Teledyne Carbon Monoxide Alarm GFC 7001E User Manual
Operation Manual  
MODEL GFC 7001E FAMILY  
CARBON MONOXIDE ANALYZERS  
(Includes GFC 7001E, GFC 7001EM)  
TELEDYNE ELECTRONIC TECHNOLOGIES  
Analytical Instruments  
16830 Chestnut Street  
City of Industry, CA 91748  
Telephone: (626) 934-1500  
Fax: (626) 961-2538  
Web: www.teledyne-ai.com  
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Safety Messages  
Model GFC7001E Carbon Dioxide Analyzer  
SAFETY MESSAGES  
Warning and cautionary messages are provided for the purpose of avoiding risk of personal injury or  
instrument damage. These important safety messages and associated safety alert symbols are found  
throughout this manual; the safety symbols are also located inside the instrument(s). It is imperative  
that you pay close attention to these messages, the descriptions of which are as follows:  
WARNING: Electrical Shock Hazard  
HAZARD: Strong oxidizer  
GENERAL WARNING/CAUTION: Read the accompanying  
message for specific information.  
CAUTION: Hot Surface Warning  
Technician Symbol: All operations marked with this symbol are to  
be performed by qualified maintenance personnel only.  
DO NOT TOUCH: Touching some parts of the instrument without  
protection or proper tools could result in damage to the part(s)  
and/or the instrument.  
Electrical Ground: This symbol inside the instrument marks the  
central safety grounding point for the instrument.  
CAUTION – GENERAL SAFETY HAZARD  
This instrument should only be used for the purpose and in the manner described in this  
manual. If you use this instrument in a manner other than that for which it was intended,  
unpredictable behavior could ensue with possible hazardous consequences.  
Never use any gas analyzer to sample combustible gas(es).  
Note  
Technical Assistance regarding the use and maintenance of this or any other Teledyne product can be  
obtained by contacting Teledyne’s Customer Service Department:  
Telephone: 800-324-5190  
Email: [email protected]  
or by accessing various service options on our website at http://www.teledyne-api.com/.  
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Safety Messages  
Model GFC7001E Carbon Dioxide Analyzer  
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Warranty  
Model GFC7001E Carbon Dioxide Analyzer  
WARRANTY  
WARRANTY POLICY (02024D)  
Prior to shipment, TAI equipment is thoroughly inspected and tested. Should equipment failure occur, TAI  
assures its customers that prompt service and support will be available.  
COVERAGE  
After the warranty period and throughout the equipment lifetime, TAI 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 are to be performed by the customer.  
See Warranty statement on page 2.  
CAUTION – Avoid Warranty Invalidation  
Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing instructions  
and Return Merchandise Authorization (RMA) procedures when returning parts for repair or calibration  
may void your warranty. For anti-ESD handling and packing instructions please refer to “Packing  
Components for Return to Teledyne’s Customer Service” in the Primer on Electro-Static Discharge  
section of this manual, and for RMA procedures please contact Teledyne Customer Service at (626)  
934-1500.  
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Warranty  
Model GFC7001E Carbon Dioxide Analyzer  
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Manual Information  
Model GFC7001E Carbon Dioxide Analyzer  
ABOUT THIS MANUAL  
This manual is comprised of multiple documents, in PDF format, as listed below.  
Part No.  
04288  
Rev  
Name/Description  
D
GFC 7001E/EM Manual  
04906  
H
J
Menu Tree and Software Documentation, L.8 (as Appendix A of this manual)  
Spare Parts List, GFC 7001E (in Appendix B of this manual)  
05362  
05424  
H
Q
G
C
Spare Parts List, GFC 7001EM (in Appendix B of this manual)  
04302  
Recommended Spares Stocking Levels, GFC 7001E (in Appendix B of this manual)  
Recommended Spares Stocking Levels, GFC 7001EM (in Appendix B of this manual)  
Expendables Kit, GFC 7001E/EM (in Appendix B of this manual)  
04834  
009600400  
040360100 A  
Spares Kit, GFC 7001E/EM (1 unit) (in Appendix B of this manual)  
Warranty/Repair Request Questionnaire (as Appendix C of this manual)  
PCA, 03296, IR Photodetector Preamp and Sync Demodulator (In Appendix D of this manual)  
PCA, 03631, 0-20mA driver (in Appendix D of this manual)  
04305  
03297  
03632  
03976  
04354  
05703  
04089  
04136  
04216  
04217  
04259  
04468  
G
K
A
B
D
A
A
B
E
F
PCA, 03975, Keyboard & Display Driver (in Appendix D of this manual)  
Schematic, PCA 04003, Press/Flow (in Appendix D of this manual)  
PCA, 05702, Motherboard, E-Series Gen 4 (in Appendix D of this manual)  
PCA, 04088, Opto Pickup Interface (in Appendix D of this manual)  
PCA, 04135 Rev A, GFC 7001E Relay (in Appendix D of this manual)  
Interconnect Drawing - GFC 7001E SNs >=100 (in Appendix D of this manual)  
Interconnect List - GFC 7001E SNs >=100 (in Appendix D of this manual)  
PCA, 04258, Keyboard & Display Driver (in Appendix D of this manual)  
PCA, 04467, Analog Output Isolator, / Series Resistor (in Appendix D of this manual)  
A
B
NOTE  
We recommend that this manual be read in its entirety before making any attempt made to operate the  
instrument.  
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Manual Information  
Model GFC7001E Carbon Dioxide Analyzer  
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Table of Contents  
Model GFC7001E Carbon Dioxide Analyzer  
TABLE OF CONTENTS  
PART I – GENERAL INFORMATION .................................................................................... 21  
1. INTRODUCTION ................................................................................................................ 23  
1.1. GFC 7001E FAMILY Overview.....................................................................................................................23  
1.2. Additional Documentation .............................................................................................................................24  
1.2.1. Using This Manual .................................................................................................................................25  
2. SPECIFICATIONS AND APPROVALS.............................................................................. 27  
2.1. Specifications................................................................................................................................................27  
2.2. EPA Equivalency Designation ......................................................................................................................28  
2.3. TUV DESIGNATION .....................................................................................................................................29  
2.4. CE Mark Compliance ....................................................................................................................................29  
2.4.1. Emissions Compliance...........................................................................................................................29  
2.4.2. Safety Compliance.................................................................................................................................29  
3. GETTING STARTED.......................................................................................................... 31  
3.1. GFC 7001E/EM Analyzer Layout..................................................................................................................31  
3.2. Unpacking the GFC 7001E/EM Analyzer......................................................................................................36  
3.2.1. Ventilation Clearance.............................................................................................................................37  
3.3. Electrical Connections...................................................................................................................................38  
3.3.1. Power Connection..................................................................................................................................38  
3.3.2. Analog Output Connections..................................................................................................................39  
3.3.3. Connecting the Status Outputs..............................................................................................................39  
3.3.4. Connecting the Control Inputs ...............................................................................................................41  
3.3.5. Connecting the Serial Ports ...................................................................................................................42  
3.3.6. Connecting to a LAN or the Internet ......................................................................................................42  
3.3.7. Connecting to a Multidrop Network........................................................................................................42  
3.4. Pneumatic Connections ................................................................................................................................42  
3.4.1. Calibration Gases ..................................................................................................................................42  
3.4.1.1. Zero Air...........................................................................................................................................42  
3.4.1.2. Span Gas........................................................................................................................................43  
3.4.2. Pneumatic Connections to GFC 7001E/EM Basic Configuration..........................................................44  
3.4.2.1. Sample Gas Source .......................................................................................................................45  
3.4.2.2. Calibration Gas Sources ................................................................................................................45  
3.4.2.3. Input Gas Venting...........................................................................................................................46  
3.4.2.4. Exhaust Outlet................................................................................................................................46  
3.5. Initial Operation.............................................................................................................................................46  
3.5.1. Startup....................................................................................................................................................47  
3.5.2. Warm Up................................................................................................................................................48  
3.5.3. Warning Messages ................................................................................................................................48  
3.5.4. Functional Check ...................................................................................................................................50  
3.6. Initial Calibration of the GFC 7001E/EM.......................................................................................................51  
3.6.1. Interferents for CO2 Measurements.......................................................................................................51  
3.6.2. Initial Calibration Procedure for GFC 7001E/EM Analyzers without Options........................................51  
3.6.2.1. Verifying the GFC 7001E/EM Reporting Range Settings...............................................................52  
3.6.2.2. Dilution Ratio Set Up ......................................................................................................................53  
3.6.2.3. Set CO Span Gas Concentration ...................................................................................................54  
3.6.2.4. Zero/Span Calibration.....................................................................................................................55  
3.6.3. O2 Sensor Calibration Procedure...........................................................................................................56  
3.6.4. CO2 Sensor Calibration Procedure........................................................................................................56  
4. FREQUENTLY ASKED QUESTIONS................................................................................ 57  
4.1. FAQ’s ............................................................................................................................................................57  
4.2. Glossary ........................................................................................................................................................58  
5. OPTIONAL HARDWARE AND SOFTWARE..................................................................... 61  
5.1. External Pumps (OPTions 10A-10E, 11, 13) ................................................................................................61  
5.2. Rack Mount Kits (OPT 20 to OPT 23)...........................................................................................................61  
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5.3. Carrying Strap/Handle (OPT 29)...................................................................................................................62  
5.4. Current Loop Analog Outputs (Option 41) ....................................................................................................62  
5.4.1. Converting Current Loop Analog Outputs to Standard Voltage Outputs...............................................63  
5.5. Expendables and Spares Kits (Options 42A, 45) .........................................................................................64  
5.6. Calibration Valves (Options 50A, 50B, 50E, 50H) ........................................................................................64  
5.6.1. General Information Related to all Valve Options..................................................................................64  
5.6.1.1. Gas Flow Rate................................................................................................................................64  
5.6.1.2. Valve Control..................................................................................................................................64  
5.6.2. Zero/Span Valve (Option 50A)...............................................................................................................64  
5.6.2.1. Internal Pneumatics (OPT 50A) .....................................................................................................65  
5.6.2.2. Pneumatic Set Up (OPT 50A) ........................................................................................................66  
5.6.2.3. Input Gas Venting...........................................................................................................................66  
5.6.2.4. Exhaust Outlet................................................................................................................................66  
5.6.3. Zero/Span/Shutoff Valve (Option 50B) ..................................................................................................67  
5.6.3.1. Internal Pneumatics (OPT 50B) .....................................................................................................67  
5.6.3.2. Pneumatic Set Up (OPT 50B) ........................................................................................................68  
5.6.4. Zero/Span Valve with Internal CO Scrubber (Option 50H)....................................................................69  
5.6.4.1. Internal Pneumatics (OPT 50H) .....................................................................................................69  
5.6.4.2. Pneumatic Set Up (OPT 50H)........................................................................................................70  
5.6.5. Zero/Span/Shutoff with Internal Zero Air Scrubber (Option 50E) ..........................................................71  
5.6.5.1. Internal Pneumatics (OPT 50E) .....................................................................................................71  
5.6.5.2. Pneumatic Set Up (OPT 50E) ........................................................................................................72  
5.7. Communication Options................................................................................................................................73  
5.7.1. RS-232 Modem Cable (Option 60A)......................................................................................................73  
5.7.2. RS-232 Multidrop (Option 62)................................................................................................................73  
5.7.3. Ethernet (Option 63A)............................................................................................................................74  
5.7.4. Ethernet + Multidrop (OPT 63C)............................................................................................................75  
5.8. Second Gas Sensors ....................................................................................................................................75  
5.8.1. Oxygen Sensor (Option 65A).................................................................................................................75  
5.8.1.1. Theory of Operation - Paramagnetic measurement of O2..............................................................75  
5.8.1.2. Operation within the GFC 7001E/EM Analyzer..............................................................................76  
5.8.1.3. Pneumatic Operation of the O2 Sensor..........................................................................................76  
5.9. Carbon Dioxide Sensor (Option 67A) ...........................................................................................................77  
5.9.1. CO2 Sensor Ranges and Specifications................................................................................................77  
5.9.2. Theory of Operation...............................................................................................................................77  
5.9.2.1. NDIR measurement of CO2 ............................................................................................................77  
5.9.2.2. Operation within the GFC 7001E/EM Analyzer..............................................................................78  
5.9.2.3. Pneumatic Operation of the CO2 Sensor .......................................................................................78  
5.9.2.4. Electronic Operation of the CO2 Sensor.........................................................................................79  
