Teledyne gfc 7000ta User Manual

MODEL GFC 7000TA

CARBON DIOXIDE ANALYZER

Operation Manual

Also supports operation of:

GFC 7000T CO2 Analyzer

(when used in conjunction with GFC 7000T Addendum, PN 07273)

P/N M07272

DATE 06/04/13

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

Teledyne Analytical Instruments

Model GFC7000TA Carbon Dioxide Analyzer

All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91748.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction, and that our liability shall be limited to replacing or repairing at our factory (without charge, except for transportation), or at customer plant at our option, any material or construction in which defects become apparent within one year from the date of shipment, except in cases where quotations or acknowledgements provide for a shorter period. Components manufactured by others bear the warranty of their manufacturer. This warranty does not cover defects caused by wear, accident, misuse, neglect or repairs other than those performed by Teledyne or an authorized service center. We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in so far as such alterations do not adversely affect our warranty.

Important Notice

This instrument provides measurement readings to its user, and serves as a tool by which valuable data can be gathered. The information provided by the instrument may assist the user in eliminating potential hazards caused by his process; however, it is essential that all personnel involved in the use of the instrume nt o r its int e rfac e be properly trained in the process being measured, as well as all instrumentation related to it.

The safety of personnel is ultimately the responsibility of those who control process conditions. While this instrument may be able to provide early warning of imminent danger, it has no control over process conditions, and it can be misused. In particular, any alarm or control systems installed must be tested and understood, both as to how they operate and as to how they can be defeated. Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.

Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser is responsible for the training of personnel, for providing hazard warning methods and instrumentation per the appropriate standards, and for ensuring that hazard warning devices and instrumentation are maintained and operated properly.

Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept responsibility for conditions beyond its knowledge and control. No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents, is to be construed as a warranty of adequate safety control under the user’s process conditions.

Trademarks

All trademarks, registered trademarks, brand names or product names appearing in this document are the property of their respective owners and are used herein for identification purposes only.

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Model GFC7000TA Carbon Dioxide Analyzer

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Teledyne Analytical Instruments iii

Safety Messages Model GFC7000TA Carbon Dioxide Analyzer

SAFETY MESSAGES

Important safety messages are provided throughout this manual for the purpose of avoiding personal injury or instrument damage. Please read these messages carefully. Each safety message is associated with a safety alert symbol, and are placed throughout this manual; the safety symbols are also located inside the instrument.

descriptions of which are as follows:

It is imperative that you pay close attention to these messages, the

WARNING: Electrical Shock Hazard

HAZARD: Strong oxidizer

GENERAL WARNING/CAUTION: Read the accompanying message for

specific information.

CAUTION: Hot Surface Warning

Do Not Touch: Touching some parts of the instrument without

protection or proper tools could result in damage to the part(s) and/or the instrument.

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

Electrical Ground: This symbol inside the instrument marks the central safety grounding point for the instrument.

CAUTION

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

NEVER use any gas analyzer to sample combustible gas(es)!

Note: Technical Assistance regarding the use and maintenance of the GFC7001TA or

any other Teledyne product can be obtained by contacting Teledyne Customer Service Department:

Phone: 888-789-8168

Email: ask_tai@teledyne.com

or by accessing various service options on our website at

http://www.teledyne-ai.com/

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Safety Messages Model GFC7000TA Carbon Dioxide Analyzer

CONSIGNES DE SÉCURITÉ

Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes. Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments. Les symboles correspondent aux consignes suivantes :

AVERTISSEMENT : Risque de choc électrique

DANGER : Oxydant puissant

AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne

complémentaire pour des renseignements spécifiques

MISE EN GARDE : Surface chaude

Ne pas toucher : Toucher à certaines parties de l’instrument sans protection ou

sans les outils appropriés pourrait entraîner des dommages aux pièces ou à l’instrument.

Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent être effectuées uniquement par du personnel de maintenance qualifié.

Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central de la mise à la terre sécuritaire de l’instrument.

MISE EN GARDE

Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans ce manuel. Si vous utilisez cet instrument d’une autre manière que celle pour laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible et entraîner des conséquences dangereuses.

NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz combustibles!

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Safety Messages Model GFC7000TA Carbon Dioxide Analyzer

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Manual Information Model GFC7000TA Carbon Dioxide Analyzer

ABOUT THIS MANUAL

This manual, PN 07272, provides operation instructions for the GFC 7000TA Analyzer, and supports operation of the Model GFC 7000T (when used in conjunction with the GFC 7000T Addendum, PN 07273). This manual is comprised of multiple documents as listed below.

Part No. Rev Name/Description

07272 A GFC 7000TA Carbon Dioxide Analyzer Operation Manual

05233 H Menu trees and software documentation (inserted as Appendix A of this manual)

06879

04411 M Recommended Spare Parts Stocking Levels 05235 C Repair Request Questionnaire (inserted as Appendix C of this manual)

0691201 B Interconnect Wire List (located in Appendix D of this manual)

069121 B Interconnect Wiring Diagram (located in Appendix D of this manual)

03297 K PCA, 03296, IR Photodetector Preamp and Sync Demodulator

03632 A PCA, 03631, 0-20mA driver

04003 N PCA, 04003, Pressure/Flow Transducer Interface

04089 A PCA, 04088, Opto Pickup Interface

04136 B PCA, 04135 Rev A, Relay

04468 B PCA, 04467, Analog Output Series Res

05803 B SCH, PCA 05802, MOTHERBOARD, GEN-5

06698 D SCH, PCA 06697, INTRFC, LCD TCH SCRN,

06882 B SCH, LVDS TRANSMITTER BOARD

06731 A SCH, AUXILLIARY-I/O BOARD

1/4/2011

Interconnects and Schematics included in Appendix D of this manual

Spare Parts List (located in Appendix B, this manual)

NOTE

Please read this manual in its entirety before operating the instrument.

