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Teledyne GFC7000E User's Manual

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1. 120 6 13 2 6 Remote Access by Modem esee dees etd sat nd RAN 120 6 13 2 7 COM Port Password 5 aieri as teres inr te eee Na HR e 122 6 13 2 8 APICOM Remote Control eene 122 6 13 3 Additional Communications 22 22 2422 2 2 244 2 4 4 123 6 13 4 Using the MGFC7000E with Hessen Protocol 123 6 13 4 1 General Overview of Hessen ERE RER ELLER ERR 123 6 13 4 2 Hessen COMM Port Configuration 4 12 6 6 124 6 13 4 3 Activating Hessen Protocol 1 E A 1 menie sensisse esee een 124 6 13 4 4 Selecting a Hessen Protocol Type 2 2 2211 mee semester ens 125 6 13 4 5 Setting The Hessen Protocol Response 126 6 13 4 6 Hessen Protocol Gas ID Renee rr lida pe ERREUR NR RR RAN RR 126 6 13 4 7 Setting Hessen Protocol Status Flags menm 127 6 13 4 8 Instr ment ID Code
2. 54 04584 Rev A1 ii Model GFC7000E Instruction Manual GFC7000E Documentation 6 7 SETUP RNGE Analog Output Reporting Range Configuration sess 56 6 7 1 Physical Range versus Analog Output Reporting 56 6 7 2 Reporting Range Modes ede E npa sa Ee aaa E date a ER e ua FR Ries 57 6 7 3 Single Range mode SNGL 58 6 7 4 Dual Range Mode DUAL eee cpa vey dite trt tes ua proe eo gan Du sw er ep VU 60 6 7 5 Auto Range Mode AUTO Rite eoa da iu per tigre 61 6 7 6 Rarige Units rre teu evenerit tiny vei ER HE EN 62 6 7 7 Dil tioti Ratio iiid retener ena ea Exe ae gd FEE I RE ead dalek dou aaa hea A DARK n Pe 63 6 8 SETUP VARS Using the Internal tt REE ERE REEL ERE SEERE 64 6 9 SETUP DIAG Using the Diagnostics 1 ERE REE RE esee 66 6 9 1 Accessing the Diagnostic Features nun randa stris A kan nena 67 6 9 2 Signal OU
3. 15 3 1 2 1 Basic Pneumatic Connections 2 ren Gti daly a al rir Ro AMAA ER ERU 15 3 1 2 2 Connections with Internal Valve Options 0 19 3 2 Initial Operations cioe deed seu e Pia atte aged M ER MEE 21 3i2sT c5tartupsiis cease sedens adnate cess 22 22222 Warm Ups eterne vete gcc DE UP ien DIE LE 0 23 3 2 3 Warring Messages o cor er ree terere Puer ao Dues 24 3 2 4 Functional Che kaa cases cone SPESE ETIN EIN SERVA SERM ek dant tu KEIRA RARI 25 3 3 initial Calibration Proced re rii ix t ar e en ux mie ea KORR DENT RON fied 26 4 FREQUENTLY ASKED QUESTI 5 33 LATO 33 42 GIOSSANY saree T ES 34 5 OPTIONAL HARDWARE AND SOFTWARE 37 5 1 Rack Mount Kits Options 20a 20b amp 210 110051 37 5 2 Current Loop Analog Outputs Option 41 37 5 3 Expendable Kits Options 42C 42D and 43 eee 38 5 4 Calib
4. 1 nnn 52 Secondary Setup Mode Features and Functions 52 Variable Names VARS Revision 4 6 6 nnns 64 GFC7000E Diagnostic DIAG 11 66 DIAG Analog I O a nina 69 Analog Output Voltage 0060 69 Analog Output Current Loop 5002 mense 70 Analog Output Pin semen meses nenne 70 Voltage Tolerances for Analog Output Calibration 73 Current Loop Output Calibration with Resistor 2 111 mmm 76 Test Parameters Available for Analog Output 81 COM1 and COM2 DB 9 Pin 85 COMM Port Communication 4 1 4 2 86 Ethernet Status Indicators correo od trea erp da 89 LAN Internet Configuration 1 6 6 66 90 Internet Configuration Key
5. 4 4 4 24 44 95 6 12 SETUP DAS Using the Data Acquisition System 5 0 96 6 12 1 T Y 96 6 1 2 1 4 5 e eei aleae exe Rex e nat EM REN ane 97 6 12 12 IDAS Parameters eset eter Eng ER E IR UAR HE RW es SURREY YRERURKtRRR XAR IR Te REN ER RR 98 6 12 13 IDAS Triggering Events oe Ene RR D Rea E LR ERR EI EIE RM QE eA DM ME ERR ant 98 6 12 2 Default iDAS Channels eere teneceaedaacdaiaed seve ted onan ced EEEN Sis KAU castes acd Broe EDR 99 6 12 2 1 Viewing iDAS Data and 05 1111 enne 103 6 12 2 2 Editing IDAS Data Channels Eee xe era rax ennt cerae 104 6 12 2 3 Trigger Events ie ioter iR Re Ra AR eroi RR XR ES A ARA X EE EU ERN AE 105 6 12 2 4 Editing IDAS Parameters supe iesu npa RR raa ER based tea 106 6 12 2 5 Sample Period and Report 2 meses 107 6 12 2 6 Number of Records ueste e ites erae ond e ta erae ra des oak 109 6 12 2 7 RS 232 Report F nctioniu iei eate m ER x Ie n FERAI D Ada ie DUREE ER EE dE 110 6 12 2 8 Compact RepOFt ies oret vy dete De e a
6. 1 23 Possible Warning Messages at 54 2 1 1 1 4 24 Zero Span Valve Operating States for Options 50 amp 51 38 Zero Span Valve Operating States for Options 52 amp 53 40 Analyzer Operating 2 66 6 anna sena sea ana nnn nn 46 04584 Rev A1 viii Model GFC7000E Instruction Manual GFC7000E Documentation Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 6 6 Table 6 7 Table 6 8 Table 6 9 Table 6 10 Table 6 11 Table 6 12 Table 6 13 Table 6 14 Table 6 15 Table 6 16 Table 6 17 Table 6 18 Table 6 19 Table 6 20 Table 6 21 Table 6 22 Table 6 23 Table 6 24 Table 6 25 Table 6 26 Table 6 27 Table 6 28 Table 6 29 Table 6 30 Table 6 31 Table 7 1 Table 7 2 Table 7 3 Table 9 1 Table 9 2 Table 9 3 Table 10 1 Table 10 2 Table 10 3 Table 11 1 Table 11 2 Table 11 3 Table 11 4 Table 11 5 Table 11 6 Table 11 7 Table 11 8 Table 11 9 Table 11 10 Table 11 11 Table 11 12 Table 12 1 Table 12 2 Table A 1 Test F nctions Defined 46 List of Warning Messages Ger bi gne a Fo 49 Primary Setup Mode Features and
7. DER ED Rao 128 7 CALIBRATION 129 7 1 Before Calibration ad chine irr ek EDI EORR a aha veined T RE ax sS Reve 129 7 1 1 Zero Air and Span GAS vances c epe ve eh aeta exit ipa bebe sient Pe REA Fuge 129 71 2 Calibration G s Traceability earem a ate eai ne e dette p e e x pede xr Pe Ede 130 7 1 3 Data Recording DEVICES ree eene n Subd at eat mre PER RR SR zi pets 130 7 2 Manual Calibration without Zero Span Valves esee nemen enne 130 7 3 Manual Calibration Checks den rh rans es RARE RR SR RR ised 133 7 4 Manual Calibration with Zero Span 2 1 1 6 nnn 133 7 5 Manual Calibration Checks with Zero Span Valves 1 enne 137 7 5 1 Zero Span Calibration on Auto Range or Dual 137 7 5 2 Use of Zero Span Valves with Remote Contact Er 138 7 6 Automatic Zero Span Cal Check 0 1 011 nennen 139
8. ID HESSEN COM1 COM2 SET SET gt EDIT VARIATION RESPONSE MODE GAS LIST STATUS FLAGS SET gt EDIT TYPE 1 CMD MODE BAUD RATE TEST PORT CO2 310 REPORTED PREV NEXT PREV NEXT TEST PREV NEXT INS DEL EDIT PRNT 300 SAMPLE FLOW WARNING BENCH TEMP WARNI NG QUIEF 1200 SOURCE WARNI NG COMPUTER 2400 BOX TEMP WARNI NG SECURITY 4800 WHEEL TEMP WARNING HESSEN PROTOCOL 9600 SAMPLE TEMP WARNING COM 1 2 7 1 19200 SAMPLE PRESSURE WARNING RS 485 38400 INVALID CONC MULTI DROP 57760 INSTRUMENT OFF ENABLE MODEM 115200 IN MANUAL CALI BRATI ON MODE IN ZERO CALI BRATI ON MODE ENABLE INTERNET IGNORE ERRORS 1 4 es Only appears if a valve is installed IN SPAN CALI BRATI ON DISABLE XON Only appears when the HESSEN MGM COMMAND PROMPT mode is enabled for either COM1 See Table 6 27 for PPB or COM2 Flag Assignments PPM ON OFF Figure A 7 Secondary Setup Menu COMM Menu with HESSEN 045840110 Rev B 3 229 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SETUP 1 ENTER SETUP PASS 818 CFG DAS RNGE PASS CLK MORE DI AG COMM VARS PREV NEXT SIGNAL ANALOG ANALOG 1 ELECTRI CAL DARK PRESSURE FLOW TEST 1 0 OUTPUT CONFIGURATION TEST CALIBRATION CALIBRATION CALIBRATION CHANNE
9. Pressing EXIT from any of the above display menus causes the Ethernet option to reinitialize its internal interface INITIALIZING INET 0 firmware med INITIALIZING INET 100 INITIALIZATION SUCCEEDED INITIALIZATION FAILED Teledyne Instruments Customer Service personnel SETUP X X COMMUNICATIONS MENU Contact your IT Network Administrator ID INET 04584 Rev Al 93 Model GFC7000E Instruction Manual Operating Instructions 6 10 9 4 Changing the Analyzer s HOSTNAME The HOSTNAME is the name by which the analyzer appears on your network The default name for all Teledyne Instruments Model GFC7000E analyzers is MGFC7000E To change this name particularly if you have more than one Model GFC7000E analyzer on your network press Y SAMPLE RANGE 500 000 PPM CO2 DHCP ON lt TST TST gt CAL SETUP SAMPLE ENTER SET 4 Continue pressing SET UNTIL SETUP PRI MARY SETUP MENU HOSTNAME M360E CFG DAS RNGE PASS CLK MORE EXIT EDIT SETUP SECONDARY SETUP MENU HOSTNAME M 360E COMM EXIT CH CH INS DEL ENTR EXIT SETUP X X COMMUNI CATI ONS MENU HOSTNAME M360E FI ELD1 ID INET EXIT EXIT 6 INITIALIZING INET 0 2 INITIALIZING INET 100 INITIALIZATION SUCCEEDED INITIALIZATION FAILED SETUP X X COMMUNICATIONS MENU
10. eate rare Dese Eripe pr e ERR RE EIE RE 205 11 4 7 5 Control Inputs Remote Zero 1 205 11 48 TRIER 206 14 429 RS 232 COMMUNICATIONS SENE SX SE 206 11 4 9 1 General RS 232 Troubleshooting a 206 11 4 9 2 Troubleshooting Analyzer Modem or Terminal 207 11 5 Repair Procedures o oett eee te ERU IOS e cR cR EDU RR ay Ra bera E RES TENTE ERE 207 11 5 1 Repairing Sample Flow Control Assembly 1 1 RE TEE REELT REE 207 11 5 2 Removing Replacing the Wheel using rer eee eee mem ies isindi r menie esee enne 209 11 5 3 Disk On Chip Replacement 210 12 PRIMER ELECTRO STATI 5 213 12 1 How Static Charges are 2 2 eren I 213 12 2 How Electro Static Charges Cause Damage 1 0 214 12 3 Common Myths About ESD Damage 4 1 44441
11. strange 200 IBN ILI T uH 200 11 4 4 Keyboard Display 1 3 1 1 2 2 1 1 esee senis esiste seems 201 11 4 5 Relay Board aiii ape sso re c Du te ces 201 11 4 6 Sensor Assembly 202 11 4 6 1 Sync Demodulator Assembly 202 11 4 6 2 eee 202 11 4 6 3 GFEW heel Drivers RR PUER HEURE RES DEN 203 O 4 IR SOURCE ottenere te al a dae 203 11 4 6 5 Pressure Flow Sensor Assembly pa Ran Pana goa RR RR d Rn 203 11 4 7 Motherboard eite kie dat bie iran 204 11 4 7 1 A D FUNGON S i vedas sin la Rx 204 11 4 7 2 Analog Outputs Voltage entiers raa AAE 204 11 4 7 3 Analog Qutp ts CUFFENE 204 11 4 7 4 Status Outputs
12. CFG DAS RNGE PASS CLK MORE EXIT SET SET gt EXIT SETUP X X SECONDARY SETUP MENU SUBNET MASK 0 0 0 0 COMM EXIT SET SET gt EXIT SETUP X X COMMUNI CATI ONS MENU INET SET SET gt From this point on EXIT returns to COMMUNICATIONS MENU HOSTNAME M360E Don not alter unless directed to by Teledyne Instruments Customer Service personnel 04584 Rev A1 91 Model GFC7000E Instruction Manual Operating Instructions 6 10 9 3 Manually Configuring the Network IP Addresses There are several circumstances when you may need to manually configure the interface settings of the analyzer s Ethernet card The INET sub menu may also be used to edit the Ethernet card s configuration properties e Your LAN is not running a DHCP software package e The DHCP software is unable to initialize the analyzer s interface e You wish to program the interface with a specific set of IP addresses that may not be the ones automatically chosen by DHCP Editing the Ethernet Interface properties is a two step process STEP 1 Turn DHCP OFF While DHCP is turned ON the ability to manually set INSTRUMENT IP GATEWAY IP and SUBNET MASK is disabled SAMPLE RANGE 500 000 PPM 2 SETUP X X COMMUNICATIONS MENU lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 DHCP ON 8 1 8 ENTR EDIT SETUP X X PRI MARY SETUP MENU DHCP ON CFG DAS RNGE PASS CLK MORE EXIT
13. SET SET EDIT PRINT ENTR accepts the new string and returns to the previous menu EXIT ignores the new string and returns to the previous menu NAME CONC SETUP X X N ENTR EXIT Press each key repeatedly to cycle through the available character set 0 9 A Z space 9 96 amp lt gt 2 6 12 2 3 Trigger Events To edit the list of data parameters associated with a specific data channel press From the DATA ACQUISITION menu see Section 6 12 2 2 Edit Data Channel Menu SETUP X X 0 CONC ATIMER 1 900 Exits to the Main Data Acquisition menu INS DEL EDIT y NAME CONC PREV NEXT SETUP X X SET SET EDIT PRINT SETUP SET SET gt EDIT PRINT ENTR accepts the new string and returns to the previous menu EXIT ignores the new string and returns to the previous menu SETUP PREV gt EXIT Press each key repeatedly to cycle through the list of available trigger events 04584 Rev A1 105 Model GFC7000E Instruction Manual Operating Instructions 6 12 2 4 Editing iDAS Parameters Data channels can be edited individually from the front panel without affecting other data channels How
14. Table 6 11 Analog Output Pin Assignments PIN ANALOG VOLTAGE CURRENT OUTPUT SIGNAL SIGNAL Ground I Out V Out I Out V Out I Out Ground I Out A2 A4 A3 Not Used Not Used See Figure 3 2 for a the location of the analog output connector on the instruments rear panel 04584 Rev Al 70 Model GFC7000E Instruction Manual Operating Instructions 6 9 4 1 Analog Output Signal Type and Range Span Selection To select an output signal type DC Voltage or current and level for one output channel activate the ANALOG 1 CONFI GURATI ON MENU see Section 6 9 1 then press FROM ANALOG I O CONFIGURATION MENU DIAG ANALOG I CONFIGURATION PREV NEXT ENTR DIAG AIO AOUTS CALIBRATED NO Press SET gt to select the analog output channel to be configured Press EDIT to continue SET SET CAL DIAG AIO CONC OUT 2 5V CAL SET SET EDIT EXIT DIAG AIO CONC OUT 2 RANGE 5V EDIT DIAG AIOOUTPUT RANGE 5V These keys set the signal level and type of the selected channel Pressing ENTR records the new setting DIAG AIOOUTPUT RANGE 10V and returns to the previous menu Pressing EXIT ignores the new setting and ENTR EXIT returns to the previous menu 6 9 4 2 Analog Output Calibration Mode The analog outputs can be calibrated automatically or manually In its default mode the instrument is configured for automatic calib
15. 67 6 9 3 Analog Output Step Test cea faded cad rite dite iva sau sl aera Ee cael 68 6 9 4 Analog 1 0 Configuration oct Hera tent Dura ete axe eaten 69 6 9 4 1 Analog Output Signal Type and Range Span 71 6 9 4 2 Analog Output Calibration Modus renere SEER esee emen menn emnes eremi 71 6 9 4 3 Manual Analog Output Calibration and Voltage Adjustment 73 6 9 4 4 Current Loop Output 111 eese heme nemen 75 6 9 4 5 AIN eared deua 77 6 95 Electric r RE 77 6 9 6 Dark Calibration TeSt rri eigenes aae re pua fap 78 6 9 7 Pressure Calibration oiii ra AY RE FEE Xa EXT adu RN 78 6 9 8 Flow CaliDratiOn 80 6 9 9 Test Channel OUEDpUE e a Ie ex rid case sau ted sees 81 6 10 SETUP COMM Using the Analyser s Communication 00 1 82 6 10 1 Analyzer ID COE w iseasi anki Dir
16. REOR REA 160 10 2 1 3 Sample EIoWSefsOF usc rn inn ewe pax xeu ener ea Fu ERES EAS 160 10 2 1 4 Valve OptiOns arcis ce nes yao eei ented eo asd a baeo abe a EN PR EAR donee cle 161 10 2 2 Purge Gas Pressure and Flow Control 4 122 4 4 4 41 4 4 41 mene 161 04584 Rev A1 iv Model GFC7000E Instruction Manual GFC7000E Documentation 10 3 Electronic Opetation oet tro tH Ie tee ede xe A Ke E iurc d eue chasers 161 109 3 1 OVEN EW EE ihe inn tied sad Fes Ded cate tise LE cer eludere 161 GI EAE 163 10 3 3 Optical Bench amp Wheel isisi iiir nentes cise acess Run an ERR RR RR PAGAR 163 10 3 3 1 Sample Gas and GFC Temperature 163 10 3 3 2 IR SOUECG erg er veg cata dar pua x tie eias pede ea cede OX REN E amr REN ra ME RIEN Idi ER 164 10 3 3 3 GFC Wheel rers re reser Ha reri tesia iai ie reeds 164 10 3 3 4 IR Photo DetectOr ipud eusexta aa FA RA Pai 165 10 3 4 Synchronous Demodulator Sync Demod 165 10 342 1 OVERVIEW ssi 165
17. 178 10 5 1 Adaptive Filter eiae rt xi Ya ce exa Trash au ea we coa Ces exa edu ats dena 179 10 5 2 Calibration Slope and 2 sireni rea ntu na aiu RR uaa PY RR pre 179 10 5 3 Measurement Algorithm etae radere ner ca ax terne enda E ied rn epa pa rep DERE D 180 10 5 4 Temperature and Pressure Compensation 1 0 180 10 5 5 Internal Data Acquisition System 5 180 11 TROUBLESHOOTING amp REPAIR PROCEDURES 183 11 1 General Troubleshooting EDEN sas aura nad 183 13 1 01 interpreting WARNING Messages rete rhe exe vn xa RE ra HER RENE ena ERE 184 11 1 2 Fault Diagnosis with TEST 4 2 1 1 1 1 186 11 1 3 Using the Diagnostic Signal I O 188 11 1 4 Internal Electronic Status site pe eras ran Rina 189 11 1 4 1 CPU Status Indicator s en reu a eu MP DM
18. Table 3 4 Model GFC7000E Rear Panel Pneumatic Connections Rear Panel Label Function Connect a gas line from the source of sample gas here SAMPLE Calibration gasses are also inlet here on units without zero span shutoff valve or IZS options installed EXHAUST Connect an exhaust gas line of not more than 10 meters long here PRESSURE SPAN On units with zero span shutoff valve options installed connect a gas line to the source of calibrated span gas here Span gas vent outlet for units with zero span shutoff valve options VENT SPAN installed Connect an exhaust gas line of not more than 10 meters long here Internal zero air scrubber on units with zero span shutoff valve options installed but NO 175 2 internal zero air scrubber attach a gas line to the source of zero air here This inlet supplies purge air to the GFC wheel housing see section PURGE IN 10 2 2 Connect a source of dried air that has been scrubbed of CO Calibrated CO gas at desired span gas concentration VENT Source of SAMPLE Gas Needle Removed valve to control flow during Calibration Indicating soda lime Sample Exhaust MODEL 7000 Vent Span Pressure Span MODEL 701 Zero Air 125 Generator Purge In Figure 3 3 Pneumatic Connections Basic Configuration Using Bottled Span Gas 04584 Rev A1 16 Model GFC7000E Instruction Manual Getting Started
19. pa dy er 171 10 3 6 4 Analog QUtputs ere ree xen kt MERE EUER Tra Ni 172 10 3 6 5 Internal Digital tee p ane etch ae eR Re E DE re Ed mete eere Nba SEE RR ER e 172 10 3 6 6 1 due ere ren renean rau pue ivan Ce Sena ded ARR NE CEU RR 173 105354 BE Data petu ciatis ose ou ra iE DO MT S 173 10 3 8 Power Supply Circuit Breaker seii ise secet inane keen FLERE YR RR RR RX REG YI Pa p adi Paene 173 Interface cioe der ter Saree cate erbe Ho bep Haden ceo te Durex tat e desk Xx ecu aat or ay cos Uae dere ER E 174 10 41 Eront Panel Interface E ale Re ces rada Ras 175 10 4 1 1 Analyzer Status LED S ciii desees REN GR 175 10 4 1 2 Keyboard itr seemed peser cyanate dv san e tid RE R e ARA DENM daria BEER 176 10 42 1 3 DISplay ette erige eR Da IR C T dU i eR DR an sees REA RE EE 176 10 4 1 4 Keyboard Display Interface mene 177 10 5 Software Opefation z e entera pe ue M mu RM RA RENI Dar E EM veers
20. 5 4 Calibration Valves Options There are four available options involving Zero Span Shutoff valves From an operational and software standpoint all of the options are the same only the source of the span and zero gases are different 5 4 1 Zero Span Shutoff Valve Option 50 This option requires that both zero air and span gas be supplied from external sources It is specifically designed for applications where span gas will be supplied from a pressurized bottle of calibrated CO gas A critical flow control orifice internal to the instrument ensures that the proper flow rate is maintained An internal vent line isolated by a shutoff valve ensures that the gas pressure of the span gas is reduced to ambient atmospheric pressure normally zero air would be supplied from zero air module such as a Teledyne Instruments Model 701 In order to ensure that span gas does not migrate backwards through the vent line and alter the concentration of the span gas a gas line not less than 2 meters in length should be attached to the vent span outlet on the rear panel of the analyzer To prevent the buildup of back pressure this vent line should not be greater than 10 meters in length The following table describes the state of each valve during the analyzer s various operational modes Table 5 1 2 Span Valve Operating States for Options 50 amp 51 MODE VALVE CONDI TI ON VALVE PORT CONNECTI ON Fig 5 2
21. DAR ER ER RARE MERO YEN 189 11 1 4 2 Sync Demodulator Status LED S lesse esses se nana nha hara haha nara agen dann raa a 190 11 1 4 3 Relay Board Status LEDS 22 cien etna hau ea ad asa dee 191 11 15 GaS 192 11 1 6 Typical Sample Gas Flow 5 2 2 2 2 4 4 193 11 1 6 1 FIOW IS ZOO outer prt ides cle onl Dut sa Cush aed 193 11511622 dre IPTE 193 11 1 6 3 HIGH FIOW 194 11 1 6 4 Displayed ka SALEEN 194 11 1 6 5 Actual Flow Does Not Match Displayed Flow 1 1111 194 11 1 6 6 Sample Een zoe LIE ese S RON EMQUE ERA 194 11 1 7 Poor or Stopped Flow of Purge 222 2 ae kan rao Dara ae na aX RR 194 11 2 Calibration Problems 2 5 195 11 2 1 Miss CaliBr ted Le ie er tutae dae epe FREE bees 195 04584 Rev A1 v Model GFC7000E Instruction Manual GFC7000E Documentation 11 2 2 Non Repeatable Zero and Span
22. R A a risa tania rasa naa nena naa 195 11 2 3 Inability to Span SPAN dud AR tens 196 11 2 4 Inability to Zero ZERO rn ura ga Fa 196 11 3 Other Performance Problems S s br aa a uk ia Pasa d 196 143 10 Temperature Problems sepe ausu ADAE oun RE Ra 197 11 3 1 1 Box or Sample Temperatures air rn 197 11 3 1 2 Bench Temperature Rowe ied 197 11 3 1 3 GFC Wheel Temperature re uade BER 198 11 3 1 4 IR Photo Detector TEC Temperature 1 198 11 3 2 Excessive NOISC Er ERE Y RYE 198 11 4 Subsystem Checkout uicta ener ditare rest mE RN tay aren LUE pU Nu EE deca 199 11 4 1 AC Mains Configuration irent RR RR EAE EVEA YR ded 199 11 4 2 pedea be naked cd dee dea
23. Wait until STABIL falls below1 0 ppb This may take several minutes M P CAL STABIL XXX X PPM XXX X lt TST TST gt CALZ CALS M P CAL STABIL XXX X PPM CO2 XXX X lt TST TST gt ZERO CONC EXIT M P CAL STABIL XXX X PPM CO2 XXX X v lt TST TST gt ENTR CONC EXIT lt ACTION Allow span gas to enter the sample port at the rear of the instrument Press ENTR to changes the OFFSET amp SLOPE values for the measurements Press EXIT to leave the calibration unchanged and return to the previous menu The value of STABIL may jump significantly Wait until it falls back M P CAL STABIL XXX X PPM CO2 lt TST 5 gt SPAN CAL RANGE 500 000 PPM CO2 XXX X v lt TST TST ENTR SPAN CONC EXIT M P CAL RANGE 500 000 PPM CO2 TST TST CONC below 1 0 ppb This may take several minutes Press ENTR to change the OFFSET amp SLOPE values for the CO measurements Press EXIT to leave the calibration unchanged and return to the previous menu EXIT returns to the main EXIT SAMPLE display 04584 Rev A1 136 Model GFC7000E Instruction Manual Calibration Procedures 7 5 Manual Calibration Checks with Zero Span Valves Zero and span checks using the VARIOUS zero span valve options available for
24. 1 6666 nnn 223 Sample Display Menu Units with 7 5 Valve IZS Option installed 224 Primary Setup Menu Except iDAS 12 1 66 225 Primary Setup Menu 5 1 nen nnn 226 Secondary Setup Menu COMM amp 5 4 2 4 0 40 4 227 Secondary Setup Menu COMM Menu with Ethernet 228 Secondary Setup Menu COMM Menu with HESSEN 229 Secondary Setup Menu 1 4 6 66 nnn 230 LIST OF TABLES Table 2 1 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 5 1 Table 5 2 Table 6 1 Model GFC7000E Basic Unit Specifications 4 4 4 7 4 441 5 GFC7000E Analog Output Pin Outs 13 GFC7000E Status Output Pin 2 2 4 2 1 14 GFC7000E Control Input Pin 1 444 46 15 Model GFC7000E Rear Panel Pneumatic Connections 16 Front Panel Display During System
25. Diagnostic Logon Test measurement Variable lt Warning 6 13 2 4 Data Types Data types consist of integers hexadecimal integers floating point numbers Boolean expressions and text strings Integer data are used to indicate integral quantities such as a number of records a filter length etc They consist of an optional plus or minus sign followed by one or more digits For example 1 12 123 are all valid integers Hexadecimal integer data are used for the same purposes as integers They consist of the two characters Ox followed by one or more hexadecimal digits 0 9 A F a f which is the C programming language convention No plus or minus sign is permitted For example Ox1 0x12 0x1234abcd are all valid hexadecimal integers Floating point numbers are used to specify continuously variable values such as temperature set points time intervals warning limits voltages etc They consist of an optional plus or minus sign followed by zero or more digits an optional decimal point and zero or more digits At least one digit must appear before or after the decimal point Scientific notation is not permitted For example 1 0 1234 5678 0 1 1 are all valid floating point numbers Boolean expressions are used to specify the value of variables or I O signals that may assume only two values They are denoted by the keywords ON and OFF Text strings are used to r
26. RANGE RANGE1 RANGE2 STABIL CO2 MEAS CO2 REF MR RATIO PRES Refer to SAMP FL Table 6 2 SAMP TEMP for BENCH TEMP definitions WHEEL TEMP of these BOX TEMP test Toggle TST TST gt keys to scroll through list of functions functions 1 Only appears instrument is set PHT DRIVE for DUAL or AUTO reporting SLOPE range modes OFFSET TEST TI ME Figure 6 2 Viewing MGFC7000E TEST Functions NOTE A value of XXXX displayed for any of the TEST functions indicates an out of range reading or the analyzer s inability to calculate it All pressure measurements are represented in terms of absolute pressure Absolute atmospheric pressure is 29 92 in Hg A at sea level It decreases about 1 in Hg per 300 m gain in altitude A variety of factors such as air conditioning and passing storms can cause changes in the absolute atmospheric pressure 6 2 2 Warning Messages The most common instrument failures will be reported as a warning on the analyzer s front panel and through the COM ports Section 11 1 1 explains how to use these messages to troubleshoot problems Section 3 2 3 shows how to view and clear warning messages Table 6 3 lists all warning messages for the current version of software 04584 Rev A1 48 Model GFC7000E Instruction Manual Operating I nstructions Table 6 3 List of Warning Messages ANALOG CAL WARNI NG The instruments A D circuitry or one of its analog outputs is not calibrated BENCH
27. 167 Location of relay board Status LED S 6 nnn 170 Power Distribution Block Diagram 3 1 1 ERE EE 174 Interface Block Diagtam teet crines enhn ro dedi ao a eni 175 MGFC7000E Front Panel 1 175 Keyboard and Display Interface Block 177 Basic Software Operation nennen ases essa aene nn 179 Viewing and Clearing Warning 8 011 184 Example of Signal I O 4 4 6 66 nennen nnn 189 CPU Status Indicator 190 Sync Demod Board Status LED Locations 2 2 2 2 2 2 2 20202 22 2 2 191 Relay Board Status LEDS nennen nennen nennen rna 191 Critical Flow Restrictor Assembly mmn 208 Opening the Wheel Housing 1 209 Removing the GFE Wheel ERA RAT OFEN 210 Triboelectric Charging 222 on dise hito res aan dede pe ec be ed rds 213 Basic anti ESD Work En nnne nnn 216 Basic Sample Display
28. Phone Number Site Address Can we connect to the instrument If so provide IP address or modem Model GFC7000E Serial Number Fax Number Email Firmware revision The serial number can be found on the back of the instrument the firmware revision is displayed in the upper left corner of the display when pressing SETUP on the front panel Example C 3 1 List all front panel error warning messages 2 Please complete the following table Depending on options installed not all test parameters shown below may be available in your instrument RECORDED ACCEPTABLE RECORDED ACCEPTABLE PARAMETER VALUE VALUE VALUE VALUE RANGE ppb ppm 50 ppb 20 ppm SLOPE 1 0 0 3 STABIL ppb lt 1 ppb with zero OFFSET mV 250 air SAMP FL cm3 min 500 50 HVPS V 5500 900 PMT SIGNAL mV 20 to 150 ETEST mV 2000 1000 WI TH ZERO AIR PMT SIGNAL mV 0 5000 OTEST mV 2000 1000 AT ppb ppm 0 20 000 ppb SPAN GAS CONC NORM PMT mV 0 5000 RCELL TEMP oc 50 1 AT ppb ppm 0 20 000 ppb SPAN GAS CONC UV LAMP mV 2 000 to 4 000 BOX TEMP 9C Ambient 5 STR LGT ppm lt 100 ppb zero PMT TEMP 7 2 air DARK PMT mV 50 to 200 125 TEMP 50 3 DARK LAMP mV 50 to 200 3 Has the analyzer been checked for leaks Yes L No L For proper flows Yes No L 4 What are the failure symptoms Continue on back if necessary 5 W
29. CO SLOPE1 1 0 001 999 999 CO slope for range 1 OFFSETI 0 0 10 CO offset for range 1 1 CO SPAN2 Conc 40 400 1 10000 Target CO concentration 1 20000 38 during span calibration of range 2 1 CO SLOPE2 1 20 01 999 999 CO slope for range 2 CO OFFSET2 0 0 10 CO offset for range 2 RANGE MODE SNGL SNGL DUAL Range control mode AUTO CONC RANGE1 50 2005 50028 0 1 50000 D A concentration range 1 RANGE2 50 2005 500 8 0 1 50000 D A concentration range 2 CO2 045840110 Rev B 3 233 Model GFC7000E I nstruction Manual APPENDIX A 2 Setup Variables For Serial 1 Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 SETUP VARI ABLE NUMERI C DEFAULT VALUE VALUE RANGE DESCRI PTI ON UNITS BitFlag 0 65535 RS 232 COM1 mode flags Add values to combine flags 1 quiet mode 2 computer mode 4 enable security 8 enable hardware handshaking 16 enable Hessen protocol 32 enable multi drop 64 enable modem 128 ignore RS 232 line errors 256 disable XON XOFF support 512 disable hardware FIFOs 1024 enable RS 485 mode 2048 even parity 7 data bits 1 stop bit 4096 enable command prompt AT YO amp D0 amp amp 10 Any character in RS 232 COM1 modem 50 2 amp BO amp N6 the allowed initialization string Sent EO Qi amp WO character set Up verbatim plus carriage return B
30. ON enables adaptive filter OFF disables it CO2 FILT ADAPT ON OFF ON enables adaptive filter OFF disables it CO2 FILT SIZE 2 1 300 CO moving average filter size CO2 FILT ASIZE 19 Samples 1 1 300 CO moving average filter size in adaptive mode CO2 FILT DELTA 19 0 5 0 01 10 Absolute CO conc change to trigger adaptive filter CO2 FILT PCT 9 6 5 0 1 100 Percent CO conc change to trigger adaptive filter CO2 FILT DELAY 19 Seconds 5 0 300 Delay before leaving CO adaptive filter mode 045840110 Rev B 3 231 Model GFC7000E I nstruction Manual APPENDIX A 2 Setup Variables For Serial 1 Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 SETUP VARI ABLE NUMERI C DEFAULT VALUE VALUE RANGE DESCRI PTI ON UNITS USER UNITS PPM 9 PPB PPM 38 Concentration units for user UGM MGM 8 interface DIL_FACTOR 1 0 1 1000 Dilution factor Used only if is dilution enabled with FACTORY_OPT variable DARK CAL DURATION Seconds 180 10 600 Duration of dark cal First 607 two thirds is stabilization period final third is measure period DARK MEAS MV 1000 1000 Dark offset for measure reading DARK REF MV mV 1000 1000 Dark offset for reference reading LIN TARGET CONCI Conc 300 1 10000 Target concentration during linearity adjustment for range 1 LIN NORM CONCI PPM 300 0 01 10000 Target concentration during linearity adjustment normalized for T P for range 1 LIN RATIO1 1 0 01 100
31. 2 Sample LED Green _ z Cal LED Yellow 2 x 40 CHAR VACUUM FLUORESCENT DISPLAY FRONT PANEL Fault LED KEYBOARD Red Beeper Figure 10 18 Keyboard and Display I nterface Block Diagram keyboard display interface electronics of the MGFC7000E Analyzer watches the status of the eight front panel keys alerts the CPU when keys are depressed translates data from parallel to serial and back and manages communications between the keyboard the CPU and the front panel display Except for the Keyboard interrupt status bit all communication between the CPU and the keyboard display is handle by way of the instrument s buss CPU controls the clock signal and determines when the various devices on the bus are allowed to talk or required to listen Data packets are labeled with addresses that identify for which device the information is intended Keypad Decoder Each key on the front panel communicates with a decoder IC via a separate analog line Whena key is depressed the decoder chip notices the change of state of the associated signal latches and holds the state of all eight lines in effect creating an 8 bit data word alerts the key depress detect circuit a flip flop IC translates the 8 bit word into serial data and sends this to the 2 interface chip Key Depress Detect Circuit This circuit flips the state of one of the inputs to the I C interface chip causin
32. 5 22 2 4 113 iDAS Configuration Through a Terminal Emulation 114 Status Output CODnector zc IA x RID E RE APR EY NI VIA RIEN 115 Control INPUTS a REN X RO DAS EXER XV eeu NAR TEN eos 117 APICOM Remote Control Program 10 11122 123 Pneumatic Connections Basic Configuration Using Bottled Span Gas 130 Pneumatic Connections Basic Configuration Using Gas Dilution Calibrator 131 Pneumatic Connections MGFC7000E with Zero Span Shutoff Valves OPT 50 134 Pneumatic Connections MGFC7000E with Zero Span Shutoff Valves and External Zero Air Scr bber OPT 51 e ek EX ER ERE ERES A EET RE VERRE 134 Pneumatic Connections MGFC7000E with Zero Span Valves 52 135 04584 Rev A1 vii Model GFC7000E Instruction Manual GFC7000E Documentation Figure 7 6 Figure 9 1 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 10 12 10 13 10 14 10 15 10 16 10 17 10 18 10 19 11 1 11 2 11 3 11 4 11 5 11 6 11 7 11 8 12 1 12 2 Figure A 1 Figure A 2 Figure A 3 Figure A 4 Figure A
33. Logic Level voltages are output through an optically isolated 8 pin connector located on the rear panel of the analyzer These outputs convey good bad and on off information about certain analyzer conditions They can be used to interface with certain types of programmable devices see Section 6 13 1 1 Control I nputs By applying 5VDC power supplied from an external source such as a PLC or Datalogger see Section 6 13 1 2 Zero and Span calibrations can be initiated by contact closures on the rear panel 10 3 7 1 C Data Bus An I C data bus is used to communicate data and commands between the cpu and the keyboard display interface and the relay board is a two wire clocked digital serial i o bus that is used widely in commercial and consumer electronic systems A transceiver on the motherboard converts data and control signals from the PC 104 bus to The data is then fed to the keyboard display interface and finally onto the relay board Interface circuits on the keyboard display interface and relay boards convert the i c data to parallel inputs and outputs An additional interrupt line from the keyboard to the motherboard allows the CPU to recognize and service key presses on the keyboard Power up Circuit This circuit monitors the 5V power supply during start up and sets the Analog outputs external digital I O ports and circuitry to specific values until the CPU boots and the instrument software can establish
34. 0 go into zero calibration 1 exit zero calibration 3 1 0 go into span calibration REMOTE RANGE HI exit span calibration remote select high range 1 default range 35 Spare PF Always Control inputs 014 J 1006 pins 1 6 bits 0 5 default I C Spare Always Control outputs 017 J 1008 pins 1 8 bits 0 7 default 1 o Spare Control outputs 021 J 1008 pins 9 12 bits 0 3 default 1 Spare P U21 JI pins 1 12 bits 4 7 default I ST SYSTEM OK2 system OK any alarm condition or in diagnostics mo ST CONC ALARM 1 1 conc limit 1 exceeded ST CONC ALARM 2 1 conc limit 2 exceeded status outputs 924 J 1017 pins 1 8 bits 0 7 default 1 ST SYSTEM OK 0 system OK 1 any alarm condition ST CONC VALID conc valid hold off or other conditions low auto range in zero calibration not in zero Oje Oje high auto range in use 045840110 Rev B 3 240 Model 360E Instruction Manual APPENDI X 4 MGFC7000E Signal Definitions Revision E O BIT OR CHANNEL NUMBER DESCRIPTION 0 in span calibration 1 not in span 0 in diagnostic mode 1 not in diagnostic mode 0 conc limit 1 exceeded 1 OK 0 conc limit 2 exceeded 1 conc OK B status outputs 927 1018 pins 1 8 bits 0 7 default 1 0 in auto reference mode 1 not in auto reference mode Spare Front
35. 1500 2500 13 045840110 235 Model GFC7000E I nstruction Manual APPENDIX A 2 Setup Variables For Serial 1 Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 SETUP VARI ABLE NUMERI C DEFAULT VALUE VALUE RANGE DESCRI PTI ON UNITS BENCH DERIV 2 0 100 Optical bench temperature PID derivative coefficient WHEEL GNE Seconds 0 5 30 Wheel temperature control cycle period WHEEL aL E 1 9C 0 100 Wheel temperature PID proportional coefficient Proportional band is the reciprocal of this setting WHEEL INTEG 0 135 0 035 0 100 Wheel temperature PID integral coefficient NLIS DERIV 0 100 Wheel temperature PID derivative coefficient ENABLE OFF ON ON enables temperature pressure compensation OFF disables it CONC LIN ENABLE OFF ON ON enables concentration linearization OFF disables it SERIAL NUMBER 00000000 Any character in Unique serial number for the allowed instrument character set Up to 100 characters long DISP INTENSITY Front panel display intensity 2 RESET ENABLE ON ON enables automatic reset of the I C bus in the event of communication failures OFF disables automatic reset FACTORY OPT BitFlag 0 4 0 65535 Factory option flags Add values to combine flags 1 enable dilution factor 2 zero span valves installed 4 conc alarms routed to relays 8 enable linearity adjustment factor 16 display units in concentration field 32 en
36. Calibrated Source of CO Gas MODEL 700 SAMPLE Gas Gas Dilution Removed Calibrator during Calibration Indicating soda lime Sample Exhaust MODEL ves GFC7000E Pressure Span MODEL 701 Zero Air Generator 175 Figure 3 4 Pneumatic Connections Basic Configuration Using Gas Dilution Calibrator 1 Attach a sample inlet line to the sample inlet port The SAMPLE input line should not be more than 2 meters long NOTE Ideally the pressure of the sample gas should be at ambient pressure 0 psig Maximum pressure of sample gas should not exceed 1 5 in Hg over ambient I n applications where the sample gas is received from a pressurized manifold a vent must be placed as shown to equalize the sample gas with ambient atmospheric pressure before it enters the analyzer This vent line must be e Atleast 0 2m long e No more than 2m long and vented outside the shelter or immediate area surrounding the instrument 04584 Rev A1 17 Model GFC7000E Instruction Manual Getting Started 2 Attach sources of zero air and span gas see Figures 3 3 through 3 8 inclusive Span Gas is gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired measurement range In the case of CO measurements made with the Teledyne Analytical Instruments Model GFC7000E Analyzer it is recommended that you use a gas calibrated to have a CO
37. EXHAUST GAS Purge Gas Motor I OUTLET Flow Control I p GFC Motor Purge Gas Heat Sync Pressure n Control Assy 3 e SEC Whael PURGE GAS Housing INLET FLOW PRESSURE SAMPLE SENSOR Q PRESSURE 1 SAMPLE CHAMBER e VENT SPAN RELOWA 1 OUTLET m 1 m I 5 PRESSURE I 3 SPAN INLET I 2 SHUT OFF ZERO SPAN SAMPLE CAL 9 VALVE VALVE VALVE 9 ao IA E BI gt PARTICULATE g 2 FILTER I IZS INLET 1 Figure 5 2 Internal Pneumatic Flow Zero Span Shutoff Valves 50 amp 51 04584 Rev A1 39 Model GFC7000E Instruction Manual Optional Hardware and Software 5 4 2 Zero Span Shutoff with External CO Scrubber Option 51 Option 51 is operationally and pneumatically identical to Option 50 above see section 5 4 1 except that the zero air is generated by an externally mounted zero air scrubber filled with indicating soda lime that changes color from white to pink as it becomes saturated 5 4 3 Zero Span Valve Option 52 This valve option is intended for applications where zero air is supplied by a zero air generator like the Teledyne Instruments Model 701 and span gas are being supplied by Gas Dilution Calibrator Like the Teledyne Instruments Model 700 or 702 Internal zero span and sample cal valves control the flow of gas through the instrument but because the calibrator limits the flow of s
38. FASTENER SAMPLE A RANGE 500 0 PPM 2 400 0 TST TST CAL SETUP KEY DEFINITIONS KEYBOARD OFF SWITCH Figure 10 17 GFC7000E Front Panel Layout The most commonly used method for communicating with the MGFC7000E Analyzer is via the instrument s front panel which includes a set of three status LEDs a vacuum florescent display and a keyboard with 8 context sensitive keys 10 4 1 1 Analyzer Status LED s Three LEDS are used to inform the user of the instruments basic operating status 04584 Rev Al 175 Model GFC7000E Instruction Manual THEORY OF OPERATION Table 10 3 Front Panel Status LED s NAME COLOR DEFINITION SAMPLE Green Off Unit is not operating in sample mode iDAS is disabled On Sample Mode active Front Panel Display being updated iDAS data being stored Unit is operating in sample mode front panel display being updated iDAS hold off Blinking mode is ON iDAS disabled CAL Yellow Off Auto Cal disabled On Auto Cal enabled Blinking Unit is in calibration mode FAULT Red Off CO warnings exist Blinking Warnings exist 10 4 1 2 Keyboard A row of eight keys just below the vacuum florescent display see Figure 10 17 is the main method by which the user interacts with the analyzer As the software is operated labels appear on the bottom row of the display directly above each active key defining the function of that key as it is relevant for the operation
39. Failed sync demod board IR photo detector improperly attached to the sample chamber Bench temp too high Warning only appears on serial i o com port s Front panel display will be frozen blank or will not respond Massive failure of mother board RELAY BOARD WARN The CPU cannot communicate with the Relay Board failure Failed relay board Loose connectors wiring SAMPLE FLOW WARN Sample flow rate is 500 cc min or 1000 cc min Failed sample pump Blocked sample inlet gas line Dirty particulate filter Leak downstream of critical flow orifice Failed flow sensor circuitry 04584 Rev A1 185 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES Table 11 1 Warning Messages Indicated Failures cont WARNI NG MESSAGE FAULT CONDI TI ON POSSIBLE CAUSES SAMPLE PRES Sample Pressure is If sample pressure is 10 in hg WARN 10 in Hg or o Blocked particulate filter 35 in Hg o Blocked sample inlet gas line Normally 29 92 in Hg at sea level decreasing at 1 in Hg per 1000 ft of altitude with no flow pump disconnected o Failed pressure sensor circuitry If sample pressure is 35 in hg o Blocked vent line on pressurized sample zero span gas supply o Bad pressure sensor circuitry SAMPLE TEMP WARN Sample temperature is 10 or gt 100 C Ambient temperature outside of specified range Failed bench heater Failed
40. Main Data Acquisition Menu SETUP X X DATA ACQUISITION VIEW EDIT EXIT Edit Data Channel Menu Moves the display up amp SETUP X X 0 CONC ATIMER 1 900 Exits to the Main Data Acquisition down the list of PREV NEXT INS DEL EDIT PRNT EXIT Data Channels Menu Exports the configuration of all data channels to RS 232 interface Inserts a new Data Channel into the list BEFORE the Channel currently being displayed Deletes The Data Channel currently being displayed Moves the display SETUP X X Exits returns to the between the previous Menu PROPERTIES for this SET SET EDIT PRNT data channel Reports the configuration of current data channels to the RS 232 ports Allows to edit the channel name see next key sequence When editing the data channels the top line of the display indicates some of the configuration parameters For example the display line 0 CONC ATI MER 4 800 translates to the following configuration Channel No 0 NAME CONC TRIGGER EVENT ATIMER 04584 Rev A1 104 Model GFC7000E Instruction Manual Operating I nstructions PARAMETERS Four parameters are included in this channel EVENT This channel is set up to record 800 data points To edit the name of a data channel follow the above key sequence and then press From the end of the previous key sequence SETUP
41. contact the factory 1 For complete failures assuming that the power supplies are operating properly and the wiring is intact the CPU is bad if on powering the instrument e The vacuum fluorescent display shows a dash in the upper left hand corner e The CPU Status LED DS5 is not flashing see Section 11 1 4 1 e There is no activity from the primary RS 232 port COM A on the rear panel even if lt ret gt is pressed e In some rare circumstances this failure may be caused by a bad IC on the Motherboard specifically U57 the large 44 pin device on the lower right hand side of the board If this is true removing U57 from its socket will allow the instrument to startup but the measurements will be incorrect 2 If the analyzer stops part way through initialization there are words on the vacuum fluorescent display then it is likely that the DOC has been corrupted 11 4 9 RS 232 Communications 11 4 9 1 General RS 232 Troubleshooting Teledyne Instruments analyzers use the RS 232 communications protocol to allow the instrument to be connected to a variety of computer based equipment RS 232 has been used for many years and as equipment has become more advanced connections between various types of hardware have become increasingly difficult Generally every manufacturer observes the signal and timing requirements of the protocol very carefully 04584 Rev A1 206 Model GFC7000E Instruction Manual TROUBLESHOOTI NG am
42. 1 days between 0 0 2 ENTR EXIT procedures 1 367 y SETUP X X DELTA DAYS 2 lt SET SET gt EDIT EXIT SETUP X X DELTA TIME00 00 lt SET SET gt EDIT EXIT Toggle keys to set SETUP MODE ZERO SETUP X X DELTA TIME 00 00 0 0 3 0 ENTR EXIT delay time for each iteration ofthe sequence HH MM 0 24 00 v PREV NEXT ENTR EXIT SETUP MODE ZERO SPAN PREV ENTR EXIT SETUP DELTA TIEM 00 30 SET SET EDIT EXIT y SETUP SEQ 2 ZERO SPAN 1 00 00 PREV NEXT MODE SET EXIT SETUP DURATION 15 0 MINUTES SET SET EDIT EXIT Toggle keys to set Y duration for each iteration of Default value is ON SETUP ENABLE ON SET EDIT EXIT SETUP X X DURATION 15 0MINUTES 3 0 0 ENTR EXIT the p Sequence Set in Decimal minutes from SETUP STARTING DATE 01 JAN 02 lt SET SET gt EDIT EXIT SETUP DURATION 30 0 MINUTES lt SET SET gt EDIT EXIT 0 1 60 0 y Toggle keys to set day month amp SETUP STARTING DATE 01 JAN 02 year 0 4 SEP 0 3 ENTR EXIT Format DD MON YY y SETUP X X STARTING DATE 04 SEP 03 lt SET SET gt EDIT EXIT y SETUP X X STARTING DATE 04 SEP
43. 10 3 4 2 Signal Synchronization Demodulation mme 166 10 3 4 3 Phase Lock Warning x baia Rae aya ded 167 10 3 4 4 Sync Demod Status LEDS ss eriperet te re euer cee ak pepe sa aaa Fay nya ois 167 10 3 4 5 Photo Detector Temperature 2 4 4 1 41 1 REEL ERE TERRE TERE EN 168 10 3 4 6 Dark Calibration lt 2 2 5 2 enti ir nen te ERI RADAR FERE R ARR RR RRAN 168 10 3 4 7 Electric Test Switches iei iier cee tote gna de sauces E pup oun nae Falsa Paga Dia 168 10 3 5 Relay Bo rd ius R XXE EAR ANARREIERIRP PAR IRR 168 10 3 5 1 Stat s LED Suc iceberg ere pa e eda ue alte ERA e NEM Era 169 10 3 5 2 I C Watch Dog 170 10 3 6 ee eben RARE e EU Ei AME ERE AEE Sade gnes NEAR ins 170 10 3 6 1 A to D GONVErSION iiber ick NAE ad deals bas ENDO N 170 10 3 6 2 Sensor Inputs mies iE ORE Ee E aa AE E A T 171 10 3 6 3 Thermistor Interface sese rmt ce iege npe else sa on cbs
44. DC POWER 4 Sync Demod PS 2 12 VDC IR Source Y Cooling Fan M R amp Segment Valve Sensors Options Pump Heaters Figure 10 15 Power Distribution Block Diagram 10 4 I nterface The analyzer has several ways to communicate the outside world see Figure 10 16 Users can input data and receive information directly via the Front panel keypad and display Direct communication with the CPU is also available by way of the analyzer s RS232 amp RS485 I O ports or an optional Ethernet port The analyzer can also send and receive different kinds of information via its external digital I O connectors and the three analog outputs located on the rear panel 04584 Rev A1 174 Model GFC7000E Instruction Manual THEORY OF OPERATI ON COMMA male RS 232 ONLY RS 232 or RS 485 COMMB m p 4 CPU Control Inputs ETHERNET 1 69 gt Board OPTION Status Outputs amp Mm PC 104 BUS Analog Outputs KEYBOARD A1 ice Optional 2 1 4 20 PC BUS I A3 A4ST FRONT PANEL DISPLAY RELAY BOARD Figure 10 16 I nterface Block Diagram 10 4 1 Front Panel I nterface MODE FIELD MESSAGE FIELD LOCKING SCREW CONCENTRATION FIELD STATUS LED s FASTENER
45. DI SABLED Disables the Sequence ZERO Causes the Sequence to perform a zero calibration check ZERO SPAN Causes the Sequence to perform a zero and span concentration calibration check SPAN Causes the Sequence to perform a span concentration calibration check For each mode there are seven parameters that control operational details of the SEQUENCE They are Table 7 2 AutoCal ATTRIBUTE Setup Parameters ATTRI BUTE NAME ACTI ON TIMER ENABLED Turns the Sequence timer STARTI NG DATE Sequence will operate after Starting Date STARTING TIME Time of day sequence will run DELTA DAYS Number of days to skip between each Seq execution DELTA TI ME Number of hours later each Delta Days Seq is to be run DURATI ON Number of minutes the sequence operates CALI BRATE Enable to do a calibration Disable to do a cal check only 04584 Rev A1 139 Model GFC7000E Instruction Manual Calibration Procedures The following example sets Sequence 2 to do a Zero Span Calibration every other day starting at 1 am on September 4 2001 lasting 15 minutes without calibration This will start V hour later each iteration MODE AND ATTRI BUTE Sequence Mode Timer Enable Starting Date Starting Time Delta Days Delta Time Duration Calibrate VALUE 2 ZERO SPAN ON Sept 4 2001 01 00 2 00 30 15 0 NO COMMENT Define Sequence 2 Select Zero and Span Mode Enable the timer Start after Sept 4 2001 First Span starts at
46. EDIT t a EXAMPLE S SERE I HEE SETUP X X COM1 BAUD RATE 19200 keys to move between available lt SET SET gt EDIT baud rates ey SETUP COM1 BAUD RATE 19200 4800 9600 PREV NEXT ENTR 19200 38400 57600 1 UP X X M1 BAUD RATE E TUA co U 9600 NEXT ON ENTR EXIT returns to the previous menu key ignores the new setting ENTR key accepts the new setting 04584 Rev A1 88 Model GFC7000E Instruction Manual Operating Instructions 6 10 8 COM Port Testing The serial ports can be tested for correct connection and output in the COMM menu This test sends a string of 256 w characters to the selected COM port While the test is running the red LED on the rear panel of the analyzer should flicker To initiate the test press the following key sequence SAMPLE a 500000 GOD SXOXXX COMMUNICATIONS MENU Select which COM port to TST gt CAL SETUP um test SAMPLE ENTER SETUP PASS 818 SETUP XK COR MODES 8 1 8 ENTR SET gt EDIT EXIT SETUP X X PRIMARY SETUP MENU SETUP X X BAUD RATE 19200 DAS RNGE PASS CLK MORE EXIT SET SET EDIT SETUP SECONDARY SETUP MENU SETUP X X TEST PORT COMM VARS DIAG ALRM EXIT lt SET TEST SETUP X X TRANSMITTING TO COM1 Test runs e EXIT returns to autom
47. Keypad Analog Output Data PC 104 BUS RS232 amp RS485 External Digital I O Measurement Algorithm Linearization Table Figure 10 19 Basic Software Operation 10 5 1 Adaptive Filter The MGFC7000E software processes the CO2 MEAS and CO2 REF signals after they are digitized by the motherboard through an adaptive filter built into the software Unlike other analyzers that average the output signal over a fixed time period the MGFC7000E averages over a set number of samples where each sample is 0 2 seconds This is technique is known as boxcar averaging During operation the software automatically switches between two different length filters based on the conditions at hand Once triggered the short filter remains engaged for a fixed time period to prevent chattering During conditions of constant or nearly constant concentration the software by default computes an average of the last 750 samples or approximately 150 seconds This provides the calculation portion of the software with smooth stable readings If a rapid change in concentration is detected the filter includes by default the last 48 samples approximately 10 seconds of data to allow the analyzer to more quickly respond If necessary these boxcar lengths can be changed between 1 and 1000 samples but with corresponding tradeoffs in rise time and signal to noise ratio contact customer service for more information Two conditi
48. M320E GFC7000E M306E Except GFC7000EU APR version 045840110 Rev B 3 243 Model 360E Instruction Manual APPENDI X A 5 GFC7000E iDAS Functions Revision Table A 6 MGFC7000E iDAS Functions Revision E O UNITS 25 1 Concentration for range 1 during zero span calibration just before PPM computing new slope and offset ZSCNC2 Concentration for range 2 during zero span calibration just before PPM computing new slope and offset CO2ZSC 5 concentration during zero span calibration just before 9o computing new slope and offset SMPFLW BNCDTY Bench temperature control duty cycle Fraction 0 off 1 WHLDTY Fraction 1 2 M300ES 3 320 GFC7000E 5 M306E Except GFC7000EU APR version 7 The units including the concentration units are always fixed regardless of the current instrument units 045840110 Rev B 3 244 Model 360E Instruction Manual APPENDIX 6 Terminal Command Designators Revision 0 APPENDIX 6 Terminal Command Designators Revision 0 Table A 7 Terminal Command Designators Revision COMMAND ADDI TI ONAL COMMAND SYNTAX DESCRI PTI ON ID Display help screen and commands list LOGON ID password Establish connection to instrument LOGOFF ID SET ALL name hexmask Terminate connection to instrument Display test s LIST ALL name hexmask NAMES
