Teledyne GFC7001T User Manual

Operation Manual
Model GFC7001T
Carbon Monoxide Analyzer
P/N M90914
DATE 07/22/13
TELEDYNE ELECTRONIC TECHNOLOGIES
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 GFC7001T Carbon Monoxide 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.
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Model GFC7001T Carbon Monoxide Analyzer
INFORMATION ABOUT THE SPECIFIC CONFIGURATION OF YOUR MODEL GFC 7001T CARBON MONOXIDE ANALYZER
Selected Versions of the Model GFC 7001T
MODEL GFC 7001T— STANDARD VERSION
This Model GFC7001T CO Analyzer is a touch screen version designed for analyzing the CO concentration in a background gas specified by the customer. It has a minimum settable range of 0-1 ppm and a maximum settable range of 0-1000 ppm. The standard version is designed for positive pressure applications. The analyzer may have one or two analysis ranges with or without auto-ranging as listed below. Alarm relays are included with this version.
M
ODEL GFC 7001TA AMBIENT PRESSURE VERSION
The Model GFC7001TA CO Analyzer is a touch screen version designed for analyzing the CO concentration in a background gas specified by the customer. It has a minimum settable range of 0-1 ppm and a maximum settable range of 0-1000 ppm. The TA version is designed for ambient pressure applications. The analyzer may have one or two analysis ranges with or without auto-ranging as listed below. Alarm relays are an optional feature and if included, that option will be checked below.
M
ODEL GFC 7001TU ULTRA LOW RANGE VERSION
The Model GFC7001TU CO Analyzer is a touch screen version designed for analyzing trace CO concentrations in a background gas specified by the customer. It has a minimum settable range of 0-100 ppb and a maximum settable range of 0-100 ppm. The TU version is designed for positive pressure applications. The analyzer may have one or two analysis ranges with or without auto-ranging as listed below. Alarm relays are an optional feature and if included, that option will be checked below.
P
OWER REQUIREMENTS
This Model GFC 7001T is configured to operate from the following AC Power source:
100-120 VAC 60 Hz 220-240 VAC 60 Hz 100V 60 Hz
100-120 VAC 50 Hz 220-240 VAC 50 Hz 100V 50 Hz
NALOG OUTPUT SIGNALS
A
Analog output signals are available at A1 and A2 on the rear panel. This instrument is configured with the following analog outputs:
A1: 4-20 mA A2: 0-5 V A2: 4-20 mA
R
ANGE MODE
The analyzer can be designed with a single or dual analysis ranges with auto-ranging or dual independent ranges. This analyzer is configured with the following range mode:
Single Range:
Dual Range/Auto-ranging: Dual Range/Independent:
Low Range: Low Range:
High Range: High Range:
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Model GFC7001T Carbon Monoxide Analyzer
Selected Options for the Model GFC 7001T
MOUNTING OPTIONS
19” rack mounting with 26” sliders with ears 19” rack mounting with ears only
R
EAR PANEL GAS FITTINGS
1/4” SS Standard 6 mm SS Optional
V
ALVE OPTIONS
No Valves. The standard unit does not include internal span and zero valves. Internal Zero/Span Valves
A
LARM RELAYS
The standard instrument is equipped with two configurable concentration alarms and one fixed system failure alarm. This is an optional feature for GFC 7001TU version. The alarm relays for this instrument are configured as:
Hi, Hi-Hi, and System APCI Configuration:
AL1 energized when there is no fault detected and de-energized in a fault condition. AL2 configured as High Range Status and is energized when in high range. AL3 configured as Zero Calibration Status and is energized in zero calibration mode.
T
EST OPTIONS
The following optional tests with data reports must be requested at the time of order:
10 Point Linearity Test: For enhanced accuracy, a 10-point linearity test is performed at the factory during the setup and testing phase for this analyzer. Data results are included.
Temperature Compensation Test: Thermal testing is performed at the factory to accurately determine the temperature coefficient to be used in specific applications. Data results are included.
P
ROFIBUS MOUNTING OPTION
RS232 to Profibus Circuit Board: Special RS232 to Profibus PCB card for Profibus
communication using the existing RS232 port.
BACKGROUND GAS:
N
OTES:
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Model GFC7001T Carbon Monoxide Analyzer
ABOUT THIS MANUAL
This manual describes operation, specifications, and maintenance for the Model GFC 7001T.
In addition this manual contains important SAFETY messages for this instrument. It is strongly recommended that you read that operation manual in its entirety before operating the instrument.
ORGANIZATION
This manual is divided among three main parts and a collection of appendices at the end.
Part I contains introductory information that includes an overview of the analyzer,
descriptions of the available options, specifications, installation and connection instructions, and the initial calibration and functional checks. The last two sections contain Frequently Asked Questions (FAQs) followed by a glossary, and a description of available options.
Part II comprises the operating instructions, which include basic, advanced and remote
operation, calibration, diagnostics, testing, validating and verifying, and ends with specifics of calibrating for use in EPA monitoring.
Part III provides detailed technical information, such as theory of operation,
maintenance, and troubleshooting and repair. It also contains a section that provides important information about electro-static discharge and avoiding its consequences.
The appendices at the end of this manual provide support information such as, version­specific software documentation, lists of spare parts and recommended stocking levels, and schematics.
C
ONVENTIONS USED
In addition to the safety symbols as presented in the Important Safety Information page, this manual provides special notices related to the safety and effective use of the
analyzer and other pertinent information.
Special Notices appear as follows:
ATTENTION
COULD DAMAGE INSTRUMENT AND VOID WARRANTY
This special notice provides information to avoid damage to your instrument and possibly invalidate the warranty.
IMPORTANT
IMPACT ON READINGS OR DATA
Could either affect accuracy of instrument readings or cause loss of data.
Note Pertinent information associated with the proper care, operation or
maintenance of the analyzer or its parts.
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Model GFC7001T Carbon Monoxide Analyzer
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Safety Information Teledyne API – Model T300/T300M CO Analyzer
IMPORTANT SAFETY INFORMATION
Important safety messages are provided throughout this manual. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is
associated with a safety alert symbol. These symbols are found in the manual and inside the instrument. The definition of these symbols is described below:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying message for specific information.
CAUTION: Hot Surface Warning
Note
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).
Technical Assistance regarding the use and maintenance of the GFC7001T or any other Teledyne product can be obtained by contacting Teledyne Customer Service Department:
Phone: 888-789-8168
Email: ask_tai@teledyne.com
or by accessing various service options on our website at
http://www.teledyne-ai.com/.
Teledyne Analytical Instruments
Safety Information Model GFC7001T Carbon Monoxide Analyzer
CONSIGNES DE SÉCURITÉ
Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes. Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments. Les symboles correspondent aux consignes suivantes :
AVERTISSEMENT : Risque de choc électrique
DANGER : Oxydant puissant
AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne
complémentaire pour des renseignements spécifiques
MISE EN GARDE : Surface chaude
Ne pas toucher : Toucher à certaines parties de l’instrument sans protection ou
sans les outils appropriés pourrait entraîner des dommages aux pièces ou à l’instrument.
Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent être effectuées uniquement par du personnel de maintenance qualifié.
Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central de la mise à la terre sécuritaire de l’instrument.
MISE EN GARDE
Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans ce manuel. Si vous utilisez cet instrument d’une autre manière que celle pour laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible et entraîner des conséquences dangereuses.
NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz combustibles!