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Manual Information Model GFC7000TA Carbon Dioxide Analyzer

2010, T360 Manual, PN0 Rev A, DCN

Document PN Rev DCN Change Summary

For the purpose of capturing this manual’s construct at its initial release, the following list documents the current Rev of each part comprising Rev A of this manual. Any future changes to this manual will be recorded in this Revision History section, most recent changes at the top. Their new Rev letters will be updated in the preceding About This Manual section:

0xxxx

X Initial Release

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Table of Contents Model GFC7000TA Carbon Dioxide Analyzer

TABLE OF CONTENTS

SAFETY MESSAGES ............................................................................................................................................... v

CONSIGNES DE SÉCURITÉ ................................................................................................................................... vi

ABOUT this MANUAL .............................................................................................................................................. ix

TABLE OF CONTENTS ........................................................................................................................................... xi

1. INTRODUCTION ........................................................................................................................................................ 1

1.1. Features ............................................................................................................................................................. 1

1.2. Using This Manual .............................................................................................................................................. 1

2. SPECIFICATIONS AND APPROVALS ..................................................................................................................... 5

2.1. Specifications ..................................................................................................................................................... 5

2.2. CE Mark Compliance ......................................................................................................................................... 7

3. GETTING STARTED ................................................................................................................................................. 9

3.1. Unpacking and Initial Set Up .............................................................................................................................. 9

3.2. Front Panel ....................................................................................................................................................... 11

3.3. Rear Panel ....................................................................................................................................................... 15

3.4. Internal Layout ................................................................................................................................................. 17

3.5. Electrical Connections ...................................................................................................................................... 19

3.5.1. Power Connection .................................................................................................................................... 20

3.5.2. Connecting Analog Inputs (Option 64) ...................................................................................................... 20

3.5.3. Connecting Analog Outputs ...................................................................................................................... 21

3.5.4. Connecting the Status Outputs ................................................................................................................. 23

3.5.5. Connecting the Control Inputs .................................................................................................................. 24

3.5.6. Connecting the Communications Interfaces ............................................................................................. 25

3.6. Pneumatic Connections ................................................................................................................................... 25

3.6.1. Basic Pneumatic Connections .................................................................................................................. 26

3.6.2. Connections with Internal Valve Options Installed .................................................................................... 30

3.6.3. Pneumatic Connections in Multipoint Calibration Applications.................................................................. 32

3.6.4. Setting the Internal Purge Air Pressure .................................................................................................... 32

3.7. Initial Operation ................................................................................................................................................ 33

3.7.1. Startup ...................................................................................................................................................... 33

3.7.2. Warm Up................................................................................................................................................... 34

3.7.3. Warning Messages ................................................................................................................................... 34

3.7.4. Functional Check ...................................................................................................................................... 36

3.8. Initial Calibration Procedure ............................................................................................................................. 37

3.8.1. Initial O

4. FREQUENTLY ASKED QUESTIONS ..................................................................................................................... 45

4.1. FAQ’s ............................................................................................................................................................... 45

4.2. Glossary ........................................................................................................................................................... 46

5. OPTIONAL HARDWARE AND SOFTWARE .......................................................................................................... 51

5.1. Rack Mount Kits (Options 20A, 20B, 21 and 23) .............................................................................................. 51

5.2. Current Loop Analog Outputs (Option 41) ........................................................................................................ 51

5.2.1. Converting Current Loop Analog Outputs to Standard Voltage Outputs ................................................... 52

5.3. Expendable Kits (Options 42C, 42D and 43) .................................................................................................... 53

5.4. Calibration Valves Options ............................................................................................................................... 54

5.4.1. Ambient Zero/Pressurized Span Valve ..................................................................................................... 54

5.4.2. Ambient Zero/Ambient Span Valve ........................................................................................................... 55

5.5. Communication Options ................................................................................................................................... 57

5.5.1. Communications Cables ........................................................................................................................... 57

5.5.2. RS-232 Multidrop (Option 62) ................................................................................................................... 57

5.6. Oxygen Sensor (OPT 65) ................................................................................................................................. 58

5.6.1. Theory of Operation .................................................................................................................................. 58

5.7. Special Features .............................................................................................................................................. 61

5.7.1. Dilution Ratio Option ................................................................................................................................. 61

5.7.2. Maintenance Mode Switch ........................................................................................................................ 61

5.7.3. Second Language Switch ......................................................................................................................... 61

6. OPERATING INSTRUCTIONS ................................................................................................................................ 63

6.1. Overview of Operating modes .......................................................................................................................... 63

6.2. Sample Mode ................................................................................................................................................... 64

Sensor Calibration Procedure .................................................................................................... 40

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6.2.1. Test Functions .......................................................................................................................................... 65

6.2.2. Warning Messages ................................................................................................................................... 67

6.3. Calibration Mode .............................................................................................................................................. 68

6.4. SETUP MODE.................................................................................................................................................. 69

6.5. SETUP  CFG: Viewing the Analyzer’s Configuration Information ................................................................. 70

6.6. SETUP  ACAL: Automatic Calibration .......................................................................................................... 70

6.7. SETUP  DAS: Using the Data Acquisition System (DAS) ............................................................................. 71

6.7.1. DAS Structure ........................................................................................................................................... 72

6.7.2. Default DAS Channels .............................................................................................................................. 74

6.7.3. Remote DAS Configuration....................................................................................................................... 88