49. Q How do I make the display and datalogger analog input agree A This most commonly occurs when an independent metering device is used besides the datalogger recorded to determine gas concentration levels while calibrating the analyzer These disagreements result from the analyzer the metering device and the datalogger having slightly different ground levels If the only difference is a DC offset then it is possible to enter a compensating value in the analog outputs This procedure is described in Section 6 9 4 3 of this manual Alternately use the datalogger itself as the metering device during calibrations procedures Q How do I perform a leak check See Section 9 3 3 Q How do I measure the sample flow A Sample flow is measured by attaching a calibrated rotameter wet test meter or other flow measuring device to the sample inlet port when the instrument is operating The sample flow should be 800 cm min 10 See Section 9 3 4 04584 Rev A1 33 Model GFC7000E Instruction Manual Frequently Asked Questions Q How long does the IR source last A Typical lifetime is about 2 3 years Q Where is the sintered filter sample flow control orifice A These components are located inside the flow control assembly that is attached to the inlet side of the sample pump see Figure 3 13 See Section 11 5 1 for instructions on disassembly and replacement Q How do I set up a SEQUENCE to run a nightly calibration check A T
50. SELECT START OR REMOTE 752 START CHECKI NG FLASH STATUS 1 System is checking the format of the instrument s flash memory chip If at this point FLASH FORMAT INVALI D appears contact customer service STARTING INSTRUMENT CODE STARTING INSTRUMENT W FLASH The instruments loading configuration and calibration data from the flash chip M200E NOX ANALYZER The instrument is loading the analyzer BOOT PROGRESS XXXXX 50 firmware SOFTWARE SI ON D 6 The revision level of the firmware installed in your BOOT PROGRESS XXXXXXXX 80 _ analyzer is briefly displayed CO2zX XXX SAMPLE SYSTEM RESET Firmware fully booted TEST CAL CLR SETUP Press CLR to clear initial warning messages see Section 3 2 3 04584 Rev A1 22 Model GFC7000E Instruction Manual Getting Started The analyzer should automatically switch to SAMPLE mode after completing the boot up sequence and start monitoring CO gas Warm Up 3 2 2 Warm Up The MGFC7000E requires about 30 minutes warm up time before reliable measurements be taken During that time various portions of the instrument s front panel will behave as follows See Figure 3 10 for locations Table 3 5 Front Panel Display During System Warm Up Name coo Behavior Concentration
51. Sample Cal Open to SAMPLE inlet 322 SAMPLE Zero Span Open to ZERO AIR inlet 322 Normal State Shutoff Valve Closed N A Sample Cal Open to zero span inlet 122 ZERO CAL Zero Span Open to ZERO AIR inlet 322 Shutoff Valve Closed N A Sample Cal Open to ZERO SPAN inlet 122 SPAN CAL Zero Span Open to SPAN GAS inlet 122 Shutoff Valve Open to PRESSURE SPAN Inlet 277 minimum span gas flow rate required for this option is 800 cm min 04584 Rev A1 38 Model GFC7000E Instruction Manual Optional Hardware and Software The state of the zero span valves can also be controlled e Manually from the analyzer s front panel by using the SIGNAL 1 controls located under the DIAG Menu Section 6 9 2 e By activating the instrument s AutoCal feature Section 7 6 e Remotely by using the external digital control inputs Section 6 13 1 2 and Section 7 5 2 or e Remotely through the RS 232 485 serial I O ports see Appendix A 6 for the appropriate commands pe cy crc ETE iy INSTRUMENT CHASSIS I SAMPLE GAS E I INLET Eg Os 55 mE I PUMP 8 GFC Wheel
52. Sample Gas Pressure Sensor Optical Bench Gas Outlet Optional Ethernet Card Rear Panel 04584 Rev Al 30 Model GFC7000E Instruction Manual Getting Started Sample Gas Outlet Sample Gas Flow fitting Sensor E lt Sample Chamber 4 A 4 Sync Demod Housing Pressure Sensor s Bench Temperature Thermistor Shock Absorbing Mounting Bracket Opto Pickup PCA Purge Gas Pressure Regulator IR Source Heat Sync GFC Wheel Motor GFC Temperature Sensor Purge Gas Inlet zi GFC Heater Figure 3 12 Optical Bench Layout INSTRUMENT CHASSIS 1 1 m SAMPLE GAS INLET 5 g I I 56 9 ri 5 Purge Gas GFC Wheel EXHAUST GAS Flow Rate Motor OUTLET Control 1 Orifice I RES Morc motor 5 Heat Sync Pressure Control Assy IGFC Wheel PURGE GAS Housing I INLET 4 ek 1 I FLOW PRESSURE SAMPLE SENSOR PRESSURE 1 SENSOR I ea SAMPLE CHAMBER I SENSOR OUTLET I PRESSURE SPAN INLET I 1 PARTICULATE I FILTER I IZS INLET I
53. Table A 1 MGFC7000E Setup Variables Revision E O SETUP VARI ABLE NUMERI C DEFAULT VALUE VALUE RANGE DESCRI PTI ON UNITS STANDARD SETUP VARI ABLES DAS HOLD OFF Minutes 15 0 5 20 Duration of DAS hold off period CONC PRECI SI ON 3 AUTO 0 1 2 3 Number of digits to display to 4 the right of the decimal point for concentrations on the display DYN ZERO OFF ON enables remote dynamic zero calibration OFF disables it DYN SPAN ON enables remote dynamic m calibration OFF disables CLOCK ADJ Sec Day 60 60 Time of day clock speed adjustment MEDIUM ACCESS LEVEL SETUP VARI ABLES LANGUAGE SELECT ENGL 1 Selects the language to use for the user interface MAINT_TIMEOUT Hours 2 1 Time until automatically switching out of software controlled maintenance mode CONV TIME 33 MS 33 MS 66 MS Conversion time for 133 MS measure reference detector 266 MS channel 533 MS 1 SEC 2 SEC CO DWELL Seconds 0 2 0 1 30 Dwell time before taking measure or reference sample CO SAMPLE Samples 1 1 30 Number of samples to take in measure or reference mode FILT SIZE 750 20024 1 1000 Moving average filter size FILT ASIZE Samples 48 20 1 1000 Moving average filter size in adaptive mode FILT DELTA PPM 4 1538 1 1000 Absolute change to trigger adaptive filter FILT PCT 9 0 10 1 100 Percent change to trigger adaptive filter FILT DELAY Seconds 0 180 Delay before leaving adaptive filter mode FILT ADAPT
54. Y previous menu N EXIT ignores the new setting SETUP X X CHANNEL ENABLE ON and returns to the previous Toggle key to turn menu channel ON or OFF lt lt OFF ENTR EXT 6 12 2 11 HOLDOFF Feature The iDAS HOLDOFF feature allows to prevent data collection during calibrations and during the DAS HOLDOFF period enabled and specified in the VARS Section 6 8 To enable or disable the HOLDOFF follow the instruction shown in section 6 12 2 2 then press From the DATA ACQUISITION menu see Section 6 12 2 2 Edit Data Channel Menu SETUP X X 0 ATIMER 1 900 Exits to the main PREV NEXT INS DEL EDIT EXIT Data Acquisition menu SETUP X X SET SET EDIT PRINT Press SET key until SETUP X X CAL HOLD OFF ON SET EDIT PRINT EXIT ENTR accepts the new setting and returns to the previous menu SETUP XX CAL HOLD OFF ON EXIT ignores the new setting and returns to the previous HOLDOFF ON or OFF ON ENTR EXIT menu Toggle key to turn 04584 Rev A1 112 Model GFC7000E Instruction Manual Operating Instructions 6 12 3 Remote iDAS Configuration Editing channels parameters and triggering events as described in this section can be performed via the APICOM remote control program using the graphic interface shown in Figure 6 8 Refer to Section 6 13 for details on remote access to the MGFC7000E analyzer 1 M200E at T APLenglab1 1 xl
55. ZERO CALA Unit is performing zero cal procedure initiated automatically by the analyzer s AUTOCAL feature ZERO CALM Unit is performing zero cal procedure initiated manually by the user ZERO CALR JUnit is performing zero cal procedure initiated remotely via the RS 232 RS 4485 or digital I O control inputs The revision of the Teledyne Instruments software installed in this analyzer will be displayed following the word SETUP E g SETUP 0 Finally the various CAL modes allow calibration of the analyzer Because of its importance this mode is described separately in Chapter 7 6 2 Sample Mode This is the analyzer s standard operating mode In this mode the instrument is analyzing the gas in the sample chamber calculating concentration and reporting this information to the user via the front panel display the analog outputs and if set up properly the RS 232 485 Ethernet ports NOTE A value of displayed in the CO2 Concentration field means that the M R ratio is invalid because CO2 REF is either too high gt 4950 mVDC or too low 1250 VDC 6 2 1 Test Functions A series of test functions is available at the front panel while the analyzer is in SAMPLE mode These parameters provide information about the present operating status of the instrument and are useful during troubleshooting Section 11 1 2 They can also be recorded in one of the iDAS channels Section 6 12 for data analysis
56. if an optional current output driver has been installed and the signal level that matches the input requirements of the recording device attached to the channel see Sections 6 9 4 1 e Calibrating the output channel This can be done automatically or manually for each channel see Sections 6 9 4 2 and 6 9 4 3 e Adding a bipolar recorder offset to the signal if required Section 6 9 4 2 In its standard configuration the analyzer s outputs can be set for the following DC voltages Each range is usable from 5 to 5 of the nominal range Table 6 9 Analog Output Voltage Ranges RANGE MINIMUM OUTPUT MAXIMUM OUTPUT 0 0 1 V 5 mV 105 mV 0 1V 0 05 V 1 05 V 0 5 V 0 25 V 5 25 V 0 10 V 0 5 V 10 5V The default offset for all ranges is 0 VDC 04584 Rev Al 69 Model GFC7000E Instruction Manual Operating Instructions The following DC current output limits apply to the current loop modules Table 6 10 Analog Output Current Loop Range RANGE MI NI MUM OUTPUT MAXI MUM OUTPUT 0 20 mA 0 mA 20 mA These are the physical limits of the current loop modules typical applications use 2 20 or 4 20 mA for the lower and upper limits Please specify desired range when ordering this option The default offset for all ranges is 0 mA Pin assignments for the output connector at the rear panel of the instrument are shown in Table 6 11 ANALOG OUT 1 2 4
57. repair the equipment will be returned freight prepaid User Notes 04584 Rev A1 7 Model GFC7000E Instruction Manual Getting Started 3 GETTING STARTED 3 1 Unpacking and Initial Set Up CAUTI ON To avoid personal injury always use two persons to lift and carry the Model GFC7000E 1 Verify that there is no apparent external shipping damage If damage has occurred please advise the shipper first then Teledyne Analytical Instruments 2 Included with your analyzer is a printed record of the final performance characterization performed on your instrument at the factory This record titled Final Test and Validation Data Sheet part number 04307 is an important quality assurance and calibration record for this instrument It should be placed in the quality records file for this instrument 3 Carefully remove the top cover of the analyzer and check for internal shipping damage e Remove the set screw located in the top center of the rear panel e Remove the four screws fastening the top cover to the unit two per side e Lift the cover straight up Do not slide backwards NOTE Some versions of the GFC7000E CO Analyzer may have a spring loaded fastener at the top center of the rear panel and as many as eight screws four per side fastening the top cover to the chassis NOTE Static sensitive parts are present on PCA Printed Circuit Assemblies Before touching PCAs touch a bare me
58. 10 Status Output Connector 04584 Rev A1 115 Model GFC7000E Instruction Manual Operating Instructions The pin assignments for the Status Outputs are Table 6 24 Status Output Pin Assignments Status H Out EN SYSTEM OK On if no faults are present On if CO concentration measurement is valid CONC VALID If the concentration measurement is invalid this bit is OFF HIGH RANGE On if unit is in high range of DUAL or AUTO range modes ZERO CAL On whenever the instruments zero point is being calibrated SPAN CAL On whenever the instruments span point is being calibrated 1 DIAG MODE On whenever the instrument is in diagnostic mode 7 ALARM1 On whenever the measured CO concentration is above the set point for ALM1 ALARM2 On whenever the measured CO concentration is above the set point for ALM2 ne E EMITTER BUSS The emitters of the transistors on pins 1 8 are bussed together DC POWER 5 VDC Digital Ground The ground level from the analyzer s internal DC power supplies 6 13 1 2 Control Inputs These inputs allow the user to remotely initiate Zero and Span calibrations Two methods for energizing the inputs is provided below the first using the internal 5V available on the CONTROL IN connector and the second if an external isolated supply is employed Table 6 25 Control Input Pin Assignments Input Status Condition when enabled EXTERNAL ZERO Zero calibration
59. 4 Manual Calibration with Zero Span Valves There are four different zero span valve option configurations see Section 5 4 They all operate identically differing only in the method used to supply calibration gas to the Analyzer STEP ONE Connect the sources of Zero Air and Span Gas as shown below Figures 7 3 through 7 6 show the proper pneumatic connections for GFC7000E s with various optional internal valve sets installed 04584 Rev A1 133 Model GFC7000E Instruction Manual Calibration Procedures SS Source of SAMPLE Gas VENT if input is pressurized Certified Gas Sample Needle valve to Exhaust MO D E L control MODEL 701 flow GFC7000E 2 125 Indicating soda lime Figure 7 3 Pneumatic 5 MGFC7000E with Zero Span Shutoff Valves 50 Source of SAMPLE Gas VENT if input is pressurized Certified Gas Sample OLEI 701 Exhaust MODEL Zero Air Vent Span GFC7000E Generator Pressure Span External Zero 125 Air Scrubber Indicating Purge In soda lime Figure 7 4 Pneumatic Connections MGFC7000E with Zero Span Shutoff Valves and External Zero Air Scrubber OPT 51 Source of SAMPLE Gas MODEL 700 Gas Dilution Calibrator VENT if input is pressurized Sample N
60. 4 1 441 4 lt lt enne en 215 12 4 Basic Principles of Static Control ra nada 216 12 41 G n ral eR DAE 216 12 4 2 Basic anti ESD Procedures for Analyzer Repair Maintenance 218 12 4 2 1 Working at the Instrument Rack ec neget haee era annu aaa aa a RN RR 218 12 4 2 2 Working at a Anti ESD Work 4 4 2 41 2 4 11 nnn 218 12 4 2 3 Transferring Components from Rack To Bench and 219 12 4 2 4 Opening Shipments from and Packing Components for Return to Teledyne Instruments C stomer SEVICE EM 219 04584 1 Model GFC7000E Instruction Manual GFC7000E Documentation LIST OF APPENDI CES APPENDIX A VERSION SPECIFIC SOFTWARE DOCUMENTATION APPENDIX A 1 APPENDIX A 2 APPENDIX A 3 APPENDIX A 4 APPENDIX A 5 MGFC7000E Software Menu Trees Revision 0 Setup Variables For Serial I O Revision 0 Warnings and Test Functions Revision 0 MGFC7000E Signal I O Definitions Revision 0 MGFC7000E iDAS Functions Revision 0 APPENDIX A 6 Terminal Command Designators Revision 0 APPENDI X B GFC7000E SPARE PARTS LIST APPENDIX C REPAI
61. 82 Model GFC7000E Instruction Manual Operating I nstructions SAMPLE RANGE 500 000 PPM CO2 TST TST gt CAL ETUP SAMPLE ENTER SETUP PASS 818 SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP SECONDARY SETUP MENU COMM SETUP X X COMMUNICATIONS MENU ID COM2 EXIT Toggle these keys to cycle through the available character set 0 9 ENTR key accepts the SETUP X MACHINE ID 360 ID new settings EXIT key ignores the ENTR EXIT new settings The ID number is only important if more than one analyzer is connected to the same communications channel e g a multi drop setup Different models of Teledyne Instruments analyzers have different default ID numbers but if two analyzers of the same model type are used on one channel for example two MGFC7000E s the ID of one instrument needs to be changed The ID can also be used for to identify any one of several analyzers attached to the same network but situated in different physical locations 6 10 2 COMM Port Default Settings Received from the factory the analyzer is set up to emulate a DCE or modem with pin 3 of the DB 9 connector designated for receiving data and pin 2 designated for sending data e COMI RS 222 fixed DB 9 male connector o Baud rate 19200 bits per second baud o Data Bits 8 data bits with 1 stop bit o Parity None e COM2 RS 232 configurable DB 9 f
62. A1 192 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES independent flow meter to perform a flow check as described in Section 9 3 4 If this test shows the flow to be correct check the pressure sensors as described in Section 11 4 6 5 11 1 6 Typical Sample Gas Flow Problems 11 1 6 1 Flow is Zero The unit displays a SAMPLE FLOW warning message on the front panel display or the SAMPLE FLOW test function reports a zero or very low flow rate Confirm that the sample pump is operating turning If not use an AC voltmeter to make sure that power is being supplied to the pump If no power is present at the electrical leads of the pump 1 If AC power is being supplied to the pump but it is not turning replace the pump 2 Ifthe pump is operating but the unit reports no gas flow perform a flow check as described in Section 9 3 4 3 If no independent flow meter is available e Disconnect the gas lines from both the sample inlet and the exhaust outlet on the rear panel of the instrument e Make sure that the unit is in basic SAMPLE Mode e Place a finger over an Exhaust outlet on the rear panel of the instrument e If gas is flowing through the analyzer you will feel pulses of air being expelled from the Exhaust outlet 4 If gas flows through the instrument when it is disconnected from its sources of zero air span gas or sample gas the flow problem is most likely not internal to the analy
63. A1 108 Model GFC7000E Instruction Manual Operating I nstructions To define the REPORT PERI OD follow the instruction shown in section 6 12 2 2 then press From the DATA ACQUISITION menu see Section 6 12 2 2 Edit Data Channel Menu Use the PREV and NEXT keys to scroll to the data 0 CONC 1 900 channel to be edited Exits to the main PREV NEXT INS DEL EDIT PRNT EXIT Data Acquisition menu SETUP X X SET SET EDIT PRINT Press SET key until you reach REPORT PERIOD SETUP X X REPORT PERIOD 000 01 00 SET SET EDIT PRINT SETUP X X REPORT PERIODD DAYS 0 Set the number of days between reports 0 366 ENTR EXIT 0 0 0 Press keys to set hours between reports in the format HH MM max 23 59 This is a 24 hour clock PM hours are 13 thru 23 midnight is 00 00 Example 2 15 PM 14 15 SETUP X X REPORT PERIODD TIME 01 01 ENTR accepts the new string and returns to the previous menu EXIT ignores the new string and 0 1 0 0 ENTR EXIT returns to the previous menu Ilf at any time an illegal entry is selected e g days gt 366 the ENTR key will disappear from the display lt 6 12 2 6 Number of Records The number of data records in the MGFC7OOOE is limited to about a cumulative one million data points in all channels one megabyte of space on the disk on
64. AIO 6 9 4 parameters such as signal span and offset are available for viewing and configuration ELECTRIC TEST The analyzer is performing an electric test This test simulates IR detector signal in a known DI AG 6 9 5 manner so that the proper functioning of the sync demod board be verified DARK CALI BRATI ON The analyzer is performing a dark calibration procedure This procedure measures and stores the inherent dc offset of the sync demod board DING ELEC DIE electronics PRESSURE CALI BRATI ON The analyzer records the current output of the sample gas pressure sensor This value is used by the CPU to compensate the DIAG Rene concentration FLOW CALI BRATI ON This function is used to calibrate the gas flow output signals of sample gas and ozone DI AG FCAL 6 9 8 supply These settings are retained when exiting DI AG iode OUTPUT Configures the A4 analog output DIAG TCHN 6 9 9 04584 Rev A1 66 Model GFC7000E Instruction Manual Operating Instructions 6 9 1 Accessing the Diagnostic Features To access the DI AG functions press the following keys SAMPLE RANGE 500 00 PPM CO2 ANALOG I CONFIGURATION lt TST TST gt CAL SETUP NEXT ENTR EXIT SAMPLE ENTER SETUP PASS 818 ELECTRICAL TEST ENTR ENTR EXIT SETUP X X PRI MARY SETUP MENU EXIT returns to the main SAMPLE CFG DAS RNGE PASS CLK MORE display ENTR EXIT DARK CALIBRA
65. DHCP you will have to configure the analyzer s interface manually See Section 6 10 9 3 3 3 Initial Calibration Procedure The next task is to calibrate the analyzer To perform the following calibration you must have sources for zero air and span gas available for input into the sample port on the back of the analyzer See Section 3 1 2 for instructions for connecting these gas sources While it is possible to perform this procedure with any range setting we recommend that you perform this initial checkout using the 50 ppm range NOTE The following procedure assumes that the instrument does not have any of the available Zero Span Valve Options installed See Section 7 4 for instructions for calibrating instruments possessing Z S valve options 1 Set the Analog Output Range of the MGFC7000E 04584 Rev A1 26 Model GFC7000E Instruction Manual Getting Started Press this button to set the analyzer for SNGL DUAL or AUTO ranges To change the value of the reporting range span enter the number by pressing the key under each digit until the expected value appears 4 lt SAMPLE RANGE 500 000 PPM X XXX lt TST TST gt CAL SETUP v SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR EXIT SETUP X X CFG DAS RNGE PASS CLK MORE EXIT SETUP X X RANGE CONTROL MENU MODE SET UNIT EXIT Press this button to select the concentration units of measure PP
66. Displays current Field compensated CO Concentration Mode Field N A Displays blinking Instrument is in sample mode but is still in the SAMPLE process of warming up STATUS LED s Sample Green On Unit is operating in sample mode front panel display is being updated Flashes On Off when adaptive filter is active The instrument s calibration is not enabled Fault Blinking The analyzer is warming up and hence out of specification for a fault free reading various warning messages will appear MODE FIELD MESSAGE FIELD LOCKI NG SCREW CONCENTRATION FIELD STATUS LED s FASTENER FASTENER SAMPLE A RANGE 500 0 PPM CO2 400 0 lt TST TST gt CAL SETUP KEY DEFINITIONS KEYBOARD OFF SWITCH Figure 3 10 Front Panel Layout 04584 Rev Al 23 Model GFC7000E Instruction Manual Getting Started 3 2 3 Warning Messages Because internal temperatures and other conditions may be outside be specified limits during the analyzer s warm up period the software will suppress most warning conditions for 30 minutes after power up If warning messages persist after the 30 minutes warm up period is over investigate their cause using the troubleshooting guidelines in Chapter 11 of this manual The following table includes a brief description of the various warning mess
67. EXIT 04584 Rev Al 51 Model GFC7000E I nstruction Manual Operating Instructions 6 4 SETUP Mode The SETUP mode contains a variety of choices that are used to configure the analyzer s hardware and software features perform diagnostic procedures gather information on the instruments performance and configure or access data from the internal data acquisition system iDAS For a visual representation of the software menu trees refer to Appendix A 1 The areas access under the Setup mode are Table 6 4 Primary Setup Mode Features and Functions KEYPAD MANUAL MODE OR FEATURE LABEL DESCRIPTI ON SECTION Analyzer Configuration CFG Lists key hardware and software configuration 6 5 information Used to set up an operate the AutoCal feature Auto Cal Feature ACAL Only appears if the analyzer has one of the internal 7 6 valve options installed Internal Data Acquisition 3 iDAS DAS Used to set up the iDAS system and view recorded data 6 12 Analog Output Reporting Used to configure the output signals generated by the RNGE 6 7 Range Configuration instruments Analog outputs Calibration Password PASS Turns the calibration password feature ON OFF 6 3 1 Security Internal CLK Used to Set or adjust the instrument s internal clock 6 6 Configuration J This button accesses the instruments secondary setup See Advanced SETUP features MORE menu Table 6 5 Table 6 5 Secondary S
68. Exhaust MO D E L control flow Vent Span G FC7000 E Pressure Span Indicating soda lime 125 MODEL 701 Zero Air Generator Figure 3 7 Pneumatic Connections MGFC7000E with Zero Span Valves 52 Source of SAMPLE Gas VENT if input is pressurized Certified MODEL 700 CO Gas Gas Dilution Calibrator Sample Exhaust MODEL ventspan GFC7000E Pressure Span Indicating soda lime External Zero Air Scrubber 125 MODEL 701 Zero Air Generator Purge In Figure 3 8 Pneumatic Connections MGFC7000E with Zero Span Valves with External Zero air Scrubber OPT 53 04584 Rev A1 20 Model 7 Instruction Manual Getting Started Some applications may require multipoint calibration checks where span gas of several different concentrations is needed We recommend using high concentration certified calibration gas supplied to the analyzer through a Gas Dilution Calibrator such as a Teledyne Instruments Model 700 This type of calibrator precisely mixes Span Gas and Zero Air to produce any concentration level between 0 ppm and the concentration of the calibrated gas Figure 3 8 depicts the pneumatic set up in this sort of application of a Model GFC7000E CO Analyzer with zero span shutoff valve option 50 installed a common configuration for this type of application Gas Pressure should be regulated at 30 35 PSIG Source of SAMPLE Gas SE VENT if input i
69. Figure 3 13 Internal Pneumatic Flow Basic Configuration 04584 Rev A1 31 Model GFC7000E Instruction Manual Getting Started User Notes 04584 Rev A1 32 Model GFC7000E Instruction Manual Frequently Asked Questions 4 FREQUENTLY ASKED QUESTI ONS 4 1 FAQ s The following is a list from the Teledyne Instruments Customer Service Department of the most commonly asked questions relating to the Model CO Analyzer How do I get the instrument to zero Why is the zero key not displayed See Section 11 2 4 Inability to zero How do I get the instrument to span Why is the span key not displayed See Section 11 2 3 Inability to span gt o gt o Why does the ENTR key sometimes disappear on the Front Panel Display A During certain types of adjustments or configuration operations the ENTR key will disappear if you select a setting that is nonsensical such as trying to set the 24 hour clock to 25 00 00 or out of the allowable range for that parameter such as selecting an iDAS Holdoff period of more than 20 minutes Once you adjust the setting in question to an allowable value the ENTR key will re appear Q Is there an optional midpoint calibration A There is an optional mid point linearity adjustment however midpoint adjustment is applicable only to applications where CO measurements are expected above 100 ppm Call Teledyne Instruments Service Department for more information on this topic
70. Filter Correlation Analyzer was tested found to be fully compliant with 61010 1 90 A1 92 A2 95 Tested on 02 06 2002 at Nemko Report Number 2002 012219 2 3 Warranty Warranty Policy 02024 Prior to shipment Teledyne Instruments Incorporated equipment is thoroughly inspected and tested Should equipment failure occur Teledyne Instruments Incorporated assures its customers that prompt service and support will be available Coverage After the warranty period and throughout the equipment lifetime Teledyne Instruments Incorporated stands ready to provide on site or in plant service at reasonable rates similar to those of other manufacturers in the industry All maintenance and the first level of field troubleshooting is to be performed by the customer Non API Manufactured Equipment Equipment provided but not manufactured by Teledyne Instruments Incorporated is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturers warranty General Teledyne Instruments Incorporated warrants each product manufactured by Teledyne Instruments Incorporated to be free from defects in material and workmanship under normal use and service for a period of one year from the date of delivery All replacement parts and repairs are warranted for 90 days after the purchase If a product fails to conform to its specifications within the warranty period
71. Functions NOTE CO MEAS and CO REF will be artificially altered to enforce a reading of 40 0 ppm All other Test Functions will report the correct operational value 04584 Rev Al 77 Model GFC7000E I nstruction Manual Operating Instructions 6 9 6 Dark Calibration Test The dark calibration test interrupts the signal path between the IR photo detector and the remainder of the sync demod board circuitry This allows the instrument to compensate for any voltage levels inherent in the sync demod circuitry that might effect the calculation of CO concentration Performing this calibration returns two offset voltages One for CO MEAS and on for CO REF that are automatically added to the CPU s calculation routine The two offset voltages from the last calibration procedure may be reviewed by the user via the front panel display To activate the dark calibration procedure or review the results of a previous calibration press SAMPLE RANGE 500 000 PPM CO2 lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 i 8 1 8 ENTR DIAG SIGNAL I O Y NEXT ENTR EXIT SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT C Repeat Pressing NEXT until 3 SETUP X X SECONDARY SETUP MENU DIAG DARK CALIBRATION COMM VARS DIAG ALRM EXIT PREV NEXT ENTR EXIT DIAG DARK CO DARK CALI
72. If the Range is too big the device will show minimal or no apparent change in readings STABIL Indicates noise level of instrument or CO concentration of sample gas see Section 11 3 2 for causes If the value displayed is too high the IR Source has become brighter Adjust the variable gain potentiometer on the sync demod board If the value displayed is too low or constantly changing and the REF is OK Failed multiplexer on the mother board Failed sync demod board CO2 MEAS Loose connector or wiring on sync demod board amp Flow of purge gas to the GFC wheel housing may have stopped If the value displayed is too low or constantly changing and the CO REF is BAD CO2 REF je GFC wheel stopped or rotation is too slow Failed sync demod board IR source Failed IR source Failed relay board Failed I C buss Failed IR photo detector When the analyzer is sampling zero air and the ratio is too low The reference cell of the GFC wheel is contaminated or leaking The alignment between the GFC wheel and the segment sensor the M R sensor or both is incorrect MR RATIO Failed sync demod board Flow of purge gas to the GFC wheel housing may have stopped When the analyzer is sampling zero air and the ratio is too high Zero air is contaminated Failed IR photo detector PRES See Table 11 1 for SAMPLE PRES WARN SAMPLE FL Check for gas flow problems see Section 11 1 6 SAMPLE SAMPLE TEMP should be close to BENCH TEMP Temperatures outside of the specified T
73. Instruction Manual MGFC7000E Documentation 1 MGFC7000E DOCUMENTATI ON Thank you for purchasing the Model GFC7000E Gas Filter Correlation Carbon Dioxide Analyzer The documentation for this instrument is available in several different formats e Printed format part number 045840100 e Electronic format on a CD ROM part number 045840200 The electronic manual is in Adobe Systems Inc Portable Document Format The Adobe Acrobat Reader software which is necessary to view these files can be downloaded for free from the internet at http www adobe com The electronic version of the manual has many advantages e Keyword and phrase search feature e Figures tables and internet addresses are linked so that clicking on the item will display the associated feature or open the website e A list of chapters and sections as well as thumbnails of each page are displayed to the left of the text e Entries in the table of contents are linked to the corresponding locations the manual e Ability to print sections or all of the manual Additional documentation for the Model GFC7000E Analyzer is available from Teledyne Analytical Instruments website at http www teledyne ai com manuals e APICOM software manual part number 03945 e Multi drop manual part number 01842 e DAS Manual part number 02837 1 1 Using This Manual This manual has the following data structures 1 0 Table of Contents Outlines the contents
74. Instruction Manual THEORY OF OPERATI 10 THEORY OF OPERATI ON The Model GFC7000E Gas Filter Correlation Carbon Dioxide Analyzer is a microprocessor controlled analyzer that determines the concentration of carbon dioxide CO a sample gas drawn through the instrument It requires that sample and calibration gasses be supplied at ambient atmospheric pressure in order to establish a stable gas flow through the sample chamber where the gases ability to absorb infrared radiation is measured Calibration of the instrument is performed in software and does not require physical adjustments to the instrument During calibration the microprocessor measures the current state of the IR Sensor output and various other physical parameters of the instrument and stores them in memory The microprocessor uses these calibration values the ir absorption measurements made on the sample gas along with data regarding the current temperature and pressure of the gas to calculate a final concentration This concentration value and the original information from which it was calculated are stored in one of the unit s internal data acquisition system iDAS see Sections 6 12 as well as reported to the user via a vacuum florescent display or a variety of digital and analog signal outputs 10 1 Measurement Method 10 1 1 Beer s Law The basic principle by which the analyzer works is called Beer s Law It defines the how light of a specific wavelen
75. MULTI DROP 19200 ENABLE MODEM 38400 ENABLE I NTERNET 57760 IGNORE ERRORS ON 115200 T Only appears if a valve is installed OFF Figure 5 Secondary Setup Menu COMM amp VARS 045840110 Rev B 3 227 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SETUP ENTER SETUP PASS 818 CLK MORE CFG RNGE PASS COMM VARS DI AG PREV NEXT JUMP EDIT PRINT DAS HOLD OFF CONC PRECI SI ON DYN ZERO OFF DYN SPAN OFF CLOCK ADJ COMM MENU TREE Fig A 5 SET SET gt INSTRUMENT IP GATEWAY IP SUBNET MASK TCP PORT HOSTNAME Go To DI AG MENU TREE Fig A 6 INSTRUMENT 1 GATEWAY IP SUBNET MASK TCP PORT Only appears if a valve option is installed 2 Only appears when the Ethernet card option 63 is installed 3 Although TCP PORT is editable regardless of the DHCP state do not change the setting for this property unless instructed to by Teledyne Instruments Customer Service personnel HOST NAME is only editable when DHCP is ON 5 INSTRUMENT GATEWAY IP amp SUBNET MASK are only editable when DHCP is OFF Figure A 6 Secondary Setup Menu COMM Menu with Ethernet Card 045840110 Rev B 3 228 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SETUP I ENTER SETUP PASS 818 CFG RNGE PASS CLK MORE COMM VARS DIAG
76. NEXT INS DEL EDIT PRNT EXIT pata aera SETUP X X SET SET EDIT PRINT Press SET key until SETUP X X NUMBER OF RECORDS 000 SET SET EDIT PRINT EXIT SETUP X X EDIT RECOPRDS DELET DATA NO returns to the previous menu ENTR accepts the new setting and returns to the previous menu YES will delete all data 4 in this channel pork NG Toggle keys to set number of records 1 99999 SETUP X X REPORT PERIODD DAYS 0 EXIT ignores the new setting and returns to the previous menu 0 ENTR EXIT 0 0 0 6 12 2 7 RS 232 Report Function MGFC7000E iDAS can automatically report data to the communications ports where they can be captured with a terminal emulation program or simply viewed by the user 04584 Rev A1 110 Model GFC7000E Instruction Manual Operating Instructions To enable automatic COM port reporting follow the instruction shown in section 6 12 2 2 then press From the DATA ACQUISITION menu see Section 6 12 2 2 SETUP X X 0 CONC ATIMER 1 900 Exits to the main Data Acquisition menu PREV NEXT INS DEL EDIT PRNT EXIT E SETUP SET SET EDIT PRINT Press SET gt key until SETUP X X 5 232 REPORT OFF SET SET EDIT PRINT SETUP X X RS 232 REPORT OFF Toggle key to turn reporting ON or OFF OFF ENTR EXIT 6 1
77. O CONFI GURATI ON MENU see Section 6 9 1 then press DIAG ANALOG I O CONFIGURATION EXIT to Return to the main Sample Display PREV NEXT ENTR EXIT DIAG AIO AOUTS CALIBRATED NO CAL Press SET gt to select the Analog Output channel to be configured Then Press EDIT to continue DIAG AIO CONC OUT 2 5V CAL SET SET EDIT DIAG AIO CONC OUT 2 RANGE 5V DIAG AIO SET SET DIAG AIO CONC OUT 2 REC OFS 0 mV DIAG AIO SET SET EDIT EXIT DIAG AIO CONC OUT 2 AUTO CAL ON DIAG AIO SET SET EXIT SET CONC OUT 2 CALIBRATED NO CAL EXIT AUTO CALIBRATING CONC OUT 2 CONC OUT 2 CALIBRATED YES CAL EXIT 04584 Rev A1 72 Model GFC7000E Instruction Manual Operating Instructions To select manual output calibration for a particular channel activate the ANALOG I O CONFI GURATI ON MENU see Section 6 9 1 then press DIAG ANALOG I O CONFIGURATION DIAG AIO CONC OUT 2 REC OFS 0 mV Exit to return to the main sample display PREV NEXT ENTR EXIT lt SET SET gt EDIT EXIT AOUTS CALIBRATED NO DIAGAIO CONC OUT 2 AUTO CAL ON SET SET CAL SET SET EDIT Press SET gt to select the analog output channel to be configured Then press EDIT to continue DIAG AIO CONC OUT 2 AUTO CAL ON DIAG AIO CONC OU
78. Options 5 5 1 RS232 Modem Cable Option 60 This option consists of a cable to connect the analyzer s 1 port to a computer a code activated switch or any other communications device that is equipped with a DB 9 male connector The cable is terminated with two DB 9 female connectors one of which fits the analyzer s COM1 port Some older computers or code activated switches with a DB 25 serial connector will need a different cable or an appropriate adapter 04584 Rev A1 41 Model GFC7000E Instruction Manual Optional Hardware and Software 5 5 2 RS 232 Multidrop Option 62 The multidrop option is used with any of the RS 232 serial ports to enable communications of several analyzers with the host computer over a chain of RS 232 cables The option consists of a small box which can be attached to the analyzer with a termination switch a power connector and two serial ports one incoming from the analyzer cable supplied and one outgoing requires additional cable to the next analyzer s multi drop box One Option 62 is required per analyzer The first incoming port on the first box connects to the host computer and the outgoing port on the last multi drop box needs to be terminated Setup and user instructions are covered in the Teledyne Instruments multi drop manual part number 021790000 5 5 3 Ethernet Option 63 The Ethernet option allows the analyzer to be connected to any Ethernet local area network LAN running T
79. Ring M R Sensor Ring Figure 10 10 Light Mask M R Sensor The emitter detector assembly that produces this signal shines through a portion of the mask that allows light to pass for half of a full revolution of the wheel The resulting light signal tells the analyzer whether the IR beam is shining through the measurement or the reference side of the GFC wheel Segment Sensor This emitter detector shines through a portion of the mask that is divided into the same number of segments as the portion of the mask through which the IR beam passes It is used by the 04584 Rev A1 164 Model GFC7000E Instruction Manual THEORY OF OPERATI synchronous demodulation circuitry of the analyzer to latch onto the most stable part of each measurement and reference IR pulse Measurement Pulses Reference Pulses IR Beam Pulses Segment Sensor MR Sensor LL buises Figure 10 11 Segment Sensor and M Sensor Output Schmidt Triggers To ensure that the waveforms produced by the Segment Sensor and the M R Sensor are properly shaped and clean these signals are passed through a set of Schmidt Triggers circuits 10 3 3 4 IR Photo Detector The IR beam is converted into an electrical signal by a cooled solid state photo conductive detector The detector is composed of a narrow band optical filter a piece of lead salt crystal whose electr
80. SAMPLE display 7 5 2 Use of Zero Span Valves with Remote Contact Closure Contact closures for controlling calibration are located on the rear panel CONTROL IN connector Instructions for setup and use of these contacts are found in Section 6 11 1 2 When the contacts are closed for at least 5 seconds the instrument switches into zero or span mode The remote calibration contact closures may be activated in any order Itis recommended that contact closures remain closed for at least 10 minutes to establish a reliable reading The instrument will stay in the selected mode for as long as the contacts remain closed If calibration is enabled the MGFC7000E will re calibrate when the contact is opened then go into SAMPLE mode If calibration is disabled the instrument will return to SAMPLE mode leaving the calibration unchanged 04584 Rev A1 138 Model GFC7000E Instruction Manual Calibration Procedures 7 6 Automatic Zero Span Cal Check AutoCal The AutoCal system allows unattended periodic operation of the ZERO SPAN valve options by using the MGFC7000E s internal time of day clock AutoCal operates by executing SEQUENCES programmed by the user to initiate the various calibration modes of the analyzer and open and close valves appropriately It is possible to program and run up to 3 separate sequences 5 01 SEQ2 and SEQ3 Each sequence can operate in one of 3 Modes or be disabled Table 7 1 AUTOCAL Modes MODE NAME ACTION
81. SETUP SECONDARY SETUP MENU DHCP ON COMM EXIT Continue with editing of Ethernet interface ENTR accept new settings properties see Step 2 below EXIT ignores new settings 04584 Rev A1 92 Model GFC7000E Instruction Manual Operating Instructions STEP 2 Configure the INSTRUMENT IP GATEWAY IP and SUBNET MASK addresses by pressing Internet Configuration Keypad Functions KEY FUNCTION From Step 1 above 0 Press this key to cycle through the range of numerals and available characters 0 9 amp CH CH Moves the cursor one character left or right DHCP OFF DEL Deletes a character at the cursor location Accepts the new setting and returns to the previous SEIS menu Ignores the new setting and returns to the previous menu INST IP 000 000 000 000 Some keys only appear as needed SET SET EDIT Cursor location is indicated by brackets INST IP 0 00 000 000 CH gt DEL 0 ENTR EXIT GATEWAY IP 000 000 000 000 SET SET EMIT GATEWAY 0 00 000 000 lt gt DEL 2 SUBNET MASK 255 255 255 0 lt SET SET gt EDIT ale MASK 2 55 255 255 0 TCP PORT 3000 CH CH DEL ENTR EXIT Y k lt SET The PORT number needs to remain at 3000 Do not change this setting unless instructed to by
82. The A1 and A2 channels output a signal that is proportional to the concentration of the sample gas Several modes are available which allow them to operate independently or be slaved together see Section 6 7 The user may also select between a variety of reporting range spans see Sections 6 7 3 6 7 4 and 6 7 5 EXAMPLE A1 OUTPUT Output Signal 0 5 VDC representing 0 1000 ppm concentration values A2 OUTPUT Output Signal 0 10 VDC representing 0 500 ppm concentration values The output labeled A3 is special It can be set by the user see Section 6 9 9 to output several of the test functions accessible through the lt TST TST gt keys of the units sample display Output A4 is not available on the Model GFC7000E analyzer 6 7 1 Physical Range versus Analog Output Reporting Ranges Functionally the Model GFC7000E Gas Filter Correlation CO Analyzer has one hardware Physical Range that is capable of determining CO concentrations between 50 ppb and 2 000 ppm This architecture improves reliability and accuracy by avoiding the need for extra switchable gain amplification circuitry Once properly calibrated the analyzer s front panel will accurately report concentrations along the entire span of its 50 ppb and 2 000 ppm physical range Because most applications use only a small part of the analyzer s physical range the width of the Model GFC7000E s physical range can create data resolution problems for most analog recording
83. To view the test functions press one of the TST TST keys repeatedly in either direction Table 6 2 Test Functions Defined Parameter Display Units Meaning 04584 Rev A1 46 Model GFC7000E Instruction Manual Operating Instructions Title Range RANGE PPB PPM The full scale limit at which the reporting range of the RANGE1 UGM analyzer is currently set RANGE2 MGM THIS IS NOT the Physical Range of the instrument See Section 6 7 for more information Stability STABIL PPB PPM Standard deviation of CO concentration readings Data UGM points are recorded every ten second The calculation uses MGM the last 25 data points CO Measure CO MV The demodulated peak IR detector output during the MEAS measure portion of the CFG Wheel cycle Reference CO REF MV The demodulated peak IR detector output during the reference portion of the CFG wheel cycle Measurement MR Ratio The result of CO2 MEAS divided by CO2 REF This ratio is Reference the primary value used to compute CO concentration The Ratio value displayed is not linearized Sample PRES In Hg A The absolute pressure of the Sample gas as measured by a Pressure solid state pressure sensor located inside the sample chamber Sample Flow SAMPLE cc min Sample mass flow rate This is computed from the differential FL between the pressures measured up stream and down stream of the sample critical flow
84. a problem with the wiring or the A D converter e If they are not then either the sync demodulator board or the IR photodetector are bad See also section 11 3 1 4 for problems with the IR Photodetector TEC drive 11 4 6 2 Opto Pickup Assembly Operation of the opto pickup PCA 04088 can be verified with a voltmeter Measure the AC and DC voltage between digital ground on the Relay board or Keyboard and TP1 and TP2 on the sync pickup PCA For a working board with the GFC motor spinning they should read 2 4 0 1 VAC 2 5 0 15 VDC Further confirmation that the pickups and motor are operating properly can be obtained by measuring the frequency at TP1 and TP2 using a frequency counter a digital volt meter with a frequency counter or an oscilloscope per the table below Table 11 9 Opto Pickup Board Nominal Output Frequencies NOMI NAL MEASURED FREQUENCY AC MAINS FREQ TP1 TP2 50 Hz 25 300 60 Hz 30 360 04584 Rev A1 202 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 11 4 6 3 GFC Wheel Drive If the D1 and D2 on the sync demodulator board are not flashing then 1 Check for power to the motor by measuring between pins 1 and 3 on the connector feeding the motor For instruments configured for 120 or 220 240VAC there should be approximately 88 VAC for instruments configured for 100VAC it should be the voltage of the AC mains approximately 100VAC Verify th
85. accurate this can be done by switching between two span gas tanks If the CO concentration is different there is a problem with one of the tanks 2 Check for leaks in the pneumatic systems as described in Section 9 3 3 3 Make sure that the expected span gas concentration entered into the instrument during calibration is the correct span gas concentration and not too different from expected span value This can be viewed via the RNG Menu see Section 6 7 4 Check to make sure that there is no ambient air or zero air leaking into span gas line 11 2 4 I nability to Zero No ZERO Key 1 Confirm that there is a good source of zero air Dilute a tank of span gas with the same amount of zero air from two different sources If the CO Concentration of the two measurements is different there is a problem with one of the sources of zero air 2 Check for leaks in the pneumatic systems as described in Section 9 3 3 3 The Internal zero air scrubber may need maintenance This device is only present if the analyzer has had zero span valve options 51 or 53 installed this 4 Check to make sure that there is no ambient air leaking into zero air line 11 3 Other Performance Problems Dynamic problems i e problems which only manifest themselves when the analyzer is monitoring sample gas can be the most difficult and time consuming to isolate and resolve The following section provides an itemized list of the most common dynamic problems wi
86. be easily replaced The table below lists the control device associated with a particular function Table 11 8 Relay Board Control Devices FUNCTI ON sti iig IN SOCKET Wheel Heater Yes Bench Heater K2 Yes Spare AC Control K3 Yes IZS Valves 04 Yes 04584 Rev A1 201 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES IR Source Drive U5 No The IR source drive output can be verified by measuring the voltage at J16 with the IR source disconnected It should be 11 5 0 5 VDC 11 4 6 Sensor Assembly 11 4 6 1 Sync Demodulator Assembly To verify that the Sync Demodulator Assembly is working follow the procedure below 1 Verify that D1 and D2 are flashing e If not check the opto pickup assembly Section 11 4 6 2 and the GFC wheel drive Section 11 4 6 3 e If the wheel drive and opto pickup are working properly then verify that there is 2 4 0 1 VAC and 2 5 0 15 VDC between digital ground and TP 5 on the sync demod board If not then check the wiring between the sync demod and opto pickup assembly see interconnect drawing 04216 If good then the sync demod board is bad 2 Verify that the IR source is operating Section 11 4 6 4 3 With the analyzer connected to zero air measure between TP11 measure and analog ground and TP12 reference and analog ground e If they are similar to values recorded on the Factory Data sheet then there is likely
87. bench temperature sensor Relay controlling the bench heater Failed relay board buss SOURCE WARNING lt when Ref is lt 1250 or 24950 mVDC Either of these conditions will result in an invalid M R ratio GFC wheel stopped Failed sync demod board If status LED s on the sync demod board ARE flashing the cause is most likely a failed IR source Relay board I C buss IR photo detector SYNC WARNI NG SYSTEM RESET WHEEL TEMP WARNI NG Phase Lock Loop PLL has lost lock on wheel rotation The computer has rebooted The filter wheel temperature is controlled at 68 5 GFC wheel stopped GFC wheel rotation very slow dragging Failed sync demod board If status LED s on the sync demod board ARE flashing the cause is most likely an a problem with the analyzer s main power Intermittent loss of the power supply too short to cause a SYSTEM RESET warning Frequency problem with the AC mains This message occurs at power on If it is confirmed that power has not been interrupted Failed 5 VDC power Fatal error caused software to restart Loose connector wiring Blocked Cooling Vents below GFC Assembly Analyzer s top cover removed Wheel heater Wheel temperature sensor Relay controlling the wheel heater Entire relay board 12 buss 11 1 2 Fault Diagnosis with TEST Functions Besides being useful as predictive diagnostic tools the test
88. chip However the actual number of records is also limited by the total number of parameters and channels and other settings in the iDAS configuration Every additional data channel parameter number of samples setting etc will reduce the maximum amount of data points somewhat In general however the maximum data capacity is divided amongst all channels max 20 and parameters max 50 per channel The iDAS will check the amount of available data space and prevent the user from specifying too many records at any given point If for example the iDAS memory space can accommodate 375 more data records the ENTR key will disappear when trying to specify more than that number of records This check for memory space may also make an upload of an iDAS configuration with APICOM or a Terminal program fail if the combined number of records would be exceeded In this case it is suggested to either try from the front panel what the maximum number of records can be or use trial and error in designing the iDAS script or calculate the number of records using the DAS or AICOM manuals To set the number of records for one channel from the front panel press SETUP DAS EDIT ENTR and the following key sequence 04584 Rev Al 109 Model GFC7000E Instruction Manual Operating I nstructions From the DATA ACQUISITION menu see Section 6 12 2 2 Edit Data Channel Menu SETUP X X 0 ATIMER 1 2 900 Exits to the main PREV
89. content equaling 80 of the range of compositions being measured EXAMPLE If the application is to measure between 0 ppm and 500 ppm an appropriate Span Gas would be 400 ppm If the application is to measure between 0 ppm and 100 ppm an appropriate Span Gas would be 80 ppm e Span Gas be purchased in pressurized canisters or created using Dynamic Dilution Calibrator such as the Teledyne Analytical Instruments Model 700 and a source of dried air scrubbed of CO such as a Teledyne Analytical Instruments Model 701 Zero Air Generator in combination with a canister of indicating soda lime Zero Air is similar in chemical composition to the earths atmosphere but scrubbed of all components that might affect the analyzer s readings In the case of CO measurements this means CO less than 0 1 ppm of CO and Water Vapor Zero Air can be purchased in pressurized canisters or created using a Teledyne Instruments Model 701 Zero Air Generator in combination with a canister of indicating soda lime 3 Attach an exhaust line to the exhaust outlet port e The exhaust from the pump and vent lines should be vented to atmospheric pressure using maximum of 10 meters of 14 PTEF tubing CAUTI ON Venting should be outside the shelter or immediate area surrounding the instrument 4 Attach a source of dried air scrubbed of CO to the purge inlet port NOTE The source of purge air should be at 20 25 psig and capable of mai