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Table of Contents Teledyne API – Model T300/T300M CO Analyzer
TABLE OF CONTENTS
ABOUT THIS MANUAL ............................................................................................................ V
IMPORTANT SAFETY INFORMATION .................................................................................. VII
CONSIGNES DE SÉCURITÉ ............................................................................................................................. viii
TABLE OF CONTENTS ........................................................................................................... IX
LIST OF APPENDICES ....................................................................................................................................... xv
List of Figures ...................................................................................................................................................... xvi
List of Tables ...................................................................................................................................................... xvii
PART I GENERAL INFORMATION ...................................................................................... XXI
1. INTRODUCTION, FEATURES AND OPTIONS .................................................................. 23
1.1. GFC7001T Family Overview........................................................................................................................ 23
1.2. Features ....................................................................................................................................................... 24
1.3. GFC7001T/GFC7001TM Documentation .................................................................................................... 24
1.4. Options ......................................................................................................................................................... 24
2. SPECIFICATIONS AND APPROVALS ............................................................................... 29
2.1. Specifications ............................................................................................................................................... 29
2.2. EPA Equivalency Designation ..................................................................................................................... 31
2.3. Approvals and Certifications ........................................................................................................................ 31
2.3.1. Safety ..................................................................................................................................................... 32
2.3.2. EmC ....................................................................................................................................................... 32
2.3.3. Other Type Certifications ....................................................................................................................... 32
3. GETTING STARTED ........................................................................................................... 33
3.1. Unpacking the GFC7001T/GFC7001TM Analyzer ...................................................................................... 33
3.1.1. Ventilation Clearance ............................................................................................................................. 34
3.2. Instrument Layout ........................................................................................................................................ 35
3.2.1. Front Panel ............................................................................................................................................ 35
3.2.2. Rear panel ............................................................................................................................................. 39
3.2.3. GFC7001T/GFC7001TM Analyzer Layout ............................................................................................ 40
3.3. Connections and Setup ................................................................................................................................ 43
3.3.1. Electrical Connections ........................................................................................................................... 44
3.3.1.1. Connecting Power .......................................................................................................................... 44
3.3.1.2. Connecting Analog Inputs (Option) ................................................................................................ 44
3.3.1.3. Connecting Analog Outputs ........................................................................................................... 45
3.3.1.4. Current Loop Analog Outputs (Option 41) Setup .......................................................................... 46
3.3.1.5. Connecting the Status Outputs ...................................................................................................... 48
3.3.1.6. Connecting the Control Inputs ........................................................................................................ 49
3.3.1.7. Concentration Alarm Relay (Option 61) Standard Configuration ................................................... 50
3.3.1.8. Concentration Alarm Relay (Option 61) Air Products Configuration .............................................. 52
3.3.1.9. Connecting the Communication Interfaces .................................................................................... 52
3.3.2. Pneumatic Connections ......................................................................................................................... 59
3.3.2.1. Pneumatic Connections for Basic Configuration ............................................................................ 61
3.3.2.2. Pneumatic Layout for Basic configuration ...................................................................................... 62
3.3.2.3. Pneumatic Connections for Zero/Span Valve Option ..................................................................... 63
3.3.2.4. Pneumatic Layout for Zero/ Span Valve Option ............................................................................. 64
3.3.2.5. Pneumatic Layout for Internal Zero/ Span Valve Option ................................................................ 65
3.3.2.6. Pneumatic Connections for Zero Scrubber/Pressurized Span Option ........................................... 66
3.3.2.7. Pneumatic Layout for Zero Scrubber/Pressurized Span Option .................................................... 68
3.3.2.8. Pneumatic Connections for Zero Scrubber/Ambient Span Option ................................................. 68
3.3.2.9. Pneumatic Layout for Zero scrubber/ Ambient Span OPTion ........................................................ 70
3.3.2.10. Calibration Gases ......................................................................................................................... 71
Teledyne Analytical Instruments
Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
3.4. Startup, Functional Checks, and Initial Calibration ...................................................................................... 72
3.4.1. Startup .................................................................................................................................................... 72
3.4.2. Warning Messages ................................................................................................................................ 72
3.4.3. Functional Checks ................................................................................................................................. 74
3.4.4. Initial Calibration .................................................................................................................................... 75
3.4.4.1. Interferents for CO Measurements ................................................................................................. 76
3.4.4.2. Initial Calibration Procedure ........................................................................................................... 76
3.4.4.3. O2 Sensor Calibration Procedure ................................................................................................... 81
3.4.4.4. CO2 Sensor Calibration Procedure ................................................................................................ 81
PART II OPERATING INSTRUCTIONS .................................................................................. 83
4. OVERVIEW OF OPERATING MODES ............................................................................... 85
4.1. Sample Mode ............................................................................................................................................... 86
4.1.1. Test Functions ....................................................................................................................................... 86
4.1.2. Warning Messages ................................................................................................................................ 88
4.2. Calibration Mode .......................................................................................................................................... 90
4.3. Setup MODE ................................................................................................................................................ 91
4.3.1. Password Security ................................................................................................................................. 91
4.3.2. Primary Setup Menu .............................................................................................................................. 91
4.3.3. Secondary Setup Menu (SETUP>MORE) ............................................................................................. 92
5. SETUP MENU 93
5.1. SETUP CFG: Configuration Information ................................................................................................. 93
5.2. SETUP ACAL: Automatic Calibration ...................................................................................................... 94
5.3. SETUP DAS: Internal Data Acquisition System ....................................................................................... 94
5.4. SETUP RNGE: Analog Output Reporting Range Configuration ............................................................. 94
5.4.1. Analog Output Ranges for CO Concentration ....................................................................................... 94
5.4.2. Physical Range vs Analog Output Reporting Ranges ........................................................................... 95
5.4.3. Reporting Range Modes: Single, Dual, Auto Ranges ........................................................................... 96
5.4.3.1. SINGLE Range Mode (SNGL) ....................................................................................................... 98
5.4.3.2. DUAL Range Mode (DUAL) ........................................................................................................... 99
5.4.3.3. AUTO Range Mode (AUTO) ........................................................................................................101
5.4.4. Range Units .........................................................................................................................................103
5.4.5. Dilution Ratio (Option) ..........................................................................................................................104
5.5. SETUP PASS: Password Protection .....................................................................................................105
5.6. SETUP CLK: Setting the Internal Time-of-Day Clock and Adjusting Speed .........................................108
5.6.1.1. Setting the Internal Clock’s Time and Day ...................................................................................108
5.6.1.2. Adjusting the Internal Clock’s Speed ............................................................................................108
5.7. SETUP Comm: Communications Ports .................................................................................................110
5.7.1. ID (Machine Identification) ...................................................................................................................110
5.7.2. INET (Ethernet) ....................................................................................................................................110
5.7.3. COM1 and COM2 (Mode, Baud Rate and Test Port) ..........................................................................110
5.8. SETUP VARS: Variables Setup and Definition ......................................................................................111
5.9. SETUP Diag: Diagnostics Functions ......................................................................................................112
5.9.1. Signal I/O .............................................................................................................................................115
5.9.2. Analog Output ......................................................................................................................................116
5.9.3. Analog I/O Configuration ......................................................................................................................116
5.9.3.1. Analog Output Voltage / Current Range Selection .......................................................................119
