Teledyne GFC 7001EM, GFC 7001E User Manual

Operation Manual

MODEL GFC 7001E FAMILY

CARBON MONOXIDE ANALYZERS

(Includes GFC 7001E, GFC 7001EM)

TELEDYNE ELECTRONIC TECHNOLOGIES

Analytical Instruments

16830 Chestnut Street
City of Industry, CA 91748

Telephone: [phone]
Fax: [phone]

Web: www.teledyne-ai.com

Teledyne Analytical Instruments

Model GFC7001E Carbon Dioxide Analyzer

Copyright © 2013 Teledyne Analytical Instruments

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 instrument or its interface 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.

Teledyne Analytical Instruments 2

Safety Messages Model GFC7001E Carbon Dioxide Analyzer

SAFETY MESSAGES

Warning and cautionary messages are provided for the purpose of avoiding risk of personal injury or
instrument damage. These important safety messages and associated safety alert symbols are found
throughout this manual; the safety symbols are also located inside the instrument(s). It is imperative
that you pay close attention to these messages, the descriptions of which are as follows:

WARNING: Electrical Shock Hazard

HAZARD: Strong oxidizer

GENERAL WARNING/CAUTION: Read the accompanying
message for specific information.

CAUTION: Hot Surface Warning

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

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.

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

CAUTION – GENERAL SAFETY HAZARD

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 this or any other Teledyne product can be

obtained by contacting Teledyne’s Customer Service Department:

Telephone: [phone]

Email: [e-mail]

or by accessing various service options on our website at http://www.teledyne-api.com/.

Teledyne Analytical Instruments 3

Safety Messages Model GFC7001E Carbon Dioxide Analyzer

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Teledyne Analytical Instruments 4

Warranty Model GFC7001E Carbon Dioxide Analyzer

WARRANTY

WARRANTY POLICY (02024D)

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

COVERAGE

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

See Warranty statement on page 2.

CAUTION – Avoid Warranty Invalidation

Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing instructions
and Return Merchandise Authorization (RMA) procedures when returning parts for repair or calibration
may void your warranty. For anti-ESD handling and packing instructions please refer to “Packing
Components for Return to Teledyne’s Customer Service” in the Primer on Electro-Static Discharge
section of this manual, and for RMA procedures please contact Teledyne Customer Service at (626)
934-1500.

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Warranty Model GFC7001E Carbon Dioxide Analyzer

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Manual Information Model GFC7001E Carbon Dioxide Analyzer

ABOUT THIS MANUAL

This manual is comprised of multiple documents, in PDF format, as listed below.

Part No. Rev Name/Description

04288 D GFC 7001E/EM Manual

04906 H Menu Tree and Software Documentation, L.8 (as Appendix A of this manual)

05362 J Spare Parts List, GFC 7001E (in Appendix B of this manual)

05424 H Spare Parts List, GFC 7001EM (in Appendix B of this manual)

04302 Q Recommended Spares Stocking Levels, GFC 7001E (in Appendix B of this manual)

04834 G Recommended Spares Stocking Levels, GFC 7001EM (in Appendix B of this manual)

009600400 C Expendables Kit, GFC 7001E/EM (in Appendix B of this manual)

040360100 A Spares Kit, GFC 7001E/EM (1 unit) (in Appendix B of this manual)

04305 G Warranty/Repair Request Questionnaire (as Appendix C of this manual)

03297 K PCA, 03296, IR Photodetector Preamp and Sync Demodulator (In Appendix D of this manual)

03632 A PCA, 03631, 0-20mA driver (in Appendix D of this manual)

03976 B PCA, 03975, Keyboard & Display Driver (in Appendix D of this manual)

04354 D Schematic, PCA 04003, Press/Flow (in Appendix D of this manual)

05703 A PCA, 05702, Motherboard, E-Series Gen 4 (in Appendix D of this manual)

04089 A PCA, 04088, Opto Pickup Interface (in Appendix D of this manual)

04136 B PCA, 04135 Rev A, GFC 7001E Relay (in Appendix D of this manual)

04216 E Interconnect Drawing - GFC 7001E SNs >=100 (in Appendix D of this manual)

04217 F Interconnect List - GFC 7001E SNs >=100 (in Appendix D of this manual)

04259 A PCA, 04258, Keyboard & Display Driver (in Appendix D of this manual)

04468 B PCA, 04467, Analog Output Isolator, / Series Resistor (in Appendix D of this manual)

NOTE

We recommend that this manual be read in its entirety before making any attempt made to operate the

instrument.

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Manual Information Model GFC7001E Carbon Dioxide Analyzer

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Teledyne Analytical Instruments 8

Table of Contents Model GFC7001E Carbon Dioxide Analyzer

TABLE OF CONTENTS

PART I – GENERAL INFORMATION .................................................................................... 21

1. INTRODUCTION ................................................................................................................ 23

1.1. GFC 7001E FAMILY Overview ..................................................................................................................... 23

1.2. Additional Documentation ............................................................................................................................. 24

1.2.1. Using This Manual ................................................................................................................................. 25

2. SPECIFICATIONS AND APPROVALS .............................................................................. 27

2.1. Specifications ................................................................................................................................................ 27

2.2. EPA Equivalency Designation ...................................................................................................................... 28

2.3. TUV DESIGNATION ..................................................................................................................................... 29

2.4. CE Mark Compliance .................................................................................................................................... 29

2.4.1. Emissions Compliance ........................................................................................................................... 29

2.4.2. Safety Compliance ................................................................................................................................. 29

3. GETTING STARTED .......................................................................................................... 31

3.1. GFC 7001E/EM Analyzer Layout .................................................................................................................. 31

3.2. Unpacking the GFC 7001E/EM Analyzer ...................................................................................................... 36

3.2.1. Ventilation Clearance ............................................................................................................................. 37

3.3. Electrical Connections ................................................................................................................................... 38

3.3.1. Power Connection .................................................................................................................................. 38

3.3.2. Analog Output Connections .................................................................................................................. 39

3.3.3. Connecting the Status Outputs .............................................................................................................. 39

3.3.4. Connecting the Control Inputs ............................................................................................................... 41

3.3.5. Connecting the Serial Ports ................................................................................................................... 42

3.3.6. Connecting to a LAN or the Internet ...................................................................................................... 42

3.3.7. Connecting to a Multidrop Network ........................................................................................................ 42

3.4. Pneumatic Connections ................................................................................................................................ 42

3.4.1. Calibration Gases .................................................................................................................................. 42

3.4.1.1. Zero Air ........................................................................................................................................... 42

3.4.1.2. Span Gas ........................................................................................................................................ 43

3.4.2. Pneumatic Connections to GFC 7001E/EM Basic Configuration .......................................................... 44

3.4.2.1. Sample Gas Source ....................................................................................................................... 45

3.4.2.2. Calibration Gas Sources ................................................................................................................ 45

3.4.2.3. Input Gas Venting ........................................................................................................................... 46

3.4.2.4. Exhaust Outlet ................................................................................................................................ 46

3.5. Initial Operation ............................................................................................................................................. 46

3.5.1. Startup .................................................................................................................................................... 47

3.5.2. Warm Up ................................................................................................................................................ 48

3.5.3. Warning Messages ................................................................................................................................ 48

3.5.4. Functional Check ................................................................................................................................... 50

3.6. Initial Calibration of the GFC 7001E/EM ....................................................................................................... 51

3.6.1. Interferents for CO2 Measurements ....................................................................................................... 51

3.6.2. Initial Calibration Procedure for GFC 7001E/EM Analyzers without Options ........................................ 51

3.6.2.1. Verifying the GFC 7001E/EM Reporting Range Settings ............................................................... 52

3.6.2.2. Dilution Ratio Set Up ...................................................................................................................... 53

3.6.2.3. Set CO Span Gas Concentration ................................................................................................... 54

3.6.2.4. Zero/Span Calibration ..................................................................................................................... 55

3.6.3. O2 Sensor Calibration Procedure ........................................................................................................... 56

3.6.4. CO2 Sensor Calibration Procedure ........................................................................................................ 56

4. FREQUENTLY ASKED QUESTIONS ................................................................................ 57

4.1. FAQ’s ............................................................................................................................................................ 57

4.2. Glossary ........................................................................................................................................................ 58

5. OPTIONAL HARDWARE AND SOFTWARE ..................................................................... 61

5.1. External Pumps (OPTions 10A-10E, 11, 13) ................................................................................................ 61

5.2. Rack Mount Kits (OPT 20 to OPT 23) ........................................................................................................... 61

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

5.3. Carrying Strap/Handle (OPT 29) ................................................................................................................... 62

5.4. Current Loop Analog Outputs (Option 41) .................................................................................................... 62

5.4.1. Converting Current Loop Analog Outputs to Standard Voltage Outputs ............................................... 63

5.5. Expendables and Spares Kits (Options 42A, 45) ......................................................................................... 64

5.6. Calibration Valves (Options 50A, 50B, 50E, 50H) ........................................................................................ 64

5.6.1. General Information Related to all Valve Options.................................................................................. 64

5.6.1.1. Gas Flow Rate ................................................................................................................................ 64

5.6.1.2. Valve Control .................................................................................................................................. 64

5.6.2. Zero/Span Valve (Option 50A) ............................................................................................................... 64

5.6.2.1. Internal Pneumatics (OPT 50A) ..................................................................................................... 65

5.6.2.2. Pneumatic Set Up (OPT 50A) ........................................................................................................ 66

5.6.2.3. Input Gas Venting ........................................................................................................................... 66

5.6.2.4. Exhaust Outlet ................................................................................................................................ 66

5.6.3. Zero/Span/Shutoff Valve (Option 50B) .................................................................................................. 67

5.6.3.1. Internal Pneumatics (OPT 50B) ..................................................................................................... 67

5.6.3.2. Pneumatic Set Up (OPT 50B) ........................................................................................................ 68

5.6.4. Zero/Span Valve with Internal CO Scrubber (Option 50H) .................................................................... 69

5.6.4.1. Internal Pneumatics (OPT 50H) ..................................................................................................... 69

5.6.4.2. Pneumatic Set Up (OPT 50H) ........................................................................................................ 70

5.6.5. Zero/Span/Shutoff with Internal Zero Air Scrubber (Option 50E) .......................................................... 71

5.6.5.1. Internal Pneumatics (OPT 50E) ..................................................................................................... 71

5.6.5.2. Pneumatic Set Up (OPT 50E) ........................................................................................................ 72

5.7. Communication Options ................................................................................................................................ 73

5.7.1. RS-232 Modem Cable (Option 60A) ...................................................................................................... 73

5.7.2. RS-232 Multidrop (Option 62) ................................................................................................................ 73

5.7.3. Ethernet (Option 63A) ............................................................................................................................ 74

5.7.4. Ethernet + Multidrop (OPT 63C) ............................................................................................................ 75

5.8. Second Gas Sensors .................................................................................................................................... 75

5.8.1. Oxygen Sensor (Option 65A) ................................................................................................................. 75

5.8.1.1. Theory of Operation - Paramagnetic measurement of O2 .............................................................. 75

5.8.1.2. Operation within the GFC 7001E/EM Analyzer .............................................................................. 76

5.8.1.3. Pneumatic Operation of the O2 Sensor .......................................................................................... 76

5.9. Carbon Dioxide Sensor (Option 67A) ........................................................................................................... 77

5.9.1. CO2 Sensor Ranges and Specifications ................................................................................................ 77

5.9.2. Theory of Operation ............................................................................................................................... 77

5.9.2.1. NDIR measurement of CO2 ............................................................................................................ 77

5.9.2.2. Operation within the GFC 7001E/EM Analyzer .............................................................................. 78

5.9.2.3. Pneumatic Operation of the CO2 Sensor ....................................................................................... 78

5.9.2.4. Electronic Operation of the CO2 Sensor ......................................................................................... 79

5.10. CONCENTRATION ALARM RELAY (Option 61) ....................................................................................... 80

5.11. Special Features ......................................................................................................................................... 82

5.11.1. Dilution Ratio Option ............................................................................................................................ 82

5.11.2. Maintenance Mode Switch ................................................................................................................... 82

5.11.3. Second Language Switch .................................................................................................................... 82

PART II – OPERATING INSTRUCTIONS .............................................................................. 83

6. BASIC OPERATION .......................................................................................................... 85

6.1. Overview of Operating Modes ...................................................................................................................... 85

6.2. Sample Mode ................................................................................................................................................ 86

6.3. Warning Messages ....................................................................................................................................... 88

6.4. Calibration Mode ........................................................................................................................................... 89

6.5. Setup MODE ................................................................................................................................................. 90

6.5.1. SETUP  CFG: Configuration Information ........................................................................................... 91

6.5.2. SETUP  ACAL: Automatic Calibration ................................................................................................ 91

6.5.3. SETUP  PASS: Password Feature..................................................................................................... 92

6.5.4. SETUP  CLK: Setting the GFC 7001E/EM Analyzer’s Internal Clock ................................................ 95

6.5.4.1. Setting the internal Clock’s Time and Day ..................................................................................... 95

6.5.4.2. Adjusting the Internal Clock’s Speed .............................................................................................. 96

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

6.6. SETUP  RNGE: Analog Output Reporting Range Configuration .............................................................. 97

6.6.1. Physical Range versus Analog Output Reporting Ranges .................................................................... 97

6.6.2. Analog Output Ranges for CO Concentration ....................................................................................... 98

6.6.3. Reporting Range Modes ........................................................................................................................ 99

6.6.3.1. RNGE  MODE  SNGL: Configuring the GFC 7001E/EM Analyzer for SINGLE Range Mode100

6.6.3.2. RNGE  MODE  DUAL: Configuring the GFC 7001E/EM Analyzer for DUAL Range Mode ..101

6.6.3.3. RNGE  MODE  AUTO: Configuring the GFC 7001E/EM Analyzer for AUTO Range Mode .103

6.6.4. SETUP  RNGE  UNIT: Setting the Reporting Range Units of Measure .......................................105

6.6.5. SETUP RNGE  DIL: Using the Optional Dilution Ratio Feature ...................................................106

7. ADVANCED FEATURES ................................................................................................. 107

7.1. SETUP  IDAS: Using the Data Acquisition System (iDAS) .....................................................................107

7.1.1. IDAS Status .........................................................................................................................................107

7.1.2. IDAS Structure .....................................................................................................................................108

7.1.2.1. iDAS Channels .............................................................................................................................108

7.1.3. Default iDAS Channels ........................................................................................................................109

7.1.4. SETUP DAS VIEW: Viewing iDAS Channels and Individual Records ........................................111

7.1.5. SETUP DAS EDIT: Accessing the iDAS Edit Mode ....................................................................112

7.1.5.1. Editing iDAS Data Channel Names ..............................................................................................113

7.1.5.2. Editing iDAS Triggering Events ....................................................................................................114

7.1.5.3. Editing iDAS Parameters ..............................................................................................................115

7.1.5.4. Editing Sample Period and Report Period....................................................................................117

7.1.5.5. Report Periods in Progress When Instrument Is Powered Off .....................................................118

7.1.5.6. Editing the Number of Records ....................................................................................................119

7.1.5.7. RS-232 Report Function ...............................................................................................................120

7.1.5.8. Enabling/Disabling the HOLDOFF Feature ..................................................................................121

7.1.5.9. The Compact Report Feature .......................................................................................................122

7.1.5.10. The Starting Date Feature ..........................................................................................................122

7.1.6. Disabling/Enabling Data Channels ......................................................................................................122

7.1.7. Remote iDAS Configuration .................................................................................................................123

7.1.7.1. iDAS Configuration Using APICOM .............................................................................................123

7.1.7.2. iDAS Configuration Using Terminal Emulation Programs ............................................................124

7.2. SETUP  MORE  VARS: Internal Variables (VARS) .............................................................................125

7.3. SETUP  MORE  DIAG: Using the Diagnostics Functions ...................................................................127

7.3.1. Accessing the Diagnostic Features .....................................................................................................128

7.4. Using the GFC 7001E/EM Analyzer’s Analog Outputs. ..............................................................................129

7.4.1. Accessing the Analog Output Signal Configuration Submenu ............................................................129

7.4.2. Analog Output Voltage / Current Range Selection ..............................................................................131

7.4.3. Calibration of the Analog Outputs ........................................................................................................133

7.4.3.1. Enabling or Disabling the AutoCal for an Individual Analog Output .............................................133

7.4.3.2. Automatic Calibration of the Analog Outputs ...............................................................................134

7.4.3.3. Individual Calibration of the Analog Outputs ................................................................................136

7.4.3.4. Manual Calibration of the Analog Outputs Configured for Voltage Ranges .................................137

7.4.3.5. Manual Adjustment of Current Loop Output Span and Offset .....................................................139

7.4.4. Turning an analog output Over-Range Feature ON/OFF ....................................................................142

7.4.5. Adding a Recorder Offset to an analog output ....................................................................................143

7.4.6. Selecting a Test Channel Function for Output A4 ...............................................................................144

7.4.7. AIN Calibration .....................................................................................................................................146

7.5. SETUP MORE  ALRM: Using the Gas Concentration Alarms ............................................................147

7.5.1. Setting the GFC 7001E Concentration Alarm Limits ...........................................................................147

8. REMOTE OPERATION .................................................................................................... 149

8.1. SETUP  MORE COMM: Using the Analyser’s Communication Ports .................................................149

8.1.1. RS-232 DTE and DCE Communication ...............................................................................................149

8.1.2. COMM Port Default Settings................................................................................................................149

8.1.3. COMM Port Baud Rate ........................................................................................................................151

8.1.4. COMM Port Communication Modes ....................................................................................................152

8.1.5. COMM Port Testing .............................................................................................................................154

8.1.6. Machine ID ...........................................................................................................................................155

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

8.1.7. Terminal Operating Modes ..................................................................................................................156

8.1.7.1. Help Commands in Terminal Mode ..............................................................................................156

8.1.7.2. Command Syntax .........................................................................................................................157

8.1.7.3. Data Types ...................................................................................................................................157

8.1.7.4. Status Reporting ...........................................................................................................................158

8.1.7.5. COMM Port Password Security ....................................................................................................159

8.2. Multidrop RS-232 Set Up ............................................................................................................................160

8.3. RS-485 Configuration of COM2 ..................................................................................................................162

8.4. Remote Access via the Ethernet .................................................................................................................164

8.4.1. Ethernet Card COM2 Communication Modes and Baud Rate ............................................................164

8.4.2. Configuring the Ethernet Interface Option using DHCP ......................................................................165

8.4.3. Manually Configuring the Network IP Addresses ................................................................................167

8.4.4. Changing the Analyzer’s HOSTNAME ................................................................................................170

8.5. MODBUS SetUp .........................................................................................................................................171

8.5.1. Remote Access by Modem ..................................................................................................................172

8.6. Using the GFC 7001E/EM with a Hessen Protocol Network ......................................................................175

8.6.1. General Overview of Hessen Protocol .................................................................................................175

8.6.2. Hessen COMM Port Configuration ......................................................................................................175