5.10. CONCENTRATION ALARM RELAY (Option 61) .......................................................................................80  
5.11. Special Features .........................................................................................................................................82  
5.11.1. Dilution Ratio Option............................................................................................................................82  
5.11.2. Maintenance Mode Switch...................................................................................................................82  
5.11.3. Second Language Switch....................................................................................................................82  
PART II – OPERATING INSTRUCTIONS.............................................................................. 83  
6. BASIC OPERATION .......................................................................................................... 85  
6.1. Overview of Operating Modes ......................................................................................................................85  
6.2. Sample Mode................................................................................................................................................86  
6.3. Warning Messages .......................................................................................................................................88  
6.4. Calibration Mode...........................................................................................................................................89  
6.5. Setup MODE.................................................................................................................................................90  
6.5.1. SETUP CFG: Configuration Information ...........................................................................................91  
6.5.2. SETUP ACAL: Automatic Calibration................................................................................................91  
6.5.3. SETUP PASS: Password Feature.....................................................................................................92  
6.5.4. SETUP CLK: Setting the GFC 7001E/EM Analyzer’s Internal Clock................................................95  
6.5.4.1. Setting the internal Clock’s Time and Day .....................................................................................95  
6.5.4.2. Adjusting the Internal Clock’s Speed..............................................................................................96  
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Model GFC7001E Carbon Dioxide Analyzer  
6.6. SETUP RNGE: Analog Output Reporting Range Configuration ..............................................................97  
6.6.1. Physical Range versus Analog Output Reporting Ranges....................................................................97  
6.6.2. Analog Output Ranges for CO Concentration .......................................................................................98  
6.6.3. Reporting Range Modes........................................................................................................................99  
6.6.3.1. RNGE MODE SNGL: Configuring the GFC 7001E/EM Analyzer for SINGLE Range Mode100  
6.6.3.2. RNGE MODE DUAL: Configuring the GFC 7001E/EM Analyzer for DUAL Range Mode..101  
6.6.3.3. RNGE MODE AUTO: Configuring the GFC 7001E/EM Analyzer for AUTO Range Mode.103  
6.6.4. SETUP RNGE UNIT: Setting the Reporting Range Units of Measure.......................................105  
6.6.5. SETUP RNGE DIL: Using the Optional Dilution Ratio Feature...................................................106  
7. ADVANCED FEATURES ................................................................................................. 107  
7.1. SETUP IDAS: Using the Data Acquisition System (iDAS).....................................................................107  
7.1.1. IDAS Status .........................................................................................................................................107  
7.1.2. IDAS Structure.....................................................................................................................................108  
7.1.2.1. iDAS Channels .............................................................................................................................108  
7.1.3. Default iDAS Channels ........................................................................................................................109  
7.1.4. SETUP DAS VIEW: Viewing iDAS Channels and Individual Records ........................................111  
7.1.5. SETUP DAS EDIT: Accessing the iDAS Edit Mode ....................................................................112  
7.1.5.1. Editing iDAS Data Channel Names..............................................................................................113  
7.1.5.2. Editing iDAS Triggering Events....................................................................................................114  
7.1.5.3. Editing iDAS Parameters..............................................................................................................115  
7.1.5.4. Editing Sample Period and Report Period....................................................................................117  
7.1.5.5. Report Periods in Progress When Instrument Is Powered Off.....................................................118  
7.1.5.6. Editing the Number of Records ....................................................................................................119  
7.1.5.7. RS-232 Report Function...............................................................................................................120  
7.1.5.8. Enabling/Disabling the HOLDOFF Feature..................................................................................121  
7.1.5.9. The Compact Report Feature.......................................................................................................122  
7.1.5.10. The Starting Date Feature..........................................................................................................122  
7.1.6. Disabling/Enabling Data Channels ......................................................................................................122  
7.1.7. Remote iDAS Configuration.................................................................................................................123  
7.1.7.1. iDAS Configuration Using APICOM .............................................................................................123  
7.1.7.2. iDAS Configuration Using Terminal Emulation Programs............................................................124  
7.2. SETUP MORE VARS: Internal Variables (VARS).............................................................................125  
7.3. SETUP MORE DIAG: Using the Diagnostics Functions...................................................................127  
7.3.1. Accessing the Diagnostic Features .....................................................................................................128  
7.4. Using the GFC 7001E/EM Analyzer’s Analog Outputs...............................................................................129  
7.4.1. Accessing the Analog Output Signal Configuration Submenu ............................................................129  
7.4.2. Analog Output Voltage / Current Range Selection..............................................................................131  
7.4.3. Calibration of the Analog Outputs........................................................................................................133  
7.4.3.1. Enabling or Disabling the AutoCal for an Individual Analog Output.............................................133  
7.4.3.2. Automatic Calibration of the Analog Outputs ...............................................................................134  
7.4.3.3. Individual Calibration of the Analog Outputs................................................................................136  
7.4.3.4. Manual Calibration of the Analog Outputs Configured for Voltage Ranges.................................137  
7.4.3.5. Manual Adjustment of Current Loop Output Span and Offset .....................................................139  
7.4.4. Turning an analog output Over-Range Feature ON/OFF....................................................................142  
7.4.5. Adding a Recorder Offset to an analog output ....................................................................................143  
7.4.6. Selecting a Test Channel Function for Output A4 ...............................................................................144  
7.4.7. AIN Calibration.....................................................................................................................................146  
7.5. SETUP MORE ALRM: Using the Gas Concentration Alarms ............................................................147  
7.5.1. Setting the GFC 7001E Concentration Alarm Limits ...........................................................................147  
8. REMOTE OPERATION .................................................................................................... 149  
8.1. SETUP MORECOMM: Using the Analyser’s Communication Ports .................................................149  
8.1.1. RS-232 DTE and DCE Communication...............................................................................................149  
8.1.2. COMM Port Default Settings................................................................................................................149  
8.1.3. COMM Port Baud Rate........................................................................................................................151  
8.1.4. COMM Port Communication Modes....................................................................................................152  
8.1.5. COMM Port Testing .............................................................................................................................154  
8.1.6. Machine ID...........................................................................................................................................155  
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Model GFC7001E Carbon Dioxide Analyzer  
8.1.7. Terminal Operating Modes ..................................................................................................................156  
8.1.7.1. Help Commands in Terminal Mode..............................................................................................156  
8.1.7.2. Command Syntax.........................................................................................................................157  
8.1.7.3. Data Types ...................................................................................................................................157  
8.1.7.4. Status Reporting...........................................................................................................................158  
8.1.7.5. COMM Port Password Security....................................................................................................159  
8.2. Multidrop RS-232 Set Up ............................................................................................................................160  
8.3. RS-485 Configuration of COM2..................................................................................................................162  
8.4. Remote Access via the Ethernet.................................................................................................................164  
8.4.1. Ethernet Card COM2 Communication Modes and Baud Rate............................................................164  
8.4.2. Configuring the Ethernet Interface Option using DHCP ......................................................................165  
8.4.3. Manually Configuring the Network IP Addresses ................................................................................167  
8.4.4. Changing the Analyzer’s HOSTNAME ................................................................................................170  
8.5. MODBUS SetUp .........................................................................................................................................171  
8.5.1. Remote Access by Modem..................................................................................................................172  
8.6. Using the GFC 7001E/EM with a Hessen Protocol Network ......................................................................175  
8.6.1. General Overview of Hessen Protocol.................................................................................................175  
8.6.2. Hessen COMM Port Configuration ......................................................................................................175  
8.6.3. Activating Hessen Protocol..................................................................................................................176  
8.6.4. Selecting a Hessen Protocol Type.......................................................................................................177  
8.6.5. Setting The Hessen Protocol Response Mode....................................................................................178  
8.6.6. Hessen Protocol Gas List Entries........................................................................................................179  
8.6.6.1. Gas List Entry Format and Definitions..........................................................................................179  
8.6.6.2. Editing or Adding HESSEN Gas List Entries................................................................................180  
8.6.6.3. Deleting HESSEN Gas List Entries..............................................................................................181  
8.6.7. Setting Hessen Protocol Status Flags .................................................................................................182  
8.6.8. Instrument ID Code..............................................................................................................................183  
8.7. APICOM Remote Control Program.............................................................................................................184  
9. CALIBRATION PROCEDURES....................................................................................... 185  
9.1. Before Calibration .......................................................................................................................................186  
9.1.1. Required Equipment, Supplies, and Expendables ..............................................................................186  
9.1.2. Calibration Gases ................................................................................................................................186  
9.1.2.1. Zero Air.........................................................................................................................................186  
9.1.2.2. Span Gas......................................................................................................................................187  
9.1.2.3. Traceability ...................................................................................................................................187  
9.1.3. Data Recording Devices ......................................................................................................................187  
9.2. Manual Calibration Checks and Calibration of the GFC 7001E/EM Analyzer in its Base Configuration....188  
9.2.1. Setup for Basic Calibration Checks and Calibration............................................................................188  
9.2.2. Performing a Basic Manual Calibration Check ....................................................................................190  
9.2.3. Performing a Basic Manual Calibration ...............................................................................................191  
9.2.3.1. Setting the Expected Span Gas Concentration............................................................................191  
9.2.3.2. Zero/Span Point Calibration Procedure........................................................................................192  
9.3. Manual Calibration with Zero/Span Valves.................................................................................................193  
9.3.1. Setup for Calibration Using Valve Options ..........................................................................................193  
9.3.2. Manual Calibration Checks with Valve Options Installed ....................................................................195  
9.3.3. Manual Calibration Using Valve Options .............................................................................................196  
9.3.3.1. Setting the Expected Span Gas Concentration............................................................................196  
9.3.3.2. Zero/Span Point Calibration Procedure........................................................................................197  
9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure ...............................................................198  
9.4. Automatic Zero/Span Cal/Check (AutoCal) ................................................................................................198  
9.4.1. SETUP ACAL: Programming and AUTO CAL Sequence...............................................................201  
9.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected...................................................203  
9.5. CO Calibration Quality ................................................................................................................................204  
9.6. Calibration of the GFC 7001E/EM’s Electronic Subsystems ......................................................................205  
9.6.1. Dark Calibration Test ...........................................................................................................................205  
9.6.2. Pressure Calibration ............................................................................................................................206  
9.6.3. Flow Calibration ...................................................................................................................................207  
9.6.4. Electrical Test Calibration ....................................................................................................................208  
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9.7. Calibration of Optional Sensors ..................................................................................................................209  
9.7.1. O2 Sensor Calibration Procedure.........................................................................................................209  
