Teledyne GFC7001T User manual
Teledyne Analytical Instruments
Operation Manual
Model GFC7001T
Carbon Monoxide 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
P/N M90914
DATE 12/01/14
Model GFC7001T Carbon Monoxide Analyzer
Teledyne Analytical Instruments ii
Copyright © 2014 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.
Model GFC7001T Carbon Monoxide Analyzer
Teledyne Analytical Instruments iii
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, version-
specific 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.
Model GFC7001T Carbon Monoxide Analyzer
Teledyne Analytical Instruments iv
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Safety Information Teledyne API – Model T300/T300M CO Analyzer
Teledyne Analytical Instruments
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: [email protected]
or by accessing various service options on our website at
http://www.teledyne-ai.com/.
Safety Information Model GFC7001T Carbon Monoxide Analyzer
Teledyne Analytical Instruments vi
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
ABOUT THIS MANUAL ........................................................................................................... III
IMPORTANT SAFETY INFORMATION ....................................................................................V
CONSIGNES DE SÉCURITÉ ...............................................................................................................................vi
TABLE OF CONTENTS ..........................................................................................................VII
LIST OF APPENDICES ...................................................................................................................................... xiii
List of Figures...................................................................................................................................................... xiii
List of Tables....................................................................................................................................................... xvi
PART I GENERAL INFORMATION ......................................................................................XIX
1. INTRODUCTION, FEATURES AND OPTIONS .................................................................. 21
1.1. GFC7001T Family Overview........................................................................................................................21
1.2. Features.......................................................................................................................................................22
1.3. GFC7001T/GFC7001TM Documentation ....................................................................................................22
1.4. Options.........................................................................................................................................................22
2. SPECIFICATIONS AND APPROVALS............................................................................... 27
2.1. Specifications...............................................................................................................................................27
2.2. EPA Equivalency Designation .....................................................................................................................29
2.3. Approvals and Certifications ........................................................................................................................29
2.3.1. Safety.....................................................................................................................................................30
2.3.2. EmC .......................................................................................................................................................30
2.3.3. Other Type Certifications .......................................................................................................................30
3. GETTING STARTED........................................................................................................... 31
3.1. Unpacking the GFC7001T/GFC7001TM Analyzer ......................................................................................31
3.1.1. Ventilation Clearance.............................................................................................................................32
3.2. Instrument Layout ........................................................................................................................................33
3.2.1. Front Panel ............................................................................................................................................33
3.2.2. Rear panel .............................................................................................................................................37
3.2.3. GFC7001T/GFC7001TM Analyzer Layout ............................................................................................38
3.3. Connections and Setup................................................................................................................................41
3.3.1. Electrical Connections ...........................................................................................................................42
3.3.1.1. Connecting Power ..........................................................................................................................42
3.3.1.2. Connecting Analog Inputs (Option) ................................................................................................42
3.3.1.3. Connecting Analog Outputs ...........................................................................................................43
3.3.1.4. Current Loop Analog Outputs (Option 41) Setup ..........................................................................44
3.3.1.5. Connecting the Status Outputs ......................................................................................................46
3.3.1.6. Connecting the Control Inputs........................................................................................................47
3.3.1.7. Concentration Alarm Relay (Option 61) Standard Configuration ...................................................48
3.3.1.8. Concentration Alarm Relay (Option 61) Air Products Configuration ..............................................50
3.3.1.9. Connecting the Communication Interfaces ....................................................................................50
3.3.2. Pneumatic Connections.........................................................................................................................57
3.3.2.1. Pneumatic Connections for Basic Configuration............................................................................59
3.3.2.2. Pneumatic Layout for Basic configuration......................................................................................60
3.3.2.3. Pneumatic Connections for Zero/Span Valve Option.....................................................................61
3.3.2.4. Pneumatic Layout for Zero/ Span Valve Option.............................................................................62
3.3.2.5. Pneumatic Layout for Internal Zero/ Span Valve Option................................................................63
3.3.2.6. Pneumatic Connections for Zero Scrubber/Pressurized Span Option...........................................64
3.3.2.7. Pneumatic Layout for Zero Scrubber/Pressurized Span Option ....................................................66
3.3.2.8. Pneumatic Connections for Zero Scrubber/Ambient Span Option.................................................66
3.3.2.9. Pneumatic Layout for Zero scrubber/ Ambient Span OPTion........................................................68
3.3.2.10. Calibration Gases.........................................................................................................................69
3.4. Startup, Functional Checks, and Initial Calibration......................................................................................70
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3.4.1. Startup....................................................................................................................................................70
3.4.2. Warning Messages ................................................................................................................................70
3.4.3. Functional Checks .................................................................................................................................72
3.4.4. Initial Calibration ....................................................................................................................................73
3.4.4.1. Interferents for CO Measurements.................................................................................................74
3.4.4.2. Initial Calibration Procedure ...........................................................................................................74
3.4.4.3. O2Sensor Calibration Procedure ...................................................................................................79
3.4.4.4. CO2Sensor Calibration Procedure ................................................................................................79