8.6.3. Activating Hessen Protocol ..................................................................................................................176

8.6.4. Selecting a Hessen Protocol Type .......................................................................................................177

8.6.5. Setting The Hessen Protocol Response Mode ....................................................................................178

8.6.6. Hessen Protocol Gas List Entries ........................................................................................................179

8.6.6.1. Gas List Entry Format and Definitions ..........................................................................................179

8.6.6.2. Editing or Adding HESSEN Gas List Entries ................................................................................180

8.6.6.3. Deleting HESSEN Gas List Entries ..............................................................................................181

8.6.7. Setting Hessen Protocol Status Flags .................................................................................................182

8.6.8. Instrument ID Code ..............................................................................................................................183

8.7. APICOM Remote Control Program .............................................................................................................184

9. CALIBRATION PROCEDURES ....................................................................................... 185

9.1. Before Calibration .......................................................................................................................................186

9.1.1. Required Equipment, Supplies, and Expendables ..............................................................................186

9.1.2. Calibration Gases ................................................................................................................................186

9.1.2.1. Zero Air .........................................................................................................................................186

9.1.2.2. Span Gas ......................................................................................................................................187

9.1.2.3. Traceability ...................................................................................................................................187

9.1.3. Data Recording Devices ......................................................................................................................187

9.2. Manual Calibration Checks and Calibration of the GFC 7001E/EM Analyzer in its Base Configuration ....188

9.2.1. Setup for Basic Calibration Checks and Calibration ............................................................................188

9.2.2. Performing a Basic Manual Calibration Check ....................................................................................190

9.2.3. Performing a Basic Manual Calibration ...............................................................................................191

9.2.3.1. Setting the Expected Span Gas Concentration ............................................................................191

9.2.3.2. Zero/Span Point Calibration Procedure ........................................................................................192

9.3. Manual Calibration with Zero/Span Valves .................................................................................................193

9.3.1. Setup for Calibration Using Valve Options ..........................................................................................193

9.3.2. Manual Calibration Checks with Valve Options Installed ....................................................................195

9.3.3. Manual Calibration Using Valve Options .............................................................................................196

9.3.3.1. Setting the Expected Span Gas Concentration ............................................................................196

9.3.3.2. Zero/Span Point Calibration Procedure ........................................................................................197

9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure ...............................................................198

9.4. Automatic Zero/Span Cal/Check (AutoCal) ................................................................................................198

9.4.1. SETUP  ACAL: Programming and AUTO CAL Sequence ...............................................................201

9.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected ...................................................203

9.5. CO Calibration Quality ................................................................................................................................204

9.6. Calibration of the GFC 7001E/EM’s Electronic Subsystems ......................................................................205

9.6.1. Dark Calibration Test ...........................................................................................................................205

9.6.2. Pressure Calibration ............................................................................................................................206

9.6.3. Flow Calibration ...................................................................................................................................207

9.6.4. Electrical Test Calibration ....................................................................................................................208

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9.7. Calibration of Optional Sensors ..................................................................................................................209

9.7.1. O2 Sensor Calibration Procedure .........................................................................................................209

9.7.1.1. O2 Calibration Setup .....................................................................................................................209

9.7.1.2. Set O2 Span Gas Concentration...................................................................................................210

9.7.1.3. Activate O2 Sensor Stability Function ...........................................................................................211

9.7.1.4. O2ZERO/SPAN CALIBRATION ....................................................................................................212

9.7.2. CO2 Sensor Calibration Procedure ......................................................................................................213

9.7.2.1. CO2 Calibration Setup ..................................................................................................................213

9.7.2.2. Set CO2 Span Gas Concentration: ...............................................................................................213

9.7.2.3. Activate CO2 Sensor Stability Function ........................................................................................214

9.7.2.4. CO2 Zero/Span Calibration ...........................................................................................................215

10. EPA CALIBRATION PROTOCOL ................................................................................. 217

10.1. Calibration Requirements ..........................................................................................................................217

10.1.1. Calibration of Equipment - General Guidelines .................................................................................217

10.1.2. Calibration Equipment, Supplies, and Expendables ..........................................................................218

10.1.2.1. Data Recording Device...............................................................................................................218

10.1.2.2. Spare Parts and Expendable Supplies .......................................................................................218

10.1.3. Recommended Standards for Establishing Traceability ....................................................................219

10.1.4. Calibration Frequency ........................................................................................................................220

10.1.5. Level 1 Calibrations versus Level 2 Checks ......................................................................................220

10.2. ZERO and SPAN Checks .........................................................................................................................221

10.2.1. Zero/Span Check Procedures ...........................................................................................................222

10.2.2. Precision Check .................................................................................................................................222

10.3. Precisions Calibration ...............................................................................................................................222

10.3.1. Precision Calibration Procedures ......................................................................................................223

10.4. Auditing Procedure ....................................................................................................................................223

10.4.1. Calibration Audit .................................................................................................................................223

10.4.2. Data Reduction Audit .........................................................................................................................223

10.4.3. System Audit/Validation .....................................................................................................................224

10.5. Dynamic Multipoint Calibration Procedure ................................................................................................224

10.5.1. Linearity test .......................................................................................................................................224

10.6. References ................................................................................................................................................226

PART III – TECHNICAL INFORMATION ............................................................................. 227

11. THEORY OF OPERATION ............................................................................................ 229

11.1. Measurement Method ...............................................................................................................................229

11.1.1. Beer’s Law .........................................................................................................................................229

11.2. Measurement Fundamentals ....................................................................................................................229

11.2.1. Gas Filter Correlation .........................................................................................................................230

11.2.1.1. The GFC Wheel ..........................................................................................................................231

11.2.1.2. The Measure Reference Ratio ...................................................................................................232

11.2.1.3. Summary Interference Rejection ................................................................................................233

11.3. Pneumatic Operation ................................................................................................................................234

11.4. Flow Rate Control .....................................................................................................................................235

11.4.1.1. Critical Flow Orifice .....................................................................................................................235

11.4.2. Particulate Filter .................................................................................................................................236

11.4.3. Pneumatic Sensors ............................................................................................................................236

11.4.3.1. Sample Pressure Sensor ...........................................................................................................236

11.4.3.2. Sample Flow Sensor ..................................................................................................................236

11.5. Electronic Operation ..................................................................................................................................237

11.5.1. Overview ............................................................................................................................................237

11.5.2. Central Processing Unit (CPU) ..........................................................................................................239

11.5.3. Optical Bench & GFC Wheel .............................................................................................................240

11.5.3.1. Temperature Control ..................................................................................................................240

11.5.3.2. IR Source ....................................................................................................................................240

11.5.3.3. GFC Wheel .................................................................................................................................240

11.5.3.4. IR Photo-Detector .......................................................................................................................242

11.5.4. Synchronous Demodulator (Sync/Demod) Assembly .......................................................................242

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

11.5.4.1. Overview .....................................................................................................................................242

11.5.4.2. Signal Synchronization and Demodulation ................................................................................243

11.5.4.3. Sync/Demod Status LED’s .........................................................................................................244

11.5.4.4. Photo-Detector Temperature Control .........................................................................................244

11.5.4.5. Dark Calibration Switch ..............................................................................................................244

11.5.4.6. Electric Test Switch ....................................................................................................................245

11.5.5. Relay Board .......................................................................................................................................245

11.5.5.1. Heater Control ............................................................................................................................245

11.5.5.2. GFC Wheel Motor Control: .........................................................................................................245

11.5.5.3. Zero/Span Valve Options ...........................................................................................................245

11.5.5.4. IR Source ....................................................................................................................................245

11.5.5.5. Status LED’s ...............................................................................................................................246

11.5.5.6. I2C Watch Dog Circuitry ..............................................................................................................246

11.5.6. MotherBoard ......................................................................................................................................247

11.5.6.1. A to D Conversion ......................................................................................................................247

11.5.6.2. Sensor Inputs .............................................................................................................................247

11.5.6.3. Thermistor Interface ...................................................................................................................247

11.5.6.4. Analog Outputs ...........................................................................................................................248

11.5.6.5. Internal Digital I/O .......................................................................................................................248

11.5.6.6. External Digital I/O ......................................................................................................................248

11.5.7. I2C Data Bus ......................................................................................................................................249

11.5.8. Power Supply/ Circuit Breaker ...........................................................................................................249

11.5.9. Communication Interface ...................................................................................................................251

11.5.10. Front Panel Interface .......................................................................................................................252

11.5.10.1. Analyzer Status LED’s ..............................................................................................................252

11.5.10.2. Keyboard ..................................................................................................................................252

11.5.10.3. Display ......................................................................................................................................253

11.5.10.4. Keyboard/Display Interface Electronics....................................................................................253

11.5.11. Software Operation ..........................................................................................................................256

11.5.12. Adaptive Filter ..................................................................................................................................256

11.5.13. Calibration - Slope and Offset ..........................................................................................................257

11.5.14. Measurement Algorithm ...................................................................................................................257

11.5.15. Temperature and Pressure Compensation ......................................................................................257

11.5.16. Internal Data Acquisition System (iDAS) .........................................................................................257

12. MAINTENANCE SCHEDULE & PROCEDURES .......................................................... 259

12.1. Maintenance Schedule ..............................................................................................................................259

12.2. Predicting Failures Using the Test Functions ...........................................................................................263

12.3. Maintenance Procedures ..........................................................................................................................264

12.3.1. Replacing the Sample Particulate Filter .............................................................................................264

12.3.2. Rebuilding the Sample Pump ............................................................................................................264

12.3.3. Performing Leak Checks ....................................................................................................................265

12.3.3.1. Vacuum Leak Check and Pump Check ......................................................................................265

12.3.3.2. Pressure Leak Check .................................................................................................................265

12.3.4. Performing a Sample Flow Check .....................................................................................................266

12.3.5. Cleaning the Optical Bench ...............................................................................................................266

12.3.6. Cleaning Exterior Surfaces of the GFC 7001E/EM ...........................................................................266

13. TROUBLESHOOTING & REPAIR ................................................................................. 267

13.1. General Troubleshooting ...........................................................................................................................267

13.1.1. Fault Diagnosis with WARNING Messages .......................................................................................268

13.1.2. Fault Diagnosis with TEST Functions ................................................................................................270

13.1.3. DIAG  SIGNAL I/O: Using the Diagnostic Signal I/O Function ......................................................273

13.1.4. Internal Electronic Status LED’s ........................................................................................................274

13.1.4.1. CPU Status Indicator ..................................................................................................................274

13.1.4.2. Sync Demodulator Status LED’s ................................................................................................275

13.1.4.3. Relay Board Status LED’s ..........................................................................................................276

13.2. Gas Flow Problems ...................................................................................................................................278

13.2.1. GFC 7001E/EM Internal Gas Flow Diagrams ....................................................................................278

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

13.2.2. Typical Sample Gas Flow Problems ..................................................................................................282

13.2.2.1. Flow is Zero ................................................................................................................................282

13.2.2.2. Low Flow ....................................................................................................................................282

13.2.2.3. High Flow ....................................................................................................................................282

13.2.2.4. Displayed Flow = “Warnings” .....................................................................................................283

13.2.2.5. Actual Flow Does Not Match Displayed Flow ............................................................................283

13.2.2.6. Sample Pump .............................................................................................................................283

13.3. Calibration Problems .................................................................................................................................283

13.3.1. Miscalibrated ......................................................................................................................................283

13.3.2. Non-Repeatable Zero and Span ........................................................................................................284

13.3.3. Inability to Span – No SPAN Key .......................................................................................................284

13.3.4. Inability to Zero – No ZERO Key .......................................................................................................284

13.4. Other Performance Problems ...................................................................................................................285

13.4.1. Temperature Problems ......................................................................................................................285

13.4.1.1. Box or Sample Temperature ......................................................................................................285

13.4.1.2. Bench Temperature ....................................................................................................................285

13.4.1.3. GFC Wheel Temperature ...........................................................................................................286

13.4.1.4. IR Photo-Detector TEC Temperature .........................................................................................286

13.4.2. Excessive Noise .................................................................................................................................287

13.5. Subsystem Checkout ................................................................................................................................288

13.5.1. AC Mains Configuration .....................................................................................................................288

13.5.2. DC Power Supply ...............................................................................................................................288

13.5.3. I2C Bus ...............................................................................................................................................289

13.5.4. Keyboard/Display Interface ................................................................................................................289

13.5.5. Relay Board .......................................................................................................................................290

13.5.6. Sensor Assembly ...............................................................................................................................291

13.5.6.1. Sync/Demodulator Assembly .....................................................................................................291

13.5.6.2. Electrical Test .............................................................................................................................291

13.5.6.3. Opto Pickup Assembly ...............................................................................................................292

13.5.6.4. GFC Wheel Drive .......................................................................................................................292

13.5.6.5. IR Source ....................................................................................................................................292

13.5.6.6. Pressure/Flow Sensor Assembly ...............................................................................................293

13.5.7. Motherboard .......................................................................................................................................294

13.5.7.1. A/D Functions .............................................................................................................................294

13.5.7.2. Test Channel / Analog Outputs Voltage .....................................................................................294

13.5.7.3. Analog Outputs: Current Loop ....................................................................................................295

13.5.7.4. Status Outputs ............................................................................................................................296

13.5.7.5. Control Inputs – Remote Zero, Span ..........................................................................................297

13.5.8. CPU ....................................................................................................................................................297

13.5.9. RS-232 Communications ...................................................................................................................297

13.5.9.1. General RS-232 Troubleshooting ...............................................................................................297

13.5.9.2. Troubleshooting Analyzer/Modem or Terminal Operation .........................................................298

13.5.10. The Optional CO2 Sensor ................................................................................................................298

13.6. Repair Procedures ....................................................................................................................................299

13.6.1. Repairing Sample Flow Control Assembly ........................................................................................299

13.6.2. Removing/Replacing the GFC Wheel ................................................................................................300

13.6.3. Checking and Adjusting the Sync/Demodulator, Circuit Gain (CO MEAS) ......................................302

13.6.3.1. Checking the Sync/Demodulator Circuit Gain ............................................................................302

13.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain ...........................................................................303

13.6.4. Disk-On-Module Replacement Procedure .........................................................................................304

13.7. Technical Assistance ................................................................................................................................304

14. A PRIMER ON ELECTRO-STATIC DISCHARGE ......................................................... 305

14.1. How Static Charges are Created ..............................................................................................................305

14.2. How Electro-Static Charges Cause Damage ............................................................................................306

14.3. Common Myths About ESD Damage .......................................................................................................307

14.4. Basic Principles of Static Control ..............................................................................................................307

14.4.1. General Rules ....................................................................................................................................307

14.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ..................................................309

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

14.4.2.1. Working at the Instrument Rack .................................................................................................309

14.4.2.2. Working at an Anti-ESD Work Bench .........................................................................................309

14.4.2.3. Transferring Components from Rack to Bench and Back ..........................................................310

14.4.2.4. Opening Shipments from Teledyne API’ Customer Service ......................................................310

14.4.2.5. Packing Components for Return to Teledyne’s Customer Service ............................................311

LIST OF APPENDICES

APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION (Revision L.8)

APPENDIX A-1: GFC 7001E/EM Software Menu Trees
APPENDIX A-2: Setup Variables For Serial I/O
APPENDIX A-3: Warnings and Test Functions
APPENDIX A-4: GFC 7001E/EM Signal I/O Definitions
APPENDIX A-5: GFC 7001E/EM iDAS Functions
APPENDIX A-6: Terminal Command Designators

APPENDIX A-7: MODBUS Register
APPENDIX B - GFC 7001E/EM SPARE PARTS LIST
APPENDIX C - REPAIR QUESTIONNAIRE - GFC 7001E
APPENDIX D - ELECTRONIC SCHEMATICS

LIST OF FIGURES

Figure 3-1: Front Panel Layout ....................................................................................................................... 31

Figure 3-2: Rear Panel Layout ....................................................................................................................... 32

Figure 3-3: Internal Layout – GFC 7001E ...................................................................................................... 33

Figure 3-4: Internal Layout – GFC 7001EM with CO2 and O2 Sensor Option ................................................ 34

Figure 3-5: Optical Bench Layout ................................................................................................................... 35

Figure 3-6: GFC 7001E/EM Internal Gas Flow (Basic Configuration) ........................................................... 36

Figure 3-7: Analog Output Connector ............................................................................................................ 39

Figure 3-8: Status Output Connector ............................................................................................................. 40

Figure 3-9: Control Input Connector ............................................................................................................... 41

Figure 3-10: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ..................................... 44

Figure 3-11: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator ............................. 45

Figure 5-1: GFC 7001E/EM with Carrying Strap Handle and Rack Mount Brackets ..................................... 62

Figure 5-2: Current Loop Option Installed on the Motherboard ..................................................................... 63

Figure 5-3: Internal Pneumatic Flow OPT 50A – Zero/Span Valves .............................................................. 65

Figure 5-4: Pneumatic Connections – Option 50A: Zero/Span Calibration Valves ........................................ 66

Figure 5-5: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves ................................................. 67

Figure 5-6: Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves .................... 68

Figure 5-7: Internal Pneumatic Flow OPT 50H – Zero/Span Valves with Internal Zero Air Scrubber ........... 69

Figure 5-8: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves ....................................... 70

Figure 5-9: Internal Pneumatic Flow OPT 50E – Zero/Span/Shutoff Valves with Internal Zero Air Scrubber71

Figure 5-10: Pneumatic Connections – Option 50E: Zero/Span Calibration Valves ........................................ 72

Figure 5-11: GFC 7001E/EM Multidrop Card Seated on CPU above Disk on Module .................................... 73

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

Figure 5-12: GFC 7001E/EM Ethernet Card .................................................................................................... 74

Figure 5-13: GFC 7001E/EM Rear Panel with Ethernet Installed .................................................................... 74

Figure 5-14: Oxygen Sensor - Principle of Operation ...................................................................................... 75

Figure 5-15: GFC 7001E/EM – Internal Pneumatics with O2 Sensor Option 65A ........................................... 76

Figure 5-16: CO2 sensor Theory of Operation ................................................................................................. 78

Figure 5-17: GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66 ........................................... 79

Figure 5-18: CO2 Sensor Option PCA Layout and Electronic Connections ..................................................... 79

Figure 5-19: Concentration Alarm Relay .......................................................................................................... 80

Figure 6-1: Front Panel Display ...................................................................................................................... 85

Figure 6-2: Viewing GFC 7001E/EM Test Functions ..................................................................................... 86

Figure 6-3: Viewing and Clearing GFC 7001E/EM WARNING Messages .................................................... 89

Figure 6-4: Analog Output Connector Pin Out ............................................................................................... 98

Figure 7-1: Default iDAS Channel Setup .....................................................................................................110

Figure 7-2: APICOM User Interface for Configuring the iDAS .....................................................................123

Figure 7-3: iDAS Configuration Through a Terminal Emulation Program ....................................................124

Figure 7-4: Accessing the Analog I/O Configuration Submenus ..................................................................130

