Teledyne GFC-7001E Instruction Manual
INSTRUCTION MANUAL
MODEL GFC7001E
CARBON MONOXIDE ANALYZER
© TELEDYNE ANALYTICAL INSTRUMENTS
(TAI)
16830 Chestnut St.
City of Industry, Ca. 91748
TEL:
626-961-9221
TEL:
626-934-1500
FAX:
626-961-2538
E-MAIL:
ai-sales@teledyne.com
WEB SITE:
www.teledyne-ai.com
GFC7001E
Revision A7
Copyright 2004 TAI Inc.
November 30, 2004
ii
GFC7001E Rev A7
INTENTIONALLY BLANK
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
iii
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 WARNING/CAUTION: Refer to the instructions
for details on the specific danger.
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.
iv
GFC7001E Rev A7
INTENTIONALLY BLANK
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
v
TABLE OF CONTENTS
1. GFC7001E DOCUMENTATION.......................................................................1
1.1. USING THIS MANUAL ......................................................................................................................2
2. SPECIFICATIONS, AGENCY APPROVALS, AND WARRANTY.....................5
2.1. SPECIFICATIONS ............................................................................................................................5
2.2. EPA EQUIVALENCY DESIGNATION ...................................................................................................7
2.3. WARRANTY....................................................................................................................................8
3. GETTING STARTED........................................................................................10
3.1. UNPACKING AND INITIAL SET UP....................................................................................................10
3.1.1. Electrical Connections........................................................................................................12
3.1.2. Pneumatic Connections: ....................................................................................................16
3.2. INITIAL OPERATION.......................................................................................................................22
3.2.1. Start Up .............................................................................................................................22
3.2.2. Warm Up ...........................................................................................................................23
3.2.3. Warning Messages ............................................................................................................23
3.2.4. Functional Check ...............................................................................................................24
3.3. INITIAL CALIBRATION PROCEDURE .................................................................................................25
4. FREQUENTLY ASKED QUESTIONS..............................................................31
5. OPTIONAL HARDWARE AND SOFTWARE ..................................................33
5.1. RACK MOUNT OPTION ..................................................................................................................33
5.2. ZERO/SPAN/SHUTOFF VALVE OPTIONS..........................................................................................33
5.2.1. Zero/Span/Shutoff Valve Option 50 ....................................................................................34
5.2.2. Zero/Span Valve Option 51 ................................................................................................35
5.2.3. Zero/Span Valve Option 52 ................................................................................................35
5.2.4. Zero/Span Valve Option 53 ................................................................................................36
5.3. CURRENT LOOP OPTION...............................................................................................................38
5.4. MULTIDROP, RS-232 OPTION .......................................................................................................39
5.5. ETHERNET INTERFACE OPTION .....................................................................................................39
5.6. DILUTION RATIO OPTION...............................................................................................................39
6. OPERATING INSTRUCTIONS ........................................................................41
6.1. OPERATING MODES .....................................................................................................................41
6.2. SAMPLE MODE.............................................................................................................................42
6.2.1. Warning Message Display..................................................................................................43
6.2.2. Test Functions ...................................................................................................................43
6.2.3. Calibration Functions .........................................................................................................46
6.3. SET-UP MODE .............................................................................................................................47
6.3.1. RNGE Menu ......................................................................................................................47
6.3.2. Automatic Calibration (AutoCal) .........................................................................................47
GFC7001E DOCUMENTATION
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
vi
GFC7001E Rev A7
6.3.3. Password Enable / Security Mode (PASS)..........................................................................47
6.3.4. Configuration Information (CFG).........................................................................................49
6.3.5. Time of Day Clock (CLK)....................................................................................................50
6.3.6. Communications Menu (COMM) ........................................................................................52
6.3.7. GFC7001E Internal Variables.............................................................................................52
6.4. ANALOG OUTPUTS – RANGE CONFIGURATION ................................................................................55
6.4.1. Physical Range vs. Measurement Range ...........................................................................55
6.4.2. A1 & A2 Measurement Range Modes.................................................................................57