5.9.3.2. Analog Output Calibration ............................................................................................................121
5.9.3.3. Enabling or Disabling the AutoCal for an Individual Analog Output .............................................121
5.9.3.4. Automatic Calibration of the Analog Outputs ...............................................................................122
5.9.3.5. Individual Calibration of the Analog Outputs ................................................................................124
5.9.3.6. Manual Calibration of the Analog Outputs Configured for Voltage Ranges .................................125
5.9.3.7. Manual Adjustment of Current Loop Output Span and Offset .....................................................127
5.9.3.8. Turning an Analog Output Over-Range Feature ON/OFF ...........................................................130
5.9.3.9. Adding a Recorder Offset to an Analog Output ............................................................................131
5.9.3.10. AIN Calibration ...........................................................................................................................132
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Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
5.9.3.11. Analog Inputs (XIN1…XIN8) Option Configuration ....................................................................133
5.9.4. Electrical Test ......................................................................................................................................133
5.9.5. Dark Calibration ...................................................................................................................................134
5.9.6. Pressure Calibration ............................................................................................................................134
5.9.7. Flow Calibration ...................................................................................................................................134
5.9.8. Test Chan Output .................................................................................................................................134
5.9.8.1. Selecting a Test Channel Function for Output A4 ........................................................................135
5.10. SETUP MORE ALRM (Option): Using the Gas Concentration Alarms ...........................................136
5.10.1. Setting the GFC7001T Concentration Alarm Limits ..........................................................................137
6. COMMUNICATIONS SETUP AND OPERATION ............................................................. 139
6.1. Data Terminal/Communication Equipment (DTE DCE) .............................................................................139
6.2. Communication Modes, Baud Rate and Port Testing ...................................................................................139
6.2.1. Communication Modes ........................................................................................................................139
6.2.2. COM Port Baud Rate ...........................................................................................................................141
6.2.3. Com Port Testing .................................................................................................................................142
6.3. RS-232 .......................................................................................................................................................143
6.4. RS-485 (Option) .........................................................................................................................................143
6.5. Ethernet ......................................................................................................................................................143
6.5.1. Configuring Ethernet Communication Manually (Static IP Address) ...................................................144
6.5.2. Configuring Ethernet Communication Using Dynamic Host Configuration Protocol (DHCP) .............146
6.5.3. Changing the Analyzer’s HOSTNAME ................................................................................................147
6.6. USB Port (Option) for Remote Access ......................................................................................................148
6.7. Communications Protocols ........................................................................................................................150
6.7.1. MODBUS .............................................................................................................................................150
6.7.2. Hessen .................................................................................................................................................152
6.7.2.1. Hessen COMM Port Configuration ...............................................................................................152
6.7.2.2. Activating Hessen Protocol ..........................................................................................................153
6.7.2.3. Selecting a Hessen Protocol Type ...............................................................................................154
6.7.2.4. Setting The Hessen Protocol Response Mode ............................................................................156
6.7.3. Hessen Protocol Gas List Entries ........................................................................................................157
6.7.3.1. Hessen Protocol Gas ID ...............................................................................................................157
6.7.3.2. Editing or Adding HESSEN Gas List Entries ................................................................................158
6.7.3.3. Deleting HESSEN Gas List Entries ..............................................................................................159
6.7.3.4. Setting Hessen Protocol Status Flags ..........................................................................................160
6.7.3.5. Instrument ID ................................................................................................................................161
7. DATA ACQUISITION SYSTEM (DAS) AND APICOM ...................................................... 163
7.1. DAS Structure ............................................................................................................................................164
7.1.1. DAS Data Channels .............................................................................................................................164
7.1.2. Default DAS Channels .........................................................................................................................165
7.1.3. Viewing DAS Channels and Individual Records ..................................................................................168
7.1.4. Editing DAS Channels .........................................................................................................................169
7.1.4.1. Editing DAS Data Channel Names ...............................................................................................170
7.1.5. Editing DAS Triggering Events ............................................................................................................171
7.1.6. Editing DAS Parameters ......................................................................................................................172
7.1.7. Sample Period and Report Period .......................................................................................................175
7.1.8. Number of Records ..............................................................................................................................177
7.1.9. RS-232 Report Function ......................................................................................................................178
7.1.9.1. The Compact Report Feature .......................................................................................................178
7.1.9.2. The Starting Date Feature ............................................................................................................179
7.1.10. Disabling/Enabling Data Channels ....................................................................................................179
7.1.11. HOLDOFF Feature ............................................................................................................................180
7.2. Remote DAS Configuration ........................................................................................................................181
7.2.1. DAS Configuration via APICOM ..........................................................................................................181
7.2.2. DAS Configuration Using Terminal Emulation Programs ....................................................................183
8. REMOTE OPERATION ..................................................................................................... 185
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Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
8.1. Computer Mode .........................................................................................................................................185
8.1.1. Remote Control via APICOM ...............................................................................................................185
8.2. Interactive Mode ........................................................................................................................................185
8.2.1. Remote Control via a Terminal Emulation Program ............................................................................186
8.2.1.1. Help Commands in Interactive Mode ...........................................................................................186
8.2.1.2. Command Syntax .........................................................................................................................186
8.2.1.3. Data Types ...................................................................................................................................187
8.2.1.4. Status Reporting ...........................................................................................................................188
8.2.1.5. General Message Format .............................................................................................................188
8.3. Remote Access by Modem ........................................................................................................................188
8.4. Password Security for Serial Remote Communications ............................................................................191
9. CALIBRATION PROCEDURES ........................................................................................ 193
9.1. Calibration Preparations ............................................................................................................................193
9.1.1. Required Equipment, Supplies, and Expendables ..............................................................................193
9.1.1.1. Zero Air .........................................................................................................................................194
9.1.1.2. Span Gas ......................................................................................................................................194
9.1.1.3. Calibration Gas Standards and Traceability .................................................................................194
9.1.2. Data Recording Devices ......................................................................................................................195
9.2. Manual Calibration .....................................................................................................................................195
9.2.1. Setup for Basic Calibration Checks and Calibration ............................................................................195
9.2.2. Performing a Basic Manual Calibration Check ....................................................................................197
9.2.3. Performing a Basic Manual Calibration ...............................................................................................198
9.2.3.1. Setting the Expected Span Gas Concentration ............................................................................198
9.2.3.2. Zero/Span Point Calibration Procedure ........................................................................................200
9.3. Manual Calibration with Zero/Span Valves ................................................................................................201
9.3.1. Setup for Calibration Using Valve Options ..........................................................................................201
9.3.2. Manual Calibration Checks with Valve Options Installed ....................................................................204
9.3.3. Manual Calibration Using Valve Options .............................................................................................205
9.3.3.1. Setting the Expected Span Gas Concentration ............................................................................205
9.3.3.2. Zero/Span Point Calibration Procedure ........................................................................................206
9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure ...............................................................208