9.7.1.1. O2 Calibration Setup.....................................................................................................................209  
9.7.1.2. Set O2 Span Gas Concentration...................................................................................................210  
9.7.1.3. Activate O2 Sensor Stability Function...........................................................................................211  
9.7.1.4. O2ZERO/SPAN CALIBRATION....................................................................................................212  
9.7.2. CO2 Sensor Calibration Procedure......................................................................................................213  
9.7.2.1. CO2 Calibration Setup ..................................................................................................................213  
9.7.2.2. Set CO2 Span Gas Concentration:...............................................................................................213  
9.7.2.3. Activate CO2 Sensor Stability Function........................................................................................214  
9.7.2.4. CO2 Zero/Span Calibration...........................................................................................................215  
10. EPA CALIBRATION PROTOCOL................................................................................. 217  
10.1. Calibration Requirements..........................................................................................................................217  
10.1.1. Calibration of Equipment - General Guidelines .................................................................................217  
10.1.2. Calibration Equipment, Supplies, and Expendables..........................................................................218  
10.1.2.1. Data Recording Device...............................................................................................................218  
10.1.2.2. Spare Parts and Expendable Supplies.......................................................................................218  
10.1.3. Recommended Standards for Establishing Traceability....................................................................219  
10.1.4. Calibration Frequency........................................................................................................................220  
10.1.5. Level 1 Calibrations versus Level 2 Checks......................................................................................220  
10.2. ZERO and SPAN Checks .........................................................................................................................221  
10.2.1. Zero/Span Check Procedures ...........................................................................................................222  
10.2.2. Precision Check.................................................................................................................................222  
10.3. Precisions Calibration ...............................................................................................................................222  
10.3.1. Precision Calibration Procedures ......................................................................................................223  
10.4. Auditing Procedure....................................................................................................................................223  
10.4.1. Calibration Audit.................................................................................................................................223  
10.4.2. Data Reduction Audit.........................................................................................................................223  
10.4.3. System Audit/Validation.....................................................................................................................224  
10.5. Dynamic Multipoint Calibration Procedure................................................................................................224  
10.5.1. Linearity test.......................................................................................................................................224  
10.6. References................................................................................................................................................226  
PART III – TECHNICAL INFORMATION ............................................................................. 227  
11. THEORY OF OPERATION ............................................................................................ 229  
11.1. Measurement Method ...............................................................................................................................229  
11.1.1. Beer’s Law .........................................................................................................................................229  
11.2. Measurement Fundamentals ....................................................................................................................229  
11.2.1. Gas Filter Correlation.........................................................................................................................230  
11.2.1.1. The GFC Wheel..........................................................................................................................231  
11.2.1.2. The Measure Reference Ratio ...................................................................................................232  
11.2.1.3. Summary Interference Rejection................................................................................................233  
11.3. Pneumatic Operation ................................................................................................................................234  
11.4. Flow Rate Control .....................................................................................................................................235  
11.4.1.1. Critical Flow Orifice.....................................................................................................................235  
11.4.2. Particulate Filter.................................................................................................................................236  
11.4.3. Pneumatic Sensors............................................................................................................................236  
11.4.3.1. Sample Pressure Sensor ...........................................................................................................236  
11.4.3.2. Sample Flow Sensor ..................................................................................................................236  
11.5. Electronic Operation..................................................................................................................................237  
11.5.1. Overview ............................................................................................................................................237  
11.5.2. Central Processing Unit (CPU)..........................................................................................................239  
11.5.3. Optical Bench & GFC Wheel .............................................................................................................240  
11.5.3.1. Temperature Control ..................................................................................................................240  
11.5.3.2. IR Source....................................................................................................................................240  
11.5.3.3. GFC Wheel.................................................................................................................................240  
11.5.3.4. IR Photo-Detector.......................................................................................................................242  
11.5.4. Synchronous Demodulator (Sync/Demod) Assembly .......................................................................242  
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Model GFC7001E Carbon Dioxide Analyzer  
11.5.4.1. Overview.....................................................................................................................................242  
11.5.4.2. Signal Synchronization and Demodulation ................................................................................243  
11.5.4.3. Sync/Demod Status LED’s.........................................................................................................244  
11.5.4.4. Photo-Detector Temperature Control.........................................................................................244  
11.5.4.5. Dark Calibration Switch..............................................................................................................244  
11.5.4.6. Electric Test Switch ....................................................................................................................245  
11.5.5. Relay Board .......................................................................................................................................245  
11.5.5.1. Heater Control ............................................................................................................................245  
11.5.5.2. GFC Wheel Motor Control:.........................................................................................................245  
11.5.5.3. Zero/Span Valve Options ...........................................................................................................245  
11.5.5.4. IR Source....................................................................................................................................245  
11.5.5.5. Status LED’s...............................................................................................................................246  
11.5.5.6. I2C Watch Dog Circuitry..............................................................................................................246  
11.5.6. MotherBoard ......................................................................................................................................247  
11.5.6.1. A to D Conversion ......................................................................................................................247  
11.5.6.2. Sensor Inputs .............................................................................................................................247  
11.5.6.3. Thermistor Interface ...................................................................................................................247  
11.5.6.4. Analog Outputs...........................................................................................................................248  
11.5.6.5. Internal Digital I/O.......................................................................................................................248  
11.5.6.6. External Digital I/O......................................................................................................................248  
11.5.7. I2C Data Bus ......................................................................................................................................249  
11.5.8. Power Supply/ Circuit Breaker...........................................................................................................249  
11.5.9. Communication Interface...................................................................................................................251  
11.5.10. Front Panel Interface .......................................................................................................................252  
11.5.10.1. Analyzer Status LED’s..............................................................................................................252  
11.5.10.2. Keyboard ..................................................................................................................................252  
11.5.10.3. Display......................................................................................................................................253  
11.5.10.4. Keyboard/Display Interface Electronics....................................................................................253  
11.5.11. Software Operation..........................................................................................................................256  
11.5.12. Adaptive Filter..................................................................................................................................256  
11.5.13. Calibration - Slope and Offset..........................................................................................................257  
11.5.14. Measurement Algorithm...................................................................................................................257  
11.5.15. Temperature and Pressure Compensation......................................................................................257  
11.5.16. Internal Data Acquisition System (iDAS) .........................................................................................257  
12. MAINTENANCE SCHEDULE & PROCEDURES .......................................................... 259  
12.1. Maintenance Schedule..............................................................................................................................259  
12.2. Predicting Failures Using the Test Functions ...........................................................................................263  
12.3. Maintenance Procedures ..........................................................................................................................264  
12.3.1. Replacing the Sample Particulate Filter.............................................................................................264  
12.3.2. Rebuilding the Sample Pump ............................................................................................................264  
12.3.3. Performing Leak Checks....................................................................................................................265  
12.3.3.1. Vacuum Leak Check and Pump Check......................................................................................265  
12.3.3.2. Pressure Leak Check .................................................................................................................265  
12.3.4. Performing a Sample Flow Check .....................................................................................................266  
12.3.5. Cleaning the Optical Bench ...............................................................................................................266  
12.3.6. Cleaning Exterior Surfaces of the GFC 7001E/EM ...........................................................................266  
13. TROUBLESHOOTING & REPAIR................................................................................. 267  
13.1. General Troubleshooting...........................................................................................................................267  
13.1.1. Fault Diagnosis with WARNING Messages.......................................................................................268  
13.1.2. Fault Diagnosis with TEST Functions................................................................................................270  
13.1.3. DIAG SIGNAL I/O: Using the Diagnostic Signal I/O Function......................................................273  
13.1.4. Internal Electronic Status LED’s ........................................................................................................274  
13.1.4.1. CPU Status Indicator..................................................................................................................274  
13.1.4.2. Sync Demodulator Status LED’s................................................................................................275  
13.1.4.3. Relay Board Status LED’s..........................................................................................................276  
13.2. Gas Flow Problems...................................................................................................................................278  
13.2.1. GFC 7001E/EM Internal Gas Flow Diagrams....................................................................................278  
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Model GFC7001E Carbon Dioxide Analyzer  
13.2.2. Typical Sample Gas Flow Problems..................................................................................................282  
13.2.2.1. Flow is Zero................................................................................................................................282  
13.2.2.2. Low Flow ....................................................................................................................................282  
13.2.2.3. High Flow....................................................................................................................................282  
13.2.2.4. Displayed Flow = “Warnings” .....................................................................................................283  
13.2.2.5. Actual Flow Does Not Match Displayed Flow ............................................................................283  
13.2.2.6. Sample Pump.............................................................................................................................283  
13.3. Calibration Problems.................................................................................................................................283  
13.3.1. Miscalibrated......................................................................................................................................283  
13.3.2. Non-Repeatable Zero and Span........................................................................................................284  
13.3.3. Inability to Span – No SPAN Key.......................................................................................................284  
13.3.4. Inability to Zero – No ZERO Key .......................................................................................................284  
13.4. Other Performance Problems ...................................................................................................................285  
13.4.1. Temperature Problems ......................................................................................................................285  
13.4.1.1. Box or Sample Temperature ......................................................................................................285  
13.4.1.2. Bench Temperature....................................................................................................................285  
13.4.1.3. GFC Wheel Temperature...........................................................................................................286  
