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: (626) 934-1500
Fax: (626) 961-2538
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: 800-324-5190
Email: api-customerservice@teledyne.com
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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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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Teledyne Analytical Instruments 6
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.
Teledyne Analytical Instruments 7
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 - 40C operating, 10 - 40C 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 40C.
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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