Teledyne GFC7001T User Manual

4 (1)

Operation Manual

Model GFC7001T

Carbon Monoxide Analyzer

P/N M90914

DATE 07/22/13

TELEDYNE ELECTRONIC TECHNOLOGIES

Analytical Instruments

16830 Chestnut Street

City of Industry, CA 91748

Telephone: (626) 934-1500

Fax: (626) 961-2538

Web: www.teledyne-ai.com

Teledyne Analytical Instruments

Model 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.

MODEL 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.

MODEL 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.

POWER 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

ANALOG OUTPUT SIGNALS

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

RANGE 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

REAR PANEL GAS FITTINGS

1/4” SS Standard

6 mm SS Optional

VALVE OPTIONS

No Valves. The standard unit does not include internal span and zero valves. Internal Zero/Span Valves

ALARM 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.

TEST 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.

PROFIBUS MOUNTING OPTION

RS232 to Profibus Circuit Board: Special RS232 to Profibus PCB card for Profibus communication using the existing RS232 port.

BACKGROUND GAS:

NOTES:

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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.

CONVENTIONS 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

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

DO NOT TOUCH: Touching some parts of the instrument without protection or proper tools could result in damage to the part(s) and/or the instrument.

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

 

CAUTION - General Safety Hazard

 

This instrument should only be used for the purpose and in the manner

 

described in this manual. If you use this instrument in a manner other

 

than that for which it was intended, unpredictable behavior could ensue

 

with possible hazardous consequences.

 

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

Note

Technical Assistance regarding the use and maintenance of 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

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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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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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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:

Front Panel Layout.......................................................................................................................

35

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 250Ω 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

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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 of ContentsTeledyne API – Model T300/T300M CO Analyzer

 

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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Table of ContentsTeledyne API – Model T300/T300M CO Analyzer

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Part I General InformationTeledyne API – Model T300/T300M CO Analyzer

PART I

GENERAL INFORMATION

Teledyne Analytical Instruments

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 FEATURES:

Ranges, 0-1 ppm to 0-1000 ppm, user selectable

14 meter path length for sensitivity

GFC7001TM 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

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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

 

 

Option

 

Description/Notes

 

Reference

 

 

 

Number

 

 

 

 

 

 

 

 

 

 

 

 

Pumps

 

 

 

 

 

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

 

Rack Mount

 

 

 

 

 

Options for mounting the analyzer in standard 19” racks

 

 

 

 

Kits

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

Carrying Strap/Handle

 

Side-mounted strap for hand-carrying analyzer

 

 

 

 

 

 

 

 

 

 

Extends from “flat” position to accommodate hand for carrying.

 

 

 

 

 

29

 

 

Recesses to 9mm (3/8”) dimension for storage.

 

N/A

 

 

 

 

Can be used with rack mount brackets, Option 21.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cannot be used with rack mount slides.

 

 

 

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

 

 

Used for connecting external voltage signals from other instrumentation (such as

 

 

 

 

meteorological instruments).

 

 

 

 

 

 

 

 

64

 

 

Also can be used for logging these signals in the analyzer’s internal

Sections 3.3.1.2,

 

 

 

DAS

5.9.3.11, and 7

 

 

 

 

 

 

 

Current Loop Analog

 

Adds isolated, voltage-to-current conversion circuitry to the analyzer’s analog

 

 

Outputs

 

outputs.

 

 

 

 

 

 

Can be configured for any output range between 0 and 20 mA.

Sections 3.3.1.3,

 

41

 

 

3.3.1.4, 5.9.1,

 

 

 

May be ordered separately for any of the analog outputs.

 

 

 

 

 

5.9.2 and 5.9.3.7

 

 

 

 

 

 

 

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IntroductionTeledyne API – Model T300/T300M CO Analyzer

 

Option

Option

 

 

Description/Notes

Reference

 

Number

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Can be installed at the factory or retrofitted in the field.

 

 

 

Parts Kits

 

 

 

Spare parts and expendables

 

 

 

 

 

 

 

Expendables Kit includes a recommended set of expendables for

 

 

 

 

42A

 

one year of operation of this instrument including replacement sample

Appendix B

 

 

 

 

 

particulate filters.

 

 

 

 

45

 

 

Spare Parts Kit includes spares parts for one unit.

Appendix B

 

Calibration Valves

 

 

Used to control the flow of calibration gases generated from external sources, rather

 

 

 

 

than manually switching the rear panel pneumatic connections.

 

 

 

 

 

 

 

 

 

 

 

50A

 

Ambient Zero and Ambient Span.

Sections 3.3.2.3

 

 

 

and 3.3.2.4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sections Error!

 

 

 

 

 

 

 

Reference

 

 

50B

 

Ambient Zero and Pressurized Span

source not

 

 

 

 

 

 

 

found. and

 

 

 

 

 

 

 

3.3.2.5

 

 

 

50E

 

Zero Scrubber and Pressurized Span

Sections 3.3.2.6

 

 

 

and 3.3.2.7

 

 

 

 

 

 

 

 

 

50H

 

Zero Scrubber and Ambient Span

Sections 3.3.2.8

 

 

 

and 3.3.2.9

 

 

 

 

 

 

 

 

Communication Cables

 

For remote serial, network and Internet communication with the analyzer.

 

 

 

 

 

 

Type

Description

 

 

 

 

 

 

 

 

Shielded, straight-through DB-9F to DB-25M cable, about

Section 3.3.1.9

 

 

60A

 

RS-232

1.8 m long. Used to interface with older computers or

 

 

 

and 6.3

 

 

 

 

 

 

code activated switches with DB-25 serial connectors.