6.4.3. A1 & A2 Single Range Mode..............................................................................................58
6.4.4. A1 & A2 Dual Range Mode ................................................................................................59
6.4.5. A1 & A2 Auto Range Mode ................................................................................................61
6.4.6. Setting the Measurement Range Unit Type ........................................................................62
6.4.7. TEST Channel Output........................................................................................................64
6.4.8. Using the Dilution Option....................................................................................................65
6.5. ANALOG OUTPUTS - ELECTRONIC CONFIGURATION ........................................................................66
6.5.1. Voltage Output Range Selection and Offset Adjustment .....................................................68
6.5.2. Current Loop Output Span and Offset Adjustment ..............................................................69
6.6. DIAGNOSTIC MODE (DIAG)...........................................................................................................72
6.6.1. Signal I/O Diagnostic Functions..........................................................................................74
6.6.2. Analog Output Step Test ....................................................................................................75
6.6.3. Analog I/O Configuration ....................................................................................................76
6.6.4. Electric Test.......................................................................................................................79
6.6.5. Dark Calibration Test .........................................................................................................80
6.6.6. Flow Calibration .................................................................................................................81
6.7. EXTERNAL DIGITAL I/O .................................................................................................................81
6.7.1. Status Outputs ...................................................................................................................81
6.7.2. Control Inputs ....................................................................................................................82
6.8. SERIAL INTERFACES .....................................................................................................................84
6.8.1. Serial I/O Default Settings ..................................................................................................84
6.8.2. Serial I/O Physical Connections .........................................................................................85
6.8.3. COM-B RS-232/485 Configuration .....................................................................................85
6.8.4. DTE versus DCE Communication.......................................................................................87
6.8.5. Setting the Serial I/O Communication Mode .......................................................................88
6.8.6. Setting the Serial I/O Baud Rate.........................................................................................90
6.8.7. Testing the Serial I/O .........................................................................................................91
6.9. OPERATING THE ANALYZER FROM A TERMINAL OR COMPUTER ........................................................92
6.9.1. Obtaining Help ...................................................................................................................93
6.9.2. Command Line Interface ....................................................................................................93
6.9.3. Data Types ........................................................................................................................94
6.9.4. Asynchronous Status Reporting .........................................................................................95
6.9.5. Connecting the Analyzer to a Modem .................................................................................96
6.9.6. Serial Port Password Security Feature ...............................................................................98
6.9.7. APIcom..............................................................................................................................99
6.10. THE INTERNAL DATA ACQUISITION SYSTEM (IDAS) .....................................................................100
6.10.1. When the iDAS Is Operating ..........................................................................................100
6.10.2. Disabling the iDAS.........................................................................................................101
6.10.3. iDAS Record Structure...................................................................................................101
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
vii
6.10.4. Default iDAS Channels ..................................................................................................104
6.10.5. Viewing Existing Data Channels.....................................................................................106
6.11. CONFIGURING THE IDAS...........................................................................................................107
6.11.1. Editing the List of Data Channels ...................................................................................107
6.11.2. Editing the Data Channel Name .....................................................................................108
6.11.3. Editing the Data Channel Trigger Event..........................................................................109
6.11.4. Adding or Deleting Data Parameters ..............................................................................110
6.11.5. Configuring the Data Parameter Functions.....................................................................112
6.11.6. Editing the Data Channel Report Period .........................................................................113
6.11.7. Selecting the Data Channel Number of Records.............................................................114
6.11.8. Turning the RS-232 Report Function On/Off...................................................................115
6.11.9. Disabling/Enabling the Data Channel .............................................................................116