9.4. Automatic Zero/Span Cal/Check (AutoCal) ...............................................................................................208
9.4.1. SETUP ACAL: Programming and AUTO CAL Sequence ...............................................................211
9.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected ...................................................213
9.5. CO Calibration Quality ...............................................................................................................................214
9.6. Calibration of the GFC7001T/GFC7001TM Electronic Subsystems .........................................................215
9.6.1. Dark Calibration Test ...........................................................................................................................215
9.6.2. Pressure Calibration ............................................................................................................................216
9.6.3. Flow Calibration ...................................................................................................................................217
9.7. Calibration of Optional Sensors .................................................................................................................218
9.7.1. O2 Sensor Calibration ..........................................................................................................................218
9.7.1.1. O2 Pneumatics Connections ........................................................................................................218
9.7.1.2. Set O2 Span Gas Concentration ..................................................................................................218
9.7.1.3. Activate O2 Sensor Stability Function ..........................................................................................220
9.7.1.4. O2 ZERO/SPAN CALIBRATION ..................................................................................................221
9.7.2. CO2 Sensor Calibration Procedure ......................................................................................................222
9.7.2.1. CO2 Pneumatics Connections .....................................................................................................222
9.7.2.2. Set CO2 Span Gas Concentration: ..............................................................................................222
9.7.2.3. Activate CO2 Sensor Stability Function .......................................................................................224
9.7.2.4. CO2 Zero/Span Calibration ..........................................................................................................225
10. EPA CALIBRATION PROTOCOL .................................................................................. 226
10.1. Calibration Requirements ........................................................................................................................226
10.1.1. Calibration of Equipment - General Guidelines .................................................................................226
10.1.2. Calibration Equipment, Supplies, and Expendables ..........................................................................227
10.1.2.1. Data Recording Device...............................................................................................................227
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Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
10.1.2.2. Spare Parts and Expendable Supplies .......................................................................................227
10.1.3. Recommended Standards for Establishing Traceability ....................................................................228
10.1.4. Calibration Frequency ........................................................................................................................229
10.1.5. Level 1 Calibrations versus Level 2 Checks ......................................................................................229
10.2. ZERO and SPAN Checks ........................................................................................................................230
10.2.1. Zero/Span Check Procedures ...........................................................................................................231
10.2.2. Precision Check .................................................................................................................................231
10.3. Precision Calibration ................................................................................................................................232
10.3.1. Precision Calibration Procedures ......................................................................................................232
10.4. Auditing Procedure ..................................................................................................................................232
10.4.1. Calibration Audit .................................................................................................................................232
10.4.2. Data Reduction Audit .........................................................................................................................233
10.4.3. System Audit/Validation .....................................................................................................................233
10.5. Dynamic Multipoint Calibration Procedure ..............................................................................................233
10.5.1. Linearity test .......................................................................................................................................233
10.6. References ..............................................................................................................................................235
PART III TECHNICAL INFORMATION ................................................................................ 237
11. MAINTENANCE SCHEDULE & PROCEDURES ............................................................ 241
11.1. Maintenance Schedule ............................................................................................................................241
11.2. Predicting Failures Using the Test Functions ..........................................................................................245
11.3. Maintenance Procedures .........................................................................................................................246
11.3.1. Replacing the Sample Particulate Filter .............................................................................................246
11.3.2. Performing Leak Checks ....................................................................................................................247
11.3.2.1. Pressure Leak Check .................................................................................................................247
11.3.3. Performing a Sample Flow Check .....................................................................................................247
11.3.4. Cleaning the Optical Bench ...............................................................................................................248
11.3.5. Cleaning Exterior Surfaces of the GFC7001T/GFC7001TM .............................................................248
12. TROUBLESHOOTING AND SERVICE ........................................................................... 249
12.1. General Troubleshooting .........................................................................................................................249
12.1.1. Fault Diagnosis with WARNING Messages .......................................................................................250
12.1.2. Fault Diagnosis with TEST Functions ................................................................................................253
12.1.3. the Diagnostic Signal I/O Function ....................................................................................................255
12.1.4. Status LEDs .......................................................................................................................................256
12.1.4.1. Motherboard Status Indicator (Watchdog) .................................................................................257
12.1.4.2. Sync Demodulator Status LEDs .................................................................................................258
12.1.4.3. Relay Board Status LEDs ...........................................................................................................259
12.2. Gas Flow Problems .................................................................................................................................261
12.2.1. GFC7001T/GFC7001TM Internal Gas Flow Diagrams .....................................................................262
12.2.2. Typical Sample Gas Flow Problems ..................................................................................................265
12.2.2.1. Flow is Zero ................................................................................................................................265
12.2.2.2. Low Flow ....................................................................................................................................265
12.2.2.3. High Flow ....................................................................................................................................266
12.2.2.4. Displayed Flow = “Warnings” .....................................................................................................266
12.2.2.5. Actual Flow Does Not Match Displayed Flow ............................................................................266
12.3. Calibration Problems ...............................................................................................................................266
12.3.1. Miscalibrated ......................................................................................................................................266
12.3.2. Non-Repeatable Zero and Span ........................................................................................................267
12.3.3. Inability to Span – No SPAN Button (CALS) ......................................................................................267
12.3.4. Inability to Zero – No ZERO Button (CALZ) .......................................................................................267
12.4. Other Performance Problems ..................................................................................................................268
12.4.1. Temperature Problems ......................................................................................................................268
12.4.1.1. Box or Sample Temperature ......................................................................................................268
12.4.1.2. Bench Temperature ....................................................................................................................268
12.4.1.3. GFC Wheel Temperature ...........................................................................................................269
12.4.1.4. IR Photo-Detector TEC Temperature .........................................................................................269
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12.4.2. Excessive Noise .................................................................................................................................270
12.5. Subsystem Checkout ...............................................................................................................................271
12.5.1. AC Mains Configuration .....................................................................................................................271
12.5.2. DC Power Supply ...............................................................................................................................271
12.5.3. I2C Bus ...............................................................................................................................................272
12.5.4. Touchscreen Interface .......................................................................................................................272
12.5.5. LCD Display Module ..........................................................................................................................272
12.5.6. Relay Board .......................................................................................................................................272
12.5.7. Sensor Assembly ...............................................................................................................................273
12.5.7.1. Sync/Demodulator Assembly .....................................................................................................273
12.5.7.2. Electrical Test .............................................................................................................................274
12.5.7.3. Opto Pickup Assembly ...............................................................................................................274
12.5.7.4. GFC Wheel Drive .......................................................................................................................274
12.5.7.5. IR Source ....................................................................................................................................275
12.5.7.6. Pressure/Flow Sensor Assembly ...............................................................................................275