13.4.1.4. IR Photo-Detector TEC Temperature.........................................................................................286  
13.4.2. Excessive Noise.................................................................................................................................287  
13.5. Subsystem Checkout ................................................................................................................................288  
13.5.1. AC Mains Configuration.....................................................................................................................288  
13.5.2. DC Power Supply...............................................................................................................................288  
13.5.3. I2C Bus...............................................................................................................................................289  
13.5.4. Keyboard/Display Interface................................................................................................................289  
13.5.5. Relay Board .......................................................................................................................................290  
13.5.6. Sensor Assembly...............................................................................................................................291  
13.5.6.1. Sync/Demodulator Assembly .....................................................................................................291  
13.5.6.2. Electrical Test.............................................................................................................................291  
13.5.6.3. Opto Pickup Assembly ...............................................................................................................292  
13.5.6.4. GFC Wheel Drive .......................................................................................................................292  
13.5.6.5. IR Source....................................................................................................................................292  
13.5.6.6. Pressure/Flow Sensor Assembly ...............................................................................................293  
13.5.7. Motherboard.......................................................................................................................................294  
13.5.7.1. A/D Functions.............................................................................................................................294  
13.5.7.2. Test Channel / Analog Outputs Voltage.....................................................................................294  
13.5.7.3. Analog Outputs: Current Loop....................................................................................................295  
13.5.7.4. Status Outputs............................................................................................................................296  
13.5.7.5. Control Inputs – Remote Zero, Span..........................................................................................297  
13.5.8. CPU....................................................................................................................................................297  
13.5.9. RS-232 Communications...................................................................................................................297  
13.5.9.1. General RS-232 Troubleshooting...............................................................................................297  
13.5.9.2. Troubleshooting Analyzer/Modem or Terminal Operation .........................................................298  
13.5.10. The Optional CO2 Sensor ................................................................................................................298  
13.6. Repair Procedures ....................................................................................................................................299  
13.6.1. Repairing Sample Flow Control Assembly ........................................................................................299  
13.6.2. Removing/Replacing the GFC Wheel................................................................................................300  
13.6.3. Checking and Adjusting the Sync/Demodulator, Circuit Gain (CO MEAS) ......................................302  
13.6.3.1. Checking the Sync/Demodulator Circuit Gain............................................................................302  
13.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain...........................................................................303  
13.6.4. Disk-On-Module Replacement Procedure.........................................................................................304  
13.7. Technical Assistance ................................................................................................................................304  
14. A PRIMER ON ELECTRO-STATIC DISCHARGE......................................................... 305  
14.1. How Static Charges are Created ..............................................................................................................305  
14.2. How Electro-Static Charges Cause Damage............................................................................................306  
14.3. Common Myths About ESD Damage .......................................................................................................307  
14.4. Basic Principles of Static Control..............................................................................................................307  
14.4.1. General Rules....................................................................................................................................307  
14.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ..................................................309  
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Model GFC7001E Carbon Dioxide Analyzer  
14.4.2.1. Working at the Instrument Rack.................................................................................................309  
14.4.2.2. Working at an Anti-ESD Work Bench.........................................................................................309  
14.4.2.3. Transferring Components from Rack to Bench and Back..........................................................310  
14.4.2.4. Opening Shipments from Teledyne API’ Customer Service ......................................................310  
14.4.2.5. Packing Components for Return to Teledyne’s Customer Service............................................311  
LIST OF APPENDICES  
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION (Revision L.8)  
APPENDIX A-1: GFC 7001E/EM Software Menu Trees  
APPENDIX A-2: Setup Variables For Serial I/O  
APPENDIX A-3: Warnings and Test Functions  
APPENDIX A-4: GFC 7001E/EM Signal I/O Definitions  
APPENDIX A-5: GFC 7001E/EM iDAS Functions  
APPENDIX A-6: Terminal Command Designators  
APPENDIX A-7: MODBUS Register  
APPENDIX B - GFC 7001E/EM SPARE PARTS LIST  
APPENDIX C - REPAIR QUESTIONNAIRE - GFC 7001E  
APPENDIX D - ELECTRONIC SCHEMATICS  
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 5-1:  
Figure 5-2:  
Figure 5-3:  
Figure 5-4:  
Figure 5-5:  
Figure 5-6:  
Figure 5-7:  
Figure 5-8:  
Figure 5-9:  
Figure 5-10:  
Figure 5-11:  
Front Panel Layout.......................................................................................................................31  
Rear Panel Layout .......................................................................................................................32  
Internal Layout – GFC 7001E......................................................................................................33  
Internal Layout – GFC 7001EM with CO2 and O2 Sensor Option................................................34  
Optical Bench Layout...................................................................................................................35  
GFC 7001E/EM Internal Gas Flow (Basic Configuration) ...........................................................36  
Analog Output Connector ............................................................................................................39  
Status Output Connector .............................................................................................................40  
Control Input Connector...............................................................................................................41  
Pneumatic Connections–Basic Configuration–Using Bottled Span Gas.....................................44  
Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator.............................45  
GFC 7001E/EM with Carrying Strap Handle and Rack Mount Brackets.....................................62  
Current Loop Option Installed on the Motherboard .....................................................................63  
Internal Pneumatic Flow OPT 50A – Zero/Span Valves..............................................................65  
Pneumatic Connections – Option 50A: Zero/Span Calibration Valves........................................66  
Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves .................................................67  
Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves....................68  
Internal Pneumatic Flow OPT 50H – Zero/Span Valves with Internal Zero Air Scrubber ...........69  
Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .......................................70  
Internal Pneumatic Flow OPT 50E – Zero/Span/Shutoff Valves with Internal Zero Air Scrubber71  
Pneumatic Connections – Option 50E: Zero/Span Calibration Valves........................................72  
GFC 7001E/EM Multidrop Card Seated on CPU above Disk on Module....................................73  
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Model GFC7001E Carbon Dioxide Analyzer  
Figure 5-12:  
Figure 5-13:  
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Figure 5-17:  
Figure 5-18:  
Figure 5-19:  
Figure 6-1:  
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Figure 7-1:  
Figure 7-2:  
Figure 7-3:  
Figure 7-4:  
Figure 7-5:  
Figure 7-6:  
Figure 7-7:  
Figure 8-1:  
Figure 8-2:  
Figure 8-3:  
Figure 8-4:  
Figure 8-5:  
Figure 8-6:  
Figure 8-7:  
Figure 8-8:  
Figure 9-1:  
Figure 9-2:  
Figure 9-3:  
Figure 9-4:  
Figure 9-5:  
Figure 9-6:  
Figure 9-7:  
Figure 9-8:  
Figure 11-1:  
Figure 11-2:  
Figure 11-3:  
Figure 11-4:  
Figure 11-5:  
Figure 11-6:  
Figure 11-7:  
Figure 11-8:  
Figure 11-9:  
Figure 11-10:  
Figure 11-11:  
Figure 11-12:  
Figure 11-13:  
Figure 11-14:  
Figure 11-15:  
Figure 11-16:  
Figure 11-17:  
Figure 11-18:  
Figure 11-19:  
Figure 12-1:  
Figure 13-1:  
Figure 13-2:  
Figure 13-3:  
GFC 7001E/EM Ethernet Card....................................................................................................74  
GFC 7001E/EM Rear Panel with Ethernet Installed....................................................................74  
Oxygen Sensor - Principle of Operation ......................................................................................75  
GFC 7001E/EM – Internal Pneumatics with O2 Sensor Option 65A ...........................................76  
CO2 sensor Theory of Operation .................................................................................................78  
GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66 ...........................................79  
CO2 Sensor Option PCA Layout and Electronic Connections.....................................................79  
Concentration Alarm Relay..........................................................................................................80  
Front Panel Display......................................................................................................................85  
Viewing GFC 7001E/EM Test Functions .....................................................................................86  
Viewing and Clearing GFC 7001E/EM WARNING Messages ....................................................89  
Analog Output Connector Pin Out ...............................................................................................98  
Default iDAS Channel Setup .....................................................................................................110  
APICOM User Interface for Configuring the iDAS.....................................................................123  
iDAS Configuration Through a Terminal Emulation Program....................................................124  
Accessing the Analog I/O Configuration Submenus..................................................................130  
Setup for Checking / Calibrating DCV Analog Output Signal Levels.........................................137  
Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter..................139  
Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ................141  
Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE) ........150  
Default Pin Assignments for CPU COM Port connector (RS-232)............................................150  
Location of JP2 on RS-232-Multidrop PCA (Option 62) ............................................................160  
RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram ...................................................161  
CPU RS-485 Setup....................................................................................................................162  
Back Panel Connector Pin-Outs for COM2 in RS-485 Mode. ...................................................163  
CPU Connector Pin-Outs for COM2 in RS-485 Mode...............................................................163  
APICOM Remote Control Program Interface.............................................................................184  
Pneumatic Connections – Basic Configuration – Using Bottled Span Gas...............................188  
Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator.......................189  
Pneumatic Connections – Option 50A: Zero/Span Calibration Valves......................................193  
Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves..................193  
Pneumatic Connections – Option 51B: Zero/Span Calibration Valves......................................194  
Pneumatic Connections – Option 51C: Zero/Span Calibration Valves .....................................194  
O2 Sensor Calibration Set Up ....................................................................................................209  
CO2 Sensor Calibration Set Up..................................................................................................213  
Measurement Fundamentals.....................................................................................................230  
GFC Wheel ................................................................................................................................230  
Measurement Fundamentals with GFC Wheel..........................................................................231  
Effect of CO in the Sample on CO MEAS & CO REF ...............................................................232  
Effects of Interfering Gas on CO MEAS & CO REF ..................................................................233  
Chopped IR Signal.....................................................................................................................233  
Internal Pneumatic Flow – Basic Configuration.........................................................................234  
Flow Control Assembly & Critical Flow Orifice...........................................................................235  
GFC 7001E/EM Electronic Block Diagram ................................................................................238  
GFC Light Mask.........................................................................................................................241  
Segment Sensor and M/R Sensor Output .................................................................................241  
GFC 7001E/EM Sync/Demod Block Diagram ...........................................................................243  
Sample & Hold Timing ...............................................................................................................244  
Location of relay board Status LED’s ........................................................................................246  
Power Distribution Block Diagram .............................................................................................250  
Interface Block Diagram.............................................................................................................251  
GFC 7001E/EM Front Panel Layout..........................................................................................252  
Keyboard and Display Interface Block Diagram........................................................................253  
Basic Software Operation ..........................................................................................................256  
Sample Particulate Filter Assembly...........................................................................................264  
Viewing and Clearing Warning Messages.................................................................................268  
Example of Signal I/O Function .................................................................................................273  
CPU Status Indicator .................................................................................................................274  
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Model GFC7001E Carbon Dioxide Analyzer  
Figure 13-4:  
Figure 13-5:  
Figure 13-6:  
Figure 13-7:  
Figure 13-8:  
Figure 13-9:  
Figure 13-10:  
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Figure 13-14:  
Figure 13-15:  
Figure 13-16:  
Figure 13-17:  
Figure 13-18:  
Figure 13-19:  
Figure 13-20:  
Figure 14-1:  
Figure 14-2:  
Sync/Demod Board Status LED Locations................................................................................275  
Relay Board Status LEDs ..........................................................................................................276  
GFC 7001E/EM – Basic Internal Gas Flow ...............................................................................278  
Internal Pneumatic Flow OPT 50A – Zero/Span Valves (OPT 50A & 50B) ..............................279  
Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves ...............................................279  
Internal Pneumatic Flow OPT 51B – Zero/Span Valves with Internal Zero Air Scrubber..........280  
Internal Pneumatic Flow OPT 51C – Zero/Span/Shutoff w/ Internal Zero Air Scrubber ...........280  
GFC 7001E/EM – Internal Pneumatics with O2 Sensor Option 65............................................281  
GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66 .........................................281  