6.11.10. Turning the HOLDOFF Feature On/Off.........................................................................117
6.11.11. Maximum Number of Channels, Parameters, and Records...........................................118
6.11.12. RS-232 Interface to the iDAS.......................................................................................118
7. CALIBRATION PROCEDURES.....................................................................120
7.1. BEFORE CALIBRATION ................................................................................................................120
7.1.1. Zero Air and Span Gas.....................................................................................................121
7.2. MANUAL CALIBRATION WITHOUT ZERO/SPAN VALVES ...................................................................122
7.3. MANUAL CALIBRATION WITH ZERO/SPAN VALVES .........................................................................125
7.3.1. Zero/Span Calibration on Auto Range or Dual Ranges .....................................................128
7.3.2. Use of Zero/Span Valves with Remote Contact Closure....................................................128
7.4. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL)..........................................................................129
8. EPA PROTOCOL CALIBRATION ................................................................. 134
8.1.1. GFC7001E Calibration – General Guidelines....................................................................134
8.1.2. Calibration Equipment, Supplies, and Expendables ..........................................................135
8.1.3. Level 1 Calibrations versus Level 2 Checks......................................................................135
8.1.4. Performing EPA Calibrations and Checks.........................................................................137
8.1.5. Precision Check ...............................................................................................................138
8.1.6. Auditing Procedure...........................................................................................................138
8.1.7. Calibration Frequency ......................................................................................................139
8.1.8. Summary of Quality Assurance Checks............................................................................140
8.1.9. Dynamic Multipoint Calibration Procedure ........................................................................140
8.2. REFERENCES.............................................................................................................................142
9. MAINTENANCE SCHEDULE & PROCEDURES ..........................................143
9.1. MAINTENANCE SCHEDULE ..........................................................................................................143
9.2. PREDICTING FAILURES USING THE TEST FUNCTIONS.....................................................................147
9.3. MAINTENANCE PROCEDURES ......................................................................................................148
9.3.1. Replacing the Sample Particulate Filter ............................................................................148
9.3.2. Rebuilding the Sample Pump ...........................................................................................149
9.3.3. Performing Leak Checks ..................................................................................................149
9.3.4. Performing a Sample Flow Check ....................................................................................151
9.3.5. Flow Calibration ...............................................................................................................152
9.3.6. Cleaning the Optical Bench ..............................................................................................153
GFC7001E DOCUMENTATION
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
viii
GFC7001E Rev A7
9.3.7. Cleaning Exterior Surfaces of the GFC7001E...................................................................153
10. THEORY OF OPERATION ..........................................................................155
10.1. MEASUREMENT METHOD ..........................................................................................................156
10.1.1. Beer’s Law.....................................................................................................................156
10.1.2. Measurement Fundamentals..........................................................................................156
10.1.3. Gas Filter Correlation.....................................................................................................157
10.2. PNEUMATIC OPERATION ...........................................................................................................161
10.2.1. Sample Gas Flow ..........................................................................................................161
10.2.2. Critical Flow Orifice ........................................................................................................162
10.2.3. Sample Pressure Sensor ...............................................................................................162
10.2.4. Sample Flow Sensor......................................................................................................163
10.2.5. Particulate Filter.............................................................................................................163
10.2.6. Valve Options ................................................................................................................163
10.3. ELECTRONIC OPERATION..........................................................................................................165
10.3.1. Overview .......................................................................................................................165
10.3.2. CPU ..............................................................................................................................167
10.3.3. Optical Bench & GFC Wheel..........................................................................................167
10.3.4. Synchronous Demodulator (Sync/Demod) Assembly......................................................170
10.3.5. Relay Board...................................................................................................................174
10.3.6. Mother Board.................................................................................................................176
10.3.7. Power Supply/ Circuit Breaker........................................................................................179