PART II OPERATING INSTRUCTIONS.................................................................................. 81
4. OVERVIEW OF OPERATING MODES ............................................................................... 83
4.1. Sample Mode...............................................................................................................................................84
4.1.1. Test Functions .......................................................................................................................................84
4.1.2. Warning Messages ................................................................................................................................86
4.2. Calibration Mode..........................................................................................................................................88
4.3. Setup MODE................................................................................................................................................89
4.3.1. Password Security .................................................................................................................................89
4.3.2. Primary Setup Menu ..............................................................................................................................89
4.3.3. Secondary Setup Menu (SETUP>MORE).............................................................................................90
5. SETUP MENU 91
5.1. SETUP ÆCFG: Configuration Information .................................................................................................91
5.2. SETUP ÆACAL: Automatic Calibration......................................................................................................92
5.3. SETUP ÆDAS: Internal Data Acquisition System.......................................................................................92
5.4. SETUP ÆRNGE: Analog Output Reporting Range Configuration .............................................................92
5.4.1. Analog Output Ranges for CO Concentration .......................................................................................92
5.4.2. Physical Range vs Analog Output Reporting Ranges ...........................................................................93
5.4.3. Reporting Range Modes: Single, Dual, Auto Ranges ...........................................................................94
5.4.3.1. SINGLE Range Mode (SNGL) .......................................................................................................96
5.4.3.2. DUAL Range Mode (DUAL) ...........................................................................................................97
5.4.3.3. AUTO Range Mode (AUTO) ..........................................................................................................99
5.4.4. Range Units .........................................................................................................................................101
5.4.5. Dilution Ratio (Option)..........................................................................................................................102
5.5. SETUP ÆPASS: Password Protection.....................................................................................................103
5.6. SETUP ÆCLK: Setting the Internal Time-of-Day Clock and Adjusting Speed.........................................106
5.6.1.1. Setting the Internal Clock’s Time and Day ...................................................................................106
5.6.1.2. Adjusting the Internal Clock’s Speed............................................................................................106
5.7. SETUP ÆComm: Communications Ports .................................................................................................108
5.7.1. ID (Machine Identification) ...................................................................................................................108
5.7.2. INET (Ethernet)....................................................................................................................................108
5.7.3. COM1 and COM2 (Mode, Baud Rate and Test Port)..........................................................................108
5.8. SETUP ÆVARS: Variables Setup and Definition ......................................................................................109
5.9. SETUP ÆDiag: Diagnostics Functions......................................................................................................110
5.9.1. Signal I/O .............................................................................................................................................113
5.9.2. Analog Output ......................................................................................................................................114
5.9.3. Analog I/O Configuration......................................................................................................................114
5.9.3.1. Analog Output Voltage / Current Range Selection.......................................................................117
5.9.3.2. Analog Output Calibration ............................................................................................................119
5.9.3.3. Enabling or Disabling the AutoCal for an Individual Analog Output.............................................119
5.9.3.4. Automatic Calibration of the Analog Outputs ...............................................................................120
5.9.3.5. Individual Calibration of the Analog Outputs ................................................................................122
5.9.3.6. Manual Calibration of the Analog Outputs Configured for Voltage Ranges.................................123
5.9.3.7. Manual Adjustment of Current Loop Output Span and Offset .....................................................125
5.9.3.8. Turning an Analog Output Over-Range Feature ON/OFF ...........................................................128
5.9.3.9. Adding a Recorder Offset to an Analog Output............................................................................129
5.9.3.10. AIN Calibration ...........................................................................................................................130
5.9.3.11. Analog Inputs (XIN1…XIN8) Option Configuration ....................................................................131
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5.9.4. Electrical Test ......................................................................................................................................131
5.9.5. Dark Calibration ...................................................................................................................................132
5.9.6. Pressure Calibration ............................................................................................................................132
5.9.7. Flow Calibration ...................................................................................................................................132
5.9.8. Test Chan Output.................................................................................................................................132
5.9.8.1. Selecting a Test Channel Function for Output A4........................................................................133
5.10. SETUP ÆMORE ÆALRM (Option): Using the Gas Concentration Alarms...........................................134
5.10.1. Setting the GFC7001T Concentration Alarm Limits ..........................................................................135
6. COMMUNICATIONS SETUP AND OPERATION ............................................................. 137
6.1. Data Terminal/Communication Equipment (DTE DCE).............................................................................137
6.2. Communication Modes, Baud Rate and Port Testing ...................................................................................137
6.2.1. Communication Modes ........................................................................................................................137
6.2.2. COM Port Baud Rate...........................................................................................................................139
6.2.3. Com Port Testing .................................................................................................................................140
6.3. RS-232.......................................................................................................................................................141
6.4. RS-485 (Option).........................................................................................................................................142
6.5. Ethernet......................................................................................................................................................142
6.5.1. Configuring Ethernet Communication Manually (Static IP Address) ...................................................142
6.5.2. Configuring Ethernet Communication Using Dynamic Host Configuration Protocol (DHCP) .............144
6.5.3. Changing the Analyzer’s HOSTNAME ................................................................................................145