Figure 7-5: Setup for Checking / Calibrating DCV Analog Output Signal Levels .........................................137

Figure 7-6: Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter ..................139

Figure 7-7: Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ................141

Figure 8-1: Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE) ........150

Figure 8-2: Default Pin Assignments for CPU COM Port connector (RS-232) ............................................150

Figure 8-3: Location of JP2 on RS-232-Multidrop PCA (Option 62) ............................................................160

Figure 8-4: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram ...................................................161

Figure 8-5: CPU RS-485 Setup ....................................................................................................................162

Figure 8-6: Back Panel Connector Pin-Outs for COM2 in RS-485 Mode. ...................................................163

Figure 8-7: CPU Connector Pin-Outs for COM2 in RS-485 Mode ...............................................................163

Figure 8-8: APICOM Remote Control Program Interface .............................................................................184

Figure 9-1: Pneumatic Connections – Basic Configuration – Using Bottled Span Gas ...............................188

Figure 9-2: Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator .......................189

Figure 9-3: Pneumatic Connections – Option 50A: Zero/Span Calibration Valves ......................................193

Figure 9-4: Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves ..................193

Figure 9-5: Pneumatic Connections – Option 51B: Zero/Span Calibration Valves ......................................194

Figure 9-6: Pneumatic Connections – Option 51C: Zero/Span Calibration Valves .....................................194

Figure 9-7: O2 Sensor Calibration Set Up ....................................................................................................209

Figure 9-8: CO2 Sensor Calibration Set Up ..................................................................................................213

Figure 11-1: Measurement Fundamentals .....................................................................................................230

Figure 11-2: GFC Wheel ................................................................................................................................230

Figure 11-3: Measurement Fundamentals with GFC Wheel ..........................................................................231

Figure 11-4: Effect of CO in the Sample on CO MEAS & CO REF ...............................................................232

Figure 11-5: Effects of Interfering Gas on CO MEAS & CO REF ..................................................................233

Figure 11-6: Chopped IR Signal .....................................................................................................................233

Figure 11-7: Internal Pneumatic Flow – Basic Configuration .........................................................................234

Figure 11-8: Flow Control Assembly & Critical Flow Orifice...........................................................................235

Figure 11-9: GFC 7001E/EM Electronic Block Diagram ................................................................................238

Figure 11-10: GFC Light Mask .........................................................................................................................241

Figure 11-11: Segment Sensor and M/R Sensor Output .................................................................................241

Figure 11-12: GFC 7001E/EM Sync/Demod Block Diagram ...........................................................................243

Figure 11-13: Sample & Hold Timing ...............................................................................................................244

Figure 11-14: Location of relay board Status LED’s ........................................................................................246

Figure 11-15: Power Distribution Block Diagram .............................................................................................250

Figure 11-16: Interface Block Diagram .............................................................................................................251

Figure 11-17: GFC 7001E/EM Front Panel Layout ..........................................................................................252

Figure 11-18: Keyboard and Display Interface Block Diagram ........................................................................253

Figure 11-19: Basic Software Operation ..........................................................................................................256

Figure 12-1: Sample Particulate Filter Assembly ...........................................................................................264

Figure 13-1: Viewing and Clearing Warning Messages .................................................................................268

Figure 13-2: Example of Signal I/O Function .................................................................................................273

Figure 13-3: CPU Status Indicator .................................................................................................................274

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

Figure 13-4: Sync/Demod Board Status LED Locations ................................................................................275

Figure 13-5: Relay Board Status LEDs ..........................................................................................................276

Figure 13-6: GFC 7001E/EM – Basic Internal Gas Flow ...............................................................................278

Figure 13-7: Internal Pneumatic Flow OPT 50A – Zero/Span Valves (OPT 50A & 50B) ..............................279

Figure 13-8: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves ...............................................279

Figure 13-9: Internal Pneumatic Flow OPT 51B – Zero/Span Valves with Internal Zero Air Scrubber..........280

Figure 13-10: Internal Pneumatic Flow OPT 51C – Zero/Span/Shutoff w/ Internal Zero Air Scrubber ...........280

Figure 13-11: GFC 7001E/EM – Internal Pneumatics with O2 Sensor Option 65 ............................................281

Figure 13-12: GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66 .........................................281

Figure 13-13: Location of Diagnostic LED’s onCO2 Sensor PCA ....................................................................298

Figure 13-14: Critical Flow Restrictor Assembly Disassembly .........................................................................299

Figure 13-15: Opening the GFC Wheel Housing .............................................................................................300

Figure 13-16: Removing the Opto-Pickup Assembly .......................................................................................301

Figure 13-17: Removing the GFC Wheel Housing ...........................................................................................301

Figure 13-18: Removing the GFC Wheel .........................................................................................................302

Figure 13-19: Location of Sync/Demod Housing Mounting Screws .................................................................303

Figure 13-20: Location of Sync/Demod Gain Potentiometer............................................................................303

Figure 14-1: Triboelectric Charging ................................................................................................................305

Figure 14-2: Basic anti-ESD Workbench........................................................................................................307

LIST OF TABLES

Table 2-1: M 300E/300EM Basic Unit Specifications .................................................................................... 27

Table 3-1: Front Panel Nomenclature ........................................................................................................... 31

Table 3-2: Inlet / Outlet Connector Nomenclature ........................................................................................ 32

Table 3-3: Ventilation Clearance ................................................................................................................... 37

Table 3-4: Analog Output Pin-Outs ............................................................................................................... 39

Table 3-5: Status Output Signals .................................................................................................................. 40

Table 3-6: Control Input Signals .................................................................................................................... 41

Table 3-7: NIST-SRM's Available for Traceability of CO Calibration Gases .................................................. 43

Table 3-8: Front Panel Display during System Warm-Up ............................................................................. 48

Table 3-9: Possible Warning Messages at Start-Up ..................................................................................... 49

Table 5-1: Zero/Span Valve Operating States for Option 52 ........................................................................ 65

Table 5-2: Zero/Span Valve Operating States for Option 50B ...................................................................... 67

Table 5-3: Zero/Span Valve Operating States for Option 50H ..................................................................... 69

Table 5-4: Zero/Span Valve Operating States for Option 50E ...................................................................... 71

Table 5-5: GFC 7001E/EM Modem Cable Options ....................................................................................... 73

Table 5-6: CO2 Sensor - Available Ranges ................................................................................................... 77

Table 5-7: CO2 Sensor Specifications ........................................................................................................... 77

Table 6-1: Analyzer Operating Modes .......................................................................................................... 85

Table 6-2: Test Functions Defined ................................................................................................................ 87

Table 6-3: List of Warning Messages............................................................................................................ 88

Table 6-4: Primary Setup Mode Features and Functions ............................................................................. 90

Table 6-5: Secondary Setup Mode Features and Functions ........................................................................ 90

Table 6-6: Password Levels .......................................................................................................................... 92

Table 6-7: GFC 7001E Family Physical range by Model .............................................................................. 97

Table 7-1: Front Panel LED Status Indicators for iDAS ..............................................................................107

Table 7-2: iDAS Data Channel Properties ..................................................................................................108

Table 7-3: iDAS Data Parameter Functions ................................................................................................115

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Table of Contents Model GFC7001E Carbon Dioxide Analyzer

Table 7-4: Variable Names (VARS) ............................................................................................................125

Table 7-5: Diagnostic Mode (DIAG) Functions ...........................................................................................127

Table 7-6: DIAG - Analog I/O Functions .....................................................................................................129

Table 7-7: Analog Output Voltage Range Min/Max ....................................................................................131

Table 7-8: Voltage Tolerances for the TEST CHANNEL Calibration ..........................................................137

Table 7-9: Current Loop Output Check .......................................................................................................141

Table 7-10: Test Channels Functions available on the GFC 7001E/EM’s Analog Output ...........................144

Table 7-11: CO Concentration Alarm Default Settings .................................................................................147

Table 8-1: COMM Port Communication Modes ..........................................................................................152

Table 8-2: Terminal Mode Software Commands ........................................................................................156

Table 8-3: Teledyne’s Serial I/O Command Types .....................................................................................157

Table 8-4: Ethernet Status Indicators..........................................................................................................164

Table 8-5: LAN/Internet Configuration Properties .......................................................................................165

Table 8-6: RS-232 Communication Parameters for Hessen Protocol ........................................................175

Table 8-7: Teledyne’s Hessen Protocol Response Modes .........................................................................178

Table 8-8: Default Hessen Status Flag Assignments .................................................................................182

Table 9-1: NIST-SRMs Available for Traceability of CO Calibration Gases ................................................187

Table 9-2: AUTOCAL Modes ......................................................................................................................198

Table 9-3: AutoCal Attribute Setup Parameters ..........................................................................................199

Table 9-4: Example AutoCal Sequence ......................................................................................................200

Table 9-5: Calibration Data Quality Evaluation ...........................................................................................204

Table 10-1: Matrix for Calibration Equipment & Supplies .............................................................................219

Table 10-2: Activity Matrix for Quality Assurance Checks ............................................................................220

Table 10-3: Definition of Level 1 and Level 2 Zero and Span Checks ..........................................................221

Table 11-1: Absorption Path Lengths for GFC 7001E and GFC 7001EM ....................................................230

Table 11-2: Sync DEMOD Sample and Hold Circuits ...................................................................................243

Table 11-3: Sync/Demod Status LED Activity ...............................................................................................244

Table 11-4: Relay Board Status LED’s .........................................................................................................246

Table 11-5: Front Panel Status LED’s ...........................................................................................................252

Table 12-1: GFC 7001E/EM Maintenance Schedule ....................................................................................261

Table 12-2: GFC 7001E/EM Test Function Record ......................................................................................262

Table 12-3: Predictive uses for Test Functions .............................................................................................263

Table 13-1: Warning Messages - Indicated Failures ....................................................................................269

Table 13-2: Test Functions - Indicated Failures ............................................................................................271

Table 13-3: Sync/Demod Board Status Failure Indications ..........................................................................275

Table 13-4: I2C Status LED Failure Indications .............................................................................................276

Table 13-5: Relay Board Status LED Failure Indications ..............................................................................277

Table 13-6: DC Power Test Point and Wiring Color Codes ..........................................................................288

Table 13-7: DC Power Supply Acceptable Levels ........................................................................................289

Table 13-8: Relay Board Control Devices .....................................................................................................290

Table 13-9: Opto Pickup Board Nominal Output Frequencies ......................................................................292

Table 13-10: Analog Output Test Function - Nominal Values Voltage Outputs .............................................294

Table 13-11: Analog Output Test Function - Nominal Values Voltage Outputs .............................................295

Table 13-12: Status Outputs Check ................................................................................................................296

Table 14-1: Static Generation Voltages for Typical Activities .......................................................................305

Table 14-2: Sensitivity of Electronic Devices to Damage by ESD ................................................................306

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Part 1 General Information Model GFC7001E Carbon Dioxide Analyzer

PART I

–

GENERAL INFORMATION

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Part 1 General Information Model GFC7001E Carbon Dioxide Analyzer

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Introduction Model GFC7001E Carbon Dioxide Analyzer

1. INTRODUCTION

1.1. GFC 7001E FAMILY OVERVIEW

The family includes the GFC 7001E and the GFC 7001EM Gas Filter Correlation (GFC) Carbon Monoxide
Analyzer. The GFC 7001E family of analyzers is a microprocessor-controlled analyzer that determines the
concentration of carbon monoxide (CO) in a sample gas drawn through the instrument. It uses a method based
on the Beer-Lambert law, an empirical relationship that relates the absorption of light to the properties of the
material through which the light is traveling over a defined distance. In this case the light is infrared radiation (IR)
traveling through a sample chamber filled with gas bearing a varying concentration of CO.

The GFC 7001E/EM uses Gas Filter Correlation (GFC) to overcome the interfering effects of various other gases
(such as water vapor) that also absorb IR. The analyzer passes the IR beam through a spinning wheel made up
of two separate chambers, one containing a high concentration of CO, known as the reference, and the other
containing a neutral gas known as the measure. The concentration of CO in the sample chamber is computed by
taking the ratio of the instantaneous measure and reference values and then compensating the ratio for sample
temperature and pressure.

The GFC 7001E/EM Analyzer’s multi-tasking software gives the ability to track and report a large number of
operational parameters in real time. These readings are compared to diagnostic limits kept in the analyzers
memory and should any fall outside of those limits the analyzer issues automatic warnings.

Built-in data acquisition capability, using the analyzer's internal memory, allows the logging of multiple
parameters including averaged or instantaneous concentration values, calibration data, and operating
parameters such as pressure and flow rate. Stored data are easily retrieved through the serial port or optional
Ethernet port via our APICOM software or from the front panel, allowing operators to perform predictive
diagnostics and enhanced data analysis by tracking parameter trends. Multiple averaging periods of one minute
to 365 days are available for over a period of one year.

Some of the common features of your GFC 7001E family of analyzers are:

 Microprocessor controlled for versatility
 Multi-tasking software allows viewing of test variables during operation
 Continuous self checking with alarms
 Bi-directional RS-232 for remote operation
 Digital status outputs indicate instrument operating condition
 Adaptive signal filtering optimizes response time
 Gas Filter Correlation Wheel for CO specific measurement
 GFC Wheel guaranteed against leaks for 5 years
 Temperature & Pressure compensation
 Internal data logging with 1 min to 365 day multiple average
 Remote operation when used with Teledyne APICOM software

GFC 7001E FEATURES:

 Ranges, 0-1 ppm to 0-1000 ppm, user selectable
 14-meter path length for sensitivity

GFC 7001EM FEATURES:

 Ranges, 0-1 ppm; Max: 0-5000 ppm, user selectable
 2.5 meter path length for dynamic range

Teledyne Analytical Instruments 23

Introduction Model GFC7001E Carbon Dioxide Analyzer

Several options can be purchased for the analyzer that allows the user to more easily supply and manipulate
Zero Air and Span Gas. For more information of these options, see Section 5.6.

1.2. ADDITIONAL DOCUMENTATION

Additional documentation for the GFC 7001E/EM CO Analyzer is available from Teledyne’s website at
http://www.teledyne-ai.com/manuals/.

 APICOM software manual, P/N 03945.
 DAS Manual, P/N 02837.

Teledyne Analytical Instruments 24

Introduction Model GFC7001E Carbon Dioxide Analyzer

1.2.1. USING THIS MANUAL

NOTE

This manual explains the operation and use of both the GFC 7001E and the GFC 7001EM Gas Filter

Correlation Carbon Monoxide Analyzer.

For the most part these two instruments are nearly identical in their features and functions.

The examples and illustrations shown in this manual represent the GFC 7001E. Where a significant

difference does exist between the different models, each version is shown.

NOTE

Throughout this manual, words printed in capital, bold letters, such as SETUP or ENTR represent

messages as they appear on the analyzer’s display.

This manual has the following structure:

TABLE OF CONTENTS:

Outlines the contents of the manual in the order the information are presented. This is a good overview of the
topics covered in the manual. There is also a list of appendices, figures and tables.

PART I – GENERAL INFORMATION

INTRODUCTION

A brief description of the GFC 7001E/EM Analyzer architecture as well as a description of the layout of
the manual and what information is located in its various sections.

SPECIFICATIONS AND WARRANTY

Lists the performance specifications of the analyzers . If applicable, a description of the conditions and
configuration under which EPA equivalency was approved as well as the Teledyne’s warranty statement.

GETTING STARTED

This section provides instructions for setting up, installing and running your analyzer for the first time.

GLOSSARY

Answers to the most frequently asked questions about operating the analyzer and a glossary of acronyms
and technical terms.

OPTIONAL HARDWARE & SOFTWARE

The section describes the optional equipment and their functions for your analyzer.

Teledyne Analytical Instruments 25

Introduction Model GFC7001E Carbon Dioxide Analyzer

PART II – OPERATING INSTRUCTIONS

BASIC OPERATION OF THE GFC 7001E/EM ANALYZER

Step-by-Step instructions for using the display/keyboard to set up and operate the GFC 7001E/EM
Analyzer.

ADVANCED FEATURES OF THE GFC 7001E/EM ANALYZER

Step-by-Step instructions for using the GFC 7001E/EM Analyzer’s more advanced features such as the
iDAS system, the DIAG and VARS menus and the and the TEST channel analog output.

REMOTE OPERATION OF THE GFC 7001E/EM Analyzer

Information and instructions for interacting with the GFC 7001E/EM Analyzer via its several remote
interface options (e.g. via RS-232, Ethernet, its built in digital control inputs/outputs, etc.)

GFC 7001E/EM VALIDATION AND VERIFICATION

Methods and procedures for verifying the correct operation of your GFC 7001E/EM Analyzer as well as
step by step instructions for calibrating it.

EPA PROTOCOL CALIBRATION

Specific information regarding calibration requirements for analyzers used in EPA monitoring.

PART III – TECHNICAL INFORMATION

THEORY OF OPERATION

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

MAINTENANCE SCHEDULE AND PROCEDURES

Description of preventative maintenance procedures that should be regularly performed on the analyzer
to assure good operating condition.

GENERAL TROUBLESHOOTING & REPAIR OF THE GFC 7001E/EM ANALYZER

This section includes pointers and instructions for diagnosing problems with the analyzer in general and
the Terminus as well as instructions on performing repairs of on the Terminus.

A PRIMER ON ELECTRO-STATIC DISCHARGE

This section describes how static electricity occurs; why it is a significant concern and; how to avoid it and
avoid allowing ESD to affect the reliable and accurate operation of your analyzer.

APPENDICES

For easier access and better updating, some information has been separated out of the manual and placed in a
series of appendices at the end of this manual. These include version-specific software menu trees, warning
messages, definitions Modbus registers and serial I/O variables as well as spare part listings, repair
questionnaires, interconnect drawing, detailed pneumatic and electronic schematics.

NOTE

The flowcharts in this manual contain typical representations of the analyzer’s display during the various

operations being described. These representations are not intended to be exact and may differ slightly

from the actual display of the instrument.