10.4. INTERFACE ..............................................................................................................................180
10.5. SOFTWARE OPERATION ............................................................................................................183
10.5.1. Adaptive Filter................................................................................................................184
10.5.2. Calibration - Slope and Offset ........................................................................................185
10.5.3. Measurement Algorithm .................................................................................................185
10.5.4. Internal Data Acquisition System (iDAS).........................................................................186
11. TROUBLESHOOTING & REPAIR PROCEDURES .................................... 189
11.1. GENERAL TROUBLESHOOTING HINTS.........................................................................................189
11.1.1. Interpreting WARNING Messages..................................................................................190
11.1.2. Fault Diagnosis with TEST Functions .............................................................................193
11.1.3. Using the Diagnostic Signal I/O Function........................................................................195
11.1.4. Internal Electronic Status LED’s .....................................................................................197
11.2. GAS FLOW PROBLEMS..............................................................................................................201
11.2.1. Typical Flow Problems ...................................................................................................201
11.3. CALIBRATION PROBLEMS ..........................................................................................................203
11.3.1. Miss-Calibrated..............................................................................................................203
11.3.2. Non-Repeatable Zero and Span.....................................................................................204
11.3.3. Inability to Span – No SPAN Key....................................................................................204
11.3.4. Inability to Zero – No ZERO Key ....................................................................................205
11.4. OTHER PERFORMANCE PROBLEMS............................................................................................205
11.4.1. Temperature Problems ..................................................................................................205
11.4.2. Excessive Noise ............................................................................................................207
11.5. SUBSYSTEM CHECKOUT ...........................................................................................................208
11.5.1. AC Mains Configuration .................................................................................................208
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
ix
11.5.2. DC Power Supply ..........................................................................................................209
11.5.3. I2C Bus ..........................................................................................................................211
11.5.4. Keyboard/Display Interface ............................................................................................211
11.5.5. Relay Board...................................................................................................................211
11.5.6. Sensor Assembly...........................................................................................................212
11.5.7. Motherboard ..................................................................................................................215
11.5.8. CPU ..............................................................................................................................217
11.5.9. RS-232 Communications ...............................................................................................218
11.6. REPAIR PROCEDURES ..............................................................................................................219
11.6.1. Repairing Sample Flow Control Assembly......................................................................220
11.6.2. Removing/Replacing the GFC Wheel .............................................................................221
11.6.3. Disk-On-Chip Replacement Procedure...........................................................................224
GFC7001E DOCUMENTATION
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
x
GFC7001E Rev A7
List of Appendices
APPENDIX A – Software Version-Specific Documentation
APPENDIX A-1 - Software Menu Trees and Index
APPENDIX A-2 - Setup Variables Available Via Serial I/O
APPENDIX A-3 - Warning Messages and Test Measurements Available Via Serial I/O
APPENDIX A-4 - Signal I/O Definitions
APPENDIX A-5 - iDAS Functions
APPENDIX A-6 – Terminal Command Designators
APPENDIX B – GFC7001E Spare Parts List
APPENDIX C – Test Functions and Repair Questionnaire for GFC7001E
APPENDIX D – ELECTRONIC SCHEMATICS, INTERCONNECTION
DRAWING AND INTERCONNECTION LIST
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
xi
INTENTIONALLY BLANK
GFC7001E DOCUMENTATION
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
xii
GFC7001E Rev A7
List of Figures
Figure 3–1: Removal of Shipping Screws.................................................................... 11
Figure 3–2: Rear Panel Connectors............................................................................ 16
Figure 3–3: Basic Pneumatic Connections Flow Diagram .............................................. 18
Figure 3–4: Pneumatic Connections Flow Diagram w/ Valve Options ............................. 20
Figure 3–5: Example Pneumatic Connections Flow Diagram through Gas Dilution
Calibrator.............................................................................................. 21
Figure 3–6: Assembly Layout.................................................................................... 29
Figure 5–1: Pneumatic Diagram – Zero/Span/Shutoff Valves & Internal Zero ................. 34
Figure 5–2: Pneumatic Diagram – Zero/Span/Shutoff Valves & Internal Zero with Zero
Air Scrubber.......................................................................................... 35
Figure 5-3: Pneumatic Diagram – Zero/Span/ Valves & Internal Zero............................ 35