6.6. USB Port (Option) for Remote Access ......................................................................................................147
7. DATA ACQUISITION SYSTEM (DAS) AND APICOM...................................................... 151
7.1. DAS Structure ............................................................................................................................................152
7.1.1. DAS Data Channels.............................................................................................................................152
7.1.2. Default DAS Channels.........................................................................................................................153
7.1.3. Viewing DAS Channels and Individual Records..................................................................................156
7.1.4. Editing DAS Channels .........................................................................................................................157
7.1.4.1. Editing DAS Data Channel Names...............................................................................................158
7.1.5. Editing DAS Triggering Events ............................................................................................................159
7.1.6. Editing DAS Parameters......................................................................................................................160
7.1.7. Sample Period and Report Period .......................................................................................................163
7.1.8. Number of Records..............................................................................................................................165
7.1.9. RS-232 Report Function ......................................................................................................................166
7.1.9.1. The Compact Report Feature.......................................................................................................166
7.1.9.2. The Starting Date Feature............................................................................................................167
7.1.10. Disabling/Enabling Data Channels ....................................................................................................167
7.1.11. HOLDOFF Feature ............................................................................................................................168
7.2. Remote DAS Configuration........................................................................................................................169
7.2.1. DAS Configuration via APICOM ..........................................................................................................169
7.2.2. DAS Configuration Using Terminal Emulation Programs ....................................................................171
8. REMOTE OPERATION ..................................................................................................... 173
8.1. Computer Mode .........................................................................................................................................173
8.1.1. Remote Control via APICOM...............................................................................................................173
8.2. Interactive Mode ........................................................................................................................................173
8.2.1. Remote Control via a Terminal Emulation Program ............................................................................174
8.2.1.1. Help Commands in Interactive Mode ...........................................................................................174
8.2.1.2. Command Syntax.........................................................................................................................174
8.2.1.3. Data Types ...................................................................................................................................175
8.2.1.4. Status Reporting...........................................................................................................................176
8.2.1.5. General Message Format.............................................................................................................176
8.3. Remote Access by Modem........................................................................................................................176
8.4. Password Security for Serial Remote Communications............................................................................179
9. CALIBRATION PROCEDURES........................................................................................ 181
9.1. Calibration Preparations ............................................................................................................................181
9.1.1. Required Equipment, Supplies, and Expendables ..............................................................................181
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9.1.1.1. Zero Air.........................................................................................................................................182
9.1.1.2. Span Gas......................................................................................................................................182
9.1.1.3. Calibration Gas Standards and Traceability.................................................................................182
9.1.2. Data Recording Devices ......................................................................................................................183
9.2. Manual Calibration .....................................................................................................................................183
9.2.1. Setup for Basic Calibration Checks and Calibration............................................................................183
9.2.2. Performing a Basic Manual Calibration Check ....................................................................................185
9.2.3. Performing a Basic Manual Calibration ...............................................................................................186
9.2.3.1. Setting the Expected Span Gas Concentration............................................................................186
9.2.3.2. Zero/Span Point Calibration Procedure........................................................................................188
9.3. Manual Calibration with Zero/Span Valves................................................................................................189
9.3.1. Setup for Calibration Using Valve Options ..........................................................................................189
9.3.2. Manual Calibration Checks with Valve Options Installed ....................................................................192
9.3.3. Manual Calibration Using Valve Options .............................................................................................193
9.3.3.1. Setting the Expected Span Gas Concentration............................................................................193
9.3.3.2. Zero/Span Point Calibration Procedure........................................................................................194
9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure ...............................................................196
9.4. Automatic Zero/Span Cal/Check (AutoCal) ...............................................................................................196
9.4.1. SETUP ÆACAL: Programming and AUTO CAL Sequence...............................................................199
9.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected ...................................................201
9.5. CO Calibration Quality ...............................................................................................................................202
9.6. Calibration of the GFC7001T/GFC7001TM Electronic Subsystems .........................................................203
9.6.1. Dark Calibration Test ...........................................................................................................................203
9.6.2. Pressure Calibration ............................................................................................................................204
9.6.3. Flow Calibration ...................................................................................................................................205
9.7. Calibration of Optional Sensors .................................................................................................................206
9.7.1. O2Sensor Calibration ..........................................................................................................................206
9.7.1.1. O2 Pneumatics Connections........................................................................................................206
9.7.1.2. Set O2 Span Gas Concentration..................................................................................................206
9.7.1.3. Activate O2 Sensor Stability Function..........................................................................................208
9.7.1.4. O2 ZERO/SPAN CALIBRATION..................................................................................................209