6.8. SETUP  RNGE: Analog Output Reporting Range Configuration .................................................................. 89

6.8.1. Physical Range versus Analog Output Reporting Ranges ........................................................................ 90

6.8.2. Reporting Range Modes ........................................................................................................................... 90

6.8.3. Single Range Mode (SNGL) ..................................................................................................................... 92

6.8.4. Dual Range Mode (DUAL) ........................................................................................................................ 93

6.8.5. Auto Range Mode (AUTO)........................................................................................................................ 94

6.8.6. Range Units .............................................................................................................................................. 95

6.8.7. Dilution Ratio ............................................................................................................................................ 96

6.9. SETUP  PASS: Password Feature ............................................................................................................... 97

6.10. SETUP  CLK: Setting the Internal Time-of-Day Clock ................................................................................ 99

6.11. SETUP  MORE COMM: Using the Analyzer’s Communication Ports .................................................... 101

6.11.1. Analyzer ID ........................................................................................................................................... 101

6.11.2. COM Port Default Settings .................................................................................................................... 102

6.11.3. RS-485 Configuration of COM2 ............................................................................................................ 105

6.11.4. DTE and DCE Communication ............................................................................................................. 105

6.11.5. COM Port Communication Modes ........................................................................................................ 106

6.11.6. Remote Access via the Ethernet ........................................................................................................... 108

6.11.7. Multidrop RS-232 Set Up ...................................................................................................................... 114

6.11.8. COM Port Baud Rate ............................................................................................................................ 116

6.11.9. COM Port Testing ................................................................................................................................. 117

6.12. SETUP  MORE  VARS: Internal Variables (VARS) ............................................................................... 118

6.13. SETUP  MORE  DIAG: Using the Diagnostics Functions ..................................................................... 120

6.13.1. Accessing the Diagnostic Features ....................................................................................................... 121

6.13.2. Signal I/O .............................................................................................................................................. 121

6.13.3. Analog Output Step Test ...................................................................................................................... 122

6.13.4. Analog I/O Configuration ...................................................................................................................... 123

6.13.5. Electric Test .......................................................................................................................................... 136

6.13.6. Dark Calibration Test ............................................................................................................................ 137

6.13.7. Pressure Calibration ............................................................................................................................. 138

6.13.8. Flow Calibration .................................................................................................................................... 139

6.13.9. Test Channel Output ............................................................................................................................. 140

6.14. SETUP MORE  ALRM: Using the Gas Concentration Alarms ............................................................... 141

6.14.1. Setting the Concentration Alarm Limits ................................................................................................. 142

6.15. Remote Operation of the Analyzer ............................................................................................................... 142

6.15.1. Remote Operation Using the External Digital I/O .................................................................................. 142

6.15.2. Remote Operation Using the External Serial I/O .................................................................................. 146

6.15.3. Additional Communications Documentation ......................................................................................... 153

6.15.4. Using the GFC 7000TA with a Hessen Protocol Network ..................................................................... 153

7. CALIBRATION PROCEDURES ............................................................................................................................ 161

7.1. Before Calibration ........................................................................................................................................... 161

7.1.1. Zero Air and Span Gas ........................................................................................................................... 161

7.1.2. Calibration Gas Traceability .................................................................................................................... 162

7.1.3. Data Recording Devices ......................................................................................................................... 162

7.2. Manual Calibration without Zero/Span Valves ................................................................................................ 162

7.3. Manual Calibration Checks ............................................................................................................................ 165

7.4. Manual Calibration with Zero/Span Valves ..................................................................................................... 166

7.5. Manual Calibration Checks with Zero/Span Valves ........................................................................................ 171

7.5.1. Zero/Span Calibration on Auto Range or Dual Ranges .......................................................................... 172

7.5.2. Use of Zero/Span Valves with Remote Contact Closure ........................................................................ 173

7.6. Automatic Zero/Span Cal/Check (AutoCal) .................................................................................................... 173

7.6.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected .............................................................. 176

7.7. Calibration Quality .......................................................................................................................................... 176

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8. MAINTENANCE SCHEDULE & PROCEDURES .................................................................................................. 179

8.1. Maintenance Schedule ................................................................................................................................... 179

8.2. Predicting Failures Using the Test Functions ................................................................................................. 183

8.3. Maintenance Procedures ............................................................................................................................... 184

8.3.1. Replacing the Sample Particulate Filter .................................................................................................. 184

8.3.2. Rebuilding the Sample Pump ................................................................................................................. 185

8.3.3. Performing Leak Checks ........................................................................................................................ 185

8.3.4. Performing a Sample Flow Check .......................................................................................................... 186

8.3.5. Cleaning the Optical Bench .................................................................................................................... 186

8.3.6. Cleaning Exterior Surfaces of the GFC 7000TA ..................................................................................... 186

9. THEORY OF OPERATION .................................................................................................................................... 187

9.1. Measurement Method .................................................................................................................................... 187

9.1.1. Beer’s Law .............................................................................................................................................. 187

9.1.2. Measurement Fundamentals .................................................................................................................. 187

9.1.3. Gas Filter Correlation .............................................................................................................................. 188

9.1.4. Interference and Signal to Noise Rejection ............................................................................................. 190

9.2. Pneumatic Operation ...................................................................................................................................... 193

9.2.1. Sample Gas Flow ................................................................................................................................... 194

9.2.2. Flow Rate Control ................................................................................................................................... 194

9.2.3. Purge Gas Pressure Control ................................................................................................................... 196

9.2.4. Particulate Filter ...................................................................................................................................... 196

9.2.5. Pneumatic Sensors ................................................................................................................................. 196