Teledyne Analytical Instruments 26

Specifications Model GFC7001E Carbon Dioxide Analyzer

2. SPECIFICATIONS AND APPROVALS

2.1. SPECIFICATIONS

Table 2-1: M 300E/300EM Basic Unit Specifications

Ranges

Measurement Units

Zero Noise GFC 7001E: < 0.02 ppm RMS1; GFC 7001EM: ≤ 0.1 ppm RMS
Span Noise

Lower Detectable Limit1 GFC 7001E: < 0.04 ppm; GFC 7001EM: 0.2 ppm
Zero Drift (24 hours) 2 GFC 7001E: < 0.1 ppm; GFC 7001EM: <0.5 ppm
Zero Drift (7 days) 2 GFC 7001E: < 0.2 ppm; GFC 7001EM: <1.0ppm
Span Drift (24 hour2s) The greater of < 0.5% of reading or 0.1ppm (GFC 7001E), 0.5ppm(GFC 7001EM)
Span Drift (7 days) 2 The greater of < 1% of reading or 0.5ppm (GFC 7001E), 1 ppm(GFC 7001EM)
Linearity

Precision GFC 7001E: The greater of 0.5% of reading or 0.2ppm;

Lag Time 1 10 sec1
Rise/Fall Time 1 <60 sec to 95%1
Sample Flow Rate

Temperature Range

Humidity Range 0-95% RH, Non-Condensing
Temp Coefficient

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

Environmental Conditions Installation Category (Over voltage Category) II Pollution Degree 2
Analog Outputs 4 user configurable outputs
Analog Output Ranges

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

Alarm outputs (optional) 2 opto-isolated alarm outputs and 2 dry contact alarm outputs
Certifications

GFC 7001E: Min: 0-1 ppm; Max: 0-1000 ppm of Full Scale (User selectable)
GFC 7001EM: Min: 0-5 ppm; Max: 0-5000 ppm of Full Scale (User selectable)

GFC 7001E: ppb, ppm, µg/m
GFC 7001EM: ppm, mg/m

GFC 7001E:<0.5% of rdg RMS over 5ppm
over 20ppm

GFC 7001E: Better than 1% Full Scale
GFC 7001EM: 0 - 3000 ppm: 1% full scale; 3000 - 5000 ppm: 2% full scale

GFC 7001EM: The greater of 1.0% of reading or 1ppm

800 cm
O

Sensor option adds 120 cm³/min to total flow though when installed

2

5 - 40C operating, 10 - 40C EPA Equivalency (GFC 7001E only)

< 0.05 % per C (minimum 50 ppb/C)

100V 50/60 Hz (3.25A), 115 V 60 Hz (3.0A),
220 – 240 V 50/60 Hz (2.5A)

All Outputs: 0.1V, 1V, 5V or 10V
Three outputs convertible to 4-20 mA isolated current loop.
All Ranges with 5% under/over-range

One (1) RS-232/optional multidrop; One (1) RS-232/optional RS-485 (2 connecters in
parallel)
Baud Rate : 300 - 115200

USEPA: Reference Method Number EQOA-0992-087
CE: EN61010-1:90 + A1:92 + A2:95, EN61326 - Class A

3

/min. ±10%

3

, mg/m3 (user selectable)

3

(user selectable)

1, 3

; GFC 7001EM:>0.5% of rdg RMS

5;

Teledyne Analytical Instruments 27

Specifications Model GFC7001E Carbon Dioxide Analyzer

1

As defined by the USEPA

2

At constant temperature and pressure

2.2. EPA EQUIVALENCY DESIGNATION

Teledyne’s GFC 7001E Carbon Monoxide Analyzer is designated as Reference Method Number EQOA-0992­087 as defined in 40 CFR Part 53, when operated under the following conditions:

 Range: Any range from 10 ppm to 50 ppm.
 Ambient temperature range of 10 to 40C.
 Line voltage range of 90 – 127 and 200 – 230 VAC, 50/60 Hz.
 Sample filter: Equipped with PTFE filter element in the internal filter assembly.

3

 Sample flow of 800  80 cm
 Internal sample pump.
 Software settings:

/min at sea level.

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:

 Rack mount with slides.
 Rack mount without slides, ears only.
 Zero/span valve options.

 Option 50A – Sample/Cal valves, or;
 Option 50B – Sample/Cal valves with span shutoff & flow control.

 Internal zero/span (IZS) option with either:

 Option 51A – Sample/Cal valves, or;

 Option 51C – Sample/Cal valves with span shutoff & flow control.
 Status outputs.
 Control inputs.
 RS-232 output.
 Ethernet output.
 4-20mA, isolated output.

Teledyne Analytical Instruments 28

Specifications Model GFC7001E Carbon Dioxide Analyzer

2.3. TUV DESIGNATION

On behalf of Teledyne TÜV Rheinland Immissionsschutz und Energiesysteme GmbH has performed the
suitability test of the measuring system GFC 7001E for the component carbon monoxide.

The suitability test was carried out in compliance with the following guidelines and requirements:

 EN 14626 Ambient Air Quality – Standard method for the measurement of the concentration of carbon

monoxide by nondispersive infrared spectroscopy, March 2005.

The measuring system GFC 7001E operates using the non-dispersive infrared spectroscopy.

The investigations have been carried out in the laboratory and during a field test, lasting three months. The
tested measuring ranges are:

Component Measuring Range

Carbon Monoxide CO 100 mg/m3 EN 14626

NOTE: 0-100 ppm correlates to 0-100 µmol/mol or 0-116 mg/m3 (at 293 K and 1013
mbar).

The minimum requirements have been fulfilled in the suitability test.

Therefore the TÜV Immissionsschutz and Energiesysteme GmbH proposes the publication as a suitability-tested
measuring system for continuous monitoring of carbon monoxide in the ambient air.

2.4. CE MARK COMPLIANCE

2.4.1. EMISSIONS COMPLIANCE

Teledyne’s GFC 7001E/EM 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.

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

2.4.2. SAFETY COMPLIANCE

Teledyne’s GFC 7001E/EM Gas Filter Correlation CO Analyzer was tested and found to be fully compliant with:

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

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

Teledyne Analytical Instruments 29

Specifications Model GFC7001E Carbon Dioxide Analyzer

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Getting Started Model GFC7001E Carbon Dioxide Analyzer

3. GETTING STARTED

3.1. GFC 7001E/EM ANALYZER LAYOUT

Figure 3-1: Front Panel Layout

Table 3-1: Front Panel Nomenclature

Name Significance
Mode Field Displays the name of the analyzer’s current operating mode.

Message Field

Concentration
Field

Keypad
Definition Field

STATUS LED’s
Name Color State Definition

SAMPLE Green

CAL Yellow

FAULT Red

Displays a variety of informational messages such as warning messages, operational data, test function
values and response messages during interactive tasks.

Displays the actual concentration of the sample gas currently being measured by the analyzer in the
currently selected units of measure.

Displays dynamic, context sensitive definitions for the row of keys just below the display.

Off
On
Blinking

Off
On
Blinking

Off
Blinking

Unit is not operating in sample mode, iDAS is disabled.
Sample Mode active; Front Panel Display being updated; iDAS data being stored.
Unit is operating in sample mode, front panel display being updated, iDAS hold-off mode

is ON, iDAS disabled
Auto Cal disabled

Auto Cal enabled
Unit is in calibration mode

No warnings exist
Warnings exist

Teledyne Analytical Instruments 31

Getting Started Model GFC7001E Carbon Dioxide Analyzer

Figure 3-2: Rear Panel Layout

Table 3-2: Inlet / Outlet Connector Nomenclature

REAR PANEL LABEL FUNCTION

Connect a gas line from the source of sample gas here.

SAMPLE

EXHAUST

Pressure Span

Vent/Span

Calibration gases are also inlet here on units without zero/span/shutoff valve options
installed.

Connect an exhaust gas line of not more than 10 meters long here that leads outside
the shelter or immediate area surrounding the instrument.

On units with zero/span/shutoff valve options installed, connect a gas line to the source
of calibrated span gas here.

Span gas vent outlet for units with zero/span/shutoff valve options installed.
Connect an exhaust gas line of not more than 10 meters long here that leads outside

the shelter or immediate area surrounding the instrument.
Internal Zero Air: On units with zero/span/shutoff valve options installed but no internal

IZS

zero air scrubber attach a gas line to the source of zero air here.

Teledyne Analytical Instruments 32

Getting Started Model GFC7001E Carbon Dioxide Analyzer

Figure 3-3: Internal Layout – GFC 7001E

Teledyne Analytical Instruments 33

Getting Started Model GFC7001E Carbon Dioxide Analyzer

Figure 3-4: Internal Layout – GFC 7001EM with CO

and O2 Sensor Option

2

Teledyne Analytical Instruments 34

Getting Started Model GFC7001E Carbon Dioxide Analyzer

Sample Gas Flow

Sensor

Sync/Demod PCA

Housing

Sample Gas Outlet

fitting

Sample Chamber

Pressure Sensor(s)

Bench

Temperature

Thermistor

Shock Absorbing

Mounting Bracket

Opto-Pickup

PCA

GFC Temperature

Sensor

Purge Gas

Pressure Regulator

IR Source

GFC Wheel

Heat Sync

GFC Wheel Motor

Purge Gas

Inlet

GFC Heater

Figure 3-5: Optical Bench Layout

Teledyne Analytical Instruments 35

Getting Started Model GFC7001E Carbon Dioxide Analyzer

Figure 3-6: GFC 7001E/EM Internal Gas Flow (Basic Configuration)

NOTE

For pneumatic diagrams of GFC 7001E/EM Analyzer with various calibration valve options, see Section

5.6.

3.2. UNPACKING THE GFC 7001E/EM ANALYZER

CAUTION

GENERAL SAFETY HAZARD

To avoid personal injury, always use two persons to lift and carry the GFC 7001E/EM.

CAUTION

ELECTRICAL SHOCK HAZARD

Never disconnect PCAs, wiring harnesses or electronic subassemblies while under

power.

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.

Teledyne Analytical Instruments 36

Getting Started Model GFC7001E Carbon Dioxide Analyzer

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

NOTE

It is recommended that you store shipping containers/materials for future use if/when the instrument should be
returned to the factory for repair and/or calibration serivce. See Warranty section in this manual and shipping
procedures on our Website at http://www.teledyne-api.com under Customer Support > Return Authorization.

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

2. Included with your analyzer is a printed record (Final Test and Validation Data Sheet: GFC 7001E PN
04307; GFC 7001EM PN 04311) of the final performance characterization performed on your
instrument at the factory. This record 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 by:

 Removing the setscrew located in the top, center of the Front panel;
 Removing the two flat head, Phillips screws on the sides of the instrument (one per side towards the

rear);

 Sliding the cover backwards until it clears the analyzer’s front bezel, and;
 Lifting the cover straight up.

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.

3.2.1. VENTILATION CLEARANCE

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

Table 3-3: Ventilation Clearance

AREA MINIMUM REQUIRED CLEARANCE

Back of the instrument

Sides of the instrument

Above and below the instrument

Various rack mount kits are available for this analyzer. See Section 5.2 of this manual for more information.

4 in.
1 in.
1 in.

Teledyne Analytical Instruments 37

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.3. ELECTRICAL CONNECTIONS

NOTE

To maintain compliance with EMC standards, it is required that the cable length be no greater than 3 meters for
all I/O connections, which include Analog In, Analog Out, Status Out, Control In, Ethernet/LAN, USB, RS-232,
and RS-485.

3.3.1. POWER CONNECTION

Attach the power cord to the analyzer and plug it into a power outlet capable of carrying at least 10 A current at
your AC voltage and that it is equipped with a functioning earth ground.

CAUTION

ELECTRICAL SHOCK HAZARD

High Voltages are present inside the analyzer’s case.

Power connection must have functioning ground connection.

Do not defeat the ground wire on power plug.

Turn off analyzer power before disconnecting or

connecting electrical subassemblies.

Do not operate with cover off.

CAUTION

GENERAL SAFETY HAZARD

The GFC 7001E/EM Analyzer can be configured for both

100-130 V and 210-240 V at either 47 Hz or 63 Hz.

To avoid damage to your analyzer, make sure that the AC power voltage matches

the voltage indicated on the analyzer’s serial number label tag (See Figure 3-2)

before plugging the GFC 7001E/EM into line power.

Teledyne Analytical Instruments 38

Getting Started Model GFC7001E Carbon Dioxide Analyzer

A

3.3.2. ANALOG OUTPUT CONNECTIONS

The GFC 7001E is equipped with several analog output channels accessible through a connector on the back
panel of the instrument. The standard configuration for these outputs is mVDC. An optional current loop output
is available for each.

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

Output A3 is only used on the GFC 7001E/EM if the optional CO

or O2 sensor is installed.

2

Channel A4 is special. It can be set by the user (see Section 7.4.6) to output any one of the parameters
accessible through the <TST TST> keys of the units sample display.

To access these signals attach a strip chart recorder and/or data-logger to the appropriate analog output
connections on the rear panel of the analyzer.

A1 A2 A3 A4
+ - + - + - + -

NALOG OUT

Figure 3-7: Analog Output Connector

Table 3-4: Analog Output Pin-Outs

PIN ANALOG OUTPUT VOLTAGE SIGNAL CURRENT SIGNAL

1
2 Ground I Out ­3
4 Ground I Out ­5

(Only used if CO

6 Ground I Out -

7
8 Ground I Out -

A1

A2

A3

Sensor is

O

2

installed)

A4

or

2

V Out I Out +

V Out I Out +

V Out I Out +

V Out I Out +

3.3.3. CONNECTING THE STATUS OUTPUTS

The status outputs report analyzer conditions via optically isolated NPN transistors, which sink up to 50 mA of
DC current. These outputs can be used interface with devices that accept logic-level digital inputs, such as
Programmable Logic Controllers (PLCs). Each status bit is an open collector output that can withstand up to 40
VDC. All of the emitters of these transistors are tied together and available at D.

NOTE

Most PLC’s have internal provisions for limiting the current that the input will draw from an external

device. When connecting to a unit that does not have this feature, an external dropping resistor must be

used to limit the current through the transistor output to less than 50 mA.

At 50 mA, the transistor will drop approximately 1.2V from its collector to emitter.

Teledyne Analytical Instruments 39

Getting Started Model GFC7001E Carbon Dioxide Analyzer

The status outputs are accessed via a 12-pin connector on the analyzer’s rear panel labeled STATUS (see
Figure 3-2). Pin-outs for this connector are:

1 2 3 4 5 6 7 8 D +

SYSTEM OK

CONC VALID

HIGH RANGE

ZERO CAL

STATUS

SPAN CAL

DIAG MODE

CAL

2

Optional O

Figure 3-8: Status Output Connector

Table 3-5: Status Output Signals

REAR PANEL

LABEL

1 SYSTEM OK ON if no faults are present.

2 CONC VALID

3 HIGH RANGE
4 ZERO CAL
5 SPAN CAL
6 DIAG MODE

7 CO2 CAL

8 O2 CAL

D EMITTER BUS The emitters of the transistors on pins 1-8 are bussed together.
SPARE
+ DC POWER + 5 VDC, 300 mA source (combined rating with Control Output, if used).

STATUS

DEFINITION

CONDITION

OFF any time the HOLD OFF feature is active, such as during calibration or when
other faults exist possibly invalidating the current concentration measurement
(example: sample flow rate is outside of acceptable limits).

ON if concentration measurement is valid.
ON if unit is in high range of either the DUAL or AUTO range modes.
ON whenever the instrument’s ZERO point is being calibrated.
ON whenever the instrument’s SPAN point is being calibrated.
ON whenever the instrument is in DIAGNOSTIC mode.
If this analyzer is equipped with an optional CO2 sensor, this Output is ON when that

sensor is in calibration mode.
Otherwise this output is unused.

If this analyzer is equipped with an optional O2 sensor, this Output is ON when that
sensor is in calibration mode.

Otherwise this output is unused.

Digital Ground The ground level from the analyzer’s internal DC power supplies.

Teledyne Analytical Instruments 40

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.3.4. CONNECTING THE CONTROL INPUTS

If you wish to use the analyzer to remotely activate the zero and span calibration modes, several digital control
inputs are provided through a 10-pin connector labeled CONTROL IN on the analyzer’s rear panel.

There are two methods for energizing the control inputs. The internal +5V available from the pin labeled “+” is
the most convenient method. However, if full isolation is required, an external 5 VDC power supply should be
used.

A B C D E F U

ZERO

LOW SPAN

CONTROL IN

CAL HIGH RANGE

Local Power Connections

+

A B C D E F U

ZERO

LOW SPAN

External Powe r Connections

CONTROL IN

CAL HIGH RANGE

5 VDC Power

-

Supply

+

+

Figure 3-9: Control Input Connector

Table 3-6: Control Input Signals

INPUT # STATUS DEFINITION ON CONDITION

A

B

C

D, E

& F

REMOTE ZERO CAL

REMOTE SPAN CAL

REMOTE CAL HIGH
RANGE

SPARE

Digital Ground

U External Power input Input pin for +5 VDC required to activate pins A – F.

+

5 VDC output

The analyzer is placed in Zero Calibration mode. The mode field of the
display will read ZERO CAL R.

The analyzer is placed in span calibration mode as part of performing a low
span (midpoint) calibration. The mode field of the display will read LO CAL
R.

The analyzer is forced into high range for zero or span calibrations. This
only applies when the range mode is either DUAL or AUTO. The mode field
of the display will read HI CAL R.

The ground level from the analyzer’s internal DC power supplies (same as
chassis ground).

Internally generated 5V DC power. To activate inputs A – F, place a jumper
between this pin and the “U” pin. The maximum amperage through this port
is 300 mA (combined with the analog output supply, if used).

Teledyne Analytical Instruments 41

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.3.5. CONNECTING THE SERIAL PORTS

If you wish to utilize either of the analyzer’s two serial interface COMM ports, refer to Section 8 for instructions on
their configuration and usage.

3.3.6. CONNECTING TO A LAN OR THE INTERNET

If your unit has a Teledyne’s Ethernet card, plug one end into the 7’ CAT5 cable supplied with the option into the
appropriate place on the back of the analyzer and the other end into any nearby Ethernet access port.

NOTE

The GFC 7001E/EM firmware supports dynamic IP addressing or DHCP.

If your network also supports DHCP, the analyzer will automatically configure its LAN connection

appropriately (see Section 8.4.2).

If your network does not support DHCP, see Section 8.4.3 for instructions on manually configuring the

LAN connection.

3.3.7. CONNECTING TO A MULTIDROP NETWORK

If your unit has a Teledyne’s RS-232 multidrop card, see Section 8.2 for instructions on setting it up.

3.4. PNEUMATIC CONNECTIONS

CAUTION

GENERAL SAFETY HAZARD

CARBON MONOXIDE (CO) IS A TOXIC GAS.

Obtain a Material Safety Data Sheet (MSDS) for this material. Read and rigorously

Do not vent calibration gas and sample gas into enclosed areas.

3.4.1. CALIBRATION GASES

3.4.1.1. Zero Air

Zero air is a gas that is similar in chemical composition to the earth’s atmosphere but scrubbed of all
components that might affect the analyzers readings, in this case CO and water vapor. If your analyzer is
equipped with an IZS or External Zero Air scrubber option, it is capable of creating zero air.

follow the safety guidelines described there.

If the analyzer is NOT equipped with the optional CO
as this gas can also have an interfering effect on CO measurements.

For analyzers without an IZS or external zero air scrubber option, a zero air generator such as the
Teledyne’s M701 can be used.

sensor, zero air should be scrubbed of CO2 as well

2

Teledyne Analytical Instruments 42

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.4.1.2. Span Gas

Span gas is a gas specifically mixed to match the chemical composition of the type of gas being
measured at near full scale of the desired measurement range. In the case of CO measurements made
with the GFC 7001E/EM Analyzer, it is recommended that you use a span gas with a CO concentration
equal to 80-90% of the measurement range for your application.

EXAMPLE: If the application is to measure between 0 ppm and 500 ppb, an appropriate span gas
concentration would be 400-450 ppb CO in N2.