9.7.2. CO2Sensor Calibration Procedure......................................................................................................210
9.7.2.1. CO2 Pneumatics Connections .....................................................................................................210
9.7.2.2. Set CO2 Span Gas Concentration: ..............................................................................................210
9.7.2.3. Activate CO2 Sensor Stability Function .......................................................................................212
9.7.2.4. CO2 Zero/Span Calibration ..........................................................................................................213
10. EPA CALIBRATION PROTOCOL .................................................................................. 215
10.1. Calibration Requirements ........................................................................................................................215
10.1.1. Calibration of Equipment - General Guidelines .................................................................................215
10.1.2. Calibration Equipment, Supplies, and Expendables..........................................................................216
10.1.2.1. Data Recording Device...............................................................................................................216
10.1.2.2. Spare Parts and Expendable Supplies.......................................................................................216
10.1.3. Recommended Standards for Establishing Traceability....................................................................217
10.1.4. Calibration Frequency........................................................................................................................218
10.1.5. Level 1 Calibrations versus Level 2 Checks......................................................................................218
10.2. ZERO and SPAN Checks........................................................................................................................219
10.2.1. Zero/Span Check Procedures ...........................................................................................................220
10.2.2. Precision Check .................................................................................................................................220
10.3. Precision Calibration................................................................................................................................221
10.3.1. Precision Calibration Procedures ......................................................................................................221
10.4. Auditing Procedure ..................................................................................................................................221
10.4.1. Calibration Audit.................................................................................................................................221
10.4.2. Data Reduction Audit.........................................................................................................................222
10.4.3. System Audit/Validation.....................................................................................................................222
10.5. Dynamic Multipoint Calibration Procedure ..............................................................................................222
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10.5.1. Linearity test.......................................................................................................................................222
10.6. References ..............................................................................................................................................224
PART III TECHNICAL INFORMATION ................................................................................ 225
11. MAINTENANCE SCHEDULE & PROCEDURES............................................................ 227
11.1. Maintenance Schedule ............................................................................................................................227
11.2. Predicting Failures Using the Test Functions..........................................................................................231
11.3. Maintenance Procedures.........................................................................................................................232
11.3.1. Replacing the Sample Particulate Filter.............................................................................................232
11.3.2. Performing Leak Checks....................................................................................................................233
11.3.2.1. Pressure Leak Check .................................................................................................................233
11.3.3. Performing a Sample Flow Check .....................................................................................................233
11.3.4. Cleaning the Optical Bench ...............................................................................................................234
11.3.5. Cleaning Exterior Surfaces of the GFC7001T/GFC7001TM .............................................................234
12. TROUBLESHOOTING AND SERVICE........................................................................... 235
12.1. General Troubleshooting .........................................................................................................................235
12.1.1. Fault Diagnosis with WARNING Messages.......................................................................................236
12.1.2. Fault Diagnosis with TEST Functions................................................................................................239
12.1.3. the Diagnostic Signal I/O Function ....................................................................................................241
12.1.4. Status LEDs .......................................................................................................................................242
12.1.4.1. Motherboard Status Indicator (Watchdog) .................................................................................243
12.1.4.2. Sync Demodulator Status LEDs.................................................................................................244
12.1.4.3. Relay Board Status LEDs...........................................................................................................245
12.2. Gas Flow Problems .................................................................................................................................247
12.2.1. GFC7001T/GFC7001TM Internal Gas Flow Diagrams .....................................................................248
12.2.2. Typical Sample Gas Flow Problems..................................................................................................251
12.2.2.1. Flow is Zero ................................................................................................................................251
12.2.2.2. Low Flow ....................................................................................................................................251
12.2.2.3. High Flow....................................................................................................................................252
12.2.2.4. Displayed Flow = “Warnings” .....................................................................................................252
12.2.2.5. Actual Flow Does Not Match Displayed Flow ............................................................................252
12.3. Calibration Problems ...............................................................................................................................252
12.3.1. Miscalibrated......................................................................................................................................252
12.3.2. Non-Repeatable Zero and Span........................................................................................................253
12.3.3. Inability to Span – No SPAN Button (CALS)......................................................................................253
12.3.4. Inability to Zero – No ZERO Button (CALZ).......................................................................................253
12.4. Other Performance Problems..................................................................................................................254
12.4.1. Temperature Problems ......................................................................................................................254
12.4.1.1. Box or Sample Temperature ......................................................................................................254
12.4.1.2. Bench Temperature....................................................................................................................254
12.4.1.3. GFC Wheel Temperature ...........................................................................................................255
12.4.1.4. IR Photo-Detector TEC Temperature.........................................................................................255