Location of Diagnostic LED’s onCO2 Sensor PCA ....................................................................298  
Critical Flow Restrictor Assembly Disassembly.........................................................................299  
Opening the GFC Wheel Housing .............................................................................................300  
Removing the Opto-Pickup Assembly .......................................................................................301  
Removing the GFC Wheel Housing...........................................................................................301  
Removing the GFC Wheel.........................................................................................................302  
Location of Sync/Demod Housing Mounting Screws.................................................................303  
Location of Sync/Demod Gain Potentiometer............................................................................303  
Triboelectric Charging................................................................................................................305  
Basic anti-ESD Workbench........................................................................................................307  
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 3-7:  
Table 3-8:  
Table 3-9:  
Table 5-1:  
Table 5-2:  
Table 5-3:  
Table 5-4:  
Table 5-5:  
Table 5-6:  
Table 5-7:  
Table 6-1:  
Table 6-2:  
Table 6-3:  
Table 6-4:  
Table 6-5:  
Table 6-6:  
Table 6-7:  
Table 7-1:  
Table 7-2:  
Table 7-3:  
M 300E/300EM Basic Unit Specifications....................................................................................27  
Front Panel Nomenclature...........................................................................................................31  
Inlet / Outlet Connector Nomenclature ........................................................................................32  
Ventilation Clearance...................................................................................................................37  
Analog Output Pin-Outs...............................................................................................................39  
Status Output Signals ..................................................................................................................40  
Control Input Signals....................................................................................................................41  
NIST-SRM's Available for Traceability of CO Calibration Gases..................................................43  
Front Panel Display during System Warm-Up.............................................................................48  
Possible Warning Messages at Start-Up.....................................................................................49  
Zero/Span Valve Operating States for Option 52........................................................................65  
Zero/Span Valve Operating States for Option 50B......................................................................67  
Zero/Span Valve Operating States for Option 50H .....................................................................69  
Zero/Span Valve Operating States for Option 50E......................................................................71  
GFC 7001E/EM Modem Cable Options.......................................................................................73  
CO2 Sensor - Available Ranges...................................................................................................77  
CO2 Sensor Specifications...........................................................................................................77  
Analyzer Operating Modes ..........................................................................................................85  
Test Functions Defined................................................................................................................87  
List of Warning Messages............................................................................................................88  
Primary Setup Mode Features and Functions .............................................................................90  
Secondary Setup Mode Features and Functions ........................................................................90  
Password Levels..........................................................................................................................92  
GFC 7001E Family Physical range by Model..............................................................................97  
Front Panel LED Status Indicators for iDAS..............................................................................107  
iDAS Data Channel Properties ..................................................................................................108  
iDAS Data Parameter Functions................................................................................................115  
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Model GFC7001E Carbon Dioxide Analyzer  
Table 7-4:  
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Table 9-2:  
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Table 9-4:  
Table 9-5:  
Table 10-1:  
Table 10-2:  
Table 10-3:  
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Table 11-3:  
Table 11-4:  
Table 11-5:  
Table 12-1:  
Table 12-2:  
Table 12-3:  
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Table 13-2:  
Table 13-3:  
Table 13-4:  
Table 13-5:  
Table 13-6:  
Table 13-7:  
Table 13-8:  
Table 13-9:  
Table 13-10:  
Table 13-11:  
Table 13-12:  
Table 14-1:  
Table 14-2:  
Variable Names (VARS) ............................................................................................................125  
Diagnostic Mode (DIAG) Functions ...........................................................................................127  
DIAG - Analog I/O Functions .....................................................................................................129  
Analog Output Voltage Range Min/Max ....................................................................................131  
Voltage Tolerances for the TEST CHANNEL Calibration..........................................................137  
Current Loop Output Check.......................................................................................................141  
Test Channels Functions available on the GFC 7001E/EM’s Analog Output ...........................144  
CO Concentration Alarm Default Settings .................................................................................147  
COMM Port Communication Modes..........................................................................................152  
Terminal Mode Software Commands ........................................................................................156  
Teledyne’s Serial I/O Command Types.....................................................................................157  
Ethernet Status Indicators..........................................................................................................164  
LAN/Internet Configuration Properties.......................................................................................165  
RS-232 Communication Parameters for Hessen Protocol ........................................................175  
Teledyne’s Hessen Protocol Response Modes.........................................................................178  
Default Hessen Status Flag Assignments .................................................................................182  
NIST-SRMs Available for Traceability of CO Calibration Gases ................................................187  
AUTOCAL Modes ......................................................................................................................198  
AutoCal Attribute Setup Parameters..........................................................................................199  
Example AutoCal Sequence......................................................................................................200  
Calibration Data Quality Evaluation...........................................................................................204  
Matrix for Calibration Equipment & Supplies .............................................................................219  
Activity Matrix for Quality Assurance Checks ............................................................................220  
Definition of Level 1 and Level 2 Zero and Span Checks..........................................................221  
Absorption Path Lengths for GFC 7001E and GFC 7001EM....................................................230  
Sync DEMOD Sample and Hold Circuits...................................................................................243  
Sync/Demod Status LED Activity...............................................................................................244  
Relay Board Status LED’s .........................................................................................................246  
Front Panel Status LED’s...........................................................................................................252  
GFC 7001E/EM Maintenance Schedule....................................................................................261  
GFC 7001E/EM Test Function Record......................................................................................262  
Predictive uses for Test Functions.............................................................................................263  
Warning Messages - Indicated Failures ....................................................................................269  
Test Functions - Indicated Failures............................................................................................271  
Sync/Demod Board Status Failure Indications ..........................................................................275  
I2C Status LED Failure Indications.............................................................................................276  
Relay Board Status LED Failure Indications..............................................................................277  
DC Power Test Point and Wiring Color Codes..........................................................................288  
DC Power Supply Acceptable Levels ........................................................................................289  
Relay Board Control Devices.....................................................................................................290  
Opto Pickup Board Nominal Output Frequencies......................................................................292  
Analog Output Test Function - Nominal Values Voltage Outputs .............................................294  
Analog Output Test Function - Nominal Values Voltage Outputs .............................................295  
Status Outputs Check................................................................................................................296  
Static Generation Voltages for Typical Activities.......................................................................305  
Sensitivity of Electronic Devices to Damage by ESD................................................................306  
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Model GFC7001E Carbon Dioxide Analyzer  
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Part 1 General Information  
Model GFC7001E Carbon Dioxide Analyzer  
PART I  
–
GENERAL INFORMATION  
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Part 1 General Information  
Model GFC7001E Carbon Dioxide Analyzer  
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Introduction  
Model GFC7001E Carbon Dioxide Analyzer  
1. INTRODUCTION  
1.1. GFC 7001E FAMILY OVERVIEW  
The family includes the GFC 7001E and the GFC 7001EM Gas Filter Correlation (GFC) Carbon Monoxide  
Analyzer. The GFC 7001E family of analyzers is a microprocessor-controlled analyzer that determines the  
concentration of carbon monoxide (CO) in a sample gas drawn through the instrument. It uses a method based  
on the Beer-Lambert law, an empirical relationship that relates the absorption of light to the properties of the  
material through which the light is traveling over a defined distance. In this case the light is infrared radiation (IR)  
traveling through a sample chamber filled with gas bearing a varying concentration of CO.  
The GFC 7001E/EM uses Gas Filter Correlation (GFC) to overcome the interfering effects of various other gases  
(such as water vapor) that also absorb IR. The analyzer passes the IR beam through a spinning wheel made up  
of two separate chambers, one containing a high concentration of CO, known as the reference, and the other  
containing a neutral gas known as the measure. The concentration of CO in the sample chamber is computed by  
taking the ratio of the instantaneous measure and reference values and then compensating the ratio for sample  
temperature and pressure.  
The GFC 7001E/EM Analyzer’s multi-tasking software gives the ability to track and report a large number of  
operational parameters in real time. These readings are compared to diagnostic limits kept in the analyzers  
memory and should any fall outside of those limits the analyzer issues automatic warnings.  
Built-in data acquisition capability, using the analyzer's internal memory, allows the logging of multiple  
parameters including averaged or instantaneous concentration values, calibration data, and operating  
parameters such as pressure and flow rate. Stored data are easily retrieved through the serial port or optional  
Ethernet port via our APICOM software or from the front panel, allowing operators to perform predictive  
diagnostics and enhanced data analysis by tracking parameter trends. Multiple averaging periods of one minute  
to 365 days are available for over a period of one year.  
Some of the common features of your GFC 7001E family of analyzers are:  
Microprocessor controlled for versatility  
Multi-tasking software allows viewing of test variables during operation  
Continuous self checking with alarms  
Bi-directional RS-232 for remote operation  
Digital status outputs indicate instrument operating condition  
Adaptive signal filtering optimizes response time  
Gas Filter Correlation Wheel for CO specific measurement  
GFC Wheel guaranteed against leaks for 5 years  
Temperature & Pressure compensation  
Internal data logging with 1 min to 365 day multiple average  
Remote operation when used with Teledyne APICOM software  
GFC 7001E FEATURES:  
Ranges, 0-1 ppm to 0-1000 ppm, user selectable  
14-meter path length for sensitivity  
GFC 7001EM FEATURES:  
Ranges, 0-1 ppm; Max: 0-5000 ppm, user selectable  
2.5 meter path length for dynamic range  
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Introduction  
Model GFC7001E Carbon Dioxide Analyzer  
Several options can be purchased for the analyzer that allows the user to more easily supply and manipulate  
Zero Air and Span Gas. For more information of these options, see Section 5.6.  
1.2. ADDITIONAL DOCUMENTATION  
Additional documentation for the GFC 7001E/EM CO Analyzer is available from Teledyne’s website at  
http://www.teledyne-ai.com/manuals/.  
APICOM software manual, P/N 03945.  
DAS Manual, P/N 02837.  
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Introduction  
Model GFC7001E Carbon Dioxide Analyzer  
1.2.1. USING THIS MANUAL  
NOTE  
This manual explains the operation and use of both the GFC 7001E and the GFC 7001EM Gas Filter  
Correlation Carbon Monoxide Analyzer.  
For the most part these two instruments are nearly identical in their features and functions.  
The examples and illustrations shown in this manual represent the GFC 7001E. Where a significant  
difference does exist between the different models, each version is shown.  
NOTE  
Throughout this manual, words printed in capital, bold letters, such as SETUP or ENTR represent  
messages as they appear on the analyzer’s display.  
This manual has the following structure:  
TABLE OF CONTENTS:  
Outlines the contents of the manual in the order the information are presented. This is a good overview of the  
topics covered in the manual. There is also a list of appendices, figures and tables.  
PART I – GENERAL INFORMATION  
INTRODUCTION  
A brief description of the GFC 7001E/EM Analyzer architecture as well as a description of the layout of  
the manual and what information is located in its various sections.  
SPECIFICATIONS AND WARRANTY  
Lists the performance specifications of the analyzers . If applicable, a description of the conditions and  
configuration under which EPA equivalency was approved as well as the Teledyne’s warranty statement.  
GETTING STARTED  
This section provides instructions for setting up, installing and running your analyzer for the first time.  
GLOSSARY  
Answers to the most frequently asked questions about operating the analyzer and a glossary of acronyms  
and technical terms.  
OPTIONAL HARDWARE & SOFTWARE  
The section describes the optional equipment and their functions for your analyzer.  
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Introduction  
Model GFC7001E Carbon Dioxide Analyzer  
PART II – OPERATING INSTRUCTIONS  
BASIC OPERATION OF THE GFC 7001E/EM ANALYZER  
Step-by-Step instructions for using the display/keyboard to set up and operate the GFC 7001E/EM  
Analyzer.  
ADVANCED FEATURES OF THE GFC 7001E/EM ANALYZER  
Step-by-Step instructions for using the GFC 7001E/EM Analyzer’s more advanced features such as the  
iDAS system, the DIAG and VARS menus and the and the TEST channel analog output.  
REMOTE OPERATION OF THE GFC 7001E/EM Analyzer  
Information and instructions for interacting with the GFC 7001E/EM Analyzer via its several remote  
interface options (e.g. via RS-232, Ethernet, its built in digital control inputs/outputs, etc.)  
GFC 7001E/EM VALIDATION AND VERIFICATION  
Methods and procedures for verifying the correct operation of your GFC 7001E/EM Analyzer as well as  
step by step instructions for calibrating it.  
EPA PROTOCOL CALIBRATION  
Specific information regarding calibration requirements for analyzers used in EPA monitoring.  
PART III – TECHNICAL INFORMATION  
THEORY OF OPERATION  
An in-depth look at the various principals by which the analyzer operates as well as a description of how  
the various electronic, mechanical and pneumatic components of the analyzer work and interact with  
each other. A close reading of this section is invaluable for understanding the analyzer’s operation.  
MAINTENANCE SCHEDULE AND PROCEDURES  
Description of preventative maintenance procedures that should be regularly performed on the analyzer  
to assure good operating condition.  
GENERAL TROUBLESHOOTING & REPAIR OF THE GFC 7001E/EM ANALYZER  
This section includes pointers and instructions for diagnosing problems with the analyzer in general and  
the Terminus as well as instructions on performing repairs of on the Terminus.  