12.5.8. Motherboard .......................................................................................................................................276
12.5.8.1. A/D Functions .............................................................................................................................276
12.5.8.2. Test Channel / Analog Outputs Voltage .....................................................................................276
12.5.8.3. Analog Outputs: Current Loop ....................................................................................................278
12.5.8.4. Status Outputs ............................................................................................................................278
12.5.8.5. Control Inputs – Remote Zero, Span ..........................................................................................279
12.5.9. CPU ....................................................................................................................................................279
12.5.10. RS-232 Communications .................................................................................................................279
12.5.10.1. General RS-232 Troubleshooting .............................................................................................279
12.5.10.2. Troubleshooting Analyzer/Modem or Terminal Operation .......................................................280
12.5.11. The Optional CO2 Sensor ................................................................................................................280
12.6. Repair Procedures ...................................................................................................................................281
12.6.1. Repairing Sample Flow Control Assembly ........................................................................................281
12.6.2. Removing/Replacing the GFC Wheel ................................................................................................282
12.6.3. Checking and Adjusting the Sync/Demodulator, Circuit Gain (CO MEAS) ......................................284
12.6.3.1. Checking the Sync/Demodulator Circuit Gain ............................................................................284
12.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain ...........................................................................285
12.6.4. Disk-On-Module Replacement ...........................................................................................................286
12.7. Frequently Asked Questions ...................................................................................................................287
12.8. Technical Assistance ...............................................................................................................................288
13. THEORY OF OPERATION .............................................................................................. 289
13.1. Measurement Method ..............................................................................................................................289
13.1.1. Beer’s Law .........................................................................................................................................289
13.2. Measurement Fundamentals ...................................................................................................................290
13.2.1. Gas Filter Correlation .........................................................................................................................291
13.2.1.1. The GFC Wheel ..........................................................................................................................291
13.2.1.2. The Measure Reference Ratio ...................................................................................................292
13.2.1.3. Summary Interference Rejection ................................................................................................294
13.3. Flow Rate Control ....................................................................................................................................295
13.3.1.1. Critical Flow Orifice .....................................................................................................................295
13.3.2. Particulate Filter .................................................................................................................................296
13.3.3. Pneumatic Sensors ............................................................................................................................297
13.3.3.1. Sample Pressure Sensor ...........................................................................................................297
13.3.3.2. Sample Flow Sensor ..................................................................................................................297
13.4. Electronic Operation ................................................................................................................................297
13.4.1. CPU ....................................................................................................................................................299
13.4.1.1. Disk-On-Module (DOM) ..............................................................................................................299
13.4.1.2. Flash Chip ..................................................................................................................................299
13.4.2. Optical Bench & GFC Wheel .............................................................................................................300
13.4.2.1. Temperature Control ..................................................................................................................300
13.4.2.2. IR Source ....................................................................................................................................300
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13.4.2.3. GFC Wheel .................................................................................................................................300
13.4.2.4. IR Photo-Detector .......................................................................................................................302
13.4.3. Synchronous Demodulator (Sync/Demod) Assembly .......................................................................302
13.4.3.1. Signal Synchronization and Demodulation ................................................................................303
13.4.3.2. Sync/Demod Status LEDs ..........................................................................................................304
13.4.3.3. Photo-Detector Temperature Control .........................................................................................304
13.4.3.4. Dark Calibration Switch ..............................................................................................................305
13.4.3.5. Electric Test Switch ....................................................................................................................305
13.4.4. Relay Board .......................................................................................................................................305
13.4.4.1. Heater Control ............................................................................................................................305
13.4.4.2. GFC Wheel Motor Control ..........................................................................................................305
13.4.4.3. Zero/Span Valve Options ...........................................................................................................306
13.4.4.4. IR Source ....................................................................................................................................306
13.4.4.5. Status LEDs ................................................................................................................................306
13.4.4.6. I2C Watch Dog Circuitry .............................................................................................................307
13.4.5. MotherBoard ......................................................................................................................................307
13.4.5.1. A to D Conversion ......................................................................................................................307
13.4.5.2. Sensor Inputs .............................................................................................................................308
13.4.5.3. Thermistor Interface ...................................................................................................................308
13.4.5.4. Analog Outputs ...........................................................................................................................309
13.4.5.5. Internal Digital I/O .......................................................................................................................309
13.4.5.6. External Digital I/O ......................................................................................................................309
13.4.6. I2C Data Bus ......................................................................................................................................309
13.4.7. Power Supply/ Circuit Breaker ...........................................................................................................310
13.4.8. Front Panel Touchscreen/Display Interface .......................................................................................312
13.4.8.1. LVDS Transmitter Board ............................................................................................................312
13.4.8.2. Front Panel Touchscreen/Display Interface PCA .......................................................................312
13.5. Software Operation ..................................................................................................................................313
13.5.1. Adaptive Filter ....................................................................................................................................313
13.5.2. Calibration - Slope and Offset ............................................................................................................314
13.5.3. Measurement Algorithm .....................................................................................................................314
13.5.4. Temperature and Pressure Compensation ........................................................................................314
13.5.5. Internal Data Acquisition System (DAS) ............................................................................................314
14. A PRIMER ON ELECTRO-STATIC DISCHARGE .......................................................... 315
14.1. How Static Charges are Created .............................................................................................................315
14.2. How Electro-Static Charges Cause Damage ..........................................................................................316
14.3. Common Myths About ESD Damage ......................................................................................................317
14.4. Basic Principles of Static Control .............................................................................................................318
14.4.1. General Rules ....................................................................................................................................318
14.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ..................................................319
14.4.2.1. Working at the Instrument Rack .................................................................................................320
14.4.2.2. Working at an Anti-ESD Work Bench .........................................................................................320
14.4.2.3. Transferring Components from Rack to Bench and Back ..........................................................320
14.4.2.4. Opening Shipments from Teledyne Customer Service ..............................................................321
14.4.2.5. Packing Components for Return to Teledyne Customer Service ..............................................322
GLOSSARY ................................................................................................................ 323
LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION APPENDIX B - GFC7001T/GFC7001TM SPARE PARTS LIST APPENDIX C - REPAIR QUESTIONNAIRE - GFC7001T APPENDIX D - SCHEMATICS
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LIST OF FIGURES
Figure 3-1:
Figure 3-2: Display Screen and Touch Control .............................................................................................. 36
Figure 3-3: Display/Touch Control Screen Mapped to Menu Charts ............................................................. 38
Figure 3-4: Rear Panel Layout ....................................................................................................................... 39
Figure 3-5: Internal Layout – GFC7001T ....................................................................................................... 41
Figure 3-6: Internal Layout – GFC7001TM .................................................................................................... 42