Some applications, such as EPA monitoring, require a multipoint calibration procedure where span gases
of different concentrations are needed. We recommend using a bottle of calibrated CO gas of higher
concentration in conjunction with a gas dilution calibrator such as a Teledyne’s M700. This type of
calibrator precisely mixes a high concentration gas with zero air (both supplied externally) to accurately
produce span gas of the correct concentration. Linearity profiles can be automated with this model and
run unattended over night.

Cylinders of calibrated CO gas traceable to NIST-Standard Reference Material specifications (also
referred to as SRMs or EPA protocol calibration gases) are commercially available. Table 3-7 lists specific
NIST-SRM reference numbers for various concentrations of CO.

Table 3-7: NIST-SRM's Available for Traceability of CO Calibration Gases

NIST-SRM TYPE

1680b CO in N2 500 ppm
1681b CO in N2 1000 ppm
2613a CO in Zero Air 20 ppm
2614a CO in Zero Air 45 ppm

1

2659a

2626a CO2 in N2 4% by weight
2745* CO2 in N2 16% by weight

1

Used to calibrate optional O2 sensor.

2

Used to calibrate optional CO2 sensor.

O2 in N2 21% by weight

NOMINAL

CONCENTRATION

Teledyne Analytical Instruments 43

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.4.2. PNEUMATIC CONNECTIONS TO GFC 7001E/EM BASIC

CONFIGURATION

NOTE

In order to prevent dust from getting into the gas flow channels of your analyzer, it was shipped with

small plugs inserted into each of the pneumatic fittings on the back panel.

Make sure that all of these dust plugs are removed before attaching

exhaust and supply gas lines.

See Figure 3-2 and Table 3-2 for the location and descriptions of the various pneumatic inlets/outlets referred to
in this section.

See Section 5.6 for information regarding the pneumatic setup of GFC 7001E/EM Analyzers with various optional
calibration valve options in stalled

CAUTION

GENERAL SAFETY HAZARD

Sample and calibration gases should only come into contact with PTFE (Teflon), FEP,

glass, stainless steel or brass.

The exhaust from the analyzer’s internal pump MUST be vented outside the immediate

It is important to conform to all safety requirements regarding exposure to CO.

area or shelter surrounding the instrument.

Figure 3-10: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas

Teledyne Analytical Instruments 44

Getting Started Model GFC7001E Carbon Dioxide Analyzer

Figure 3-11: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator

3.4.2.1. Sample Gas Source

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

 Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure

and ideally should equal ambient atmospheric pressure.

 In applications where the sample gas is received from a pressurized manifold, a vent must be placed on

the sample gas before it enters the analyzer.

3.4.2.2. Calibration Gas Sources

The source of calibration gas is also attached to the SAMPLE inlet, but only when a calibration operation is
actually being performed.

NOTE

Zero air and span gas inlets should supply their respective gases in excess of the 800 cc3/min demand

of the analyzer.

Teledyne Analytical Instruments 45

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.4.2.3. Input Gas Venting

The span gas, zero air supply and sample gas line MUST be vented in order to ensure that the gases input do
not exceed the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects.
These vents should be:

 At least 0.2m long;
 No more than 2m long and;
 Vented outside the shelter or immediate area surrounding the instrument.

3.4.2.4. Exhaust Outlet

Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:

 PTEF tubing; minimum O.D ¼”;
 A maximum of 10 meters long;
 Vented outside the GFC 7001E/EM Analyzer’s enclosure.

NOTE

Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks

using the procedures defined in Section 12.3.3.

NOTE

For information on attaching gas lines to GFC 7001E/EM Analyzers with various calibration valve

options,

see Section 5.6.

3.5. INITIAL OPERATION

NOTE

The analyzer’s cover must be installed to ensure that the temperatures of the GFC Wheel and absorption

cell assemblies are properly controlled.

If you are unfamiliar with the GFC 7001E/EM theory of operation, we recommend that you read Section Error!
Reference source not found.. For information on navigating the analyzer’s software menus, see the menu

trees described in Appendix A.1.

Teledyne Analytical Instruments 46

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.5.1. STARTUP

After the electrical and pneumatic connections are made, turn on the instrument. The pump and exhaust fan
should start immediately. The display should immediately display a single, horizontal dash in the upper left
corner of the display. This will last approximately 30 seconds while the CPU loads the operating system.

Once the CPU has completed this activity it will begin loading the analyzer firmware and configuration data.
During this process, astring of messages will appear on the analyzer’s front panel display.

System waits 3 seconds then

automatically begins its

initialization routine.

System is checking the validity and

functionality of the Terminus

memory and firmware.

.

If at this point,

appears, contact Teledyne

Instruments customer service

.

The instrument is loading

configuration and calibration data

from the flash chip.

The instrument is loading the

system firmware.

The startup process may hesitate at this point if:

· The Ethernet option is installed;

· DHCP mode is turned on and;

· The instrument is not connected to a

functioning network.

The analyzer should automatically switch to Sample Mode after completing the boot-up sequence and start
monitoring CO gas.

Teledyne Analytical Instruments 47

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.5.2. WARM UP

The GFC 7001E/EM requires about 60 minutes warm-up time before reliable CO measurements can be taken.
During that time, various portions of the instrument’s front panel will behave as shown in Table 3-8. See Figure
3-1 for the layout.

Table 3-8: Front Panel Display during System Warm-Up

NAME COLOR BEHAVIOR SIGNIFICANCE

Concentration
Field

Mode Field N/A

STATUS LED’s

Sample Green On

Cal Yellow Off The instrument’s calibration is not enabled.

Fault Red Blinking

N/A

Displays current,
compensated CO
Concentration

Displays blinking
“SAMPLE”

This is normal operation.

Instrument is in sample mode but is still in the process of
warming up. (iDAS holdoff period is active)

Unit is operating in sample mode; front panel display is being
updated.

Flashes On/Off when adaptive filter is active

The analyzer is warming up and hence out of specification
for a fault-free reading. Various warning messages will
appear.

3.5.3. WARNING MESSAGES

Because internal temperatures and other conditions may be outside the specified limits during the analyzer’s
warm-up period, the software will suppress most warning conditions for 30 minutes after power up. If warning
messages persist after the 60 minutes warm-up period is over, investigate their cause using the troubleshooting
guidelines in Section Error! Reference source not found..

To view and clear warning messages, press:

Table 3-6 lists brief descriptions of the warning messages that may occur during start up.

Teledyne Analytical Instruments 48

Getting Started Model GFC7001E Carbon Dioxide Analyzer

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

Message MEANING

ANALOG CAL WARNING

BENCH TEMP WARNING

BOX TEMP WARNING

CANNOT DYN SPAN2

CANNOT DYN ZERO3

CONFIG INITIALIZED

DATA INITIALIZED

FRONT PANEL WARN

PHOTO TEMP WARNING

REAR BOARD NOT DET

RELAY BOARD WARN

SAMPLE FLOW WARN

SAMPLE PRESS WARN

The instrument's A/D circuitry or one of its analog outputs is not calibrated.

Optical bench temperature is outside the specified limits.

The temperature inside the GFC 7001E/EM chassis is outside the specified
limits.

Remote span calibration failed while the dynamic span feature was set to
turned on.

Remote zero calibration failed while the dynamic zero feature was set to turned
on.

Configuration was reset to factory defaults or was erased.

iDAS data storage was erased.

CPU is unable to communicate with the front panel.

Photometer temperature outside of warning limits specified by
PHOTO_TEMP_SET variable.

Motherboard was not detected during power up.

CPU is unable to communicate with the relay PCA.

The flow rate of the sample gas is outside the specified limits.

Sample pressure outside of operational parameters.

SAMPLE TEMP WARN

SOURCE WARNING

SYSTEM RESET1

WHEEL TEMP WARNING

1

Clears 45 minutes after power up.

2

Clears the next time successful zero calibration is performed.

3

Clears the next time successful span calibration is performed.

The temperature of the sample gas is outside the specified limits.

The IR source may be faulty.

The computer was rebooted.

The Gas Filter Correlation Wheel temperature is outside the specified limits.

Teledyne Analytical Instruments 49

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.5.4. FUNCTIONAL CHECK

After the analyzer’s components have warmed up for at least 60 minutes, verify that the software properly
supports any hardware options that were installed.

For information on navigating through the analyzer’s software menus, see the menu trees described in
Appendix A.1.

 Check to make sure that the analyzer is functioning within allowable operating parameters.

 Appendix C includes a list of test functions viewable from the analyzer’s front panel as well as their

expected values.

 These functions are also useful tools for diagnosing performance problems with your analyzer (see

Section 13.1.2).

 The enclosed Final Test and Validation Data Sheet (P/N 04307) lists these values before the

instrument left the factory.

To view the current values of these parameters press the following key sequence on the analyzer’s front
panel. Remember that until the unit has completed its warm-up these parameters may not have stabilized.

If your analyzer has an Ethernet card installed and your network is running a Dynamic Host Configuration
Protocol (DHCP) software package, the Ethernet option will automatically configure its interface with your LAN.

 However, it is a good idea to check these settings to make sure that the DHCP has successfully

downloaded the appropriate network settings from your network server (See Section 8.4.2).

 If your network is not running DHCP, you will have to configure the analyzer’s interface manually (See

Section 8.4.3).

Teledyne Analytical Instruments 50

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.6. INITIAL CALIBRATION OF THE GFC 7001E/EM

To perform the following calibration you must have sources for zero air and span gas available for input into the
sample port on the back of the analyzer. See Section 3.4 for instructions for connecting these gas sources.

The initial calibration should be carried out using the same reporting range set up as used during the analyzer’s
factory calibration. This will allow you to compare your calibration results to the factory calibration as listed on
the Final Test and Validation Data Sheet.

If both available iDAS parameters for a specific gas type are being reported via the instruments analog outputs
e.g. CONC1 and CONC2 when the DUAL range mode is activated, separate calibrations should be carried out
for each parameter.

 Use the LOW button when calibrating for CONC1 (equivalent to RANGE1).
 Use the HIGH button when calibrating for CONC2 (equivalent to RANGE2).

See Manual Addendum, P/N 06270 for more information on the configurable analog output reporting ranges.

NOTE

The following procedure assumes that the instrument does not have any of the available Valve Options

installed.

See Section 9.3 for instructions for calibrating instruments possessing valve options.

3.6.1. INTERFERENTS FOR CO

It should be noted that the gas filter correlation method for detecting CO is subject to interference from a number
of other gases that absorb IR in a similar fashion to CO. Most notable of these are water vapor, CO
(nitrous oxide) and CH
interference from of these sources, however high concentrations of these gases can interfere with the
instrument’s ability to make low-level CO measurements.

For a more detailed discussion of this topic, see Section 11.2.1.3.

(methane). The GFC 7001E/EM has been successfully tested for its ability to reject

4

MEASUREMENTS

2

, N2O

2

3.6.2. INITIAL CALIBRATION PROCEDURE FOR GFC 7001E/EM

ANALYZERS WITHOUT OPTIONS

The following procedure assumes that:

 The instrument DOES NOT have any of the available calibration valve or gas inlet options installed;
 Cal gas will be supplied through the SAMPLE gas inlet on the back of the analyzer (see Figure 3-2), and;
 The pneumatic setup matches that described in Section 3.4.2.

Teledyne Analytical Instruments 51

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.6.2.1. Verifying the GFC 7001E/EM Reporting Range Settings

While it is possible to perform the following procedure with any range setting we recommend that you perform
this initial checkout using following reporting range settings:

 Unit of Measure: PPM
 Analog Output Reporting Range: 50 ppm
 Mode Setting: SNGL

While these are the default setting for the GFC 7001E/EM Analyzer, it is recommended that you verify them
before proceeding with the calibration procedure, by pressing:

SAMPLE RANGE=50.0 PPM CO= XX.XX

<TST TST> CAL SETUP

SETUP X.X PRIMARY SETUP MENU

CFG DAS RNGE PASS CLK MORE EXIT

Verify that the MODE

is set for SNGL.
If it is not, press

SINGL

ENTR.

Verify that the RANGE is

set for 50.0

If it is not, toggle each

numeric key until the

proper range is set, then

press ENTR.

SETUP X.X RANGE CONTROL MENU

MODE SET UNIT DIL EXIT

SETUP X.X RANGE MODE:SINGL

SNGL DUAL AUTO ENTR EXIT

SETUP X.X RANGE CONTROL MENU

MODE SET UNIT DIL EXIT

SETUP X.X RANGE: 50.0 Conc

00050.0ENTREXIT

SETUP X.X RANGE CONTROL MENU

MODE SET UNIT DIL EXIT

Press EXIT

3x’s to return
the M200E to
the SAMPLE

mode.

Verify that the UNITs

SETUP X.X CONC UNITS:PPM

is set for PPM

If it is not, press

PPB PPM UGM MGM ENTR EXIT

PPM

ENTR.

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Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.6.2.2. Dilution Ratio Set Up

If the dilution ration option is enabled on your GFC 7001E/EM Analyzer and your application involves diluting the
sample gas before it enters the analyzer, set the dilution ration as follows:

Teledyne Analytical Instruments 53

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.6.2.3. Set CO Span Gas Concentration

Set the expected CO pan gas concentration. This should be 80-90% of range of concentration range for which
the analyzer’s analog output range is set.

Teledyne Analytical Instruments 54

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.6.2.4. Zero/Span Calibration

To perform the zero/span calibration procedure, press:

SAMPLE RANGE=0.0 PPm CO= XX.XX

< TST TST > CAL SETUP

Toggle TST> button until ...

SAMPLE STABIL= XXXX PPM CO=XX.XX

< TST TST > CAL SETUP

Allow zero gas to enter the sample port

at the rear of the analyzer.

SAMPLE STABIL= XXXX PPM CO=XX.XX

< TST TST > CAL SETUP

M-P CAL STABIL= XXXX PPM CO=XX.XX

<TST TST> ZERO CONC EXIT

M-P CAL STABIL= XXXX PPM CO=XX.XX

<TST TST> ENTR CONC EXIT

Set the Display to show

the STABIL test function.

This function calculates

the stability of the CO

measurement.

Wait until STABIL

falls below 0.5 ppm.

This may take several

minutes.

Press ENTR to changes

the OFFSET & SLOPE

values for the CO

measurements.

Press EXIT to leave the

calibration unchanged and

return to the previous

menu.

Allow span gas to enter the sample port

The SPAN key now appears

during the transition from

zero to span.

You may see both keys.

If either the ZERO or SPAN

buttons fail to appear see the

Troubleshooting section for

tips.

at the rear of the analyzer.

SAMPLE STABIL= XXXX PPM CO=XX.XX

< TST TST > CAL SETUP

M-P CAL STABIL= XXXX PPM CO=XX.XX

<TST TST> ZERO SPAN CONC EXIT

M-P CAL STABIL= XXXX PPM CO=XX.XX

<TST TST> ENTR CONC EXIT

M-P CAL STABIL= XXXX PPM CO=XX.XX

<TST TST> ENTR CONC EXIT

Wait until STABIL

falls below 0.5 PPM.

This may take several

minutes.

Press ENTR to changes

the OFFSET & SLOPE

values for the CO

measurements.

Press EXIT to leave the

calibration unchanged and

return to the previous

menu.

EXIT at this point

returns to the

SAMPLE menu.

Teledyne Analytical Instruments 55

Getting Started Model GFC7001E Carbon Dioxide Analyzer

3.6.3. O2 SENSOR CALIBRATION PROCEDURE

If your GFC 7001E/EM is equipped with the optional O2 sensor, this sensor should be calibrated during
installation of the instrument. See Section 9.7.1 for instructions.

3.6.4. CO2 SENSOR CALIBRATION PROCEDURE

If your GFC 7001E/EM is equipped with the optional CO2 sensor, this sensor should be calibrated during
installation of the instrument. See Section 9.7.2 for instructions.

The GFC 7001E/EM Analyzer is now ready for operation

NOTE

Once you have completed the above set-up procedures, please fill out the Quality Questionnaire that

was shipped with your unit and return it to Teledyne API.

This information is vital to our efforts in continuously improving our service and our products.

THANK YOU.

.

Teledyne Analytical Instruments 56

FAQs Model GFC7001E Carbon Dioxide Analyzer

4. FREQUENTLY ASKED QUESTIONS

4.1. FAQ’S

The following is a list from the Teledyne’s Customer Service Department of the most commonly asked questions
relating to the GFC 7001E/EM CO Analyzer.

Q: Why does the ENTR key sometimes disappear on the Front Panel Display?

A: During certain types of adjustments or configuration operations, the ENTR key will disappear if you select

a setting that is nonsensical (such as trying to set the 24-hour clock to 25:00:00) or out of the allowable
range for that parameter (such as selecting an iDAS hold off period of more than 20 minutes).

Once you adjust the setting in question to an allowable value, the ENTR key will re-appear.

Q: Why is the ZERO or SPAN key not displayed during calibration?

A: The GFC 7001E/EM disables certain these keys expected span or zero value entered by the users is too

different from the gas concentration actually measured value at the time. This is to prevent the accidental
recalibration of the analyzer to an out-of-range response curve.

EXAMPLE: The span set point is 40 ppm but gas concentration being measured is only 5 ppm.

For more information, see Sections 13.3.3 and 13.3.4.

Q: How do I enter or change the value of my Span Gas?

A: Press the CONC key found under the CAL or CALS buttons of the main SAMPLE display menus to enter

the expected CO span concentration.

See Section 3.6.2.3 or Zero/Span Calibration3.6.2.4 for more information.

Q: Why does the analyzer not respond to span gas?

A: Section 13.3.3 has some possible answers to this question.

Q: Is there an optional midpoint calibration?

A: There is an optional mid-point linearity adjustment; however, midpoint adjustment is applicable only to

applications where CO measurements are expected above 100 ppm. Call Teledyne’s Service Department
for more information on this topic.

Q: What do I do if the concentration on the instrument's front panel display does not match the value recorded or

displayed on my data logger even if both instruments are properly calibrated?
A: This most commonly occurs for one of the following reasons:

 A difference in circuit ground between the analyzer and the data logger or a wiring problem;
 A scale problem with the input to the data logger.

The analog outputs of the GFC 7001E/EM can be manually adjusted to compensate for either or both of
these effects, see Section 7.4.5;

 The analog outputs are not calibrated, which can happen after a firmware upgrade.

Both the electronic scale and offset of the analog outputs can be adjusted (see Section 7.4.3).
Alternately, use the data logger itself as the metering device during calibrations procedures.

Q: How do I perform a leak check?

A: See Section 12.3.3.

Teledyne Analytical Instruments 57

FAQs Model GFC7001E Carbon Dioxide Analyzer

Q: How do I measure the sample flow?

A: Sample flow is measured by attaching a calibrated rotameter, wet test meter, or other flow-measuring

device to the sample inlet port when the instrument is operating. The sample flow should be 800 cm
10%. See Section 12.3.4.

Q: How long does the IR source last?