9.3. Electronic Operation ....................................................................................................................................... 197

9.3.1. Overview ................................................................................................................................................. 197

9.3.2. CPU ........................................................................................................................................................ 199

9.3.3. Optical Bench & GFC Wheel .................................................................................................................. 200

9.3.4. Synchronous Demodulator (Sync/Demod) Assembly ............................................................................. 202

9.3.5. Relay Board ............................................................................................................................................ 205

9.3.6. Mother Board .......................................................................................................................................... 207

9.3.7. I

9.3.8. Power Supply/ Circuit Breaker ................................................................................................................ 211

9.4. Front Panel Touchscreen/Display Interface ................................................................................................... 212

9.4.1. LVDS Transmitter Board ......................................................................................................................... 212

9.4.2. Front Panel Touchscreen/Display Interface PCA .................................................................................... 212

9.5. Software Operation ........................................................................................................................................ 213

9.5.1. Adaptive Filter ......................................................................................................................................... 213

9.5.2. Calibration - Slope and Offset ................................................................................................................. 214

9.5.3. Measurement Algorithm .......................................................................................................................... 214

9.5.4. Temperature and Pressure Compensation ............................................................................................. 215

9.5.5. Internal Data Acquisition System (DAS) ................................................................................................. 215

10. TROUBLESHOOTING & REPAIR PROCEDURES ............................................................................................ 217

10.1. General Troubleshooting Hints ..................................................................................................................... 217

10.1.1. Interpreting WARNING Messages ........................................................................................................ 218

10.1.2. Fault Diagnosis with TEST Functions ................................................................................................... 221

10.1.3. Using the Diagnostic Signal I/O Function ............................................................................................. 223

10.1.4. Internal Electronic Status LEDs ............................................................................................................ 224

10.2. Gas Flow Problems ...................................................................................................................................... 228

10.2.1. GFC 7000TA Internal Gas Flow Diagrams ........................................................................................... 229

10.2.2. Typical Sample Gas Flow Problems ..................................................................................................... 232

10.2.3. Poor or Stopped Flow of Purge Gas ..................................................................................................... 234

10.3. Calibration Problems .................................................................................................................................... 235

10.3.1. Miscalibrated ......................................................................................................................................... 235

10.3.2. Non-Repeatable Zero and Span ........................................................................................................... 236

10.3.3. Inability to Span – Touchscreen SPAN Button Not Visible ................................................................... 236

10.3.4. Inability to Zero – Touchscreen ZERO Button Not Visible .................................................................... 237

10.4. Other Performance Problems ....................................................................................................................... 238

10.4.1. Temperature Problems ......................................................................................................................... 238

10.4.2. Excessive Noise ................................................................................................................................... 240

10.5. Subsystem Checkout ................................................................................................................................... 241

10.5.1. AC Mains Configuration ........................................................................................................................ 241

10.5.2. DC Power Supply ................................................................................................................................. 241

10.5.3. I

C Data Bus ........................................................................................................................................... 210

C Bus .................................................................................................................................................. 242

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10.5.4. Touchscreen Interface .......................................................................................................................... 242

10.5.5. LCD Display Module ............................................................................................................................. 242

10.5.6. Relay Board .......................................................................................................................................... 243

10.5.7. Sensor Assembly .................................................................................................................................. 243

10.5.8. Motherboard ......................................................................................................................................... 245

10.5.9. CPU ...................................................................................................................................................... 249

10.5.10. RS-232 Communications .................................................................................................................... 249

10.6. Repair Procedures ....................................................................................................................................... 251

10.6.1. Repairing Sample Flow Control Assembly ............................................................................................ 251

10.6.2. Removing/Replacing the GFC Wheel ................................................................................................... 252

10.6.3. Disk-On-Module Replacement Procedure ............................................................................................ 253

11. A PRIMER ON ELECTRO-STATIC DISCHARGE ............................................................................................... 255

11.1. How Static Charges are Created .................................................................................................................. 255

11.2. How Electro-Static Charges Cause Damage ............................................................................................... 256

11.3. Common Myths About ESD Damage ........................................................................................................... 257

11.4. Basic Principles of Static Control .................................................................................................................. 257

LIST OF APPENDICES

APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION, L.8

APPENDIX A-1: Models GFC 7000TA and GFC 7000E Software Menu Trees APPENDIX A-2: GFC 7000 Series Setup Variables APPENDIX A-3: GFC 7000 Series Warnings and Test Measurements APPENDIX A-4: GFC 7000 Series Signal I/O Definitions APPENDIX A-5: GFC 7000 Series DAS Triggering Events APPENDIX A-6: GFC 7000 Series DAS Parameters APPENDIX A-7: Terminal Command Designators APPENDIX A-8: Terminal Key Assignments APPENDIX A-9: GFC 7000 Series MODBUS Register

APPENDIX B - SPARE PARTS LIST and RECOMMENDED SPARES STOCKING LEVELS APPENDIX C - REPAIR QUESTIONNAIRE APPENDIX D - ELECTRONIC SCHEMATICS

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Table of Contents Model GFC7000TA Carbon Dioxide Analyzer

LIST OF FIGURES

Figure 3-1: Front Panel Layout ...................................................................................................................... 11

Figure 3-2: Display Screen and Touch Control ............................................................................................. 12

Figure 3-3: Display/Touch Control Screen Mapped to Menu Charts ............................................................. 14

Figure 3-4: Rear Panel Layout ....................................................................................................................... 15

Figure 3-5: Internal Chassis Layout ............................................................................................................... 17

Figure 3-6: Optical Bench Layout .................................................................................................................. 18