90. control 10 3 8 Power Supply Circuit Breaker The analyzer operates 100 VAC 115 VAC or 230 VAC power at either 50Hz or 60Hz Individual units are set up at the factory to accept any combination of these five attributes As illustrated in Figure 10 15 power enters the analyzer through a standard IEC 320 power receptacle located on the rear panel of the instrument From there it is routed through the On Off switch located in the lower right corner of the Front Panel A 6 75 Amp circuit breaker is built into the ON OFF Switch AC power is distributed directly to the sample gas pump The bench and GFC wheel heaters as well as the GFC wheel receive AC power via the relay board AC Line power is converted stepped down and converted to DC power by two DC power supplies One supplies 12 VDC for valves and the IR source while a second supply provides 5 VDC and 15 for logic and analog circuitry DC voltages are distributed via the relay board 04584 Rev A1 173 Model GFC7000E Instruction Manual THEORY OF OPERATI ON CAUTI ON Should the AC power circuit breaker trip investigate and correct the condition causing this situation before turning the analyzer back on ON OFF SWITCH AC POWER Display Pressure ee ENTRANCE Sensors ee Keypad 1 CPU 4 PS 1 5 VDC 15 VDC RELAY Mother BOARD Board KEY AC POWER
91. correct position Also make sure the MGFC7000E COM port is set for a baud rate that is compatible with the modem which needs to operate with an 8 bit word length with one stop bit The first step is to turn on the MODEM ENABLE communication mode Mode 64 Section 6 10 6 Once this is completed the appropriate setup command line for your modem can be entered into the analyzer The default setting for this feature is AT YO amp DO amp HO 810 50 2 amp BO amp N6 amp MO EO Q1 amp WO 04584 Rev A1 120 Model GFC7000E I nstruction Manual Operating Instructions This string can be altered to match your modem s initialization can be up to 100 characters long To change this setting press SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP i SAMPLE ENTER SETUP PASS 818 SETUP X X COM1 MODE 0 SET gt EDIT EXIT 8 1 8 ENTR SETUP 1 BAUD RATE 19200 f SET SET EDIT EXIT SETUP X X PRI MARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT EXIT returns SETUP X X COM1 MODEM INIT AT 2 amp D amp H SET SET EDIT EXIT to the a2 X X SECONDARY SETUP MENU previous menu COMM EXIT ENTR accepts the new string and ret
92. customer service 04584 Rev A1 189 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES because it may be possible to recover operation of the analyzer If after 30 60 seconds neither the DS5 is flashing or no characters have been written to the front panel display then the CPU is bad and must be replaced CPU Status LED Figure 11 3 CPU Status Indicator 11 1 4 2 Sync Demodulator Status LED s Two LED s located on the Sync Demod Board and are there to make it obvious that the Wheel is spinning and the synchronization signals are present Table 11 3 Sync Demod Board Status Failure I ndications LED Function Fault Status Indicated Failure s D1 M R Sensor LED is stuck GFC Wheel is not turning Status ON or OFF M R Sensor on Opto Pickup Board failed Sync Demod Board failed JP 4 Connector Wiring faulty Failed Faulty 5 VDC Power Supply PS1 D2 Segment LED is stuck GFC Wheel is not turning Sensor Status ON or OFF Segment Sensor on Opto Pickup Board failed Sync Demod Board failed JP 4 Connector Wiring faulty Failed Faulty 5 VDC Power Supply PS1 04584 Rev Al 190 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES JP4 Connector to Opto Pickup D1 M R Sensor Status Board D2 Segment Sensor Status Figure 11 4 Sync Demod Board Status LED Locations 11 1 4 3 Relay Board Status LED s There are eight LED s located
93. customized from the front panel to fit a specific application They can also be deleted to make room for custom user programmed Data Channels Appendix A 5 lists the firmware specific iDAS configuration in plain text format This text file can either be loaded into APICOM and then modified and uploaded to the instrument or can be copied and pasted into a terminal program to be sent to the analyzer NOTE Sending an iDAS configuration to the analyzer through its COM ports will replace the existing configuration and will delete all stored data Back up any existing data and the iDAS configuration before uploading new settings 04584 Rev A1 102 Model GFC7000E I nstruction Manual Operating I nstructions 6 12 2 1 Viewing iDAS Data and Settings iDAS data and settings can be viewed on the front panel through the following keystroke sequence SAMPLE RANGE 500 000 PPM CO2 lt TST TST CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X DATA ACQUISITION VIEW KEYPAD FUNCTIONS KEY FUNCTION PRM Moves to the next Parameter gt Moves to the previous Parameter NX10 Moves the view forward 10 data points channels NEXT Moves to the next data point channel PREV Moves to the previous data point channel PV10 Moves the view back 10 data p
94. demodulated into 2 MEAS and CO2 REF by the sync demod board and converted to digital data by the mother board the MGFC7000E analytical software calculates the ratio between CO2 MEAS and CO2 REF this value is compared to a look up table is used with interpolation to linearize the response of the instrument The linearized concentration value is combined with calibration slope and offset values then normalized for changes in sample gas pressure to produce the final concentration This is the value that is displayed on the instrument front panel display and is stored in memory by the analyzer s iDAS system 10 5 4 Temperature and Pressure Compensation Changes in pressure can have a noticeable effect on the concentration calculation To account for this the Model GFC7000E software includes a feature which allows the instrument to compensation of the calculations based on changes in ambient pressure The TPC feature multiplies the analyzer s concentration by a factor which is based on the difference between the ambient pressure of the sample gas normalized to standard atmospheric pressure As ambient pressure increases the compensated concentration is increased 10 5 5 Internal Data Acquisition System iDAS The iDAS is designed to implement predictive diagnostics that stores trending data for users to anticipate when an instrument will require service Large amounts of data can be stored in non vola
95. devices For example in an application where the expected concentration of CO is typically less 04584 Rev A1 56 Model GFC7000E Instruction Manual Operating I nstructions than 500 ppm the full scale of expected values is only 25 of the instrument s 2 000 ppm physical range Unmodified the corresponding output signal would also be recorded across only 25 of the range of the recording device The MGFC7000E solves this problem by allowing the user to select a scaled reporting range for the analog outputs that only includes that portion of the physical range relevant to the specific application Only the reporting range of the analog outputs is scaled the physical range of the analyzer and the readings displayed on the front panel remain unaltered 6 7 2 Reporting Range Modes The MGFC7000E provides three analog output range modes to choose from e Single range SNGL mode sets a single maximum range for the analog output If single range is selected see Section 6 7 3 both outputs are slaved together and will represent the same measurement span e g 0 50 ppm however their electronic signal levels may be configured for different ranges e g 0 10 VDC vs 0 1 VDC See Section 6 9 4 1 Dual range DUAL allows the A1 and A2 outputs to be configured with different measurement spans see Section 6 7 4 as well as separate electronic signal levels see Section 6 9 4 1 e Auto range AUTO mode gives the analyzer to ability to out
96. dud nce de dented ERR 82 6 10 2 COMM Port Default Settings i e ERR RR RR Rr Papa ea ARE 83 6 10 3 COMM Port Cable 4 4 4 4 2 44 1 REE esiste seen nnn 84 6 10 4 RS 485 Configuration Of COM2 2 IRE LN EE bed BER CHAR E E ERE M 84 6 10 5 DTE and DCE Commu nicatiOn eiie oe cone 85 6 10 6 COMM Port Communication 11202 emis emn enne enne 85 6 10 7 COM Port Baud Rate iint reto ea i ded ERR RUE ERR eR E caa ae aa ded 88 6 10 8 COM Port Testing o cereo erret ret ea DEN E ra eru aT 89 6 10 9 Ethernet card Configuration uteri rre eee eo De xa eR RF rudd tae rere nap ARE anneaux MER Ke 89 6 10 9 1 Ethernet Card COM2 Communication Modes and Baud 90 6 10 9 2 Configuring the Ethernet Interface Option using 0552 90 6 10 9 3 Manually Configuring the Network IP 08 92 6 10 9 4 Changing the Analyzer s 5 42 12 1 1 6 1 94 6 11 SETUP ALRM Using the Gas Concentration
97. hold circuits that capture various voltage levels found in the amplified detector signal needed to determine the value of CO2 MEAS and CO2 REF They are activated by logic signals under the control of a compact programmable logic device PLD which in turn responds to the output of the Segment Sensor and M R Sensor described in Figure 10 11 04584 Rev A1 166 Model GFC7000E Instruction Manual THEORY OF OPERATI The four sample and hold circuits are DESI GNATI ON ACTIVE WHEN SEGMENT SENSOR PULSE IS Measure Dark Gate LOW Reference Gate HIGH Reference Dark Gate REFERENCE cell of GFC Wheel LOW Timing for activating the Sample and Hold circuits is provided by a phase lock loop circuit PLL Using the segment sensor output as a reference signal the PLL generates clock signal at ten times that frequency This faster clock signal is used by the PLD to make the sample and hold circuits capture the signal during the center portions of the detected waveform ignore the rising and falling edges of the detector signal Sample amp Hold Active Detector Output Sample amp Hold Inactive Figure 10 13 Sample amp Hold Timing 10 3 4 3 Phase Lock Warning In order to detect critical fault conditions such as a failure of either the segment sensor or the GFC wheel motor the synch demod board also performs a simple check of the above signal synchronization to make sure everyt
98. in dual range mode or auto range mode then the high and low ranges must be independently calibrated When the analyzer is in either dual or auto range modes the user must run a separate calibration procedure for each range After pressing the CAL CALZ or CALS keys the user is prompted for the range that is to be calibrated as seen in the CALZ example below 04584 Rev A1 137 Model GFC7000E Instruction Manual Calibration Procedures SAMPLE RANGE 500 000 PPM CO2 Set the Display to show the STABIL test function lt TST TST gt CALZ CALS SETUP This function calculates the stability of the measurement SAMPLE STABIL XXX X PPM CO2 XXX X lt TST TST gt CALZ CALS SETUP ACTION Allow zero gas to enter the sample port at the rear of the instrument Wait until STABIL falls below 1 0 ppb This may take several minutes M P CAL STABIL XXX X PPM XXX X lt TST TST gt cAz CALS SETUP SAMPLE RANGE TO CAL LOW LOW HIGH ENTR SETUP SAMPLE RANGE TO CAL HIGH LOW HIGH ENTR SETUP ANALYZER ENTERS F ZERO CAL MODE ZERO CAL M RANGE 500 000 PPB 502 X XXX lt TST TST gt ZERO SPAN CONC EXIT Continue Calibration as per Standard Procedure Once this selection is made the calibration procedure continues as previously described in Section 7 2 The other range may be calibrated by starting over from the main
99. make sure to press CAL or CALS button prior to introducing span gas into the analyzer To enable either of the CO concentration alarms and set the Limit points press SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP d SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR SETUP ALARM MENU SETUP X X PRIMARY SETUP MENU ALM1 ALM2 EXIT CFG DAS RNGE PASS CLK MORE EXIT SETUP X ALARM 1 LIMIT OFF SETUP SECONDARY SETUP MENU OFF ENTR EXIT ALRM SETUP X ALARM 1 LIMIT ON ON ENTR EXIT Toggle these keys to cycle through the available character set SETUP ALARM 1 LIMIT 200 00 PPM ENTR key accepts the new settings 0 1 0 0 0 0 ENTR EXIT EXIT key ignores the new settings 04584 Rev A1 95 Model GFC7000E Instruction Manual Operating I nstructions 6 12 SETUP DAS Using the Data Acquisition System IDAS MGFC7000E analyzer contains a flexible and powerful internal data acquisition system iDAS that enables the analyzer to store concentration and calibration data as well as a host of diagnostic parameters The iDAS of the MGFC7000E can store up to about one million data points which can depending on individual configurations cover days weeks or months of valuable measurements The data are stored in non volatile memory and are retained even when the instrument is powered off Data are stored in plain text forma
100. number of samples in average APICOM user interface for configuring the iDAS Figure 6 8 Once an iDAS configuration is edited which can be done offline and without interrupting DAS data collection it is conveniently uploaded to the instrument and can be stored on a computer for later review alteration or documentation and archival Refer to the APICOM manual for details on these procedures The APICOM user manual Teledyne Instruments part number 039450000 is included in the APICOM installation file which can be downloaded at http www teledyne api com software apicom Although Teledyne Analytical Instruments recommends the use of APICOM the iDAS can also be accessed and configured through a terminal emulation program such as HyperTerminal Figure 6 9 However all configuration commands must be created following a strict syntax or be pasted in from of a text file which was edited offline and then uploaded through a specific transfer procedure 04584 Rev A1 113 Model GFC7000E Instruction Manual Operating Instructions gt M200E at CAS HyperTerminal 101 File Edit View Cal Transfer SETUP PROPERTIES FOR ENGDAT NAME ENGDAT EVENT ATIMER REPORT PERIOD 000 00 02 NUMBER RECORDS 2000 RS 232 REPORT CHANNEL ENABLED ON CAL HOLD OFF OFF PARAMETERS 14 PARAMETER RCTEMP MODE AVG PRECISION 4 STORE_SAMPLES OFF PRRRMETER CNVTMP MODE AVG PRECISION 4 STORE SRMPLES OFF PRRRMETER PM
101. of the bench heater also includes circuitry that selects which one of its two separate heating elements is activated depending on whether the instrument is running on 100 VAC 115 VAC or 230 VAC line power 04584 Rev A1 168 Model GFC7000E Instruction Manual THEORY OF OPERATION GFC Wheel Motor Control The GFC wheel operates from a AC voltage supplied by a multi input transformer located on the relay board The step down ratio of this transformer is controlled by factory installed jumpers to adjust for 100 VAC 115 VAC or 230 VAC line power Other circuitry slightly alters the phase of the AC power supplied to the motor during start up based on whether line power is 50Hz or 60 Hz Normally the GFC Wheel Motor is always turning while the analyzer is on A physical switch located on the relay board can be used to turn the motor off for certain diagnostic procedures Zero Span Valve Options Any zero span shutoff valve options installed in the analyzer are controlled by a set of electronic switches located on the relay board These switches under CPU control supply the 12VDC needed to activate each valve s solenoid Source The Relay board supplies a constant 11 5VDC to the IR Source Under normal operation the IR source is always on 10 3 5 1 Status LED s Eight LED s are located on the analyzer s relay board to show the current status on the various control functions performed by the relay board see Figure 10 14 Th
102. of the display keyboard driver PCA on the right side To activate this feature the instrument must also have a specially programmed Disk on Chip containing the second language User Notes 04584 Rev A1 44 Model GFC7000E Instruction Manual Operating I nstructions 6 OPERATI NG INSTRUCTI ONS To assist in navigating the analyzer s software a series of menu trees can be found in Appendix A 1 of this manual NOTES The flow charts appearing in this section contain typical representations of the analyzer s display during the various operations being described These representations may differ slightly from the actual display of your instrument The ENTR key may disappear if you select a setting that is invalid or out of the allowable range for that parameter such as trying to set the 24 hour clock to 25 00 00 Once you adjust the setting to an allowable value the ENTR key will re appear 6 1 Overview of Operating modes The MGFC7000E software has a variety of operating modes Most commonly the analyzer will be operating in SAMPLE mode In this mode a continuous read out of the CO concentration is displayed on the front panel and output as an analog voltage from rear panel terminals calibrations can be performed and TEST functions and WARNI NG messages can be examined The second most important operating mode is SETUP mode This mode is used for performing certain configuration operations such as for the iDAS sy
103. protection gear These include everything needed to create a temporary anti ESD work area anywhere Always wear an Anti ESD wrist strap when working on the electronic assemblies of your analyzer An anti ESD wrist strap keeps the person wearing it at or near the same potential as other grounded objects in the work area and allows static charges to dissipate before they can build to dangerous levels Anti ESD wrist straps terminated with 04584 Rev A1 216 Model GFC7000E Instruction Manual A Primer on Electro Static Discharge alligator clips are available for use in work areas where there is no available grounded plug Also anti ESD wrist straps include a current limiting resistor usually around one meg ohm that protects you should you accidentally short yourself to the instrument s power supply e Simply touching a grounded piece of metal is insufficient While this may temporarily bleed off static charges present at the time once you stop touching the grounded metal new static charges will immediately begin to re build In some conditions a charge large enough to damage a component can rebuild in just a few seconds Always store sensitive components and assemblies in anti ESD storage bags or bins Even when you are not working on them store all devices and assemblies in a closed anti Static bag or bin This will prevent induced charges from building up on the device or assembly and nearby static fields from discharging throu
104. pump periodically wears out and must be replaced A sample rebuild kit is available see Appendix B of this manual for the part number of the pump rebuild kit Instructions and diagrams are included with the kit Always perform a Flow and Leak Check after rebuilding the Sample Pump 9 3 3 Performing Leak Checks Leaks are the most common cause of analyzer malfunction Section 9 3 3 1 presents a simple leak check procedure Section 9 3 3 2 details a more thorough procedure 9 3 3 1 Vacuum Leak Check and Pump Check This method is easy and fast It detects but does not locate most leaks it also verifies that the sample pump is in good condition 1 Turn the analyzer ON and allow enough time for flows to stabilize 2 Cap the sample inlet port 3 After several minutes when the pressures have stabilized note the following In the TEST menu note the SAMPLE PRESSURE reading 4 Ifthe reading is 10 in Hg the pump is in good condition and there are no large leaks 5 If both readings are equal within 1096 the instrument is free of large leaks 9 3 3 2 Pressure Leak Check If you can t locate the leak by the above procedure use the following procedure Obtain a leak checker similar to the Teledyne Instruments part number 01960 which contains a small pump shut off valve and pressure gauge Alternatively a convenient source of low pressure gas is a tank of span gas with the two stage regulator adjusted to less than 15 psi wit
105. response when performing a zero point calibration during an AutoCal Chapter 7 DYN_ SPAN ON OFF Note that the DYN_ZERO and DYN_SPAN features are not allowed for applications requiring EPA equivalency Adjusts the speed of the analyzer s clock Choose the CLOCK ADJ sign if the clock is too slow choose the sign if 60 to 60 s day the clock is too fast 04584 Rev A1 64 Model GFC7000E Instruction Manual Operating Instructions To access and navigate the VARS menu use the following key sequence SAMPLE RANGE 500 000 PPM 2 X XXX lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 ENTR SETUP X X PRI MARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT ignores the new setting SECONDARY SETUP MENU ENTR accepts the new setting COMM VARS DIAG ALRM SETUP X X 0 DAS_HOLD_OFF 15 0 Minutes SETUP X X DAS_HOLD_OFF 15 0 Minutes NEXT JUMP EDIT PRNT EXIT 1 5 0 ENTR EXIT Toggle this keys to change setting SETUP X X CONC_PRECUISION 3 SETUP X X 6 CONC_PRECUISION 3 PREV NEXT JUMP EDIT PRNT EXIT AUTO 0 1 2 3 4 ENTR EXIT Toggle these keys to change setting 4 DYN ZERO ON PREV NEXT JUMP EDIT PRNT EXIT SETUP X X ZERO ON ON ENTR EXIT SETUP X X 5 SPAN ON Toggle this keys to change setting PREV NEXT JUMP EDIT EXIT SETUP X X DYN SPAN ON
106. several inches or sometimes even feet away from the surface bearing the charge It still works so there was no damage Sometimes the damaged caused by electro static discharge can completely sever a circuit trace causing the device to fail immediately More likely the trace will be only partially occluded by the damage causing degraded performance of the device or worse weakening the trace This weakened circuit may seem to function fine for a short time but even the very low voltage and current levels of the device s normal operating levels will eat away at the defect over time causing the device to fail well before its designed lifetime is reached These latent failures are often the most costly since the failure of the equipment in which the damaged device is installed causes down time lost data lost productivity as well as possible failure and damage to other pieces of equipment or property Static Charges can t build up on a conductive surface There are two errors in this statement Conductive devices can build static charges if they are not grounded The charge will be equalized across the entire device but without access to earth ground they are still trapped and can still build to high enough levels to cause damage when they are discharged A charge can be induced onto the conductive surface and or discharge triggered in the presence of a charged field such as a large static charge clinging to the surface of a nylon jacket of s
107. single gas instrument that measures As such it s default gas ID has already been set to 310 There is no need to change this setting 04584 Rev A1 126 Model GFC7000E Instruction Manual Operating Instructions 6 13 4 7 Setting Hessen Protocol Status Flags Teledyne Instruments implementation of Hessen protocols includes a set of status bits that the instrument includes in responses to inform the host computer of its condition Each bit can be assigned to one operational and warning message flag The default settings for these bit flags are Table 6 31 Default Hessen Status Bit Assignments STATUS FLAG NAME DEFAULT BIT ASSI GNMENT INVALID CONC 0080 The Instrument s Front Panel Display Will Show The Concentration As XXXX Relay Board Warning Front Panel Warning NOTES It is possible to assign more than one flag to the same Hessen status bit This allows the grouping of similar flags such as all temperature warnings under the same status bit Be careful not to assign conflicting flags to the same bit as each status bit will be triggered if any of the assigned flags is active 04584 Rev A1 127 Model GFC7000E Instruction Manual Operating Instructions To assign or reset the status flag bit assignments press SAMPLE RANGE 500 000 PPM CO2 lt TST TST CAL lt SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR SETUP X X PRIMARY SE
108. strikes a solid state photo detector that converts the light signal into a modulated voltage signal representing the attenuated intensity of the beam 10 1 3 Gas Filter Correlation Unfortunately water vapor absorbs light at 4 3 um too To overcome the interfering effects of water vapor the Model GFC7000E adds another component to the IR light path called a gas filter correlation GFC wheel see Figure 10 2 04584 Rev A1 154 Model GFC7000E Instruction Manual THEORY OF OPERATI ON Measurement Cell Pure Reference Cell with Figure 10 2 GFC Wheel A GFC wheel is a metallic wheel into which two chambers are carved The chambers are sealed on both sides with material transparent to 4 3 IR radiation creating two airtight cavities Each cavity is filled with specially composed gases One cell is filled with pure Nz the measure cell The other is filled with a combination of and a high concentration of CO the reference cell IR unaffected by N in Measurement Cell i IR IS affected by CO in Reference Cell IR Source Photo Detector GFC Wheel Figure 10 3 Measurement Fundamentals with GFC Wheel As the GFC wheel spins the IR light alternately passes through the two cavities When the beam is exposed to the reference cell the CO the gas filter wheel strips the beam of most of the IR at 4 3um When the light beam is exposed to the measurement cell the Nz in the filter wh
109. those in response to a command line request are in the format X DDD HH MM Id MESSAGE CRLF Where X is a command type designator a single character indicating the message type as shown in the Table 6 27 DDD HH MM is the time stamp the date and time when the message was issued It consists of the Day of year DDD as a number from 1 to 366 the hour of the day HH as a number from 00 to 23 and the minute MM as a number from 00 to 59 ID is the analyzer ID a number with 1 to 4 digits MESSAGE is the message content that may contain warning messages test measurements iDAS reports variable values etc CRLF is a carriage return line feed pair which terminates the message The uniform nature of the output messages makes it easy for a host computer to parse them into an easy structure Keep in mind that the front panel display does not give any information on the time a message was issued hence it is useful to log such messages for trouble shooting and reference purposes Terminal emulation programs such as HyperTerminal can capture these messages to text files for later review 6 13 2 6 Remote Access by Modem The MGFC7000E can be connected to a modem for remote access This requires a cable between the analyzer s COM port and the modem typically a DB 9F to DB 25M cable available from Teledyne Instruments with part number WR0000024 Once the cable has been connected check to make sure the DTE DCE is in the
110. voltage in use if 1 The Sample Pump is running 2 The GFC wheel motor is spinning a slight vibration should be apparent to the touch 3 If incorrect power is suspected check that the correct voltage and frequency is present at the line input on the rear panel e If the unit is set for 230 VAC and is plugged into 115VAC or 100 the sample pump will not start and the heaters will not come up to temperature e If the unit is set for 115 or 100 VAC and is plugged into a 230 VAC circuit the circuit breaker built into the ON OFF Switch on the Front Panel will trip to the OFF position immediately after power is switched on 04584 Rev A1 199 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 11 4 2 DC Power Supply If you have determined that the analyzer s AC mains power is working but the unit is still not operating properly there may be a problem with one of the instrument s switching power supplies The supplies can have two faults namely no DC output and noisy output To assist tracing DC Power Supply problems the wiring used to connect the various printed circuit assemblies and DC Powered components and the associated test points on the relay board follow a standard color coding scheme as defined in Table Table 11 6 DC Power Test Point and Wiring Color Codes NAME TEST POI NT TP AND WIRE COLOR Dgnd 1 Black 5V 2 Red Agnd 3 Green 15V 4 Blue 1
111. will not change Only the voltage reading of your voltmeter will change 7 46 DIAG AIO CONC OUT 1 CALIBRATED YES SET CAL EXIT 04584 Rev A1 74 Model GFC7000E Instruction Manual Operating Instructions 6 9 4 4 Current Loop Output Adjustment A current loop option is available and can be installed as a retrofit for each of the analog outputs of the analyzer Sections 5 2 This option converts the DC voltage analog output to a current signal with 0 20 mA output current The outputs can be scaled to any set of limits within that 0 20 mA range However most current loop applications call for either 2 20 mA or 4 20 mA range All current loop outputs have a 5 over range Ranges with the lower limit set to more than 1 mA e g 2 20 or 4 20 mA also have a 5 under range To switch an analog output from voltage to current loop after installing the current output printed circuit assembly follow the instructions in Section 6 9 4 4 and select CURR from the list of options on the RANGE menu Adjusting the signal zero and span values of the current loop output is done by raising or lowering the voltage of the respective analog output This proportionally raises or lowers the current produced by the current loop option Similar to the voltage calibration the software allows this current adjustment to be made in 100 10 or 1 count increments Since the exact current increment per voltage count varies from outpu
112. 000 CO slope for current range computed during zero span calibration CO2OFFSET 2 OFFSET 0 000 7 offset for current range computed during zero span calibration 17 7 CO concentration for current range CO2 CO2 15 0 concentration for current range TESTCHAN 5 1751 4 MV Value output to TEST OUTPUT analog output selected with TEST CHAN ID variable CLOCKTI ME 09 52 20 Current instrument time of day clock The name is used to request a message via the RS 232 interface as T Engineering software Current instrument units M300ES M300EH Except GFC7000EU APR version M306E Sample pressure or differential pressure flow measurement option GFC7000E 045840110 Rev B 3 239 Model 360E Instruction Manual APPENDIX 4 MGFC7000E Signal Definitions Revision APPENDIX 4 MGFC7000E Signal 1 Definitions Revision 0 Table A 4 GFC7000E Signal I O Definitions Revision 0 BI T OR CHANNEL DESCRIPTION NUMBER SYNC OK sync OK sync error SE Internal outputs 98 J 108 pins 1 8 bits 0 7 default I C ELEC TEST electrical test on off DARK CAL 1 dark calibration on 0 off ae ee ee Spare I2C_RESET 1 reset I2C peripherals 0 normal I2C_DRV_RST 7 0 hardware reset 8584 chip 1 normal Control inputs U11 J 1004 pins 1 6 bits 0 5 default 1 address 321 hex ica ds
113. 000E I nstruction Manual APPENDIX A 2 Setup Variables For Serial 1 Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 SETUP VARI ABLE NUMERI C DEFAULT VALUE VALUE RANGE DESCRI PTI ON UNITS ET TARGET CONC PPM 40 400 1 10000 Target concentration during electrical test ET CONC RANGE Conc 50 5000 28 0 1 50000 D A concentration range during electrical test STD TEMP oK 321 1 500 Standard temperature for temperature compensation STD PRESS Hg 28 5 28 7 8 28 8 1 50 Standard pressure for 28 14 pressure compensation BENCH SET 48 0 100 Optical bench temperature Warnings 43 53 set point and warning limits WHEEL SET oc 68 0 100 Wheel temperature set point Warnings 63 73 and warning limits ZERO ENABLE 5 8 ON OFF OFF ON ON enables auto zero calibration using scrubber OFF disables it ZERO FREQ Minutes 5 20 0 1 1440 Auto zero calibration frequency ZERO DWELL 3 5 8 Seconds 7 55 1 60 1 30 gt Dwell time after closing or Minutes opening zero scrubber valve ZERO SAMPLES 58 Samples 15 1 1000 Number of zero samples to average ZERO FILT SIZE Samples 5 1 100 Auto zero offset moving average filter size ZERO LIMIT 3 5 8 Ratio 0 5 Minimum auto zero ratio allowed must be greater than this value to be valid ZERO_CAL Calibrated auto zero ratio 5 1 40 400 8 1 10000 1 20000 38 during span calibration of range 1
114. 00E s display can begin to show garbled information or lock up if the DC voltage supplied to it falls too low even momentarily To alleviate this a brown out watchdog circuit monitors the level of the power supply and in the event that the voltage level falls below a certain level turns the display off then on resetting it 1 C Link To The Relay While the CPU s IC communication with the relay board is also routed through the keyboard display interface information passed to and from the relay board via this channel is not recognized by acted upon or affected by the circuitry of the keyboard display interface 10 5 Software Operation The Model GFC7000E Gas Filter Correlation Carbon Dioxide Analyzer is at its heart a high performance 386 based microcomputer running MS DOS Inside the DOS shell special software developed by Teledyne Instruments interprets user commands via the various interfaces performs procedures and tasks stores data in the CPU s various memory devices and calculates the concentration of the sample gas 04584 Rev A1 178 Model GFC7000E Instruction Manual THEORY OF OPERATION AI FIRMWARE Memorv Handlin Analyzer Operations Calibration Procedures IDAS Records Calibration Data Configuration Procedures Autonomic Systems System Status Data Diagnostic Routines PC 104 BUS ANALYZER HARDWARE Interface Handling Sensor input Data Display Messages
115. 03 SETUP X X CALIBRATE OFF lt SET SET gt EDIT EXIT Toggle key SETUP X X CALIBRATE OFF between LI Off and ON ENTR EXIT ON SETUP CALIBRATE ON lt SET SET gt EDIT EXIT clock PM hours are SET SET EDIT EXIT Toggle keys to set time SETUP STARTING 00 00 Format This is a 24 hr SET SET EDIT EXIT SETUP X X us ZERO SPAN 2 00 39 EXIT returns to the SETUP re Menu 13 24 Example 2 15 PM 14 15 SETUP X X STARTING TIME 00 00 1 4 1 5 ENTR EXIT PREV NEXT SET ANT EXIT iub Delta Time MODE Delta Days 04584 Rev A1 141 Model GFC7000E Instruction Manual Calibration Procedures 7 6 1 AutoCal with Auto or Dual Reporting Ranges Modes Selected SETUP C 4 RANGE TO CAL LOW SET EDIT SETUP C 4 RANGE TO CAL LOW LOW HIGH ENTR SETUP SETUP C 4 RANGE TO CAL HIGH SET EXIT SETUP C 4 SEQ 2 ZERO SPAN 2 00 30 EXIT returns to the PRIMARY SETUP PREV NEXT SET EXIT Menu NOTE I n order to automatically calibrate both the HIGH and LOW ranges you must set up a separate sequence for each 7 7 Calibration Quality After completing one of the calibration procedures described above it is important to evaluate the analyzer s calibration SLOPE and OFFSET parameters These values describe the linear response c
116. 04584 Rev A1 40 Model GFC7000E Instruction Manual Optional Hardware and Software INSTRUMENT CHASSIS SAMPLE GAS INLET m1 _ Sample Gas Critical Flow Orifice I PUMP GFC Wheel EXHAUST GAS Purge Gas el OUTLET Flow Control Pee Orifice M Motor Heat Sync Pressure Control Assy xx GFC Wheel I I I I I I I I I I I I FLOW PRESSURE SAMPLE SENSOR PRESSURE PURGE GAS Housing INLET 1 SENSOR RON SAMPLE CHAMBER VENT SPAN SENSOR OUTLET EE Y I I PRESSURE SPAN INLET ZERO SPAN SAMPLE CAL VALVE External CO Scrubber Option 53 Only 7 PARTICULATE FILTER Ly IZS INLET AN Figure 5 3 Internal Pneumatic Flow Zero Span OPT 52 amp 53 5 4 4 Span Valve with External Scrubber Option 53 Option 53 is operationally and pneumatically identical to Option 52 above see Section 5 4 3 except that the zero air is generated by an externally mounted zero air scrubber filled with indicating soda lime that changes color from white to pink as it becomes saturated 5 5 Communication
117. 1 The vacuum fluorescent display is good if on power up a character is visible on the upper left hand corner of the display The CPU Status LED DS5 is flashing see Section 11 1 4 1 If there is a character on the display at power up and D1 on the relay board is flashing then the keyboard display interface PCA is bad If the analyzer starts operation with a normal display but pressing a key on the front panel does not change the display then there are three possible problems e One or more of the keys is bad e The interrupt signal between the Keyboard Display interface and the motherboard is broken or e The Keyboard Display Interface PCA is bad 11 4 5 Relay Board The relay board PCA 04135 can be most easily checked by observing the condition of the its status LEDs on the relay board as described in Section 11 1 4 3 and the associated output when toggled on and off through signal I O function in the diagnostic menu see Section 11 1 3 1 If the front panel display responds to key presses D1 on the relay board is NOT flashing then either the wiring between the Keyboard and the relay board is bad or the relay board is bad If D1 on the relay board is flashing and the status indicator for the output in question heater power valve drive etc toggles properly using the signal I O function then the associated control device on the relay board is bad Several of the control devices are in sockets and can
118. 1 then press sume FROM ANALOG I CONFIGURATION eu DIAG ANALOG I CONFIGURATION Exit at any time to return to the main DIAG menu PREV NEXT ENTR EXIT Continue pressing SET until DIAG AIN CALIBRATED NO SET SET Instrument DIAG AIO e CALIBRATING A D ZERO D calibrates automatically CALIBRATING A D SPAN d sz O Mt Exit to return to the DIAG AIO AIN CALIBRATED YES ANALOG 1 0 CONFIGURATION SET SET CAL EXIT MENU 6 9 5 Electric Test The electric test function substitutes simulated signals for CO MEAS and CO REF generated by circuitry on the sync demod board for the output of the IR photo detector While in this mode the user can also view the same test functions viewable from the main SAMPLE display When the test is running the concentration reported on the front panel display should be 40 0 ppm SAMPLE RANGE 500 000 PPM CO2 X XXX DIAG SIGNAL I O lt TST TST gt CAL SETUP NEXT ENTR EXIT SAMPLE ENTER SETUP PASS 818 Repeat Pressing NEXT unti 8 1 8 ENTR DIAG ELECTRIC TEST SETUP X X PRIMARY SETUP MENU PREV NEXT CFG DAS RNGE PASS CLK MORE EXIT DIAG ELEC RANGE 50 000 PPM CO2 40 0 SETUP X X SECONDARY SETUP MENU Exit returns to the TST 5 gt EXIT DIAG Menu COMM VARS DIAG ALRM EXIT Press lt TST TST gt to view Test
119. 1 00AM Do Sequence 2 every other day Do Sequence 2 hr later each day Operate Span valve for 15 min Do not calibrate at end of Sequence NOTE The programmed STARTING TI ME must be a minimum of 5 minutes later than the real time clock See Section 6 6 for setting real time clock NOTE Avoid setting two or more sequences at the same time of the day Any new sequence which is initiated whether from a timer the COM ports or the contact closure inputs will override any sequence which is in progress NOTE If at any time an illegal entry is selected Example Delta Days gt 367 the ENTR key will disappear from the display 04584 Rev A1 140 Model GFC7000E Instruction Manual Calibration Procedures To program the Sequence i SETUP STARTING TIME 14 15 SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL CALZ CALS SETUP v SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR v SETUP X X PRIMARY SETUP MENU CFG ACAL DAS RNGE PASS CLK MORE EXIT SETUP X X SEQ 1 DISABLED NEXT MODE EXIT NE SETUP X X SEQ 2 DISABLED PREV NEXT MODE EXIT SETUP X X MODE DISABLED NEXT ENTR EXIT SET SET EDIT EXIT SETUP X X DELTA DAYS 1 SET SET EDIT EXIT Toggle keys y to set S 24 number of SETUP X X DELTA DAYS
120. 18 PRI MARY SETUP MENU SETUP X X CFG DAS RNGE PASS CLK MORE EXIT returns to the previous COMM menu SETUP X X SECONDARY SETUP MENU Select which COM SETUP COMMUNICATIONS MENU port to configure ID COM1 COM2 The sum of the mode IDs of the selected modes is displayed here SET gt EDIT SETUP X X COM1 QUIET MODE OFF NEXT ENTR EXIT Continue pressing next until SETUP X X COM1 HESSEN PROTOCOL OFF Use PREV and NEXT keys to move between available modes PREV NEXT ENTR EXIT A mode is enabled by toggling the ON OFF key ENTR key accepts the new settings SETUP COM1 HESSEN PROTOCOL ON EXIT key ignores the new settings PREV NEXT ENTR Continue pressing the NEXT and PREV keys to select any other modes you which to enable or disable 04584 Rev Al 87 Model GFC7000E I nstruction Manual Operating Instructions 6 10 7 COM Port Baud Rate To select the baud rate of one of the COM Ports press SAMPLE RANGE 500 000 PPM CO2 lt TST TST CAL SETUP SAMPLE ENTER SETUP PASS 818 SETUP X X PRI MARY SETUP MENU CFG DAS RNGE PASS CLK MORE SECONDARY SETUP MENU SETUP X X COMMUNICATIONS MENU Select which COM port to configure ID COM1 2 SETUP 1 MODE 0 Press SET until you reach COM1 BAUD RATE SET
121. 2 A obstruction upstream or downstream of the flow sensor 3 Bad Flow Sensor Board 4 Bad pump To determine which is the case view the sample pressure and sample flow functions on the front panel If the sample pressure is reading abnormally low then the cause is likely a flow obstruction upstream of the flow sensor First check the sample filter and make sure it is not plugged and then systematically check all the other components upstream of the orifice to ensure that they are not obstructed If the sample pressure is reading normal but the sample flow is reading low then it is likely that the pump diaphragm is worn or there is an obstruction downstream of the flow sensor 11 1 6 5 Actual Flow Does Not Match Displayed Flow If the actual flow measured does not match the displayed flow but is within the limits of 720 880 cc min adjust the calibration of the flow measurement as described in Section 6 9 8 11 1 6 6 Sample Pump The sample pump should start immediately after the front panel power switch is turned ON With the Sample Inlet plugged the test function PRES should read about 10 Hg for a pump in good condition Readings above 15 Hg indicate that the pump needs rebuilding If the test function SAMP FL is greater than 10 cc the instrument s there is a leak in the pneumatic lines 11 1 7 Poor or Stopped Flow of Purge Gas If sufficient purge gas is not supplied to the GFC wheel housing cyclical fluctuations in reading
122. 2 2 8 Compact Report ENTR accepts the new setting and returns to the previous menu EXIT ignores the new setting and returns to the previous menu When enabled this option avoids unnecessary line breaks on all RS 232 reports Instead of reporting each parameter in one channel on a separate line up to five parameters are reported in one line 6 12 2 9 Starting Date This option allows to specify a starting date for any given channel in case the user wants to start data acquisition only after a certain time and date If the Starting Date is in the past the iDAS ignores this setting 6 12 2 10 Disabling Enabling Data Channels Data channels can be temporarily disabled which can reduce the read write wear on the disk on chip The ALL 01 channel of the MGFC7000E for example is disabled by default 04584 Rev A1 111 Model GFC7000E Instruction Manual Operating Instructions To disable a data channel follow the instruction shown in section 6 12 2 2 then press From the DATA ACQUISITION menu see idi 6 12 2 2 Edit Data Channel Menu i SETUP X X 0 1 900 Exits to the main Data Acquisition PREV NEXT INS DEL EDIT PRNT EXIT menu SETUP SET SET EDIT PRINT EXIT Press SET key until SETUP X X CHANNEL ENABLE ON SET SET gt EDIT PRINT EXIT ENTR accepts the new L setting and returns to the
123. 4584 Rev A1 100 Model GFC7000E I nstruction Manual Operating Instructions Triggering Events and Data Parameters Functions for these default channels are LIST OF CHANNELS NAME CONC EVENT ATIMER REPORT PERIOD 000 01 00 NO OF RECORDS 800 5 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF ON NAME PNUMTC EVENT ATIMER REPORT PERIOD 001 00 00 NO OF RECORDS 360 5 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF NAME CALDAT EVENT SLPCHG REPORT PERIOD N A NO OF RECORDS 200 5 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF NAME STBZRO EVENT EXITZR REPORT PERIOD N A NO OF RECORDS 200 5 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF NAME STBSPN EVENT EXITSP REPORT PERIOD N A NO OF RECORDS 200 5 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF NAME TEMP EVENT ATIMER REPORT PERIOD 000 06 00 NO OF RECORDS 400 5 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF Figure 6 7 LIST OF PARAMETERS PARAMETER CONC1 MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER SMPLFLW MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER SMPLPRS MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER SLOPE1 MODE INST PRECISION 3 STORE NUM SAMPLES OFF PARAMETER OFSET1 MODE INST PRECISION 1 STORE NUM SAMPLES OFF PARAMETER ZSCNC1 MODE INST PRECISION 1 STORE NUM SA
124. 5 Figure A 6 Figure A 7 Figure A 8 Pneumatic Connections MGFC7000E with Zero Span Valves with External Zero air Scrubber OPI 53 EE eaa Due a Fus Sume nct rins ix 135 Sample Particulate Filter Assembly ennemi nnn 149 Measurement Fundamentals 6 6 ERR REESE REE nn nnn 154 ema og eye xe ER base EP RA En Se DK Ere EN EE 155 Measurement Fundamentals with 1 2 155 Affect of the Sample CO2 MEAS amp CO2 156 Effects of Interfering Gas on CO2 MEAS amp CO2 157 Chopped IR Signal aov kd a Du Saeed n 157 Internal Pneumatic Flow Basic Configuration 111111 159 Flow Control Assembly amp Critical Flow Orifice cesses mmm 160 GFC7000E Electronic Block Diagram 0 162 GFE LIGNE Mask nne ode et a er t n ab nce a eR dc t 164 Segment Sensor and M R Sensor 1 4441 21 1 nnn 165 GFC7000E Sync Demod Block Diagram 166 amp Hold adiit cerner t th rests d Debe ea
125. 5V 5 Yellow 12V 6 Purple 12R 7 Orange A voltmeter should be used to verify that the DC voltages are correct per the values in Table below and an oscilloscope AC mode with band limiting turned can be used to evaluate if the supplies are producing excessive noise 100 mV p p Table 11 7 DC Power Supply Acceptable Levels CHECK RELAY BOARD TEST POINTS VOLTAG FROM TEST E POINT TO TEST POINT MIN V MAX V s 11 4 3 I1 C Bus Operation of the buss can be verified by observing the behavior of D1 on the Relay Board in conjunction with the performance of the front panel display Assuming that the DC power supplies are operating properly and the wiring from the Motherboard to the Keyboard and the wiring from the keyboard to the Relay board is intact the buss is operating properly if 04584 Rev A1 200 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES e D1 on the relay board is flashing or e D1 is not flashing but pressing a key on the front panel results in a change to the display 11 4 4 Keyboard Display I nterface The front panel keyboard display and Keyboard Display Interface PCA 03975 or 04258 can be verified by observing the operation of the display when power is applied to the instrument and when a key is pressed on the front panel Assuming that there are no wiring problems and that the DC power supplies are operating properly
126. 6 Model GFC7000E I nstru ction Manual Operating I nstructions To configure a specific data parameter press FROM THE EDIT DATA PARAMETER MENU see previous section PREV NEXT INS SETUP X X 0 PARAM CONC1 MODE AVG DEL EDIT EXIT gt EDIT SETUP PARAMETERS CONC SETUP PARAMETERS PMTDET ENTR EXIT If more than parameter is active for this channel these cycle through list of existing Parameters SET SET gt EDIT o SETUP X X SAMPLE MODE AVG EXIT SETUP X X SAMPLE MODE INST INST AVG MIN MAX EXIT Press the key for the desired mode SET SET EDIT SETUP X X PRECISION 1 EXIT SETUP X X PRECISION 1 i 1 Set for 0 4 SETUP STORE NUI lt SET EDIT SAMPLES OFF EXIT EXIT SETUP STORE NUM SAMPLES OFF OFF ENTR EXIT NE Turn ON or OFF 6 12 2 5 Sample Period and Report Period accepts the new setting and returns to the previous menu EXIT ignores the new setting and returns to the previous SET Returns to previous Functions The iDAS defines two principal time periods by which sample readings are taken and permanently recorded SAMPLE PERIOD Determines how often iDAS temporarily records a sample reading of the par
127. 7 6 1 AutoCal with Auto or Dual Reporting Ranges Modes 142 7 4 Calibration Quallty Medea xt aa rea aM M KR rade 142 8 EPA PROTOCOL CALI BRATION 143 9 MAINTENANCE SCHEDULE amp PROCEDURES 145 9 1 Maintenance Schedules iiir oinin sinni der RR RR GR 145 9 2 Predicting Failures Using the Test Functions 148 9 3 Maintenance Procedures a ER dA Mae rua ob anes EN MENU iE ek 148 9 3 1 Replacing the Sample Particulate 1 149 9 3 2 Rebuilding the Sample PUMP ral ere Re FR XE 150 9 3 3 Performing Leak Checks et dem se exe on tree gee ing EO oth hal ake reru di xe desta edlen 150 9 3 3 1 Vacuum Leak Check and Pump 242 1 1 150 9 3 3 2 Pressure beak Check 150 9 3 4 Performing a Sample Flow Check etit eee nn ren Ra dad Pagi 151 9 3 5 Gleaning the Optical Bench ii
128. 78 mm x 432 mm x 597 mm 38 Ibs 17 kg add 1 Ibs 0 5 kg for IZS AC Power Rating 100 V 50 60 Hz 3 25 115 V 60 Hz 3 0 A 220 240 V 50 60 Hz 2 5 A Environmental Analog Outputs Installation category over voltage category II Pollution degree 2 Three 3 Outputs Analog Output Ranges 0 1V 1 V 5 V 10 V 2 20 or 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 Status Outputs Control Inputs 8 Status outputs opto isolated including 2 alarm outputs 6 Control Inputs 3 defined 3 spare Serial I O One 1 RS 232 One 1 RS 485 Baud Rate 300 115200 Optional Ethernet Interface Certifications CE EN61010 1 90 A1 92 A2 95 EN61326 Class A At constant temperature and voltage 04584 Rev A1 Model GFC7000E Instruction Manual Specifications Approvals and Warranty 2 2 CE Mark Compliance Emissions Compliance The Teledyne Instruments Model GFC7000E Gas Filter Correlation Analyzer was tested found to be fully compliant with 61326 1997 w A1 98 Class A FCC Part 15 Subpart B Section 15 107 Class ICES 003 Class A ANSI C63 4 1992 amp AS NZS 3548 w A1 amp A2 97 Class A Tested 11 29 2001 at Laboratories Inc Report Number 01 249 Safety Compliance The Teledyne Instruments Model GFC7000E Gas
129. AIO CONC OUT 2 SPAN 10000 mV Continue adjustments until the correct current is measured with the current meter DIAG CONC OUT 2 RANGE CURR U100 UP10 UP DOWN DN10 D100 SET SET EDIT EXIT DIAG AIO OUT 2 ZERO 9731 mV EXIT ignores the new setting ENTR DIAG AIO CONC OUT 2 CALIBRATED NO 9100 UP10 UP DOWN DN10 D100 ENTR EXIT accepts the new setting SET CAL EXIT DIAG AIO CONC OUT 2 CALIBRATED YES DIAG AUTO CALI BRATI CONC OUT 2 SET CAL EXIT If a current meter is not available an alternative method for calibrating the current loop outputs is to connect a 250 1 resistor across the current loop output Using a voltmeter connected across the resistor follow the procedure above but adjust the output to the following values Table 6 13 Current Loop Output Calibration with Resistor Voltage for 2 20 mA Voltage for 4 20 mA Full scale 3 measured across resistor measured across resistor 0 0 5 V 1 0 V 100 5 0 V 5 0 V 04584 Rev A1 76 Model GFC7000E Instruction Manual Operating Instructions 6 9 4 5 AI N Calibration This is the sub menu to conduct the analog input calibration This calibration should only be necessary after major repair such as a replacement of CPU motherboard or power supplies Activate the ANALOG 1 CONFI GURATI ON MENU see Section 6 9
130. AMP LAMP RATIO STR LGT DARK PMT DARK LAMP SLOPE OFFSET HVPS TEST FUNCTIONS RCELL TEMP Viewable by user while Only appears when warning messages are activated BOX TEMP instrument is in see Section 6 2 2 PMT TEMP SAMPLE Mode Press this key to cycle through list of active warning 125 TEMP see Section 6 2 1 messages TEST Press this key to clear erase the warning message TI ME currently displayed Figure A 1 Basic Sample Display Menu 045840110 Rev B 3 223 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SAMPLE TEST CAL CALZ CALS MSG CLR SETUP Only appear if reporting range TST TST gt is set for LOW HI GH LOW HI GH LOW HI AUTO range mode RANGE ZERO SPAN 2 SPAN CONC ENTER SETUP PASS 818 STABIL CO2 MEAS CO2 REF MR RATIO PRES SAMP FL Primary Setup Menu SAMP TEMP BENCH TEMP WHEEL TEMP BOX TEMP CFG DAS RANG 55 CLK MORE PHT DRIVE SLOPE OFFSET FEST TEST FUNCTIONS Secondary Setup Menu Viewable by user while instrument is in SAMPLE Mode see Section 6 2 1 1 Only appears when warning messages are activated see Section 6 2 2 COMM VARS DIAG nly appears instrument 15 set Tor 2 i 2 DUAL or AUTO reporting range 2 to cycle through list of active warning modes 3 Press this key to clear erase the warning message currently displayed Figure A 2 Sample Disp