Figure 3-7: Optical Bench Layout (shorter bench, GFC7001TM, shown) ...................................................... 43
Figure 3-8: Analog In Connector .................................................................................................................... 45
Figure 3-9: Analog Output Connector ............................................................................................................ 46
Figure 3-10: Current Loop Option Installed on Motherboard ........................................................................... 47
Figure 3-11: Status Output Connector ............................................................................................................. 48
Figure 3-12: Control Input Connector ............................................................................................................... 50
Figure 3-13: Concentration Alarm Relay .......................................................................................................... 51
Figure 3-14: Rear Panel Connector Pin-Outs for RS-232 Mode ...................................................................... 54
Figure 3-15: Default Pin Assignments for CPU COM Port connector (RS-232) .............................................. 55
Figure 3-16: Jumper and Cables for Multidrop Mode ....................................................................................... 57
Figure 3-17: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram ..................................................... 58
Figure 3-18: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ..................................... 61
Figure 3-19: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator ............................. 61
Figure 3-20: GFC7001T/GFC7001TM Internal Gas Flow ................................................................................ 62
Figure 3-21: Pneumatic Connections – Option 50A: Zero/Span Calibration Valves ........................................ 63
Figure 3-22 Internal Pneumatic Flow OPT 50A – Zero/Span Valves .............................................................. 64
Figure 3-24: Internal Pneumatic Flow – Zero/Span/Shutoff Valves (Opt 50B) ................................................ 65
Figure 3-25: Pneumatic Connections – Zero Scrubber/Pressurized Span Calibration Valves (Opt 50E) ....... 66
Figure 3-26: Internal Pneumatic Flow Zero Scrubber/Pressurized Span Calibration Valves (Opt 50E) .......... 68
Figure 3-27: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves ....................................... 69
Figure 3-28: Internal Pneumatic Flow OPT 50H – Zero Scrubber/Ambient Span ........................................... 70
Figure 3-29: Zero/Span Calibration Procedure ................................................................................................ 80
Figure 4-1: Front Panel Display ...................................................................................................................... 85
Figure 4-2: Viewing GFC7001T/GFC7001TM Test Functions ....................................................................... 87
Figure 4-3: Viewing and Clearing GFC7001T/GFC7001TM WARNING Messages ...................................... 90
Figure 5-1: Analog Output Connector Pin Out ............................................................................................... 95
Figure 5-2: COMM– Machine ID ..................................................................................................................110
Figure 5-3: Accessing the Analog I/O Configuration Submenus ..................................................................118
Figure 5-4: Setup for Checking / Calibrating DCV Analog Output Signal Levels .........................................125
Figure 5-5: Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter ..................127
Figure 5-6: Alternative Setup Using 250 Resistor for Checking Current Output Signal Levels ................129
Figure 5-7. DIAG – Analog Inputs (Option) Configuration Menu .................................................................133
Figure 6-1: COM1[2] – Communication Modes Setup .................................................................................141
Figure 6-2: COMM Port Baud Rate ..............................................................................................................142
Figure 6-3: COMM – COM1 Test Port ..........................................................................................................142
Figure 6-4: COMM – LAN / Internet Manual Configuration ..........................................................................145
Figure 6-5 : COMM – LAN / Internet Automatic Configuration (DHCP) ........................................................146
Figure 7-1: Default DAS Channel Setup ......................................................................................................167
Figure 7-2: APICOM Remote Control Program Interface .............................................................................181
Figure 7-3: APICOM User Interface for Configuring the DAS ......................................................................182
Figure 7-4: DAS Configuration Through a Terminal Emulation Program .....................................................183
Figure 9-1: Pneumatic Connections – Basic Configuration – Using Bottled Span Gas ...............................196
Figure 9-2: Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator .......................196
Figure 9-3: Pneumatic Connections – Option 50A: Ambient Zero/Ambient Span Calibration Valves .........201
Figure 9-4: Pneumatic Connections – Option 50B: Ambient Zero/Pressurized Span Calibration Valves ...202
Figure 9-5: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .....................................202
Front Panel Layout ....................................................................................................................... 35
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Figure 9-6: Pneumatic Connections – Option 50E: Zero/Span Calibration Valves ......................................203
Figure 9-7: O2 Sensor Calibration Set Up ....................................................................................................218
Figure 9-8: CO2 Sensor Calibration Set Up ..................................................................................................222
Figure 11-1: Sample Particulate Filter Assembly ...........................................................................................246
Figure 12-1: Viewing and Clearing Warning Messages .................................................................................252
Figure 12-2: Example of Signal I/O Function .................................................................................................256
Figure 12-3: CPU Status Indicator .................................................................................................................257
Figure 12-4: Sync/Demod Board Status LED Locations ................................................................................258
Figure 12-5: Relay Board Status LEDs ..........................................................................................................259
Figure 12-6: GFC7001T/GFC7001TM – Basic Internal Gas Flow .................................................................262
Figure 12-7: Internal Pneumatic Flow OPT 50A – Zero/Span Valves (OPT 50A & 50B) ..............................262
Figure 12-8: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves ..............................................263
Figure 12-9: Internal Pneumatic Flow OPT 50H – Zero/Span Valves with Internal Zero Air Scrubber .........263
Figure 12-10: Internal Pneumatic Flow OPT 50E – Zero/Span/Shutoff w/ Internal Zero Air Scrubber ............264
Figure 12-11: GFC7001T/GFC7001TM – Internal Pneumatics with O2 Sensor Option 65A ...........................264
Figure 12-12: GFC7001T/GFC7001TM – Internal Pneumatics with CO2 Sensor Option 67A ........................265
Figure 12-13: Location of Diagnostic LEDs onCO2 Sensor PCA .....................................................................280
Figure 12-14: Critical Flow Restrictor Assembly/Disassembly .........................................................................281
Figure 12-15: Opening the GFC Wheel Housing .............................................................................................282
Figure 12-16: Removing the Opto-Pickup Assembly .......................................................................................283
Figure 12-17: Removing the GFC Wheel Housing ...........................................................................................283
Figure 12-18: Removing the GFC Wheel .........................................................................................................284
Figure 12-19: Location of Sync/Demod Housing Mounting Screws .................................................................285
Figure 12-20: Location of Sync/Demod Gain Potentiometer............................................................................285
Figure 13-1: Measurement Fundamentals .....................................................................................................291
Figure 13-2: GFC Wheel ................................................................................................................................291
Figure 13-3: Measurement Fundamentals with GFC Wheel ..........................................................................292
Figure 13-4: Affect of CO in the Sample on CO MEAS & CO REF ...............................................................293
Figure 13-5: Effects of Interfering Gas on CO MEAS & CO REF ..................................................................294
Figure 13-6: Chopped IR Signal .....................................................................................................................294
Figure 13-7: Internal Pneumatic Flow – Basic Configuration ........................................................................295
Figure 13-8: Flow Control Assembly & Critical Flow Orifice...........................................................................296
Figure 13-9: Electronic Block Diagram ...........................................................................................................298
Figure 13-10. CPU Board .................................................................................................................................299
Figure 13-11: GFC Light Mask .........................................................................................................................301
Figure 13-12: Segment Sensor and M/R Sensor Output .................................................................................302
Figure 13-13: GFC7001T/GFC7001TM Sync/Demod Block Diagram .............................................................303
Figure 13-14: Sample & Hold Timing ...............................................................................................................304
Figure 13-15: Location of relay board Status LEDs .........................................................................................307
Figure 13-16: Power Distribution Block Diagram .............................................................................................311
Figure 13-17: Front Panel and Display Interface Block Diagram .....................................................................312
Figure 13-18: Basic Software Operation ..........................................................................................................313
Figure 14-1: Triboelectric Charging ................................................................................................................315
Figure 14-2: Basic anti-ESD Workbench........................................................................................................318
LIST OF TABLES
Table 1-1: Analyzer Options .......................................................................................................................... 25
Table 2-1: GFC7001T/GFC7001TM Basic Unit Specifications ..................................................................... 29
Table 2-2: O2 Sensor Option Specifications .................................................................................................. 30
Table 2-3: CO2 Sensor Option Specifications ............................................................................................... 30
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Table 3-1: Ventilation Clearance ................................................................................................................... 34
Table 3-2: Display Screen and Touch Control Description ........................................................................... 37
Table 3-3: Rear Panel Description ................................................................................................................ 40
Table 3-4: Analog Input Pin Assignments ..................................................................................................... 45
Table 3-5: Analog Output Pin-Outs ............................................................................................................... 46
Table 3-6: Status Output Signals .................................................................................................................. 49
Table 3-7: Control Input Signals .................................................................................................................... 50
Table 3-8: Zero/Span Valve Operating States for Option 50A ...................................................................... 65