12.4.2. Excessive Noise.................................................................................................................................256
12.5. Subsystem Checkout...............................................................................................................................257
12.5.1. AC Mains Configuration.....................................................................................................................257
12.5.2. DC Power Supply...............................................................................................................................257
12.5.3. I2C Bus ...............................................................................................................................................258
12.5.4. Touchscreen Interface .......................................................................................................................258
12.5.5. LCD Display Module ..........................................................................................................................258
12.5.6. Relay Board .......................................................................................................................................258
12.5.7. Sensor Assembly ...............................................................................................................................259
12.5.7.1. Sync/Demodulator Assembly .....................................................................................................259
12.5.7.2. Electrical Test .............................................................................................................................260
12.5.7.3. Opto Pickup Assembly ...............................................................................................................260
12.5.7.4. GFC Wheel Drive .......................................................................................................................260
12.5.7.5. IR Source....................................................................................................................................261
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12.5.7.6. Pressure/Flow Sensor Assembly ...............................................................................................261
12.5.8. Motherboard.......................................................................................................................................262
12.5.8.1. A/D Functions .............................................................................................................................262
12.5.8.2. Test Channel / Analog Outputs Voltage.....................................................................................262
12.5.8.3. Analog Outputs: Current Loop....................................................................................................264
12.5.8.4. Status Outputs............................................................................................................................264
12.5.8.5. Control Inputs – Remote Zero, Span..........................................................................................265
12.5.9. CPU....................................................................................................................................................265
12.5.10. RS-232 Communications.................................................................................................................265
12.5.10.1. General RS-232 Troubleshooting.............................................................................................265
12.5.10.2. Troubleshooting Analyzer/Modem or Terminal Operation .......................................................266
12.5.11. The Optional CO2Sensor ................................................................................................................266
12.6. Repair Procedures...................................................................................................................................267
12.6.1. Repairing Sample Flow Control Assembly ........................................................................................267
12.6.2. Removing/Replacing the GFC Wheel................................................................................................268
12.6.3. Checking and Adjusting the Sync/Demodulator, Circuit Gain (CO MEAS) ......................................270
12.6.3.1. Checking the Sync/Demodulator Circuit Gain............................................................................270
12.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain ...........................................................................271
12.6.4. Disk-On-Module Replacement...........................................................................................................272
12.7. Frequently Asked Questions ...................................................................................................................273
12.8. Technical Assistance...............................................................................................................................274
13. THEORY OF OPERATION.............................................................................................. 275
13.1. Measurement Method..............................................................................................................................275
13.1.1. Beer’s Law .........................................................................................................................................275
13.2. Measurement Fundamentals...................................................................................................................276
13.2.1. Gas Filter Correlation.........................................................................................................................277
13.2.1.1. The GFC Wheel..........................................................................................................................277
13.2.1.2. The Measure Reference Ratio ...................................................................................................278
13.2.1.3. Summary Interference Rejection................................................................................................280
13.3. Flow Rate Control....................................................................................................................................281
13.3.1.1. Critical Flow Orifice.....................................................................................................................281
13.3.2. Particulate Filter .................................................................................................................................282
13.3.3. Pneumatic Sensors............................................................................................................................283
13.3.3.1. Sample Pressure Sensor ...........................................................................................................283
13.3.3.2. Sample Flow Sensor ..................................................................................................................283
13.4. Electronic Operation ................................................................................................................................283
13.4.1. CPU....................................................................................................................................................285
13.4.1.1. Disk-On-Module (DOM)..............................................................................................................285
13.4.1.2. Flash Chip ..................................................................................................................................285
13.4.2. Optical Bench & GFC Wheel .............................................................................................................286
13.4.2.1. Temperature Control ..................................................................................................................286
13.4.2.2. IR Source....................................................................................................................................286
13.4.2.3. GFC Wheel.................................................................................................................................286
13.4.2.4. IR Photo-Detector.......................................................................................................................288
13.4.3. Synchronous Demodulator (Sync/Demod) Assembly .......................................................................288
13.4.3.1. Signal Synchronization and Demodulation ................................................................................289
13.4.3.2. Sync/Demod Status LEDs..........................................................................................................290
13.4.3.3. Photo-Detector Temperature Control .........................................................................................290
13.4.3.4. Dark Calibration Switch ..............................................................................................................291
13.4.3.5. Electric Test Switch ....................................................................................................................291