Figure 5-4: Pneumatic Diagram – Zero/Span/ Valves & Internal Zero with Zero Air
Scrubber............................................................................................... 36
Figure 5–5: Current Loop Option Installed.................................................................. 38
Figure 6–1: Front Panel Display ................................................................................ 41
Figure 6–2: Analog Output Pin Assignments ............................................................... 68
Figure 6–3: Setup for Checking Current Output Signal Levels....................................... 70
Figure 6–4: Status Output Connector......................................................................... 81
Figure 6–5: Control Inputs ....................................................................................... 83
Figure 6–6: Default iDAS Channels Setup..................................................................105
Figure 7-1: Pneumatic Connections for Manual Calibration w/o Z/S Valves....................122
Figure 7–2: Pneumatic connections for Manual Calibration With Z/S Valves ..................125
Figure 9–1: Replacing the Particulate Filter................................................................148
Figure 10-1: Measurement Fundamentals .................................................................157
Figure 10-2: GFC Wheel ..........................................................................................157
Figure 10-3: Measurement Fundamentals with GFC Wheel ..........................................158
Figure 10-4: Affect of CO in the Sample on CO MEAS & CO REF...................................159
Figure 10-5: Effects of Interfering Gas on CO MEAS & CO REF.....................................160
Figure 10-6: Chopped IR Signal ...............................................................................160
Figure 10-7: Model GFC7001E Pneumatic Operation ...................................................161
Figure 10-8: GFC7001E Electronic Block Diagram.......................................................165
Figure 10-9: GFC Light Mask....................................................................................169
Figure 10-10: Segment Sensor and M/R Sensor Output ..............................................169
Figure 10-11: GFC7001E Sync / Demod Block Diagram ..............................................171
Figure 10-12: Sample & Hold Timing ........................................................................172
Figure 10-13: Location of Relay Board Status LED’s ...................................................175
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
xiii
Figure 10-14: Power Distribution Block Diagram ........................................................180
Figure 10-15: Interface Block Diagram .....................................................................181
Figure 10-16: Front Panel........................................................................................182
Figure 10-17: Basic Software Operation ....................................................................184
Figure 11-1: Viewing and Clearing Warning Messages ................................................191
Figure 11-2: Example of Signal I/O Function .............................................................196
Figure 11-3: CPU Status Indicator ............................................................................197
Figure 11-4: Sync/Demod Board Status LED Locations ...............................................198
Figure 11-5: Relay Board Status LEDs ......................................................................199
Figure 11-6: Critical Flow Restrictor Assembly Disassembly.........................................221
Figure 11-7: Removing the GFC Sensor Heater Cover.................................................222
Figure 11-8: Removing the Opto-Pickup Assembly .....................................................223
Figure 11-9: Removing the GFC Wheel Housing .........................................................223
Figure 11-10: Removing the GFC Wheel....................................................................224
GFC7001E DOCUMENTATION
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
xiv
GFC7001E Rev A7
LIST OF TABLES
Table 2–1: Model GFC7001E Specifications................................................................... 5
Table 3–1: Inlet Outlet Nomenclature ........................................................................ 17
Table 5–1: Valve Option Operating States .................................................................. 37
Table 6–1: Mode Field of the Display ......................................................................... 42
Table 6–2: Test Functions Defined............................................................................. 45
Table 6–3: Password Levels...................................................................................... 48
Table 6–4: Variable Names (VARS)............................................................................ 52
Table 6–5: Test Functions available to the TEST Analog Output Channel........................ 65
Table 6–6: Analog Output Voltage Range Min/Max ....................................................... 67
Table 6–7: Analog Output Current Loop Min/Max ......................................................... 67
Table 6–8: Analog Output Pin Assignments ................................................................ 67
Table 6–9: Current loop Output Check ....................................................................... 72
Table 6–10: Diagnostic Mode (DIAG) Functions........................................................... 72
Table 6–11: DIAG – Analog I/O Functions .................................................................. 76
Table 6–12: Status Output Pin Assignments ............................................................... 82
Table 6–13: Control Input Pin Assignments ................................................................ 83
Table 6–14: COM-A and COM-B Default Pin Assignments ............................................. 87
Table 6–15: COMM Port Communication Modes........................................................... 88
Table 6–16: Basic Terminal Mode Software Commands................................................ 92
Table 6–17: Terminal Mode Help Commands .............................................................. 93
Table 6–18: Serial I/O Command Designations ........................................................... 93
Table 6–19: Serial Interface Documents ..........................Error! Bookmark not defined.