A: Typical lifetime is about 2-3 years.

Q: Can I automate the calibration of my analyzer?

A: Any analyzer with zero/span valve or IZS option can be automatically calibrated using the instrument’s

AutoCal feature. The setup of this option is located in Section 9.4.

Q: Can I use the IZS option to calibrate the analyzer?

A: Yes. However, whereas this may be acceptable for basic calibration checks, the IZS option is not

permitted as a calibration source in applications following US EPA protocols.

To achieve highest accuracy, it is recommended to use cylinders of calibrated span gases in combination

with a zero air source.

Q: My analyzer has the optional, user-configurable analog output channels. How do I program and use them?

A: Instructions for this can be found in Appendix E .

3

/min

Q: What is the averaging time for an GFC 7001E/EM?

A: The default averaging time, optimized for ambient pollution monitoring, is 150 seconds for stable

concentrations and 10 seconds for rapidly changing concentrations; See Section 11.5.12 for more
information. However, it is adjustable over a range of 0.5 second to 200 seconds (please contact
customer service for more information).

4.2. GLOSSARY

Term Description/Definition

10BaseT An Ethernet standard that uses twisted (“T”) pairs of copper wires to transmit at

10 megabits per second (Mbps).

100BaseT Same as 10BaseT except ten times faster (100 Mbps).

APICOM Name of a remote control program offered by Teledyne to its customers.

ASSY

3

cm

metric abbreviation for cubic centimeter. Same as the obsolete abbreviation “cc”.

Chemical formulas that may be included in this document:

CO

2

C3H8 propane
CH4 methane
H2O water vapor
HC general abbreviation for hydrocarbon
HNO3 nitric acid
H2S hydrogen sulfide
NO nitric oxide
NO2 nitrogen dioxide

Assembly.

carbon dioxide

Teledyne Analytical Instruments 58

FAQs Model GFC7001E Carbon Dioxide Analyzer

Term Description/Definition

NOX nitrogen oxides, here defined as the sum of NO and NO2
NOy nitrogen oxides, often called odd nitrogen. The sum of NO, NO2 (NOX) plus other

compounds such as HNO
N

O and other compounds.

2

NH3 ammonia
O

2

O3 ozone
SO2 sulfur dioxide

molecular oxygen

Definitions vary widely and may include nitrate (NO3), PAN,

3

DAS

Data Acquisition System
DIAG Diagnostics, the diagnostic settings of the analyzer.
DHCP Dynamic Host Configuration Protocol. A protocol used by LAN or Internet

servers to automatically set up the interface protocols between themselves and

any other addressable device connected to the network
DOM Disk On Module, the analyzer’s central storage area for analyzer firmware,

configuration settings and data This is a 44-pin IDE flash disk that can hold up to

128MB.

DOS

Disk Operating System

DRAM Dynamic Random Access Memory

DR-DOS Digital Research DOS

Ethernet a standardized (IEEE 802.3) computer networking technology for local area

networks (LANs), facilitating communication and sharing resources

FLASH flash memory is non-volatile, solid-state memory

GFC

Gas Filter Correlation

I2C bus a clocked, bi-directional, serial bus for communication between individual

analyzer components
IC Integrated Circuit, a modern, semi-conductor circuit that can contain many basic

components such as resistors, transistors, capacitors etc in a miniaturized

package used in electronic assemblies

IP

IZS

LAN

LCD

LED

LPM

M/R

Internet Protocol

Internal Zero Span

Local Area Network

Liquid Crystal Display

Light Emitting Diode

Liters Per Minute

Measure/Reference

NDIR Non-Dispersive Infrared.
NIST-SRM National Institute of Standards and Technology - Standard Reference Material.

PC Printed Circuit Assembly, the  PCB with electronic components, ready to use
PC/AT Personal Computer / Advanced Technology.

Teledyne Analytical Instruments 59

FAQs Model GFC7001E Carbon Dioxide Analyzer

Term Description/Definition

PCB Printed Circuit Board, the bare board without electronic component.
PLC Programmable Logic Controller, a device that is used to control instruments

based on a logic level signal coming from the analyzer
PFA Per-Fluoro-Alkoxy, an inert polymer. One of the polymers that du Pont markets

as Teflon

PLD

PLL

Programmable Logic Device

Phase Lock Loop

®

PMT Photo Multiplier Tub e, a vacuum tube of electrodes that multiply electrons

collected and charged to create a detectable current signal

P/N (or PN)

PSD

Part Number

Prevention of Significant Deterioration

PTFE Poly-Tetra-Fluoro-Ethylene, a very inert polymer material used to handle gases

that may react on other surfaces One of the polymers that du Pont markets as

®

Teflon

PVC Poly Vinyl Chloride, a polymer used for downstream tubing

Rdg Reading.

RS-232 specification and standard describing a serial communication method between

two devices, DTE (Data Terminal Equipment) and DCE (Data Circuit-terminating

Equipment), using a maximum cable-length of 50 feet.

RS-485 specification and standard describing a binary serial communication method

among multiple devices at a data rate faster than RS-232 with a much longer

distance between the host and the furthest device.
SAROAD Storage and Retrieval of Aerometric Data.
SLAMS State and Local Air Monitoring Network Plan.
SLPM Standard Liters Per Minute; liters per minute of a gas at standard temperature

and pressure.
STP Standard Temperature and Pressure.
TCP/IP Transfer Control Protocol / Internet Protocol, the standard communications

protocol for Ethernet devices.
TEC Thermal Electric Cooler.

USB Universal Serial Bus is a standard connection method to establish

communication between peripheral devices and a host controller, such as a

mouse and/or keyboard and a personal computer.
VARS Variables, the variable settings of the analyzer.
Z/S Zero / Span.

Teledyne Analytical Instruments 60

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5. OPTIONAL HARDWARE AND SOFTWARE

This includes a brief description of the hardware and software options available for the GFC 7001E/EM Gas
Filter Correlation Carbon Monoxide Analyzer. For assistance with ordering these options please contact the
Sales department of Teledyne Analytical Instruments at:

TELEDYNE ELECTRONIC TECHNOLOGIES

Analytical Instruments

16830 Chestnut Street
City of Industry, CA 91748

Telephone: [phone]
Fax: [phone]

Web: www.teledyne-ai.com

5.1. EXTERNAL PUMPS (OPTIONS 10A-10E, 11, 13)

A variety of optional pumps are available for the GFC 7001E/EM Analyzer. The range of available pump options
meets all typical AC power supply standards while exhibiting the same pneumatic performance.

OPTION

NUMBER

10A External Pump 115V @ 60 Hz
10B External Pump 220V @ 50 Hz
10C External Pump 220V @ 60 Hz
10D External Pump 100V @ 50 Hz
10E External Pump 100V @ 60 Hz
11 Pumpless, external Pump Pack/Rack
13 High Voltage Internal Pump 240V/50Hz

DESCRIPTION

5.2. RACK MOUNT KITS (OPT 20 TO OPT 23)

There are several options for mounting the analyzer in standard 19” racks. The slides are three-part extensions,
one mounts to the rack, one mounts to the analyzer chassis and the middle part remains on the rack slide when
the analyzer is taken out. The analyzer locks into place when fully extended and cannot be pulled out without
pushing two buttons, one on each side.

The rack mount brackets for the analyzer require that you have a support structure in your rack to support the
weight of the analyzer. The brackets cannot carry the full weight of an analyzer and are meant only to fix the
analyzer to the front of a rack, preventing it from sliding out of the rack accidentally.

OPTION NUMBER DESCRIPTION

20A Rack mount brackets with 26 in. chassis slides.
20B Rack mount brackets with 24 in. chassis slides.
21 Rack mount brackets only.
23 Rack Mount for External Pump Pack (No Slides).

Each of these options permits the analyzer to be mounted in a standard 19" x 30" RETMA rack.

Teledyne Analytical Instruments 61

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.3. CARRYING STRAP/HANDLE (OPT 29)

The chassis of the GFC 7001E/EM Analyzer allows the user to attach a strap handle for carrying the instrument.
The handle is located on the right side and pulls out to accommodate a hand for transport. When pushed in, the
handle is nearly flush with the chassis, only protruding out about 9 mm (3/8”).

Figure 5-1: GFC 7001E/EM with Carrying Strap Handle and Rack Mount Brackets

Installing the strap handle prevents the use of the rack mount slides, although the rack mount brackets, Option
21, can still be used.

CAUTION

GENERAL SAFETY HAZARD

A fully configured GFC 7001E/EM with valve options weighs about 23 kg (51 pounds).

To avoid personal injury we recommend two persons lift and carry the analyzer.

Ensure to disconnect all cables and tubing from the analyzer before carrying it.

5.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41)

The current loop option adds isolated, voltage-to-current conversion circuitry to the analyzer’s analog outputs. It
converts the DC voltage analog output to a current signal with 0-20 mA output current. The outputs can be
scaled to any set of limits within that 0-20 mA range. However, most current loop applications call for either 2-20
mA or 4-20 mA range. All current loop outputs have a +5% over-range. Ranges with the lower limit set to more
than 1 mA (e.g., 2-20 or 4-20 mA) also have a -5% under-range,

This option may be ordered separately for three of the analog outputs and can be installed as a retrofit.

Figure 5-2 provides installation instructions and illustrates a sample combination of one current output and two
voltage outputs configuration. Section 5.4.1 provides instructions for converting current loop analog outputs to
standard 0-to-5 VDC outputs. Information on calibrating or adjusting these outputs can be found in Section

7.4.3.5.

Teledyne Analytical Instruments 62

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

Figure 5-2: Current Loop Option Installed on the Motherboard

5.4.1. CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD

VOLTAGE OUTPUTS

NOTE

Servicing or handling of circuit components requires electrostatic discharge protection, i.e. ESD

grounding straps, mats and containers. Failure to use ESD protection when working with electronic

assemblies will void the instrument warranty.

See Section 14 for more information on preventing ESD damage.

To convert an output configured for current loop operation to the standard 0 to 5 VDC output operation:

1. Turn off power to the analyzer.

2. If a recording device was connected to the output being modified, disconnect it.

3. Remove the top cover.

 Remove the screw located in the top, center of the front panel.
 Remove the screws on both sides that fasten the top cover to the unit.
 Slide the cover back and lift straight up.

4. Remove the screw holding the current loop option to the motherboard.

Teledyne Analytical Instruments 63

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5. Disconnect the current loop option PCA from the appropriate connector on the motherboard (see Figure
5-2).

6. Each connector, J19 and J23, requires two shunts. Place one shunt on the two left most pins and the
second shunt on the two pins next to it (see Figure 5-2).

 6 spare shunts (P/N CN0000132) were shipped with the instrument attached to JP1 on the back of

the instruments keyboard and display PCA.

7. Reattach the top case to the analyzer.

8. The analyzer is now ready to have a voltage-sensing, recording device attached to that output.

9. Calibrate the analog output as described in Section 7.4.3.

5.5. EXPENDABLES AND SPARES KITS (OPTIONS 42A, 45)

Expendables Kit, Option 42A: one-year supply of replacement particulate filters (47mm diameter)

Spares Kit, Option 45: spare parts for one unit

5.6. CALIBRATION VALVES (OPTIONS 50A, 50B, 50E, 50H)

The GFC 7001E/EM Gas Filter Correlation Carbon Monoxide Analyzer has a variety of available options
involving various valves for controlling the flow of calibration gases. From an operational and software
standpoint, all of the options are the same, only the source of the span and zero gases are different.

5.6.1. GENERAL INFORMATION RELATED TO ALL VALVE OPTIONS

5.6.1.1. Gas Flow Rate

 The minimum span gas flow rate required is 800 cm3/min; however, the US EPA recommends that there

be an excess of flow at least 800 cm

 Zero air will be supplied at ambient pressure from the local atmosphere.

3

/min of calibration gas.

5.6.1.2. Valve Control

The state of the various valves included in these options can be controlled as follows:

 Manually from the analyzer’s front panel by using the SIGNAL I/O controls located under the DIAG Menu

(see Section 7.3),

 By activating the instrument’s AutoCal feature (see Section 9.4),
 Remotely by using the external digital control inputs (see Section 9.3.3.3), or
 Remotely through the RS-232/485/Ethernet serial I/O ports (see Appendix A-6 for the appropriate

commands).

5.6.2. ZERO/SPAN VALVE (OPTION 50A)

This valve option is intended for applications where:

 Zero air is supplied by a zero air generator like the Teledyne’s M701 and;
 Span gas is supplied by Gas Dilution Calibrator like the Teledyne’s M700E or M702.

Internal zero/span and sample/cal valves control the flow of gas through the instrument, but because the
generator and calibrator limit the flow of zero air and span gas, no shutoff valves are required.

Teledyne Analytical Instruments 64

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.2.1. Internal Pneumatics (OPT 50A)

Figure 5-3: Internal Pneumatic Flow OPT 50A – Zero/Span Valves

Table 5-1: Zero/Span Valve Operating States for Option 52

MODE VALVE CONDITION

SAMPLE

(Normal

State)

ZERO CAL

SPAN CAL

Sample/Cal Open to SAMPLE inlet

Zero/Span Open to IZS inlet

Sample/Cal Open to ZERO/SPAN valve

Zero/Span Open to IZS inlet

Sample/Cal Open to ZERO/SPAN valve

Zero/Span Open to PRESSURE SPAN inlet

Teledyne Analytical Instruments 65

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.2.2. Pneumatic Set Up (OPT 50A)

 See Figure 3-2 for the location of gas inlets and

Figure 5-4: Pneumatic Connections – Option 50A: Zero/Span Calibration Valves

SAMPLE GAS SOURCE:

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

 Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure

and ideally should equal ambient atmospheric pressure.

 In applications where the sample gas is received from a pressurized manifold, a vent must be placed on

the sample gas before it enters the analyzer.

CALIBRATION GAS SOURCES:

A vent is required when an M700 is used with this option. However, if an M700E is used, a vent may or may not
be required depending on how the M700E output manifold is configured.

SPAN GAS:

 Attach a gas line from the source of calibration gas (e.g. a Teledyne’s M700E Dynamic Dilution

Calibrator) to the SPAN inlet at 30 psig.

ZERO AIR:

 Zero air is supplied via a zero air generator such as a Teledyne’s M701.
 An adjustable valve is installed in the zero air supply line to regulate the gas flow.

5.6.2.3. Input Gas Venting

The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These
vents should be:

 At least 0.2m long;
 No more than 2m long and;
 Vented outside the shelter or immediate area surrounding the instrument.

5.6.2.4. Exhaust Outlet

Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:

 PTEF tubing; minimum O.D ¼”;
 A maximum of 10 meters long;
 Vented outside the analyzer’s enclosure.

Teledyne Analytical Instruments 66

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.3. ZERO/SPAN/SHUTOFF VALVE (OPTION 50B)

This option requires that both zero air and span gas be supplied from external sources.

 Span gas will be supplied from a pressurized bottle of calibrated CO gas.

 A critical flow control orifice, internal to the instrument ensures that the proper flow rate is maintained.
 An internal vent line ensures that the gas pressure of the span gas is reduced to ambient atmospheric

pressure.

 A SHUTOFF valve preserves the span gas source when it is not in use.

 Zero gas is supplied by either an external scrubber or a zero air generator such as the Teledyne’s M701.

5.6.3.1. Internal Pneumatics (OPT 50B)

Figure 5-5: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves

Table 5-2: Zero/Span Valve Operating States for Option 50B

MODE VALVE CONDITION

SAMPLE

(Normal

State)

ZERO CAL

SPAN CAL

Sample/Cal Open to SAMPLE inlet

Zero/Span Open to IZS inlet

Shutoff Valve Closed

Sample/Cal Open to ZERO/SPAN valve

Zero/Span Open to IZS inlet

Shutoff Valve Closed

Sample/Cal Open to ZERO/SPAN valve

Zero/Span Open to SHUTOFF valve

Shutoff Valve Open to PRESSURE SPAN Inlet

Teledyne Analytical Instruments 67

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.3.2. Pneumatic Set Up (OPT 50B)

See Figure 3-2 for the location of gas inlets and outlets.

Figure 5-6: Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves

SAMPLE GAS SOURCE:

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

 Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure

and ideally should equal ambient atmospheric pressure.

 In applications where the sample gas is received from a pressurized manifold, a vent must be placed on

the sample gas before it enters the analyzer.

CALIBRATION GAS SOURCES:

SPAN GAS:

 Attach a gas line from the pressurized source of calibration gas (e.g. a bottle of NIST-SRM gas) to the

SPAN inlet at 30 psig.

ZERO AIR:

 Zero air is supplied via a zero air generator such as a Teledyne’s M701.
 An adjustable valve is installed in the zero air supply line to regulate the gas flow.

INPUT GAS VENTING:

The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These
vents should be:

 At least 0.2m long;
 No more than 2m long and;
 Vented outside the shelter or immediate area surrounding the instrument.

A similar vent line should be connected to the VENT SPAN outlet on the back of the analyzer.

EXHAUST OUTLET

Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:

 PTEF tubing; minimum O.D ¼”;
 A maximum of 10 meters long;
 Vented outside the analyzer’s enclosure.

Teledyne Analytical Instruments 68

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.4. ZERO/SPAN VALVE WITH INTERNAL CO SCRUBBER (OPTION 50H)

Option 50H is operationally and pneumatically similar to Option 50A above, except that the zero air is generated
by an internal zero air scrubber. This means that the IZS inlet can simply be left open to ambient air.

Internal zero/span and sample/cal valves control the flow of gas through the instrument, but because the
generator and calibrator limit the flow of zero air and span gas no shutoff valves are required.

5.6.4.1. Internal Pneumatics (OPT 50H)

Figure 5-7: Internal Pneumatic Flow OPT 50H – Zero/Span Valves with Internal Zero Air Scrubber

Table 5-3: Zero/Span Valve Operating States for Option 50H

MODE VALVE CONDITION

SAMPLE

(Normal

State)

ZERO CAL

SPAN CAL

Sample/Cal Open to SAMPLE inlet

Zero/Span Open to ZERO AIR scrubber

Sample/Cal Open to ZERO/SPAN valve

Zero/Span Open to ZERO AIR scrubber

Sample/Cal Open to ZERO/SPAN valve

Zero/Span Open to PRESSURE SPAN inlet

Teledyne Analytical Instruments 69

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.4.2. Pneumatic Set Up (OPT 50H)

See Figure 3-2 for the location of gas inlets and outlets and span gas no shutoff valves are required.

Figure 5-8: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves

SAMPLE GAS SOURCE:

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

 Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-Hg above ambient pressure

and ideally should equal ambient atmospheric pressure.

 In applications where the sample gas is received from a pressurized manifold, a vent must be placed on

the sample gas before it enters the analyzer.

CALIBRATION GAS SOURCES:

SPAN GAS:

 Attach a gas line from the source of calibration gas (e.g. a Teledyne’s M700E Dynamic Dilution

Calibrator) to the SPAN inlet.

ZERO AIR:

 Zero air is supplied internally via a zero air scrubber that draws ambient air through the IZS inlet.