13.4.4. Relay Board .......................................................................................................................................291
13.4.4.1. Heater Control ............................................................................................................................291
13.4.4.2. GFC Wheel Motor Control..........................................................................................................291
13.4.4.3. Zero/Span Valve Options ...........................................................................................................292
13.4.4.4. IR Source....................................................................................................................................292
13.4.4.5. Status LEDs................................................................................................................................292
Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
Teledyne Analytical Instruments xiii
13.4.4.6. I2C Watch Dog Circuitry.............................................................................................................293
13.4.5. MotherBoard ......................................................................................................................................293
13.4.5.1. A to D Conversion ......................................................................................................................293
13.4.5.2. Sensor Inputs .............................................................................................................................294
13.4.5.3. Thermistor Interface ...................................................................................................................294
13.4.5.4. Analog Outputs...........................................................................................................................295
13.4.5.5. Internal Digital I/O.......................................................................................................................295
13.4.5.6. External Digital I/O......................................................................................................................295
13.4.6. I2C Data Bus ......................................................................................................................................295
13.4.7. Power Supply/ Circuit Breaker...........................................................................................................296
13.4.8. Front Panel Touchscreen/Display Interface.......................................................................................298
13.4.8.1. LVDS Transmitter Board ............................................................................................................298
13.4.8.2. Front Panel Touchscreen/Display Interface PCA.......................................................................298
13.5. Software Operation..................................................................................................................................299
13.5.1. Adaptive Filter ....................................................................................................................................299
13.5.2. Calibration - Slope and Offset............................................................................................................300
13.5.3. Measurement Algorithm.....................................................................................................................300
13.5.4. Temperature and Pressure Compensation........................................................................................300
13.5.5. Internal Data Acquisition System (DAS) ............................................................................................300
14. A PRIMER ON ELECTRO-STATIC DISCHARGE .......................................................... 301
14.1. How Static Charges are Created.............................................................................................................301
14.2. How Electro-Static Charges Cause Damage ..........................................................................................302
14.3. Common Myths About ESD Damage......................................................................................................303
14.4. Basic Principles of Static Control.............................................................................................................304
14.4.1. General Rules ....................................................................................................................................304
14.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ..................................................305
14.4.2.1. Working at the Instrument Rack .................................................................................................306
14.4.2.2. Working at an Anti-ESD Work Bench.........................................................................................306
14.4.2.3. Transferring Components from Rack to Bench and Back..........................................................306
14.4.2.4. Opening Shipments from Teledyne Customer Service..............................................................307
14.4.2.5. Packing Components for Return to Teledyne Customer Service ..............................................308
GLOSSARY 309
LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION
APPENDIX B - GFC7001T/GFC7001TM SPARE PARTS LIST
APPENDIX C - REPAIR QUESTIONNAIRE - GFC7001T
APPENDIX D - SCHEMATICS
LIST OF FIGURES
Figure 3-1:Front Panel Layout.......................................................................................................................33
Figure 3-2:Display Screen and Touch Control ..............................................................................................34
Figure 3-3:Display/Touch Control Screen Mapped to Menu Charts .............................................................36
Figure 3-4:Rear Panel Layout .......................................................................................................................37
Figure 3-5:Internal Layout – GFC7001T .......................................................................................................39
Figure 3-6:Internal Layout – GFC7001TM ....................................................................................................40
Figure 3-7:Optical Bench Layout (shorter bench, GFC7001TM, shown)......................................................41
Figure 3-8:Analog In Connector ....................................................................................................................43
Figure 3-9:Analog Output Connector ............................................................................................................44
Figure 3-10:Current Loop Option Installed on Motherboard ...........................................................................45
Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
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Figure 3-11:Status Output Connector .............................................................................................................46
Figure 3-12:Control Input Connector...............................................................................................................48
Figure 3-13:Concentration Alarm Relay..........................................................................................................49
Figure 3-14:Rear Panel Connector Pin-Outs for RS-232 Mode......................................................................52
Figure 3-15:Default Pin Assignments for CPU COM Port connector (RS-232) ..............................................53
Figure 3-16:Jumper and Cables for Multidrop Mode.......................................................................................55
Figure 3-17:RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram .....................................................56
Figure 3-18:Pneumatic Connections–Basic Configuration–Using Bottled Span Gas.....................................59
Figure 3-19:Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator.............................59
Figure 3-20:GFC7001T/GFC7001TM Internal Gas Flow................................................................................60
Figure 3-21:Pneumatic Connections – Option 50A: Zero/Span Calibration Valves........................................61
Figure 3-22Internal Pneumatic Flow OPT 50A – Zero/Span Valves..............................................................62
Figure 3-24:Internal Pneumatic Flow – Zero/Span/Shutoff Valves (Opt 50B) ................................................63
Figure 3-25:Pneumatic Connections – Zero Scrubber/Pressurized Span Calibration Valves (Opt 50E) .......64
Figure 3-26:Internal Pneumatic Flow Zero Scrubber/Pressurized Span Calibration Valves (Opt 50E)..........66
Figure 3-27:Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .......................................67
Figure 3-28:Internal Pneumatic Flow OPT 50H – Zero Scrubber/Ambient Span ...........................................68
Figure 3-29:Zero/Span Calibration Procedure ................................................................................................78
Figure 4-1:Front Panel Display......................................................................................................................83
Figure 4-2:Viewing GFC7001T/GFC7001TM Test Functions.......................................................................85
Figure 4-3:Viewing and Clearing GFC7001T/GFC7001TM WARNING Messages ......................................88
Figure 5-1:Analog Output Connector Pin Out ...............................................................................................93
Figure 5-2:COMM– Machine ID ..................................................................................................................108
Figure 5-3:Accessing the Analog I/O Configuration Submenus..................................................................116
Figure 5-4:Setup for Checking / Calibrating DCV Analog Output Signal Levels.........................................123
Figure 5-5:Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter..................125
Figure 5-6:Alternative Setup Using 250ΩResistor for Checking Current Output Signal Levels ................127
Figure 5-7.DIAG – Analog Inputs (Option) Configuration Menu .................................................................131
Figure 6-1:COM1[2] – Communication Modes Setup .................................................................................139
Figure 6-2:COMM Port Baud Rate..............................................................................................................140
Figure 6-3:COMM – COM1 Test Port..........................................................................................................141
Figure 6-4:COMM – LAN / Internet Manual Configuration..........................................................................144
Figure 6-5 :COMM – LAN / Internet Automatic Configuration (DHCP) ........................................................145
Figure 7-1:Default DAS Channel Setup ......................................................................................................155
Figure 7-2:APICOM Remote Control Program Interface.............................................................................169
Figure 7-3:APICOM User Interface for Configuring the DAS......................................................................170
Figure 7-4:DAS Configuration Through a Terminal Emulation Program.....................................................171
Figure 9-1:Pneumatic Connections – Basic Configuration – Using Bottled Span Gas...............................184
Figure 9-2:Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator.......................184
Figure 9-3:Pneumatic Connections – Option 50A: Ambient Zero/Ambient Span Calibration Valves .........189
Figure 9-4:Pneumatic Connections – Option 50B: Ambient Zero/Pressurized Span Calibration Valves ...190
Figure 9-5:Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .....................................190
Figure 9-6:Pneumatic Connections – Option 50E: Zero/Span Calibration Valves......................................191
Figure 9-7:O2Sensor Calibration Set Up ....................................................................................................206
Figure 9-8:CO2Sensor Calibration Set Up..................................................................................................210
Figure 11-1:Sample Particulate Filter Assembly ...........................................................................................232
Figure 12-1:Viewing and Clearing Warning Messages.................................................................................238
Figure 12-2:Example of Signal I/O Function .................................................................................................242
Figure 12-3:CPU Status Indicator .................................................................................................................243
Figure 12-4:Sync/Demod Board Status LED Locations................................................................................244
Figure 12-5:Relay Board Status LEDs ..........................................................................................................245
Figure 12-6:GFC7001T/GFC7001TM – Basic Internal Gas Flow .................................................................248
Figure 12-7:Internal Pneumatic Flow OPT 50A – Zero/Span Valves (OPT 50A & 50B) ..............................248
Figure 12-8:Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves ..............................................249
Figure 12-9:Internal Pneumatic Flow OPT 50H – Zero/Span Valves with Internal Zero Air Scrubber .........249
Figure 12-10:Internal Pneumatic Flow OPT 50E – Zero/Span/Shutoff w/ Internal Zero Air Scrubber............250
Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
Teledyne Analytical Instruments xv
Figure 12-11:GFC7001T/GFC7001TM – Internal Pneumatics with O2Sensor Option 65A ...........................250
Figure 12-12:GFC7001T/GFC7001TM – Internal Pneumatics with CO2Sensor Option 67A ........................251
Figure 12-13:Location of Diagnostic LEDs onCO2Sensor PCA.....................................................................266
Figure 12-14:Critical Flow Restrictor Assembly/Disassembly.........................................................................267
Figure 12-15:Opening the GFC Wheel Housing .............................................................................................268
Figure 12-16:Removing the Opto-Pickup Assembly .......................................................................................269
Figure 12-17:Removing the GFC Wheel Housing...........................................................................................269
Figure 12-18:Removing the GFC Wheel.........................................................................................................270
Figure 12-19:Location of Sync/Demod Housing Mounting Screws.................................................................271
Figure 12-20:Location of Sync/Demod Gain Potentiometer............................................................................271
Figure 13-1:Measurement Fundamentals .....................................................................................................277
Figure 13-2:GFC Wheel ................................................................................................................................277
Figure 13-3:Measurement Fundamentals with GFC Wheel..........................................................................278
Figure 13-4:Affect of CO in the Sample on CO MEAS & CO REF ...............................................................279
Figure 13-5:Effects of Interfering Gas on CO MEAS & CO REF ..................................................................280
Figure 13-6:Chopped IR Signal.....................................................................................................................280
Figure 13-7:Internal Pneumatic Flow – Basic Configuration ........................................................................281
Figure 13-8:Flow Control Assembly & Critical Flow Orifice...........................................................................282
Figure 13-9:Electronic Block Diagram...........................................................................................................284
Figure 13-10.CPU Board.................................................................................................................................285
Figure 13-11:GFC Light Mask .........................................................................................................................287
Figure 13-12:Segment Sensor and M/R Sensor Output .................................................................................288
Figure 13-13:GFC7001T/GFC7001TM Sync/Demod Block Diagram .............................................................289
Figure 13-14:Sample & Hold Timing ...............................................................................................................290
Figure 13-15:Location of relay board Status LEDs .........................................................................................293
Figure 13-16:Power Distribution Block Diagram .............................................................................................297
Figure 13-17:Front Panel and Display Interface Block Diagram.....................................................................298
Figure 13-18:Basic Software Operation ..........................................................................................................299
Figure 14-1:Triboelectric Charging................................................................................................................301
Figure 14-2:Basic anti-ESD Workbench........................................................................................................304
Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
Teledyne Analytical Instruments xvi
LIST OF TABLES
Table 1-1:Analyzer Options..........................................................................................................................23
Table 2-1:GFC7001T/GFC7001TM Basic Unit Specifications.....................................................................27
Table 2-2:O2Sensor Option Specifications..................................................................................................28
Table 2-3:CO2Sensor Option Specifications...............................................................................................28
Table 3-1:Ventilation Clearance...................................................................................................................32
Table 3-2:Display Screen and Touch Control Description...........................................................................35
Table 3-3:Rear Panel Description................................................................................................................38
Table 3-4:Analog Input Pin Assignments.....................................................................................................43
Table 3-5:Analog Output Pin-Outs...............................................................................................................44
Table 3-6:Status Output Signals ..................................................................................................................47
Table 3-7:Control Input Signals....................................................................................................................48
Table 3-8:Zero/Span Valve Operating States for Option 50A......................................................................63
Table 3-9:Zero/Span Valve Operating States for Option 50B......................................................................64
Table 3-10:Zero/Span Valve Operating States for Option 50E......................................................................66
Table 3-11:Zero/Span Valve Operating States for Option 50H .....................................................................68
Table 3-12:NIST-SRM's Available for Traceability of CO Calibration Gases..................................................69
Table 3-13:Possible Warning Messages at Start-Up.....................................................................................71
Table 3-14:Possible Startup Warning Messages – GFC7001T Analyzers with Options ...............................72
Table 4-1:Analyzer Operating Modes ..........................................................................................................84
Table 4-2:Test Functions Defined................................................................................................................85
Table 4-3:List of Warning Messages............................................................................................................86
Table 4-4:Primary Setup Mode Features and Functions .............................................................................89
Table 4-5:Secondary Setup Mode (SETUP>MORE) Features and Functions............................................90
Table 5-1:GFC7001T Family Physical Range by Model..............................................................................94
Table 5-2:Password Levels........................................................................................................................103
Table 5-3:Variable Names (VARS) ............................................................................................................109
Table 5-4:Diagnostic Mode (DIAG) Functions ...........................................................................................111
Table 5-5:DIAG - Analog I/O Functions .....................................................................................................115
Table 5-6:Analog Output Voltage Ranges .................................................................................................117
Table 5-7:Voltage Tolerances for the TEST CHANNEL Calibration..........................................................123
Table 5-8:Current Loop Output Check.......................................................................................................127
Table 5-9:Test Channels Functions available on the GFC7001T/GFC7001TM’s Analog Output .............133
Table 5-10:CO Concentration Alarm Default Settings .................................................................................135
Table 6-1:COMM Port Communication Modes ..........................................................................................138
Table 6-2:Ethernet Status Indicators..........................................................................................................142
Table 6-3:LAN/Internet Default Configuration Properties ..........................................................................143
Table 7-1:Front Panel LED Status Indicators for DAS...............................................................................151
Table 7-2:DAS Data Channel Properties ...................................................................................................153
Table 7-3:DAS Data Parameter Functions ................................................................................................161
Table 8-1:Interactive Mode Software Commands......................................................................................174
Table 8-2:Teledyne’s Serial I/O Command Types.....................................................................................175
Table 9-1:NIST-SRMs Available for Traceability of CO Calibration Gases ................................................182
Table 9-2:AUTOCAL Modes ......................................................................................................................196
Table 9-3:AutoCal Attribute Setup Parameters..........................................................................................197
Table 9-4:Example AutoCal Sequence......................................................................................................198
Table 9-5:Calibration Data Quality Evaluation ...........................................................................................202
Table 10-1:Matrix for Calibration Equipment & Supplies .............................................................................217
Table 10-2:Activity Matrix for Quality Assurance Checks ............................................................................218
Table 10-3:Definition of Level 1 and Level 2 Zero and Span Checks..........................................................219
Table 11-1:GFC7001T/GFC7001TM Maintenance Schedule .....................................................................229
Table 11-2:GFC7001T/GFC7001TM Test Function Record........................................................................230
Table 11-3:Predictive uses for Test Functions.............................................................................................231
Table 12-1:Warning Messages - Indicated Failures ....................................................................................238
Table 12-2:Test Functions - Indicated Failures............................................................................................240
Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
Teledyne Analytical Instruments xvii
Table 12-3:Sync/Demod Board Status Failure Indications ..........................................................................244
Table 12-4:I2C Status LED Failure Indications.............................................................................................245
Table 12-5:Relay Board Status LED Failure Indications..............................................................................246
Table 12-6:DC Power Test Point and Wiring Color Codes..........................................................................257
Table 12-7:DC Power Supply Acceptable Levels ........................................................................................258
Table 12-8:Relay Board Control Devices.....................................................................................................259
Table 12-9:Opto Pickup Board Nominal Output Frequencies......................................................................260
Table 12-10:Analog Output Test Function - Nominal Values Voltage Outputs .............................................263
Table 12-11:Analog Output Test Function - Nominal Values Voltage Outputs .............................................264
Table 12-12:Status Outputs Check................................................................................................................264
Table 13-1:Absorption Path Lengths for GFC7001T and GFC7001TM ......................................................276
Table 13-2:Sync DEMOD Sample and Hold Circuits...................................................................................290
Table 13-3:Sync/Demod Status LED Activity...............................................................................................290
Table 13-4:Relay Board Status LEDs ..........................................................................................................292
Table 14-1:Static Generation Voltages for Typical Activities .......................................................................302
Table 14-2:Sensitivity of Electronic Devices to Damage by ESD ................................................................302
Table of ContentsTeledyne API – Model T300/T300M CO Analyzer
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Part I General Information Teledyne API – Model T300/T300M CO Analyzer
Teledyne Analytical Instruments xix
PART I
GENERAL INFORMATION
Part I General Information Teledyne API – Model T300/T300M CO Analyzer
Teledyne Analytical Instruments xx
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