	158
10.2. Pneumatic Operation..........................................................................................................	158
10.2.1. Sample Gas Flow.........................................................................................................	159
10.2.1.1. Critical Flow Orifice ...............................................................................................	159
10.2.1.2. Sample Pressure Sensor ........................................................................................	160
10.2.1.3. Sample Flow Sensor ..............................................................................................	160
10.2.1.4. Valve Options .......................................................................................................	161
10.2.2. Purge Gas Pressure and Flow Control .............................................................................	161
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10.3. Electronic Operation...........................................................................................................	161
10.3.1. Overview ...................................................................................................................	161
10.3.2. CPU...........................................................................................................................	163
10.3.3. Optical Bench & GFC Wheel...........................................................................................	163
10.3.3.1. Sample Gas and GFC Temperature Control ...............................................................	163
10.3.3.2. IR Source ............................................................................................................	164
10.3.3.3. GFC Wheel...........................................................................................................	164
10.3.3.4. IR Photo-Detector .................................................................................................	165
10.3.4. Synchronous Demodulator (Sync/Demod) Assembly.........................................................	165
10.3.4.1. Overview .............................................................................................................	165
10.3.4.2. Signal Synchronization and Demodulation ................................................................	166
10.3.4.3. Phase Lock Warning ..............................................................................................	167
10.3.4.4. Sync/Demod Status LED’s ......................................................................................	167
10.3.4.5. Photo-Detector Temperature Control........................................................................	168
10.3.4.6. Dark Calibration Switch..........................................................................................	168
10.3.4.7. Electric Test Switch ...............................................................................................	168
10.3.5. Relay Board................................................................................................................	168
10.3.5.1. Status LED’s.........................................................................................................	169
10.3.5.2. I2C Watch Dog Circuitry ........................................................................................	170
10.3.6. Mother Board..............................................................................................................	170
10.3.6.1. A to D Conversion .................................................................................................	170
10.3.6.2. Sensor Inputs.......................................................................................................	171
10.3.6.3. Thermistor Interface..............................................................................................	171
10.3.6.4. Analog Outputs.....................................................................................................	172
10.3.6.5. Internal Digital I/O................................................................................................	172
10.3.6.6. External Digital I/O ...............................................................................................	173
10.3.7. I2C Data Bus...............................................................................................................	173
10.3.8. Power Supply/ Circuit Breaker .......................................................................................	173
10.4. Interface ..........................................................................................................................	174
10.4.1. Front Panel Interface ...................................................................................................	175
10.4.1.1. Analyzer Status LED’s............................................................................................	175
10.4.1.2. Keyboard.............................................................................................................	176
10.4.1.3. Display................................................................................................................	176
10.4.1.4. Keyboard/Display Interface Electronics.....................................................................	177
10.5. Software Operation ............................................................................................................	178
10.5.1. Adaptive Filter ............................................................................................................	179
10.5.2. Calibration - Slope and Offset........................................................................................	179
10.5.3. Measurement Algorithm ...............................................................................................	180
10.5.4. Temperature and Pressure Compensation .......................................................................	180
10.5.5. Internal Data Acquisition System (iDAS) .........................................................................	180
11. TROUBLESHOOTING & REPAIR PROCEDURES ........................................................................	183
11.1. General Troubleshooting Hints .............................................................................................	183
11.1.1. Interpreting WARNING Messages...................................................................................	184
11.1.2. Fault Diagnosis with TEST Functions...............................................................................	186
11.1.3. Using the Diagnostic Signal I/O Function.........................................................................	188
11.1.4. Internal Electronic Status LED’s.....................................................................................	189
11.1.4.1. CPU Status Indicator .............................................................................................	189
11.1.4.2. Sync Demodulator Status LED’s ..............................................................................	190
11.1.4.3. Relay Board Status LED’s .......................................................................................	191
11.1.5. Gas Flow Problems ......................................................................................................	192