Figure 3-7: GFC 7000TA Internal Gas Flow .................................................................................................. 19

Figure 3-8: Analog In Connector .................................................................................................................... 20

Figure 3-9: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas .................................... 27

Figure 3-10: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator ............................ 27

Figure 3-11: Pneumatic Connections with Ambient Zero/Ambient Span Valves (OPT 50A) .......................... 30

Figure 3-12: Pneumatic Connections with Ambient Zero/Ambient Span Valves (Opt 50A) and

External Zero Air Scrubber .......................................................................................................... 30

Figure 3-13: Pneumatic Connections with Ambient Zero/Pressurized Span Valves (OPT 50B) .................... 31

Figure 3-14: Pneumatic Connections with Ambient Zero/Pressurized Span Valves (Opt 50B) and

External Zero Air Scrubber .......................................................................................................... 31

Figure 3-15: Example of Pneumatic Set up for Multipoint Calibration ............................................................. 32

Figure 3-16: O2 Sensor Calibration Set Up ..................................................................................................... 40

Figure 5-1: Current Loop Option Installed on the Motherboard ..................................................................... 52

Figure 5-2: Internal Pneumatic Flow – Ambient Zero/Pressurized Span Valves ........................................... 55

Figure 5-3: Internal Pneumatic Flow – Ambient Zero/Ambient Span ............................................................ 56

Figure 5-4: Multi-drop/LVDS PCA Seated on CPU ....................................................................................... 58

Figure 5-5: Oxygen Sensor - Principle of Operation ...................................................................................... 59

Figure 5-6: GFC 7000TA – Internal Pneumatics with O2 Sensor Option 65 ................................................. 60

Figure 6-1: Front Panel Display ..................................................................................................................... 63

Figure 6-2: Viewing TEST Functions ............................................................................................................. 66

Figure 6-3: Viewing and Clearing GFC 7000TA WARNING Messages ........................................................ 68

Figure 6-4: Default DAS Channels Setup ...................................................................................................... 75

Figure 6-5: APICOM User Interface for DAS Configuration .......................................................................... 88

Figure 6-6: Analog Output Connector Pin Out ............................................................................................... 89

Figure 6-7: Rear Panel Connector Pin-Outs for COM1 & COM2 in RS-232 Mode ..................................... 103

Figure 6-8: CPU Connector Pin-Outs for COM1 & COM2 in RS-232 Mode ............................................... 104

Figure 6-9: Multidrop/LVDS PCA Seated on CPU ....................................................................................... 114

Figure 6-10: RS232-Multidrop PCA Host/Analyzer Interconnect Diagram .................................................... 115

Figure 6-11: Setup for Calibrating Analog Voltage Outputs .......................................................................... 130

Figure 6-12: Setup for Calibrating Current Outputs ....................................................................................... 132

Figure 6-13: Status Output Connector ........................................................................................................... 143

Figure 6-14: Control Inputs ............................................................................................................................ 145

Figure 6-15: APICOM Remote Control Program Interface ............................................................................ 152

Figure 7-1: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas .................................. 162

Figure 7-2: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator .......................... 163

Figure 7-3: Pneumatic Connections – Ambient Zero/Pressurized Span Valves ........................................ 166

Figure 7-4: Pneumatic Connections – Ambient Zero/Pressurized Span Valves and External Zero Air

Scrubber .................................................................................................................................... 167

Figure 7-5: Pneumatic Connections – Ambient Zero/Ambient Span Valves ............................................... 167

Figure 7-6: Pneumatic Connections – Ambient Zero/Ambient Span Valves with External Zero Air

Scrubber .................................................................................................................................... 168

Figure 8-1: Sample Particulate Filter Assembly .......................................................................................... 184

Figure 9-1: Measurement Fundamentals ..................................................................................................... 188

Figure 9-2: GFC Wheel ................................................................................................................................ 188

Figure 9-3: Measurement Fundamentals with GFC Wheel ......................................................................... 189

Figure 9-4: Affect of CO2 in the Sample on CO2 MEAS & CO2 REF ......................................................... 190

Figure 9-5: Effects of Interfering Gas on CO2 MEAS & CO2 REF .............................................................. 191

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Figure 9-6: Chopped IR Signal .................................................................................................................... 191

Figure 9-7: Internal Pneumatic Flow – Basic Configuration ........................................................................ 194

Figure 9-8: Flow Control Assembly & Critical Flow Orifice .......................................................................... 195

Figure 9-9: GFC 7000TA Electronic Block Diagram .................................................................................... 198

Figure 9-10: CPU Board ................................................................................................................................ 199

Figure 9-11: GFC Light Mask ........................................................................................................................ 201

Figure 9-12: Segment Sensor and M/R Sensor Output ................................................................................. 202

Figure 9-13: GFC 7000TA Sync / Demod Block Diagram ............................................................................. 203

Figure 9-14: Sample & Hold Timing ............................................................................................................... 204

Figure 9-15: Location of relay board Status LED’s ........................................................................................ 207

Figure 9-16: Power Distribution Block Diagram ............................................................................................. 211

Figure 9-17: Front Panel and Display Interface Block Diagram .................................................................... 212

Figure 9-18: Basic Software Operation .......................................................................................................... 213

Figure 10-1: Viewing and Clearing Warning Messages ................................................................................ 219

Figure 10-2: Example of Signal I/O Function ................................................................................................. 224

Figure 10-3: CPU Status Indicator ................................................................................................................. 225

Figure 10-4: Sync/Demod Board Status LED Locations ............................................................................... 226

Figure 10-5: Relay Board Status LEDs .......................................................................................................... 226