A PRIMER ON ELECTRO-STATIC DISCHARGE  
This section describes how static electricity occurs; why it is a significant concern and; how to avoid it and  
avoid allowing ESD to affect the reliable and accurate operation of your analyzer.  
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 version-specific software menu trees, warning  
messages, definitions Modbus registers and serial I/O variables as well as spare part listings, repair  
questionnaires, interconnect drawing, detailed pneumatic and electronic schematics.  
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 the instrument.  
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Specifications  
Model GFC7001E Carbon Dioxide Analyzer  
2. SPECIFICATIONS AND APPROVALS  
2.1. SPECIFICATIONS  
Table 2-1: M 300E/300EM Basic Unit Specifications  
Ranges  
GFC 7001E: Min: 0-1 ppm; Max: 0-1000 ppm of Full Scale (User selectable)  
GFC 7001EM: Min: 0-5 ppm; Max: 0-5000 ppm of Full Scale (User selectable)  
Measurement Units  
GFC 7001E: ppb, ppm, µg/m3, mg/m3 (user selectable)  
GFC 7001EM: ppm, mg/m3 (user selectable)  
Zero Noise  
Span Noise  
GFC 7001E: < 0.02 ppm RMS1;  
GFC 7001E:<0.5% of rdg RMS over 5ppm1, 3  
over 20ppm  
GFC 7001EM: ≤ 0.1 ppm RMS  
;
GFC 7001EM:>0.5% of rdg RMS  
Lower Detectable Limit1  
Zero Drift (24 hours) 2  
Zero Drift (7 days) 2  
Span Drift (24 hour2s)  
Span Drift (7 days) 2  
Linearity  
GFC 7001E: < 0.04 ppm; GFC 7001EM: 0.2 ppm  
GFC 7001E: < 0.1 ppm; GFC 7001EM: <0.5 ppm  
GFC 7001E: < 0.2 ppm; GFC 7001EM: <1.0ppm  
The greater of < 0.5% of reading or 0.1ppm (GFC 7001E), 0.5ppm(GFC 7001EM)  
The greater of < 1% of reading or 0.5ppm (GFC 7001E), 1 ppm(GFC 7001EM)  
GFC 7001E: Better than 1% Full Scale5;  
GFC 7001EM: 0 - 3000 ppm: 1% full scale; 3000 - 5000 ppm: 2% full scale  
Precision  
GFC 7001E: The greater of 0.5% of reading or 0.2ppm;  
GFC 7001EM: The greater of 1.0% of reading or 1ppm  
Lag Time 1  
10 sec1  
Rise/Fall Time 1  
<60 sec to 95%1  
Sample Flow Rate  
800 cm3/min. ±10%  
O2 Sensor option adds 120 cm³/min to total flow though when installed  
Temperature Range  
Humidity Range  
Temp Coefficient  
Voltage Coefficient  
Dimensions (HxWxD)  
Weight  
5 - 40C operating, 10 - 40C EPA Equivalency (GFC 7001E only)  
0-95% RH, Non-Condensing  
< 0.05 % per C (minimum 50 ppb/C)  
< 0.05 % per V  
7" x 17" x 23.5" (178 mm x 432 mm x 597 mm)  
50 lb (22.7 kg)  
AC Power  
100V 50/60 Hz (3.25A), 115 V 60 Hz (3.0A),  
220 – 240 V 50/60 Hz (2.5A)  
Environmental Conditions  
Analog Outputs  
Installation Category (Over voltage Category) II Pollution Degree 2  
4 user configurable outputs  
Analog Output Ranges  
All Outputs: 0.1V, 1V, 5V or 10V  
Three outputs convertible to 4-20 mA isolated current loop.  
All Ranges with 5% under/over-range  
Analog Output Resolution  
Status Outputs  
Control Inputs  
1 part in 4096 of selected full-scale voltage  
8 Status outputs from opto-isolators  
6 Control Inputs, 2 defined, 4 spare  
Serial I/O  
One (1) RS-232/optional multidrop; One (1) RS-232/optional RS-485 (2 connecters in  
parallel)  
Baud Rate : 300 - 115200  
Alarm outputs (optional)  
Certifications  
2 opto-isolated alarm outputs and 2 dry contact alarm outputs  
USEPA: Reference Method Number EQOA-0992-087  
CE: EN61010-1:90 + A1:92 + A2:95, EN61326 - Class A  
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Specifications  
Model GFC7001E Carbon Dioxide Analyzer  
1 As defined by the USEPA  
2 At constant temperature and pressure  
2.2. EPA EQUIVALENCY DESIGNATION  
Teledyne’s GFC 7001E Carbon Monoxide Analyzer is designated as Reference Method Number EQOA-0992-  
087 as defined in 40 CFR Part 53, when operated under the following conditions:  
Range: Any range from 10 ppm to 50 ppm.  
Ambient temperature range of 10 to 40C.  
Line voltage range of 90 – 127 and 200 – 230 VAC, 50/60 Hz.  
Sample filter: Equipped with PTFE filter element in the internal filter assembly.  
Sample flow of 800 80 cm3/min at sea level.  
Internal sample pump.  
Software settings:  
Dilution factor  
AutoCal  
1.0  
ON or OFF  
ON or OFF  
OFF  
Dynamic Zero  
Dynamic Span  
Dual range  
ON or OFF  
ON or OFF  
ON  
Auto range  
Temp/Pres compensation  
Under the designation, the analyzer may be operated with or without the following options:  
Rack mount with slides.  
Rack mount without slides, ears only.  
Zero/span valve options.  
Option 50A – Sample/Cal valves, or;  
Option 50B – Sample/Cal valves with span shutoff & flow control.  
Internal zero/span (IZS) option with either:  
Option 51A – Sample/Cal valves, or;  
Option 51C – Sample/Cal valves with span shutoff & flow control.  
Status outputs.  
Control inputs.  
RS-232 output.  
Ethernet output.  
4-20mA, isolated output.  
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Specifications  
Model GFC7001E Carbon Dioxide Analyzer  
2.3. TUV DESIGNATION  
On behalf of Teledyne TÜV Rheinland Immissionsschutz und Energiesysteme GmbH has performed the  
suitability test of the measuring system GFC 7001E for the component carbon monoxide.  
The suitability test was carried out in compliance with the following guidelines and requirements:  
EN 14626 Ambient Air Quality – Standard method for the measurement of the concentration of carbon  
monoxide by nondispersive infrared spectroscopy, March 2005.  
The measuring system GFC 7001E operates using the non-dispersive infrared spectroscopy.  
The investigations have been carried out in the laboratory and during a field test, lasting three months. The  
tested measuring ranges are:  
Component  
Carbon Monoxide  
Measuring Range  
mg/m3  
EN 14626  
CO  
100  
NOTE: 0-100 ppm correlates to 0-100 µmol/mol or 0-116 mg/m3 (at 293 K and 1013  
mbar).  
The minimum requirements have been fulfilled in the suitability test.  
Therefore the TÜV Immissionsschutz and Energiesysteme GmbH proposes the publication as a suitability-tested  
measuring system for continuous monitoring of carbon monoxide in the ambient air.  
2.4. CE MARK COMPLIANCE  
2.4.1. EMISSIONS COMPLIANCE  
Teledyne’s GFC 7001E/EM Gas Filter Correlation CO Analyzer was tested and found to be fully compliant with:  
EN61326 (1997 w/A1: 98) Class A, FCC Part 15 Subpart B section 15.107 Class A, ICES-003 Class A (ANSI  
C63.4 1992) & AS/NZS 3548 (w/A1 & A2; 97) Class A.  
Tested on 11-29-2001 at CKC Laboratories, Inc., Report Number CE01-249.  
2.4.2. SAFETY COMPLIANCE  
Teledyne’s GFC 7001E/EM Gas Filter Correlation CO Analyzer was tested and found to be fully compliant with:  
IEC 61010-1:90 + A1:92 + A2:95,  
Tested on 02-06-2002 at NEMKO, Report Number 2002-012219.  
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Specifications  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
3. GETTING STARTED  
3.1. GFC 7001E/EM ANALYZER LAYOUT  
Figure 3-1:  
Front Panel Layout  
Table 3-1: Front Panel Nomenclature  
Name  
Significance  
Mode Field  
Displays the name of the analyzer’s current operating mode.  
Displays a variety of informational messages such as warning messages, operational data, test function  
values and response messages during interactive tasks.  
Message Field  
Concentration  
Field  
Displays the actual concentration of the sample gas currently being measured by the analyzer in the  
currently selected units of measure.  
Keypad  
Definition Field  
Displays dynamic, context sensitive definitions for the row of keys just below the display.  
STATUS LED’s  
Name  
Color  
State  
Definition  
Off  
Unit is not operating in sample mode, iDAS is disabled.  
On  
Sample Mode active; Front Panel Display being updated; iDAS data being stored.  
SAMPLE Green  
Blinking  
Unit is operating in sample mode, front panel display being updated, iDAS hold-off mode  
is ON, iDAS disabled  
Off  
Auto Cal disabled  
CAL  
Yellow  
Red  
On  
Auto Cal enabled  
Blinking  
Unit is in calibration mode  
Off  
Blinking  
No warnings exist  
Warnings exist  
FAULT  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
Figure 3-2:  
Rear Panel Layout  
Table 3-2: Inlet / Outlet Connector Nomenclature  
REAR PANEL LABEL  
FUNCTION  
Connect a gas line from the source of sample gas here.  
SAMPLE  
Calibration gases are also inlet here on units without zero/span/shutoff valve options  
installed.  
Connect an exhaust gas line of not more than 10 meters long here that leads outside  
the shelter or immediate area surrounding the instrument.  
EXHAUST  
On units with zero/span/shutoff valve options installed, connect a gas line to the source  
of calibrated span gas here.  
Pressure Span  
Span gas vent outlet for units with zero/span/shutoff valve options installed.  
Vent/Span  
IZS  
Connect an exhaust gas line of not more than 10 meters long here that leads outside  
the shelter or immediate area surrounding the instrument.  
Internal Zero Air: On units with zero/span/shutoff valve options installed but no internal  
zero air scrubber attach a gas line to the source of zero air here.  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
Figure 3-3:  
Internal Layout – GFC 7001E  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
Figure 3-4:  
Internal Layout – GFC 7001EM with CO2 and O2 Sensor Option  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
Sample Gas Outlet  
fitting  
Sample Gas Flow  
Sensor  
Sample Chamber  
Sync/Demod PCA  
Housing  
Pressure Sensor(s)  
Bench  
Temperature  
Thermistor  
Shock Absorbing  
Mounting Bracket  
Opto-Pickup  
PCA  
Purge Gas  
Pressure Regulator  
IR Source  
GFC Wheel  
Heat Sync  
GFC Wheel Motor  
GFC Temperature  
Sensor  
Purge Gas  
Inlet  
GFC Heater  
Figure 3-5:  
Optical Bench Layout  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
Figure 3-6:  
GFC 7001E/EM Internal Gas Flow (Basic Configuration)  
NOTE  
For pneumatic diagrams of GFC 7001E/EM Analyzer with various calibration valve options, see Section  
5.6.  
3.2. UNPACKING THE GFC 7001E/EM ANALYZER  
CAUTION  
GENERAL SAFETY HAZARD  
To avoid personal injury, always use two persons to lift and carry the GFC 7001E/EM.  