 

 

 

 

 

 

 

 

 

 

60B

 

RS-232

Shielded, straight-through DB-9F to DB-9F cable of about

Sections 3.3.1.9,

 

 

 

1.8 m length.

and 6.3

 

 

 

 

 

 

 

 

60C

 

Ethernet

Patch cable, 2 meters long, used for Internet and LAN

Sections 3.3.1.9

 

 

 

communications.

and 6.5

 

 

 

 

 

 

 

 

60D

 

USB

Cable for direct connection between instrument (rear

Sections 3.3.1.9

 

 

 

panel USB port) and personal computer.

and 6.6

 

 

 

 

 

 

 

Concentration Alarm Relay

 

Issues warning when gas concentration exceeds limits set by user.

 

 

 

 

 

 

Four (4) “dry contact” relays on the rear panel of the instrument. This

Section 3.3.1.7

 

 

61

 

 

relay option is different from and in addition to the “Contact Closures”

 

 

 

 

 

 

 

 

 

 

 

that come standard on all TAI instruments.

 

 

 

 

 

 

 

RS-232 Multidrop

 

Enables communications between host computer and up to eight analyzers.

 

 

 

62

 

 

Multidrop card seated on the analyzer’s CPU card.

Sections 3.3.1.9

 

 

 

 

Each instrument in the multidrop network requires this card and a

 

 

 

 

and 5.7.1

 

 

 

 

 

communications cable (Option 60B).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Second Gas Sensors

 

Choice of one additional gas sensor.

 

 

 

 

65A

 

Oxygen (O2) Sensor

• Sections 3.3.1.3

 

 

 

and 9.7.1

 

 

 

 

 

 

 

 

 

67A

 

Carbon Dioxide (CO2) Sensor

• Sections 3.3.1.3

 

 

 

and 9.7.2

 

 

 

 

 

 

 

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IntroductionTeledyne API – Model T300/T300M CO Analyzer

Option

Option

 

Description/Notes

Reference

 

Number

 

 

 

 

 

 

 

Special Features

 

 

Built in features, software activated

 

 

 

 

 

Maintenance Mode Switch, located inside the instrument, places the

 

 

 

 

 

analyzer in maintenance mode where it can continue sampling, yet

 

 

 

N/A

 

ignore calibration, diagnostic, and reset instrument commands. This

N/A

 

 

 

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

 

 

 

N/A

 

messages in a language other than the instrument’s default language.

N/A

 

 

 

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

N/A 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.

Sections 3.4.4.2 and 5.4.5

Refer to page iii in this manual for configuration and specific options included with this instrument.

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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

GFC7001T: ppb, ppm, µg/m3, mg/m3 (user selectable)

 

 

 

GFC7001TM: ppm, mg/m3 (user selectable)

 

 

Zero Noise1

GFC7001T: < 0.02 ppm RMS

 

 

 

GFC7001TM: ≤ 0.1 ppm RMS

 

 

Span Noise1

GFC7001T:<0.5% of rdg RMS over 5ppm 3

 

 

 

GFC7001TM:>0.5% of rdg RMS over 20ppm

 

 

Lower Detectable Limit1

GFC7001T: < 0.04 ppm

 

 

 

GFC7001TM: 0.2 ppm

 

 

Zero Drift (24 hours) 2

GFC7001T: < 0.1 ppm

 

 

 

GFC7001TM: <0.5 ppm

 

 

Span Drift (24 hours) 2

GFC7001T: < 0.5% of reading

 

 

 

GFC7001TM: 0.5ppm

 

 

Lag Time1

10 seconds

 

 

Rise/Fall Time 1

<60 seconds to 95%

 

 

Linearity

GFC7001T: 1% of full scale5;

 

 

 

GFC7001TM: 0 - 3000 ppm: 1% full scale; 3000 - 5000 ppm: 2% full scale

 

 

Precision

GFC7001T: The greater of 0.5% of reading or 0.2ppm;

 

 

 

GFC7001TM: The greater of 1.0% of reading or 1ppm

 

 

 

 

 

 

Sample Flow Rate

800 cm3/min. ±10%

 

 

 

(O2 Sensor option adds 120 cm³/min to total flow when installed)

 

 

AC Power

100V-120V, 220V-240V, 50/60 Hz

 

 

Analog Output Ranges

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

 

 

Analog Output Resolution

1 part in 4096 of selected full-scale voltage

 

 

Recorder Offset

±10%

 

 

Standard I/O

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

 

 

 

 

 

Teledyne Analytical Instruments

Teledyne GFC7001T User Manual

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 - 40 C operating, 10 - 40 C 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 Noise1

 

 

<0.02% O2

 

Lower Detectable Limit2

 

<0.04% O2

 

Zero Drift (24 hours) 3

 

<± 0.02% O2

 

Zero Drift (7 days)

 

<±- 0.05% O2

 

 

 

 

 

 

Span Noise1

 

 

<± 0.05% O2

 

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%

 

 

 

 

 

1As defined by the USEPA

2Defined as twice the zero noise level by the USEPA

3Note: zero drift is typically <± 0.1% O2 during the first 24 hrs of operation

Table 2-3:

CO2 Sensor Option Specifications

 

 

Parameter

Description

Ranges

 

0-1% to 0-20% user selectable. Dual ranges and auto-ranging supported.

Zero Noise1

 

<0.02% CO2

Lower Detectable Limit2

<0.04% CO2

Zero Drift (24 hours)

<± 0.02% CO2

Zero Drift (7 days)

<± 0.05% CO2

Span Noise1

 

<± 0.1% CO2

Span Drift (7 days)

<± 0.1% CO2

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