Table 3-9: Zero/Span Valve Operating States for Option 50B ...................................................................... 66
Table 3-10: Zero/Span Valve Operating States for Option 50E ...................................................................... 68
Table 3-11: Zero/Span Valve Operating States for Option 50H ..................................................................... 70
Table 3-12: NIST-SRM's Available for Traceability of CO Calibration Gases .................................................. 71
Table 3-13: Possible Warning Messages at Start-Up ..................................................................................... 73
Table 3-14: Possible Startup Warning Messages – GFC7001T Analyzers with Options ............................... 74
Table 4-1: Analyzer Operating Modes .......................................................................................................... 86
Table 4-2: Test Functions Defined ................................................................................................................ 87
Table 4-3: List of Warning Messages............................................................................................................ 88
Table 4-4: Primary Setup Mode Features and Functions ............................................................................. 91
Table 4-5: Secondary Setup Mode (SETUP>MORE) Features and Functions ............................................ 92
Table 5-1: GFC7001T Family Physical Range by Model .............................................................................. 96
Table 5-2: Password Levels ........................................................................................................................105
Table 5-3: Variable Names (VARS) ............................................................................................................111
Table 5-4: Diagnostic Mode (DIAG) Functions ...........................................................................................113
Table 5-5: DIAG - Analog I/O Functions .....................................................................................................117
Table 5-6: Analog Output Voltage Ranges .................................................................................................119
Table 5-7: Voltage Tolerances for the TEST CHANNEL Calibration ..........................................................125
Table 5-8: Current Loop Output Check .......................................................................................................129
Table 5-9: Test Channels Functions available on the GFC7001T/GFC7001TM’s Analog Output .............135
Table 5-10: CO Concentration Alarm Default Settings .................................................................................137
Table 6-1: COMM Port Communication Modes ..........................................................................................140
Table 6-2: Ethernet Status Indicators..........................................................................................................143
Table 6-3: LAN/Internet Default Configuration Properties ..........................................................................144
Table 6-4: RS-232 Communication Parameters for Hessen Protocol ........................................................152
Table 6-5: Teledyne’s Hessen Protocol Response Modes .........................................................................156
Table 6-6: Default Hessen Status Flag Assignments .................................................................................160
Table 7-1: Front Panel LED Status Indicators for DAS ...............................................................................163
Table 7-2: DAS Data Channel Properties ...................................................................................................165
Table 7-3: DAS Data Parameter Functions ................................................................................................173
Table 8-1: Interactive Mode Software Commands ......................................................................................186
Table 8-2: Teledyne’s Serial I/O Command Types .....................................................................................186
Table 9-1: NIST-SRMs Available for Traceability of CO Calibration Gases ................................................194
Table 9-2: AUTOCAL Modes ......................................................................................................................208
Table 9-3: AutoCal Attribute Setup Parameters ..........................................................................................209
Table 9-4: Example AutoCal Sequence ......................................................................................................210
Table 9-5: Calibration Data Quality Evaluation ...........................................................................................214
Table 10-1: Matrix for Calibration Equipment & Supplies .............................................................................228
Table 10-2: Activity Matrix for Quality Assurance Checks ............................................................................229
Table 10-3: Definition of Level 1 and Level 2 Zero and Span Checks ..........................................................230
Table 11-1: GFC7001T/GFC7001TM Maintenance Schedule .....................................................................243
Table 11-2: GFC7001T/GFC7001TM Test Function Record ........................................................................244
Table 11-3: Predictive uses for Test Functions .............................................................................................245
Table 12-1: Warning Messages - Indicated Failures ....................................................................................252
Table 12-2: Test Functions - Indicated Failures ............................................................................................254
Table 12-3: Sync/Demod Board Status Failure Indications ..........................................................................258
Table 12-4: I2C Status LED Failure Indications .............................................................................................259
Table 12-5: Relay Board Status LED Failure Indications ..............................................................................260
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Table 12-6: DC Power Test Point and Wiring Color Codes ..........................................................................271
Table 12-7: DC Power Supply Acceptable Levels ........................................................................................272
Table 12-8: Relay Board Control Devices .....................................................................................................273
Table 12-9: Opto Pickup Board Nominal Output Frequencies ......................................................................274
Table 12-10: Analog Output Test Function - Nominal Values Voltage Outputs .............................................277
Table 12-11: Analog Output Test Function - Nominal Values Voltage Outputs .............................................278
Table 12-12: Status Outputs Check ................................................................................................................278
Table 13-1: Absorption Path Lengths for GFC7001T and GFC7001TM ......................................................290
Table 13-2: Sync DEMOD Sample and Hold Circuits ...................................................................................304
Table 13-3: Sync/Demod Status LED Activity ...............................................................................................304
Table 13-4: Relay Board Status LEDs ..........................................................................................................306
Table 14-1: Static Generation Voltages for Typical Activities .......................................................................316
Table 14-2: Sensitivity of Electronic Devices to Damage by ESD ................................................................316
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Part I General InformationTeledyne API – Model T300/T300M CO Analyzer
PART I
GENERAL INFORMATION
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Part I General Information Teledyne API – Model T300/T300M CO Analyzer
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IntroductionTeledyne API – Model T300/T300M CO Analyzer
1. INTRODUCTION, FEATURES AND OPTIONS
This section provides an overview of the Model GFC7001T or GFC7001TM Analyzer, its features and its options, followed by a description of how this user manual is arranged.
1.1. GFC7001T FAMILY OVERVIEW
The family includes the GFC7001T and the GFC7001TM Gas Filter Correlation Carbon Monoxide Analyzer. The GFC7001T 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 GFC7001T/GFC7001TM 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 GFC7001T/GFC7001TM 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 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.
Teledyne Analytical Instruments
IntroductionTeledyne API – Model T300/T300M CO Analyzer
1.2. FEATURES
Some of the common features of your GFC7001T family of analyzers include:
LCD color graphics with touch screen interface Microprocessor controlled for versatility Multi-tasking software allows viewing of test variables during operation Continuous self checking with alarms Bi-directional USB, RS-232, and 10/100Base-T Ethernet ports for remote
operation (optional RS-485)
Front panel USB ports for peripheral devices and software downloads Digital status outputs indicate instrument operating condition Adaptive signal filtering optimizes response time Gas Filter Correlation (GFC) Wheel for CO specific measurement GFC Wheel guaranteed against leaks for 5 years Temperature and pressure compensation Comprehensive internal data logging with programmable averaging periods Remote operation when used with TAI’s APICOM software
GFC7001T
GFC7001TM
FEATURES:
Ranges, 0-1 ppm to 0-1000 ppm, user selectable 14 meter path length for sensitivity
FEATURES:
Ranges, 0-1 ppm; Max: 0-5000 ppm, user selectable 2.5 meter path length for dynamic range
1.3. GFC7001T/GFC7001TM DOCUMENTATION
In addition to this operation manual (part number M90914), two other manuals are available for download from Teledyne’s website at http://www.teledyne­api.com/manuals/, to support the operation of this instrument:.
APICOM software manual, part number 07463 DAS Manual, part number 02837
1.4. OPTIONS
The options available for your analyzer are presented in Table 1-1 with name, option number, a description and/or comments, and if applicable, cross-references to technical details in this manual, such as setup and calibration. To order these options or to learn more about them, please contact the Sales department of Teledyne Analytical Instruments at:
Teledyne Analytical Instruments 24
IntroductionTeledyne API – Model T300/T300M CO Analyzer
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 or your local representative.
Table 1-1: Analyzer Options
Option
Pumps
Rack Mount Kits
Carrying Strap/Handle Side-mounted strap for hand-carrying analyzer
29
Option
Number
Pumps meet all typical AC power supply standards while exhibiting same pneumatic performance.
10A External Pump 100V - 120V @ 60 Hz N/A 10B External Pump 220V - 240V @ 50 Hz N/A 10C External Pump 220V - 240V @ 60 Hz N/A 10D External Pump 100V – 12V @ 50 Hz N/A 10E External Pump 100V @ 60 Hz N/A 11 Pumpless, internal or external Pump Pack N/A 13 High Voltage Internal Pump 240V @ 50Hz N/A
Options for mounting the analyzer in standard 19” racks
20A Rack mount brackets with 26 in. chassis slides N/A 20B Rack mount brackets with 24 in. chassis slides N/A 21 Rack mount brackets only (compatible with carrying strap, Option 29) N/A 23 Rack mount for external pump pack (no slides) N/A
Extends from “flat” position to accommodate hand for carrying. Recesses to 9mm (3/8”) dimension for storage. Can be used with rack mount brackets, Option 21. Cannot be used with rack mount slides.
Description/Notes Reference
N/A
CAUTION - GENERAL SAFETY HAZARD
A fully loaded GFC7001T with valve options weighs about 18 kg or 40 lbs. (GFC7001TM weighs 22.7 kg or 50 lbs).
To avoid personal injury we recommend that two persons lift and carry the analyzer. Disconnect all cables and tubing from the analyzer before moving it.
Analog Inputs
64
Current Loop Analog Outputs
41
Used for connecting external voltage signals from other instrumentation (such as meteorological instruments).
Also can be used for logging these signals in the analyzer’s internal DAS
Adds isolated, voltage-to-current conversion circuitry to the analyzer’s analog outputs.
Can be configured for any output range between 0 and 20 mA. May be ordered separately for any of the analog outputs.
Sections 3.3.1.2,
5.9.3.11, and 7
Sections 3.3.1.3,
3.3.1.4, 5.9.1,
5.9.2 and 5.9.3.7
Teledyne Analytical Instruments 25
IntroductionTeledyne API – Model T300/T300M CO Analyzer
Option
Parts Kits Spare parts and expendables
Calibration Valves
50A Ambient Zero and Ambient Span.
50B Ambient Zero and Pressurized Span
50E Zero Scrubber and Pressurized Span
50H Zero Scrubber and Ambient Span
Communication Cables For remote serial, network and Internet communication with the analyzer.
Type Description
60A RS-232
60B RS-232
60C Ethernet
60D USB
Concentration Alarm Relay Issues warning when gas concentration exceeds limits set by user.
61
RS-232 Multidrop Enables communications between host computer and up to eight analyzers.