CAUTION  
ELECTRICAL SHOCK HAZARD  
Never disconnect PCAs, wiring harnesses or electronic subassemblies while under  
power.  
CAUTION – Avoid Warranty Invalidation  
Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to  
be felt by the human nervous system. Damage resulting from failure to use ESD  
protection when working with electronic assemblies will void the instrument warranty.  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
See A Primer on Electro-Static Discharge in this manual for more information on preventing  
ESD damage.  
NOTE  
It is recommended that you store shipping containers/materials for future use if/when the instrument should be  
returned to the factory for repair and/or calibration serivce. See Warranty section in this manual and shipping  
procedures on our Website at http://www.teledyne-api.com under Customer Support > Return Authorization.  
1. Verify that there is no apparent external shipping damage. If damage has occurred, please advise the  
shipper first, then Teledyne API.  
2. Included with your analyzer is a printed record (Final Test and Validation Data Sheet: GFC 7001E PN  
04307; GFC 7001EM PN 04311) of the final performance characterization performed on your  
instrument at the factory. This record 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 by:  
Removing the setscrew located in the top, center of the Front panel;  
Removing the two flat head, Phillips screws on the sides of the instrument (one per side towards the  
rear);  
Sliding the cover backwards until it clears the analyzer’s front bezel, and;  
Lifting the cover straight up.  
4. Inspect the interior of the instrument to make sure all circuit boards and other components are in good  
shape and properly seated.  
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.  
3.2.1. VENTILATION CLEARANCE  
Whether the analyzer is set up on a bench or installed into an instrument rack, be sure to leave sufficient  
ventilation clearance.  
Table 3-3: Ventilation Clearance  
AREA  
Back of the instrument  
MINIMUM REQUIRED CLEARANCE  
4 in.  
1 in.  
1 in.  
Sides of the instrument  
Above and below the instrument  
Various rack mount kits are available for this analyzer. See Section 5.2 of this manual for more information.  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
3.3. ELECTRICAL CONNECTIONS  
NOTE  
To maintain compliance with EMC standards, it is required that the cable length be no greater than 3 meters for  
all I/O connections, which include Analog In, Analog Out, Status Out, Control In, Ethernet/LAN, USB, RS-232,  
and RS-485.  
3.3.1. POWER CONNECTION  
Attach the power cord to the analyzer and plug it into a power outlet capable of carrying at least 10 A current at  
your AC voltage and that it is equipped with a functioning earth ground.  
CAUTION  
ELECTRICAL SHOCK HAZARD  
High Voltages are present inside the analyzer’s case.  
Power connection must have functioning ground connection.  
Do not defeat the ground wire on power plug.  
Turn off analyzer power before disconnecting or  
connecting electrical subassemblies.  
Do not operate with cover off.  
CAUTION  
GENERAL SAFETY HAZARD  
The GFC 7001E/EM Analyzer can be configured for both  
100-130 V and 210-240 V at either 47 Hz or 63 Hz.  
To avoid damage to your analyzer, make sure that the AC power voltage matches  
the voltage indicated on the analyzer’s serial number label tag (See Figure 3-2)  
before plugging the GFC 7001E/EM into line power.  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
3.3.2. ANALOG OUTPUT CONNECTIONS  
The GFC 7001E is equipped with several analog output channels accessible through a connector on the back  
panel of the instrument. The standard configuration for these outputs is mVDC. An optional current loop output  
is available for each.  
When the instrument is in its default configuration, channels A1 and A2 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.  
Output A3 is only used on the GFC 7001E/EM if the optional CO2 or O2 sensor is installed.  
Channel A4 is special. It can be set by the user (see Section 7.4.6) to output any one of the parameters  
accessible through the <TST TST> keys of the units sample display.  
To access these signals attach a strip chart recorder and/or data-logger to the appropriate analog output  
connections on the rear panel of the analyzer.  
ANALOG OUT  
A1  
A2  
A3  
A4  
+
-
+
-
+
-
+
-
Figure 3-7:  
Analog Output Connector  
Table 3-4: Analog Output Pin-Outs  
PIN  
1
ANALOG OUTPUT  
VOLTAGE SIGNAL  
V Out  
CURRENT SIGNAL  
I Out +  
A1  
A2  
2
Ground  
I Out -  
3
V Out  
I Out +  
4
Ground  
I Out -  
5
A3  
V Out  
I Out +  
(Only used if CO2 or  
O2 Sensor is  
installed)  
6
Ground  
I Out -  
7
8
V Out  
I Out +  
I Out -  
A4  
Ground  
3.3.3. CONNECTING THE 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 (PLCs). 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.  
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Getting Started  
Model GFC7001E Carbon Dioxide Analyzer  
The status outputs are accessed via a 12-pin connector on the analyzer’s rear panel labeled STATUS (see  
Figure 3-2). Pin-outs for this connector are:  
STATUS  
1
2
3
4
5
6
7
8
D
+
Figure 3-8:  
Status Output Connector  
Table 3-5: Status Output Signals  
REAR PANEL  
LABEL  
STATUS  
DEFINITION  
CONDITION  
1
SYSTEM OK  
ON if no faults are present.  
OFF any time the HOLD OFF feature is active, such as during calibration or when  
other faults exist possibly invalidating the current concentration measurement  
(example: sample flow rate is outside of acceptable limits).  
2
CONC VALID  
ON if concentration measurement is valid.  
3
4
5
6
HIGH RANGE  
ZERO CAL  
ON if unit is in high range of either the DUAL or AUTO range modes.  
ON whenever the instrument’s ZERO point is being calibrated.  
ON whenever the instrument’s SPAN point is being calibrated.  
ON whenever the instrument is in DIAGNOSTIC mode.  
SPAN CAL  
DIAG MODE  
If this analyzer is equipped with an optional CO2 sensor, this Output is ON when that  
sensor is in calibration mode.  
7
CO2 CAL  
O2 CAL  
Otherwise this output is unused.  
If this analyzer is equipped with an optional O2 sensor, this Output is ON when that  
sensor is in calibration mode.  
8
Otherwise this output is unused.  
D
EMITTER BUS  
SPARE  
The emitters of the transistors on pins 1-8 are bussed together.  
+
DC POWER  
+ 5 VDC, 300 mA source (combined rating with Control Output, if used).  
The ground level from the analyzer’s internal DC power supplies.  
Digital Ground  
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3.3.4. CONNECTING THE CONTROL INPUTS  
If you wish to use the analyzer to remotely activate the zero and span calibration modes, several digital control  
inputs are provided through a 10-pin connector labeled CONTROL IN on the analyzer’s rear panel.  
There are two methods for energizing the control inputs. The internal +5V available from the pin labeled “+” is  
the most convenient method. However, if full isolation is required, an external 5 VDC power supply should be  
used.  
CONTROL IN  
CONTROL IN  
A
B
C
D
E
F
U
+
A
B
C
D
E
F
U
+
5 VDC Power  
Supply  
+
-
External Power Connections  
Local Power Connections  
Figure 3-9:  
Control Input Connector  
Table 3-6: Control Input Signals  
INPUT #  
STATUS DEFINITION  
ON CONDITION  
The analyzer is placed in Zero Calibration mode. The mode field of the  
display will read ZERO CAL R.  
A
REMOTE ZERO CAL  
The analyzer is placed in span calibration mode as part of performing a low  
B
C
REMOTE SPAN CAL  
span (midpoint) calibration. The mode field of the display will read LO CAL  
R.  
The analyzer is forced into high range for zero or span calibrations. This  
only applies when the range mode is either DUAL or AUTO. The mode field  
of the display will read HI CAL R.  
REMOTE CAL HIGH  
RANGE  
D, E  
& F  
SPARE  
The ground level from the analyzer’s internal DC power supplies (same as  
chassis ground).  
Digital Ground  
U
+
External Power input  
Input pin for +5 VDC required to activate pins A – F.  
Internally generated 5V DC power. To activate inputs A – F, place a jumper  
between this pin and the “U” pin. The maximum amperage through this port  
is 300 mA (combined with the analog output supply, if used).  
5 VDC output  
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3.3.5. CONNECTING THE SERIAL PORTS  
If you wish to utilize either of the analyzer’s two serial interface COMM ports, refer to Section 8 for instructions on  
their configuration and usage.  
3.3.6. CONNECTING TO A LAN OR THE INTERNET  
If your unit has a Teledyne’s Ethernet card, plug one end into the 7’ CAT5 cable supplied with the option into the  
appropriate place on the back of the analyzer and the other end into any nearby Ethernet access port.  
NOTE  
The GFC 7001E/EM firmware supports dynamic IP addressing or DHCP.  
If your network also supports DHCP, the analyzer will automatically configure its LAN connection  
appropriately (see Section 8.4.2).  
If your network does not support DHCP, see Section 8.4.3 for instructions on manually configuring the  
LAN connection.  
3.3.7. CONNECTING TO A MULTIDROP NETWORK  
If your unit has a Teledyne’s RS-232 multidrop card, see Section 8.2 for instructions on setting it up.  
3.4. PNEUMATIC CONNECTIONS  
CAUTION  
GENERAL SAFETY HAZARD  
CARBON MONOXIDE (CO) IS A TOXIC GAS.  
Obtain a Material Safety Data Sheet (MSDS) for this material. Read and rigorously  
follow the safety guidelines described there.  
Do not vent calibration gas and sample gas into enclosed areas.  
3.4.1. CALIBRATION GASES  
3.4.1.1. Zero Air  
Zero air is a gas that is similar in chemical composition to the earth’s atmosphere but scrubbed of all  
components that might affect the analyzers readings, in this case CO and water vapor. If your analyzer is  
equipped with an IZS or External Zero Air scrubber option, it is capable of creating zero air.  
If the analyzer is NOT equipped with the optional CO2 sensor, zero air should be scrubbed of CO2 as well  
as this gas can also have an interfering effect on CO measurements.  
For analyzers without an IZS or external zero air scrubber option, a zero air generator such as the  
Teledyne’s M701 can be used.  
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3.4.1.2. Span Gas  
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. In the case of CO measurements made  
with the GFC 7001E/EM Analyzer, it is recommended that you use a span gas with a CO concentration  
equal to 80-90% of the measurement range for your application.  
EXAMPLE: If the application is to measure between 0 ppm and 500 ppb, an appropriate span gas  
concentration would be 400-450 ppb CO in N2.  
Some applications, such as EPA monitoring, require a multipoint calibration procedure where span gases  
of different concentrations are needed. We recommend using a bottle of calibrated CO gas of higher  
concentration in conjunction with a gas dilution calibrator such as a Teledyne’s M700. This type of  
calibrator precisely mixes a high concentration gas with zero air (both supplied externally) to accurately  
produce span gas of the correct concentration. Linearity profiles can be automated with this model and  
run unattended over night.  
Cylinders of calibrated CO gas traceable to NIST-Standard Reference Material specifications (also  
referred to as SRMs or EPA protocol calibration gases) are commercially available. Table 3-7 lists specific  
NIST-SRM reference numbers for various concentrations of CO.  
Table 3-7: NIST-SRM's Available for Traceability of CO Calibration Gases  
NOMINAL  
NIST-SRM  
TYPE  
CONCENTRATION  
1680b  
1681b  
2613a  
2614a  
2659a1  
2626a  
2745*  
CO in N2  
CO in N2  
500 ppm  
1000 ppm  
CO in Zero Air  
CO in Zero Air  
O2 in N2  
20 ppm  
45 ppm  
21% by weight  
4% by weight  
16% by weight  
CO2 in N2  
CO2 in N2  
1 Used to calibrate optional O2 sensor.  
2 Used to calibrate optional CO2 sensor.  
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3.4.2. PNEUMATIC CONNECTIONS TO GFC 7001E/EM BASIC  
CONFIGURATION  
NOTE  
In 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.  