Table 6–20: iDAS Data Channel Properties ................................................................102
Table 6–21: iDAS Data Parameter Functions..............................................................103
Table 7-1: NIST – Standard Reference Materials (SRM) for Carbon Monoxide................121
Table 7–2: AUTOCAL Modes.....................................................................................129
Table 7–3: AutoCal Attribute Setup Parameters .........................................................129
Table 9–1: GFC7001E Maintenance Schedule.............................................................145
Table 9–2: GFC7001E Test Function Record...............................................................146
Table 9-3: Predictive uses for Test Functions .............................................................147
Table 10–1: Relay Board Status LED’s ......................................................................175
Table 10-2: Front Panel Status LED’s........................................................................183
Table 11-1 Warning Messages...................................................................................191
Table 11-2: Test Functions - Indicated Failures...........................................................194
Table 11-3: Sync/Demod Board Status Failure Indications ...........................................198
Table 11-4: DC Power Test Point and Wiring Color Codes............................................209
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
xv
Table 11-5: DC Power Supply Acceptable Levels ........................................................209
Table 11-6: Relay Board Control Devices...................................................................212
Table 11-7: Opto Pickup Board Nominal Output Frequencies .......................................213
Table 11-8: Analog Output Test Function - Nominal Values Voltage Outputs ..................215
Table 11-9: Analog Output Test Function - Nominal Values Current Outputs ..................216
Table 11-10: Status Outputs Check ..........................................................................217
Table A-1: GFC7001E Setup Variables, Revision E.3 ................................................. 10
Table A-2: GFC7001E Warning Messages, Revision E.3 ............................................. 19
Table A-3: GFC7001E Test Functions, Revision E.3................................................... 21
Table A-5: GFC7001E DAS Trigger Events, Revision E.3............................................ 25
Table A-6: GFC7001E iDAS Functions, Revision E.3 .................................................. 26
Table A-7: Terminal Command Designators, Revision E.3 ......................................... 27
Table A-8: Terminal Key Assignments, Revision E.3 ................................................. 28
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
1
1. GFC7001E DOCUMENTATION
TAI is pleased that you have purchased the Model GFC7001E Gas Filter Correlation
Carbon Monoxide Analyzer.
The documentation for this instrument is available in several different formats:
1. Printed format.
2. Electronic format on a CD-ROM.
The electronic manual is in Adobe Systems Inc. “Portable Document Format”.
The PDF reader software can be downloaded from the Internet at
www.adobe.com.
The electronic version of the manual has many advantages:
Keyword and phrase search feature.
Figures and Tables are linked so that clicking on the Figure number will
display the associated graphic.
A list of Chapters and Sections are displayed at the left of the text.
Entries in the Table of Contents are linked to the corresponding locations in
the manual.
Links embedded in the manual will take you to the corresponding location
on the Internet if the computer used for viewing is connected to the
Internet.
Ability to print sections (or all) of the manual.
3. Additional documentation for the Model GFC7001E Gas Filter Correlation
Carbon Monoxide Analyzer is available from TAI’s website at
http://www.teledyne-AI.com/manuals.
Ai.com Software Manual p/n 03945
RS-232 Manual p/n 01350
Multidrop Manual p/n 01842
GFC7001E DOCUMENTATION
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
2
GFC7001E Rev A7
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 and List of Figures. In the electronic version of the manual, clicking on a
specific entry in one of these tables automatically moves the view to the desired
section.
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 TAI’s warranty statement.
3.0 Getting Started
A concise set of instructions for unpacking your analyzer, installing it and running it
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 the various options available that 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 such as the Serial I/O Ports and the iDAS.
NOTE
The flowcharts appearing 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.
7.0 Calibration Procedures
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
GFC7001E DOCUMENTATION
GFC7001E Rev A7
3
General information and step-by-step instructions for calibrating or checking the
calibration of your analyzer.
8.0 EPA Protocol Calibration
Specific information regarding calibration requirements for analyzers used in EPA
monitoring.
9.0 Maintenance
Descriptions and schedule for certain preventative maintenance procedure that
should be regularly performed on you instrument to keep it in peak operating
condition. This section also includes information on using the iDAS to record
diagnostic functions useful in predicting possible component failures BEFORE they
happen.
10.0 Theory of Operation
An in depth look at the various operating 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 learning how to identify the source of problems with
the instrument should they occur.
11.0 Troubleshooting Section:
This section includes pointers and instructions for diagnosing problems with the
instrument, such as excessive noise or drift. It also includes instructions on
performing certain simple repairs of the instrument’s major subsystems.