Figure 10-6: GFC 7000TA – Basic Internal Gas Flow ................................................................................... 229

Figure 10-7: Internal Pneumatic Flow – Ambient Zero/Pressurized Span Valves ......................................... 230

Figure 10-8: Internal Pneumatic Flow – Ambient Zero/Ambient Span .......................................................... 231

Figure 10-9: GFC 7000TA – Internal Pneumatics with O2 Sensor Option 65A ............................................. 232

Figure 10-10: Critical Flow Restrictor Assembly Disassembly ........................................................................ 251

Figure 10-11: Opening the GFC Wheel Housing ............................................................................................. 252

Figure 10-12: Removing the GFC Wheel ........................................................................................................ 253

Figure 11-1: Triboelectric Charging ............................................................................................................... 255

Figure 11-2: Basic anti-ESD Work Station ..................................................................................................... 258

LIST OF TABLES

Table 2-1: Model GFC 7000TA Basic Unit Specifications ..................................................................................... 5

Table 3-1: Display and Touchscreen Control Description ................................................................................... 13

Table 3-2: Rear Panel Description ....................................................................................................................... 16

Table 3-3: Analog Input Pin Assignments ............................................................................................................ 21

Table 3-4: GFC 7000TA Analog Output Pin Outs ................................................................................................ 22

Table 3-5: Status Output Pin-outs ........................................................................................................................ 23

Table 3-6: Control Input Pin-outs ......................................................................................................................... 24

Table 3-7: Rear Panel Pneumatic Connections ................................................................................................... 26

Table 3-8: Front Panel Display During System Warm-Up ................................................................................... 34

Table 3-9: Possible Warning Messages at Start-Up ............................................................................................ 35

Table 5-1: Ambient Zero/Pressurized Span Valve Operating States .................................................................. 54

Table 5-2: Ambient Zero/Ambient Span Valve Operating States ........................................................................ 55

Table 6-1: Analyzer Operating modes ................................................................................................................. 64

Table 6-2: Test Functions Defined ....................................................................................................................... 65

Table 6-3: List of Warning Messages .................................................................................................................. 67

Table 6-4: Primary Setup Mode Features and Functions .................................................................................... 69

Table 6-5: Secondary Setup Mode Features and Functions ............................................................................... 69

Table 6-6: Front Panel Sample LED Status Indicators for DAS .......................................................................... 71

Table 6-7: DAS Data Channel Properties ............................................................................................................ 72

Table 6-8: DAS Data Parameter Functions ......................................................................................................... 73

Table 6-9: Password Levels ................................................................................................................................. 97

Table 6-10: Com Port Communication Modes ..................................................................................................... 106

Table 6-11: Ethernet Status Indicators ................................................................................................................ 108

Table 6-12: LAN/Internet Configuration Properties .............................................................................................. 109

Table 6-13: Internet Configuration Touchscreen Functions ................................................................................. 113

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Table of Contents Model GFC7000TA Carbon Dioxide Analyzer

Table 6-14: Variable Names (VARS) Revision B.3 .............................................................................................. 118

Table 6-15: GFC 7000TA Diagnostic (DIAG) Functions ...................................................................................... 120

Table 6-16: DIAG - Analog I/O Functions ............................................................................................................ 123

Table 6-17: Analog Output Voltage Ranges ....................................................................................................... 124

Table 6-18: Analog Output Current Loop Range ................................................................................................. 125

Table 6-19: Analog Output Pin Assignments ....................................................................................................... 125

Table 6-20: Voltage Tolerances for Analog Output Calibration ........................................................................... 129

Table 6-21: Current Loop Output Calibration with Resistor ................................................................................. 133

Table 6-22: Test Parameters Available for Analog Output A4 ............................................................................. 140

Table 6-23: CO

Table 6-24: Status Output Pin Assignments ........................................................................................................ 144

Table 6-25: Control Input Pin Assignments ......................................................................................................... 145

Table 6-26: Terminal Mode Software Commands ............................................................................................... 146

Table 6-27: Command Types .............................................................................................................................. 147

Table 6-28: Serial Interface Documents .............................................................................................................. 153

Table 6-29: RS-232 Communication Parameters for Hessen Protocol ............................................................... 154

Table 6-30: Teledyne Instruments Hessen Protocol Response Modes .............................................................. 156

Table 6-31: Default Hessen Status Bit Assignments ........................................................................................... 158

Table 7-1: AUTOCAL Modes ............................................................................................................................. 173

Table 7-2: AutoCal ATTRIBUTE Setup Parameters .......................................................................................... 173

Table 7-3: Calibration Data Quality Evaluation .................................................................................................. 176

Table 8-1: GFC 7000TA Maintenance Schedule ............................................................................................... 181

Table 8-2: GFC 7000TA Test Function Record ................................................................................................. 182

Table 8-3: Predictive uses for Test Functions.................................................................................................... 183

Table 9-1: Sync/Demod Status LED Activity ...................................................................................................... 204

Table 9-2: Relay Board Status LED’s ................................................................................................................ 206

Table 10-1: Warning Messages - Indicated Failures ........................................................................................... 220

Table 10-2: Test Functions - Indicated Failures .................................................................................................. 222

Table 10-3: Sync/Demod Board Status Failure Indications ................................................................................. 225

Table 10-4: I2C Status LED Failure Indications ................................................................................................... 226

Table 10-5: Relay Board Status LED Failure Indications .................................................................................... 227

Table 10-6: DC Power Test Point and Wiring Color Codes ................................................................................. 241

Table 10-7: DC Power Supply Acceptable Levels ............................................................................................... 242

Table 10-8: Relay Board Control Devices ............................................................................................................ 243