INPUT GAS VENTING:

The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These
vents should be:

 At least 0.2m long;
 No more than 2m long and;
 Vented outside the shelter or immediate area surrounding the instrument.

EXHAUST OUITLET

Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:

 PTEF tubing; minimum O.D ¼”;
 A maximum of 10 meters long;
 Vented outside the analyzer’s enclosure.

Teledyne Analytical Instruments 70

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.5. ZERO/SPAN/SHUTOFF WITH INTERNAL ZERO AIR SCRUBBER

(OPTION 50E)

5.6.5.1. Internal Pneumatics (OPT 50E)

Figure 5-9: Internal Pneumatic Flow OPT 50E – Zero/Span/Shutoff Valves with Internal Zero Air

Scrubber

Table 5-4: Zero/Span Valve Operating States for Option 50E

Mode Valve Condition

SAMPLE
(Normal
State)

ZERO CAL

SPAN CAL

Sample/Cal Open to SAMPLE inlet
Zero/Span Open to internal ZERO AIR scrubber
Shutoff Valve Closed

Sample/Cal Open to zero/span valve
Zero/Span Open to internal ZERO AIR scrubber
Shutoff Valve Closed

Sample/Cal Open to ZERO/SPAN valve
Zero/Span Open to SHUTOFF valve
Shutoff Valve Open to PRESSURE SPAN inlet

Teledyne Analytical Instruments 71

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.6.5.2. Pneumatic Set Up (OPT 50E)

See Figure 3-2 for the location of gas inlets and outlets.

Figure 5-10: Pneumatic Connections – Option 50E: Zero/Span Calibration Valves

SAMPLE GAS SOURCE:

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

 Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure

and ideally should equal ambient atmospheric pressure.

 In applications where the sample gas is received from a pressurized manifold, a vent must be placed on

the sample gas before it enters the analyzer.

CALIBRATION GAS SOURCES:

SPAN GAS:

 Attach a gas line from the pressurized source of calibration gas (e.g. a bottle of NIST-SRM gas) to the

span inlet.

 Span gas can by generated by a M700E Dynamic Dilution Calibrator.

ZERO AIR:

 Zero air is supplied internally via a zero air scrubber that draws ambient air through the IZS inlet.

INPUT GAS VENTING:

The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These
vents should be:

 At least 0.2m long;
 No more than 2m long and;
 Vented outside the shelter or immediate area surrounding the instrument.

A similar vent line should be connected to the VENT SPAN outlet on the back of the analyzer.

EXHAUST OUITLET

Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:

 PTEF tubing; minimum O.D ¼”;
 A maximum of 10 meters long;
 Vented outside the analyzer’s enclosure.

Teledyne Analytical Instruments 72

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.7. COMMUNICATION OPTIONS

5.7.1. RS-232 MODEM CABLE (OPTION 60A)

Table 5-5: GFC 7001E/EM Modem Cable Options

OPTION NO. DESCRIPTION

Shielded, straight-through DB-9F to DB-25M cable of about 1.8 m length.

60A

60B

60C

5.7.2. RS-232 MULTIDROP (OPTION 62)

The multidrop option is used with RS232 and utilizes both DB-9 connectors on the rear panel to enable
communications of up to eight analyzers with the host computer over a chain of RS-232 cables. It is subject to
the distance limitations of the RS-232 standard.

 This cable is used to interface with older computers or code activated switches with

a DB-25 serial connectors.

Shielded, straight-through DB-9F to DB-9F cable of about 1.8 m length, which should fit
most computers of recent build.

CAT5 7’ cable, a shielded straight through cable, 2 meters in length, terminated with
RJ45 connectors.

 For use with the GFC 7001E/EM Analyzer’s optional Ethernet Card (Option 63A).

Figure 5-11: GFC 7001E/EM Multidrop Card Seated on CPU above Disk on Module

The option consists of a small printed circuit assembly, which plugs into to the analyzer’s CPU card and is
connected to the RS-232 and COM2 DB9 connectors on the instrument’s back panel via a cable to the
motherboard.

 One OPT 62 and one OPT 60B are required for each analyzer along the multidrop network.

See Section 8.2 for information regarding setting up a multidrop network for GFC 7001E/EM Analyzers.

Teledyne Analytical Instruments 73

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.7.3. ETHERNET (OPTION 63A)

The ETHERNET option allows the analyzer to be connected to any Ethernet Local Area Network (LAN) running
TCP/IP. The local area network must have routers capable of operating at 10BaseT. If internet access is
available through the LAN, this option also allows communication with the instrument over the public internet.
Maximum communication speed is limited by the RS-232 port to 115.2 kBaud.

When installed, this option is electronically connected to the instrument’s COM2 serial port making that port no
longer available for RS-232/RS-485 communications.

The option consists of a Teledyne’s designed Ethernet card (see Figure 5-12 and Figure 5-13), and a 7-foot long
CAT-5 network cable, terminated at both ends with standard RJ-45 connectors.

Figure 5-12: GFC 7001E/EM Ethernet Card

Figure 5-13: GFC 7001E/EM Rear Panel with Ethernet Installed

For more information on setting up and using this option, see Section 8.4.

Teledyne Analytical Instruments 74

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.7.4. ETHERNET + MULTIDROP (OPT 63C)

This option allows the instrument to communicate on both RS-232 and ETHERNET networks simultaneously. It
includes the following:

 RS-232 MULTIDROP (OPT 62)
 ETHERNET (OPT 63A)

5.8. SECOND GAS SENSORS

5.8.1. OXYGEN SENSOR (OPTION 65A)

5.8.1.1. Theory of Operation - Paramagnetic measurement of O2

The oxygen sensor used in the GFC 7001E/EM Analyzer utilizes the fact that oxygen is attracted into strong
magnetic field while most other gases are not, to obtain fast, accurate oxygen measurements.

The sensor’s core is made up of two nitrogen filled glass spheres, which are mounted on a rotating suspension
within a magnetic field (see Figure 5-14). A mirror is mounted centrally on the suspension and light is shone
onto the mirror that reflects the light onto a pair of photocells. The signal generated by the photocells is passed
to a feedback loop, which outputs a current to a wire winding (in effect, a small DC electric motor) mounted on
the suspended mirror.

Oxygen from the sample stream is attracted into the magnetic field displacing the nitrogen filled spheres and
causing the suspended mirror to rotate. This changes the amount of light reflected onto the photocells and
therefore the output levels of the photocells. The feedback loop increases the amount of current fed into the
winding in order to move the mirror back into its original position. The more O
moves and the more current is fed into the winding by the feedback control loop.

A sensor measures the amount of current generated by the feedback control loop which is directly proportional to
the concentration of oxygen within the sample gas mixture.

present, the more the mirror

2

Figure 5-14: Oxygen Sensor - Principle of Operation

Teledyne Analytical Instruments 75

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.8.1.2. Operation within the GFC 7001E/EM Analyzer

The oxygen sensor option is transparently integrated into the core analyzer operation. All functions can be
viewed or accessed through the front panel, just like the functions for CO.

 The O
 Test functions for O

functions.

 O

manner as the standard CO calibration. See Section 9.7.1 for more details.

 Stability of the O

concentration is displayed in the upper right-hand corner, alternating with CO concentration.

2

slope and offset are viewable from the front panel along with the analyzer’s other test

2

sensor calibration is performed via the front panel CAL function and is performed in a nearly identical

2

sensor can be viewed via the front panel (see Section 9.7.1.3).

2

The O

The temperature of the O
on the front panel as test function O

The O

concentration range is 0-100% (user selectable) with 0.1% precision and accuracy.

2

sensor is maintained at a constant 50° C by means of a PID loop and can be viewed

2

TEMP.

2

sensor assembly itself does not have any serviceable parts and is enclosed in an insulated canister.

2

5.8.1.3. Pneumatic Operation of the O2 Sensor

 Pneumatically, the O2 sensor draws a flow of 80 cm³/min in addition to the normal sample flow rate. It is

separately controlled with its own critical flow orifice.

Figure 5-15: GFC 7001E/EM – Internal Pneumatics with O

Sensor Option 65A

2

Teledyne Analytical Instruments 76

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.9. CARBON DIOXIDE SENSOR (OPTION 67A)

The optional CO2 sensor allows the GFC 7001E/EM to measure both CO and CO2 simultaneously. This option
includes a CO
analyzer’s CPU that is used to compute the CO

sensor probe, a Logic PCA that conditions the probe output and issues a 0-5 VDC signal to the

2

concentration.

2

The GFC 7001E/EM receives this input, scales it based on the values of the CO

_SLOPE and CO2_OFFSET

2

recorded during calibration (see Section 9.7.2).

Figure 3-4 shows the location of the Sensor Probe and PCA within the GFC 7001E/EM.

The CO

sensor assembly itself does not have any serviceable parts and is enclosed in an insulated canister.

2

5.9.1. CO2 SENSOR RANGES AND SPECIFICATIONS

Table 5-6: CO2 Sensor - Available Ranges

OPTION NO. RANGES ANALYZER MODEL(S)

67A

Table 5-7: CO

Accuracy at 25˚C 0.02% CO + 2% of reading

Typical Temperature Dependence -0.1% FS / ˚C

Long Term Stability <+15 % FS / 2 years

Power consumption 2.5 watts

0-20% GFC 7001EM

Sensor Specifications

2

Linearity 0.5 % of full scale

Response time 20 seconds

Warm up time 5 minutes

5.9.2. THEORY OF OPERATION

5.9.2.1. NDIR measurement of CO2

The optional CO2 sensor is a silicon based Non-Dispersive Infrared (NDIR) sensor. It uses a single-beam, dual
wavelength measurement method.

An infrared source at one end of the measurement chamber emits IR radiation into the sensor’s measurement
chamber where light at the 4.7 μm wavelength is partially absorbed by any CO
called a Fabry-Perot Interferometer (FPI) is electronically tuned so that only light at the absorption wavelength of
CO

is allowed to pass and be detected by the sensor’s IR detector.

2

A reference measurement is made by electronically shifting the filter band pass wavelength so that no IR at the
CO

absorption wavelength is let through.

2

Teledyne Analytical Instruments 77

present. A special light filter

2

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

Figure 5-16: CO

sensor Theory of Operation

2

The sensor computes the ratio between the reference signal and the measurement signal to determine the
degree of light absorbed by CO

present in the sensor chamber. This dual wavelength method the CO2

2

measurement allows the instrument to compensate for ancillary effects like sensor aging and contamination.

5.9.2.2. Operation within the GFC 7001E/EM Analyzer

The CO2 sensor option is transparently integrated into the core analyzer operation. All functions can be viewed
or accessed through the front panel, just like the functions for CO.

 The CO
 Test functions for CO

concentration is displayed in the upper right-hand corner, alternating with CO concentration.

2

slope and offset are viewable from the front panel along with the analyzer’s other

2

test functions.

sensor calibration is performed via the front panel CAL function and is performed in a nearly identical

 CO

2

manner as the standard CO calibration. See Section 9.7.2 for more details.

 Stability of the CO

The CO

concentration range is 0-20%. See Section 9.7.2.1 for information on calibrating the CO2.

2

sensor can be viewed via the front panel (see Section 9.7.2.3).

2

5.9.2.3. Pneumatic Operation of the CO2 Sensor

Pneumatically, the CO2 sensor is placed in line with the sample gas line between the particulate filter and the
analyzer’s sample chamber. It does not alter the gas flow rate of the sample through the analyzer.

Teledyne Analytical Instruments 78

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

Figure 5-17: GFC 7001E/EM – Internal Pneumatics with CO

Sensor Option 66

2

5.9.2.4. Electronic Operation of the CO2 Sensor

The CO2 PCA which is mounted to the rear side of the Relay Board Mounting Bracket controls the CO2 Sensor.
It converts the sensor’s digital output to an analog voltage that is measured with the motherboard and draws 12
VDC from the analyzer via the relay card from which converts to fit the power needs of the probe and its own
onboard logic. It outputs a 0-5 VDC analog signal to the analyzer’s CPU via the motherboard that corresponds
to the concentration of CO

measured by the probe.

2

Figure 5-18: CO

Sensor Option PCA Layout and Electronic Connections

2

Teledyne Analytical Instruments 79

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

5.10. CONCENTRATION ALARM RELAY (OPTION 61)

The Teledyne “E” series analyzers have an option for four (4) “dry contact” relays on the rear panel of the
instrument. This relay option is different from and in addition to the “Contact Closures” that come standard
on all TAI instruments. The relays have 3 pins that have connections on the rear panel (see Figure 5-19).
They are a Common (C), a Normally Open (NO), & a Normally Closed (NC) pin.

Figure 5-19: Concentration Alarm Relay

Alarm 1 “System OK 2”
Alarm 2 “Conc 1”
Alarm 3 “Conc 2”
Alarm 4 “Range Bit”

“Alarm 1” Relay

Alarm 1 which is “System OK 2” (system OK 1, is the status bit) is in the energized state when the
instrument is “OK” & there are no warnings. If there is a warning active or if the instrument is put into the “DIAG”
mode, Alarm 1 will change states. This alarm has “reverse logic” meaning that if you put a meter across the
Common & Normally Closed pins on the connector you will find that it is OPEN when the instrument is OK. This
is so that if the instrument should turn off or loose power, it will change states & you can record this with a data
logger or other recording device.

“Alarm 2” Relay & “Alarm 3” Relay
The “Alarm 2 Relay” on the rear panel, is associated with the “Concentration Alarm 1” set point in the
software & the “Alarm 3 Relay” on the rear panel is associated with the “Concentration Alarm 2” set point in the
software.

Alarm 2 Relay CO Alarm 1 = xxx PPM
Alarm 3 Relay CO
Alarm 2 Relay CO Alarm 1 = xxx PPM
Alarm 3 Relay CO

The Alarm 2 Relay will be turned on any time the concentration set-point is exceeded & will return to its
normal state when the concentration value goes back below the concentration set-point.

Even though the relay on the rear panel is a NON-Latching alarm & resets when the concentration goes
back below the alarm set point, the warning on the front panel of the instrument will remain latched until it is
cleared. You can clear the warning on the front panel by either pushing the CLR button on the front panel or
through the serial port.

In instruments that sample more than one gas type, there could be more than one gas type triggering the
Concentration 1 Alarm (“Alarm 2” Relay). For example, the GFC 7001EM instrument can monitor both CO &

Alarm 2 = xxx PPM

2

Alarm 2 = xxx PPM

2

Teledyne Analytical Instruments 80

Optional Hardware and Software Model GFC7001E Carbon Dioxide Analyzer

CO2 gas. The software is flexible enough to allow you to configure the alarms so that you can have 2 alarm
levels for each gas.

CO Alarm 1 = 20 PPM
CO Alarm 2 = 100 PPM
CO

Alarm 1 = 20 PPM

2

Alarm 2 = 100 PPM

CO

2

In this example, CO Alarm 1 & CO
This allows you do have multiple alarm levels for individual gasses.
A more likely configuration for this would be to put one gas on the “Alarm 1” relay & the other gas on the “Alarm
2” relay.

CO Alarm 1 = 20 PPM
CO Alarm 2 = Disabled
CO

Alarm 1 = Disabled

2

CO

Alarm 2 = 100 PPM

2

“Alarm 4” Relay
This relay is connected to the “range bit”. If the instrument is configured for “Auto Range” & the
instrument goes up into the high range, it will turn this relay on.

Alarm 1 will both be associated with the “Alarm 2” relay on the rear panel.

2

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5.11. SPECIAL FEATURES

5.11.1. DILUTION RATIO OPTION

The Dilution Ratio Option is a software option that is designed for applications where the Sample gas is diluted
before being analyzed by the GFC 7001E. Typically this occurs in Continuous Emission Monitoring (CEM)
applications where the quality of gas in a smoke stack is being tested and the sampling method used to remove
the gas from the stack dilutes the gas.

Once the degree of dilution is known, this feature allows the user to add an appropriate scaling factor to the
analyzer’s CO concentration calculation so that the Measurement Range and concentration values displayed on
the instrument’s Front Panel Display and reported via the Analog and Serial Outputs reflect the undiluted values.

Instructions for using the dilution ratio option can be found in Section 6.6.5.

5.11.2. MAINTENANCE MODE SWITCH

TAI’s instruments can be equipped with a switch that places the instrument in maintenance mode. When
present, the switch is accessed by opening the hinged front panel and is located on the rearward facing side of
the display/keyboard driver PCA, on the left side, near the particulate filter.

When in maintenance mode the instrument ignores all commands received via the COMM ports that alter the
operation state of the instrument. This includes all calibration commands, diagnostic menu commands and the
reset instrument command. The instrument continues to measure concentration and send data when requested.

This option is of particular use for instruments connected to multidrop or Hessen protocol networks.

5.11.3. SECOND LANGUAGE SWITCH

TAI’s instruments can be equipped with a switch that activates an alternate set of display message in a language
other than the instrument’s default language. To activate this feature, the instrument must have a specially
programmed Disk-on-Module (DOM) containing the second language. Call Customer Service for this DOM.

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PART II

–

OPERATING INSTRUCTIONS

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6. BASIC OPERATION

The GFC 7001E/EM Analyzer is a computer-controlled analyzer with a dynamic menu interface that allows all
major operations to be controlled from the front panel display and keyboard through user-friendly menus (a
complete set of menu trees is located in Appendix A of this manual).

This section includes step-by-step instructions for using the display/keyboard to set up and operate the GFC
7001E/EM Analyzer's basic CO measurement features and functional modes.

6.1. OVERVIEW OF OPERATING MODES

The GFC 7001E/EM software has a variety of operating modes. Most commonly, the analyzer will be operating
in Sample Mode. In this mode a continuous read-out of the CO concentration is displayed on the front panel. If
the analyzer is configured to measure more than one gas (e.g. CO along with O
through gas list.

While in SAMPLE mode calibrations can be performed and TEST functions as well as WARNING messages can
be examined. If any of the analyzer’s analog outputs are enabled, the current concentration value will be
available at the analog output connector.

The second most important operating mode is SETUP mode. This mode is used for performing certain
configuration operations, such as programming the iDAS system or the configurable analog output channels, or
setting up the analyzer’s serial communication channels (RS-232/RS-485/Ethernet). The SETUP mode is also
used for performing various diagnostic tests during troubleshooting.

or CO2) the display will cycle

2

Mode Field

Message Field

Concentration Field

SAMPLE RANGE=50.00 PPM CO= XX.XX

<TST TST> CAL SETUP

Figure 6-1: Front Panel Display

The mode field of the front panel display indicates to the user which operating mode the unit is currently running.

Besides SAMPLE and SETUP, other modes the analyzer can be operated in are:

Table 6-1: Analyzer Operating Modes

MODE EXPLANATION

SAMPLE Sampling normally, flashing text indicates adaptive filter is on.

SAMPLE A

M-P CAL This is the basic calibration mode of the instrument and is activated by pressing the CAL key.

SETUP [X.X]

ZERO CAL [type]

LO CAL [type]

SPAN CAL [type]

DIAG Mode One of the analyzer’s diagnostic modes is active (Section 7.3).

[type:]

1

A: Initiated automatically by the AUTOCAL feature (Internal Span Only).

2

M: initiated manually by the user via the front panel controls.

3

R: initiated remotely through the COM ports or digital control inputs.

1,2 & 3

2 & 3

1,2 & 3

Indicates that unit is in Sample Mode while AUTOCAL feature is active (Internal Span Only).

SETUP mode is being used to configure the analyzer. The gas measurement will continue during this
process. The revision of the GFC 7001E/EM firmware being run will appear after the word “SETUP”

Unit is performing ZERO calibration procedure.

Unit is performing LOW SPAN (midpoint) cal check procedure.

Unit is performing SPAN calibration procedure.

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6.2. SAMPLE MODE

This is the analyzer’s standard operating mode. In this mode the instrument is analyzing the gas in the sample
chamber, calculating CO concentration and reporting this information to the user via the front panel display, the
analog outputs and, if set up properly, the RS-232/RS-485/Ethernet ports.

NOTE

A value of “XXXX” displayed in the CO Concentration field means that the M/R ratio is invalid because

CO REF is either too high (> 4950 mVDC) or too low (< 1250 VDC).

A value of “XXXX” displayed for any of the TEST functions indicates an out-of-range reading or the

analyzer’s inability to calculate it.

A variety of TEST functions are available for viewing at the front panel whenever the analyzer is at the MAIN
MENU. These functions provide information about the various functional parameters related to the analyzers

operation and its measurement of gas concentrations. This information is particularly a performance problem
during troubleshooting (see Section 13.1.2).

To view these TEST functions, press,

Figure 6-2: Viewing GFC 7001E/EM Test Functions

NOTE

All pressure measurements are represented in terms of absolute pressure. Absolute, atmospheric

pressure is 29.92 in-Hg-A at sea level. It decreases about 1 in-Hg per 300 m gain in altitude. A variety of

factors such as air conditioning and passing storms can cause changes in the absolute atmospheric

pressure.

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Table 6-2: Test Functions Defined

PARAMETER DISPLAY TITLE UNITS MEANING

3

, PPM

Stability

Range

O2 Range 1

CO2 Range2

CO Measure

CO Reference

Measurement /

Reference Ratio

Sample Pressure

Sample Flow

Sample

Temperature

Bench

Temperature

Wheel

Temperature

Box Temperature

O2 Cell

Temperature

3

STABIL

RANGE

RANGE1
RANGE2

O

2

1

1

RANGE

CO2 RANGE

CO MEAS

CO REF

MR Ratio

PRES

SAMPLE FL

SAMP TEMP

BENCH TEMP

WHEEL TEMP

BOX TEMP

O2 CELL TEMP

PPB

UGM

PPB, PPM,

UGM, MGM

3

3

, MGM

% The range setting for the optional O
% The range setting for the optional CO

MV

MV

-

In-Hg-A

cm3/min

C

C

C

C

C

Photo-detector

Temp. Control

PHT DRIVE

mV

Voltage

Slope

Offset

O2 Sensor

Slope

1

O2 Sensor Offset 1

CO2 Sensor

CO2 Sensor

Slope

Offset

2

2

Current Time

1

Only appears when the optional O2 sensor is installed.

2

Only appears when the optional CO2 sensor is installed.

3

Only available on the GFC 7001E.

SLOPE

OFFSET

SLOPE

O

2

O

OFFSET

2

CO

SLOPE

2

CO

OFFSET

2

TIME

-

-

- O

- O

- CO

- CO

-

Standard deviation of CO concentration readings. Data points are
recorded every ten seconds using the last 25 data points. This
function can be reset to show O2 or CO2 stability in instruments with
those sensor options installed.

The full scale limit at which the reporting range of the analyzer is
currently set. THIS IS NOT the Physical Range of the instrument.
See Section 6.6.1 for more information.

Sensor.

2

Sensor.

2

The demodulated, peak IR detector output during the measure
portion of the GFC Wheel cycle.

The demodulated, peak IR detector output during the reference
portion of the GFC Wheel cycle.

The result of CO MEAS divided by CO REF. This ratio is the
primary value used to compute CO concentration. The value
displayed is not linearized.

The absolute pressure of the Sample gas as measured by a
pressure sensor located inside the sample chamber.

Sample mass flow rate as measured by the flow rate sensor in the
sample gas stream.

The temperature of the gas inside the sample chamber.

Optical bench temperature.

GFC Wheel temperature.

The temperature inside the analyzer chassis.

The current temperature of the O

sensor measurement cell.

2

The drive voltage being supplied to the thermoelectric coolers of the
IR photo-detector by the sync/demod Board.

The sensitivity of the instrument as calculated during the last
calibration activity.

The overall offset of the instrument as calculated during the last
calibration activity.

slope, computed during zero/span calibration.

2

offset, computed during zero/span calibration.

2

slope, computed during zero/span calibration.

2

offset, computed during zero/span calibration.

2

The current time. This is used to create a time stamp on iDAS
readings, and by the AUTOCAL feature to trigger calibration events.

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6.3. WARNING MESSAGES

The most common instrument failures will be reported as a warning on the analyzer’s front panel and through the
COMM ports. Section 13.1.1 explains how to use these messages to troubleshoot problems. Section 6.3 shows
how to view and clear warning messages.

Table 6-3: List of Warning Messages

MESSAGE

ANALOG CAL WARNING
BENCH TEMP WARNING

BOX TEMP WARNING

CANNOT DYN SPAN2

CANNOT DYN ZERO3

CONC ALRM1 WARNING

CONC ALRM2 WARNING

CONFIG INITIALIZED

DATA INITIALIZED

O2 CELL TEMP WARN2

PHOTO TEMP WARNING

REAR BOARD NOT DET

RELAY BOARD WARN

SAMPLE FLOW WARN

SAMPLE PRESS WARN

SAMPLE TEMP WARN

SOURCE WARNING

SYSTEM RESET1

WHEEL TEMP WARNING

1

Alarm warnings only present when 0ptional alarm package is activated.

2

Only enabled when the optional O2 Sensor is installed.

The instrument’s A/D circuitry or one of its analog outputs is not calibrated.
The temperature of the optical bench is outside the specified limits.
The temperature inside the chassis is outside the specified limits.
Remote span calibration failed while the dynamic span feature was set to turned on.
Remote zero calibration failed while the dynamic zero feature was set to turned on.

1

Concentration alarm 1 is enabled and the measured CO level is ≥ the set point.

1

Concentration alarm 2 is enabled and the measured CO level is ≥ the set point.
Configuration storage was reset to factory configuration or erased.
iDAS data storage was erased.

sensor cell temperature outside of warning limits.

O

2

The temperature of the IR photo detector is outside the specified limits.
The CPU is unable to communicate with the motherboard.
The firmware is unable to communicate with the relay board.
The flow rate of the sample gas is outside the specified limits.

Sample gas pressure outside of
The temperature of the sample gas is outside the specified limits.

operational parameters.

The IR source may be faulty.

The computer was rebooted.
The Gas Filter Correlation Wheel temperature is outside the specified limits.

MEANING

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To view and clear warning messages:

Figure 6-3: Viewing and Clearing GFC 7001E/EM WARNING Messages

6.4. CALIBRATION MODE

Press the CAL key to switch the GFC 7001E/EM into calibration mode. In this mode the user can, in conjunction
with introducing zero or span gases of known concentrations into the analyzer, cause it to adjust and recalculate
the slope (gain) and offset of the its measurement range. This mode is also used to check the current calibration
status of the instrument.

 For more information about setting up and performing standard calibration operations or checks, see

Section 9.

 For more information about setting up and performing EPA equivalent calibrations, see Section 10.

If the instrument includes one of the available zero/span valve options, the SAMPLE mode display will also
include CALZ and CALS keys. Pressing either of these keys also puts the instrument into calibration mode.

The CALZ key is used to initiate a calibration of the analyzer’s zero point using internally generated zero air.
The CALS key is used to calibrate the span point of the analyzer’s current reporting range using span gas.

For more information concerning calibration valve options, see Section 5.6

For information on using the automatic calibration feature (ACAL) in conjunction with the one of the calibration
valve options, see Section 9.4.

NOTE

It is recommended that this span calibration be performed at 80-90% of full scale of the analyzer’s

currently selected reporting range.

EXAMPLES:

If the reporting range is set for 0 to 50 ppm, an appropriate span point would be 40-45 ppm.

If the of the reporting range is set for 0 to 1000 ppb, an appropriate span point would be 800-900 ppb.

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6.5. SETUP MODE

The SETUP mode contains a variety of choices that are used to configure the analyzer’s hardware and software
features, perform diagnostic procedures, gather information on the instruments performance and configure or
access data from the internal data acquisition system (iDAS).

NOTE

Any changes made to a variable during one of the following procedures is not acknowledged by the

instrument until the ENTR Key is pressed.

If the EXIT key is pressed before the ENTR key, the analyzer will beep alerting the user that the newly

entered value has been lost.

For a visual representation of the software menu trees, refer to Appendix A-1.

The areas accessible under the SETUP mode are shown in Table 6-4 and Table 6-5:

Table 6-4: Primary Setup Mode Features and Functions

MODE OR FEATURE

Analyzer Configuration

Auto Cal Feature

Internal Data Acquisition

(iDAS)

Analog Output Reporting

Range Configuration

Calibration Password Security

Internal Clock Configuration

Advanced SETUP features

KEYPAD

LABEL

CFG

ACAL

DAS

RNGE

PASS

CLK

MORE

Lists key hardware and software configuration information 6.5.1

Used to set up and operate the AutoCal feature.
Only appears if the analyzer has one of the internal valve
options installed.

Used to set up the iDAS system and view recorded data 7.1

Used to configure the output signals generated by the
instruments Analog outputs.

Turns the calibration password feature ON/OFF. 6.5.3
Used to Set or adjust the instrument’s internal clock. 6.5.4

This button accesses the instruments secondary setup menu.

Table 6-5: Secondary Setup Mode Features and Functions

MODE OR FEATURE

External Communication
Channel Configuration

System Status Variables

System Diagnostic Features
and
Analog Output Configuration

Alarm Limit Configuration

Alarm warnings only present when optional alarm package is activated.

1

KEYPAD

LABEL

COMM

VARS

DIAG

ALRM

Used to set up and operate the analyzer’s various serial
channels including RS-232,RS-485, modem communication
and/or Ethernet access.

Used to view various variables related to the instruments current
operational status.

 Changes made to any variable are not recorded in the

instrument’s memory until the ENTR key is pressed.
 Pressing the EXIT key ignores the new setting.
Used to access a variety of functions that are used to configure,

test or diagnose problems with a variety of the analyzer’s basic
systems.
Most notably, the menus used to configure the output signals
generated by the instruments Analog outputs are located here.
Used to turn the instrument’s two alarms on and off as well as
set the trigger limits for each.

DESCRIPTION

DESCRIPTION

MANUAL
SECTION

6.5.2
and

9.4

6.6

See

Table 6-5

MANUAL
SECTION

8.1

7.2

7.3

7.5

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6.5.1. SETUP  CFG: CONFIGURATION INFORMATION

Pressing the CFG key displays the instrument’s configuration information. This display lists the analyzer model,
serial number, firmware revision, software library revision, CPU type and other information.

 Special instrument or software features or installed options may also be listed here.
 Use this information to identify the software and hardware installed in your GFC 7001E/EM Analyzer when

contacting customer service.

To access the configuration table, press:

6.5.2. SETUP  ACAL: AUTOMATIC CALIBRATION

Instruments with one of the internal valve options installed can be set to automatically run calibration procedures
and calibration checks. These automatic procedures are programmed using the submenus and functions found
under the ACAL menu.

A menu tree showing the ACAL menu’s entire structure can be found in Appendix A-1 of this manual.

Instructions for using the ACAL feature are located in the Section 9.4 of this manual along with all other
information related to calibrating the GFC 7001E/EM Analyzer.

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6.5.3. SETUP  PASS: PASSWORD FEATURE

The GFC 7001E/EM provides password protection of the calibration and setup functions to prevent unauthorized
adjustments. When the passwords have been enabled in the PASS menu item, the system will prompt the user
for a password anytime a password-protected function (e.g., SETUP) is requested. This allows normal operation
of the instrument, but requires the password (101) to access to the menus under SETUP. When PASSWORD is
disabled (SETUP>OFF), any operator can enter the Primary Setup (SETUP) and Secondary Setup
(SETUP>MORE) menus. Whether PASSWORD is enabled or disabled, a password (default 818) is required to
enter the VARS or DIAG menus in the SETUP>MORE menu.

Table 6-6: Password Levels

PASSWORD LEVEL MENU ACCESS ALLOWED

Null (000) Operation

101

818

Configuration/Maintenance

Configuration/Maintenance

All functions of the MAIN menu: TEST, GEN, initiate SEQ , MSG, CLR
Access to Primary and Secondary SETUP Menus when PASSWORD

enabled
Access to Secondary SETUP Submenus VARS and DIAG whether

PASSWORD is enabled or disabled.

To enable or disable passwords, press:

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Example: If all passwords are enabled, the following keypad sequence would be required to enter the SETUP
menu:

NOTE

The instrument still prompts for a password when entering the VARS and DIAG menus, even if
passwords are disabled. It will display the default password (818) upon entering these menus.

The user only has to press ENTR to access the password-protected menus but does not have to enter

the required number code.

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6.5.4. SETUP  CLK: SETTING THE GFC 7001E/EM ANALYZER’S

INTERNAL CLOCK

6.5.4.1. Setting the internal Clock’s Time and Day

The GFC 7001E/EM has a time of day clock that supports the DURATION step of the automatic calibration
(ACAL) sequence feature, time of day TEST function, and time stamps on for the iDAS feature and most COMM
port messages.

To set the clock’s time and day, press:

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6.5.4.2. Adjusting the Internal Clock’s Speed

In order to compensate for CPU clocks which run faster or slower, you can adjust a variable called CLOCK_ADJ
to speed up or slow down the clock by a fixed amount every day.

The CLOCK_AD variable is accessed via the VARS submenu: To change the value of this variable, press:

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6.6. SETUP  RNGE: ANALOG OUTPUT REPORTING RANGE

CONFIGURATION

6.6.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING

RANGES

Functionally, the GFC 7001E Family of CO Analyzers have one hardware PHYSICAL RANGE that is capable of
determining CO concentrations between across a very wide array of values.

Table 6-7: GFC 7001E Family Physical range by Model

MODEL RANGE

GFC 7001E 0 – 1000 ppm

GFC 7001EM 0 – 5000 ppm

This architecture improves reliability and accuracy by avoiding the need for extra, switchable, gain-amplification
circuitry. Once properly calibrated, the analyzer’s front panel will accurately report concentrations along the
entire span of its physical range.

Because many applications use only a small part of the analyzer’s full physical range, this can create data
resolution problems for most analog recording devices. For example, in an application where an GFC 7001E is
being used to measure an expected concentration of typically less than 50 ppm CO, the full scale of expected
values is only 4% of the instrument’s full 1000 ppm measurement range. Unmodified, the corresponding output
signal would also be recorded across only 2.5% of the range of the recording device.

The GFC 7001E/EM Analyzers solve this problem by allowing the user to select a scaled reporting range for the
analog outputs that only includes that portion of the physical range relevant to the specific application.

Only this REPORTING RANGE of the analog outputs is scaled, the physical range of the analyzer and the
readings displayed on the front panel remain unaltered.

NOTE

Both the iDAS values stored in the CPU’s memory and the concentration values reported on the front

panel are unaffected by the settings chosen for the reporting range(s) of the instrument.

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A

6.6.2. ANALOG OUTPUT RANGES FOR CO CONCENTRATION

The analyzer has several active analog output signals related accessible through a connector on the rear panel
(see Figure 3-2).

CO concentration

A1 A2 A3 A4
+ - + - + - + -

outputs

NALOG OUT

Only active if the Optional

or O2 Sensor is

CO

2

Test Channel

LOW range when DUAL

mode is selected

HIGH range when DUAL

mode is selected

Figure 6-4: Analog Output Connector Pin Out

All four outputs can be configured either at the factory or by the user for full scale outputs of 0.1 VDC, 1VDC,
5VDC or 10VDC.

Additionally A1, A2 and A3 may be equipped with optional 0-20 mADC current loop drivers and configured for
any current output within that range (e.g. 0-20, 2-20, 4-20, etc.). The user may also adjust the signal level and
scaling of the actual output voltage or current to match the input requirements of the recorder or datalogger (See
Section 7.4.5).

The A1 and A2 channels output a signal that is proportional to the CO

concentration of the sample gas. Several

modes are available which allow them to operate independently or be slaved together (See Section 6.6.3).

EXAMPLE:

A1 OUTPUT: Output Signal = 0-5 VDC representing 0-1000 ppm concentration values

A2 OUTPUT: Output Signal = 0 – 10 VDC representing 0-500 ppm concentration values.

Output A3 is only active if the CO
currently measured CO

or O2 concentration is output on this channel.

2

or O2 sensor option is installed. In this case a signal representing the

2

The output, labeled A4 is special. It can be set by the user (See Section 7.4.6) to output several of the test
functions accessible through the <TST TST> keys of the units sample display.

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6.6.3. REPORTING RANGE MODES

The GFC 7001E/EM provides three analog output range modes to choose from.

 Single range (SNGL) mode sets a single maximum range for the analog output. If single range is selected

both outputs are slaved together and will represent the same measurement span (e.g. 0-50 ppm),
however their electronic signal levels may be configured for different ranges (e.g. 0-10 VDC vs. 0-.1
VDC).

 Dual range (DUAL) allows the A1 and A2 outputs to be configured with different measurement spans as

well as separate electronic signal levels.

 Auto range (AUTO) mode gives the analyzer to ability to output data via a low range and high range.

When this mode is selected the analyzer will automatically switch between the two ranges dynamically as
the concentration value fluctuates.

Range status is also output via the external digital I/O status outputs (See Section 3.3.3).

To select the Analog Output Range Type press:

NOTE

Upper span limit setting for the individual range modes are shared. Resetting the span limit in one mode

also resets the span limit for the corresponding range in the other modes as follows:

SNGL DUAL AUTO
Range  Range1  Low Range
Range2  High Range

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6.6.3.1. RNGE  MODE  SNGL: Configuring the GFC 7001E/EM Analyzer for SINGLE Range

Mode

NOTE

This is the default reporting range mode for the analyzer.

When the single range mode is selected (SNGL), all analog CO concentration outputs (A1 and A2) are slaved
together and set to the same reporting range limits (e.g. 500.0 ppb). The span limit of this reporting range can be
set to any value within the physical range of the analyzer.

Although both outputs share the same concentration reporting range, the electronic signal ranges of the analog
outputs may still be configured for different values (e.g. 0-5 VDC, 0-10 VDC, etc; see Section 7.4.2)

To select SNGL range mode and to set the upper limit of the range, press:

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