131. AUD RATE 300 1200 2400 RS 232 1 baud rate 4800 9600 19200 38400 57600 115200 MODEM INIT to 100 characters to modem on power up or long manually BitFlag RS 232 COM2 mode flags Same settings as RS232 MODE BAUD RATE2 300 1200 2400 RS 232 COM2 baud rate 4800 9600 19200 38400 57600 115200 MODEM INI T2 AT YO amp DO amp HO 810 Any character in RS 232 COM2 modem 50 2 amp BO amp N6 amp MO the allowed initialization string Sent EO Q1 amp WO character set Up verbatim plus carriage return to 100 characters to modem on power up or long manually 940331 0 999999 RS 232 log on password 300 3204 0 9999 Unique ID number for instrument COMMAND PROMPT Cmd Any character in RS 232 interface command the allowed prompt Displayed only if character set enabled with RS232 MODE to 100 characters variable long 045840110 234 Model GFC7000E I nstruction Manual APPENDIX A 2 Setup Variables For Serial 1 Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 SETUP VARI ABLE NUMERI C DEFAULT VALUE VALUE RANGE DESCRI PTI ON UNITS TEST CHAN ID NONE NONE Diagnostic analog output ID CO MEASURE CO REFERENCE VACUUM PRESSURE SAMPLE PRESSURE SAMPLE FLOW SAMPLE TEMP BENCH TEMP WHEEL TEMP CHASSIS TEMP PHT DRIVE REMOTE CAL MODE LOW Range to calibrate during contact closure or Hessen calibration PASS E
132. Additionally the synch demod board contains circuitry that controls the photo detector s thermoelectric cooler as well as circuitry for performing certain diagnostic tests on the analyzer 04584 Rev A1 165 Model GFC7000E Instruction Manual THEORY OF OPERATION CO MEAS Sample Photo Signal detector Conditioner Hold Circuits Generator e I CO Reference Signal Conditioner Thermo Electric Cooler Control Circuit E Test A Gate E Test B Gate Compact Programmable Logic Device Phase Lock Warning M R Sensor From GFC Segment Sensor Segment Clock X1 Reference X10 Clock Phase Lock Figure 10 12 GFC7000E Sync Demod Block Diagram E Test Control From CPU 10 Control Segment M R Status LED Status LED 10 3 4 2 Signal Synchronization and Demodulation The signal emitted by the IR photo detector goes through several stages of amplification before it can be accurately demodulated The first is a pre amplification stage that raises the signal to levels readable by the rest of the synch demod board circuitry The second is a variable amplification stage that is adjusted at the factory to compensate for performance variations of mirrors detectors and other components of the optical bench from instrument to instrument The workhorses of the sync demod board are the four sample and
133. Assignments Pin COMI RS 232 2 RS 232 COM RS 485 1 Not used Not used Not used 2 Transmit Data Receive Data DATA 3 Receive Data Transmit Data Data 4 Not used Not used Not used 5 Signal Ground Signal Ground Signal Ground 6 Not used Not used Not used 7 DATA SET READY DATA SET READY Not used 8 REQUEST TO SEND REQUEST TO SEND Not used DTE Ready 9 Not used Not used Not used Configurable for 1 at rear panel using the DTE DCE switch 6 10 5 DTE and DCE Communication RS 232 was developed for allowing communications between data terminal equipment DTE and data communication equipment DCE Basic terminals always fall into the DTE category whereas modems are always considered DCE devices The difference between the two is the pin assignment of the Data Receive and Data Transmit functions DTE devices receive data on pin 2 and transmit data on pin 3 DCE devices receive data on pin 3 and transmit data on pin 2 To allow the analyzer to be used with terminals DTE modems DCE and computers which can be either a switch mounted below the serial ports on the rear panel allows the user to switch between the two functions 6 10 6 COMM Port Communication Modes Each of the analyzer s serial ports can be configured to operate in a number of different modes listed in Table 6 16 which can be combined by adding the mode ID numbers For example quiet mode compu
134. B PPM UGM MGM SETUP X X RANGE 500 000 CONC 0 0 5 0 0 ENTR EXIT EXIT ignores the new setting and returns to the RANGE CONTROL MENU ENTR accepts the new setting and SETUP X X RANGE 500 000 Conc returns to the RANGE CONTROL MENU 0 0 0 5 0 0 ENTR EXIT 04584 Rev A1 27 Model GFC7000E Instruction Manual Getting Started 2 Set the expected CO span gas concentration SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP This sequence causes the analyzer to prompt for the expected span concentration RANGE 500 00p PPM CO2 X XXX M P CAL lt TST TST gt ZERO EXIT The span concentration values automatically default to 400 0 Conc EXIT ignores the new setting and returns to the previous display ENTR accepts the new setting and returns to the previous display M P CAL CO2 SPAN CONC 400 000 Conc To change this value to the actual concentration of the span gas enter the number by pressing the key under each digit until the expected value appears ENTR EXIT NOTE For this Initial Calibration it is important to independently verify the precise CO Concentration Value of the SPAN gas If the source of the Span Gas is from a Calibrated Bottle use the exact concentration value printed on the bottle 04584 Rev A1 28 Model GFC7000E Instruction Manual
135. BRATION gt Exit returns to the VIEW CAL EXIT previous menu Calibration runs automatically Electric offset for Reference signal Y Y DIAG DARK DARK OFFSET 0 0 mV DIAG DARK CAL 1 COMPLETE Display tracks EXIT EXIT complete Electric offset for Measurement signal DIAG DARK MEAS DARK OFFSET 0 0 mV DIAG DARK DARK CALIBRATION ABORTED EXIT EXIT 6 9 7 Pressure Calibration A sensor at the exit of the sample chamber continuously measures the pressure of the sample gas This data is used to compensate the final concentration calculation for changes atmospheric pressure and is stored in the CPU s memory as the test function PRES also viewable via the front panel 04584 Rev Al 78 Model GFC7000E Instruction Manual Operating Instructions This calibration must be performed when the pressure of the sample gas is equal to ambient atmospheric pressure Before performing the following pressure calibration procedure disconnect the sample gas pump and the sample gas line vent from the sample gas inlet on the instrument s rear panel 04584 Rev A1 79 Model GFC7000E I nstruction Manual Operating Instructions To cause the analyzer to measure and record a value for PRES press SAMPLE RANGE 500 000 PPM 2 X XXX TST TST CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR Exit at Y oo any time to return SETUP X X PRIMA
136. CEDURES SAMPLE RANGE 500 000 PPM CO2 lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU VARS EXIT DIAG SIGNAL I O PREV ENTR EXIT DIAG I O 0 EXT_ZERO_CAL ON PREV NEXT JUMP PRNT EXIT If parameter is an If parameter is an output input signal signal or control DIAG I O 28 SAMPLE_PRESSURE 2540 MV DIAG I O 22 ON PREV JUMP PRNT EXIT PREV NEXT JUMP ON EXIT Toggles parameter ON OFF DIAG I O 22 OFF PREV NEXT JUMP OFF PRNT EXIT Exit returns to 4 DIAG display amp all values return to software control Figure 11 2 Example of Signal 1 Function 11 1 4 I nternal Electronic Status LED s Several LED s are located inside the instrument to assist in determining if the analyzer s CPU buss and relay board GFC wheel and the sync demodulator board are functioning properly 11 1 4 1 CPU Status I ndicator DS5 a red LED that is located on upper portion of the motherboard just to the right of the CPU board flashes when the CPU is running the main program loop After power up approximately 30 to 60 seconds DS5 should flash on and off If characters are written to the front panel display but DS5 does not flash then the program files have become corrupted contact
137. CP IP The local area network must have routers capable of operating at 10BaseT If Internet access is available through the LAN this option also allows communication with the instrument over the public Internet When installed this option is electronically connected to the instrument s COM2 serial port making that port no longer available for RS 232 RS 485 communications through the COM2 connector on the rear panel The option consists of a Teledyne Instruments designed Ethernet card Figure 5 4 which is mechanically attached to the instrument s rear panel A 7 foot long CAT 5 network cable terminated at both ends with standard RJ 45 connectors is included as well Maximum communication speed is limited by the RS 232 port to 115 2 kBaud ETHERNET OPTION Connector RJ 45 Connector Female RJ 45 Connector AT A2 A3 A4 LED LNK LED x CONTROL IN Activity ACT LED LED ABCDEF zu TxD LED Transmit RxD LED LED unnector to t Receive Motherboan 1 1 LED 1 1 Figure 5 4 7000 Ethernet Card and rear panel With Ethernet Installed 5 6 Additional Manuals 5 6 1 Printed Manuals Option 70 Additional printed copies of this manual are available from Teledyne Instruments 04584 Rev A1 42 Model GFC7000E Instruction Manual Optional Hardware and Software 5 6 2 Manual on CD Part number 045840200 This operators manual is also available on CD The electronic docu
138. Contact your IT Network Administrator ID INET EXIT Table 6 19 Internet Configuration Keypad Functions ims inserts character before the cursor location Press this key to cycle through the range of numerals and characters available for insertion 0 9 A Z space amp _ 4 lt gt ENTR Accepts the new setting and returns to the previous menu EXIT Ignores the new setting and returns to the previous menu 04584 Rev A1 94 Model GFC7000E Instruction Manual Operating Instructions 6 11 SETUP ALRM Using the Gas Concentration Alarms The Model GFC7000E includes two CO concentration alarms Each alarm has a user settable limit and is associated with an opto isolated TTL relay accessible via the status output connector on the instrument s back panel see Section 6 13 1 1 If the CO concentration measured by the instrument rises above that limit the alarm s status output relay is closed The default settings for ALM1 and ALM2 are Table 6 20 CO Concentration Alarm Default Settings ALARM STATUS LIMIT SET POINT ALM1 Disabled 100 ppm Alma Disabled 300 ppm Iset points listed are for PPM Should the reporting range units of measure be changed see Section 6 7 6 the analyzer will automatically scale the set points to match the new range unit setting Note To prevent the concentration alarms from activating during span calibration operations
139. DARY SETUP MENU COMM VARS DIAG SETUP 0 DAS HOLD OFF 15 0 Minutes NEXT JUMP EDIT PRNT EXIT TUPX X 1 CONC PRECISION 3 REV NEXT JUMP EDIT PRNT EXIT Continue to press NEXT until SETUP X X 4 CLOCK ADJ 0 Sec Day PREV JUMP EDIT PRNT EXIT CLOCK ADJ 0 Sec Day Enter sign and number of seconds per day the clock gains or loses P SETUP X X 4 CLOCK ADJ 0 Sec Day PREV NEXT JUMP EDIT PRNT EXIT 3x EXIT returns to the main SAMPLE display 04584 Rev A1 55 Model GFC7000E Instruction Manual Operating I nstructions 6 7 SETUP RNGE Analog Output Reporting Range Configuration The analyzer has three active analog output signals accessible through a connector on the rear panel ANALOG OUT SO concentration Test Channel outputs Not Used 1 2 4 LOW range when HIGH range when DUAL mode is selected DUAL mode is selected Figure 6 4 Analog Output Connector Pin Out three outputs can be configured either at the factory or by the user for full scale outputs of 0 1 VDC 1VDC 5VDC or 10VDC Additionally A1 and A2 may be equipped with optional 0 20 mADC current loop drivers and configured for any current output within that range e g 0 20 2 20 4 20 etc The user may also adjust the signal level and scaling of the actual output voltage or current to match the input requirements of the recorder or datalogger see Section 6 9 4
140. DAS Confiquration and Downloaded Data E CO CONCEO ATIMER 100 Records Maximum Configuration Data NXCNC1 PPM AVG Set 0 0 Records NOCNCI PPM AVG Set 0 0 Records CJ N2CNC1 PPM AVG Set 0 0 Records _GetConfig Auto Ong 0 STABIL PPM AVG Set 0 0 Records S C CALDAT ATIMER 100 Records Maximum Send To nas skated NXSLP1 AVG Set 0 0 Records CI NOSLP1 AVG Set 0 0 Records Lead Config Error NXZSC1 PPM AVG Set 0 0 Records E NOZSC1 PPM AVG Set 0 0 Records Save Config Save Data 1 N2CNC1 PPM AVG Set 0 0 Records xi STABIL PPM AVG Set D 0 Records New Config Basic Advanced E ENGDAT 100 Records Maximum Basic Seti SMPFLW cc m AVG Set 0 0 Records Nene O3FLOW cc m AVG Set 0 0 Records i RCPRES InHg AVG Set 0 0 Records New Chan Number of Records 100 5MPPRS InHg AVG Set 0 0 Records BOXTMP DegC AVG Set 0 0 Records Hew Param Trigger Event JATIMER E 4 Iv Enable Channel Hold Off Duplicate aij e Coe hec Edit Automatic Timer Settings Parameter PMTDET Start Date 01 Jan 02 X Delete D Sample ava v Cancel m Bun Sample Period D DD HH MM P im Report Pernod DDD HH MM f fo Store
141. E a LOGON feature can be enabled to require a password before the instrument will accept commands This is done by turning on the SECURI TY MODE Mode 4 Section 6 10 6 Once the SECURITY MODE is enabled the following items apply e A password is required before the port will respond or pass on commands e If the port is inactive for one hour it will automatically logoff which can also be achieved with the LOGOFF command e Three unsuccessful attempts to log on with an incorrect password will cause subsequent logins to be disabled for 1 hour even if the correct password is used e If not logged on the only active command is the request for the help screen e The following messages will be returned at logon e LOGON SUCCESSFUL Correct password given e LOGON FAILED Password not given or incorrect e LOGOFF SUCCESSFUL Connection terminated successfully To log on to the model GFC7000E analyzer with SECURITY MODE feature enabled type LOGON 940331 940331 is the default password To change the default password use the variable RS232 PASS issued as follows V RS232_PASS NNNNNN Where is any numeral between 0 and 9 6 13 2 8 Remote Control Program APICOM is an easy to use yet powerful interface program that allows to access and control any of Teledyne Instruments main line of ambient and stack gas instruments from a remote connection through direct cable modem or Ethernet Running APICOM a user can Es
142. EMP range or oscillating temperatures are cause for concern Bench temp control improves instrument noise stability and drift Temperatures outside of BENCH E US TEMP the specified range or oscillating temperatures are cause for concern See Table 11 1 for BENCH TEMP WARNING WHEEL Wheel temp control improves instrument noise stability and drift Outside of set point or TEMP oscillating temperatures are cause for concern See Table 11 1 for WHEEL TEMP WARNI NG If the box temperature is out of range check fan in the power supply module Areas to the BOX TEMP side and rear of instrument should allow adequate ventilation See Table 11 1 for BOX TEMP WARNI NG 04584 Rev A1 187 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES Table 11 2 Test Functions Indicated Failures cont TEST FUNCTI ONS I NDI CATED FAILURE S As Displayed If this drive voltage is out of range it may indicate one of several problems A poor mechanical connection between the various components in inside the detector housing PHT DRIVE An electronic failure of the IR Photo Detector s built in cooling circuitry or A temperature problem inside the analyzer chassis In this case other temperature warnings would also be active such as BENCH TEMP WARNI NG or BOX TEMP WARNI NG Values outside range indicate Contamination of the zero air or span gas supply Instrument is miss calibrated Blocked gas flow SL
143. EORY OF OPERATION 10 2 1 Sample Gas Flow r INSTRUMENT CHASSIS SAMPLE GAS z INLET 5 ve 89 j e 9 8 Purge Gas Src Wheel EXHAUST GAS Flow Rate Motor OUTLET Control Orifice PURGE GAS INLET Motor Purge Gas Heat Sync Pressure Control Assy gt GFC Wheel Housing VENT SPAN OUTLET SENSOR PCA PRESSURE SENSOR a SAMPLE CHAMBER SENSOR FLOW PRESSURE O SAMPLE PRESSURE SPAN INLET I PARTICULATE FILTER IZS INLET Figure 10 7 Internal Pneumatic Flow Basic Configuration 10 2 1 1 Critical Flow Orifice The most important component of this flow control assembly is the critical flow orifice Critical flow orifices are a remarkably simple way to regulate stable gas flow rates They operate without moving parts by taking advantage of the laws of fluid dynamics By restricting the flow of gas though the orifice a pressure differential is created This pressure differential combined with the action of the analyzer s external pump draws the gas through the orifice As the pressure on the downstream side of the orifice the pump side continu
144. FAX 626 961 2538 WEB SITE www teledyne ai com 5 1 Rack Mount Kits Options 20a 20b amp 21 Option Number Description OPT 20A Rack mount brackets with 26 in chassis slides OPT 20B Rack mount brackets with 24 in chassis slides OPT 21 Rack mount brackets only Each of these options permits the Analyzer to be mounted in a standard 19 x 30 RETMA rack 5 2 Current Loop Analog Outputs Option 41 This option adds isolated voltage to current conversion circuitry to the analyzer s analog outputs This option may be ordered separately for any of the analog outputs it can be installed at the factory or added later Call Teledyne Instruments sales for pricing and availability The current loop option can be configured for any output range between 0 and 20 mA Information on calibrating or adjusting these outputs can be found in Section 6 9 4 9 Current Loop Option Installed on Analog Output A2 Figure 5 1 Current Loop Option Installed on the Motherboard 04584 Rev A1 37 Model GFC7000E Instruction Manual Optional Hardware and Software 5 3 Expendable Kits Options 42C 42D and 43 OPTI ON NUMBER DESCRI PTI ON OPT 42C 1 year s supply of replacement of 47mm dia particulate filters OPT 42D 1 full replacement s volume of indicating soda lime for the external CO scrubber included with options 51 amp 53 approximate active lifetime 1 year OPT 43 Options 42 C amp 42D
145. FC7000E Instruction Manual A Primer on Electro Static Discharge 6 Disconnecting your wrist strap is always the last action taken before leaving the work bench 12 4 2 3 Transferring Components from Rack To Bench and Back When transferring a sensitive device from an installed Teledyne Instruments analyzer to a Anti ESD workbench or back 1 Follow the instructions listed above for working at the instrument rack and work station 2 Never carry the component or assembly without placing it in a anti ESD bag or bin 3 Before using the bag or container allow any surface charges on it to dissipate e If you are at the instrument rack hold the bag in hand while your wrist strap is connected to a ground point e If you are at a anti ESD work bench lay the container down on the conductive work surface e In either case wait several seconds 4 Place the item in the container 5 Seal the container If using a bag fold the end over and fastening it with anti ESD tape Never use standard plastic adhesive tape as a sealer e Folding the open end over isolates the component s inside from the effects of static fields e Leaving the bag open or simply stapling it shut without folding it closed prevents the bag from forming a complete protective envelope around the device 6 Once you have arrived at your destination allow any surface charges that may have built up on the bag or bin during travel to dissipate e Connect your wris
146. Getting Started 3 Perform the Zero Span Calibration Procedure SAMPLE RANGE 500 000 PPM 2 XXX X Set the Display to show the STABIL test function lt TST gt SETUP This function calculates the stability of the CO NES measurement SAMPLE STABIL XXX X PPM CO2 XXX X lt TST TST gt SETUP ACTION Allow zero gas to enter the sample port at the rear of the instrument Wait until STABIL falls below 1 0 ppm This may take several minutes M P CAL STABIL XXX X PPM lt TST TST gt A M P CAL STABIL XXX X PPM CO2 XXX X TST 5 gt ZERO CONC EXIT Press ENTR to changes the OFFSET amp SLOPE values for the measurements STABIL XXX X PPM CO2 XXX X lt TST TST gt ENTR CONC EXIT Press EXIT to leave the calibration unchanged and return to the previous menu ACTION Allow span gas to enter the sample port at the rear of the instrument The value of STABIL may jump significantly Wait until it falls back below 1 0 ppm The SPAN key now appears during the transition from zero to span You may see both keys If either the ZERO or SPAN buttons fail to appear see Section 11 for troubleshooting tips This may take several minutes M P CAL STABIL XXX X PPM CO2 XXX X IST TST gt SPAN CONC EXIT Press ENTR to change the OFFSET amp SLOPE values
147. H flash memory is non volatile solid state memory GFC Acronym for Gas Filter Correlation bus a clocked bi directional serial bus for communication between individual analyzer components 04584 Rev A1 34 Model GFC7000E Instruction Manual Frequently Asked Questions iDAS acronym for internal data acquisition system IP acronym for internet protocol LAN acronym for local area network LED acronym for light emitting diode PCA acronym for printed circuit assembly the gt PCB with electronic components ready to use PCB acronym for printed circuit board the bare board without electronic components RS 232 an electronic communications type of a serial communications port RS 485 an electronic communications type of a serial communications port TCP IP acronym for transfer control protocol internet protocol the standard communications protocol for Ethernet devices VARS acronym for variables the variables settings of the analyzer User Notes 04584 Rev A1 35 Model GFC7000E Instruction Manual Optional Hardware and Software 5 OPTIONAL HARDWARE AND SOFTWARE This section includes a brief description of the hardware and software options available for the Model GFC7000E Gas Filter Correlation Carbon Dioxide Analyzer For assistance with ordering these options please contact the Sales department of Teledyne Advanced Pollution Instruments at TEL 626 961 9221 TEL 626 934 1500
148. HEX Print test s to screen T ID name Print single test CLEAR ALL name hexmask Disable test s SET ALL name hexmask Display warning s W LIST ALL name hexmask NAMES HEX Print warning s name Clear single warning CLEAR ALL name hexmask Clear warning s ZERO LOWSPAN SPAN 1121 Enter calibration mode ASEQ number Execute automatic sequence C ID COMPUTE ZERO SPAN Compute new slope offset EXIT Exit calibration mode ABORT Abort calibration sequence LIST Print all I O signals name value Examine or set I O signal LIST NAMES Print names of all diagnostic tests ENTER name Execute diagnostic test EXIT Exit diagnostic test RESET DATA CONFIG exitcode Reset instrument D ID PRINT name SCRIPT Print iDAS configuration RECORDS name Print number of iDAS records REPORT name RECORDS number FROM lt start date gt TO lt end date VERBOSE COMPACT HEX Print DAS Print iDAS records records date format MM DD YYYY or YY HH MM SS CANCEL Halt printing iDAS records LIST Print setup variables name value warn_low warn_high Modify variable V ID name value Modify enumerated variable CONFIG Print instrument configuration MAINT ON OFF Enter exit maintenance mode MODE Print current instrument mode DASBEGIN lt data channel definitions gt DASEND CHANNELBEGIN propertylist CHANNELEND Upload iDAS configuration Uplo
149. INSTRUCTION MANUAL MODEL GFC7000E CARBON DI OXI DE ANALYZER TELEDYNE ANALYTI CAL INSTRUMENTS 16830 Chestnut St City of Industry Ca 91748 USA Phone 626 961 9221 Phone 626 934 1500 Fax 626 961 2538 Fax 626 934 1651 04584 REV A1 Copyright 2003 Teledyne I nstruments Incorporated 02 August 2004 Model GFC7000E Instruction Manual GFC7000E Documentation SAFETY MESSAGES Your safety and the safety of others is very important We have provided many important safety messages in 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 GENERAL SAFETY HAZARD Refer to the instructions for details on the specific hazard CAUTI ON Hot Surface Warning CAUTI ON Electrical Shock Hazard SYMBOL All operations marked with this symbol are to be performed by qualified maintenance personnel only CAUTI ON The analyzer should only be used for the purpose and in the manner described in this manual If you use the analyzer in a manner other than that for which it was intended unpredictable behavior could ensue with possible hazardous consequences 04584 Rev A1 i Model GFC7000E Instruction Manual GFC7000E Documenta
150. L I I I ENTR ENTR ENTR ENTR OUTPUT PREV NEXT I CAL EDIT I Start step Test Starts Test Starts Test ca EXT ZERO CAL 1 EXT SPAN CAL 2 SYNCOK ENTR FAIT 3 MAINT MODE 4 LANG2 SELECT NONE CO2 MEASURE AOUTS CALI BRATED lt SET SET gt COD REFERENCE 5 SAMPLE LED 6 CALLED SAMPLE PRESSURE 7 FAULT LED SAMPLE LOW XXX X MV SAMPLE FLOW 8 AUDIBLE BEEPER CAL SAMPLE LOW X X IN HG A 9 ELEC TEST SAMPLE HIGH XXX X MV SAMPLE TEMP 11 ST SYSTEM OK LE SAMPLE HIGH IN HG A WHEEL TEMP CONC OUT 2 12 ST CONC VALID CHASSIS TEMP 13 ST HIGH RANGE TEST OUTPUT PHT DRIVE 14 ST ZERO CAL 15 ST SPAN CAL 16 ST DIAG MODE ON 17 ST SYSTEM OK2 EDIT 18 ST CONC ALARM 1 19 ST CONC ALARM 2 r 20 RELAY WATCHDOG OFF 21 WHEEL HEATER lt SET SET gt 22 BENCH HEATER 23 CAL VALVE 24 SPAN VALVE Aqu RANGE OFFSET AUTO CAL CALI BRATED 26 INTERNAL ANALOG VOLTAGE SIGNALS o 45 see Appendix A 0 1V 1V 5V 10V CURR ON CAE 46 CONC OUT 1 OFF 47 CONC OUT 2 MV 48 TEST OUTPUT Only relevant to on M200EH Only relevant to analyzers with IZS options installed Figure 8 Secondary Setup Menu DI AG 045840110 Rev B 3 230 Model GFC7000E I nstruction Manual APPENDIX A 2 Setup Variables For Serial 1 Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 APPENDIX 2 Setup Variables For Serial Revision
151. M360 21 Front Panel LayQout i us my e Ra COP E YR RE ER YA RA RR RA a 23 Assembly X CRIT S I qi E TU eo DRE 30 Optical Bench LAYOUTS uote yr eR EE 31 Internal Pneumatic Flow Basic Configuration 31 Current Loop Option Installed on the Motherboard 37 Internal Pneumatic Flow Zero Span Shutoff Valves 50 amp 51 39 Internal Pneumatic Flow Zero Span OPT 52 amp 53 41 GFC7000E Ethernet Card and rear panel With Ethernet Installed 42 Front Panel Display esce rrr en ER RE RYE REX RA 45 Viewing MGFC7000E TEST LEE LEE ERE ERE nnn 48 Viewing and Clearing MGFC7000E WARNING 50 Analog Output Connector Pin 150 memes 56 Setup for Calibrating Analog Voltage 74 Setup for Calibrating Current 2 1 1 ERE ERE RER 75 Default iDAS Channels 6 nenas ana 101 APICOM user interface for configuring the
152. MPLES OFF PARAMETER STABIL MODE INST PRECISION 2 STORE NUM SAMPLES OFF PARAMETER DETMES MODE INST PRECISION 1 STORE NUM SAMPLES OFF PARAMETER RATIO MODE INST PRECISION 3 STORE NUM SAMPLES OFF PARAMETER DETMES MODE INST PRECISION 1 STORE NUM SAMPLES OFF PARAMETER RATIO MODE INST PRECISION 3 STORE NUM SAMPLES OFF PARAMETER BNTEMP MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER BOXTMP MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER PHTDRV MODE AVG PRECISION 1 STORE NUM SAMPLES OFF Default iDAS Channels Setup 04584 Rev A1 101 Model GFC7000E Instruction Manual Operating Instructions These default Data Channels can be used as they are or they can be customized from the front panel to fit a specific application They can also be deleted to make room for custom user programmed Data Channels Appendix A 5 lists the firmware specific iDAS configuration in plain text format This text file can either be loaded into APICOM and then modified and uploaded to the instrument or can be copied and pasted into a terminal program to be sent to the analyzer NOTE Sending an iDAS configuration to the analyzer through its COM ports will replace the existing configuration and will delete all stored data Back up any existing data and the iDAS configuration before uploading new settings These default Data Channels can be used as they are or they can be
153. Measure reference ratio measured during linearity adjustment for range 1 LIN CORRECT1 1 0 001 999 999 Linearity correction factor for range 1 LIN TARGET CONC2 Conc 300 1 10000 Target concentration during linearity adjustment for range 2 LIN NORM CONC2 PPM 300 0 01 10000 Target concentration during linearity adjustment normalized for T P for range 2 LIN RATIO2 1 0 01 100 Measure reference ratio measured during linearity adjustment for range 2 LIN CORRECT2 1 0 001 999 999 Linearity correction factor for range 2 LIN TARGET CONC Conc 300 1 10000 Target concentration during linearity adjustment 0 LIN NORM CONC 0 01 10000 Target concentration during LIN RATIO linearity adjustment normalized for T P 0 01 100 Measure reference ratio measured during linearity adjustment axo zu 0 001 999 999 Linearity correction factor 30 1 1 OFF ON OFF ON enables CO compensation OFF disables it 8 1 1 LIN CORRECT CO2 COMP ENABLE comi it 700 500 40000 3 8 100 50000 CO calculation constant CO CONST2 0 13 0 198 1 448 0 10 CO calculation constant 41 458 2 0 187 0 20 CO concentration to compensate for 0 0001 9 9999 Electrical test gain factor for measure reading ET MEAS GAIN ET REF GAIN ET TARGET DET 0 0001 9 9999 Electrical test gain factor for reference reading 4375 0 5000 Target detector reading during electrical test 045840110 Rev B 3 232 Model GFC7
154. NABLE OFF ON OFF ON enables passwords OFF disables them STABIL GAS co CO Selects gas for stability CO2 measurement STABIL FREQ Seconds 10 1 300 Stability measurement sampling frequency STABIL SAMPLES Samples 25 2 4 Number of samples in concentration stability reading a PHOTO_TEMP_SET 2000 0 5000 Photometer temperature Warnings 500 3000 warning limits Set point is not used SAMP PRESS SET In Hg 29 92 0 100 Sample pressure warning Warnings 15 35 limits Set point is not used PURGE PRESS SET PSIG 7 5 0 100 Purge pressure warning Warnings 2 5 12 5 limits Set point is not used 0 SAMP FLOW SLOPE 1 0 001 100 Slope term to correct sample flow rate VAC SAMP RATIO 0 53 0 1 2 Maximum vacuum pressure 0 61 9 sample pressure ratio for valid sample flow calculation SAMP TEMP SET 30 0 100 Sample temperature warning Warnings 10 1 100 limits Set point is not used BOX SET 30 0 100 Internal box temperature Warnings 5 48 warning limits Set point is not used BENCH CYCLE Seconds 2 0 5 30 Optical bench temperature control cycle period BENCH PROP 1 9 5 0 100 Optical bench temperature PID proportional coefficient Proportional band is the reciprocal of this setting BENCH INTEG 0 5 0 100 Optical bench temperature PID integral coefficient SAMP FLOW SET cc m 750 800 2 3000 0 5000 Sample flow warning limits 2000 13 Set point is not used Warnings 500 1000 500 120034 1000 5000 400 1000
155. O STBSPN CONC TEMP VIEW PNUMTC CALDAT PRM gt PV10 PREV NEXT NX10 ZTBZRO PETA PRNG STBSPN Selects data point to view Creates changes name through NAME see Section 6 12 2 ists of EVENT parameters PARAMETERS chosen for this REPORT PERI OD BAS NUMBER OF RECORDS Seis the YES NO RS 232 REPORT amount of time CHANNEL ENABLE between each CAL HOLD report PREV NEXT S PREV NEXT INS DEL EDIT ped Cycles through YES NO available trigger events see SET 5 gt EDIT Cycles through Selects max already active no of records parameters for this channel see Section 6 12 4 PARAMETER SAMPLE MODE PRECISION PREV NEXT INST AVG Cycles through available active parameters see Only appears if a valve option is installed Figure A 4 Primary Setup Menu iDAS 045840110 Rev B 3 226 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SETUP ENTER SETUP PASS 818 CFG RNGE PASS CLK MORE COMM VARS DI AG 3 34 ID COM1 COM2 PREV NEXT JUMP EDIT PRINT DAS HOLD OFF SET SET EDIT CONC PRECISI ON DYN ZERO OFF DYN SPAN OFF CLOCK ADJ MODE BAUD RATE TEST PORT PREV NEXT PREV NEXT TEST QUIET COMPUTER 300 HESSEN D 2100 DI AG MENU TREE HESSEN PROTOCOL 2400 7 1 4800 Fig 6 RS 485 9600
156. O2 00 00 TST TST gt CAL MSG CLR SETUP The analyzer will also alert the user via the Serial I O COM port s and cause the FAULT LED on the front panel to blink To view or clear the various warning messages press SAMPLE WHEEL TEMP WARNING CO2 XX XX TEST deactivates Warning Messages until New waming s TEST CAL MSG SETUP are activated z SAMPLE RANGE 500 00 PPM CO2 XX XX MSG activates Warning Messages TST 5 gt C TST TST gt keys replaced with lt TST TST gt CAL MSG setup TES kal CO2 XX XX WHEEL TEMP WARNING SAMPLE Press CLR to clear the lt TST TST gt CAL MSG SETUP message currently being Displayed lf more than one warning is active the next message will Make sure warning messages take its place are not due to Once the last warning has been cleared the analyzer returns to legitimate problems SAMPLE Mode Figure 11 1 Viewing and Clearing Warning Messages NOTE A failure of the analyzer s CPU or mother board can result in any or all of the following messages 04584 Rev A1 184 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES PHOTO TEMP WARNING REAR BOARD NOT DET Front Panel Display Keyboard PHT DRIVE is gt 2500 mVDC Mother Board not detected on power up Table 11 1 Warning Messages I ndicate
157. ON ENTR EXIT Toggle this keys to change setting SETUP X X 7 CLOCK ADJ 0 Sec Day SETUP X X CLOCK ADJ 0 Sec Day PREV NEXT JUMP EDIT PRNT EXIT ENTR EXIT Toggle tese keys to change setting 04584 Rev A1 65 Model GFC7000E Instruction Manual Operating Instructions 6 9 SETUP DI AG Using the Diagnostics Functions A series of diagnostic tools is grouped together under the SETUPO2 MORE2DI AG menu As these parameters are dependent on firmware revision see Menu Tree A 6 in Appendix A The individual parameters however are explained in more detail in the section indicated in Table 6 7 These tools can be used in a variety of troubleshooting and diagnostic procedures and are referred to in many places of the maintenance and trouble shooting sections Table 6 7 GFC7000E Diagnostic DI AG Functions Front Panel DI AGNOSTI C FUNCTI ON AND MEANI NG Mode SECTI ON Indicator SIGNAL I Allows observation of all digital and analog signals in the instrument Allows certain digital signals DIAG I O 6 9 2 such as valves and heaters to be toggled ON and OFF ANALOG OUTPUT When entered the analyzer performs an analog output step test This can be used to calibrate DIAG AOUT 6 9 3 a chart recorder or to test the analog output accuracy ANALOG I O CONFI GURATI ON the signal levels of the instruments analog outputs may be calibrated either individually or as a group Various electronic DI AG
158. OPE Contaminated or leaking GFC wheel either chamber Faulty IR photo detector Faulty sample faulty IR photo detector pressure sensor P1 or circuitry Invalid M R ratio see above Bad incorrect span gas concentration due Values outside range indicate Contamination of the zero air supply Contaminated or leaking GFC wheel either chamber Faulty IR photo detector OFFSET 11 1 3 Using the Diagnostic Signal O Function The Signal I O parameters found under the DIAG Menu see Section 6 9 2 and Appendix A combined with a thorough understanding of the instruments theory of operation found in Chapter 10 are useful for troubleshooting in three ways e The technician can view the raw unprocessed signal level of the analyzer s critical inputs and outputs e All of the components and functions that are normally under algorithmic control of the CPU can be manually exercised e The technician can directly control the signal level Analog and Digital Output signals This allows the technician to systematically observe the effect of directly controlling these signals on the operation of the analyzer Below in Figure 11 2 is an example of how to use the signal I O menu to view the raw voltage of an input signal or to control the state of an output voltage or control signal The specific parameter will vary depending on the situation 04584 Rev A1 188 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PRO
159. OW RANGE 500 0 Conc B SETUP X X RANGE mm MENU Toggle the numeral 0 0 5 0 0 0 ENTR EXIT keys to set the LOW and HIGH MODE SET UNIT EXIT range value gt ENTR accepts the new setting EXIT ignores the new setting SETUP X X RANGE MODE SNGL SETUP X X HIGH RANGE 500 0 Conc SNGL DUAL AUTO ENTR EXIT 0 0 5 0 0 0 ENTR EXIT CAUTI ON In AUTO range mode the LOW and HI GH ranges have separate slopes and offsets for computing CO2 concentration The two ranges must be independently calibrated NOTE Avoid accidentally setting the low range of the instrument with a higher span limit than the high range This will cause the unit to stay in the low reporting range perpetually and defeat the function of the AUTO range mode 04584 Rev A1 61 Model GFC7000E Instruction Manual Operating I nstructions 6 7 6 Range Units The MGFC7000E can display concentrations in parts per billion 10 mols per mol PPB parts per million 10 mols per mol PPM micrograms per cubic meter ug m UG milligrams per cubic meter mg m MG or percent volume CO volume sample gas Changing units affects all of the display analog outputs COM port and iDAS values for all reporting ranges regardless of the analyzer s range mode NOTE Concentrations displayed in mg m3 and ug use 0 C 760 mmHg for Standard Temperature and Pressure STP Consult your local regula
160. OW and HI GH ranges have separate slopes and offsets for computing CO concentration The two ranges must be independently calibrated 04584 Rev A1 60 Model GFC7000E Instruction Manual Operating Instructions 6 7 5 Auto Range Mode AUTO In AUTO range mode the analyzer automatically switches the reporting range between two user defined ranges low and high The unit will switch from low range to high range when the CO concentration exceeds 98 of the low range span The unit will return from high range back to low range once both the CO concentration falls below 75 of the low range span In AUTO Range mode the instrument reports the same data in the same range on both the A1 and A2 outputs and automatically switches both outputs between ranges as described above Also the RANGE test function displayed on the front panel will automatically switch to show which range is in effect The high low range status is also reported through the external digital status bits Section 6 13 1 1 To set individual ranges press the following keystroke sequence SAMPLE RANGE 500 000 2 SETUP X X RANGE MODE AUTO TST TST gt CAL SETUP SNGL DUAL AUTO ENTR EXIT v SAMPLE ENTER SETUP PASS 818 SETUP RANGE CONTROL MENU EXIT velum to the main MODE SET UNIT EXIT SAMPLE display SETUP X X PRIMARY SETUP MENU gt DAS RNGE PASS CLK MORE EXIT SETUP L
161. P or ENTR represent messages as they appear on the analyzer s front panel display NOTE The flowcharts in this manual contain typical representations of the analyzer s display during the various operations being described These representations are not intended to be exact and may differ slightly from the actual display of your instrument User Notes 04584 Rev A1 3 Model GFC7000E Instruction Manual Specifications Approvals and Warranty 2 SPECIFI CATI ONS APPROVALS AND WARRANTY 2 1 Specifications Table 2 1 Model GFC7000E Basic Unit Specifications Min Max Range Physical Analog Output In 1ppb increments from 50ppb to 2 000ppm dual ranges or auto ranging Measurement Units ppb ppm ug m mg m selectable Zero Noise 0 1 ppm RMS Span Noise 1 of reading RMS Lower Detectable Limiti lt 0 2 ppm Zero Drift 24 hours 0 25 ppm Zero Drift 7 days 0 5 ppm Span Drift 7 Days 196 of reading above 50 PPM Linearity Precision 1 of full scale 0 5 of reading Temperature Coefficient 0 1 of Full Scale per oC Voltage Coefficient Lag Time 0 05 of Full Scale per V 10 sec Rise Fall Time 95 in 60 sec Sample Flow Rate 800cm min 10 Temperature Range 5 40 C Humidity Range 0 95 RH non condensing Dimensions Hx WxD Weight Analyzer 7 x 17 x 23 5 1
162. PAN value entered is the maximum expected concentration of the undiluted calibration gas and that the span gas is either supplied through the same dilution inlet system as the sample gas or has an appropriately lower actual concentration For example with a dilution set to 100 a 10 ppm gas can be used to calibrate a 1000 ppm sample gas if the span gas is not routed through the dilution system On the other hand if a 1000 ppm span gas is used it needs to pass through the same dilution steps as the sample gas 3 Setthe dilution factor as a gain e g a value of 20 means 20 parts diluting gas and 1 part of sample gas SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL E SEU SAMPLE ENTER SETUP PASS 818 PRI MARY SETUP MENU SETUP CFG DAS RNGE PASS CLK MORE DIL only appears SETUP RANGE CONTROL MENU if the dilution ratio option has been MODE SET UNIT DIL installed EXIT ignores the new setting SETUP DIL FACTOR 1 0 GAIN ENTR accepts the new setting Toggle these keys to set the dilution factor ENTR This is the number by which the analyzer will multiply the CO2 concentrations of the gas passing SETUP DIL FACTOR 20 0 GAIN through the reaction cell ENTR The analyzer multiplies the measured gas concentrations with this dilution factor and displays the result NOTE Once the above settings have been ent
163. PROCEDURES 9 3 1 Replacing the Sample Particulate Filter The particulate filter should be inspected often for signs of plugging or contamination We recommend that when you change the filter handle it and the wetted surfaces of the filter housing as little as possible Do not touch any part of the housing filter element PTFE retaining ring glass cover and the o ring To change the filter 1 Turn OFF the analyzer to prevent drawing debris into the instrument 2 Open the MGFC7000E s hinged front panel and unscrew the knurled retaining ring on the filter assembly 01628 Retaining Ring 01629 Window 024310100 O Ring PTFE Notches UP PTFE Membrane Filter Element FL 19 1um FL6 5 um OR 58 Viton O Ring 03588 Bracket FT 8 Connector Fitting FT 8 Connector Fitting Figure 9 1 Sample Particulate Filter Assembly 3 Carefully remove the retaining ring PTFE o ring glass filter cover and filter element 4 Replace the filter being careful that the element is fully seated and centered in the bottom of the holder 5 Re install the PTFE o ring with the notches up the glass cover then screw on the retaining ring and hand tighten Inspect the seal between the edge of filter and the o ring to assure a proper seal 6 Re start the Analyzer 04584 Rev Al 149 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp PROCEDURES 9 3 2 Rebuilding the Sample Pump The diaphragm in the sample
164. R QUESTI ONNAI RE MGFC7000E APPENDI X D ELECTRONI C SCHEMATI CS LIST OF FIGURES Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 Figure 6 11 Figure 6 12 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Removal of Shipping nnn nnn 10 Rear Panel Layout cede e x RT TENES 12 Pneumatic Connections Basic Configuration Using Bottled Span Gas 16 Pneumatic Connections Basic Configuration Using Gas Dilution Calibrator 17 Pneumatic Connections MGFC7000E with Zero Span Shutoff Valves OPT 50 19 Pneumatic Connections MGFC7000E with Zero Span Shutoff Valves and External Zero Air Scrubber OPT 51 oii eeu e acer e ER wt Le ERN 19 Pneumatic Connections MGFC7000E with Zero Span Valves 52 20 Pneumatic Connections MGFC7000E with Zero Span Valves with External Zero air Scrubber OPT 53 ea FREE De Sa iege 20 Example of Pneumatic Set up for Multipoint Calibration of
165. RM EXIT Adjust these values until the displayed flow rate equals the flow rate being measured by the independent flow meter DIAG SIGNAL I O NEXT E Repeat Pressing NEXT until ENTR EXIT DIAG FLOW CALIBRATION ENTR DIAG FCAL ACTUAL FLOW 607 M 0 6 0 7 ENTR EXIT ENTR accepts the new value and returns to the previous menu EXIT ignores the new value and returns to the previous menu 04584 Rev A1 80 Model GFC7000E Instruction Manual Operating Instructions 6 9 9 Test Channel Output When activated output channel A3 can be used to report one of the test functions viewable from the SAMPLE mode display To activate the A3 channel and select a test function follow this key sequence SAMPLE RANGE 500 000 PPM CO2 X XXX Continue to press NEXT until lt TST TST gt CAL m SETUP Y Cc SAMPLE ENTER SETUP PASS 818 DIAG TEST CHAN OUTPUT EXIT returns to the main PREV NEXT ENTR EXIT 8 1 8 ENTR SAMPLE display SETUP X X PRI MARY SETUP MENU DIAG TCHN TEST CHANNEL NONE CFG DAS RNGE PASS CLK MORE EXIT NEXT ENTR EXIT SETUP SECONDARY SETUP MENU COMM VARS DIAG EXIT DIAG TCHN TEST CHANNEL CO2 MEASURE PREV NEXT ENTR EXIT DIAG SIGNAL I O Press PREV or NEXT Press ENTR to select DIAG ANALOG OUTPUT
166. RT 3000 Editable which the instrument is addressed by terminal emulation software such as Internet or Teledyne Instruments APICOM The name by which your analyzer will appear when addressed from other computers on the LAN or via the Internet While the default setting for HOSTNAME IMOECZOO9E editable all Teledyne Instruments MGFC7000E analyzers is mGFC7000E the host name may be changed to fit customer needs 1 Do not change the setting for this property unless instructed to by Teledyne Instruments 04584 Rev A1 90 Model GFC7000E Instruction Manual Operating Instructions Customer Service personnel NOTE Itis a good idea to check these settings the first time you power up your analyzer after it has been physically connected to the LAN I nternet to make sure that the DHCP has successfully downloaded the appropriate information from you network server s If the gateway IP instrument IP and the subnet mask are all zeroes e g 0 0 0 0 the DCHP was not successful You may have to manually configure the analyzer s Ethernet properties See your network administrator To view the above properties press SAMPLE RANGE 500 000 PPM CO2 DHCP ON lt TST TST CAL SETUP SAMPLE ENTER zx PASS 818 INST IP 0 0 0 0 8 1 8 ENTR SET SET gt PRI MARY SETUP MENU GATEWAY 0 0 0 0 SETUP EDIT Key Disabled
167. RY SETUP MENU to main the SETUP CFG DAS RNGE PASS CLK E EXIT menu SETUP X X SECONDARY SETUP MENU COMM VARS DIAG ALRM EXIT 6 9 8 Flow Calibration DIAG SIGNAL I O NEXT ENTR EXIT DIAG SIGNAL I O NEXT ENTR EXIT Repeat Pressing NEXT until m DIAG FCAL ACTUAL Ys 27 20 IN HG A ENTR EXIT Adjust these values until the displayed flow rate equals the flow rate being measured by the independent flow meter e ENTR accepts the new value and returns to the previous menu EXIT ignores the new value and returns to the previous menu The flow calibration allows the user to adjust the values of the sample flow rates as they are displayed on the front panel and reported through COM ports to match the actual flow rate measured at the sample inlet This does not change the hardware measurement of the flow sensors only the software calculated values To carry out this adjustment connect an external sufficiently accurate flow meter to the sample inlet see Chapter 11 for more details Once the flow meter is attached and is measuring actual gas flow press SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR Exit at any time SETUP X X PRIMARY SETUP MENU to return CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU COMM VARS DIAG AL
168. Several sets of Digital I O channels Finally the CPU issues commands via a series of relays and switches also over the bus located on a separate printed circuit assembly to control the function of key electromechanical devices such as heaters motors and valves 1 2 SAMPLE TEMP BENCH TEMP WHEEL TEMP Power Up Circuit Thermistor Interface Analog Outputs 1 4 20 Analog Outputs D A MOTHER BOARD Internal Digital I O Sensor Status amp Control Schmidt i i Trigger Control Inputs Status Outputs External Digital I O Converter V F Sample Pressure Sensors A D Sensor Inputs Bus Back Panel Connectors s COM A COM B 274 Optional Ethernet Interface PC 104 CPU Card Disk On RS 232 Chip Flash Chip PC 104 Bus r Zero Span 1 Valve I PUMP Options i 4 RELAY Flow amp Keyboard amp BOSE Display CPU Status LED TEC Control Drive Detector Output Optical Bench detector Segment Sensor M R Sensor Photo GFC Wheel Heater Bench Heater my Figure 10 9 GFC7000E Electronic Block Diagram 04584 Rev A1 162 Model GFC7000E I
169. T 2 5V CAL ON ENTR EXIT Toggles the ENTR accepts the new setting auto cal mode and returns to the previous menu SET SET EDIT EXIT ON OFF for EXIT ignores the new setting and DIAG AIG PONG OUT ARANGE SV this analog returns to the previous menu output channel only SET gt EXIT Now the analog output channels should either be automatically calibrated or they should be set to manual calibration which is described next 6 9 4 3 Manual Analog Output Calibration and Voltage Adjustment For highest accuracy the voltages of the analog outputs can be manually calibrated Calibration is done through the instrument software with a voltmeter connected across the output terminals Figure 6 5 Adjustments are made using the front panel keys by setting the zero point first and then the span point Table 6 12 The software allows this adjustment to be made in 100 10 or 1 count increments Table 6 12 Voltage Tolerances for Analog Output Calibration NOTE Outputs configured for 0 1V full scale should always be calibrated manually 04584 Rev Al 73 Model GFC7000E Instruction Manual Operating I nstructions one le j See Table 3 1 for pin assignments v of Analog Out connector on the rear panel DC Gnd Recording ANALYZER Device Figure 6 5 Setup for Calibrating Analog Voltage Outputs To make these adjustments the AOUT auto cal
170. TEMP WARNI NG The Temperature of the optical bench is outside the specified limits BOX TEMP WARNI NG Remote span calibration failed while the dynamic span feature was set to turned on CANNOT DYN SPAN Remote zero calibration failed while the dynamic zero feature was set to turned on CANNOT DYN ZERO Configuration was reset to factory defaults or was erased CONC ALRM1 WARNI NG one alarm 1 is enabled and the measured level is gt the set CONC ALRM2 WARNING 4 alarm 2 is enabled and the measured level is 2 the set SAMPLE TEMP WARN The temperature of the sample gas is outside the specified limits SOURCE WARNI NG The IR source may be faulty SYNC WARNI NG The instrument is not properly tracking the rotation of the Gas Filter Correlation wheel SYSTEM RESET The computer was rebooted WHEEL TEMP WARNI NG The Gas Filter Correlation wheel temperature is outside the specified limits 04584 Rev A1 49 Model GFC7000E Instruction Manual Operating I nstructions To view and clear warning messages SAMPLE HVPS WARNING 2 0 00 TEST deactivates warning messages TEST CAL MSG CLR SETUP SAMPLE RANGE 500 000PPM CO2 0 00 MSG 5 lt TST TST gt CAL MSG SETUP MEE NUN SAMPLE HVPS WARNING CO2 0 00 Press CLR to clear the current TEST CAL MSG CLR SETUP dc NOTE x If more than one warning is active the If the warning message persists next message will take
171. TION SETUP X X SECONDARY SETUP MENU EXIT returns to the PRIMARY SETUP MENU PRESSURE CALIBRATION COMM VARS DIAG EXIT NEXT ENTR EXIT From this point FLOW CALIBRATION forward EXIT returns to the SECONDARY ENTR EXIT SETUP MENU DIAG ANALOG OUTPUT TEST CHAN OUTPUT ENTR EXIT ENTR EXIT 6 9 2 Signal I O The signal I O diagnostic mode allows to review and change the digital and analog input output functions of the analyzer See Appendix A 4 for a complete list of the parameters available for review under this menu NOTE Any changes of signal 1 settings will remain in effect only until the signal menu is exited Exceptions are the ozone generator override and the flow sensor calibration which remain as entered when exiting 04584 Rev A1 67 Model GFC7000E Instruction Manual Operating Instructions To enter the signal I O test mode press SAMPLE RANGE 500 000 PPM CO2 X XXX DIAG SIGNAL I O Use the NEXT amp PREV keys to move between ignal TST gt CAL SETUP PREV NEXT JUMP ENTR EXIT signal types SAMPLE ENTER SETUP PASS 818 DIAG I O Test Signals Displayed Here Use the JUMP key to Qgodirectly to a specific signal 8 1 8 ENTR PREV NEXT JUMP PRNT EXIT See Appendix 4 for pa returns a complete list of ome available SIGNALS SAMPLE display EXAMPLE SET
172. TTMP MODE AVG PRECISION 4 STORE SRMPLES OFF PRRRMETER BOXTMP MODE AYG PRECISION 4 STORE SRMPLES OFF PARAMETER 03FLOW MODE AYG PRECISION 4 STORE SRMPLES OFF PARAMETER SMPFLW MODE RVG PRECISION 4 STORE SRMPLES OFF PARAMETER SMPPRS MODE AVG PRECISION 4 STORE SRMPLES OFF PRRRMETER RCPRES MODE AYG PRECISION 4 STORE SRMPLES OFF PARAMETER AZERO MODE AVG PRECISION 4 STORE SRMPLES OFF PARAMETER HYPS MODE AVG PRECISION 4 STORE SRMPLES OFF PARAMETER PMTDET MODE AVG PRECISION 4 STORE_SAMPLES OFF PRRRMETER RF4096 MODE QVG PRECISION 4 STORE _SAMPLES OFF PARAMETER REFGND MODE RVG PRECISION 4 STORE SRMPLES OFF Connected 00 01 32 Auto detect TCP IP caes Num Capture Print echo Figure 6 9 iDAS Configuration Through a Terminal Emulation Program Both procedures are best started by downloading the default iDAS configuration getting familiar with its command structure and syntax conventions and then altering a copy of the original file offline before uploading the new configuration CAUTI ON Whereas the editing adding and deleting of iDAS channels and parameters of one channel through the front panel keyboard can be done without affecting the other channels uploading an iDAS configuration script to the analyzer through its communication ports will erase all data parameters and channels by replacing them with the new iDAS configuration Backup of data and the original iDAS configuration is a
173. TUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU v COMM EXIT SETUP X X COMMUNICATIONS MENU ID HESN 2 Repeat pressing SET until SETUP X HESSEN STATUS FLAGS SET gt EDIT EXIT A SETUP X SYNC WARNING 0000 PREV NEXT EDIT EXIT Repeat pressing NEXT or PREV until the desired message flag is displayed See Table 6 27 For xxample SETUP X SYSTEM RESET 0000 PREV NEXT EDIT EXIT The CH and GHS keya move SETUP X SYSTEM RESET 0 000 ENTR key accepts the the cursor left new settings and right along lt CH gt 0 ENTR EXI gt EXIT key ignores the the bit string new settings Press the key repeatedly to cycle through the available character set 0 9 Note Values of A F can also be set but are meaningless 6 13 4 8 Instrument I D Code Each instrument on a Hessen Protocol network must have a unique ID code The MGFC7000E is programmed with a default ID code of 360 To change this code see Section 6 10 1 User Notes 04584 Rev A1 128 Model GFC7000E Instruction Manual Calibration Procedures 7 CALI BRATI ON PROCEDURES This section contains a variety of information regarding the various methods for calibrating a Model GFC7000E CO Analyzer as well as other supporting information NOTE The procedures in this section assume
174. Table A 3 GFC7000E Test Functions Revision TEST FUNCTI ON MESSAGE TEXT DESCRI PTI ON NAME RANGE 50 0 PPM D A range in single or auto range modes RANGE 50 0 7 RANGE1 50 0 PPM D A 1 range dual range mode CO RANGE1 50 0 PPM 3 7 RANGE2 50 0 PPM D A 2 range in dual range mode CO RANGE2 50 0 PPM 7 RANGE3 CO2RANGE 50 0 PPM D A 3 range STABILITY STABIL 0 0 PPM Concentration stability standard deviation based on setting of CO CO2 STB 0 0 PPM gt STABIL FREQ and STABIL SAMPLES RSP 0 20 0 00 SEC Instrument response Length of each signal processing loop Time in parenthesis is standard deviation COMEAS CO MEAS 4125 0 MV Detector measure reading COREF CO REF 3750 0 MV Detector reference reading MRRATIO MR RATIO 1 100 Measure reference ratio AUTOZERO 5 AZERO RATIO 1 234 Measure reference ratio during auto reference SAMPPRESS 5 29 9 IN HG A Sample pressure SAMPFLOW 6 SAMP FL 751 CC M Sample flow rate SAMPTEMP SAMPLE TEMP 26 8 C Sample temperature BENCHTEMP BENCH TEMP 48 1 C Bench temperature WHEELTEMP WHEEL TEMP 68 1 C Wheel temperature BOXTEMP BOX TEMP 26 8 C Internal chassis temperature PHOTOTEMP PHT DRIVE 2500 0 MV Photometer temperature COSLOPE SLOPE 1 000 CO slope for current range computed during zero span SLOPE 1 000 7 calibration COOFFSET OFFSET 0 000 CO offset for current range computed during zero span CO OFFSET 0 000 7 calibration CO2SLOPE CO2 SLOPE 1
175. Teledyne Instruments Incorporated shall correct such defect by in Teledyne Instruments Incorporated s discretion repairing or replacing such defective product or refunding the purchase price of such product 04584 Rev A1 6 Model GFC7000E Instruction Manual Specifications Approvals and Warranty The warranties set forth in this section shall be of no force or effect with respect to any product i that has been altered or subjected to misuse negligence or accident or ii that has been used in any manner other than in accordance with the instruction provided by TELEDYNE ANALYTICAL INSTRUMENTS or iii not properly maintained THE WARRANTI ES SET FORTH IN THIS SECTI ON AND THE REMEDI ES THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR PARTI CULAR PURPOSE OR OTHER WARRANTY OF QUALI TY WHETHER EXPRESSED OR I MPLI ED THE REMEDI ES SET FORTH IN THIS SECTION ARE THE EXCLUSI VE REMEDI ES FOR BREACH OF ANY WARRANTY CONTAI NED HEREI N Teledyne Instruments I ncorporated SHALL NOT BE LI ABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARI SI OUT OF OR RELATED THIS AGREEMENT TELEDYNE I NSTRUMENTS INCORPORATED S PERFORMANCE HEREUNDER WHETHER FOR BREACH OF WARRANTY OR OTHERWISE Terms and Conditions units or components returned to Teledyne Amnalytical Instruments should be properly packed for handling and returned freight prepaid to the nearest designated Service Center After the
176. UP X X PRIMARY SETUP MENU DIAG I O JUMP 12 EXAMPLE CFG DAS RNGE PASS CLK MORE EXIT 1 2 ENTR EXIT Enter 12 to Jump to 12 ST CONC VALID d SETUP X X SECONDARY SETUP MENU DIAG 1 ST CONC VALID ON Exit to return to the _ DIAG COMM VARS DIAG EXIT PREV NEXT JUMP ON EXIT gt Pressing the PRNT key will send a formatted printout to the serial port and can be captured with a computer or other output device 6 9 3 Analog Output Step Test This test can be used to check the accuracy and proper operation of the analog outputs The test forces all four analog output channels to produce signals ranging from 0 to 100 of the full scale range in 20 increments This test is useful to verify the operation of the data logging recording devices attached to the analyzer To begin the Analog Output Step Test press SAMPLE RANGE 500 000 PPM 2 SIGNAL I O lt TST TST gt CAL SETUP ENTR EXIT SAMPLE ENTER SETUP PASS 818 DIAG ANALOG OUTPUT PREV NEXT ENTR EXIT ANALOG OUTPUT Performs analog output step test 0 100 SETUP PRIMARY SETUP MENU DIAG AOUT CFG DAS RNGE PASS CLK MORE Exit Exit returns to the DIAG menu DIAG AOUT ANALOG OUTPUT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG ALRM Pressing the key under 0 while performing the test will pause the test at that leve
177. V reference from MAX6241 O5 concentration sensor 221 Spare 2 SENSOR CO concentration sensor Spare DAC loopback MUX Ground reference Rear board temperature MUX analog input O S B ef REFGND 15 REF GND Internal box temperature Sample temperature Optical bench temperature Wheel temperature Diagnostic temperature input Diagnostic temperature input sensor cell temperature Spare Rear board DAC MUX analog inputs TEMP INPUT 4 TEMP INPUT 5 O2 CELL TEMP WHEEL TEMP DAC CHAN 1 DAC CHAN 0 DAC channel 0 loopback 1 DAC channel 1 loopback DAC CHAN 2 2 DAC channel 2 loopback DAC CHAN 3 3 DAC channel 3 loopback Rear board analog outputs CONC OUT 1 Concentration output 1 CONC OUT 2 1 Concentration output 2 TEST OUTPUT 2 Test measurement output CONC OUT 37 3 Concentration output 3 CO Hessen protocol 2 M300EH 3 M300ES M320E option 6 Sample pressure or differential pressure flow measurement option 7 M306E 8 Factory option enables concentration alarms on relay outputs 9 GFC7000E 10 GFC7000E 045840110 Rev B 3 242 Model 360E Instruction Manual APPENDI X A 5 GFC7000E iDAS Functions Revision APPENDIX 5 GFC7000E iDAS Functions Revision 0 Table 5 7000 DAS Trigger Events Revision E O name BESRIPHON smoww sample fow warin Sample pressure warning M300EH M300ES
178. Values Voltage Outputs FULL SCALE OUTPUT VOLTAGE 100MV 1v 5V 10V STEP NOMINAL OUTPUT VOLTAGE 1 0 0 0 0 0 2 20 20 mV 0 2 1 2 3 40 40 mV 0 4 2 4 4 60 60 mV 0 6 3 6 5 80 80 mV 0 8 4 8 6 100 100 mV 1 0 5 10 11 4 7 3 Analog Outputs Current Loop To verify that the analog outputs with the optional current mode output are working properly connect a 250 ohm resistor across the outputs and use a voltmeter to measure the output as 04584 Rev A1 204 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES described in Section 6 9 4 2 and then perform an Analog Output Step Test as described in Section 6 9 3 For each step the output should be within 1 of the nominal value listed in the table below Table 11 11 Analog Output Test Function Nominal Values Current Outputs OUTPUT RANGE 2 20 4 20 NOMI NAL OUTPUT VALUES STEP 96 CURRENT V 250 OHMS CURRENT V 250 OHMS 1 0 2 mA 0 5V 4 1 2 20 5 6 1 4 7 2 1 8 3 40 9 2 2 3 10 4 2 6 4 60 12 8 3 2 13 6 3 4 5 80 16 4 4 1 16 8 4 2 6 100 20 5 20 5 11 4 7 4 Status Outputs The procedure below can be used to test the Status outputs Connect a jumper between the D pin and the V pin on the status output connector Connect a 1000 ohm resistor between the pin and the pin for the status output that is being tested Connect a voltmeter between the V pin and the
179. X XXX lt TST TST gt ZERO CONC EXIT The SO span concentration values automatically default to 400 0 Conc i EXIT ignores the new setting To change this value to M P CAL SO2 SPAN CONC 400 000 Conc and returns to the previous the actual concentration of display the span gas enter the i ENTR EXIT ENTR accepts the new setting number by pressing the and returns to the key under each digit until previous display the expected value appears NOTE For this I nitial Calibration it is important to independently verify the PRECI SE Concentration Value of the SPAN gas If the source of the Span Gas is from a Calibrated Bottle use the exact concentration value printed on the bottle 04584 Rev Al 131 Model GFC7000E Instruction Manual Calibration Procedures STEP THREE Perform the Zero Span Calibration Procedure SAMPLE RANGE 500 000 PPM CO2 lt TST gt SETUP SAMPLE STABIL XXX X PPM CO2 XXX X lt TST 5 gt SETUP ACTION Allow zero gas to enter the sample port at the rear of the instrument M P CAL STABIL XXX X PPM CO2 XXX X lt TST TST gt CAL SETUP M P CAL STABIL XXX X PPM CO2 XXX X lt TST TST gt ZERO CONC EXIT M P CAL STABIL XXX X PPM CO2 XXX X TST TST gt ENTR CONC EXIT lt Set the Display to show the STABIL test function This function calculates the stab
180. able software controlled maintenance mode 64 3 5 span valve installed 128 enable switch controlled maintenance mode 2048 enable Internet option 7 4096 use old style numeric data entry menus when editing conc table 045840110 Rev B 3 236 Model GFC7000E I nstruction Manual APPENDIX A 2 Setup Variables For Serial 1 Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 SETUP VARI ABLE NUMERI C DEFAULT VALUE VALUE RANGE DESCRI PTI ON UNITS CLOCK FORMAT 5 Any character in Time of day clock format the allowed flags Enclose value in double character set quotes when setting from to 100 characters the RS 232 interface long Abbreviated weekday name 9ob Abbreviated month name 96d Day of month as decimal number 01 31 Hour 24 hour format 00 23 I Hour 12 hour format 01 12 Day of year as decimal number 001 366 Month as decimal number 01 12 Minute as decimal number 00 59 A M P M indicator for 12 hour clock 6 Second as decimal number 00 59 9ow Weekday as decimal number 0 6 Sunday is O Year without century as decimal number 00 99 Year with century as decimal number 959 55 Percent sign ALARM TRI Cycles 1 100 Concentration alarm trigger sensitivity ad
181. ad single iDAS channel CHANNELDELETE name Delete iDAS channels The command syntax follows the command type separated by a space character Strings in brackets are optional designators The following key assignments also apply 045840110 Rev B 3 245 Model 360E Instruction Manual APPENDIX A 6 Terminal Command Designators Revision 0 Table A 8 Terminal Key Assignments Revision 0 TERMI NAL KEY ASSI GNMENTS ESC Abort line CR ENTER Execute command Ctrl C Switch to computer mode COMPUTER MODE KEY ASSIGNMENTS LF line feed Execute command Ctrl T Switch to terminal mode 045840110 Rev B 3 246 Model 360E Instruction Manual APPENDIX A 6 Terminal Command Designators Revision 0 045840110 Rev B 3 247 Model GFC7000E I nstruction Manual APPENDIX B GFC7000E Spare Parts List APPENDIX B GFC7000E Spare Parts List NOTE The spare parts list for the Model GFC7000E is currently being compiled For information is spare parts please contact Teledyne Analytical I nstruments customer service department at 16830 Chestnut St City of Industry Ca 91748 Phone 1 626 961 9221 or 1 626 934 1500 Fax 1 626 961 2538 Email ai customerservice teledyne com 045840120 Rev B 3 249 Model GFC7000E I nstruction Manual Appendix C Repair Questionnaire GFC7000E Appendix C Repair Questionnaire GFC7000E Company Contact Name
182. ages that may appear Table 3 6 Possible Warning Messages at Start Up ANALOG CAL WARNING The instruments A D circuitry or one of its analog outputs is not calibrated BENCH TEMP WARNING The Temperature of the optical bench is outside the specified limits BOX TEMP WARNING Remote span calibration failed while the dynamic span feature was set to turned on CANNOT DYN SPAN Remote zero calibration failed while the dynamic zero feature was set to turned on CANNOT DYN ZERO Configuration was reset to factory defaults or was erased CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased CONC ALRM1 WARNING alarm 1 is enabled and the measured level is gt the set CONC ALRM2 WARNI NG E alarm 2 is enabled and the measured CO level is 2 the set DATA INITIALIZED iDAS data storage was erased FRONT PANEL WARN Firmware is unable to communicate with the front panel PHOTO TEMP WARNING The temperature of the IR photometer is outside the specified limits REAR BOSRD NOT DER The CPU is unable to communicate with the motherboard REEAT BOARD WARN The firmware is unable to communicate with the relay board SAPMIPEETEDW WARN The flow rate of the sample gas is outside the specified limits SAMPLE PRESS WARN Sample gas pressure outside of operational parameters SAMPLE TEMP WARN The temperature of the sample gas is outside the specified limits SOURCE WARNING 1 IR source may be faulty The instrumen
183. al port and CPU Once a cable is connected between the analyzer and a computer or modem both the red and green LEDs should be on If not COMI can be switched between DTE and DCE modes using a small switch on the rear panel to exchange the receive and transmit lines emulating a cross over or null modem cable If both LEDs are still not illuminated check the cable for proper wiring For 2 it may be necessary to install a null modem cable contact customer service for information 6 10 4 RS 485 Configuration of COM2 As delivered from the factory 2 is configured for RS 232 communications This port can be re configured for operation as a non isolated half duplex RS 485 port with a 150 termination resistor Table 6 15 shows the pin assignments of the DB 9 connector For RS 485 operation jumper on the CPU board should be installed and switch 6 of SW1 should be set to the ON position For RS 232 remove the jumper and set the switch to OFF default JP3 is just to the right of the third connector from the left on the top of the CPU board as seen from the inside of the analyzer SW1 is in the middle of the CPU board between disk on chip and BIOS For non terminated RS 485 operation remove the jumper on JP3 but leave switch 6 in the ON position Refer to Figure 3 11 to locate the CPU board 04584 Rev A1 84 Model GFC7000E I nstruction Manual Operating Instructions Table 6 15 COMI1 2 DB 9 Pin
184. ameter in volatile memory The SAMPLE PERI OD is set to one minute by default and generally cannot be accessed from the standard iDAS front panel menu but is available via the instruments communication ports by using APICOM or the analyzer s standard serial data protocol SAMPLE PERIOD is only used when the iDAS parameter s sample mode is set for AVG MI N or MAX 04584 Rev A1 107 Model GFC7000E Instruction Manual Operating Instructions e REPORT PERIOD Sets how often the sample readings stored in volatile memory are processed e g average minimum or maximum are calculated and the results stored permanently in the instruments Disk on Chip as well as transmitted via the analyzer s communication ports The REPORT PERI OD may be set from the front panel If the INST sample mode is selected the instrument stores and reports an instantaneous reading of the selected parameter at the end of the chosen REPORT PERIOD In AVG MI N or MAX sample modes the settings for the SAMPLE PERI OD and the REPORT PERI OD determine the number of data points used each time the average minimum or maximum is calculated stored and reported to the COMM ports The actual sample readings are not stored past the end of the of the chosen REPORT PERI OD Also the SAMPLE PERI OD and REPORT PERI OD intervals are synchronized to the beginning and end of the appropriate interval of the instruments internal clock e If SAMPLE PERI OD were set for one minute t
185. an appropriate scaling factor to the analyzer s CO concentration calculation so that the Measurement Range and concentration values displayed on the instrument s Front Panel Display and reported via the Analog and Serial Outputs reflect the undiluted values Instructions for using the dilution ratio option can be found in Section 6 7 7 5 9 Maintenance Mode Switch API s instruments can be equipped with an switch that places the instrument in maintenance mode When present the switch accessed by opening the hinged front panel and is located on the rearward facing side of the display keyboard driver PCA on the left side near the particulate filter 04584 Rev A1 43 Model GFC7000E Instruction Manual Optional Hardware and Software When in maintenance mode the instrument ignores all commands received via the COMM ports that alter the operation state of the instrument This includes all calibration commands diagnostic menu commands and the reset instrument command the instrument continues to measure concentration and send data when requested This option is of particular use for instruments connected to multidrop or Hessen protocol networks 5 10 Second Language Switch API s instruments can be equipped with switch that activates an alternate set of display message in a language other than the instruments default language When present the switch accessed by opening the hinged front panel and is located on the rearward facing side
186. ance AREA MINIMUM REQUIRED CLEARANCE Back of the instrument 4 in Sides of the instrument 1 Above below the instrument 1 e Various rack mount kits are available for this analyzer See Section 5 1 of this manual for more information 3 1 1 Electrical Connections CAUTI ON Check the voltage and frequency label on the rear panel of the instrument See Figure 3 2 for compatibility with the local power before plugging the MGFC7000E into line power Do not plug in the power cord if the voltage or frequency is incorrect CAUTI ON Power connection must have functioning ground connection Do not defeat the ground wire on power plug CAUTI ON Turn off analyzer power before disconnecting or connecting electrical subassemblies Do not operate with cover off 04584 Rev A1 11 Model GFC7000E Instruction Manual Getting Started SAMPLE Ole PURGE IN EXHAUST Of e COMB 8 VENT SPAN gt o e e 9 RXe PRESSURE SPAN 4 RS232 Oe 125 123456780 Analog Out 1 A2 A4 5 STATUS FEET TTT Figure 3 2 Rear Panel Layout 9 Attach a strip chart recorder and or data logger to the appropriate analog output connections on the rear panel of the analyzer ANALOG 1 2 4 When the instrument is in its default co
187. anel as well as their expected values These functions are also useful tools for diagnosing performance problems with your analyzer Section 11 1 2 The enclosed Final Test and Validation Data sheet part number 04307 lists these values before the instrument left the factory To view the current values of these parameters press the following key sequence on the analyzer s front panel Remember until the unit has completed its warm up these parameters may not have stabilized SAMPLE RANGE 500 000 CO2 XXX X TST TST gt CAL SETUP RANGE RANGE1 Toggle lt TST TST gt keys to RANGE2 through list of functions STABIL CO2 MEAS CO2 REF MR RATIO PRES Refer to SAMP FL Section SAMP TEMP 6 for BENCH TEMP definitions WHEEL TEMP of these BOX TEMP test functions 1 Only appears instrument is set PHT DRIVE for DUAL or AUTO reporting SLOPE range modes OFFSET TEST TI ME 04584 Rev A1 25 Model GFC7000E Instruction Manual Getting Started 3 If your analyzer has a Ethernet card Option 63 installed and your network is running a dynamic host configuration protocol DHCP software package the Ethernet option will automatically configure its interface with your LAN However it is a good idea to check these settings to make sure that the DHCP has successfully downloaded the appropriate network settings from your network server See Section 6 10 9 2 If your network is not running
188. at the frequency select jumper JP4 is properly set on the Relay Board For 50 Hz operation it should be installed For 60 Hz operation may either be missing or installed in a vertical orientation If there is power to the motor and the frequency select jumper is properly set then the motor is likely bad See Section 11 5 2 for instructions on removing and replacing the GFC assembly that the motor is bolted to 11 4 6 4 IR Source The IR source can be checked using the following procedure 1 Disconnect the source and check its resistance when cold When new the source should have a cold resistance of more than 1 5 Ohms but less than 3 5 Ohms If not then the source is bad With the source disconnected energize the analyzer and wait for it to start operating Measure the drive Voltage between pins 1 and 2 on the jack that the source is normally connected to it should be 11 5 lt 0 25 VDC If not then there is a problem with either the wiring the Relay Board or the 12 power supply If the drive voltage is correct in step 2 then remove the source from the heat sink assembly 2 screws on top and connect to its mating connector Observe the light being emitted from the source It should be centered at the bottom of the U shaped element If there is either no emission or a badly centered emission then the source is bad 11 4 6 5 Pressure Flow Sensor Assembly The pressure flow sensor PCA located on the top of the absorption b
189. atically COMM menu SET TEST EXIT 6 10 9 Ethernet Card Configuration The optional Ethernet card Option 63 allows the analyzer to communicate via standard 10BaseT Ethernet protocol through the COM2 serial port Refer to Figure and 5 4 for the physical location of this option The card has four LEDs that are visible on the rear panel of the analyzer indicating its current operating status Table 6 17 Ethernet Status Indicators LED FUNCTI ON LNK green ON when connection to the LAN is valid ACT yellow Flickers on any activity on the LAN TxD green Flickers when the RS 232 port is transmitting data RxD yellow Flickers when the RS 232 port is receiving data 04584 Rev A1 89 Model GFC7000E Instruction Manual Operating Instructions 6 10 9 1 Ethernet Card COM2 Communication Modes and Baud Rate The firmware on board the Ethernet card automatically sets the communication modes and baud rate 115 200 kBaud for the COM2 port Once the Ethernet option is installed and activated the COM2 submenu is replaced by a new submenu INET This submenu is used to manage and configure the Ethernet interface with your LAN or Internet Server s 6 10 9 2 Configuring the Ethernet I nterface Option using DHCP The Ethernet option for you MGFC7000E uses Dynamic Host Configuration Protocol DHCP to automatically configure its interface with your LAN This requires your network servers also be
190. being performed Pressing a key causes the associated instruction to be performed by the analyzer Note that the keys do not auto repeat In circumstances where the same key must be activated for two consecutive operations it must be released and re pressed 10 4 1 3 Display The main display of the analyzer is a vacuum florescent display with two lines of 40 text characters each Information is organized in the following manner see Figure 10 17 Mode Field Displays the name of the analyzer s current operating mode Message Field Displays a variety of informational messages such as warning messages operation data and response messages during interactive tasks Concentration Field Displays the actual concentration of the sample gas currently being measured by the analyzer Keypad Definition Field Displays the definitions for the row of keys just below the display These definitions dynamic context sensitive and software driven 04584 Rev Al 176 Model GFC7000E Instruction Manual THEORY OF OPERATION 10 4 1 4 Keyboard Display I nterface Electronics to Relay Board a gt O m Key Press Detect I C Interface Keyboard Interrupt Status Bit Display Data Display Decoder Controller Display Power Watchdog Keypad Decoder Parallel Data Display Write From 5 VDC Power Supply Optional Maintenance t
191. ber by pressing the key under each digit until the expected value appears 0 0 0 4 5 0 ENTR EXIT NOTE For this I nitial Calibration it is important to independently verify the PRECISE CO Concentration Value of the SPAN gas If the source of the Span Gas is from a Calibrated Bottle use the exact concentration value printed on the bottle 04584 Rev A1 135 Model GFC7000E Instruction Manual Calibration Procedures STEP THREE Perform the zero span calibration Zero and span checks using the zero span valve option are similar to that described in Section 3 3 except that zero air and span gas is supplied to the analyzer through the zero span valves rather than through the sample inlet port The zero and cal operations are initiated directly and independently with dedicated keys CALZ amp CALS The SPAN key now appears during the transition from zero to span You may see both keys If either the ZERO or SPAN buttons fail to appear see Section 11 for troubleshooting tips SAMPLE RANGE 500 000 PPM CO2 XXX X TST TST gt CALZ CALS SETUP Y SAMPLE STABIL XXX X PPM CO2 lt TST TST gt CALZ CALS SETUP Set the Display to show the STABIL test function This function calculates the stability of the measurement ACTION Allow zero gas to enter the sample port at the rear of the instrument
192. c dieser INT D enar FERE 151 9 3 6 Cleaning Exterior Surfaces of the 7000 005860 151 10 THEORY OF 153 10 1 Measurement Method osi esae nee E paa sega red ane papa sr 153 10 1 1 Beers Law iere ease re dec RR Ra X RR EAR das Ia RR 153 10 1 2 Measurement Fundamentals ar au a rasan rani nane s ka nnn nnn 154 1013 Gas Filter CotrrelatiOT s c extat rhone es e mena 154 10 1 4 Ambient CO Interference Rejection sees menses menie 158 210 2 eret rap Ser eee xen ARR Pag he cei 158 10 2 1 Sample Gas FlOW ime tee Gade nies adas ahah Ded ad de aw dels aces paa 159 10 2 11 Gritical Flow Orifice iere RI p Rx qeu ERE Eat sd deat 159 10 2 1 2 Sample Press re Sensor epa ee ta hee
193. condition is indicated by out of range Slopes and Offsets as displayed through the test functions and is frequently caused by the following 1 BAD SPAN GAS This can cause a large error in the slope and a small error in the offset Delivered from the factory the MGFC7000E s slope is within 15 of nominal Bad span gas will cause the analyzer to be calibrated to the wrong value If in doubt have the span gas checked by and independent lab 2 CONTAMINATED ZERO GAS Excess can cause a positive or negative offset and will indirectly affect the slope 3 Dilution calibrator not set up correctly or is malfunctioning This will also cause the slope but not the zero to be incorrect Again the analyzer is being calibrated to the wrong value 4 Too many analyzers on the manifold This can cause either a slope or offset error because ambient gas with its pollutants will dilute the zero or span gas 11 2 2 Non Repeatable Zero and Span As stated earlier leaks both in the MGFC7000E and in the external system are a common source of unstable and non repeatable readings 1 Check for leaks in the pneumatic systems as described in Section 9 3 3 Don t forget to consider pneumatic components in the gas delivery system outside the MGFC7000E Such as e A change in zero air source such as ambient air leaking into zero air line or A change in the span gas concentration due to zero air or ambient air leaking into the span gas line 2 Once
194. connector on the analyzer s rear panel labeled STATUS STATUS NOTE Most PLC s have internal provisions for limiting the current that the input will draw from an external device When connecting to a unit that does not have this feature an external dropping resistor must be used to limit the current through the transistor output to less than 50mA At 50mA the transistor will drop approximately 1 2V from its collector to emitter 04584 Rev A1 13 Model GFC7000E Instruction Manual Getting Started The pin assignments for the status outputs can be found in the table below Table 3 2 7000 Status Output Pin Outs Status ai SYSTEM OK On if no faults are present 2 On if CO concentration measurement is valid CONC VALID conc vat If the concentration measurement is invalid this bit is OFF HIGH RANGE On if unit is in high range of DUAL or AUTO range modes ZERO CAL On whenever the instruments ZERO point is being calibrated SPAN CAL On whenever the instruments SPAN point is being calibrated 602 DIAG MODE On whenever the instrument is in DIAGNOSTIC mode 7 ALARM1 On whenever the measured CO concentration is above the set point for ALM1 On whenever the measured CO concentration is above the set ALARM2 point for ALM2 BUSS The emitters of the transistors pins 1 8 are bussed together DC POWER 5 VDC Digital Ground The ground level from the analyzer s inter
195. d See Chapter 11 for troubleshooting tips 04584 Rev A1 132 Model GFC7000E Instruction Manual Calibration Procedures 7 3 Manual Calibration Checks Informal calibration checks which only evaluate but do not alter the analyzer s response curve are recommended as a regular maintenance item and in order to monitor the analyzer s performance To carry out a calibration check rather than a full calibration follow these steps STEP ONE Connect the sources of zero air and span gas as shown in Figures 7 1 or 7 2 STEP TWO Perform the zero span calibration check procedure ACTION Supply the instrument with zero gas SAMPLE RANGE 500 0 PPM Scroll the display to the STABIL test function lt TST 5 gt SETUP SAMPLE STABIL XXX X PPM CO2 X XXX lt TST TST gt SETUP Wait until STABIL is below 1 0 ppb This may take several minutes ACTION Record the concentration reading SAMPLE CO2 X XXX lt TST TST gt SETUP The value of STABIL may jump significantly Wait until it falls below 1 0 ppb This may take several minutes ACTION Supply span gas to the instrument ACTION Record the CO2 concentration reading SAMPLE CO2 X XXX lt TST TST gt SETUP The SPAN key appears during the transition from zero to span You may see both keys 7
196. d Failures WARNI NG MESSAGE FAULT CONDITI ON POSSIBLE CAUSES BENCH TEMP The optical bench temp Bad bench heater WARNI NG is controlled at 48 5 Bad bench temperature sensor Bad relay controlling the bench heater Entire relay board is malfunctioning I C buss malfunction BOX TEMP Box Temp is 5 Cor NOTE Box temperature typically runs 7 c warmer than WARNI NG gt 48 ambient temperature Poor blocked ventilation to the analyzer Stopped exhaust fan Ambient temperature outside of specified range CANNOT DYN Dynamic Span Measured concentration value is too high or low SPAN operation failed Concentration slope value to high or too low CANNOT DYN Dynamic Zero Measured concentration value is too high ZERO operation failed Concentration offset value to high CONFIG Configuration and Failed disk on chip INITI ALI ZED Calibration data reset User erased data to original Factory state Concentration alarm 1 CONC ALRM1 is enabled and the WARNING measured level is gt the set point Concentration alarm 2 CONC ALRMZ is enabled and the WARNING measured CO level is gt the set point DATA Data Storage in iDAS Failed disk on chip INITIALIZED was erased User cleared data FRONT PANEL The CPU is unable to Warning only appears on serial I O com port s WARN Communicate with the Front panel display will be frozen blank or will not respond Failed keyboard I C buss failure Loose connector wiring Failed IR photo detector
197. d of all is pumped into the wheel housing to purge all ambient CO see Figure 10 7 10 2 Pneumatic Operation Caution It is important that the sample airflow system is both leak tight and not pressurized over ambient pressure Regular leak checks should be performed on the analyzer as described in the maintenance schedule Table 9 1 Procedures for correctly performing leak checks can be found in Section 9 3 3 An internal pump evacuates the sample chamber creating a small vacuum that draws sample gas into the analyzer Normally the analyzer is operated with its inlet near ambient pressure either because the sample is directly drawn at the inlet or a small vent is installed at the inlet There are several advantages to this pull through configuration e By placing the pump down stream from the sample chamber several problems are avoided e First the pumping process heats and compresses the sample air complicating the measurement process Additionally certain physical parts of the pump itself are made of materials that might chemically react with the sample gas e Finally in certain applications where the concentration of the target gas might be high enough to be hazardous maintaining a negative gas pressure relative to ambient means that should a minor leak occur no sample gas will be pumped into the atmosphere surrounding analyzer 04584 Rev A1 158 Model GFC7000E Instruction Manual TH
198. devices e Computer mode is used when the analyzer is connected to a computer with a dedicated interface program such as APICOM More information regarding APICOM can be found in later in this section or on the Teledyne Instruments website at http www teledyne api com software apicom e Interactive mode is used with a terminal emulation programs such as HyperTerminal or a dumb computer terminal The commands that are used to operate the analyzer in this mode are listed in Table 6 26 04584 Rev A1 117 Model GFC7000E Instruction Manual Operating Instructions 6 13 2 2 Help Commands in Terminal Mode Table 6 26 Terminal Mode Software Commands COMMAND 05 Control T Switches the analyzer to terminal mode echo edit If mode flags 1 amp 2 are OFF the interface can be used in interactive mode with a terminal emulation program Switches the analyzer to computer mode no echo no edit A carriage return is required after each command line is typed into the TEM return terminal computer The command will not be sent to the analyzer to be executed until this is done On personal computers this is achieved by pressing the ENTER key BS Erases one character to the left of the cursor location backspace ESC Erases the entire command line escape ID CR This command prints a complete list of available commands along with the definitions of their functionality to the display device of the terminal or computer be
199. down the space bar is one way the green LED should flicker as the instrument is receiving data 8 Make sure that the communications software or Terminal emulation software is functioning properly Further help with serial communications is available in a separate manual RS 232 Programming Notes Teledyne Instruments part number 013500000 11 5 Repair Procedures This section contains procedures that might need to be performed on rare occasions when a major component of the analyzer requires repair or replacement 11 5 1 Repairing Sample Flow Control Assembly The Critical Flow Orifice is housed in the Flow Control Assembly Teledyne Instruments part number 001760400 located on the top of the optical bench A sintered filter protects the jewel orifice so it is unusual for the orifice to need replacing but if does or the filter needs replacement 04584 Rev A1 207 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES please use the following procedure see the Spare Parts list in Appendix B for part numbers and kits 1 Turn off power to the analyzer 2 Locate the assembly attached to the sample pump see Figure 3 11 3 Disconnect the pneumatic connection from the flow assembly and the assembly from the pump 4 Remove the fitting and the components as shown in the exploded view in Figure 11 6 5 Replace the o rings p n OR 01 and the sintered filter p n FL 01 6 If replacing the critical
200. dvised before attempting any iDAS changes 04584 Rev A1 114 Model GFC7000E Instruction Manual Operating I nstructions 6 13 Remote Operation of the Analyzer 6 13 1 Remote Operation Using the External Digital 1 6 13 1 1 Status Outputs The status outputs report analyzer conditions via optically isolated NPN transistors which sink up to 50 mA of DC current These outputs can be used interface with devices that accept logic level digital inputs such as programmable logic controllers PLC s Each Status bit is an open collector output that can withstand up to 40 VDC All of the emitters of these transistors are tied together and available at D NOTE Most PLC s have internal provisions for limiting the current that the input will draw from an external device When connecting to a unit that does not have this feature an external dropping resistor must be used to limit the current through the transistor output to less than 50 mA At 50 mA the transistor will drop approximately 1 2V from its collector to emitter The status outputs are accessed via a 12 pin connector on the analyzer s rear panel labeled STATUS The function of each pin is defined in Table 6 24 STATUS 1 2 3 4 5 6 7 8 D U l o si of sl 099 ul gt al of z f lt 58 of Ej lt of al 519 gt ol S NT 91 o Ela o ole 2 gt o 26 lt a Figure 6
201. e GFC wheel housing 8 Carefully remove the opto pickup printed circuit assembly 9 Remove the four 4 screws holding the GFC wheel motor heat sink assembly to the GFC wheel housing 10 Carefully remove the GFC Wheel motor heat sink assembly from the GFC wheel housing 04584 Rev A1 209 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES Figure 11 8 Removing the GFC Wheel 11 Remove the ONE 1 screw fastening the GFC wheel mask assembly to the gfc motor hub 12 Remove the GFC wheel mask assembly 13 Follow the previous steps in reverse order to put the GFC wheel motor assembly back together 11 5 3 Disk On Chip Replacement Procedure Replacing the Disk on Chip may be necessary in certain rare circumstances or to load new instrument software This will cause all of the instrument configuration parameters and iDAS data to be lost However a backup copy of the operating parameters are stored in a second non volatile memory and will be loaded into the new the Disk on Chip on power up To change the Disk on Chip follow this procedure 1 Turn off power to the instrument 2 Fold down the rear panel by loosening the thumbscrews on each side 3 Locate the Disk on Chip in the rightmost socket near the right hand side of the CPU assembly Remove the IC by gently prying it up from the socket 4 Reinstall the new Disk on Chip making sure the notch in the end of the chip is facing upward 5 Clo
202. e Section 6 9 4 for information on setting the range type and scaling factors for these output channels A3 Output The third analog output labeled A3 is special It can be set by the user see Section 6 9 9 to carry the current signal level of any one of the parameters accessible through the A3 menu of the unit s software Spare Output The fourth analog output termed SPARE is not used in the MGFC7000E In its standard configuration the analyzer comes with all four of these channels set up to output a DC voltage However 4 20 current loop drivers can be purchased for the first three of these outputs A2 A2 amp A3 Output Loop back four analog outputs are connected back to the A D converter through a Loop back circuit This permits the voltage outputs to be calibrated by the CPU without need for any additional tools or fixtures 10 3 6 5 Internal Digital 1 This channel is used to communicate digital status and control signals about the operation of key components of the Optical Bench The CPU sends signals to the synch demod board that initiate the ELECTRI CAL TEST and DARK CALI BRATI ON procedures Likewise the synch demod board uses this interface to send the SYNC warning signal to the CPU see Sections 6 9 5 6 9 6 and 11 1 1 04584 1 172 Model GFC7000E Instruction Manual THEORY OF OPERATI 10 3 6 6 External Digital 1 This External Digital I O performs two functions Status Outputs
203. e other Materials Materials Makes Separate lag Contact PROTONS 3 PROTONS 3 E PROTONS 3 PROTONS 3 ELECTRONS 3 ELECTRONS 3 LECTRONS ELECTRONS 4 NET CHARGE 0 NET CHARGE 0 NET CHARGE 1 NET CHARGE 1 Figure 12 1 Triboelectric Charging If one of the surfaces is a poor conductor or even a good conductor that is not grounded the resulting positive or negative charge can not bleed off and becomes trapped in place or static The most common example of triboelectric charging happens when someone wearing leather or rubber soled shoes walks across a nylon carpet or linoleum tiled floor With each step electrons change places and the resulting electro static charge builds up quickly reaching significant levels Pushing an epoxy printed circuit board across a workbench using a plastic handled screwdriver or even the constant jostling of Styrofoam pellets during shipment can also build hefty static charges 04584 Rev Al 213 Model GFC7000E Instruction Manual A Primer on Electro Static Discharge Table 12 1 Damage to components occurs when these static charges come in contact with an electronic 65 9096 10 2596 Walking across nylon carpet 1 500V 35 000V Walking across vinyl tile 250V 12 000V Poly bag picked up from 20 000V bench Moving around in a chair padded with urethane foam 18 000V 12 2 How Electro Static Charges Cause Damage Static Generation Voltages for Typical Activities device Cu
204. e the Hessen mode for COMM ports and configure the communication parameters for the port s appropriately Press 04584 Rev A1 124 Model GFC7000E Instruction Manual Operating Instructions SAMPLE RANGE 500 000 PPM CO2 X XXX SETUP COM1 QUIET MODE OFF Repeat the entire process to TST TST gt CAL SETUP NEXT ENTR EXIT set up the COM2 port y SAMPLE ENTER SETUP PASS 818 C M i ontinue pressing next until 8 1 8 m ENTR Y SETUP 1 HESSEN PROTOCOL OFF SETUP X X PRIMARY SETUP MENU OFF CFG DAS RNGE PASS CLK MORE EXIT Toggle OFF ON keys SETUP 1 HESSEN PROTOCOL SETUP SECONDARY SETUP MENU 2 g to change L activate deactivate comm EXIT PREV NEXT selected mode Select which COMM SETUP X X COMMUNICATIONS MENU SETUP X X E 7 1 MODE OFF port to configure ID COMi EXIT OFF _ sum of the mode cm Y IDe oFthe selected SETUP COM1 MODE 0 c he s SETUP X X 1 E 7 1 MODE ON ENTR key accepts the modes is displayed new settings here SET gt EDIT EXIT ENTR EXIT EXIT key ignores the s t new settings 6 13 4 4 Selecting a Hessen Protocol Type Currently there are two versions of Hessen Protocol in use The original implementation
205. e used to actuate control Supply inputs when connected to the U pin Pullup supply for inputs 12 If you wish to utilize either of the analyzer s two serial interface COMM ports refer to Section 6 10 of this manual for instructions on their configuration and usage 13 If your unit has a Teledyne Instruments Ethernet card Option 63 plug one end into the 7 CAT5 cable supplied with the option into the appropriate place on the back of the analyzer see Figure 5 4 in Section 5 5 3 and the other end into any nearby Ethernet access port 3 1 2 Pneumatic Connections 3 1 2 1 Basic Pneumatic Connections Figures 3 3 and 3 4 illustrate the most common configurations for gas supply and exhaust lines to the Model GFC7000E Analyzer Figure 3 13 illustrates the internal gas flow of the instrument in its basic configuration Please refer to Figure 3 2 for pneumatic connections at the rear panel and Table 3 4 for nomenclature NOTE Sample and calibration gases should only come into contact with PTFE Teflon FEP glass stainless steel or brass CAUTION 04584 Rev A1 15 Model GFC7000E Instruction Manual Getting Started CAUTI ON I n order to prevent dust from getting into the gas flow channels of your analyzer it was shipped with small plugs inserted into each of the pneumatic fittings on the back panel Make sure that all of these dust plugs are removed before attaching exhaust and supply gas lines
206. eale Exhaust MODE L control flow Vent Span 7 Pressure Span Certified Gas Indicating soda lime 125 Purge In MODEL 701 Zero Air Generator 04584 Rev A1 134 Model GFC7000E Instruction Manual Calibration Procedures Figure 7 5 Pneumatic Connections MGFC7000E with Zero Span Valves 52 Source of SAMPLE Gas VENT if input is pressurized Certified MODEL 700 CO Gas Gas Dilution Calibrator Sample Exhaust MODE L vent sen GFC7000E Pressure Span External Zero Air Scrubber 175 MODEL 701 Purge In Figure 7 6 Pneumatic Connections MGFC7000E with Zero Span Valves with External Zero air Scrubber OPT 53 Indicating soda lime STEP TWO Set the expected Span Gas concentration SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL CALZ CALS SETUP This sequence causes the analyzer to prompt for the expected CO span concentration M P CAL RANGE 500 00p PPM CO2 X XXX lt TST TST gt ZERO EXIT The SO span concentration values automatically default to 400 0 Conc EXIT ignores the new setting and returns to the previous display ENTR accepts the new setting and returns to the previous display M P CAL 502 SPAN CONC 450 000 Conc To change this value to the actual concentration of the span gas enter the num
207. eater elements by measuring between pin 2 and 4 76 Ohms 3 and 4 330 Ohms of the white five pin connector just below the sample temperature sensor on the Bench pin 1 is the pointed end 2 Assuming that the I C buss is working and that there is no other failure with the relay board the solid state relay K2 on the relay board may have failed Using the BENCH HEATER parameter under the signal I O function as described above turn on and off K2 D3 on the relay board should illuminate as the heater is turned on Check the AC voltage present between pin 2 and 4 for a 100 or 115 VAC model and pins 3 and 4 for a 220 240 VAC model WARNI NG HAZARDOUS VOLTAGES ARE PRESENT DURING THIS TEST 3 If the relay has failed there should no change in the voltage across pins 2 and 4 or 3 and 4 Note K2 is in a socket for easy replacement 4 If K2 checks out OK the thermistor temperature sensor located on the optical bench near the front of the instrument could be at fault Unplug the connector labeled Bench and measure the resistance of the thermistor At room temperature it should have approximately 30K Ohms resistance near the 48 C set point it should have 11K ohms 04584 Rev A1 197 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 11 3 1 3 GFC Wheel Temperature Like the bench heater above there are three possible causes for the GFC wheel temperature to have fa
208. eel 04584 Rev A1 155 Model GFC7000E Instruction Manual THEORY OF OPERATI ON does not absorb IR light This results in a fluctuation in the intensity of the IR light striking the photo detector See Figure 10 3 that results in the output of the detector resembling a square wave The Model GFC7000E determines the amount of CO in the sample chamber by computing the ratio between the peak of the measurement pulse CO2 MEAS and the peak of the reference pulse CO2 REF IR unaffected by N in Measurement Cell of the GDC Wheel and no additional CO in the Sample Chamber CO2 REF y IR affected by CO in Reference Cell with no interfering gas in the Sample Chamber IR shinning through Measurement Cell of the GDC Wheel is reduced by additional CO in the Sample Chamber M R is reduced IR shining through Reference Cell is also reduced by additional CO in the Sample Chamber but to a lesser extent Figure 10 4 Affect of CO in the Sample on CO2 MEAS amp CO2 REF If no gases exist in the sample chamber that absorb light at 4 3um the high concentration of CO in the gas mixture of the reference cell will attenuate the intensity of the IR beam by 60 giving a M R ratio of approximately 2 4 1 Adding CO to the sample chamber causes the peaks corresponding to both cells to be attenuated by a further percentage Since the intensity of the light passing through the measurement cell is greater the effect of th
209. emale connector o Baud rate 115000 bits per second baud o Data Bits 8 data bits with 1 stop bit o Parity None NOTE Cables that appear to be compatible because of matching connectors may incorporate internal wiring that make the link inoperable Check cables acquired from sources other than Teledyne I nstruments for pin assignments before using 04584 Rev A1 83 Model GFC7000E Instruction Manual Operating Instructions 6 10 3 COMM Port Cable Connections There are two DB 9 connectors on the MGFC7000E rear panel COMI is a male connector COM2 a female connector Table 6 15 lists pin assignments Teledyne Instruments offers two mating cables one of which should be applicable for your use Part number 000077 DB 9 female to DB 9 female cable 6 feet long allows connection of COMI with the serial port of most personal computers Also available as Option 60 Section 5 5 1 Part number WR0000024 a DB 9 female to DB 25 male cable Allows connection to the most common styles of modems e g Hayes compatible and code activated switches Both cables are configured with straight through wiring and should require no additional adapters To assist in properly connecting the serial ports to either a computer or a modem there are activity indicators just above each COM port When power is applied to the analyzer the red LED should be illuminated If this LED is dark it indicates a communications error between seri
210. ench can be checked with a Voltmeter using the following procedure which assumes that the wiring is intact and that the Motherboard and the power supplies are operating properly 1 2 For Pressure related problems e Measure the voltage across C1 it should be 5 0 25 VDC If not then the board is bad e Measure the voltage across TP4 and TP1 With the sample pump disabled it should 4500 mV 250 mV With the pump energized it should be approximately 200 mV less If not then S1 the pressure transducer is bad the board is bad or there is a pneumatic failure preventing the pressure transducer from sensing the absorption cell pressure properly For flow related problems Measure the voltage across TP2 and TP1 it should be 10 0 25 VDC If not then the board is bad 04584 Rev A1 203 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES e Measure the voltage across TP3 and TP1 With proper flow 800 sccm at the sample inlet this should be approximately 4 5V this voltage will vary with altitude With flow stopped sample inlet blocked the voltage should be approximately 1V If the voltage is incorrect the flow sensor is bad the board is bad or there is a leak upstream of the sensor 11 4 7 Motherboard 11 4 7 1 A D Functions The simplest method to check the operation of the A to D converter on the motherboard is to use the Signal I O function under the DIAG Menu to check the two A D
211. ensitive device or to close an anti ESD bag The act of pulling a piece of standard plastic adhesive tape such as Scotch tape from its roll will generate a static charge of several thousand or even tens of thousands of volts on the tape itself and an associated field effect that can discharge through or be induced upon items up to a foot away 04584 Rev A1 217 Model GFC7000E Instruction Manual A Primer on Electro Static Discharge 12 4 2 Basic anti ESD Procedures for Analyzer Repair and Maintenance 12 4 2 1 Working at the I nstrument Rack When working on the analyzer while it is in the instrument rack and plugged into a properly grounded power supply 1 Attach you anti ESD wrist strap to ground before doing anything else e Use wrist strap terminated with an alligator clip and attach it to a bare metal portion of the instrument chassis This will safely connect you to the same ground level to which the instrument and all of its components are connected 2 Pause for a second or two to allow any static charges to bleed away 3 Open the casing of the analyzer and begin work Up to this point the closed metal casing of your analyzer has isolated the components and assemblies inside from any conducted or induces static charges 4 If you must remove a component from the instrument do not lay it down on a non ESD preventative surface where static charges may lie in wait 5 Only disconnect your wrist strap after you have fin
212. enu 4 Only appears if relevant option of Feature is active 04584 Rev A1 53 Model GFC7000E Instruction Manual Operating Instructions 6 6 SETUP CLK Setting the I nternal Time of Day Clock The MGFC7000E has a time of day clock that supports the AutoCal timer time of day TEST function and time stamps on most COM port messages To set the time of day press SAMPLE RANGE 500 000 PPM TST 5 gt CAL SAMPLE ENTER SETUP PASS 818 SETUP X X PRI MARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X TIME OF DAY CLOCK ELM ime of Day Date of Year TIME DATE SETUP X X TIME 12 00 SETUP X X DATE 01 JAN 02 12 00 ENTR EXIT 01 JAN 02 ENTR EXIT SETUP X X3 TIME 12 00 SETUP X X DATE 01 JAN 02 1 2 0 0 ENTR EXIT 01 JAN 02 ENTR EXIT SETUP X X TIME OF DAY CLOCK TIME DATE SETUP X X EXIT returns to the main SAMPLE display CFG DAS RNGE PASS CLK MORE 04584 Rev A1 54 Model GFC7000E I nstruction Manual Operating Instructions In order to compensate for CPU clocks which run faster or slower you can adjust a variable called CLOCK ADJ to speed up or slow down the clock by a fixed amount every day To change this variable press SAMPLE RANGE 500 000 PPM X XXX TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR SETUP X X PRI MARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP SECON
213. epresent data that cannot be easily represented by other data types such as data channel names which may contain letters and numbers They consist of a quotation mark followed by one or more printable characters including spaces letters numbers and symbols and a final quotation mark For example a 1 123abc and are all valid text strings It is not possible to include a quotation mark character within a text string Some commands allow you to access variables messages and other items such as iDAS data channels by name When using these commands you must type the entire name of the item you cannot abbreviate any names 04584 Rev A1 119 Model GFC7000E Instruction Manual Operating Instructions 6 13 2 5 Status Reporting Reporting of status messages as an audit trail is one of the three principal uses for the RS 232 interface the other two being the command line interface for controlling the instrument and the download of data in electronic format You can effectively disable the reporting feature by setting the interface to quiet mode Section 6 10 6 Table 6 16 Status reports include iDAS data when reporting is enabled warning messages calibration and diagnostic status messages Refer to Appendix A 3 for a list of the possible messages and this section for information on controlling the instrument through the RS 232 interface General Message Format messages from the instrument including
214. er critical functions are performed here as well 10 3 3 1 Sample Gas and GFC Temperature Control Because the temperature of a gas affects its density and therefore the amount of light absorbed by that gas it is important to reduce the effect of fluctuations in ambient temperature on the Model GFC7000E s measurement of CO To accomplish this both the temperature of the sample chamber and the GFC Wheel are maintained at constant temperatures above their normal operating ranges Bench Temperature To minimize the effects of ambient temperature variations on the sample measurement the sample chamber is heated to 48 8 degrees above the maximum suggested ambient operating temperature for the analyzer A strip heater attached to the underside of the chamber housing is the heat source The temperature of the sample chamber is sensed by a thermistor also attached to the sample chamber housing Wheel Temperature To minimize the effects of temperature variations caused by the near proximity of the IR Source to the GFC wheel on the gases contained in the wheel it is also raised to a high temperature level Because the IR Source itself is very hot the set point for this heat circuit is 68 A cartridge heater is implanted into the heat sync on the motor is the heat source The temperature of the wheel motor assembly is sensed by a thermistor also inserted into the heat sync Both heaters operate off of the AC line voltage supplied to the inst
215. ered the instrument needs to be recalibrated using one of the methods discussed in Chapter 7 04584 Rev A1 63 Model GFC7000E Instruction Manual Operating I nstructions 6 8 SETUP VARS Using the I nternal Variables The MGFC7000E has several user adjustable software variables which define certain operational parameters Usually these variables are automatically set by the instrument s firmware but can be manually re defined using the VARS menu Table 6 6 lists all variables that are available within the 818 password protected level Table 6 6 Variable Names VARS Revision B 3 Changes the internal data acquisition system iDAS hold off time which is the duration when data are not stored in the iDAS because the software considers the data to be questionable That is the Can be between 0 5 and 20 DAS HOLD OFF minutes E case during warm up or just after the instrument returns from one of its calibration modes to SAMPLE mode DAS_HOLD_OFF can be disabled entirely in each iDAS channel Default 15 min Allows the user to set the number of significant digits CONC PRECISION to the right of the decimal point display of concentration and stability values Dynamic zero automatically adjusts offset and slope DYN ZERO of the CO response when performing a zero point ON OFF calibration during an AutoCal Chapter 7 AUTO 1 2 3 4 Default AUTO Dynamic span automatically adjusts slope and slope of the
216. ert 818 into the password prompt field Simply press ENTR to proceed Other password levels exist allowing access to special diagnostic tools and variables used only for specific and rarely needed troubleshooting and adjustment procedures They may be made available as needed by Teledyne Instruments Customer Service department 6 5 SETUP CFG Viewing the Analyzer s Configuration I nformation Pressing the CFG key displays the instrument configuration information This display lists the analyzer model serial number firmware revision software library revision CPU type and other information Use this information to identify the software and hardware when contacting customer service Special instrument or software features or installed options may also be listed here SAMPLE RANGE 500 000 PPB 2 lt TST 5 gt CAL SETUP SAMPLE ENTER PASS 818 Press NEXT of PREV to move back 8 1 8 ENTR EXIT and forth through the following list of Configuration information MODEL NAME SAMPLE PRI MARY SETUP MENU Press EXIT at any time to SERIAL NUMBER e SOFTWARE REVISION LI BRARY REVISI ON iCHI P SOFTWARE REVI SI ON HESSEN PROTOCOL REVISION CFG DAS RNGE PASS CLK MORE EXIT return to the SAMPLE display 7 SAMPLE GFC7000E CO2 ANALYZER Press EXIT at CPU TYPE any time to DATE FACTORY CONFIGURATION NEXT PREV EXIT return to SAVED SETUP m
217. es to drop the speed that the gas flows though the orifice continues to rise Once the ratio of upstream pressure to downstream pressure is greater than 2 1 the velocity of the gas through the orifice reaches the speed of sound As long as that ratio stays at least 2 1 the gas flow rate is unaffected by any fluctuations surges or changes in downstream pressure because such variations only travel at the speed of sound themselves and are therefore cancelled out by the sonic shockwave at the downstream exit of the critical flow orifice 04584 Rev A1 159 Model GFC7000E Instruction Manual THEORY OF OPERATI ON CRITICAL FLOW ORIFICE AREA OF AREA OF HIGH LOW PRESSURE PRESSURE Shockwave O RINGS SPRING FILTER Figure 10 8 Flow Control Assembly amp Critical Flow Orifice The actual flow rate of gas through the orifice volume of gas per unit of time depends on the size and shape of the aperture in the orifice The larger the hole the more gas molecules moving at the speed of sound pass through the orifice Also because the flow rate of gas through the orifice is only related to the minimum 2 1 pressure differential and not absolute pressure e Pressure wave created by the pump s action are filtered out e The flow rate of gas through the sample chamber will be the same regardless of whether the analyzer is at the bottom of Death Valley or on top of Pikes Peak flow rate of the gas is also unaffected by degradat
218. etector deteriorating Contaminated zero gas 20 Source Aging Detector deteriorating GFC Wheel Leaking Pneumatic Leaks Stability Zero Cal Increasing CO2 MEAS Zero Cal Decreasing Zero Cal Decreasing MR Ratio Contaminated zero gas CO Source Aging Pneumatic Leaks instrument amp sample system Span Cal Calibration system deteriorating Source Aging Decreasing GFC Wheel Leaking Calibration system deteriorating Pneumatic Leak between sample inlet Increasing gt 1 and Sample Cell Change in sampling manifold Pres Sample Dirty particulate filter Pneumatic obstruction between sample inlet and Sample Cell Obstruction in sampling manifold Any but with Mechanical Connection between IR PHT Drive Bench Temp Increasing Detector and Sample Cell deteriorating at 48 R Photodetector deteriorating See MR Ratio Zero Cal Decreasing above Decreasing See MR Ratio Zero Cal Increasing above See MR Ratio Span Cal Decreasing above See MR Ratio Span Cal I ncreasing above Increasing Decreasing gt 1 Offset Zero Cal Increasing Increasing Slope Span Cal Decreasing 9 3 Maintenance Procedures The following procedures are to be performed periodically as part of the standard maintenance of the Model GFC7000E 04584 Rev Al 148 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp
219. etup Mode Features and Functions KEYPAD MANUAL MODE OR FEATURE LABEL DESCRIPTION SECTION RT Used to set up and operate the analyzer s various ead COMM external I O channels including RS 232 RS 485 aes 9 modem communication and or Ethernet access 5 System Status Variables VARS Used to view various variables related to the 6 8 instruments current operational status System Diagnostic Used to access a variety of functions that are used to 9 DI AG configure test or diagnose problems with a variety of 6 9 Features 2 the analyzer s basic systems Used to activate the analyzer s two gas concentration Concentration Alarms ALRM status alarms and set the alarm limits 6 11 NOTE Any changes made to a variable during one of the following procedures is not acknowledged by the instrument until the ENTR Key is pressed 04584 Rev Al 52 Model GFC7000E Instruction Manual Operating I nstructions If the EXIT key is pressed before the ENTR key the analyzer will beep alerting the user that the newly entered value has been lost 6 4 1 SETUP Mode Password Security Whenever the Model GFC7000E s SETUP mode is activated the instrument will prompt the user to enter a security password The default password is 818 This allows access to all of the instruments basic functions and operating modes as well as some of its more powerful diagnostic tools and variables The analyzer will automatically ins
220. ever when editing a data channel such as during adding deleting or editing parameters all data for that particular channel will be lost because the iDAS can store only data of one format number of parameter columns etc for any given channel In addition an iDAS configuration can only be uploaded remotely as an entire set of channels Hence remote update of the iDAS will always delete all current channels and stored data To modify add or delete a parameter follow the instruction shown in section 6 12 2 2 then press From the DATA ACQUISITION menu see Section 6 12 2 2 Edit Data Channel Menu SETUP X X 0 ATIMER 1 900 i 7 Exits to the main PREV NEXT INS DEL EDIT PRNT EXIT VU u SETUP X X NAME CONC SET SET EDIT PRINT Press SET key until SETUP X X PARAMETERS 1 SET SET EDIT PRINT YES will delete SETUP EDITPARAMS DELETE DATA all data in that entire channel YES NO NO returns to the previous menu and retains all data Edit Data Parameter Menu Moves the SETUP 0 1 MODE AVG i display between Exits to the main existing PREV NEXT INS DEL EDIT EXIT Data Acquisition Parameters menu Inserts a new Parameter before the currently displayed Parameter Use to configure the functions for this Parameter Deletes the Parameter currently displayed 04584 Rev A1 10
221. ey are Table 10 2 Relay Board Status LED s LED COLOR FUNCTI ON STATUS WHEN LIT STATUS WHEN UNLIT D1 RED Watchdog Circuit Cycles On Off Every 3 Seconds under direct control of the analyzer s CPU D2 YELLOW Wheel Heater HEATING NOT HEATING D3 YELLOW Bench Heater HEATING NOT HEATING D4 YELLOW Spare N A N A D5 GREEN Sample Cal Gas Valve Open to CAL GAS Valve Open to SAMPLE GAS Valve Option FLOW FLOW D6 GREEN Zero Span Gas Valve Open to SPAN GAS Valve Open to ZERO GAS Valve Option FLOW FLOW D7 GREEN Shutoff Valve Valve Open to CAL GAS Valve CLOSED to CAL GAS Option FLOW FLOW D8 GREEN IR SOURCE Source ON Source OFF 04584 Rev Al 169 Model GFC7000E Instruction Manual THEORY OF OPERATI ON DC VOLTAGE TEST POINTS A STATUS LED s Figure 10 14 Location of relay board Status LED s 10 3 5 2 1 C Watch Dog Circuitry Special circuitry on the relay board monitors the activity on the I C bus and drives LED D1 Should this LED ever stay ON or OFF for 30 seconds the watchdog circuit will automatically shut of all valves as well as turn off the IR Source and all heaters The GFC wheel motor will still be running as will the Sample Pump which is not controlled by the relay board 10 3 6 Mother Board This printed circuit assembly provides a multitude of functions including A D conversion digital input output PC 104 to I2C translation temperature sensor signa
222. flow orifice itself p n 00094100 make sure that the side with the colored window usually red is facing upstream to the flow gas flow 7 Re assemble in reverse order 8 After reconnecting the power and pneumatic lines flow check the instrument as described in the Section 9 3 4 CS X Pneumatic Connector Male 1 8 P N 70 Spring lt HW 20 2 Sintered Filter 9 P N FL 01 Critical Flow Orifice P N 00094100 Ca O Ring Q P N OR_01 Purge Housing N P N 000850000 Figure 11 6 Critical Flow Restrictor Assembly Disassembly 04584 Rev A1 208 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 11 5 2 Removing Replacing the GFC Wheel When Removing or replacing the GFC Wheel it is important to perform the disassembly in the following order to avoid damaging the components 1 Turn off the analyzer 2 Remove the top cover as described in Getting Started Section 3 1 3 Open the Instrument s hinged front panel 4 Locate the GFC wheel motor assembly see Figure 3 11 5 unplug the following electronic components e The wheel housing temperature sensor e GFC wheel heater e wheel motor power supply e IR source 6 Unscrew the purge gas line hex nut and remove the 1 8 inch FEP purge gas line Figure 11 7 Opening the GFC Wheel Housing 7 Remove the two 2 screws holding the opto pickup printed circuit assembly to th
223. for the COz measurements RANGE 500 000 PPM 2 Press EXIT to leave the calibration unchanged and return to the previous menu lt TST TST gt ENTR SPAN CONC EXT _ RANGE 500 000 PPM CO2 XXX X EXIT returns to the main EXIT SAMPLE display IST ENTR CONC The Model GFC7000E Analyzer is now ready for operation 04584 Rev A1 29 Model GFC7000E Instruction Manual Getting Started NOTE Once you have completed the above set up procedures please fill out the Quality Questionnaire that was shipped with your unit and return it to Teledyne Instruments This information is vital to our efforts in continuously improving our service and our products THANK YOU Front Switch 6 Circuit Breaker GFC Wheel Housing Purge Gas Inlet amp Flow Control Orifice GFC Motor GFC Wheel Housing amp IR Source Heat Sample Gas Critical Flow Orifice Pump Assy Power Receptacle Fan PS1 5 VDC 15VDC PS2 12 VDC Figure 3 11 OPTICAL BENCH Purge Gas Pressure Control Assy Sample Gas Temperature Sensor Relay Board Mother SYNC DEMOD BOARD Assembly Layout IR Source Particulate Filter Optical Bench Gas Inlet Optional Sample Cal Valve Optional Zero Span Valve Gas Flow Sensor Assy Flow Sensor Optional Shutoff Valve
224. for the analyzer Table 6 30 Teledyne Instruments Hessen Protocol Response Modes MODE ID MODE DESCRI PTI ON CMD This is the Default Setting Reponses from the instrument are encoded as the traditional command format Style and format of responses depend on exact coding of the initiating command BCC Responses from the instrument are always delimited with lt 5 gt at the beginning of the response ETX at the end of the response followed by a 2 digit Block Check Code checksum regardless of the command encoding TEXT Responses from the instrument are always delimited with CR at the beginning and the end of the string regardless of the command encoding To Select a Hessen response mode press SAMPLE RANGE 500 000 PPM CO2 X XXX TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 SETUP COMMUNICATIONS MENU ID HESN COM2 EXIT SETUPX X PRIMARY SETUP MENU GrG DAS RNGE PASS CUK MORE EAT SETUP X X HESSEN VARIATION TYPE 1 SET EXIT SETUP SECONDARY SETUP MENU ENTR key accepts the v Y new settings COMM EXIT SETUP HESSEN RESPONSE MODE CMD EXIT key ignores the new settings SET gt EDIT EXIT Press to change response mode SETUP X X HESSEN RESPONSE MODE CMD BCC TEXT EDIT ENTR EXIT 6 13 4 6 Hessen Protocol Gas ID The Model GFC7000E Analyzer is a
225. fter any analyze Maintenance or Repair years Every 6 m Annually or Verify Leak after any Tight Maintenance or Repair Examine As needed Yes if and clean cleaned As needed 04584 Rev A1 146 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp PROCEDURES Table 9 2 GFC7000E Test Function Record Operating Date Recorded Mode mE P tf ff MR RATIO SAMPLE PRES SAMPLE After PHT DRI VE Warn up EN din 04584 1 147 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp PROCEDURES 9 2 Predicting Failures Using the Test Functions The Test Functions can be used to predict failures by looking at how their values change over time Initially it may be useful to compare the state of these Test Functions to the values recorded on the printed record of the final calibration performed on your instrument at the factory p n 04307 Table 9 3 can be used as a basis for taking action as these values change with time The internal data acquisition system iDAS is a convenient way to record and track these changes Use APIcom to download and review this data from a remote location Table 9 3 Predictive uses for Test Functions Function Condition Behavior Interpretation Pneumatic Leaks instrument amp sample system Detector deteriorating Source Aging Detector deteriorating Optics getting dirty or contaminated Source Aging Increasing D
226. functions viewable from the front panel can be used to isolate and identify many operational problems when combined with a thorough understanding of the analyzer s theory of operation see Chapter 10 The acceptable ranges for these test functions are listed in the Nominal Range column of the analyzer Final Test and Validation Data Sheet p n 04307 shipped with the instrument Values outside these acceptable ranges indicate a failure of one or more of the analyzer s subsystems 04584 Rev A1 186 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES Functions whose values are still within the acceptable range but have significantly changed from the measurement recorded on the factory data sheet may also indicate a failure A worksheet has been provided in Appendix C to assist in recording the value of these test functions The following table contains some of the more common causes for these values to be out of range Table 11 2 Test Functions Indicated Failures TEST FUNCTI ONS INDICATED FAI LURE S As Displayed Time of day clock is too fast or slow TI ME To adjust see Section 6 6 Battery in clock chip on CPU board may be dead Incorrectly configured measurement range s could cause response problems with a RANGE Datalogger or chart recorder attached to one of the analog output If the Range selected is too small the recording device will over range
227. g it to send an interrupt signal to the CPU 1 C Interface Chip 04584 Rev A1 177 Model GFC7000E Instruction Manual THEORY OF OPERATI ON This IC performs several functions e Using a dedicated digital status bit it sends an interrupt signal alerting the CPU that new data from the keyboard is ready to send e Upon acknowledgement by the CPU that it has received the new keyboard data the interface chip resets the key depress detect flip flop e In response to commands from the CPU it turns the front panel status LEDs on and off and activates the beeper e Informs the CPU when the optional maintenance and second language switches have been opened or closed see Chapter 5 for information on these options Display Data Decoder This decoder the serial translates the data sent by the CPU in TTY format into a bitmapped image which is sent over a parallel data bus to the display Display Controller This circuit manages the interactions between the display data decoder and the display itself It generates a clock pulse that keeps the two devices synchronized It can also in response to commands from the CPU turn off and or reset the display Additionally for analyzers with the optional maintenance switch is installed See Chapter 5 the display controller turns on an LED located on the back of the keyboard interface PCA whenever the instrument is placed in maintenance mode Display Power Watchdog The Model GFC70
228. gh the it e Use metallic anti ESD bags for storing and shipping ESD sensitive components and assemblies rather than pink poly bags The famous pink poly bags are made of a plastic that is impregnated with a liquid similar to liquid laundry detergent which very slowly sweats onto the surface of the plastic creating a slightly conductive layer over the surface of the bag While this layer may equalizes any charges that occur across the whole bag it does not prevent the build up of static charges If laying on a conductive grounded surface these bags will allow charges to bleed away but the very charges that build up on the surface of the bag itself can be transferred through the bag by induction onto the circuits of your ESD sensitive device Also the liquid impregnating the plastic is eventually used up after which the bag is as useless for preventing damage from ESD as any ordinary plastic bag Anti Static bags made of plastic impregnated with metal usually silvery in color provide all of the charge equalizing abilities of the pink poly bags but also when properly sealed create a Faraday cage that completely isolates the contents from discharges and the inductive transfer of static charges Storage bins made of plastic impregnated with carbon usually black in color are also excellent at dissipating static charges and isolating their contents from field effects and discharges Never use ordinary plastic adhesive tape near ESD s
229. gth is absorbed by a particular gas molecule over a certain distance The mathematical relationship between these three parameters is I aLc o Where I is the intensity of the light if there was no absorption I is the intensity with absorption L is the absorption path or the distance the light travels as it is being absorbed C is the concentration of the absorbing gas In the case of the Model GFC7000E carbon dioxide CO is the absorption coefficient that tells how well CO absorbs light at the specific wavelength of interest 04584 Rev A1 153 Model GFC7000E Instruction Manual THEORY OF OPERATI ON 10 1 2 Measurement Fundamentals In the most basic terms the Model GFC7000E uses a high energy heated element to generate a beam of broad band IR light with a known intensity measured during Instrument calibration This beam is directed through multi pass cell filled with sample gas The sample cell uses mirrors at each end to reflect the IR beam back and forth through the sample gas to generate a 2 5 meter absorption path see Figure 10 1 This length was chosen to give the analyzer maximum sensitivity to fluctuations in CO density Band Pass Filter Sample Chamber IR Source Photo Detector IR Beam Figure 10 1 Measurement Fundamentals Upon exiting the sample cell the beam shines through a band pass filter that allows only light at a wavelength of 4 3 um to pass Finally the beam
230. guration or erased Reference reading below 1250 mV 50 mV in N20 and high level instruments or above 4950 mV in normal sample mode Auto reference ratio below limit specified by ZERO LIMIT variable Bench temperature outside of warning limits specified by BENCH SET variable Wheel temperature outside of warning limits specified by WHEEL SET variable Sample flow outside of warning limits specified by SAMP FLOW SET variable Sample pressure outside of warning limits specified by SAMP PRESS SET variable Sample temperature outside of warning limits specified by SAMP TEMP SET variable Purge pressure outside of warning limits specified by PURGE PRESS SET variable Chassis temperature outside of warning limits specified by BOX SET variable SYNC OK digital input is off Photometer temperature outside of warning limits specified by PHOTO TEMP SET variable Contact closure zero calibration failed while DYN ZERO was set to ON Contact closure span calibration failed while DYN SPAN was set to ON Rear board was not detected during power up Firmware is unable to communicate with the relay board Firmware is unable to communicate with the front panel ANALOG CAL WARNI NG The A D or at least one D A channel has not been calibrated 045840110 Rev B 3 238 Model GFC7000E Instruction Manual Table A 3 GFC7000E Test Functions Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0
231. h a shutoff valve and pressure gauge CAUTI ON Do not use bubble solution with vacuum applied to the analyzer The solution may contaminate the instrument Do not exceed 15 PSIG pressure 1 Turn OFF power to the instrument 2 Install a leak checker or tank of gas as described above on the sample inlet at the rear panel 3 Remove the instrument cover and locate the inlet side of the sample pump Remove the flow assembly from the pump and plug it with the appropriate gas tight fitting 04584 Rev A1 150 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp PROCEDURES 4 Pressurize the instrument with the leak checker allowing enough time to fully pressurize the instrument through the critical flow orifice Check each fitting with soap bubble solution looking for bubbles Once the fittings have been wetted with soap solution do not re apply vacuum as it will suck soap solution into the instrument and contaminate it Do not exceed 15 psi pressure If the instrument has one of the zero and span valve options the normally closed ports on each valve should also be separately checked Connect the leak checker to the normally closed ports and check with soap bubble solution 6 Once the leak has been located and repaired the leak down rate should be 1 in Hg 0 4 psi in 5 minutes after the pressure is shut off 9 3 4 Performing a Sample Flow Check CAUTI ON Always use a separate calibrated f
232. he concentration value Bench Temperature Sensor This thermistor attached to the sample chamber housing reports the current temperature of the chamber housing to the CPU as part of the bench heater control loop Wheel Temperature Sensor This thermistor attached a the heat sync on the GFC wheel motor assembly reports the current temperature of the wheel motor assembly to the cpu as part of the Wheel Heater control loop Box Temperature Sensor A thermistor is attached to the mother board It measures the analyzer s inside temperature This information is stored by the CPU and can be viewed by the user for troubleshooting purposes via the front panel display see Section 11 1 2 04584 Rev A1 171 Model GFC7000E Instruction Manual THEORY OF OPERATI 10 3 6 4 Analog Outputs The analyzer comes equipped with four analog outputs A1 A2 A3 and a fourth that is a spare A2 and A1 Output The first two A2 and A1 are normally set up to operate in parallel so that the same data can be sent to two different recording devices While the names imply that one should be used for sending data to a chart recorder and the other for interfacing with a datalogger either can be used for both applications Both of these channels output a signal that is proportional to the CO concentration of the sample gas The A1 and A2 outputs can be slaved together or set up to operated independently A variety of scaling factors are available Se
233. he PHT DRI VE voltage has returned to an acceptable level 2 The two large transistor type devices mounted to the side of the Absorption Bench have come loose from the bench Tighten the retaining screws and note whether there is an improvement in the PHT DRIVE voltage 3 The photo detector has failed Contact the factory for instructions 4 The sync demodulator circuit board has failed Contact the factor for instructions 11 3 2 Excessive Noise Noise is continuously monitored in the TEST functions as the STABIL reading and only becomes meaningful after sampling a constant gas concentration for at least 10 minutes Compare the current STABIL reading with that recorded at the time of manufacture included in the 04584 Rev A1 198 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES MGFC7000E Final Test And Validation Data Sheet p n 04271 shipped with the unit from Teledyne Instruments 1 The most common cause of excessive noise is leaks Leak check and flow check the instrument described in Section 9 3 2 Detector failure caused by failure of the hermetic seal or over temperature due to poor heat sinking of the detector can to the optical bench In addition to increased noise due to poor signal to noise ratio another indicator of detector failure is a drop in the signal levels of the CO MEASURE signal and REFERENCE signal 3 Sync Demod Board failure There are many delicate high impedance pa
234. he first reading would occur at the beginning of the next full minute according to the instrument s internal clock e If the REPORT PERI OD were set for of one hour the first report activity would occur at the beginning of the next full hour according to the instrument s internal clock EXAMPLE Given the above settings if iDAS were activated at 7 57 35 the first sample would occur at 7 58 and the first report would be calculated at 8 00 consisting of data points for 7 58 7 59 and 8 00 During the next hour from 8 01 to 9 00 the instrument will take a sample reading every minute and include 60 sample readings When the STORE NUM SAMPLES feature is turned on the instrument will also store how many sample readings were used for the AVG MIN or MAX calculation but not the readings themselves REPORT PERI ODS IN PROGRESS WHEN INSTRUMENT IS POWERED OFF If the instrument is powered off in the middle of a REPORT PERIOD the samples accumulated so far during that period are lost Once the instrument is turned back on the iDAS restarts taking samples and temporarily them in volatile memory as part of the REPORT PERI OD currently active at the time of restart At the end of this REPORT PERI OD only the sample readings taken since the instrument was turned back on will be included in any AVG MIN or MAX calculation Also the STORE NUM SAMPLES feature will report the number of sample readings taken since the instrument was restarted 04584 Rev
235. he same for all parameters in one channel and needs to be specified only for one of the parameters in that channel Users can specify up to 50 parameters per data channel the MGFC7000E provides about 30 parameters However the number of parameters and channels is ultimately limited by available memory 6 12 1 3 iDAS Triggering Events Triggering events define when and how the iDAS records a measurement of any given data channel Triggering events are firmware specific and a complete list of Triggers for this model analyzer can be found in Appendix A 5 The most commonly used triggering events are ATIMER Sampling at regular intervals specified by an automatic timer Most trending information is usually stored at such regular intervals which can be instantaneous or averaged 04584 Rev A1 98 Model GFC7000E Instruction Manual Operating Instructions e EXITZR EXITSP SLPCHG exit zero exit span slope change Sampling at the end of irregularly occurring calibrations or when the response slope changes These triggering events create instantaneous data points e g for the new slope and offset concentration response values at the end of a calibration Zero and slope values are valuable to monitor response drift and to document when the instrument was calibrated e WARNINGS Some data may be useful when stored if one of several warning messages appears such as WTEMPW GFC wheel temperature warning or PPRESW purge pressu
236. he setup of this option is located in Section 7 6 Q How do I set the analog output signal range and offset A Instructions for this can be found in Section 6 9 4 which describes analog I O configuration Q What is the averaging time for an GFC7000E A The default averaging time optimized for ambient pollution monitoring is 150 seconds for stable concentrations and 10 seconds for rapidly changing concentrations see Section 10 5 1 for more information However it is adjustable over a range of 0 5 second to 200 seconds please contact customer service for more information 4 2 Glossary ASSY acronym for Assembly DAS acronym for data acquisition system the old acronym of iDAS DIAG acronym for diagnostics the diagnostic settings of the analyzer DHCP acronym for dynamic host configuration protocol A protocol used by LAN or Internet servers to automatically set up the interface protocols between themselves and any other addressable device connected to the network DOC Disk On Chip the analyzer s central storage area for analyzer firmware configuration settings and data This is a solid state device without mechanically moving parts that acts as a computer hard disk drive under gt DOS with disk label C DOC chips come with 8 mb in the E series analyzer standard configuration but are available in larger sizes DOS Disk Operating System The E series analyzers uses DR DOS EEPROM also referred to as a FLASH chip FLAS
237. hich tests have you done trying to solve the problem Continue on back if necessary 6 If possible fax a portion of a strip chart or email a data file to customer service CUSTOMER SERVICE CONTACT INFORMATION 16830 Chestnut St City of Industry Ca 91748 PHONE 1 626 961 9221 or 1 626 934 1500 FAX 1 626 961 2538 EMAIL ai customerservice teledyne com You can access and submit an online version of this form at http www teledyne api com forms csformGFC7000E asp 048450130 Rev A1 251 Notes and further information 045150130 Rev A1 252 Model GFC7000E Instruction Manual APPENDIX D ELECTRONI C SCHEMATI CS APPENDIX D ELECTRONIC SCHEMATICS Table D 1 List of Included Electronic Schematics 045840140 Rev A1 253 Model GFC7000E Instruction Manual User Notes 04584 Rev A1 254
238. hing is operation The PLD divides the X10 clock signal by ten and sends this signal back to the PLL circuit which compares it to the original segment sensor reference signal If these two signals match the PLL sends a status level to the PLD that the phase lock is OK If for some reason the two signals do not match the PLL alerts the PLD that phase lock has been lost and the PLD issues a phase lock warning to the CPU Should this occur A SYNC warning will appear on the analyzer s front panel display see Section 11 1 1 for more information 10 3 4 4 Sync Demod Status LED s The following two status LED s located on the synch demod board provide additional diagnostic tools for checking the GFC wheel rotation 04584 Rev A1 167 Model GFC7000E Instruction Manual THEORY OF OPERATION Table 10 1 Sync Demod Status LED Activity LED FUNCTI ON STATUS OK FAULT STATUS D1 M R Sensor Status LED flashes approximately LED is stuck 2 second ON or OFF D2 Segment Sensor LED flashes approximately LED is stuck Status 6 second ON or OFF See Section 11 1 4 for more information 10 3 4 5 Photo Detector Temperature Control The synch demod board also contains circuitry that controls the IR photo detector s thermoelectric coolers A drive voltage PHT DRIVE is supplied to the coolers by the synch demod board which is adjusted by the synch demod board based on a return signal called TEC control which alerts informs the sy
239. ibration feature must be turned off Section 6 9 4 2 Activate the ANALOG 1 O CONFI GURATI ON MENU see Section 6 9 1 then press FROM ANALOG I O CONFIGURATION MENU DIAG AIO CONC OUT 1 RANGE 5V DIAG ANALOG I CONFIGURATION SET EDIT EXIT PREV ENTR EXIT DIAG AIO CONC OUT 1 REC OFS 0 mV DIAG AIO AOUTS CALIBRATED NO SET SET EDIT EXIT SET SET CAL EXIT If AutoCal is ON go to Y Section 6 7 3 DIAG AIO CONC OUT 1 AUTO CAL OFF Press SET gt to select the analog output channel to be configured SET SET 4 DISPLAYED AS CHANNEL i CONC OUT 1 A1 CONC OUT 2 A2 2 V TEST OUTPUT 4 DIAG AIO CONC OUT 2 CALIBRATED NO SET CAL EXIT DIAG AIO CONC OUT 1 5V NO CAL SET SET ENT EXIT DIAG AIO CONC OUT 1 VOLT Z 0 mV 0100 UP10 UP DOWN DN10 D100 ENTR EXIT These keys increase decrease the analog output by 100 10 or 1 counts Continue adjustments until the voltage measured EXIT ignores the at the output of the analyzer and or the input of DIAG CONC OUT 1 VOLT S 4500 mV ERES the recording device matches the value in the accepts the upper fight hand corner of the display to the 0100 UP10 UP DOWN DN10 D100 ENTR EXIT new setting tolerance listed in Table 6 10 The concentration display
240. ical resistance changes with temperature and a two stage thermo electric cooler When the analyzer is on a constant electrical current is directed through the detector The IR beam is focused onto the detector surface raising its temperature and lowering its electrical resistance that results in a change in the voltage drop across the detector During those times that the IR beam is bright the temperature of the detector is high the resistance of the detector is correspondingly low and the its output voltage output is low During those times when the IR beam intensity is low or completely blocked by the GFC Wheel mask the temperature of the detector is lowered by the two stage thermo electric cooler increasing the detectors resistance and raising the output voltage 10 3 4 Synchronous Demodulator Sync Demod Assembly 10 3 4 1 Overview While the photo detector converts fluctuations of the IR beam into electronic signals the Sync Demod Board amplifies these signals and converts them into usable information Initially the output by the photo detector is a complex and continuously changing waveform made up of Measure and Reference pulses The sync demod board demodulates this waveform and outputs two analog DC voltage signals corresponding to the peak values of these pulses CO2 MEAS and CO2 REF are converted into digital signals by circuitry on the Motherboard then used by the CPU to calculate the CO concentration of the sample gas
241. igned so that problems can be rapidly detected evaluated and repaired During operation the analyzer continuously performs self check diagnostics and provides the ability to monitor the key operating parameters of the instrument without disturbing monitoring operations A systematic approach to troubleshooting will generally consist of the following four steps 1 Note any WARNI NG MESSAGES and take corrective action as required 2 Examine the values of all TEST functions and compare to factory values Note any major deviations from the factory values and take correction action as required 3 Use the internal electronic status LED s to determine whether the CPU and buses running and if the sync demodulator and relay board are operating properly Verify that the DC power supplies are operating properly by checking the voltage test points on the relay board Please note that the analyzer s DC power wiring is color coded and these colors match the color of the corresponding test points on the relay board 4 SUSPECT A LEAK FIRST Data from Teledyne Instruments service department indicates that 50 of all problems are eventually traced to leaks in the pneumatic connections and gas lines of the analyzer itself the source of zero air span gases or sample gas delivery system Check for gas flow problems such as clogged or blocked internal external gas lines damaged seals punctured gas lines a damaged pump diaphragm etc 5 Follo
242. iled 1 The wheel heater has failed Check the resistance between pins 1 and 4 on the white five pin connector just below the sample temperature sensor on the bench pin 1 is the pointed end It should be approximately 275 ohms 2 Assuming that the I C buss is working and that there is no other failure with the relay board the solid state relay K1 on the relay board may have failed Using the WHEEL HEATER parameter under the signal I O function as described above turn on and off K1 D2 on the relay board should illuminate as the heater is turned on Check the AC voltage present between pin 1 and 4 WARNI NG HAZARDOUS VOLTAGES ARE PRESENT DURING THIS TEST 3 If the relay has failed there should be no change in the voltage across pins 1 and 4 Note K1 is socketed for easy replacement 4 If K1 checks out OK the thermistor temperature sensor located at the front of the filter wheel assembly may have failed Unplug the connector labeled Wheel and measure the resistance of the thermistor The resistance near the 68 C set point is 5 7k ohms 11 3 1 4 IR Photo Detector TEC Temperature If the PHT DRI VE test parameter described above in Table 11 2 is out of range there are two four possible causes of failure 1 The screws retaining the IR photo detector to the absorption bench have become loose Carefully tighten the screws hand tight and note whether after the analyzer has come up to operating temperature whether t
243. ility of the measurement Wait until STABIL falls below 1 0 ppb This may take several minutes Press ENTR to changes the OFFSET amp SLOPE values for the CO measurements Press EXIT to leave the calibration unchanged and return to the previous menu ACTION Allow span gas to enter the sample port at the rear of the instrument The value of STABIL may jump significantly Wait until it falls back below 1 0 ppb This may take several minutes Press ENTR to change the OFFSET amp SLOPE values for the CO measurements Press EXIT to leave the calibration unchanged and return to the previous menu The SPAN key now M P CAL STABIL XXX X PPM CO2 XXX X appears during the transition from zero to Y span lt TST TST gt SPAN CONC EXIT You may see both keys 4 If either the ZERO or SEN M P CAL RANGE 500 000 PPM 2 XXX X appear see Section 11 for troubleshooting tips v 4 lt TST TST gt ENTR SPAN CONC EXIT lt CAL RANGE 500 000 PPM CO2 XXX X lt TST TST gt ENTR CONC gt EXIT EXIT returns to the main SAMPLE display If the ZERO or SPAN keys are not displayed this means that the measurement made during that part of the procedure is too far out of the allowable range to do allow a reliable calibration The reason for this must be determined before the analyzer can be calibrate
244. ing used The ID number of the analyzer is only necessary if multiple analyzers are on the same communications line such as the multi drop setup Control C Pauses the listing of commands Control P Restarts the listing of commands 6 13 2 3 Command Syntax Commands are not case sensitive and all arguments within one command i e ID numbers keywords data values etc must be separated with a space character Commands follow the syntax X ID COMMAND CR Where X is the command type one letter that defines the type of command Allowed designators are listed in Table 6 27 and Appendix A 6 ID is the analyzer identification number Section 6 10 1 Example the Command 200 followed by a carriage return would print the list of available commands for the revision of software currently installed in the instrument assigned ID Number 200 COMMAND is the command designator This string is the name of the command being issued LIST ABORT NAME EXIT etc Some commands may have additional arguments that define how the command is to be executed Press CR or refer to Appendix A 6 for a list of available command designators CR is a carriage return All commands must be terminated by a carriage return usually achieved by pressing the ENTER key on a computer 04584 Rev A1 118 Model GFC7000E Instruction Manual Operating Instructions Table 6 27 Command Types COMMAND COMMAND TYPE Calibration
245. ions in pump efficiency due to age The critical flow orifice used in the Model GFC7000E is designed to provide a flow rate of 800 cm min 10 2 1 2 Sample Pressure Sensor An absolute value pressure transducer plumbed to the outlet of the sample chamber is used to measure sample pressure The output of the sensor is used to compensate the concentration measurement for changes in air pressure This sensor is mounted to a printed circuit board with the sample flow sensor on the sample chamber see following section and Figure 3 11 10 2 1 3 Sample Flow Sensor A thermal mass flow sensor is used to measure the sample flow through the analyzer The sensor is calibrated at the factory with ambient air or N5 but can calibrated to operate with samples consisting of other gases such as CO see Section 9 3 4 This sensor is mounted to a printed circuit board with the Sample Pressure sensor on the sample chamber see previous section and Figure 3 11 04584 Rev A1 160 Model GFC7000E Instruction Manual THEORY OF OPERATI Particulate Filter The Model GFC7000E Analyzer comes equipped with a 47 mm diameter Teflon particulate filter with a 5 micron pore size The filter is accessible through the front panel which folds down to allow access and should be changed according to the suggested maintenance schedule described in Table 9 1 10 2 1 4 Valve Options A variety of optional valve sets can be purchased for the analyzer which allo
246. is additional attenuation is greater This causes CO2 MEAS to be more sensitive to the presence of CO in the sample chamber than CO2 REF and the ratio between them M R to move closer to 1 1 as the concentration of CO in the sample chamber increases Once the Model GFC7000E has computed this ratio a look up table is used with interpolation to linearize the response of the instrument This linearized concentration value is combined with 04584 Rev A1 156 Model GFC7000E Instruction Manual THEORY OF OPERATI ON calibration SLOPE and OFFSET values to produce the CO concentration which is then normalized for changes in sample pressure M R is Shifted IR shining through both cells is effected equally by interfering gas in the Sample Chamber Figure 10 5 Effects of Interfering Gas on CO2 MEAS amp CO2 REF If an interfering gas such as vapor is introduced into the sample chamber the spectrum of the IR beam is changed in a way that is identical for both the reference and the measurement cells but without changing the ratio between the peak heights of CO MEAS and CO REF In effect the difference between the peak heights remains the same Thus the difference in the peak heights and the resulting M R ratio is only due to CO and not to interfering gases In this way Gas filter correlation rejects the effects of interfering gases and so that the analyzer responds only to the presence of CO To improve the signal to no
247. ise performance of the IR photo detector the GFC wheel also incorporates an optical mask that chops the IR beam into alternating pulses of light and dark at six times the frequency of the measure reference signal This limits the detection bandwidth helping to reject interfering signals from outside this bandwidth improving the signal to noise ration The IR Signal as the Photo Detector sees it after being chopped by the GFC Wheel Screen CO MEAS CO REF Figure 10 6 Chopped IR Signal 04584 Rev A1 157 Model GFC7000E Instruction Manual THEORY OF OPERATI 10 1 4 Ambient CO I nterference Rejection CO absorbs IR light very well So well that even the narrow volume of ambient air between the IR source and the sample chamber is enough to alter the analyzer s measured concentration of Also ambient air which averages around 350 ppm to 400 ppm will vary significantly over the course of the day The ambient CO concentration can rise as high as 1 000 ppm during the time of the day when people are present It can fluctuate 300 ppm as the photosynthesis of plant life in the nearby area increases during the day and decreases at night The basic design of the GFC7000E rejects most of this interference at a 100 1 ratio however this still can allow small fluctuations in CO concentration during the course of the day To completely remove all effects of ambient CO from the analyzer s measurement of CO dried air scrubbe
248. ished work and closed the case of the analyzer 12 4 2 2 Working at a Anti ESD Work Bench When working on an instrument of an electronic assembly while it is resting on anti ESD work bench 1 Plug you anti ESD wrist strap into the grounded receptacle of the work station before touching any items on the work station and while standing at least a foot or so away This will allow any charges you are carrying to bleed away through the ground connection of the work station and prevent discharges due to field effects and induction from occurring 2 Pause for a second or two to allow any static charges to bleed away 3 Only open any anti ESD storage bins or bags containing sensitive devices or assemblies after you have plugged your wrist strap into the work station e Lay the bag or bin on the workbench surface e Before opening the container wait several seconds for any static charges on the outside surface of the container to be bled away by the work station s grounded protective mat 4 Do not pick up tools that may be carrying static charges while also touching or holding an ESD Sensitive Device e Only lay tools or ESD sensitive devices and assemblies on the conductive surface of your workstation Never lay them down on a non ESD preventative surfaces 5 Place any static sensitive devices or assemblies in anti static storage bags or bins and close the bag or bin before unplugging your wrist strap 04584 Rev A1 218 Model G
249. its place after several attempts to clear it the message may indicate Once the last warning has been real problem and not an artifact Make sure warning messages are of the warm up period not due to real problems mode Figure 6 3 Viewing and Clearing MGFC7000E WARNING Messages 6 3 Calibration Mode Pressing the CAL key switches the MGFC7000E into multi point calibration mode In this mode the user can calibrate the instrument or check the instruments calibration with the use of calibrated zero or span gases If the instrument includes either the zero span valve option or IZS option the display will also include CALZ and CALS keys Pressing either of these keys also puts the instrument into multipoint calibration mode e The CALZ key is used to initiate a calibration of the zero point e The CALS key is used to calibrate the span point of the analyzer It is recommended that this span calibration is performed at 90 of full scale of the analyzer s currently selected reporting range Because of their critical importance and complexity calibration operations are described in detail in Chapter 7 of this manual For more information concerning the zero span zero span shutoff and IZS valve options see Section 5 4 6 3 1 SETUP PASS Calibration Password Security The MGFC7000E calibration functions may be password protected for to prevent inadvertent adjustments When the calibration pass
250. justment REF d MIT 0 1 500 Reference detector standard deviation must be below this limit to switch out of startup mode Enclose value in double quotes when setting from the RS 232 interface Multi range modes Hessen protocol M300EH GFC7000E 5 M300ES 6 Fixed range special 7 jCHIP option 8 M300EM FC7000E 10 M306E 1 Must power cycle instrument for these options to take effect 12 GFC7000EU 045840110 Rev B 3 237 Model GFC7000E I nstruction Manual APPENDI X A 3 Warnings and Test Functions Revision E OAPPENDI X A 3 Warnings and Test Functions Revision 0 APPENDIX A 3 Warnings and Test Functions Revision Table 2 GFC7000E Warning Messages Revision 0 WSYSRES SYSTEM RESET WDATAINIT DATA INITIALIZED WCOMFIGINIT CONFIG INITIALIZED WSOURCE SOURCE WARNING WAUTOZERO 5 AZERO WARN 1 001 WBENCHTEMP BENCH TEMP WARNI NG WHEEL TEMP WARNING SAMPLE FLOW WARN WWHEELTEMP WSAMPFLOW 9 WSAMPPRESS SAMPLE PRESS WARN WSAMPTEMP SAMPLE TEMP WARN WPURGEPRESS PURGE PRESS WARN WBOXTEMP BOX TEMP WARNI NG WSYNC WPHOTOTEMP SYNC WARNI NG PHOTO TEMP WARNI NG WDYNZERO CANNOT DYN ZERO WDYNSPAN CANNOT DYN SPAN WREARBOARD WRELAYBOARD WFRONTPANEL WANALOGCAL REAR BOARD NOT DET RELAY BOARD WARN FRONT PANEL WARN DESCRI PTI ON Instrument was power cycled or the CPU was reset Data storage was erased Configuration storage was reset to factory confi