Table 10-9: Opto Pickup Board Nominal Output Frequencies ............................................................................. 244

Table 10-10: Analog Output Test Function - Nominal Values Voltage Outputs .................................................... 247

Table 10-11: Analog Output Test Function - Nominal Values Current Outputs ..................................................... 247

Table 10-12: Status Outputs Check ....................................................................................................................... 248

Table 11-1: Static Generation Voltages for Typical Activities .............................................................................. 255

Table 11-2: Sensitivity of Electronic Devices to Damage by ESD ....................................................................... 256

Concentration Alarm Default Settings ....................................................................................... 141

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Introduction Model GFC7000TA Carbon Dioxide Analyzer

1. INTRODUCTION

The Models GFC 7000TA and GFC 7000TM differ only in specifications; unless clearly differentiated, both models in this manual are referred to as the GFC 7000TA for simplification. The GFC 7000TA measures carbon dioxide CO reference according to the Beer-Lambert law. This is accomplished by using a Gas Filter Wheel which alternately allows a high energy infrared light source to pass through a CO with no CO

The light then travels through the sample cell, which has a folded path. The energy loss through the sample cell is compared with the zero reference signal provided by the gas filter to produce an output proportional to concentration, with little effect from interfering gases within the sample. A nitrogen purge system is provided for the GFC wheel assembly to eliminate the effects of ambient CO

This design produces superior zero and span stability and a high signal-to-noise ratio, allowing excellent sensitivity. Multi-tasking software gives real time indication of numerous operating parameters and provides automatic alarms if diagnostic limits are exceeded

present.

1.1. Features

by comparing infrared energy absorbed by a sample to that absorbed by a

filled chamber and a chamber

, if necessary.

 Ranges, GFC 7000TA: 0-2 ppm to 0-2000 ppm, GFC 7000TM: 0-4 ppm to 0-4000 ppm, user

selectable

 Gas Filter Wheel for CO

 LCD Graphical User Interface with capacitive touch screen

 Multi-tasking software allows viewing of test variables during operation

 Continuous self checking with alarms

 Bi-directional RS-232 and 10/100Base-T Ethernet (optional USB and RS-485) ports for remote

operation

 Front panel USB ports for peripheral devices

 Digital status outputs to indicate instrument operating condition

 Adaptive signal filtering to optimize response time

 Temperature & Pressure compensation

 Internal data logging with 1 min to 24 hour averages

specific measurement

1.2. Using This Manual

This manual has the following data structures:

1 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.

2 SPECIFICATIONS

This section contains a list of the analyzer’s performance specifications.

Teledyne Analytical Instruments 1

Introduction Model GFC7000TA Carbon Dioxide Analyzer

3 GETTING STARTED:

Instructions for setting up, installing, and performing a functional check and initial calibration.

4 FAQ

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

5 OPTIONAL HARDWARE & SOFTWARE

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

6 OPERATION INSTRUCTIONS

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

7 CALIBRATION PROCEDURES

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

8 EPA PROTOCOL CALIBRATION

Because CO this type of analyzer. Therefore no special calibration methods are needed to satisfy EPA requirements.

9 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 DAS to record diagnostic functions useful in predicting possible component failures before they happen.

is not declared a criteria air pollutant by the US EPA, EPA equivalency is not required for

10 THEORY 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 TROUBLESHOOTING

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.

12. A PRIMER ON ELECTRO-STATIC DISCHARGE

Very important information on how static electricity occurs, why it is so dangerous to electronic components and assemblies as well as how to prevent that damage from occurring.

APPENDICES:

These include: software menu trees, warning messages, definitions of DAS & 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. Also, 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.

Teledyne Analytical Instruments 2

Introduction Model GFC7000TA Carbon Dioxide Analyzer

Teledyne Analytical Instruments 3

Specifications Model GFC7000TA Carbon Dioxide Analyzer

2. SPECIFICATIONS AND APPROVALS

2.1. Specifications

Table 2-1: Model GFC 7000TA Basic Unit Specifications

GFC 7000TA Parameter GFC 7000TA Specification

Ranges (Physical Analog Output)

Measurement Units ppb, ppm, µg/m3, mg/m3, % (user selectable) Zero Noise < 0.1 ppm (RMS) Span Noise < 1% of reading (RMS) Lower Detectable Limit < 0.2 ppm1 Zero Drift (24 hours) <0.25 ppm1 Span Drift (24 hours) <0.5% of reading 1 Lag Time 10 seconds Rise/Fall Time <60 seconds to 95% Linearity 1% of full scale Precision 0.5% of reading Sample Flow Rate 800cm3/min. ±10%

Temperature Coefficient < 0.1% of Full Scale per oC Voltage Coefficient < 0.05% of Full Scale per V AC Power Rating 100V-120V, 220V – 240 V, 50/60 Hz Analog Output Ranges 10V, 5V, 1V, 0.1V (selectable) Analog Output Resolution 1 part in 4096 of selected full-scale voltage Recorder Offset

Standard I/O

Optional I/O

Environmental Installation category (over-voltage category) II; Pollution degree 2 Temperature Range 5-40oC Humidity Range 0 - 95% RH, non-condensing Dimensions H x W x D 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm)

Min: 0-2 ppm Full scale Max: 0-2,000 ppm Full scale Selectable, dual ranges and auto ranging supported

Sensor option adds 110 cm³/min, ±20%, to total flow through when installed.