11.1.6. Typical Sample Gas Flow Problems.................................................................................	193
11.1.6.1. Flow is Zero .........................................................................................................	193
11.1.6.2. Low Flow .............................................................................................................	193
11.1.6.3. High Flow ............................................................................................................	194
11.1.6.4. Displayed Flow = “XXXX” .......................................................................................	194
11.1.6.5. Actual Flow Does Not Match Displayed Flow ..............................................................	194
11.1.6.6. Sample Pump .......................................................................................................	194
11.1.7. Poor or Stopped Flow of Purge Gas ................................................................................	194
11.2. Calibration Problems ..........................................................................................................	195
11.2.1. Miss-Calibrated ...........................................................................................................	195
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11.2.2. Non-Repeatable Zero and Span .....................................................................................	195
11.2.3. Inability to Span – No SPAN Key....................................................................................	196
11.2.4. Inability to Zero – No ZERO Key ....................................................................................	196
11.3. Other Performance Problems ...............................................................................................	196
11.3.1. Temperature Problems .................................................................................................	197
11.3.1.1. Box or Sample Temperature ...................................................................................	197
11.3.1.2. Bench Temperature...............................................................................................	197
11.3.1.3. GFC Wheel Temperature ........................................................................................	198
11.3.1.4. IR Photo-Detector TEC Temperature ........................................................................	198
11.3.2. Excessive Noise...........................................................................................................	198
11.4. Subsystem Checkout..........................................................................................................	199
11.4.1. AC Mains Configuration ................................................................................................	199
11.4.2. DC Power Supply.........................................................................................................	200
11.4.3. I2C Bus ......................................................................................................................	200
11.4.4. Keyboard/Display Interface...........................................................................................	201
11.4.5. Relay Board................................................................................................................	201
11.4.6. Sensor Assembly.........................................................................................................	202
11.4.6.1. Sync/Demodulator Assembly ..................................................................................	202
11.4.6.2. Opto Pickup Assembly ...........................................................................................	202
11.4.6.3. GFC Wheel Drive...................................................................................................	203
11.4.6.4. IR Source ............................................................................................................	203
11.4.6.5. Pressure/Flow Sensor Assembly ..............................................................................	203
11.4.7. Motherboard...............................................................................................................	204
11.4.7.1. A/D Functions.......................................................................................................	204
11.4.7.2. Analog Outputs: Voltage ........................................................................................	204
11.4.7.3. Analog Outputs: Current Loop.................................................................................	204
11.4.7.4. Status Outputs .....................................................................................................	205
11.4.7.5. Control Inputs – Remote Zero, Span........................................................................	205
11.4.8. CPU...........................................................................................................................	206
11.4.9. RS-232 Communications ..............................................................................................	206
11.4.9.1. General RS-232 Troubleshooting .............................................................................	206
11.4.9.2. Troubleshooting Analyzer/Modem or Terminal Operation.............................................	207
11.5. Repair Procedures..............................................................................................................	207
11.5.1. Repairing Sample Flow Control Assembly ........................................................................	207
11.5.2. Removing/Replacing the GFC Wheel...............................................................................	209
11.5.3. Disk-On-Chip Replacement Procedure.............................................................................	210
12. A PRIMER ON ELECTRO-STATIC DISCHARGE..........................................................................	213
12.1. How Static Charges are Created...........................................................................................	213
12.2. How Electro-Static Charges Cause Damage ...........................................................................	214
12.3. Common Myths About ESD Damage .....................................................................................	215
12.4. Basic Principles of Static Control ..........................................................................................	216
12.4.1. General Rules .............................................................................................................	216
12.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ........................................	218
12.4.2.1. Working at the Instrument Rack..............................................................................	218
12.4.2.2. Working at a Anti-ESD Work Bench..........................................................................	218
12.4.2.3. Transferring Components from Rack To Bench and Back .............................................	219
12.4.2.4. Opening Shipments from and Packing Components for Return to Teledyne Instruments
Customer Service. ..............................................................................................................	219