251. l Brackets will appear around the value example 20 Pressing the same key again will resume the test 04584 Rev Al 68 Model GFC7000E I nstruction Manual Operating I nstructions 6 9 4 Analog I O Configuration The analog I O functions that are available in the MGFC7000E are Sub Menu Table 6 8 DIAG Analog 1 Functions Function AOUTS CALIBRATED Shows the status of the analog output calibration YES NO and initiates a calibration of all analog output channels Sets the basic electronic configuration of the A1 analog output CO There are CONC OUT 1 three options Range Selects the signal type voltage or current loop and full scale level of the output REC OFS Allows to set a voltage offset not available when RANGE is set to CURRent loop Auto CAL Performs the same calibration as AOUT CALIBRATED but on this one channel only NOTE Any change to RANGE or REC OFS requires recalibration of this output CONC OUT 2 Same as for CONC OUT 1 but for analog channel 2 CO TEST OUTPUT Same as for CONC OUT 1 but for analog channel 4 TEST AIN CALIBRATED Shows the calibration status YES NO and initiates a calibration of the analog to digital converter circuit on the motherboard To configure the analyzer s three analog outputs set the electronic signal type of each channel and calibrate the outputs This consists of e Selecting an output type voltage or current
252. l processing and is a pass through for the RS 232 and RS 485 signals 10 3 6 1 A to D Conversion Analog signals such as the voltages received from the analyzer s various sensors are converted into digital signals that the CPU can understand and manipulate by the analog to digital converter A D Under the control of the CPU this functional block selects a particular signal input e g BOX TEMP CO2 MEAS CO2 etc and then coverts the selected voltage into a digital word The A D consists of a voltage to frequency V F converter a programmable logic device PLD three multiplexers several amplifiers and some other associated devices The V F converter produces a frequency proportional to its input voltage The PLD counts the output of the V F during a specified time period and sends the result of that count in the form of a binary number to the CPU The A D can be configured for several different input modes and ranges but in the MGFC7000E is used in uni polar mode with a 5 V full scale The converter includes a 196 over and under range This allows signals from 0 05 V to 5 05 V to be fully converted 04584 Rev A1 170 Model GFC7000E Instruction Manual THEORY OF OPERATI For calibration purposes two reference voltages are supplied to the A D converter Reference Ground and 4 096 VDC During calibration the device measures these two voltages outputs their digital equivalent to the CPU The CPU uses these val
253. lay Menu Units with Z S Valve or 1ZS Option installed 045840110 Rev B 3 224 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SETUP I ENTER SETUP PASS 818 CFG ACAL DAS PASS CLK MORE 4 NEXT MENU TREE Go To iDAS Fig 5 OFF TIME DATE MODEL NAME SERIAL NUMBER SEQ 1 SOFTWARE SEQ 2 REVISION Q i LIBRARY REVISION SEQ 3 SOFTWARE MODE SET UNIT REVISION HESSEN PROTOCOL REVISION gt SPECIAL SOFTWARE PREV NEXT OPTIONS CPU TYPE SNGL DUAL AUTO DATE FACTORY CONFI GURATION SAVED PPB PPM UGM ZERO SPAN SPAN 1 Only appears if a applicable M MERIENABEE Go To option feature is installed STARTI NG DATE EDIT SECONDARY SETUP MENU and activated STARTI NG TI ME Fig A 4 2 Appears whenever the DELTA DAYS currently displayed ts rue a rn DI SABLED Only appears when CALI BRATE reporting range is set to AUTO range mode RANGE TO CAL Figure A 3 Primary Setup Menu Except iDAS 045840110 Rev B 3 225 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SETUP ENTER SETUP PASS 818 CFG DAS 7 PASS CLK MORE VIEW EDIT PREV NEXT CONC PREV NEXT INS DEL EDIT PRNT PNUMTC CALDAT l ZTBZR
254. low meter capable of measuring flows in the O 1000 cc min range to measure the gas flow rate though the analyzer DO NOT use the built in flow measurement viewable from the Front Panel of the instrument This measurement is only for detecting major flow interruptions such as clogged or plugged gas lines See Figure 3 2 for sample port location 1 Turn off power 2 Attach the Flow Meter to the sample inlet port on the rear panel Ensure that the inlet to the Flow Meter is at atmospheric f 3 Turn on instrument power 4 Sample flow should be 800 cc min 10 5 Once an accurate measurement has been recorded by the method described above adjust the analyzer s internal flow sensors see Section 6 9 8 Low flows indicate blockage somewhere in the pneumatic pathway High flows indicate leaks downstream of the Flow Control Assembly 9 3 5 Cleaning the Optical Bench The MGFC7000E sensor assembly and optical bench is complex and delicate Disassembly and cleaning is not recommended Please check with the factory before disassembling the optical bench 9 3 6 Cleaning Exterior Surfaces of the MGFC7000E If necessary the exterior surfaces of the MGFC7000E can be cleaned with a clean damp cloth Do not submerge any part of the instrument in water or cleaning solution 04584 Rev A1 151 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp PROCEDURES User Notes 04584 Rev A1 152 Model GFC7000E
255. men nn 142 GFC7000E Maintenance Schedule 4 6 66 nnns 146 GFC7000E Test Function 6 6 nens 147 Predictive uses for Test 1 1 2 244 148 Sync Demod Status LED Activity 6 168 Relay Board Status LED s 4 4 1 6 66 assa suae ann 169 Front Panel Status LED Satia a a A RS TRAE 176 Warning Messages Indicated 508 1 185 Test Functions Indicated 6 66 LER 187 Sync Demod Board Status Failure Indications 2 00 190 Status LED Failure Indications s errat otc er ap ato vocor ic vr pda pon aum d 191 Relay Board Status LED Failure Indications eem mmm 192 DC Power Test Point and Wiring Color 200 DC Power Supply Acceptable 44 nemen 200 Relay Board Control Devices 1 1 0 4 lt nnne nnn 201 Opto Pickup Board Nominal Output 202 Analog Output Tes
256. ment is stored in Adobe Systems Inc Portable Document Format PDF and is viewable with Adobe Acrobat Reader software downloadable for free at http www adobe com The CD version of the manual has many advantages e Fully searchable text e Hypertext links for figures tables table of contents and embedded references for quick access of individual manual portions e Alist of thumbnails chapters and sections displayed at the left of the text e Internet links embedded in the manual will take you to the corresponding web site requires an internet connection 5 7 Extended Warranty Options 92 amp 93 Two options are available for extending Teledyne Instruments standard warranty Section 2 3 Both options have to be specified upon ordering the analyzer Option Number Description OPT 92 Extends warranty to cover a two 2 year period from the date of purchase OPT 93 Extends warranty to cover a five 5 year period from the date of purchase 5 8 Dilution Ratio Option The Dilution Ration Option is a software option that is designed for applications where the Sample gas is diluted before being analyzed by the Model GFC7000E Typically this occurs in Continuous Emission Monitoring CEM applications where the quality of gas in a smoke stack is being tested and the sampling method used to remove the gas from the stack dilutes the gas Once the degree of dilution is known this feature allows the user to add
257. ments 9 0 Instrument Maintenance Description of certain preventative maintenance procedures that should be regularly performed on you instrument to keep it in good operating condition This section also includes information on using the iDAS to record diagnostic functions useful in predicting possible component failures before they happen 10 0 Theory of Operation An in depth look at the various principals by which your analyzer operates as well as a description of how the various electronic mechanical and pneumatic components of the instrument work and interact with each other A close reading of this section is invaluable for understanding the instrument s operation 11 0 Troubleshooting Section This section includes pointers and instructions for diagnosing problems with the instrument such as excessive noise or drift as well as instructions on performing repairs of the instrument s major subsystems 04584 Rev A1 2 Model GFC7000E Instruction Manual MGFC7000E Documentation Appendices For easier access and better updating some information has been separated out of the manual and placed in a series of appendices at the end of this manual These include software menu trees warning messages definitions of iDAS amp serial I O variables spare parts list repair questionnaire interconnect listing and drawings and electronic schematics NOTE Throughout this manual words printed in capital bold letters such as SETU
258. mes these two ranges low and high they do not have to be configured that way For example The low range can be set for a span of 0 1000 ppm while the high range is set for 0 500 ppm In DUAL range mode the RANGE test function displayed on the front panel will be replaced by two separate functions e RANGEL The range setting for the 1 output RANGE2 The range setting for the A2 output To set the ranges press following keystroke sequence SAMPLE RANGE 500 000 PPM CO2 SETUP X X RANGE MODE DUAL lt TST TST gt CAL SETUP SNGL DUAL AUTO ENTR EXIT SAMPLE ENTER SETUP PASS 818 SETUP X X RANGE CONTROL MENU MODE SET UNIT SETUP X X SETUP MENU SETUP X X LOW RANGE 500 0 Conc CFG DAS RNGE PASS CLK MORE EXIT 0 0 EXIT Toggle the Numeral Keys to set the upper limit of each SETUP RANGE CONTROL MENU SETUP HIGH RANGE 500 0 Conc range MODE SET UNIT EXIT 0 EXT SETUP XXX RANGE MODE SNGL SETUP RANGE CONTROL MENU EXIT Returns to the Main SNGL DUAL AUTO ENTR EXIT MODE SET UNIT SAMPLE Display When the instrument s range mode is set to DUAL the concentration field in the upper right hand corner of the display alternates between displaying the low range value and the high range value The concentration currently being displayed is identified as follows C1 Low or A1 and C2 High or A2 NOTE In DUAL range mode the L
259. mode is activated The mode field of the CAL display will read ZERO CAL R EXTERNAL SPAN Span calibration mode is activated The mode field of the Em ic will read SPAN CAL R eee meS rx DIGITAL GROUND Provided to ground an external device e g recorder U DC power for Input for 5 VDC required to activate inputs A F This voltage Input pull ups can be taken from an external source or from the pin Internal 5V Internal source of 5V which can be used to activate inputs Supply when connected to pin U 04584 Rev A1 116 Model GFC7000E Instruction Manual Operating Instructions There are two methods to activate control inputs The internal 5V available from the pin is the most convenient method Figure 6 11 However to ensure that these inputs are truly isolated a separate external 5 VDC power supply should be used Figure 6 11 CONTROL IN CONTROL IN LI Local Power Connections External Power Connections Figure 6 11 Control Inputs 6 13 2 Remote Operation Using the External Serial 1 6 13 2 1 Terminal Operating Modes The Model GFC7000E can be remotely configured calibrated or queried for stored data through the serial ports As terminals and computers use different communication schemes the analyzer supports two communicate modes specifically designed to interface with these two types of
260. multi instrument configuration on a single PROTOCOL communications channel Multidrop requires the use of instrument IDs ENABLE 64 Enables to send a modem initialization string at power up Asserts certain MODEM lines in the RS 232 port to enable the modem to communicate ERROR 128 Fixes certain types of parity errors at certain Hessen protocol installations CHECKING XON XOFF 256 Disables XON XOFF data flow control also known as software handshaking HANDSHAKE HARDWARE Enables CTS RTS style hardwired transmission handshaking This style of HANDSHAKE 8 data transmission handshaking is commonly used with modems or terminal emulation protocols as well as by Teledyne Instrument s APICOM software HARDWARE Improves data transfer rate when on of the COMM ports 2 512 FIFO COMMAND 4096 Enables a command prompt when in terminal mode PROMPT 1 Modes are listed in the order in which they appear in the SETUP gt MORE gt COMM gt COM 1 OR 2 gt MODE menu The default sting for this feature is ON Do not disable unless instructed to by Teledyne Instruments Customer Service personnel 04584 Rev Al 86 Model GFC7000E Instruction Manual Operating I nstructions Press the following keys to select a communication mode for a one of the COMM Ports such as the following example where HESSEN PROTOCOL mode is enabled SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 8
261. n Gas is sourced directly from a calibrated pressurized tank the gas mixture should be CO mixed with Zero Air or at the required ratio Zero air generators that condition ambient air by drying and removal of pollutants are available on the commercial market such as the Teledyne Instruments Model 701 Zero Air Generator We recommend this type of device in conjunction with a CO scrubber such as soda lime for generating zero air 04584 Rev A1 129 Model GFC7000E Instruction Manual Calibration Procedures 7 1 2 Calibration Gas Traceability equipment used to produce calibration gases should be verified against standards of the National Institute for Standards and Technology NIST To ensure NIST traceability we recommend to acquire cylinders of working gas that are certified to be traceable to NIST Standard Reference Materials SRM These are available from a variety of commercial sources 7 1 3 Data Recording Devices A strip chart recorder data acquisition system or digital data acquisition system should be used to record data from the MGFC7000E s serial or analog outputs If analog readings are used the response of the recording system should be checked against a NIST traceable voltage source or meter Data recording device should be capable of bi polar operation so that negative readings can be recorded For electronic data recording the MGFC7000E provides an internal data acquisition system iDAS which is desc
262. n Ratio Option Option 2 ex tex eder rsdn ER RS 43 5 9 Maintenance Mode Switch Option 1 1 eee eee sene enne esee enne 43 5 10 Second Language Switch Option 92 ENE a A aa Na 44 6 OPERATI INSTRUCTIONS 45 6 1 Overview of Operating 65 ditigasi sinant tame ka a aigu sa a ae ceeds 45 6 2 Sample Mode en er etit Ux eiae i x ue lane ede UE P DN NE 46 62 1 Test FUNCIONS eio sates eae wae emer eg y e terr Dee gal eee one dasa EM Ens eaten e ees Me RU O 46 6 2 2 Warnitig MESSAGES eR Dex a ne iR oan MIR REC A eg Re iR 48 6 3 Calibratiori Mode esee ner sas dese RR SERE de RARE Riga rre ieri 50 6 3 1 SETUP PASS Calibration Password Security 1 enne 50 6 4 SETUP Mode eere lr tasti ned asa uy iene Wad tel whe aay aed RAE DU EARS 52 6 4 1 SETUP Mode Password Security cocer kae oit en hx E RR ERES XR a4 KR 53 6 5 SETUP CFG Viewing the Analyzer s Configuration Information 53 6 6 SETUP CLK Setting the Internal Time of Day
263. nal DC power supplies 11 If you wish to use the analyzer s to remotely activate the zero and span calibration modes several digital control inputs are provided via a 10 pin connector labeled CONTROL IN on the analyzer s rear panel Two methods for energizing the inputs are provided below the first using the internal 5V available on the CONTROL IN connector and the second if an external isolated supply is employed CONTROL IN CONTROL IN FX U D WY U LI gt m 5 VDC Power Supply Z uu 2 gt I Local Power Connections External Power Connections 04584 Rev A1 14 Model GFC7000E Instruction Manual Getting Started The pin assignments for the digital control inputs can be found in the table below Table 3 3 GFC7000E Control Input Pin Outs On Condition Definition REMOTE ZERO The Analyzer is placed in Zero Calibration mode The mode CAL field of the display will read ZERO CAL R REMOTE The Analyzer is placed in Span Calibration mode The mode SPAN CAL field of the display will read SPAN CAL R 7 1 LINE I Digital Ground May be connected to the ground of the datalogger recorder Input pin for 5 VDC required to activate pins A F This can be from an external source or from the pin of the instruments STATUS connector Internal 5V Internal source of 5V which b
264. nch demod board of the detector s temperature The warmer the detector the harder the coolers are driven PHT DRIVE is one of the Test Functions viewable by the user via the form panel Press TST or TST gt until it appears on the display 10 3 4 6 Dark Calibration Switch This switch initiates the Dark Calibration procedure When initiated by the user see Section 6 9 6 for more details the dark calibration process opens this switch interrupting the signal from the IR photo detector This allows the analyzer to measure any offset caused by the synch demod board circuitry 10 3 4 7 Electric Test Switch When active this circuit generates a specific waveform intended to simulate the function of the IR photo detector but with a known set of value which is substituted for the detector s actual signal via the dark switch It may also be initiated by the user see Section 6 9 5 for more details 10 3 5 Relay Board By actuating various switches and relays located on this board the CPU controls the status of other key components The relay board receives instructions in the form of digital signals over the bus interprets these digital instructions and activates its various switches and relays appropriately Heater Control The two heaters attached to the sample chamber housing and the GFC wheel motor are controlled by solid state relays located on the relay board The GFC wheel heater is simply turned on or off however control
265. ncluded free of cost with the analyzer and the latest versions can also be downloaded for free at http www teledyne api com software apicom 6 13 3 Additional Communications Documentation Table 6 28 Serial Interface Documents INTERFACE TOOL DOCUMENT TITLE PART AVAILABLE NUMBER ONLI Multi drop RS 232 Multi drop Documentation 021790000 DAS Manual Detailed description of the iDAS 028370000 These documents can be downloaded at http www teledyne api com manuals 6 13 4 Using the GFC7000E with a Hessen Protocol Network 6 13 4 1 General Overview of Hessen Protocol The Hessen protocol is a multidrop protocol in which several remote instruments are connected via a common communications channel to a host computer The remote instruments are regarded as slaves of the host computer The remote instruments are unaware that they are connected to a multidrop bus and never initiate Hessen protocol messages They only respond to commands from the host computer and only when they receive a command containing their own unique ID number 04584 Rev A1 123 Model GFC7000E Instruction Manual Operating Instructions The Hessen protocol is designed to accomplish two things to obtain the status of remote instruments including the concentrations of all the gases measured and to place remote instruments into zero or span calibration or measure mode API s implementation supports both of these principal features The Hessen
266. nfiguration the 1 A2 channels output a signal that is proportional to the CO concentration of the sample gas Either can be used for connecting the analog output signal to a chart recorder or for interfacing with a datalogger The third analog output labeled A3 is special It can be set by the user see Section 6 9 9 to output any one of the parameters accessible through the TST TST keys of the units sample display The standard configuration for these outputs is mVDC An optional current loop output is available for each Output A4 is not used on the Model 306E Pin outs for the analog output connector at the rear panel of the instrument are 04584 Rev A1 12 Model GFC7000E Instruction Manual Getting Started Table 3 1 GFC7000E Analog Output Pin Outs Pin Analog Output VDC Signal mADC Signal 1 A1 V Out I Out 2 Ground I Out 3 A2 V Out I Out 4 Ground I Out 5 A3 V Out I Out 6 Ground I Out 7 A4 Spare V Out Not Available 8 Ground Not Available e The default analog output voltage setting of the GFC7000E CO Analyzer is 0 5 VDC with a range of 0 500 ppm e TO change these settings see Sections 6 9 4 and 6 7 respectively 10 If you wish utilize the analyzer s status outputs to interface with a device that accepts logic level digital inputs such as programmable logic controllers PLC s they are accessed via a 12 pin
267. nstruction Manual THEORY OF OPERATI ON 10 3 2 CPU The Model GFC7000E s CPU is a low power 5 VDC 0 8A max high performance 386 based microcomputer running MS DOS Its operation and assembly conform to the PC 104 Specification version 2 3 for embedded PC and PC AT applications It has 2 MB of DRAM on board and operates at 40MHz over an internal 32 bit data and address bus Chip to chip data handling is performed by two 4 channel DMA devices over data busses of either 8 bit or 16 bit configuration The CPU supports both RS 232 and RS 485 serial I O The CPU includes two types of non volatile data storage Disk On Chip While technically an EEPROM the Disk on Chip DOC this device appears to the CPU as behaves as and performs the same function in the system as an 8MB disk drive It is used to store the operating system for the computer the Teledyne Instruments Firmware and most of the operational data generated by the analyzer s internal data acquisition system iDAS see Section 6 12 Flash Chip Another smaller EEPROM used to store critical calibration and configuration data Segregating this data on a separate less heavily accessed chip significantly decreases the chance of this key data being corrupted 10 3 3 Optical Bench amp GFC Wheel Electronically the Model GFC7000E s optical bench GFC wheel and associated components do more than simply measure the amount of CO present in the sample chamber variety of oth
268. ntaining a flow of at least 0 5 liters min Purge source air pressure should not exceed 35 pisg 5 Once the appropriate pneumatic connections have been made check all pneumatic fittings for leaks using a procedure similar to that defined in Section 9 3 3 04584 Rev A1 18 Model GFC7000E Instruction Manual Getting Started 3 1 2 2 Connections with Internal Valve Options I nstalled Figures 3 5 through 3 8 show the proper pneumatic connections for MGFC7000E s with various optional internal valve sets installed Source of SAMPLE Gas RS VENT if input is pressurized Certified CO Gas Sample Exhaust MODEL MODEL 701 yent Span 7 Zero Air Pressure Span Generator 125 Indicating soda lime Figure 3 5 Pneumatic Connections MGFC7000E with Zero Span Shutoff Valves OPT 50 Source of SAMPLE Gas VENT if input is pressurized Certified CO Gas Sample MODEL 701 Exhaust MODEL Zero Air Generator Vent opan GFC7000E Pressure Span External Zero IZS Air Scrubber Purge In Indicating soda lime Figure 3 6 Pneumatic Connections MGFC7000E with Zero Span Shutoff Valves and External Zero Air Scrubber OPT 51 04584 Rev A1 19 Model GFC7000E Instruction Manual Getting Started Source of SAMPLE Gas MODEL 700 Gas Dilution Calibrator VENT if input is pressurized Certified Sample CO Gas Needle Nesa
269. ntration measurements temperatures of the various heater placed around the analyzer pressures and flows of the pneumatic subsystem and other diagnostic measurements as well as calibration data such as slope and offset Most data parameters have associated measurement units such as mV ppb cm3 min etc although some parameters have no units With the exception of concentration readings none of these units of measure can be changed To change the units of measure for concentration readings see Section 6 7 6 Note iDAS does not keep track of the unit of each concentration value and iDAS data files may contain concentrations in multiple units if the unit was changed during data acquisition Each data parameter has user configurable functions that define how the data are recorded Table 6 23 iDAS Data Parameter Functions FUNCTI ON EFFECT PARAMETER Instrument specific parameter name SAMPLE MODE INST Records instantaneous reading AVG Records average reading during reporting interval MIN Records minimum instantaneous reading during reporting interval MAX Records maximum instantaneous reading during reporting interval PRECI SI ON Decimal precision of parameter value 0 4 STORE NUM OFF stores only the average default SAMPLES ON stores the average and the number of samples in each average for a parameter This property is only useful when the AVG sample mode is used Note that the number of samples is t
270. o every time the instrument exits zero calibration mode Data from the last 200 zero calibrations is stored A time and date stamp is recorded for every data point logged This information is useful for performing predictive diagnostics as part of a regular maintenance schedule see Section 9 1 STBSPN Logs the electronic output of the IR detector of the most recent measure phase and the measure reference ratio every time the instrument exits span calibration mode Data from the last 200 zero calibrations is stored A time and date stamp is recorded for every data point logged This information is useful for performing predictive diagnostics as part of a regular maintenance schedule see Section 9 1 TEMP Samples the analyzer s bench temperature box temperature and PHT cooler drive voltage every five minutes and records a average once every six hours Data from the last 400 averaging periods is recorded A time and date stamp is recorded for every data point logged This information is useful for performing predictive diagnostics as part of a regular maintenance schedule see Section 9 1 Note 04584 Rev A1 99 Model GFC7000E Instruction Manual Operating I nstructions The CALDAT STBZRO and STBSPN channels collect data based on events e g a calibration operation rather than a timed interval This does not represent any specific length of time since it is dependent on how often calibrations are performed 0
271. of the manual in the order the information is presented This is a good overview of the topics covered in the manual There is also a list of tables a list of figures and a list of appendices In the electronic version of the manual clicking on a any of these table entries automatically views that section 04584 Rev A1 1 Model GFC7000E Instruction Manual MGFC7000E Documentation 2 0 Specifications and Warranty This section contains a list of the analyzer s performance specifications a description of the conditions and configuration under which EPA equivalency was approved and Teledyne Instruments Incorporated s warranty statement 3 0 Getting Started A concise set of instructions for setting up installing and running your analyzer for the first time 4 0 FAQ Answers to the most frequently asked questions about operating the analyzer 5 0 Optional Hardware amp Software A description of optional equipment to add functionality to your analyzer 6 0 Operation Instructions This section includes step by step instructions for operating the analyzer and using its various features and functions 7 0 Calibration Procedures General information and step by step instructions for calibrating your analyzer 8 0 EPA Protocol Calibration Because CO is not declared a criteria air pollutant by the US EPA EPA equivalency is not required for this type of analyzer Therefore no special calibration methods are needed to satisfy EPA require
272. oints channels Keys only appear as needed SETUP X X CONC DATA AVAILABLE y NEXT VIEW EXIT SETUP 00 00 00 1 0 0 o PV10 PREV NEXT NX10 EXIT SETUP X X PNUMTC DATA AVAILABLE PREV NEXT VIEW EXIT SETUP X X 00 00 00 SMPFLW 000 0 PRM gt EXIT SETUP X X CALDAT DATA AVAILABLE PREV NEXT VIEW EXIT j SETUP X X 00 00 00 NXSLP1 0 000 iy 4 PV10 PREV lt PRM EXIT SETUP X X STBZRO DATA AVAILABLE PREV NEXT VIEW EXIT SETUP X X 00 00 00 STABIL 0 000 PV10 PREV lt EXIT SETUP STBSPN DATA AVAILABLE PREV NEXT VIEW EXIT SETUP X X 00 00 00 DETMES 0 000 PV10 PREV lt EXIT SETUP X X TEMP DATA AVAILABLE PREV NEXT VIEW EXIT SETUP X X 00 00 00 0 000 4 PV10 PREV lt PRM EXIT 04584 Rev A1 103 Model GFC7000E Instruction Manual Operating Instructions 6 12 2 2 Editing iDAS Data Channels IDAS configuration is most conveniently done through the APICOM remote control program The following list of key strokes shows how to edit using the front panel SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 EXIT will return to the previous SAMPLE 8 1 8 ENTR display SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE
273. omeone walking up to a workbench 04584 Rev A1 215 Model GFC7000E Instruction Manual A Primer on Electro Static Discharge e As long as my analyzer is properly installed it is safe from damage caused by static discharges It is true that when properly installed the chassis ground of your analyzer is tied to earth ground and its electronic components are prevented from building static electric charges themselves This does not however prevent discharges from static fields built up on other things like you and your clothing from discharging through the instrument and damaging it 12 4 Basic Principles of Static Control It is impossible to stop the creation of instantaneous static electric charges It is not however difficult to prevent those charges from building to dangerous levels or prevent damage due to electro static discharge from occurring 12 4 1 General Rules Only handle or work on all electronic assemblies at a properly set up ESD station Setting up an ESD safe work station need not be complicated A protective mat properly tied to ground and a wrist strap are all that is needed to create a basic anti ESD workstation see figure 12 2 Protective Wrist Strap Ground Point Figure 12 2 Basic anti ESD Work Station For technicians that work in the field special lightweight and portable anti ESD kits are available from most suppliers of ESD
274. on the Relay Board The most important of which is D1 which indicates the health of the I C buss If D1 is blinking the other faults following LED s be used in conjunction with DIAG menu signal I O to identify hardware failures of the relays and switches on the relay see Section 6 9 2 and Appendix D Table 11 4 1 C Status LED Failure Indications LED FUNCTI ON FAULT STATUS I NDI CATED FAI LURE S D1 2 buss Continuously ON Failed Halted CPU Red Health or Faulty Mother Board Keyboard or Relay Watchdog Continuously OFF Board Circuit Faulty Connectors Wiring between Mother Board Keyboard or Relay Board Failed Faulty 5 VDC Power Supply PS1 DC VOLTAGE TEST POINTS deem museo STATUS LED s Figure 11 5 Relay Board Status LEDs 04584 Rev A1 191 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES Table 11 5 Relay Board Status LED Failure I ndications LED FUNCTI ON SI GNAL 1 PARAMETER ACTIVATED BY VI EW RESULT DI AGNOSTIC TECHNI QUE D2 WHEEL Yellow HEATER WHEEL HEATER WHEEL TEMP Voltage displayed should change If not Failed Heater Faulty Temperature Sensor Failed AC Relay Faulty Connectors Wiring D3 BENCH Yellow HEATER Voltage displayed should change If not Failed Heater Faulty Temperature Sensor Failed AC Relay Faulty Connectors Wiring 4 Yello
275. ons must be simultaneously met to switch to the short filter First the instantaneous concentration must exceed the average in the long filter by a fixed amount Second the instantaneous concentration must exceed the average in the long filter by a portion or percentage of the average in the long filter 10 5 2 Calibration Slope and Offset Calibration of the analyzer is performed exclusively in software 04584 Rev A1 179 Model GFC7000E Instruction Manual THEORY OF OPERATI During instrument calibration see Chapter 7 the user enters expected values for zero and span via the front panel keypad and commands the instrument to make readings of calibrated sample gases for both levels The readings taken are adjusted linearized and compared to the expected values With this information the software computes values for instrument slope and offset and stores these values in memory for use in calculating the CO concentration of the sample gas The instrument slope and offset values recorded during the last calibration can be viewed by pressing the following keystroke sequence SAMPLE RANGE 50 0 MGM CO XX XX lt TST gt CAL SETUP SAMPLE OFFSET 0 000 CO XX XX SAMPLE TIME 16 23 34 CO XX XX SELBE lt TST TST gt CAL SETUP SAMPLE SLOPE 1 000 CO XX XX TST gt CAL SETUP 10 5 3 Measurement Algorithm Once the IR photo detector is signal is
276. or iDAS changes The green SAMPLE LED on the instrument front panel which indicates the analyzer status also indicates certain aspects of the iDAS status Table 6 21 Front Panel LED Status Indicators for iDAS System is in calibration mode Data logging can be enabled or disabled for this mode Calibration data are typically stored at the end of calibration periods concentration data are typically not sampled diagnostic data should be collected Instrument is in hold off mode a short period after the system exits calibrations IDAS channels can be enabled or disabled for this period Concentration data are typically disabled whereas diagnostic should be collected Sampling normally The iDAS can be disabled only by disabling or deleting its individual data channels 6 12 1 iDAS Structure The iDAS is designed around the feature of a record A record is a single data point of one parameter stored in one or more data channels and generated by one of several triggering event The entire iDAS configuration is stored in a script which can be edited from the front panel 04584 Rev Al 96 Model GFC7000E Instruction Manual Operating Instructions or downloaded edited and uploaded to the instrument in form of a string of plain text lines through the communication ports iDAS data are defined by the PARAMETER type and are stored through different triggering EVENTS in data CHANNELS which relate triggering event
277. orifice pressures Sample SAMP C The temperature of the gas inside the sample chamber Temperature TEMP Bench BENCH C Optical bench temperature Temperature TEMP Wheel WHEEL C Filter wheel temperature Temperature TEMP Box BOX C The temperature inside the analyzer chassis Temperature TEMP Photo detector PHT mV The drive voltage being supplied to the thermoelectric coolers Temp Control DRI VE of the IR photo detector by the sync demod Board Voltage Slope SLOPE The sensitivity of the instrument as calculated during the last calibration activity The SLOPE parameter is used to set the span calibration point of the analyzer Offset OFFSET E The overall offset of the instrument as calculated during the last calibration activity The OFFSET parameter is used to set the zero point of the analyzer response Test channel TEST mV mA Displays the signal level of the TEST analog output channel output signal Only appears when the TEST channel has been activated Current Time TI ME The current time This is used to create a time stamp on iDAS readings and by the AUTOCAL feature to trigger calibration events 1 Only appears when the instrument s reporting range mode is set for DUAL or AUTO 04584 Rev 1 47 Model GFC7000E Instruction Manual Operating Instructions To view the TEST Functions press the following Key sequence SAMPLE RANGE 500 000 PP CO2 XXX X TST TST gt CAL SETUP
278. other Board The mother board collects data performs signal conditioning duties and routs incoming and outgoing signals between the cpu and the analyzer s other major components Data is generated by a gas filter correlation optical bench which outputs an analog signal corresponding to the concentration of in the sample gas This analog signal is transformed into two pre amplified DC voltages CO2 MEAS and CO2 REF by a synchronous demodulator printed circuit assembly CO2 MEAS and CO2 REF are converted into digital data by a unipolar analog to digital converter located on the mother board A variety of sensors report the physical and operational status of the analyzer s major components again through the signal processing capabilities of the mother board These status reports are used as data for the CO concentration calculation and as trigger events for certain control commands issued by the CPU They are stored in memory by the CPU and in most cases can be viewed but the user via the front panel display The CPU communicates with the user and the outside world in a variety of manners 04584 Rev A1 161 Model GFC7000E Instruction Manual THEORY OF OPERATION Through the analyzer s keyboard and vacuum florescent display over a clocked digital serial I O bus using a protocol called I2C RS 232 amp RS485 Serial I O channels Via an optional Ethernet communications card Various DCV and DCA analog outputs and
279. p REPAIR PROCEDURES Problems with RS 232 connections usually center around 4 general areas 1 Incorrect cabling and connectors See Table 6 15 for connector and pin out information 2 The BAUD rate and protocol are incorrectly configured See Section 6 10 7 3 If a modem is being used additional configuration and wiring rules must be observed See Section 6 13 2 6 4 Incorrect setting of the DTE DCE Switch is set correctly See Section 6 10 5 5 Verify that cable 03596 that connects the serial COM ports of the CPU to J12 of the Motherboard is properly seated 11 4 9 2 Troubleshooting Analyzer Modem or Terminal Operation These are the general steps for troubleshooting problems with a modem connected to a Teledyne Instruments analyzer 1 Check Cables for proper connection to the modem terminal or computer 2 Check to make sure the DTE DCE is in the correct position as described in Section 6 10 5 3 Check to make sure the set up command is correct See Section 6 13 2 7 4 Verify that the Ready to Send RTS signal is at logic high The MGFC7000E sets pin 7 RTS to greater than 3 volts to enable modem transmission 5 Make sure the BAUD rate word length and stop bit settings between modem and analyzer match see Section 6 10 7 6 Use the RS 232 test function to send w characters to the modem terminal or computer See Section 6 10 8 7 Get your terminal modem or computer to transmit data to the analyzer holding
280. pad Functions nnnm nnn 94 CO Concentration Alarm Default 5 000 12122 95 Front Panel LED Status Indicators for IDAS 2 01 2 96 iDAS Data Channel Properties 1 14 21 nnne nnns 97 iDAS Data Parameter 1 1 6 6 ns 98 Status Output Pin Assignments memes mene nnn 116 Control Input Pin Assignments 0 sese 116 Terminal Mode Software 5 1 2 6 ents 118 s esee EN ENDE EQ 119 Serial Interface 2 ERE se assa sess assa ea ann 123 RS 232 Communication Parameters for Hessen Protocol 124 Teledyne Instruments Hessen Protocol Response Modes 126 Default Hessen Status Bit 02 4 4 4 127 A 139 AutoCal ATTRIBUTE Setup Parameters 139 Calibration Data Quality mmm e
281. painstaking preventative maintenance procedures There are however a minimal number of simple procedures that when performed regularly will ensure that the analyzer continues to operate accurately and reliably over its the lifetime Repairs and troubleshooting are covered in Chapter 11 of this manual 9 1 Maintenance Schedule Table 9 1 shows a typical maintenance schedule for the analyzer Please note that in certain environments i e dusty very high ambient pollutant levels some maintenance procedures may need to be performed more often than shown NOTE A Span and Zero Calibration Check see CAL CHECK REQ D Column of Table 9 1 must be performed following certain of the maintenance procedure listed below See Sections 7 3 7 5 and 7 6 for instructions on performing checks CAUTI ON Risk of electrical shock Disconnect power before performing any of the following operations that require entry into the interior of the analyzer NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only 04584 Rev A1 145 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp PROCEDURES Particulate Filter Verify Test Functions Pump Diaphragm Perform Flow Check Perform Leak Check Pneumatic lines Cleaning Table 9 1 GFC7000E Maintenance Schedule Date Performed Manual Weekly or as ui OA Lll Weekly or Record and a
282. pan gas no shutoff valve is required In order to ensure that span gas does not migrate backwards through the vent line and alter the concentration of the span gas a gas line not less than 2 meters in length should be attached to the vent span outlet on the rear panel of the analyzer To prevent the buildup of back pressure this vent line should not be greater than 10 meters in length The following table describes the state of each valve during the analyzer s various operational modes Table 5 2 2 Span Valve Operating States for Options 52 amp 53 Mode Valve Condition Valve Port Connection Fig 5 2 SAMPLE Sample Cal Open to SAMPLE inlet 322 Normal State 7ero Span Open to ZERO AIR inlet 322 Sample Cal Open to zero span inlet 122 ZERO CAL 5 Zero Span Open to ZERO AIR inlet 322 Sample Cal Open to ZERO SPAN inlet 122 SPAN CAL Zero Span Open to SPAN GAS inlet 122 The minimum span gas flow rate required for this option is 800 cm min The state of the zero span valves can also be controlled e Manually from the analyzer s front panel by using the SIGNAL 1 controls located under the DIAG Menu Section 6 9 2 e By activating the instrument s AutoCal feature Section 7 6 e Remotely by using the external digital control inputs Section 6 13 1 2 and Section 7 5 2 or e Remotely through the RS 232 485 serial I O ports see Appendix A 6 for the appropriate commands
283. panel 12 keyboard default 12 address 4 AUDIBLE BEEPER 14 output 0 maintenance mode 1 normal mode 0 select second language 1 select first language English 0 sample LED on 1 off 0 cal LED on 1 off 0 fault LED on 1 off 0 beeper on for diagnostic testing only 1 off Relay board digital output PCF8574 default 17C adc O2 CELL HEATER 5 SHUTOFF VALVE SOURCE ON ZERO SCRUB VALV E 2 SAMPLE PRESSURE Vacuum pressure Purge pressure Alternate between 0 and 1 at least every 5 s relay board active wheel heater on off optical bench heater on off sensor cell heater on off let cal gas in let sample gas in let span gas in let zero gas in open zero scrubber valve close energize shutoff valve de energize source on off Rear board primary MUX analog inputs Sample pressure oje Oje Ole Oje Ole oje 045840110 241 Model 360E Instruction Manual APPENDI X 4 MGFC7000E Signal 1 Definitions Revision BIT OR CHANNEL NUMBER CO MESURE 2 REFERENCE 3 SAMPLE FLOW 5 PHOTO TEMP 6 TEST INPUT 7 WIN DESCRIPTION Detector measure reading Detector reference reading Temperature MUX Sample flow Photometer detector temperature Diagnostic test input TEST INPUTS 8 REF 40906 MV 9 02 SENSOR Diagnostic test input 4 096
284. pin of the output being tested see table below Under the DI AG gt SIGNAL O menu see Section 11 1 3 scroll through the inputs and outputs until you get to the output in question Alternately turn on and off the output noting the voltage on the Voltmeter it should vary between volts for ON and 5 volts for OFF Table 11 12 Status Outputs Check PIN LEFT TO RIGHT STATUS 1 SYSTEM OK CONC VALID HIGH RANGE ZERO CAL SPAN CAL DIAG MODE ALRM1 SALRM2 INIA AJJI N 11 4 7 5 Control Inputs Remote Zero Span The control input bits can be tested by the following procedure 04584 Rev A1 205 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES Connect a jumper from the 5 on the Status connector to the x5V on the Control In connector Connect a second jumper from the pin on the Status connector to the A pin on the Control In connector The instrument should switch from SAMPLE mode to ZERO CAL R mode Connect a second jumper from the pin on the Status connector to the B pin on the Control In connector The instrument should switch from SAMPLE mode to SPAN CAL R mode In each case the MGFC7000E should return to SAMPLE mode when the jumper is removed 11 4 8 CPU There are two major types of failures associated with the CPU board complete failure and a failure associated with the Disk On Chip on the CPU board If either of these failures occur
285. protocol is not well defined therefore while API s application is completely compatible with the protocol itself it may be different from implementations by other companies The following subsections describe the basics for setting up your instrument to operate over a Hessen Protocol network for more detailed information as well as a list of host computer commands and examples of command and response message syntax download the Manual Addendum for Hessen Protocol from the Teledyne Instruments web site http www teledyne ai com manuals index asp 6 13 4 2 Hessen COMM Port Configuration Hessen protocol requires the communication parameters of the MGFC7000E s COMM ports to be set differently than the standard configuration as shown in the table below Table 6 29 RS 232 Communication Parameters for Hessen Protocol To change the rest of the COMM port parameters see Section 6 10 6 To change the baud rate of the GFC7000E s COMM ports see Section 6 10 7 NOTE Make sure that the communication parameters of the host computer are also properly set Also the instrument software has a 200 ms latency before it responds to commands issued by the host computer This latency should present no problems but you should be aware of it and not issue commands to the instrument too frequently 6 13 4 3 Activating Hessen Protocol The first step in configuring the GFC7000E to operate over a Hessen protocol network is to activat
286. put data via a low range and high range When this mode is selected see Section 6 7 5 the MGFC7000E will automatically switch between the two ranges dynamically as the concentration value fluctuates Range status is also output via the External Digital I O Status Bits see Section 6 13 1 1 To select the Analog Output Range Type press 04584 Rev A1 57 Model GFC7000E I nstruction Manual Operating Instructions SAMPLE RANGE 500 000 PPM CO2 TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR SETUP X X CFG DAS RNGE PASS CLK MORE EXIT SETUP X X RANGE CONTROL MENU MODE SET UNIT EXIT SETUP X X mato SNGL EXIT Returns gt to the Main SNGL ENTR EXIT SAMPLE Display Only one of the Y Y Y range modes may be active at any Go To Go To Go To time Section Section Section 6 7 3 6 7 4 6 7 5 NOTE Upper span limit setting for the individual range modes are shared Resetting the span limit in one mode also resets the span limit for the corresponding range in the other modes as follows DUAL gt Rangel Range2 AUTO gt Low Range gt High Range 6 7 3 Single Range mode SNGL This is the default reporting range mode for the analyzer In single range mode both A1 and A2 are set to the same reporting range This reporting range can be any value between 50 ppb and 2 000 ppm While the
287. r assembly can allow enough discharge to cause damage A similar discharge can occur from a charged conductive object such as a metallic tool or fixture When static charges accumulated on a sensitive device discharges from the device to another surface such as packaging materials work surfaces machine surfaces or other device In some cases charged device discharges can be the most destructive A typical example of this is the simple act of installing an electronic assembly into the connector or wiring harness of the equipment in which it is to function If the assembly is carrying a static charge as it is connected to ground a discharge will occur Whenever a sensitive device is moved into the field of an existing electro static field a charge may be induced on the device in effect discharging the field onto the device If the device is then momentarily grounded while within the electrostatic field or removed from the region of the electrostatic field and grounded somewhere else a second discharge will occur as the charge is transferred from the device to ground 12 3 Common Myths About ESD Damage I didn t feel a shock so there was no electro static discharge The human nervous system isn t able to feel a static discharge of less than 3500 volts Most devices are damaged by discharge levels much lower than that I didn t touch it so there was no electro static discharge Electro Static charges are fields whose lines of force can extend
288. r future SAMPLE The amount of time between each data point 000 01 00 000 00 01 to PERI OD that is averaged into one mean reported every 366 23 59 REPORT PERIOD Days Hours Minutes REPORT The amount of time between each channel 000 01 00 000 00 01 to PERI OD data point 366 23 59 Days Hours Minutes NUMBER OF The number of reports that will be stored in 1 to 1 million limited RECORDS the data file Once the specified limit has been by available storage exceeded the oldest data are over written to space make space for new data RS 232 Enables the analyzer to automatically report OFF or ON REPORT channel values to the RS 232 ports CHANNEL Enables or disables the channel Provides a OFF or ON ENABLED convenient means to temporarily disable a data channel CAL HOLD Disables sampling of data parameters while OFF or ON OFF instrument is in calibration mode Section 6 12 2 11 When enabled here there is also a length of the DAS HOLD OFF after calibration mode which is set in the VARS menu 04584 Rev A1 97 Model GFC7000E Instruction Manual Operating Instructions 6 12 1 2 iDAS Parameters Data parameters are types of data that may be measured and stored by the iDAS For each Teledyne Instruments analyzer model the list of available data parameters is different fully defined and not customizable Appendix A 5 lists firmware specific data parameters for the MGFC7000E iDAS parameters include things like CO conce
289. ration Valves Options eiie ihe EP IE e ARE i EUR ae ha 38 5 4 1 Zero Span Shutoff Valve Option 50 1 1 enis 38 5 4 2 Zero Span Shutoff with External CO Scrubber Option 51 40 5 4 3 Zero Span Valve Option 52 een ne ted tumet ages Ru agua a ERN des gena 40 5 4 4 Zero Span Valve with External Scrubber Option 53 41 5 5 Communication Optiorns 2 oe dasa ath cement x Rx EK p RE RO MORIA ded ae 41 5 5 1 RS232 Modem Cable Option 60 i inan ena tainen Sahara ded ERR RR RARE FERRE Ra 41 5 5 2 RS 232 Mu ltidrop Option 62 ne eie eta ceteri eget ca a dee sn e Eye nea dx heec 42 5 5 3 Ethernet 63 2 resa ee dass SE eue Ce 42 5 6 Additional Manuals icr eau iate ego EDR EM nies ens 42 5 6 1 Printed Manuals Option 70 5 5 entia A dee RR DARE Phan DA 42 5 6 2 Manual on CD Part number 045840200 180015560 sene nnne nnns 43 5 7 Extended Warranty Options 92 amp 93 a esiste sese senis enne 43 5 8 Dilutio
290. ration of all channels Manual calibration should be used for the 0 1 range or in cases where the outputs must be closely matched to the characteristics of the recording device Outputs configured for automatic calibration can be calibrated as a group or individually Calibration of the analog outputs needs to be carried out on first startup of the analyzer performed in the factory as part of the configuration process or whenever re calibration is required 04584 Rev A1 71 Model GFC7000E I nstruction Manual Operating Instructions To calibrate the outputs as a group activate the ANALOG 1 CONFI GURATI ON MENU see Section 6 9 1 then press STARTING FROM DIAGNOSTIC MENU see Section 6 7 1 DIAG ANALOG I O CONFIGURATION Exit at any time to retur tothe PREV NEXT main DIAG menu DIAG AIO AOUTS CALIBRATED NO SET SET gt CAL R AUTO CALIBRATING CONC_OUT_1 EXIT AUTO CALIBRATING CONC_OUT_2 ED AUTO CALIBRATING TEST OUTPUT If any of the channels have not been calibrated this message will read NO DIAG AIO AOUTS CALIBRATED YES If AutoCal has been turned off for any channel the message for that channel will be similar to NOT AUTO CAL CONC OUT 1 Exit to return to the configuration menu SET SET CAL EXIT To automatically calibrate a single analog channel activate the ANALOG I
291. re warning This is helpful for trouble shooting by monitoring when a particular warning occurred 6 12 2 Default iDAS Channels A set of default Data Channels has been included in the analyzer s software for logging CO concentration and certain predictive diagnostic data These default channels include but are not limited to CONC Samples CO concentration at one minute intervals and stores an average every hour with a time and date stamp Readings during calibration and calibration hold off are not included in the data By default the last 800 hourly averages are stored Collects sample flow and sample pressure data at five minute intervals and stores average once a day with a time and date stamp This data is useful for monitoring the condition of the pump and critical flow orifice sample flow and the sample filter clogging indicated by a drop in sample pressure over time to predict when maintenance will be required The last 360 daily averages about 1 year are stored CALDAT Logs new slope and offset every time a zero or span calibration is performed This Data Channel also records the instrument readings just prior to performing a calibration This information is useful for performing predictive diagnostics as part of a regular maintenance schedule see Section 9 1 STBZRO Logs the concentration stability the electronic output of the IR detector of the most recent measure phase and the measure reference rati