62
Second Gas Sensors Choice of one additional gas sensor.
65A Oxygen (O2) Sensor
67A Carbon Dioxide (CO2) Sensor
Option
Number
42A
45
Can be installed at the factory or retrofitted in the field.
Expendables Kit includes a recommended set of expendables for one year of operation of this instrument including replacement sample particulate filters.
Spare Parts Kit includes spares parts for one unit. Used to control the flow of calibration gases generated from external sources, rather
than manually switching the rear panel pneumatic connections.
Shielded, straight-through DB-9F to DB-25M cable, about
1.8 m long. Used to interface with older computers or code activated switches with DB-25 serial connectors.
Shielded, straight-through DB-9F to DB-9F cable of about
1.8 m length. Patch cable, 2 meters long, used for Internet and LAN
communications. Cable for direct connection between instrument (rear
panel USB port) and personal computer.
Four (4) “dry contact” relays on the rear panel of the instrument. This relay option is different from and in addition to the “Contact Closures” that come standard on all TAI instruments.
Multidrop card seated on the analyzer’s CPU card. Each instrument in the multidrop network requires this card and a
communications cable (Option 60B).
Description/Notes Reference
Appendix B
Appendix B
Sections 3.3.2.3 and 3.3.2.4
Sections Error!
Reference source not found. and
3.3.2.5 Sections 3.3.2.6
and 3.3.2.7 Sections 3.3.2.8
and 3.3.2.9
Section 3.3.1.9 and 6.3
Sections 3.3.1.9, and 6.3
Sections 3.3.1.9 and 6.5
Sections 3.3.1.9 and 6.6
Section 3.3.1.7
Sections 3.3.1.9 and 5.7.1
• Sections 3.3.1.3 and 9.7.1
• Sections 3.3.1.3 and 9.7.2
Teledyne Analytical Instruments 26
IntroductionTeledyne API – Model T300/T300M CO Analyzer
Option
Special Features Built in features, software activated
N/A
N/A
N/A
Option
Number
Maintenance Mode Switch, located inside the instrument, places the
analyzer in maintenance mode where it can continue sampling, yet ignore calibration, diagnostic, and reset instrument commands. This feature is of particular use for instruments connected to Multidrop or Hessen protocol networks.
Call Customer Service for activation.
Second Language Switch activates an alternate set of display messages in a language other than the instrument’s default language.
Call Customer Service for a specially programmed Disk on Module containing the second language.
Dilution Ratio Option allows the user to compensate for diluted sample gas, such as in continuous emission monitoring (CEM) where the quality of gas in a smoke stack is being tested and the sampling method used to remove the gas from the stack dilutes the gas.
Call Customer Service for activation.
Description/Notes Reference
Refer to page iii in this manual for configuration and specific options included with this instrument.
N/A
N/A
Sections 3.4.4.2 and 5.4.5
Teledyne Analytical Instruments 27
IntroductionTeledyne API – Model T300/T300M CO Analyzer
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Teledyne Analytical Instruments 28
SpecificationsTeledyne API – Model T300/T300M CO Analyzer
2. SPECIFICATIONS AND APPROVALS
This section presents specifications for the GFC7001T/GFC7001TM analyzer and for its second gas sensor options, EPA equivalency designation, and compliance statements.
2.1. SPECIFICATIONS
Table 2-1: GFC7001T/GFC7001TM Basic Unit Specifications
Parameter Specification
Ranges Min: 0-1 ppm Full scale
Max: 0-1,000 ppm Full scale (selectable, dual ranges and auto ranging supported)
Measurement Units
Zero Noise1 GFC7001T: < 0.02 ppm RMS
Span Noise1 GFC7001T:<0.5% of rdg RMS over 5ppm 3
Lower Detectable Limit1 GFC7001T: < 0.04 ppm
Zero Drift (24 hours) 2 GFC7001T: < 0.1 ppm
Span Drift (24 hours) 2 GFC7001T: < 0.5% of reading
Lag Time1 10 seconds Rise/Fall Time 1 <60 seconds to 95% Linearity
Precision GFC7001T: The greater of 0.5% of reading or 0.2ppm;
Sample Flow Rate
AC Power 100V-120V, 220V-240V, 50/60 Hz Analog Output Ranges
Analog Output Resolution 1 part in 4096 of selected full-scale voltage Recorder Offset ±10% Standard I/O
GFC7001T: ppb, ppm, µg/m GFC7001TM: ppm, mg/m
GFC7001TM: 0.1 ppm RMS
GFC7001TM:>0.5% of rdg RMS over 20ppm
GFC7001TM: 0.2 ppm
GFC7001TM: <0.5 ppm
GFC7001TM: 0.5ppm
GFC7001T: 1% of full scale GFC7001TM: 0 - 3000 ppm: 1% full scale; 3000 - 5000 ppm: 2% full scale
GFC7001TM: The greater of 1.0% of reading or 1ppm
3
800 cm (O
All Outputs: 10V, 5V, 1V, 0.1V (selectable) Three outputs convertible to 4-20 mA isolated current loop. All Ranges with 5% under/over-range
1 Ethernet: 10/100Base-T 2 RS-232 (300 – 115,200 baud) 2 USB device ports 8 opto-isolated digital status outputs 6 opto-isolated digital control inputs (2 defined, 4 spare) 4 user configurable analog outputs
/min. ±10%
Sensor option adds 120 cm³/min to total flow when installed)
2
3
, mg/m3 (user selectable)
3
(user selectable)
5;
Teledyne Analytical Instruments
SpecificationsTeledyne API – Model T300/T300M CO Analyzer
Parameter Specification
Optional I/O 1 USB com port
1 RS485 8 analog inputs (0-10V, 12-bit) 4 digital alarm outputs (2 opto-isolated and 2 dry contact) Multidrop RS232 3 4-20mA current outputs
Temperature Range
5 - 40C operating, 10 - 40C EPA Equivalency (GFC7001T only) Humidity Range 0-95% RH, Non-Condensing Temp Coefficient
< 0.05 % per C (minimum 50 ppb/C) Voltage Coefficient < 0.05 % per V Dimensions (HxWxD) 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm) Weight GFC7001T: 40 lbs (18.1 kg); GFC7001TM: 38.4 lbs (17.2) Environmental Conditions Installation Category (Over voltage Category) II Pollution Degree 2
1
As defined by the USEPA
2
At constant temperature and pressure
Table 2-2: O2 Sensor Option Specifications
Parameter Description
Ranges 0-1% to 0-100% user selectable. Dual ranges and auto-ranging supported. Zero Noise Lower Detectable Limit2 <0.04% O2 Zero Drift (24 hours) 3 <± 0.02% O2 Zero Drift (7 days) <±- 0.05% O2 Span Noise Span Drift (7 days) <± 0.1% O2 Accuracy (intrinsic error) <± 0.1% O2 Linearity <± 0.1 % O2 Temp Coefficient <± 0.05% O2 /°C, Rise and Fall Time <60 seconds to 95%
1
As defined by the USEPA
2
Defined as twice the zero noise level by the USEPA
3
Note: zero drift is typically <± 0.1% O
1
1
<0.02% O2
<± 0.05% O2
during the first 24 hrs of operation
2
Table 2-3: CO
Sensor Option Specifications
2
Parameter Description
Ranges 0-1% to 0-20% user selectable. Dual ranges and auto-ranging supported. Zero Noise
1
<0.02% CO2 Lower Detectable Limit2 <0.04% CO2 Zero Drift (24 hours) <± 0.02% CO2 Zero Drift (7 days) <± 0.05% CO2 Span Noise
1
<± 0.1% CO2 Span Drift (7 days) <± 0.1% CO2
Teledyne Analytical Instruments 30
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