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Model GFC7000E Instruction Manual GFC7000E Documentation

LIST OF APPENDICES

APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION

APPENDIX A-1: MGFC7000E Software Menu Trees, Revision E.0

APPENDIX A-2: Setup Variables For Serial I/O, Revision E.0

APPENDIX A-3: Warnings and Test Functions, Revision E.0

APPENDIX A-4: MGFC7000E Signal I/O Definitions, Revision E.0

APPENDIX A-5: MGFC7000E iDAS Functions, Revision E.0

APPENDIX A-6: Terminal Command Designators, Revision E.0

APPENDIX B - GFC7000E SPARE PARTS LIST

APPENDIX C - REPAIR QUESTIONNAIRE - MGFC7000E

APPENDIX D - ELECTRONIC SCHEMATICS

LIST OF FIGURES

Figure 3-1: Removal of Shipping Screws..........................................................................		10
Figure 3-2: Rear Panel Layout........................................................................................		12
Figure 3-3: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ..................		16
Figure 3-4: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator ...........		17
Figure 3-5: Pneumatic Connections–MGFC7000E with Zero/Span/Shutoff Valves (OPT 50)......		19
Figure 3-6	Pneumatic Connections–MGFC7000E with Zero/Span/Shutoff Valves and External
	Zero Air Scrubber (OPT 51)..........................................................................	19
Figure 3-7: Pneumatic Connections–MGFC7000E with Zero/Span Valves (OPT 52) .................		20
Figure 3-8:	Pneumatic Connections–MGFC7000E with Zero/Span Valves with External Zero air
	Scrubber (OPT 53)......................................................................................	20
Figure 3-9: Example of Pneumatic Set up for Multipoint Calibration of M360 .........................		21
Figure 3-10: Front Panel Layout .......................................................................................		23
Figure 3-11:	Assembly Layout..........................................................................................	30
Figure 3-12: Optical Bench Layout ....................................................................................		31
Figure 3-13: Internal Pneumatic Flow – Basic Configuration .................................................		31
Figure 5-1: Current Loop Option Installed on the Motherboard............................................		37
Figure 5-2: Internal Pneumatic Flow – Zero/Span/Shutoff Valves OPT 50 & 51 ......................		39
Figure 5-3: Internal Pneumatic Flow – Zero/Span OPT 52 & 53 ...........................................		41
Figure 5-4: GFC7000E Ethernet Card and rear panel With Ethernet Installed.........................		42
Figure 6-1: Front Panel Display ......................................................................................		45
Figure 6-2	Viewing MGFC7000E TEST Functions...............................................................	48
Figure 6-3	Viewing and Clearing MGFC7000E WARNING Messages......................................	50
Figure 6-4: Analog Output Connector Pin Out ...................................................................		56
Figure 6-5: Setup for Calibrating Analog Voltage Outputs...................................................		74
Figure 6-6: Setup for Calibrating Current Outputs .............................................................		75
Figure 6-7: Default iDAS Channels Setup.......................................................................		101
Figure 6-8: APICOM user interface for configuring the iDAS..............................................		113
Figure 6-9: iDAS Configuration Through a Terminal Emulation Program..............................		114
Figure 6-10: Status Output Connector.............................................................................		115
Figure 6-11:	Control Inputs ...........................................................................................	117
Figure 6-12: APICOM Remote Control Program Interface....................................................		123
Figure 7-1: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ................		130
Figure 7-2: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator .........		131
Figure 7-3: Pneumatic Connections–MGFC7000E with Zero/Span/Shutoff Valves (OPT 50)....		134
Figure 7-4	Pneumatic Connections–MGFC7000E with Zero/Span/Shutoff Valves and External
	Zero Air Scrubber (OPT 51)........................................................................	134
Figure 7-5: Pneumatic Connections–MGFC7000E with Zero/Span Valves (OPT 52) ...............		135
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Figure 7-6:	Pneumatic Connections–MGFC7000E with Zero/Span Valves with External Zero air
	Scrubber (OPT 53)....................................................................................		135
Figure 9-1: Sample Particulate Filter Assembly ...............................................................			149
Figure 10-1:	Measurement Fundamentals ........................................................................		154
Figure 10-2:	GFC Wheel ................................................................................................		155
Figure 10-3: Measurement Fundamentals with GFC Wheel .................................................			155
Figure 10-4: Affect of CO2 in the Sample on CO2 MEAS & CO2 REF......................................			156
Figure 10-5: Effects of Interfering Gas on CO2 MEAS & CO2 REF.........................................			157
Figure 10-6: Chopped IR Signal......................................................................................			157
Figure 10-7: Internal Pneumatic Flow – Basic Configuration ...............................................			159
Figure 10-8: Flow Control Assembly & Critical Flow Orifice .................................................			160
Figure 10-9: GFC7000E Electronic Block Diagram .............................................................			162
Figure 10-10: GFC Light Mask..........................................................................................			164
Figure 10-11: Segment Sensor and M/R Sensor Output .......................................................			165
Figure 10-12: GFC7000E Sync / Demod Block Diagram .......................................................			166
Figure 10-13: Sample & Hold Timing.................................................................................			167
Figure 10-14: Location of relay board Status LED’s .............................................................			170
Figure 10-15: Power Distribution Block Diagram .................................................................			174
Figure 10-16: Interface Block Diagram..............................................................................			175
Figure 10-17: MGFC7000E Front Panel Layout....................................................................			175
Figure 10-18: Keyboard and Display Interface Block Diagram...............................................			177
Figure 10-19: Basic Software Operation ............................................................................			179
Figure 11-1: Viewing and Clearing Warning Messages........................................................			184
Figure 11-2: Example of Signal I/O Function ....................................................................			189
Figure 11-3: CPU Status Indicator ..................................................................................			190
Figure 11-4: Sync/Demod Board Status LED Locations ......................................................			191
Figure 11-5: Relay Board Status LEDs.............................................................................			191
Figure 11-6: Critical Flow Restrictor Assembly Disassembly ................................................			208
Figure 11-7: Opening the GFC Wheel Housing ..................................................................			209
Figure 11-8: Removing the GFC Wheel .............................................................................			210
Figure 12-1:	Triboelectric Charging.................................................................................		213
Figure 12-2: Basic anti-ESD Work Station........................................................................			216
Figure A-1: Basic Sample Display Menu ..........................................................................			223
Figure A-2: Sample Display Menu - Units with Z/S Valve or IZS Option installed			................... 224
Figure A-3: Primary Setup Menu (Except iDAS) ...............................................................			225
Figure A-4:	Primary Setup Menu (iDAS) .........................................................................		226
Figure A-5: Secondary Setup Menu (COMM & VARS) ........................................................			227
Figure A-6: Secondary Setup Menu (COMM Menu with Ethernet Card).................................			228
Figure A-7: Secondary Setup Menu (COMM Menu with HESSEN) ........................................			229
Figure A-8: Secondary Setup Menu (DIAG) .....................................................................			230
LIST OF TABLES
Table 2-1: Model GFC7000E Basic Unit Specifications ..........................................................			5
Table 3-1: GFC7000E Analog Output Pin Outs ..................................................................			13
Table 3-2: GFC7000E Status Output Pin Outs ...................................................................			14
Table 3-3: GFC7000E Control Input Pin Outs ....................................................................			15
Table 3-4: Model GFC7000E Rear Panel Pneumatic Connections ..........................................			16
Table 3-5: Front Panel Display During System Warm-Up ....................................................			23
Table 3-6: Possible Warning Messages at Start-Up ............................................................			24
Table 5-1: Zero/Span Valve Operating States for Options 50 & 51.......................................			38
Table 5-2: Zero/Span Valve Operating States for Options 52 & 53.......................................			40
Table 6-1: Analyzer Operating modes..............................................................................			46
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Table 6-2: Test Functions Defined...................................................................................			46
Table 6-3: List of Warning Messages ...............................................................................			49
Table 6-4: Primary Setup Mode Features and Functions .....................................................			52
Table 6-5: Secondary Setup Mode Features and Functions .................................................			52
Table 6-6: Variable Names (VARS) Revision B.3 ...............................................................			64
Table 6-7: GFC7000E Diagnostic (DIAG) Functions............................................................			66
Table 6-8: DIAG - Analog I/O Functions...........................................................................			69
Table 6-9: Analog Output Voltage Ranges........................................................................			69
Table 6-10: Analog Output Current Loop Range..................................................................			70
Table 6-11: Analog Output Pin Assignments.......................................................................			70
Table 6-12: Voltage Tolerances for Analog Output Calibration...............................................			73
Table 6-13: Current Loop Output Calibration with Resistor ...................................................			76
Table 6-14: Test Parameters Available for Analog Output A3 ................................................			81
Table 6-15: COM1 and COM2 DB-9 Pin Assignments............................................................			85
Table 6-16: COMM Port Communication modes...................................................................			86
Table 6-17: Ethernet Status Indicators..............................................................................			89
Table 6-18: LAN/Internet Configuration Properties ..............................................................			90
Table 6-19: Internet Configuration Keypad Functions ..........................................................			94
Table 6-20: CO2 Concentration Alarm Default Settings.........................................................			95
Table 6-21: Front Panel LED Status Indicators for iDAS .......................................................			96
Table 6-22: iDAS Data Channel Properties .........................................................................			97
Table 6-23: iDAS Data Parameter Functions.......................................................................			98
Table 6-24: Status Output Pin Assignments .....................................................................			116
Table 6-25: Control Input Pin Assignments ......................................................................			116
Table 6-26: Terminal Mode Software Commands ..............................................................			118
Table 6-27:	Command Types .........................................................................................		119
Table 6-28: Serial Interface Documents...........................................................................			123
Table 6-29: RS-232 Communication Parameters for Hessen Protocol		...................................	124
Table 6-30: Teledyne Instruments Hessen Protocol Response Modes		...................................	126
Table 6-31: Default Hessen Status Bit Assignments...........................................................			127
Table 7-1:	AUTOCAL Modes .........................................................................................		139
Table 7-2: AutoCal ATTRIBUTE Setup Parameters ...........................................................			139
Table 7-3: Calibration Data Quality Evaluation................................................................			142
Table 9-1: GFC7000E Maintenance Schedule ..................................................................			146
Table 9-2: GFC7000E Test Function Record....................................................................			147
Table 9-3: Predictive uses for Test Functions..................................................................			148
Table 10-1: Sync/Demod Status LED Activity ...................................................................			168
Table 10-2: Relay Board Status LED’s .............................................................................			169
Table 10-3: Front Panel Status LED’s ..............................................................................			176
Table 11-1: Warning Messages - Indicated Failures ...........................................................			185
Table 11-2: Test Functions - Indicated Failures.................................................................			187
Table 11-3: Sync/Demod Board Status Failure Indications .................................................			190
Table 11-4: I2C Status LED Failure Indications .................................................................			191
Table 11-5: Relay Board Status LED Failure Indications .....................................................			192
Table 11-6: DC Power Test Point and Wiring Color Codes ...................................................			200
Table 11-7: DC Power Supply Acceptable Levels ...............................................................			200
Table 11-8: Relay Board Control Devices .........................................................................			201
Table 11-9: Opto Pickup Board Nominal Output Frequencies...............................................			202
Table 11-10: Analog Output Test Function - Nominal Values Voltage Outputs..........................			204
Table 11-11: Analog Output Test Function - Nominal Values Current Outputs .........................			205
Table 11-12: Status Outputs Check ..................................................................................			205
Table 12-1: Static Generation Voltages for Typical Activities...............................................			214
Table 12-2: Sensitivity of Electronic Devices to Damage by ESD .........................................			214
Table A-1: GFC7000E Setup Variables, Revision E.0 ........................................................			231
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Table A-2: GFC7000E Warning Messages, Revision E.0 ....................................................	238
Table A-3: GFC7000E Test Functions, Revision E.0..........................................................	239
Table A-4: GFC7000E Signal I/O Definitions, Revision E.0 ................................................	240
Table A-5: GFC7000E DAS Trigger Events, Revision E.0 ...................................................	243
Table A-6: GFC7000E iDAS Functions, Revision E.0 .........................................................	244
Table A-7: Terminal Command Designators, Revision E.0.................................................	245
Table D-1: List of Included Electronic Schematics............................................................	251

User Notes

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1. MGFC7000E DOCUMENTATION

Thank you for purchasing the Model GFC7000E Gas Filter Correlation Carbon Dioxide Analyzer!

The documentation for this instrument is available in several different formats:

•Printed format, part number 045840100

•Electronic format on a CD-ROM, part number 045840200

The electronic manual is in Adobe® Systems Inc. “Portable Document Format”. The Adobe® Acrobat Reader® software, which is necessary to view these files, can be downloaded for free from the internet at http://www.adobe.com/.

The electronic version of the manual has many advantages:

•Keyword and phrase search feature

•Figures, tables and internet addresses are linked so that clicking on the item will display the associated feature or open the website.

•A list of chapters and sections as well as thumbnails of each page are displayed to the left of the text.

•Entries in the table of contents are linked to the corresponding locations in the manual.

•Ability to print sections (or all) of the manual

Additional documentation for the Model GFC7000E CO2 Analyzer is available from Teledyne Analytical Instruments’ website at http://www.teledyne-ai.com/manuals/

•APICOM software manual, part number 03945

•Multi-drop manual, part number 01842

•DAS Manual, part number 02837.

1.1. Using This Manual

This manual has the following data structures:

1.0 Table of Contents:

Outlines the contents of the manual in the order the information is presented. This is a good overview of the topics covered in the manual. There is also a list of tables, a list of figures and a list of appendices. In the electronic version of the manual, clicking on a any of these table entries automatically views that section.

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2.0 Specifications and Warranty

This section contains a list of the analyzer’s performance specifications, a description of the conditions and configuration under which EPA equivalency was approved and Teledyne Instruments Incorporated’s warranty statement.

3.0 Getting Started:

A concise set of instructions for setting up, installing and running your analyzer for the first time.

4.0 FAQ:

Answers to the most frequently asked questions about operating the analyzer.

5.0 Optional Hardware & Software

A description of optional equipment to add functionality to your analyzer.

6.0 Operation Instructions

This section includes step by step instructions for operating the analyzer and using its various features and functions.

7.0 Calibration Procedures

General information and step by step instructions for calibrating your analyzer.

8.0 EPA Protocol Calibration

Because CO2 is not declared a criteria air pollutant by the US EPA, EPA equivalency is not required for this type of analyzer. Therefore no special calibration methods are needed to satisfy EPA requirements.

9.0 Instrument Maintenance

Description of certain preventative maintenance procedures that should be regularly performed on you instrument to keep it in good operating condition. This section also includes information on using the iDAS to record diagnostic functions useful in predicting possible component failures before they happen.

10.0Theory of Operation

An in-depth look at the various principals by which your analyzer operates as well as a description of how the various electronic, mechanical and pneumatic components of the instrument work and interact with each other. A close reading of this section is invaluable for understanding the instrument’s operation.

11.0Troubleshooting Section:

This section includes pointers and instructions for diagnosing problems with the instrument, such as excessive noise or drift, as well as instructions on performing repairs of the instrument’s major subsystems.

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Appendices:

For easier access and better updating, some information has been separated out of the manual and placed in a series of appendices at the end of this manual. These include: software menu trees, warning messages, definitions of iDAS & serial I/O variables, spare parts list, repair questionnaire, interconnect listing and drawings, and electronic schematics.

NOTE

Throughout this manual, words printed in capital, bold letters, such as SETUP or ENTR represent messages as they appear on the analyzer’s front panel display.

NOTE

The flowcharts in this manual contain typical representations of the analyzer’s display during the various operations being described. These representations are not intended to be exact and may differ slightly from the actual display of your instrument.

User Notes

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In 1ppb increments from 50ppb to 2 000ppm, dual ranges or auto ranging

ppb, ppm, µg/m3, mg/m3, %(user selectable) < 0.1 ppm (RMS)

< 1% of reading (RMS) < 0.2 ppm1

<0.25 ppm1 <0.5 ppm1

1% of reading above 50 PPM1

1% of full scale

0.5% of reading

< 0.1% of Full Scale per oC < 0.05% of Full Scale per V 10 sec

95% in <60 sec 800cm3/min. ±10%

Table 2-1:

Model GFC7000E Basic Unit Specifications

Certifications

Analog Output Resolution Status Outputs

Control Inputs Serial I/O

Environmental

Analog Outputs Analog Output Ranges

5-40oC

0 - 95% RH, non-condensing

7" x 17" x 23.5" (178 mm x 432 mm x 597 mm) 38 lbs. (17 kg); add 1 lbs (0.5 kg) for IZS

100 V, 50/60 Hz (3.25A);

115 V, 60 Hz (3.0 A);

220 – 240 V, 50/60 Hz (2.5 A)

Installation category (over-voltage category) II; Pollution degree 2 Three (3) Outputs

0.1V, 1 V, 5 V, 10 V, 2-20 or 4-20 mA isolated current loop. All Ranges with 5% Under/Over Range

1 part in 4096 of selected full-scale voltage

8 Status outputs - opto-isolated; including 2 alarm outputs 6 Control Inputs, 3 defined, 3 spare

One (1) RS-232; One (1) RS-485

Baud Rate : 300 – 115200: Optional Ethernet Interface

CE: EN61010-1:90 + A1:92 + A2:95, EN61326 - Class A 1 At constant temperature and voltage.

Min/Max Range (Physical Analog Output)

Measurement Units Zero Noise

Span Noise

Lower Detectable Limit1 Zero Drift (24 hours) Zero Drift (7 days) Span Drift (7 Days) Linearity

Precision

Temperature Coefficient Voltage Coefficient

Lag Time Rise/Fall Time Sample Flow Rate

Temperature Range Humidity Range Dimensions H x W x D Weight, Analyzer

AC Power Rating

2. SPECIFICATIONS, APPROVALS AND WARRANTY

2.1. Specifications

Model GFC7000E Instruction Manual			Specifications, Approvals and Warranty

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2.2. CE Mark Compliance

Emissions Compliance

The Teledyne Instruments Model GFC7000E Gas Filter Correlation CO2 Analyzer was tested and found to be fully compliant with:

EN61326 (1997 w/A1: 98) Class A, FCC Part 15 Subpart B Section 15.107 Class A, ICES-003 Class A (ANSI C63.4 1992) & AS/NZS 3548 (w/A1 & A2; 97) Class A.

Tested on 11-29-2001 at CKC Laboratories, Inc., Report Number CE01-249.

Safety Compliance

The Teledyne Instruments Model GFC7000E Gas Filter Correlation CO2 Analyzer was tested and found to be fully compliant with:

IEC 61010-1:90 + A1:92 + A2:95,

Tested on 02-06-2002 at Nemko, Report Number 2002-012219.

2.3. Warranty

Warranty Policy (02024)

Prior to shipment, Teledyne Instruments Incorporated equipment is thoroughly inspected and tested. Should equipment failure occur, Teledyne Instruments Incorporated assures its customers that prompt service and support will be available.

Coverage

After the warranty period and throughout the equipment lifetime, Teledyne Instruments Incorporated stands ready to provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the industry. All maintenance and the first level of field troubleshooting is to be performed by the customer.

Non-API Manufactured Equipment

Equipment provided but not manufactured by Teledyne Instruments Incorporated is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturers warranty.

General

Teledyne Instruments Incorporated warrants each product manufactured by Teledyne Instruments Incorporated to be free from defects in material and workmanship under normal use and service for a period of one year from the date of delivery. All replacement parts and repairs are warranted for 90 days after the purchase.

If a product fails to conform to its specifications within the warranty period, Teledyne Instruments Incorporated shall correct such defect by, in Teledyne Instruments Incorporated’s discretion, repairing or replacing such defective product or refunding the purchase price of such product.

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Specifications, Approvals and Warranty

The warranties set forth in this section shall be of no force or effect with respect to any product:

(i) that has been altered or subjected to misuse, negligence or accident, or (ii) that has been used in any manner other than in accordance with the instruction provided by TELEDYNE ANALYTICAL INSTRUMENTS or (iii) not properly maintained.

THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED. THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED HEREIN. Teledyne Instruments Incorporated SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE INSTRUMENTS INCORPORATED’S PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR OTHERWISE.

Terms and Conditions

All units or components returned to Teledyne Amnalytical Instruments should be properly packed for handling and returned freight prepaid to the nearest designated Service Center. After the repair, the equipment will be returned, freight prepaid.

User Notes

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Getting Started

3. GETTING STARTED

3.1. Unpacking and Initial Set Up

CAUTION

To avoid personal injury, always use two persons to lift and carry the Model GFC7000E.

1.Verify that there is no apparent external shipping damage. If damage has occurred, please advise the shipper first, then Teledyne Analytical Instruments.

2.Included with your analyzer is a printed record of the final performance characterization performed on your instrument at the factory. This record, titled Final Test and Validation Data Sheet (part number 04307) is an important quality assurance and calibration record for this instrument. It should be placed in the quality records file for this instrument.

3.Carefully remove the top cover of the analyzer and check for internal shipping damage.

•Remove the set screw located in the top, center of the rear panel.

•Remove the four screws fastening the top cover to the unit (two per side).

•Lift the cover straight up. Do not slide backwards.

NOTE

Some versions of the GFC7000E CO2 Analyzer may have a spring loaded fastener at the top center of the rear panel and as many as eight screws (four per side) fastening the top cover to the chassis.

NOTE

Static sensitive parts are present on PCA (Printed Circuit Assemblies). Before touching PCAs, touch a bare metal part of the chassis to discharge any electrostatic potentials or connect a grounding strap to your wrist.

CAUTION

Never disconnect PCAs, wiring harnesses or electronic subassemblies while under power.

4.Inspect the interior of the instrument to make sure all circuit boards and other components are in good shape and properly seated.

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5.Check the connectors of the various internal wiring harnesses and pneumatic hoses to make sure they are firmly and properly seated.

6.Verify that all of the optional hardware ordered with the unit has been installed. These are listed on the paperwork accompanying the analyzer.

7.Once you have determined that no shipping damage exists, and the unit includes all expected hardware options, remove all red colored shipping screws from the bottom of the chassis as shown in Figure 3-1.

Shipping

Screws

Figure 3-1: Removal of Shipping Screws

NOTE

Save these shipping screws and re-install them whenever the unit is shipped to another location.

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8.VENTILATION CLEARANCE: Whether the analyzer is set up on a bench or installed into an instrument rack, be sure to leave sufficient ventilation clearance.

AREA	MINIMUM REQUIRED CLEARANCE
Back of the instrument	4 in.
Sides of the instrument	1 in.
Above and below the instrument	1 in.

•Various rack mount kits are available for this analyzer. See Section 5.1 of this manual for more information.

3.1.1. Electrical Connections

CAUTION

Check the voltage and frequency label on the rear panel of the instrument (See Figure 3-2) for compatibility with the local power before plugging the MGFC7000E into line power.

Do not plug in the power cord if the voltage or frequency is incorrect.

CAUTION

Power connection must have functioning ground connection.

Do not defeat the ground wire on power plug.

CAUTION

Turn off analyzer power before disconnecting or connecting electrical subassemblies.

Do not operate with cover off.

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Figure 3-2: Rear Panel Layout

9.Attach a strip chart recorder and/or data-logger to the appropriate analog output connections on the rear panel of the analyzer.

				ANALOG
		A1		A2	A3		A4
1		2	3	4	5	6	7	8

When the instrument is in its default configuration, the A1 and A2 channels output a signal that is proportional to the CO2 concentration of the sample gas. Either can be used for connecting the analog output signal to a chart recorder or for interfacing with a datalogger.

The third analog output, labeled A3 is special. It can be set by the user (see Section 6.9.9) to output any one of the parameters accessible through the <TST TST> keys of the units sample display.

The standard configuration for these outputs is mVDC. An optional current loop output is available for each.

Output A4 is not used on the Model 306E.

Pin-outs for the analog output connector at the rear panel of the instrument are:

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Model GFC7000E Instruction Manual								Getting Started
			Table 3-1: GFC7000E Analog Output Pin Outs
		Pin		Analog Output		VDC Signal		mADC Signal
	1			A1		V Out		I Out +
	2					Ground		I Out -
	3			A2		V Out		I Out +
	4					Ground		I Out -
	5			A3		V Out		I Out +
	6					Ground		I Out -
	7			A4 (Spare)		V Out		Not Available
	8					Ground		Not Available

•The default analog output voltage setting of the GFC7000E CO2 Analyzer is 0 – 5 VDC with a range of 0 – 500 ppm.

•TO change these settings, see Sections 6.9.4 and 6.7 respectively.

10.If you wish utilize the analyzer’s status outputs to interface with a device that accepts logiclevel digital inputs, such as programmable logic controllers (PLC’s) they are accessed via a 12pin connector on the analyzer’s rear panel labeled STATUS.

STATUS

	1 2 3 4 5 6 7 8 D	+

NOTE

Most PLC’s have internal provisions for limiting the current that the input will draw from an external device. When connecting to a unit that does not have this feature, an external dropping resistor must be used to limit the current through the transistor output to less than 50mA. At 50mA, the transistor will drop approximately 1.2V from its collector to emitter.

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The pin assignments for the status outputs can be found in the table below:

Table 3-2: GFC7000E Status Output Pin Outs

	Output #		Status	Condition
			Definition
	1		SYSTEM OK	On if no faults are present.
	2		CONC VALID	On if CO2 concentration measurement is valid.
				If the CO2 concentration measurement is invalid, this bit is OFF.
	3		HIGH RANGE	On if unit is in high range of DUAL or AUTO range modes.
	4		ZERO CAL	On whenever the instruments ZERO point is being calibrated.
	5		SPAN CAL	On whenever the instruments SPAN point is being calibrated.
	6		DIAG MODE	On whenever the instrument is in DIAGNOSTIC mode.
	7		ALARM1	On whenever the measured CO2 concentration is above the set
				point for ALM1
	8		ALARM2	On whenever the measured CO2 concentration is above the set
				point for ALM2
	D		EMITTER BUSS	The emitters of the transistors on pins 1-8 are bussed together.
	+		DC POWER	+ 5 VDC
			Digital Ground	The ground level from the analyzer’s internal DC power supplies.

11.If you wish to use the analyzer’s to remotely activate the zero and span calibration modes, several digital control inputs are provided via a 10-pin connector labeled CONTROL IN on the analyzer’s rear panel. Two methods for energizing the inputs are provided below; the first using the internal +5V available on the CONTROL IN connector and the second, if an external, isolated supply is employed.

	CONTROL IN				CONTROL IN

	A B C D E F			U +		A B C D E F			U +
					Z	S
Z	S
E	P				E	P
R	A				R	A
O	N				O	N

	-		+
		5 VDC Power
		Supply
Local Power Connections	External Power Connections

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The pin assignments for the digital control inputs can be found in the table below:

		Table 3-3:	GFC7000E Control Input Pin Outs
	Input #	Status	On Condition
		Definition
	A	REMOTE ZERO	The Analyzer is placed in Zero Calibration mode. The mode
		CAL	field of the display will read ZERO CAL R.
	B	REMOTE	The Analyzer is placed in Span Calibration mode. The mode
		SPAN CAL	field of the display will read SPAN CAL R.
	C	SPARE
	D	SPARE

ESPARE

FSPARE

			Digital Ground	May be connected to the ground of the datalogger/recorder.
	U		Pullup supply	Input pin for +5 VDC required to activate pins A – F. This
				can be from an external source or from the “+” pin of the
			for inputs
				instruments STATUS connector.
	+		Internal +5V	Internal source of +5V which can be used to actuate control
			Supply	inputs when connected to the U pin.

12.If you wish to utilize either of the analyzer’s two serial interface COMM ports, refer to Section 6.10 of this manual for instructions on their configuration and usage.

13.If your unit has a Teledyne Instruments Ethernet card (Option 63), plug one end into the 7’ CAT5 cable supplied with the option into the appropriate place on the back of the analyzer (see Figure 5-4 in Section 5.5.3) and the other end into any nearby Ethernet access port.

3.1.2. Pneumatic Connections:

3.1.2.1. Basic Pneumatic Connections

Figures 3-3 and 3-4 illustrate the most common configurations for gas supply and exhaust lines to the Model GFC7000E Analyzer. Figure 3-13 illustrates the internal gas flow of the instrument in its basic configuration.

Please refer to Figure 3-2 for pneumatic connections at the rear panel and Table 3-4 for nomenclature.

NOTE

Sample and calibration gases should only come into contact with PTFE (Teflon), FEP, glass, stainless steel or brass. CAUTION

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CAUTION

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.

Table 3-4:	Model GFC7000E Rear Panel Pneumatic Connections
Rear Panel Label						Function
				Connect a gas line from the source of sample gas here.
SAMPLE				Calibration gasses are also inlet here on units without
				zero/span/shutoff valve or IZS options installed.
EXHAUST				Connect an exhaust gas line of not more than 10 meters long here.
PRESSURE SPAN				On units with zero/span/shutoff valve options installed, connect a
				gas line to the source of calibrated span gas here.
				Span gas vent outlet for units with zero/span/shutoff valve options
VENT SPAN				installed.
				Connect an exhaust gas line of not more than 10 meters long here.
				Internal zero air scrubber.
IZS				on units with zero/span/shutoff valve options installed but NO
				internal zero air scrubber, attach a gas line to the source of zero air
				here.
				This inlet supplies purge air to the GFC wheel housing (see section
PURGE IN		10.2.2)
				Connect a source of dried air that has been scrubbed of CO2.

Calibrated CO2		VENT
gas at desired			Source of
span gas
			SAMPLE Gas
concentration	Needle
			Removed
	valve to		during
	control		Calibration
	flow
Indicating		Sample
soda-lime			MODEL
	Valve	Exhaust
		Vent Span	GFC7000E
		Pressure Span

MODEL 701

Zero Air IZS

Generator

Purge In

Figure 3-3: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas

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Model GFC7000E Instruction Manual					Getting Started

Calibrated			Source of
	MODEL 700		SAMPLE Gas
CO2 Gas
	Gas Dilution		Removed
	Calibrator		during
			Calibration
Indicating
soda-lime	VENT	Sample
			MODEL
		Exhaust
			GFC7000E
		Vent Span
MODEL 701		Pressure Span
Zero Air Generator		IZS
		Purge In

Figure 3-4: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator

1.Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters long.

NOTE

Ideally, the pressure of the sample gas should be at ambient pressure (0 psig). Maximum pressure of sample gas should not exceed 1.5 in-Hg over ambient.

In applications where the sample gas is received from a pressurized manifold, a vent must be placed as shown to equalize the sample gas with ambient atmospheric pressure before it enters the analyzer.

This vent line must be:

•At least 0.2m long

•No more than 2m long and vented outside the shelter or immediate area surrounding the instrument.

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Model GFC7000E Instruction Manual

Getting Started

2.Attach sources of zero air and span gas (see Figures 3-3 through 3-8 inclusive).

•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 CO2 measurements made with the Teledyne Analytical Instruments Model GFC7000E Analyzer it is recommended that you use a gas calibrated to have a CO2 content equaling 80% of the range of compositions being measured.

EXAMPLE: If the application is to measure between 0 ppm and 500 ppm, an appropriate Span Gas would be 400 ppm. If the application is to measure between 0 ppm and 100 ppm, an appropriate Span Gas would be 80 ppm.

•Span Gas can be purchased in pressurized canisters or created using Dynamic Dilution Calibrator such as the Teledyne Analytical Instruments Model 700 and a source of dried

air scrubbed of CO2 such as a Teledyne Analytical Instruments Model 701 Zero Air Generator in combination with a canister of indicating soda-lime.

•Zero Air is similar in chemical composition to the earths atmosphere but scrubbed of all components that might affect the analyzer’s readings.

In the case of CO2 measurements this means CO2 less than 0.1 ppm of CO2 and Water Vapor. Zero Air can be purchased in pressurized canisters or created using a Teledyne Instruments Model 701 Zero Air Generator in combination with a canister of indicating soda-lime.

3.Attach an exhaust line to the exhaust outlet port.

•The exhaust from the pump and vent lines should be vented to atmospheric pressure using maximum of 10 meters of ¼” PTEF tubing.

CAUTION

Venting should be outside the shelter or immediate area surrounding the instrument.

4. Attach a source of dried air scrubbed of CO2 to the purge inlet port

NOTE

The source of purge air should be at 20-25 psig and capable of maintaining a flow of at least 0.5 liters/min.

Purge source air pressure should not exceed 35 pisg

5.Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks using a procedure similar to that defined in Section 9.3.3.

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Model GFC7000E Instruction Manual

Getting Started

3.1.2.2. Connections with Internal Valve Options Installed

Figures 3-5 through 3-8 show the proper pneumatic connections for MGFC7000E’s with various optional internal valve sets installed.

Source of

SAMPLE Gas

VENT if input is pressurized

Certified
CO2 Gas
				Sample
	Needle			Exhaust	MODEL
	valve to
	control		VENT		GFC7000E
MODEL 701	flow			Vent Span
Zero Air				Pressure Span
Generator
		VENT		IZS
				Purge In

Indicating

soda-lime

Figure 3-5: Pneumatic Connections–MGFC7000E with Zero/Span/Shutoff Valves (OPT 50)

	Source of
	SAMPLE Gas
		VENT if input is pressurized
Certified
CO2 Gas
		Sample	MODEL
MODEL 701		Exhaust
Zero Air	VENT	Vent Span	GFC7000E
Generator
		Pressure Span
	External Zero	IZS
	Air Scrubber
	Indicating	Purge In
	soda-lime

Figure 3-6 Pneumatic Connections–MGFC7000E with Zero/Span/Shutoff Valves and External Zero Air Scrubber (OPT 51)

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