292. reference Voltages and input signals that can be easily measured with a voltmeter 1 Use the Signal I O function see Section 11 1 3 and Appendix A to view the value of REF 4096 MV and REF GND If both are within 3 mV of nominal 4096 and 0 and are stable 0 5 mV then the basic A D is functioning properly If not then the Motherboard is Bad 2 Choose a parameter in the Signal I O function such as SAMPLE PRESSURE SAMPLE FLOW CO MEASURE or CO REFERENCE Compare these Voltages at their origin see Interconnect drawing 04215 and Interconnect list 04216 with the voltage displayed through the Signal I O function If the wiring is intact but there is a large difference between the measured and displayed voltage 10 mV then the Motherboard is bad 11 4 7 2 Analog Outputs Voltage To verify that the analog outputs are working properly connect a voltmeter to the output in question and perform an analog output step test as described in Section 6 9 3 For each of the steps taking into account any offset that may have been programmed into channel see Section 6 9 4 the output should be within 1 of the nominal value listed in the table below except for the 096 step which should be within 2 to 3 mV If one or more of the steps fails to be within this range then it is likely that there has been a failure of the either or both of the DACs and their associated circuitry the Motherboard Table 11 10 Analog Output Test Function Nominal
293. referred to as TYPE 1 and a more recently released version TYPE 2 that has more flexibility when operating with instruments that can measure more than one type of gas For more specific information about the difference between TYPE 1and TYPE 2 download the Manual Addendum for Hessen Protocol from the Teledyne Instruments web site http www teledyne ai com manuals index asp To select a Hessen Protocol Type press SAMPLE RANGE 500 000 PPM CO2 X XXX TST TST CAL SETUP SETUP X X COMMUNICATIONS MENU SAMPLE ENTER SETUP PASS 818 ID HESN COM2 Y SETUP X HESSEN VARIATION TYPE 1 8 1 8 ENTR SETUP X X PRI MARY SETUP MENU SET EDIT EXIT Y ENTR key accepts the new settings SETUP X X HESSEN VARIATION TYPE 1 CFG DAS RNGE PASS CLK MORE EXIT EXIT key ignores the SETUP X X SECONDARY SETUP MENU new settings TYE1 TYPE2 ENTR EXIT v COMM SETUP X X HESSEN VARIATION TYPE 2 Press to change protocol type OFF ENTR EXIT 04584 Rev A1 125 Model GFC7000E Instruction Manual Operating Instructions NOTE While Hessen Protocol Mode can be activated independently for COM1 and 2 TYPE selection affects both Ports 6 13 4 5 Setting The Hessen Protocol Response Mode The Teledyne Instruments implementation of Hessen Protocol allows the user to choose one of several different modes of response
294. ribed in detail in Section 6 12 7 2 Manual Calibration without Zero Span Valves This is the basic method for manually calibrating the Model GFC7000E CO Analyzer without functioning zero span valve options It is identical to the method described in the GETTING STARTED Chapter 3 of this manual and is repeated her for you convenience STEP ONE Connect the Sources of Zero Air and Span Gas as shown below Calibrated CO gas at desired span gas concentration VENT Source of SAMPLE Gas Removed during Calibration Indicating soda lime Sample Exhaust MO D E L ventspan GFC7000E Pressure Span MODEL 701 Zero Air 125 Generator Purge In Figure 7 1 Pneumatic Connections Basic Configuration Using Bottled Span Gas 04584 Rev A1 130 Model GFC7000E Instruction Manual Calibration Procedures RS Calibrated Source of CO Gas MODEL 700 SAMPLE Gas Gas Dilution Removed Calibrator during Calibration I ndicating soda lime Sample Exhaust MO D E L vent sean GFC7000E Pressure Span MODEL 701 Zero Air Generator 175 Purge In Figure 7 2 Pneumatic Connections Basic Configuration Using Gas Dilution Calibrator STEP TWO Set the expected Span Gas concentration SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP This sequence causes the analyzer to prompt for the expected CO span concentration M P CAL RANGE 500 00p PPM CO2
295. rminal or data logging device over a single serial communications line Either port can be equipped with an optional RS 232 multidrop assembly Section 5 5 2 or up to eight analyzers can be connected using COM2 configured for RS 485 operation contact the factory for further information A third option is to use a code activated switch CAS which can connect typically between 2 and 16 analyzers to one communications hub Contact Teledyne Instruments sales for more information on CAS systems Ethernet Communications When equipped with the optional Ethernet interface the analyzer can be connected to any standard 10BaseT Ethernet network via low cost network hubs switches or routers The interface operates as a standard TCP IP device on port 3000 This allows a remote computer to connect through the internet to the analyzer using APIcom terminal emulators or other programs 6 10 1 Analyzer I D Code The first entry in the COMM menu is for configuration of the analyzer ID code a numerical value of up to 4 digits Each type of Teledyne Instruments analyzer is configured with a default ID code The MGFC7000E default ID code is 360 When more than one Teledyne Instruments analyzer of the same model type is connected to the same communications channel such as two Model GFC7000E s operating on the same Hessen Protocol network each analyzer needs to be addressed with a unique ID number To edit the instrument s ID code press 04584 Rev A1
296. rrent flows as the charge moves along the conductive circuitry of the device and the typically very high voltage levels of the charge overheat the delicate traces of the integrated circuits melting them or even vaporizing parts of them When examined by microscope the damage caused by electro static discharge looks a lot like tiny bomb craters littered across the landscape of the component s circuitry A quick comparison of the values in Table 12 1 with the those shown in the Table 12 2 listing device susceptibility levels shows why Semiconductor Reliability News estimates that approximately 60 of device failures are the result of damage due to electro static discharge Table 12 2 Sensitivity of Electronic Devices to Damage by ESD DAMAGE SUSCEPTIBILITY DEVI CE VOLTAGE RANGE DAMAGE BEGINS CATASTROPHIC OCCURRI NG AT DAMAGE AT MOSFET 10 100 VMOS 30 1800 NMOS 60 100 GaAsFET 60 2000 EPROM 100 100 JFET 140 7000 SAW 150 500 Op AMP 190 2500 CMOS 200 3000 Schottky Diodes 300 2500 Film Resistors 300 3000 je 7000 ECL 500 500 SCR 500 1000 Schottky TTL 500 2500 04584 Rev Al 214 Model GFC7000E Instruction Manual A Primer on Electro Static Discharge Potentially damaging electro static discharges can occur Any time a charged surface including the human body discharges to a device Even simple contact of a finger to the leads of an sensitive device o
297. rts on this board Check the CO2 MEAS and CO2 REF Test Functions via the Front Panel Display 4 The detector cooler control circuit can fail for reasons similar to the detector itself failing Symptoms would be a change in MR RATIO Test Function when zero air is being sampled Also check the SIGNAL I O parameter PHT DRI VE After warm up and at 25 ambient if PHT DRIVE 2500 mv the cooler is working properly If PHT DRIVE is 2500 mV there is a malfunction 5 The 5 and 15 VDC voltages in the MGFC7000E are provided by switching power supplies Switch mode supplies create DC outputs by switching the input AC waveform at high frequencies As the components in the switcher age and degrade the main problem observed is increased noise on the DC outputs If a noisy switcher power supply is suspected attach an oscilloscope to the DC output test points located on the top right hand edge of the Relay board Look for short period spikes 100 mV p p on the DC output 11 4 Subsystem Checkout The preceding sections of this manual discussed a variety of methods for identifying possible sources of failures or performance problems within the analyzer In most cases this included a list of possible causes This section describes how to determine individually determine if a certain component or subsystem is actually the cause of the problem being investigated 11 4 1 AC Mains Configuration The analyzer is correctly configured for the AC mains
298. rument 04584 Rev A1 163 Model GFC7000E Instruction Manual THEORY OF OPERATI ON 10 3 3 2 IR Source The light used to detect CO in the sample chamber is generated by a element heated to approximately 1100 C producing infrared radiation across a broad band This radiation is optically filtered after it has passed through the GFC Wheel and the sample chamber and just before it reaches the photo detector to eliminate all black body radiation and other extraneous IR emitted by the various components of those components 10 3 3 3 GFC Wheel A synchronous AC motor turns the GFC wheel motor For analyzers operating on 60Hz line power this motor turns at 1800 rpm For those operating on 50Hz line power the spin rate is 1500 rpm The actual spin rate is unimportant within a large rate since a phase lock loop circuit is used to generate timing pulses for signal processing In order to accurately interpret the fluctuations of the IR beam after it has passed through the sample gas the GFC wheel several other timing signals are produced by other photo emitters detectors These devices consist of a combination LED and detector mounted so that the light emitted by the LED shines through the same mask on the GFC wheel that chops the IR beam KEY Detection Beam shining 2 through MEASUREMENT 8 side of Wheel Detection Beam shining 7 through REFERENCE side of GFC Wheel IR Detection Ring Segment Sensor
299. running DHCP The analyzer will do this the first time you turn the instrument on after it has been physically connected to your network Once the instrument is connected and turned on it will appear as an active device on your network without any extra set up steps or lengthy procedures Should you need to the following Ethernet configuration properties are viewable via the analyzer s front panel Table 6 18 LAN Internet Configuration Properties PROPERTY DEFAULT STATE DESCRI PTI ON This displays whether the DHCP is turned ON or DICE On Editable OFF STATUS EDI T key i 4 INSTRUMENT Configured disabled 192 168 76 55 is the address of the IP ADDRESS by DHCP when DHCP 9 LED analyzer itself is ON EDIT key A string of numbers very similar to the Instrument GATEWAY IP Configured disabled IP address e g 192 168 76 1 that is the address ADDRESS by DHCP when DHCP of the computer used by your LAN to access the is ON Internet Also a string of four packets of 1 to 3 numbers each e g 255 255 252 0 that defines that EDIT key identifies the LAN the device is connected to SUBNET Configured disabled All addressable devices and computers on a LAN MASK by DHCP when DHCP must have the same subnet mask Any is ON transmissions sent devices with different assumed to be outside of the LAN and are routed through gateway computer onto the Internet This number defines the terminal control port by TCP PO
300. s at zero or low CO concentrations such as 100 ppm may occur These fluctuations are the result of changes in the concentration of the ambient atmosphere throughout the course of the day and night In isolated areas with relatively few people working nearby the ambient CO concentration will fall during the day and rise during the night as rate of photosynthesis of the plants in the surrounding area decreases and increases In a lab environment with a relatively high human occupancy the ambient concentration will increase during those parts of the day when the highest number of workers are present If the GFC wheel housing is allowed to fill with 04584 Rev A1 194 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES ambient air these natural diurnal fluctuations might be detected by the instrument and cause its in its calculation of the concentration of the sample gas to drift Another possible symptom of poor or stopped purge gas flow would be the inability to measure zero concentrations accurately at the end of a work day on a system that was calibrated at the beginning of a workday Again this could be due to local fluctuations in ambient CO concentration between the time of the day when the calibration was performed and other times during the day 11 2 Calibration Problems 11 2 1 Miss Calibrated There are several symptoms that can be caused by the analyzer being miss calibrated This
301. s pressurized MODEL 700 Gas Dilution Calibrator Sample Exhaust MO D E L Calibrated Vent Span GFC7000E Gas Pressure Span Indicating 125 soda lime Needle Purge In valve to control flow MODEL 701 Zero Air Generator Figure 3 9 Example of Pneumatic Set up for Multipoint Calibration of M360 3 2 Initial Operation If you are unfamiliar with the MGFC7000E theory of operation we recommend that you read Chapter 10 For information on navigating the analyzer s software menus see the menu trees described in Appendix A 1 NOTE The analyzer s cover must be installed to ensure that the temperatures of the GFC wheel and absorption cell assemblies are properly controlled 04584 Rev A1 21 Model GFC7000E Instruction Manual Getting Started 3 2 1 Startup After electrical and pneumatic connections are made turn on the instrument and pump power The exhaust and PMT cooler fans should start The display should immediately display a single horizontal dash in the upper left corner of the display This will last approximately 30 seconds while the CPU loads the operating system Once the CPU has completed this activity it will begin loading the analyzer firmware and configuration data During this process string of messages will appear on the analyzer s front panel display System waits 3 seconds then automatically begins its initialization routine No action required
302. s to data parameters and define certain operational functions related to the recording and reporting of the data 6 12 1 1 iDAS Channels The key to the flexibility of the iDAS is its ability to store a large number of combinations of triggering events and data parameters in the form of data channels Users may create up to 20 data channels and each channel can contain one or more parameters For each channel one triggering event is selected and up to 50 data parameters which can be the same or different between channels Each data channel has several properties that define the structure of the channel and allow the user to make operational decisions regarding the channel Table 6 22 Table 6 22 iDAS Data Channel Properties PROPERTY DESCRI PTI ON DEFAULT SETTI NG RANGE The name of the data channel Up to 6 letters and digits more with APICOM but only the first six are displayed on the front panel TRI GGERIN The event that triggers the data channel to ATI MER See Appendix A 5 For G EVENT measure and store its data parameters See a complete list APPENDIX 5 for a list of available triggering events NUMBER amp A User configurable list of data types to be 1 DETMES See Appendix A 5 For PARAMETER recorded in any given channel See APPENDIX a complete list LI ST A 5 for a list of available parameters STARTING The starting date when a channel starts 01 03 Any actual date in the DATE collecting data past o
303. se the rear panel and turn on power to the machine 04584 Rev A1 210 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES User Notes 04584 Rev A1 211 Model GFC7000E Instruction Manual A Primer on Electro Static Discharge 12 A PRIMER ON ELECTRO STATI C DISCHARGE Teledyne Instruments considers the prevention of damage caused by the discharge of static electricity to be extremely important part of making sure that your analyzer continues to provide reliable service for a long time This section describes how static electricity occurs why it is so dangerous to electronic components and assemblies as well as how to prevent that damage from occurring 12 1 How Static Charges are Created Modern electronic devices such as the types used in the various electronic assemblies of your analyzer are very small require very little power and operate very quickly Unfortunately the same characteristics that allow them to do these things also makes them very susceptible to damage from the discharge of static electricity Controlling electrostatic discharge begins with understanding how electro static charges occur in the first place Static electricity is the result of something called triboelectric charging which happens whenever the atoms of the surface layers of two materials rub against each other As the atoms of the two surfaces move together and separate some electrons from one surface are retained by th
304. stem the reporting ranges or the serial RS 232 RS 485 Ethernet communication channels The SET UP mode is also used for performing various diagnostic tests during troubleshooting Mode Field e SAMPLE A RANGE 500 00 PPM 2 400 00 TST TST gt CAL SETUP C2 CO CO Figure 6 1 Front Panel Display The mode field of the front panel display indicates to the user which operating mode the unit is currently running Besides SAMPLE and SETUP other modes the analyzer can be operated in are 04584 Rev A1 45 Model GFC7000E Instruction Manual Operating Instructions Table 6 1 Analyzer Operating modes MODE MEANI NG DI AG One of the analyzer s diagnostic modes is being utilized see Section 6 9 M P CAL This is the basic multi point calibration mode of the instrument and is activated by pressing the CAL key SAMPLE Sampling normally flashing indicates adaptive filter is on SAMPLE A Indicates that unit is in SAMPLE Mode and AUTOCAL feature is activated SETUP SETUP mode is being used to configure the analyzer CO sampling will continue during this process SPAN CALA JUnit is performing span cal procedure initiated automatically by the analyzer s AUTOCAL feature SPAN CALM is performing span cal procedure initiated manually by the user SPAN CALR Unit is performing span cal procedure initiated remotely via the RS 232 RS 4485 or digital i o control inputs
305. t to output and from instrument to instrument you will need to measure the change in the current with a current meter placed in series with the output circuit Figure 6 6 See Table 3 2 for 1 pin assignments of mA the Analog Out connector on the rear panel Analyzer Recording Device Figure 6 6 Setup for Calibrating Current Outputs NOTE Do not exceed 60 V between current loop outputs and instrument ground To adjust the zero and span values of the current outputs activate the ANALOG I O CONFI GURATI ON MENU see Section 6 9 1 then press 04584 Rev A1 75 Model GFC7000E Instruction Manual Operating I nstructions The instrument attempt the channel to automatically calibrate C FROM ANALOG I O CONFIGURATION MENU D then beep DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO CONC_OUT_2 D A CAL ERROR DIAG AIN CALIBRATED NO EXIT v EDIT EXIT DIAG AIO CONC_OUT_2 CURR Z 0 mV U100 UP10 UP DOWN DN10 D100 Press SET gt to select the analog output channel to be configured DIAG AIO CONC OUT 2 ZERO 27 mV Increase or decrease the current output by 100 10 or 1 counts DIAG AIO CONC OUT 2 CURR NO CAL U100 UP10 UP DOWN DN10 D100 ENTR EXIT The resulting change in output voltage is displayed in the upper lt SET SET EDIT EXIT line DIAG
306. t Function Nominal Values Voltage 204 Analog Output Test Function Nominal Values Current Outputs 205 Status Outputs Check oco eves e ERR RE DER ERE 205 Static Generation Voltages for Typical 72 7 7 2 214 Sensitivity of Electronic Devices to Damage by ESD 214 GFC7000E Setup Variables Revision 0 2 1 1 1 2 231 04584 Rev A1 ix Model GFC7000E Instruction Manual GFC7000E Documentation Table A 2 GFC7000E Warning Messages Revision E O 238 Table A 3 GFC7000E Test Functions Revision 0 6 239 Table A 4 GFC7000E Signal I O Definitions Revision 0 2 2 441 4 240 Table 5 GFC7000E DAS Trigger Events Revision 0 243 Table A 6 GFC7000E iDAS Functions Revision 0 4 4 244 Table A 7 Terminal Command Designators Revision 0 245 Table D 1 List of Included Electronic 5 66 251 User Notes 04584 Rev A1 x Model GFC7000E
307. t for easy retrieval and use in common data analysis programs such as spreadsheet type programs The iDAS is designed to be flexible users have full control over the type length and reporting time of the data The iDAS permits users to access stored data through the instrument s front panel or its communication ports Using APICOM data can even be retrieved automatically to a remote computer for further processing The principal use of the iDAS is logging data for trend analysis and predictive diagnostics which can assist in identifying possible problems before they affect the functionality of the analyzer The secondary use is for data analysis documentation and archival in electronic format To support the iDAS functionality Teledyne Instruments offers APICOM a program that provides a visual interface for remote or local setup configuration and data retrieval of the iDAS Section 6 12 The APICOM manual which is included with the program contains a more detailed description of the iDAS structure and configuration which is briefly described in this section The MGFC7000E is configured with a basic iDAS configuration which is enabled by default New data channels are also enabled by default but each channel may be turned off for later or occasional use Note that iDAS operation is suspended while its configuration is edited through the front panel To prevent such data loss it is recommended to use the APICOM graphical user interface f
308. t is not properly tracking the rotation of the Gas Filter Correlation wheel SYSTEM RESET The computer was rebooted WHEEL TEMP WARNI NG The Gas Filter Correlation wheel temperature is outside the specified limits 04584 Rev A1 24 Model GFC7000E Instruction Manual Getting Started To View and Clear the various warning messages press SAMPLE HVPS WARNING 0 00 TEST deactivates warning messages TEST CAL MSG CLR SETUP _ _ _ SAMPLE RANGE 500 000 PPM 2 0 00 MSG varning TST gt CAL MSG CLR SETUP sIST m SAMPLE HVPS WARNING CO2 0 00 Press CLR to clear the current TEST CAL MSG CLR SETUP ada 7 If more than one warning is active the If the warning message persists next message will take its place after several attempts to clear it Once the last warning has been the message may indicate a real problem and not an artifact Make sure warning messages are eS OUS of the warm up period not due to real problems moge 3 2 4 Functional Check 1 After the analyzer s components has warmed up for at least 30 minutes verify that the software properly supports any hardware options that were installed 2 Check to make sure that the analyzer is functioning within allowable operating parameters Appendix C includes a list of test functions viewable from the analyzer s front p
309. t strap to ground e If you are at the instrument rack hold the bag in one hand while your wrist strap is connected to a ground point e If you are at a anti ESD work bench lay the container down the conductive work surface e In either case wait several seconds 7 Open the container 12 4 2 4 Opening Shipments from and Packing Components for Return to Teledyne Instruments Customer Service Packing materials such as bubble pack and Styrofoam pellets are extremely efficient generators of static electric charges To prevent damage from ESD Teledyne Instruments ships all electronic components and assemblies in properly sealed ant ESD containers 04584 Rev A1 219 Model GFC7000E Instruction Manual A Primer on Electro Static Discharge Static charges will build up on the outer surface of the anti ESD container during shipping as the packing materials vibrate and rub against each other To prevent these static charges from damaging the components or assemblies being shipped make sure that you e Always unpack shipments from Teledyne Instruments Customer Service by e Opening the outer shipping box away from the anti ESD work area e Carry the still sealed ant ESD bag tube or bin to the anti ESD work area e Follow steps 6 and 7 of Section 12 4 2 3 above when opening the anti ESD container at the work station e Reserve the anti ESD container or bag to use when packing electronic components or assemblies to be returned to Teled
310. tablish a link from a remote location to the MGFC7OOOE through direct cable connection via RS 232 modem or Ethernet e View the instrument s front panel and remotely access all functions that could be accessed when standing in front of the instrument e Remotely edit system parameters and set points e Download view graph and save data for predictive diagnostics or data analysis e Retrieve view edit save and upload iDAS configurations 04584 Rev Al 122 Model GFC7000E Instruction Manual Operating Instructions e Check on system parameters for trouble shooting and quality control APICOM is very helpful for initial setup data analysis maintenance and trouble shooting Figure 6 8 shows an example of APICOM being used to remotely configuration the instruments iDAS feature Figure 6 12 shows examples of APICOM s main interface which emulates the look and functionality of the instruments actual front panel 1 APIcom N Projects APIcom Scripts and data E ngineering lab cfg File View Settings Help SteName Connection InstrumentName 0 Status M700 700 COMI Direct Cable COM2 Connected Direct Cable M2004 200 Modemi Windows Modem M300 300 TCP IP 2053 Connected For Help press F1 2 1 200 at Eng lab 200 rack x1 1 2 3 4 5 ar 8 3 AP nm Download graph save data Figure 6 12 APICOM Remote Control Program I nterface APICOM is i
311. tal part of the chassis to discharge any electrostatic potentials or connect a grounding strap to your wrist CAUTI ON Never disconnect PCAs wiring harnesses or electronic subassemblies while under power 4 Inspect the interior of the instrument to make sure all circuit boards and other components are in good shape and properly seated 04584 Rev A1 9 Model GFC7000E Instruction Manual Getting Started 5 Check the connectors of the various internal wiring harnesses and pneumatic hoses to make sure they are firmly and properly seated 6 Verify that all of the optional hardware ordered with the unit has been installed These are listed on the paperwork accompanying the analyzer 7 Once you have determined that no shipping damage exists and the unit includes all expected hardware options remove all red colored shipping screws from the bottom of the chassis as shown in Figure 3 1 Hd Shipping Screws d o 6 1 a H ji 6 gt 1 a D d Figure 3 1 Removal of Shipping Screws NOTE Save these shipping screws and re install them whenever the unit is shipped to another location 04584 Rev A1 10 Model 7 Instruction Manual Getting Started 8 VENTILATI ON CLEARANCE Whether the analyzer is set up on a bench or installed into an instrument rack be sure to leave sufficient ventilation clear
312. ter mode and internet enabled mode would carry a combined mode ID of 11 the standard configuration on the MGFC7000E COM2 port Note that each COM port needs to be configured independently 04584 Rev A1 85 Model GFC7000E Instruction Manual Operating Instructions Table 6 16 COMM Port Communication modes MODE ID DESCRI PTI ON QUIET Quiet mode suppresses any feedback from the analyzer iDAS reports and 1 warning messages to the remote device and is typically used when the port is communicating with a computer program such as APICOM Such feedback is still available but a command must be issued to receive them COMPUTER 2 Computer mode inhibits echoing of typed characters and is used when the port is communicating with a computer program such as APICOM SECURI TY 4 When enabled the serial port requires a password before it will respond The only command that is active is the help screen CR HESSEN The Hessen communications protocol is used in some European countries PROTOCOL 16 Teledyne Instruments part number 02252 contains more information on this protocol E 7 1 When turned on this mode switches the COMM port settings from 2048 No parity 8 data bits 1 stop bit to Even parity 7 data bits 1 stop bit RS 485 1024 Configures the COM2 Port for RS 485 communication RS 485 mode has precedence over multidrop mode if both are enabled MULTI DROP 32 Multidrop protocol allows a
313. th recommended troubleshooting checks and corrective actions 04584 Rev A1 196 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 11 3 1 Temperature Problems Individual control loops are used to maintain the set point of the absorption bench filter wheel and IR photo detector temperatures If any of these temperatures are out of range or are poorly controlled the MGFC7000E will perform poorly 11 3 1 1 Box or Sample Temperature Box Temperature The box temperature sensor is mounted to the motherboard and cannot be disconnected to check its resistance Rather check the BOX TEMP signal using the SIGNAL I O function under the DI AG Menu see Section 11 1 3 This parameter will vary with ambient temperature but at 30 6 79 above room temperature the signal should be 1450 mV Sample Temperature The Sample Temperature should closely track the bench temperature If it does not locate the sensor which is located at the midpoint of the optical bench in a brass fitting Unplug the connector labeled Sample and measure the resistance of the thermistor at room temperature 25 C it should be 30K Ohms at operating temperature 48 C it should be 12K Ohms 11 3 1 2 Bench Temperature There are three possible failures that could cause the Bench temperature to be incorrect 1 The heater mounted to the bottom of the Absorption bench is electrically shorted or open Check the resistance of the two h
314. that the calibration password feature is disabled the instruments default state If it is enabled a password prompt screen see Section 6 3 1 will appear after the CAL CALZ or CALS buttons are pushed but before the instrument enters the associated calibration mode 7 1 Before Calibration The calibration procedures in this section assume that the Range Type Range Span and units of measure have already been selected for the analyzer If this has not been done please do so before continuing see Section 6 7 for instructions All Gas lines should be PTFE Teflon FEP glass stainless steel or brass NOTE If any problems occur while performing the following calibration procedures refer to Chapter 11 of this manual for troubleshooting tips 7 1 1 Zero Air and Span Gas To perform the following calibration you must have sources for zero air and span gas available Zero Air is similar in chemical composition to the Earth s atmosphere but scrubbed of all components that might affect the analyzer s readings Zero air should contain less than 25 ppb of CO and other major interfering gases such as CO and Water Vapor It should have a dew point of 5 C or less Span Gas is a gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired measurement range It is recommended that the span gas used have a concentration equal to 80 of the full measurement range If Spa
315. the MGFC7000E are similar to that described in Section 7 3 except that the zero and calibration operations are initiated directly and independently with dedicated keys CALZ and CALS To perform a manual calibration check of an analyzer with a valve option installed use the following method STEP ONE Connect the sources of Zero Air and Span Gas as shown in figures 7 3 through 7 6 STEP TWO Perform the zero span check Scroll to the STABIL test function Wait until STABIL falls below 1 0 ppb This may take several minutes SAMPLE RANGE 500 000 PPM CO2 zX XXX SETUP CALZ lt TST gt SAMPLE STABIL XXX X PPM CO2 X XXX lt TST 5 gt CAL CALZ CALS SETUP ACTION Record the CO2 readings presented in the upper right corner of the display CO2 ZERO CAL M lt TST 5 gt ZERO EXIT 2 SAMPLE ACTION Record the 2 readings presented in the upper right corner of the display The value of STABIL may jump significantly Wait until STABIL falls below 1 0 ppb This may take several minutes lt TST gt CAL SETUP SPAN CAL M CO2 X XXX EXIT returns to the main lt TST 5 gt EXIT _ SAMPLE display 7 5 1 Zero Span Calibration on Auto Range or Dual Ranges If the analyzer is being operated
316. the instrument passes a leak check do a flow check see Section 9 3 4 to make sure adequate sample is being delivered to the sensor assembly 3 A failing IR photo detector may be at fault Check the CO2 MEAS and CO2 REF test functions via the front panel display to make sure the signal levels are in the normal range See Appendix A and are quiet 04584 Rev A1 195 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 4 Confirm the sample pressure wheel temperature bench temperature and sample flow readings are correct and have steady readings 5 Disconnect the exhaust line from the optical bench near the rear of the instrument and plug this line into the SAMPLE inlet creating a pneumatic loop The CO concentration either zero or span now must be constant If readings become quiet the problem is in the external pneumatics supplies for sample gas span gas or zero air 6 If pressurized span gas is being used with a zero span valve option make sure that the venting is adequate See Section 3 1 2 and 5 4 7 If it is the zero point that is non repeatable and if that non repeatability seems to only occur at a certain time of day such as when worker occupancy is highest or lowest make sure the flow of purge gas to the GFC wheel housing has not stopped see Sections 10 2 2 and 11 1 7 for more information 11 2 3 I nability to Span No SPAN Key 1 Confirm that the carbon dioxide span gas source is
317. tile memory and retrieved in plain text format for further processing with common data analysis programs The iDAS has a consistent user interface in all Teledyne Instruments analyzers New data parameters and triggering events can be added to the instrument as needed 04584 Rev Al 180 Model GFC7000E Instruction Manual THEORY OF OPERATION Depending on the sampling frequency and the number of data parameters the iDAS can store several months of data which are retained even when the instrument is powered off or a new firmware is installed The iDAS permits users to access the data through the instrument s front panel or the remote interface The latter can automatically download stored data for further processing For information on using the iDAS refer to Sections 6 12 User Notes 04584 Rev A1 181 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 11 TROUBLESHOOTING amp REPAIR PROCEDURES This section contains a variety of methods for identifying the source of performance problems with the analyzer Also included in this section are procedures that are used in repairing the instrument CAUTI ON The operations outlined in this chapter are to be performed by qualified maintenance personnel only CAUTI ON Risk of electrical shock Disconnect power before performing the following operations 11 1 General Troubleshooting Hints The analyzer has been des
318. tion TABLE OF CONTENTS SAFETY MESSAGES 1 TABLE OF CONTENTS Il LIST OF VII LIST OF FIGURES VII LIST OF TABLES Vill 1 MGFC7000E 1 1 1 Using This 3 n ree detraxit seta vane e ux aee ES UR ast SERM E 1 2 SPECIFICATIONS APPROVALS AND nnna 5 2 1 Specification Ss PEE 5 2 2 CE Mark GOm plane rne diae yeti ne RR ea ME SERA TRE Ax ER ref NS 6 6 3 5 9 3 1 Unpackirng and Initial sri ee nig anes Midday 9 3 1 1 Electrical Connections eere ex eser dev Fauna 11 8 1 2 5 cay test
319. tions for the STP used by your agency Conversion factors from volumetric to mass units are CO ppb x 1 96 ug m3 ppm x 1 96 mg m3 To change the concentration units SAMPLE RANGE 500 00 PPB CO2 X XXX lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT returns to the main menu SETUP X X RANGE CONTROL MENU MODE SET UNIT EXIT Select the preferred SETUP X X CONC UNITS PPM concentration unit PPM PPB MGM ENTER EXIT ENTR accepts the new unit SETUP CONC UNITS EXIT returns to the SETUP PPM PPB UGM MGM ENTER EXIT menu NOTE Once the units of measurement have been changed the unit MUST be recalibrated as the expected span values previously in effect will no longer be valid Simply entering new expected span values without running the entire calibration routine is not sufficient 04584 Rev Al 62 Model GFC7000E Instruction Manual Operating Instructions 6 7 7 Dilution Ratio The dilution ratio is a software option that allows the user to compensate for any dilution of the sample gas before it enters the sample inlet Using the dilution ratio option is a 4 step process 1 Select reporting range units Follow the procedure in Section 6 7 6 2 Select the range Use the procedures in Section 6 7 2 6 7 5 Make sure that the S
320. to move through the the displayed list of available parameter activating the test channel Press EXIT to return to the parameters DIAG menu Table 6 13 PREV NEXT ENTR EXIT Table 6 14 Test Parameters Available for Analog Output A3 Test Channel Zero Full Scale NONE Test Channel is turned off CO MEASURE 0 mV 5000 mV CO REFERENCE 0 mV 5000 mV SAMPLE PRESS 0 Hg 40 Hg SAMPLE FLOW 0 cc m 1000 cc m SAMPLE TEMP 0 C 70 C BENCH TEMP 0 C 70 C WHEEL TEMP 0 C 70 C CHASSIS TEMP 0 C 70 C PHT DRI VE 0 mV 5000 mV This refers to the internal voltage level of the function NOT the output signal level of the Test channel itself 04584 Rev A1 81 Model GFC7000E Instruction Manual Operating Instructions 6 10 SETUP COMM Using the Analyser s Communication Ports The MGFC7000E is equipped with two serial communication ports located on the rear panel Figure 3 2 Both ports operate similarly and give the user the ability to communicate with issue commands to and receive data from the analyzer through an external computer system or terminal By default both ports operate on the RS 232 protocol The COM2 port however can be configured for half duplex RS 485 communication or can be used for the Teledyne Instruments Ethernet interface card optional equipment Section 5 5 3 Multidrop Communications There are two options to connect multiple analyzers to a single computer te
321. two outputs always have the same reporting range the span signal offset and scaling of their electronic signals may be configured for differently e g A1 0 10 V A2 0 0 1 V See Section 6 9 4 for instructions on adjusting these parameters To select SNGLE range mode and to set the upper limit of the range press 04584 Rev 1 58 Model GFC7000E I nstruction Manual Operating I nstructions RANGE 500 000 PPM CO2 X XXX SAMPLE lt TST TST CAL SETUP SAMPLE ENTER SETUP PASS 818 adl SETUP C 3 PRI MARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 RANGE CONTROL MENU MODE SET UNIT EXIT SETUP C 3 RANGE MODE SNGL SNGE DUAL AUTO ENTR EXIT 24 SETUP RANGE SNGL SNGL DUAL AUTO ENTR EXIT RANGE CONTROL MENU MODE SET UNIT RANGE 500 0 Conc SETUP C 3 00 EXIT SETUP RANGE CONTROL MENU EXIT x 2 returns to the main MODE SET UNIT SAMPLE display 04584 Rev A1 59 Model GFC7000E Instruction Manual Operating Instructions 6 7 4 Dual Range Mode DUAL Selecting Dual Range mode allows the A1 and A2 outputs to be configured with different reporting ranges The analyzer software calls these two ranges low and high The low range setting corresponds with the analog output labeled A1 on the Rear Panel of the instrument The high Range Setting corresponds with the A2 output While the software na
322. ues to compute the converter s offset and slope and uses these factors for subsequent conversions See Section 6 9 4 for instructions on performing this calibration 10 3 6 2 Sensor Inputs The key analog sensor signals are coupled to the A D through the master multiplexer from two connectors on the motherboard 100K terminating resistors on each of the inputs prevent cross talk from appearing on the sensor signals Co Measure And Reference These are the primary signals that are used in the computation of the CO concentration They are the demodulated IR sensor signals from the sync demodulator board Sample Pressure And Flow These are analog signals from two sensors that measure the pressure and flow rate of the gas stream at the outlet of the sample chamber This information is used in two ways First the sample pressure is used by the CPU to calculate CO Concentration Second the pressure and flow rate are monitored as a test function to assist the user in predicting and troubleshooting failures 10 3 6 3 Thermistor I nterface This circuit provides excitation termination and signal selection for several negative coefficient thermistor temperature sensors located inside the analyzer They are Sample Temperature Sensor The source of this signal is a thermistor located inside the sample chamber of the Optical Bench It measures the temperature of the sample gas in the chamber This data is used to during the calculation of t
323. urns SETUP X X 1 MODEM INIT A T YS 02 amp H to the previous menu Y EXIT ignores the new SETUP X X COMMUNICATIONS MENU CH CH gt INS DEL A ENTR EXIT string and returns to Select which the previous menu COM Port is iD COM1 COM2 EXIT tested Ka Press the key repeatedly to cycle through the available character set The INS key The DEL key 0 9 inserts a character deletes a character A Z The lt CH and CH gt keys move before the cursor at the cursor space amp _ the cursor left and right location location 11 lt gt along the text string To Initialize the modem press SAMPLE RANGE 500 000 PPM CO2 X XXX lt TST TST gt CAL SETUP l SETUP 1 MODE 0 SET EDIT EXIT SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR f SETUP 1 BAUD RATE 19200 SETUP X X PRIMARY SETUP MENU lt SET SET EDIT EXIT CFG DAS RNGE PASS CLK MORE EXIT EXIT returns SETUP X X to the previous SETUP X X SECONDARY SETUP MENU lt SET SET EXIT COMM EXIT SETUP X X COM INITIALIZE MODEM SETUP X X COMMUNICATIONS MENU Select which lt SET SET gt INIT EXIT COM Port is iD COM1 COM2 EXIT tested SETUP X X INITIALIZING MODEM SET SET INIT EXIT EXIT returns to the Communications Menu 04584 1 121 Model GFC7000E Instruction Manual Operating Instructions 6 13 2 7 COM Port Password Security In order to provide security for remote access of the MGFC7000
324. urve of the analyzer The values for these terms both individually and relative to each other indicate the quality of the calibration To perform this quality evaluation you will need to record the values of both test functions Section 6 2 1 or Appendix A 3 all of which are automatically stored in the iDAS channel CALDAT for data analysis documentation and archival Make sure that these parameters are within the limits listed in Table 7 3 Table 7 3 Calibration Data Quality Evaluation FUNCTI ON MI NI MUM VALUE OPTI MUM VALUE MAXI MUM VALUE SLOPE 0 700 1 000 1 300 OFFS 0 500 0 000 0 500 These values should not be significantly different from the values recorded on the Teledyne Instruments Final Test and Validation Data sheet that was shipped with your instrument If they are refer to the troubleshooting Chapter 11 User Notes 04584 Rev A1 142 Model GFC7000E Instruction Manual EPA Protocol Calibration 8 EPA PROTOCOL CALI BRATI ON At the writing of this manual there is no EPA requirements for the monitoring of or published calibration protocols User Notes 04584 Rev A1 143 Model GFC7000E Instruction Manual MAI NTENANCE SCHEDULE amp PROCEDURES 9 MAINTENANCE SCHEDULE amp PROCEDURES Predictive diagnostic functions including failure warnings and alarms built into the analyzer s firmware allow the user to determine when repairs are necessary without performing
325. uw NER 111 6 12 2 9 Starting mee eeu Rex Nets dete dis esu eher e ted Fac amic bi ea ede ate DER 111 6 12 2 10 Disabling Enabling Data 4 eee eee eee teeta esee 111 6 12 2 11 HOEDOEF ERR RR DAR SUA nes 112 6 12 3 Remote iDAS Config Fation c iie ix ropas tesi oeste eau np ea ERA RE 113 6 13 Remote Operation of the 4 44 2 444 4 1 1 1 ese esee nn 115 6 13 1 Remote Operation Using the External Digital I O essem 115 6 43 1 1 Status DM 115 04584 1 iii Model GFC7000E Instruction Manual GFC7000E Documentation 6 13 1 2 Control INPUTS den cen occ cre eri Ro AREE ure eMe ke e 116 6 13 2 Remote Operation Using the External Serial I O ssssssssssssssseseese nennen 117 6 13 2 1 Terminal Operating 4 SEA SER RR Ra a Rn h s 117 6 13 2 2 Help Commands in Terminal emen mese menie 118 6 13 2 3 Command Syntax sete esie epe rete eye Was PR UE dan ure brio CET Y WA De oS 118 6 13 2 4 TYPES Em 119 6 13 2 5 Status
326. w SPARE N A SAMPLE CAL GAS VALVE OPTION D5 CAL VALVE Green N A Sample Cal Valve should audibly change states If not Failed Valve Failed Relay Drive IC on Relay Board Failed Relay Board Faulty 12 VDC Supply PS2 Faulty Connectors Wiring ZERO SPAN GAS VALVE OPTION D6 SPAN VALVE Green D7 SHUTOFF Green VALVE OPTION 5 VALVE D8 IR SOURCE Green IR SOURCE N A N A CO MEASURE Zero Span Valve should audibly change states If not Failed Valve Failed Relay Drive IC on Relay Board Failed Relay Board Faulty 12 VDC Supply PS2 Faulty Connectors Wiring Shutoff Valve should audibly change states If not Failed Valve Failed Relay Drive IC on Relay Board Failed Relay Board Faulty 12 VDC Supply PS2 Faulty Connectors Wiring Voltage displayed should change If not Failed IR Source Faulty 12 VDC Supply PS2 Failed Relay Board Failed IR Photo Detector Failed Sync Demod Board Faulty Connectors Wiring 11 1 5 Gas Flow Problems In general flow problems can be divided into three categories 1 Flow is too high 2 Flow is greater than zero but is too low and or unstable 3 Flow is zero no flow When troubleshooting flow problems it is a good idea to first confirm that the actual flow and not the analyzer s flow sensor and software are in error or the flow meter is in error Use an 04584 Rev
327. w the procedures defined in Section 11 4 for confirming that the analyzer s basic components are working power supplies CPU relay board sync demod board keypad GFC wheel motor etc See Figure 3 11 for general layout of components and sub assemblies the analyzer See the wiring Interconnect Drawing and Interconnect List documents 04216 and 04217 04584 Rev A1 183 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 11 1 1 Interpreting WARNING Messages The most common and or serious instrument failures will result in a warning message being displayed on the front panel Table 11 1 lists warning messages along with their meaning and recommended corrective action It should be noted that if more than two or three warning messages occur at the same time it is often an indication that some fundamental analyzer sub system power supply relay board motherboard has failed rather than indication of the of the specific failures referenced by the warnings In this case it is recommended that proper operation of power supplies see Section 11 4 2 the relay board see Section 11 4 5 and the A D Board see Section11 4 7 1 be confirmed before addressing the specific warning messages The analyzer will alert the user that a Warning Message is active by displaying the keypad label MSG on the Front Panel In this case the Front panel display will look something like the following SAMPLE RANGE 500 0 PPM C
328. w the user to more easily supply and manipulate various calibration gases such as zero air and span gas during various calibration procedures For more information of these options see Section 5 4 10 2 2 Purge Gas Pressure and Flow Control In order to ensure that all of the ambient CO is purged from the GFC Wheel housing a adequate supply of dried air scrubbed of CO must be supplied to the PURGE AIR inlet at the back of the instrument The source of purge air must be capable of maintaining a pressure of 20 25 psig at a flow rate of at least 0 5 liters min Purge source air pressure should not exceed 35 pisg In order to maintain the proper pressure differential between the inside of the GFC wheel housing and ambient air the M360 design includes a manually settable pressure regulator that maintains the pressure of the purge air feed at 7 5 psig and a flow control orifice that ensures a 0 5 liter min flow though the GFC wheel housing 10 3 Electronic Operation 10 3 1 Overview Figure 10 9 shows a block diagram of the major electronic components of the Model GFC7000E At its heart the analyzer is a microcomputer CPU that controls various internal processes interprets data makes calculations and reports results using specialized firmware developed by Teledyne Instruments It communicates with the user as well as receives data from and issues commands to a variety of peripheral devices via a separate printed circuit assembly called the M
329. word has been enabled using the PASS menu item found under the Setup Menu see below the system will prompt the user for a password anytime CAL CALZ CALS activated 04584 Rev A1 50 Model GFC7000E Instruction Manual Operating Instructions The default status of the calibration password is OFF To enable the calibration password press SAMPLE RANGE 500 000 PPM CO2 TST TST CAL SETUP ENTER SETUP PASS 818 ENTR accepts displayed password value SAMPLE EXIT returns to SAMPLE display SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X AL PASSWORD ENABLE OFF CAL PASSWORD SSMO 9 Eu i Toggles default state is OFF ENTR EXIT password status On Off PASSWORD ENABLE ON ENTR EXIT ENTR accepts the change SETUP X X PASSWORD ENABLE ON EXIT ignores the change ON ENTR EXIT If the calibration password 101 is enabled the following keypad sequence will be required to enter one of the calibration modes SAMPLE RANGE 500 000 PPM CO2 TST TST CAL CALZ CALS SETUP SAMPLE ENTER SETUP PASS 0 Prompts password number T 0 0 0 ENTR EXIT 7 SAMPLE ENTER SETUP PASS 0 Press individual 1 0 4 ENTR EXIT keys toset 1 1 9 101 A M P CAL RANGE 500 040 PPM CO2 X XXX lt TST TST gt ZERO CONC Continue calibration process
330. yne Instruments e Always pack electronic components and assemblies to be sent to Teledyne Instruments Customer Service in anti ESD bins tubes or bags e Do not use pink poly bags e If you do not already have an adequate supply of anti ESD bags or containers available Teledyne Instruments Customer Service department will supply them see Section 11 7 for contact information e Always follow steps 1 through 5 of Section 12 4 1 3 User Notes 04584 Rev A1 220 Model GFC7000E Instruction ManualAPPENDI X Version Specific Software Documentation APPENDIX A Version Specific Software Documentation APPENDIX A 1 APPENDIX A 2 APPENDIX A 3 APPENDIX A 4 APPENDIX A 5 Model GFC7000E Software Menu Trees Model GFC7000E Setup Variables Available Via Serial 1 Model GFC7000E Warnings and Test Measurements Via Serial 1 Model GFC7000E Signal 1 Definitions Model GFC7000E iDAS Functions 045150110 Rev A1 221 Model GFC7000E Instruction Manual APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 APPENDIX 1 MGFC7000E Software Menu Trees Revision 0 SAMPLE TEST CAL MsG CLR SETUP Only appear if ENTER SETUP PASS 818 reporting range lt TST TST gt ig set for LOW HIGH AUTO range Primary Setup Menu mode CFG DAS RANG PASS CLK MORE ZERO SPAN CONC RANGE STABIL Secondary Setup Menu PRES SAMP FL PMT NORM PMT COMM VARS DI AG UV L
331. zer Check to make sure that e All calibrators generators are turned on and working correctly e Gas bottles are not empty or low e Valves regulators gas lines are not clogged or dirty 11 1 6 2 Low Flow 1 Check if the pump diaphragm is in good condition If not rebuild the pump see Section 9 3 2 Check the Spare Parts List for information of pump rebuild kits 2 Check for leaks as described in Section 9 3 3 Repair the leaking fitting line or valve and re check 3 Check for the sample filter and the orifice filter for dirt Replace filters see Sections 9 3 1 and 11 5 1 respectively 4 Check for partially plugged pneumatic lines orifices or valves Clean or replace them 04584 Rev A1 193 Model GFC7000E Instruction Manual TROUBLESHOOTI NG amp REPAIR PROCEDURES 5 If an IZS option is installed in the instrument press CALZ and CALS If the flow increases then suspect a bad sample cal valve 11 1 6 3 High Flow The most common cause of high flow is a leak in the sample flow control assembly or between there and the pump If no leaks or loose connections are found in the fittings or the gas line between the orifice and the pump rebuild clean the sample flow control assembly as described in Section 11 5 1 11 1 6 4 Displayed Flow XXXX This warning means that there is inadequate gas flow There are four conditions that might cause this 1 A leak upstream or downstream of the flow sensor

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