±10% 1 Ethernet: 10/100Base-T

2 RS-232 (300 – 115,200 baud) 2 USB device ports 8 opto-isolated digital status outputs 6 opto-isolated digital control inputs (3 defined, 3 spare)

4 analog outputs 1 USB com port

1 RS485 8 analog inputs (0-10V, 12-bit) 4 digital alarm outputs Multidrop RS232 3 4-20mA current outputs

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Specifications Model GFC7000TA Carbon Dioxide Analyzer

GFC 7000TA Parameter GFC 7000TA Specification

Weight 40 lbs. (18.1 kg) Certifications CE: EN61010-1:90 + A1:92 + A2:95, EN61326 - Class A

At constant temperature and voltage.

Table 2-2: Model GFC 7000TM Basic Unit Specifications

GFC 7000TM Parameter GFC 7000TM Specification

Ranges (Physical Analog Output)

Measurement Units ppb, ppm, µg/m3, mg/m3, (selectable) Zero Noise < 0.2 ppm (RMS) Span Noise < 1% of reading (RMS) Lower Detectable Limit < 0.4 ppm1 Zero Drift (24 hours) <0.5 ppm1 Span Drift (24 hours) <0.5% of reading1 Lag Time 10 seconds Rise/Fall Time <60 seconds to 95% Linearity 1% of full scale Precision 0.5% of reading Sample Flow Rate

Temperature Coefficient < 0.1% of Full Scale per oC or 0.1 ppm per oC, whichever is greater Voltage Coefficient < 0.05% of Full Scale per V AC Power Requirements 100V – 120V, 220V – 240V, 50/60 Hz Analog Output Ranges 10V, 5V, 1V, 0.1V Recorder Offset

Analog Output Resolution 1 part in 4096 of selected full-scale voltage Standard I/O

Optional I/O

Operating Temperature Range 5-40oC Humidity Range 0 - 95% RH, non-condensing Dimensions H x W x D 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm) Weight 40 lbs. (18.1 kg) Environmental Installation category (over-voltage category) II; Pollution degree 2

Min: 0-4 ppm Full scale Max: 0-4000 ppm Full scale Selectable, dual ranges and auto ranging supported

800cm

/min. ±10%

O2 Sensor option adds 110 cm³/min, ±20%, to total flow though when installed

±10%

1 Ethernet: 10/100Base-T 2 RS232 (300-115,200 baud) 2 USB device ports 8 Status opto-isolated digital status outputs 6 Opto-isolated digital control inputs (3 defined, 3 spare) 4 Analog outputs

1 USB com port 1 RS485 8 Analog inputs (0-10V, 12-bit) 4 Digital alarm outputs Multidrop RS232 3 4-20mA current outputs

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Specifications Model GFC7000TA Carbon Dioxide Analyzer

GFC 7000TM Parameter GFC 7000TM Specification

Certifications CE: EN61010-1:90 + A1:92 + A2:95, EN61326 - Class A

At constant temperature and voltage.

2.2. CE Mark Compliance

Emissions Compliance

The Teledyne Instruments Model GFC 7000TA Gas Filter Correlation CO

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.

Safety Compliance

The Teledyne Instruments Model GFC 7000TA Gas Filter Correlation CO

Analyzer was tested and found

to be fully compliant with:

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

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Getting Started Model GFC7000TA Carbon Dioxide Analyzer

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 GFC

Never disconnect PCAs, wiring harnesses or electronic subassemblies while the

CAUTION – Avoid Warranty Invalidation

Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Damage resulting from failure to use ESD protection when working with electronic assemblies will void the instrument warranty.

See A Primer on Electro-Static Discharge in this manual for more information on preventing ESD damage.

instrument is under power.

7000TA.

WARNING

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 service. See Warranty section in this manual and shipping procedures on our Website at:

http://www.teledyne-api.com under Customer Support > Return Authorization.

1. Verify that there is no apparent external shipping damage. If damage has occurred, please advise the shipper first, then Teledyne 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 (P/N 04596) 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 Front panel.  Remove the 2 screws fastening the top cover to the unit (one per side towards the rear).  Slide the cover backwards until it clears the analyzer’s front bezel.

Lift the cover straight up.

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Getting Started Model GFC7000TA Carbon Dioxide Analyzer

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

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.

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

Above and below the instrument

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

1 in. 1 in.

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Getting Started Model GFC7000TA Carbon Dioxide Analyzer

3.2. Front Panel

Figure 3-1 shows the analyzer’s front panel layout, followed by a close-up of the display screen in Figure 3-2, which is described in Table 3-1. The two USB ports on the front panel are provided for the connection of peripheral devices:

 plug-in mouse (not included) to be used as an alternative to the touchscreen interface

 thumb drive (not included) to download updates to instruction software (contact TAI Customer

Service for information).

Figure 3-1: Front Panel Layout

Teledyne Analytical Instruments 11

Getting Started Model GFC7000TA Carbon Dioxide Analyzer

Figure 3-2: Display Screen and Touch Control

CAUTION – Avoid Damaging Touchscreen

Do not use hard-surfaced instruments such as pens to operate the touchscr een.

The front panel liquid crystal display includes touch control. Upon analyzer start-up, the display shows a splash screen and other initialization indicators before the main display appears, similar to Figure 3-2 above (may or may not display a Fault alarm). The LEDs on the display screen indicate the Sample, Calibration and Fault states; also on the screen is the gas concentration field (Conc), which displays realtime readouts for the primary gas and for the secondary gas if installed. The display screen also shows which mode the analyzer is currently in (Mode field), as well as messages and data (Param field). Along the bottom of the screen is a row of touch control buttons; only those that are currently applicable will have a label. Table 3-1 provides detailed information for each component of the screen.

Teledyne Analytical Instruments 12

+ 250 hidden pages

Teledyne gfc 7000ta User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual