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Teledyne GFC 7000E Operation Manual (358 pages)

CARBON DIOXIDE ANALYZER

Brand: Teledyne | Category: Measuring Instruments | Size: 6 MB

Safety Messages
5
Consignes de Sécurité
6
Warranty
7
About this Manual
9
Table of Contents
11
Introduction
19
Features
19
Using this Manual
19
Options
20
Specifications and Approvals
23
Specifications
23
Table 2-1: Model T360 Basic Unit Specifications
23
Table 2-2: Model T360M Basic Unit Specifications
24
Approvals and Certifications
25
Safety
25
Emc
25
Getting Started
27
Unpacking and Initial Set up
27
Front Panel
29
Figure 3-1: Front Panel Layout
29
Figure 3-2: Display Screen and Touch Control
30
Table 3-1: Display and Touchscreen Control Description
31
Figure 3-3: Display/Touch Control Screen Mapped to Menu Charts
32
Rear Panel
33
Figure 3-4: Rear Panel Layout
33
Table 3-2: Rear Panel Description
34
Internal Layout
35
Figure 3-5: Internal Chassis Layout
35
Figure 3-6: Optical Bench Layout
36
Electrical Connections
37
Power Connection
37
Connecting Analog Inputs (Option 64B)
38
Connecting Analog Outputs
38
Figure 3-7: Analog in Connector
38
Table 3-3: Analog Input Pin Assignments
38
Table 3-4: T360 Analog Output Pin Outs
39
Connecting the Status Outputs
40
Table 3-5: Status Output Pin-Outs
40
Current Loop Analog Outputs (Option 41)
41
Figure 3-8: Current Loop Option Installed on the Motherboard
41
Connecting the Control Inputs
42
Figure 3-9: Control Inputs Power Connections
43
Table 3-6: Control Input Pin-Outs
43
Connecting the Alarm Relay Option (OPT 61)
44
Figure 3-10: Alarm Relay Output Pin Assignments
44
Table 3-8: Concentration Alarm Relay Output Operation
44
Connecting the Communications Interfaces
45
Pneumatic Connections
46
Basic Pneumatic Connections
46
Figure 3-11: Basic Internal Gas Flow
47
Figure 3-12: Pneumatic Connections-Basic Configuration-Using Bottled Span Gas
48
Figure 3-13: Pneumatic Connections-Basic Configuration-Using Gas Dilution Calibrator
48
Connections with Ambient Zero/Ambient Span Valve
50
Figure 3-14: Pneumatic Connections with Ambient Zero/Ambient Span Valves (OPT 50A)
50
Figure 3-15: Pneumatic Connections with Ambient Zero/Ambient Span Valves (Opt 50A) and External Zero Air Scrubber
50
Figure 3-16: Internal Pneumatic Flow - Ambient Zero/Ambient Span
51
Table 3-9: Ambient Zero/Ambient Span Valve Operating States
51
Connections with Ambient Zero/Pressurized Span Valve Option
52
Figure 3-17: Pneumatic Connections with Ambient Zero/Pressurized Span Valves (OPT 50B)
52
Figure 3-18: Pneumatic Connections with Ambient Zero/Pressurized Span Valves (Opt 50B) and External Zero Air Scrubber
53
Figure 3-19: Internal Pneumatic Flow - Ambient Zero/Pressurized Span Valves
54
Table 3-10: Ambient Zero/Pressurized Span Valve Operating States
54
Pneumatic Connections in Multipoint Calibration Applications
55
Setting the Internal Purge Air Pressure
55
Figure 3-20: Example of Pneumatic Set up for Multipoint Calibration
55
Initial Operation
56
Startup
56
Warm up
57
Warning Messages
57
Table 3-11: Front Panel Display During System Warm-Up
57
Table 3-12: Possible Warning Messages at Start-Up
58
Functional Checks
59
Initial Calibration Procedure
60
Initial O 2 Sensor Calibration Procedure
63
Figure 3-21: O2 Sensor Calibration Set up
63
Figure 3-22: Internal Pneumatics with O2 Sensor Option 65
64
Operating Instructions
69
Overview of Operating Modes
69
Figure 4-1: Front Panel Display
69
Sample Mode
70
Table 4-1: Analyzer Operating Modes
70
Test Functions
71
Table 4-2: Test Functions Defined
71
Warning Messages
72
Figure 4-2: Viewing TEST Functions
72
Table 4-3: List of Warning Messages
73
Calibration Mode
74
Figure 4-3: Viewing and Clearing T360 WARNING Messages
74
Setup Mode
75
Table 4-4: Primary Setup Mode Features and Functions
75
Table 4-5: Secondary Setup Mode Features and Functions
75
Setup  Cfg: Viewing the Analyzer'sconfiguration Information
76
SETUP  ACAL: Automatic Calibration
76
SETUP  DAS: Using the Data Acquisition System (DAS)
77
Table 4-6: Secondary Setup Mode Features and Functions
77
DAS Structure
78
Table 4-7: das Data Channel Properties
78
Table 4-8: das Data Parameter Functions
79
Default das Channels
80
Figure 4-4: Default das Channels Setup
82
Remote das Configuration
96
Figure 4-5: APICOM User Interface for das Configuration
96
SETUP  RNGE: Analog Output Reporting Range Configuration
97
Figure 4-6: Analog Output Connector Pin out
97
Physical Range Versus Analog Output Reporting Ranges
98
Reporting Range Modes
98
Single Range Mode (SNGL)
100
Dual Range Mode (DUAL)
101
Auto Range Mode (AUTO)
102
Range Units
103
Dilution Ratio
104
SETUP  PASS: Password Feature
105
Table 6-9: Password Levels
105
SETUP  CLK: Setting the Internal Time-Of-Day Clock
107
Setup  More Comm: Using the Analyzer'scommunication Ports
109
Machine ID
109
COM Port Default Settings
110
Figure 4-7: Rear Panel Connector Pin-Outs for COM1 & COM2 in RS-232 Mode
111
Figure 4-8: CPU Connector Pin-Outs for COM1 & COM2 in RS-232 Mode
112
Configuration of COM2
113
DTE and DCE Communication
113
COM Port Communication Modes
114
Table 4-9: Com Port Communication Modes
114
Remote Access Via the Ethernet
116
Table 4-10: Ethernet Status Indicators
116
Table 4-11: Lan/Internet Configuration Properties
117
Table 4-12: Internet Configuration Touchscreen Functions
121
USB Port Setup
122
Multidrop RS-232 Setup
124
Figure 4-9: Jumper and Cables for Multidrop Mode
125
Figure 4-10: RS-232-Multidrop Host-To-Analyzer Interconnect Diagram
126
MODBUS Setup
127
COM Port Baud Rate
129
COM Port Testing
130
SETUP  more  VARS: Internal Variables (VARS)
131
Table 4-13: Variable Names (VARS)
131
SETUP  more  DIAG: Using the Diagnostics Functions
133
Table 4-14: T360 Diagnostic (DIAG) Functions
133
Accessing the Diagnostic Features
134
Signal I/O
135
Analog Output Step Test
136
Analog I/O Configuration
137
Table 4-15: DIAG - Analog I/O Functions
137
Table 4-16: Analog Output Voltage Ranges
137
Table 4-17: Analog Output Current Loop Range
138
Table 4-18: Analog Output Pin Assignments
138
Table 4-19: Voltage Tolerances for Analog Output Calibration
142
Figure 4-11: Setup for Calibrating Analog Voltage Outputs
143
Figure 4-12: Setup for Calibrating Current Outputs
144
Table 4-20: Current Loop Output Calibration with Resistor
145
Electric Test
148
Dark Calibration Test
149
Pressure Calibration
150
Flow Calibration
151
Test Channel Output
152
Table 4-21: Test Parameters Available for Analog Output A4
152
SETUP MORE  ALRM: Using the Gas Concentration Alarms
153
Setting the Concentration Alarm Limits
153
Table 4-22: CO2 Concentration Alarm Default Settings
153
Remote Operation of the Analyzer
154
Remote Operation Using the External Digital I/O
154
Figure 4-13: Status Output Connector
154
Table 4-23: Status Output Pin Assignments
155
Figure 4-14: Control Inputs
156
Table 4-24: Control Input Pin Assignments
156
Remote Operation Using the External Serial I/O
157
Table 4-25: Terminal Mode Software Commands
157
Table 4-26: Command Types
158
Additional Communications Documentation
163
Figure 4-15: APICOM Remote Control Program Interface
163
Table 4-27: Serial Interface Documents
163
Using the T360 with a Hessen Protocol Network
164
Table 4-28: RS-232 Com Parameters for Hessen Protocol
164
Table 4-29: Teledyne API Hessen Protocol Response Modes
167
Table 4-30: Default Hessen Status Bit Assignments
168
Calibration Procedures
171
Before Calibration
171
Zero Air and Span Gas
171
Calibration Gas Traceability
172
Data Recording Devices
172
Manual Calibration Without Zero/Span Valves
172
Figure 5-1: Pneumatic Connections-Basic Configuration-Using Bottled Span Gas
172
Figure 5-2: Pneumatic Connections-Basic Configuration-Using Gas Dilution Calibrator
173
Manual Calibration Checks
175
Manual Calibration with Zero/Span Valves
175
Figure 5-3: Pneumatic Connections - Ambient Zero/Pressurized Span Valves
176
Figure 5-4: Pneumatic Connections - Ambient Zero/Pressurized Span Valves and External Zero Air Scrubber
176
Figure 5-5: Pneumatic Connections - Ambient Zero/Ambient Span Valves
177
Figure 5-6: Pneumatic Connections - Ambient Zero/Ambient Span Valves with External Zero Air Scrubber
177
Manual Calibration Checks with Zero/Span Valves
180
Zero/Span Calibration on Auto Range or Dual Ranges
181
Use of Zero/Span Valves with Remote Contact Closure
182
Automatic Zero/Span Cal/Check (Autocal)
182
Table 5-1: AUTOCAL Modes
182
Table 5-2: Autocal ATTRIBUTE Setup Parameters
182
Autocal with Auto or Dual Reporting Ranges Modes Selected
185
Calibration Quality
186
Table 5-3 : Calibration Data Quality Evaluation
186
Maintenance Schedule and Procedures
187
Maintenance Schedule
187
Table 6-1: T360 Maintenance Schedule
189
Table 6-2: T360 Test Function Record
190
Predicting Failures Using the Test Functions
191
Table 6-3: Predictive Uses for Test Functions
191
Maintenance Procedures
192
Replacing the Sample Particulate Filter
192
Figure 6-1: Sample Particulate Filter Assembly
192
Rebuilding the Sample Pump
193
Performing Leak Checks
193
Performing a Sample Flow Check
194
Cleaning the Optical Bench
194
Cleaning the Chassis
194
Principles of Operation
195
Measurement Method
195
Beer's Law
195
Measurement Fundamentals
196
Gas Filter Correlation
196
Figure 7-1: Measurement Fundamentals
196
Figure 7-2: GFC Wheel
196
Figure 7-3: Measurement Fundamentals with GFC Wheel
197
Figure 7-4: Affect of CO2 in the Sample on CO2 MEAS & CO2 REF
198
Interference and Signal to Noise Rejection
199
Figure 7-5: Effects of Interfering Gas on CO2 MEAS & CO2 REF
199
Figure 7-6: Chopped IR Signal
199
Oxygen Sensor (OPT 65)
200
Paramagnetic Measurement of O
200
Figure 7-7: Oxygen Sensor - Principle of Operation
201
Pneumatic Operation
202
Sample Gas Flow
202
Figure 7-8: Internal Pneumatic Flow - Basic Configuration
202
Flow Rate Control
203
Figure 7-9: Flow Control Assembly & Critical Flow Orifice
203
Purge Gas Pressure Control
204
Particulate Filter
204
Pneumatic Sensors
204
Pneumatic Operation of the O Sensor
205
Figure 7-10: Gas Flow with O2 Sensor Option
205
Electronic Operation
206
Overview
206
Figure 7-11: T360 Electronic Block Diagram
207
Cpu
208
Figure 7-12: CPU Board
208
Optical Bench & GFC Wheel
209
Figure 7-13: GFC Light Mask
210
Figure 7-14: Segment Sensor and M/R Sensor Output
211
Synchronous Demodulator (Sync/Demod) Assembly
212
Figure 7-15: T360 Sync / Demod Block Diagram
212
Figure 7-16: Sample & Hold Timing
213
Relay Board
214
Table 7-1: Sync/Demod Status LED Activity
214
Figure 7-17: Location of Relay Board Status Led's
216
Table 7-2: Relay Board Status Led's
216
Motherboard
217
C Data Bus
219
Power Supply/Circuit Breaker
220
Figure 7-18: Power Distribution Block Diagram
220
Front Panel Touchscreen/Display Interface
221
LVDS Transmitter Board
221
Front Panel Touchscreen/Display Interface PCA
221
Figure 7-19: Front Panel and Display Interface Block Diagram
221
Software Operation
222
Adaptive Filter
222
Figure 7-20: Basic Software Operation
222
Calibration - Slope and Offset
223
Measurement Algorithm
223
Temperature and Pressure Compensation
224
Internal Data Acquisition System (DAS)
224
Troubleshooting and Service
225
General Troubleshooting Hints
225
Interpreting WARNING Messages
226
Figure 8-1: Viewing and Clearing Warning Messages
228
Table 8-1: Warning Messages - Indicated Failures
229
Fault Diagnosis with TEST Functions
230
Table 8-2: Test Functions - Indicated Failures
231
Using the Diagnostic Signal I/O Function
232
Internal Electronic Status Leds
233
Figure 8-2: Example of Signal I/O Function
233
Figure 8-3: CPU Status Indicator
234
Table 8-3: Sync/Demod Board Status Failure Indications
234
Figure 8-4: Sync/Demod Board Status LED Locations
235
Figure 8-5: Relay Board Status Leds
235
Table 8-4: I2C Status LED Failure Indications
235
Table 8-5: Relay Board Status LED Failure Indications
236
Gas Flow Problems
237
T360 Internal Gas Flow Diagrams
238
Figure 8-6: T360 - Basic Internal Gas Flow
238
Figure 8-7: Internal Pneumatic Flow - Ambient Zero/Pressurized Span Valves
239
Figure 8-8: Internal Pneumatic Flow - Ambient Zero/Ambient Span
239
Typical Sample Gas Flow Problems
240
Figure 8-9: T360 - Internal Pneumatics with O Sensor Option 65A
240
Poor or Stopped Flow of Purge Gas
242
Calibration Problems
243
Miscalibrated
243
Non-Repeatable Zero and Span
244
Inability to Span - Touchscreen SPAN Button Not Visible
244
Inability to Zero - Touchscreen ZERO Button Not Visible
245
Other Performance Problems
246
Temperature Problems
246
Excessive Noise
248
Subsystem Checkout
249
AC Mains Configuration
249
DC Power Supply
249
Table 8-6: DC Power Test Point and Wiring Color Codes
249
I 2 C Bus
250
Touchscreen Interface
250
Table 8-7: DC Power Supply Acceptable Levels
250
LCD Display Module
251
Relay Board
251
Sensor Assembly
251
Table 8-8: Relay Board Control Devices
251
Table 8-9: Opto Pickup Board Nominal Output Frequencies
252
Motherboard
254
Table 8-10: Analog Output Test Function - Nominal Values Voltage Outputs
254
Table 8-11: Analog Output Test Function - Nominal Values Current Outputs
255
Table 8-12: Status Outputs Check
255
Cpu
256
Communications
257
Repair Procedures
258
Repairing Sample Flow Control Assembly
258
Removing/Replacing the GFC Wheel
259
Figure 8-10: Critical Flow Restrictor Assembly Disassembly
259
Figure 8-11: Opening the GFC Wheel Housing
260
Figure 8-12: Removing the GFC Wheel
260
Disk-On-Module Replacement Procedure
261
Frequently Asked Questions
262
A Primer on Electro-Static Discharge
265
How Static Charges Are Created
265
Figure 9-1: Triboelectric Charging
265
How Electro-Static Charges Cause Damage
266
Table 9-1: Static Generation Voltages for Typical Activities
266
Table 9-2: Sensitivity of Electronic Devices to Damage by ESD
266
Common Myths about ESD Damage
267
Basic Principles of Static Control
268
General Rules
268
Figure 9-2: Basic Anti-ESD Work Station
268
Basic Anti-ESD Procedures for Analyzer Repair and Maintenance
270

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