Appendices
In order to make them easier to access, certain often-referred-to sets of
information have been separated out of the manual and placed a series of
appendices at the end of this manual, including: Software Menu Trees; Warning
Messages; definitions of iDAS & Serial I/O Variables; Spare Parts Lists; Repair
Questionnaire; Interconnect List/Drawing and; Electronic Schematics.
NOTE
Throughout this manual words printed in capital letters and emboldened, such as SETUP or ENTR
represent messages as they appear on the analyzers front panel display.
GFC7001E DOCUMENTATION
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
4
GFC7001E Rev A7
INTENTIONALLY BLANK
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
Specifications, Agency Approvals, and
Warranty
GFC7001E Rev A7
5
2. SPECIFICATIONS, AGENCY APPROVALS,
AND WARRANTY
2.1. Specifications
Table 2–1: Model GFC7001E Specifications
Ranges
User selectable to any full scale range from 0-1 ppm to
0-1000 ppm
Measurement Units
ppb, ppm, µg/m3, mg/m3 (user selectable)
Zero Noise
≤ 0.02 ppm RMS
(1)
Span Noise
< 0.5% of reading RMS over 5 ppm
(1) (3)
Lower Detectable Limit
< 0.04 ppm
(1)
Zero Drift (24 hours)
< 0.1 ppm
(2)
Zero Drift (7 days)
< 0.2 ppm
(2)
Span Drift (24 hours)
< 0.5% of reading
(2) (4)
Span Drift (7 days)
< 1% of reading
(2) (4)
Linearity
Better than 1% full scale
(5)
Precision
0.5% reading
(1) (5)
Lag Time
<10 sec
(1)
Rise/Fall Time
<60 sec to 95%
(1)
Sample Flow Rate
800 scc/min. ± 10%
Temperature Range
5 - 40°C operating, 10 - 40°C EPA Equivalency
Humidity Range
0-95% RH, Non-Condensing
Temp Coefficient
< 0.05 % per °C
Voltage Coefficient
< 0.05 % per V
Dimensions (HxWxD)
7" x 17" x 23.5" (178 mm x 432 mm x 597 mm)
Weight
50 lb (22.7 kg)
AC Power
100V 50/60 Hz (3.25A), 115 V 60 Hz (3.0A),
220 – 240 V 50/60 Hz (2.5A)
Environmental
Conditions
Installation Category (Over voltage Category) II Pollution Degree 2
Analog Outputs
Three (3) Outputs
Analog Output Ranges
100 mV, 1 V, 5 V, 10 V, 2-20 or 4-20 mA isolated current loop.
All Ranges with 5% Under/Over Range
Analog Output
Resolution
1 part in 4096 of selected full-scale voltage
Status Outputs
8 Status outputs from opto-isolators
Control Inputs
6 Control Inputs, 2 defined, 4 spare
Serial I/O
One (1) RS-232; One (1) RS-485 (2 connecters in parallel)
Baud Rate : 300 - 115200
Certifications
USEPA: Reference Method Number EQOA-0992-087
CE: EN61010-1:90 + A1:92 + A2:95, EN61326 - Class A
(1)
As defined by the USEPA
(2)
At constant temperature and voltage
(3)
Or 0.2 ppm, whichever is greater
(4)
Or 0.1 ppm, whichever is greater
Specifications, Agency Approvals, and
Warranty
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
6
GFC7001E Rev A7
(5)
Above 10 ppm range, otherwise 0.2 ppm for lower ranges
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
Specifications, Agency Approvals, and
Warranty
GFC7001E Rev A7
7
2.2. EPA Equivalency Designation
Teledyne Analytical Instruments, Model GFC7001E Carbon monoxide Analyzer is
designated as Reference Method Number EQOA-0992-087 as defined in 40 CFR Part
53, when operated under the following conditions:
1. Range: Any range from 10 ppm to 50 ppm
2. Ambient temperature range of 10 to 40°C
3. Line voltage range of 90 – 127 and 200 – 230 VAC, 50/60 Hz
4. With 5-micron TFE filter element installed in the internal filter assembly
5. Sample flow of 800 ± 80 cc/min at sea level
6. Internal sample pump
7. Software settings:
Dilution factor
1.0
AutoCal
ON or OFF
Dynamic Zero
ON or OFF
Dynamic Span
OFF
Dual range
ON or OFF
Auto range
ON or OFF
Temp/Pres compensation
ON
Under the designation, the Analyzer may be operated with or without the following
options:
1. Rack mount with slides
2. Rack mount without slides, ears only
3. Option 52 Sample/Cal valves
4. Option 53 Sample/Cal valves with internal zero air
5. Option 50 Sample/Cal valves with span shutoff & flow control
6. Option 51 Sample/Cal valves with span shutoff & flow control & internal
zero air
7. 4-20mA, isolated output
Specifications, Agency Approvals, and
Warranty
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
8
GFC7001E Rev A7
2.3. Warranty
Warranty Policy (02024c)
Prior to shipment, TAI equipment is thoroughly inspected and tested. Should equipment
failure occur, TAI assures its customers that prompt service and support will be available.
Coverage
After the warranty period and throughout the equipment lifetime, TAI stands ready to
provide on-site or in-plant service at reasonable rates similar to those of other
manufacturers in the industry. All maintenance and the first level of field troubleshooting is
to be performed by the customer.
Non-TAI Manufactured Equipment
Equipment provided but not manufactured by TAI is warranted and will be repaired to the
extent and according to the current terms and conditions of the respective equipment
manufacturers warranty.
General
TAI warrants each Product manufactured by TAI 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, TAI shall correct
such defect by, in TAI's discretion, repairing or replacing such defective Product or refunding
the purchase price of such Product.
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 TAI
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. TAI SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT
OF TAI'S PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR
OTHERWISE.
Terms and Conditions
All units or components returned to TAI 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.
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
Specifications, Agency Approvals, and
Warranty
GFC7001E Rev A7
9
INTENTIONALLY BLANK
Getting Started
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
10
GFC7001E Rev A7
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 GFC7001E.
1. Verify that there is no apparent external shipping damage. If damage has
occurred, please advise the shipper first, then TAI.
2. Included with your analyzer is a printed record of the final performance
characterization performed on your instrument at the factory. This record, P/N
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 GFC7001E CO 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.
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
Getting Started
GFC7001E Rev A7
11
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.
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.
Figure 3–1: Removal of Shipping Screws
NOTE
Save these shipping screws and re-install them whenever the unit is shipped to another location.
Shipping
Screws
Getting Started
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
12
GFC7001E Rev A7
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 GFC7001E into line power.
CAUTION
Power connection MUST have functioning ground connection.
1. Refer to Figure 3-2 for the location of the rear panel electrical connections.
2. 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
The A1 and A2 channels output a signal that is proportional to the CO
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.
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
Getting Started
GFC7001E Rev A7
13
The third analog output, labeled A3 is special. It can be set by the user (see
Section 6.4.7) 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.
Pin-outs for the Analog Output connector at the rear panel of the instrument
are:
PIN
Analog Output
VDC Signal
mADC Signal
1
V Out
I Out +
2A1Ground
I Out -
3
V Out
I Out +
4A2Ground
I Out -
5
V Out
I Out +
6A3Ground
I Out -
7
V Out
Not Available
8
A4 (Spare)
Ground
Not Available
The default analog output voltage setting of the GFC7001E CO Analyzer is 0
– 5 VDC with a range of 0 – 50 ppm.
TO change these settings, see Sections 6.4 and 6.5
3. If you wish utilize the analyzer’s Status Outputs to interface with a device that
accepts logic-level digital inputs, such as Programmable Logic Controllers
(PLC’s) they are accessed via a 12-pin connector on the analyzer’s rear panel
labeled STATUS.
STATUS
1 2 3 4 5 6 7 8 D +
Getting Started
Model GFC7001E Carbon Monoxide
Analyzer
Instruction Manual
14
GFC7001E Rev A7
The pin assignments for the Status Outputs can be found in the table below:
Output #
Status
Definition
Condition
1
SYSTEM OK
On if no faults are present.
2
CONC VALID
On if CO concentration measurement is valid.
If the CO 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
SPARE
8
SPARE
D
EMITER 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.
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.
4. 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.
Loading...