See Figure 3-2 and Table 3-2 for the location and descriptions of the various pneumatic inlets/outlets referred to  
in this section.  
See Section 5.6 for information regarding the pneumatic setup of GFC 7001E/EM Analyzers with various optional  
calibration valve options in stalled  
CAUTION  
GENERAL SAFETY HAZARD  
Sample and calibration gases should only come into contact with PTFE (Teflon), FEP,  
glass, stainless steel or brass.  
The exhaust from the analyzer’s internal pump MUST be vented outside the immediate  
area or shelter surrounding the instrument.  
It is important to conform to all safety requirements regarding exposure to CO.  
Figure 3-10:  
Pneumatic Connections–Basic Configuration–Using Bottled Span Gas  
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Figure 3-11:  
Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator  
3.4.2.1. Sample Gas Source  
Attach a sample inlet line to the SAMPLE inlet port. The sample input line should not be more than 2 meters  
long.  
Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure  
and ideally should equal ambient atmospheric pressure.  
In applications where the sample gas is received from a pressurized manifold, a vent must be placed on  
the sample gas before it enters the analyzer.  
3.4.2.2. Calibration Gas Sources  
The source of calibration gas is also attached to the SAMPLE inlet, but only when a calibration operation is  
actually being performed.  
NOTE  
Zero air and span gas inlets should supply their respective gases in excess of the 800 cc3/min demand  
of the analyzer.  
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3.4.2.3. Input Gas Venting  
The span gas, zero air supply and sample gas line MUST be vented in order to ensure that the gases input do  
not exceed the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects.  
These vents should be:  
At least 0.2m long;  
No more than 2m long and;  
Vented outside the shelter or immediate area surrounding the instrument.  
3.4.2.4. Exhaust Outlet  
Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:  
PTEF tubing; minimum O.D ¼”;  
A maximum of 10 meters long;  
Vented outside the GFC 7001E/EM Analyzer’s enclosure.  
NOTE  
Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks  
using the procedures defined in Section 12.3.3.  
NOTE  
For information on attaching gas lines to GFC 7001E/EM Analyzers with various calibration valve  
options,  
see Section 5.6.  
3.5. INITIAL OPERATION  
NOTE  
The analyzer’s cover must be installed to ensure that the temperatures of the GFC Wheel and absorption  
cell assemblies are properly controlled.  
If you are unfamiliar with the GFC 7001E/EM theory of operation, we recommend that you read Section Error!  
Reference source not found.. For information on navigating the analyzer’s software menus, see the menu  
trees described in Appendix A.1.  
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3.5.1. STARTUP  
After the electrical and pneumatic connections are made, turn on the instrument. The pump and exhaust fan  
should start immediately. 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, astring of messages will appear on the analyzer’s front panel display.  
System waits 3 seconds then  
automatically begins its  
initialization routine.  
.
System is checking the validity and  
functionality of the Terminus  
memory and firmware.  
If at this point,  
appears, contact Teledyne  
Instruments customer service.  
The instrument is loading  
configuration and calibration data  
from the flash chip.  
The instrument is loading the  
system firmware.  
The startup process may hesitate at this point if:  
· The Ethernet option is installed;  
· DHCP mode is turned on and;  
· The instrument is not connected to a  
functioning network.  
The analyzer should automatically switch to Sample Mode after completing the boot-up sequence and start  
monitoring CO gas.  
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3.5.2. WARM UP  
The GFC 7001E/EM requires about 60 minutes warm-up time before reliable CO measurements can be taken.  
During that time, various portions of the instrument’s front panel will behave as shown in Table 3-8. See Figure  
3-1 for the layout.  
Table 3-8: Front Panel Display during System Warm-Up  
NAME  
COLOR  
BEHAVIOR  
SIGNIFICANCE  
Displays current,  
compensated CO  
Concentration  
Concentration  
Field  
N/A  
This is normal operation.  
Displays blinking  
“SAMPLE”  
Instrument is in sample mode but is still in the process of  
warming up. (iDAS holdoff period is active)  
Mode Field  
N/A  
STATUS LED’s  
Unit is operating in sample mode; front panel display is being  
updated.  
Sample  
Cal  
Green  
Yellow  
Red  
On  
Flashes On/Off when adaptive filter is active  
Off  
The instrument’s calibration is not enabled.  
The analyzer is warming up and hence out of specification  
for a fault-free reading. Various warning messages will  
appear.  
Fault  
Blinking  
3.5.3. WARNING MESSAGES  
Because internal temperatures and other conditions may be outside the 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 60 minutes warm-up period is over, investigate their cause using the troubleshooting  
guidelines in Section Error! Reference source not found..  
To view and clear warning messages, press:  
Table 3-6 lists brief descriptions of the warning messages that may occur during start up.  
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Table 3-9: Possible Warning Messages at Start-Up  
Message  
MEANING  
ANALOG CAL WARNING  
BENCH TEMP WARNING  
The instrument's A/D circuitry or one of its analog outputs is not calibrated.  
Optical bench temperature is outside the specified limits.  
The temperature inside the GFC 7001E/EM chassis is outside the specified  
limits.  
BOX TEMP WARNING  
CANNOT DYN SPAN2  
CANNOT DYN ZERO3  
Remote span calibration failed while the dynamic span feature was set to  
turned on.  
Remote zero calibration failed while the dynamic zero feature was set to turned  
on.  
CONFIG INITIALIZED  
DATA INITIALIZED  
Configuration was reset to factory defaults or was erased.  
iDAS data storage was erased.  
FRONT PANEL WARN  
CPU is unable to communicate with the front panel.  
Photometer temperature outside of warning limits specified by  
PHOTO_TEMP_SET variable.  
PHOTO TEMP WARNING  
REAR BOARD NOT DET  
RELAY BOARD WARN  
SAMPLE FLOW WARN  
SAMPLE PRESS WARN  
SAMPLE TEMP WARN  
SOURCE WARNING  
Motherboard was not detected during power up.  
CPU is unable to communicate with the relay PCA.  
The flow rate of the sample gas is outside the specified limits.  
Sample pressure outside of operational parameters.  
The temperature of the sample gas is outside the specified limits.  
The IR source may be faulty.  
SYSTEM RESET1  
The computer was rebooted.  
WHEEL TEMP WARNING  
The Gas Filter Correlation Wheel temperature is outside the specified limits.  
1
2
3
Clears 45 minutes after power up.  
Clears the next time successful zero calibration is performed.  
Clears the next time successful span calibration is performed.  
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3.5.4. FUNCTIONAL CHECK  
After the analyzer’s components have warmed up for at least 60 minutes, verify that the software properly  
supports any hardware options that were installed.  
For information on navigating through the analyzer’s software menus, see the menu trees described in  
Appendix A.1.  
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 panel as well as their  
expected values.  
These functions are also useful tools for diagnosing performance problems with your analyzer (see  
Section 13.1.2).  
The enclosed Final Test and Validation Data Sheet (P/N 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 that until the unit has completed its warm-up these parameters may not have stabilized.  
If your analyzer has an Ethernet card 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 8.4.2).  
If your network is not running DHCP, you will have to configure the analyzer’s interface manually (See  
Section 8.4.3).  
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3.6. INITIAL CALIBRATION OF THE GFC 7001E/EM  
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 3.4 for instructions for connecting these gas sources.  
The initial calibration should be carried out using the same reporting range set up as used during the analyzer’s  
factory calibration. This will allow you to compare your calibration results to the factory calibration as listed on  
the Final Test and Validation Data Sheet.  
If both available iDAS parameters for a specific gas type are being reported via the instruments analog outputs  
e.g. CONC1 and CONC2 when the DUAL range mode is activated, separate calibrations should be carried out  
for each parameter.  
Use the LOW button when calibrating for CONC1 (equivalent to RANGE1).  
Use the HIGH button when calibrating for CONC2 (equivalent to RANGE2).  
See Manual Addendum, P/N 06270 for more information on the configurable analog output reporting ranges.  
NOTE  
The following procedure assumes that the instrument does not have any of the available Valve Options  
installed.  
See Section 9.3 for instructions for calibrating instruments possessing valve options.  
3.6.1. INTERFERENTS FOR CO2 MEASUREMENTS  
It should be noted that the gas filter correlation method for detecting CO is subject to interference from a number  
of other gases that absorb IR in a similar fashion to CO. Most notable of these are water vapor, CO2, N2O  
(nitrous oxide) and CH4 (methane). The GFC 7001E/EM has been successfully tested for its ability to reject  
interference from of these sources, however high concentrations of these gases can interfere with the  
instrument’s ability to make low-level CO measurements.  
For a more detailed discussion of this topic, see Section 11.2.1.3.  
3.6.2. INITIAL CALIBRATION PROCEDURE FOR GFC 7001E/EM  
ANALYZERS WITHOUT OPTIONS  
The following procedure assumes that:  
The instrument DOES NOT have any of the available calibration valve or gas inlet options installed;  
Cal gas will be supplied through the SAMPLE gas inlet on the back of the analyzer (see Figure 3-2), and;  
The pneumatic setup matches that described in Section 3.4.2.  
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3.6.2.1. Verifying the GFC 7001E/EM Reporting Range Settings  
While it is possible to perform the following procedure with any range setting we recommend that you perform  
this initial checkout using following reporting range settings:  
Unit of Measure: PPM  
Analog Output Reporting Range: 50 ppm  
Mode Setting: SNGL  
While these are the default setting for the GFC 7001E/EM Analyzer, it is recommended that you verify them  
before proceeding with the calibration procedure, by pressing:  
SAMPLE  
RANGE=50.0 PPM  
CO= XX.XX  
SETUP  
<TST TST> CAL  
SETUP X.X  
PRIMARY SETUP MENU  
CFG DAS RNGE PASS CLK MORE  
EXIT  
EXIT  
SETUP X.X  
RANGE CONTROL MENU  
MODE SET UNIT DIL  
Verify that the MODE  
SETUP X.X  
RANGE MODE:SINGL  
is set for SNGL.  
SNGL DUAL AUTO  
ENTR EXIT  
If it is not, press  
SINGL ENTR.  
SETUP X.X  
RANGE CONTROL MENU  
MODE SET UNIT DIL  
EXIT  
Verify that the RANGE is  
set for 50.0  
SETUP X.X RANGE: 50.0 Conc  
If it is not, toggle each  
numeric key until the  
proper range is set, then  
press ENTR.  
0
0
0
5
0
.0 ENTR EXIT  
Press EXIT  
3x’s to return  
the M200E to  
the SAMPLE  
mode.  
SETUP X.X  
RANGE CONTROL MENU  
MODE SET UNIT DIL  
EXIT  
Verify that the UNITs  
SETUP X.X  
CONC UNITS:PPM  
is set for PPM  
PPB PPM UGM MGM  
ENTR EXIT  
If it is not, press  
PPM ENTR.  
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3.6.2.2. Dilution Ratio Set Up  
If the dilution ration option is enabled on your GFC 7001E/EM Analyzer and your application involves diluting the  
sample gas before it enters the analyzer, set the dilution ration as follows:  
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3.6.2.3. Set CO Span Gas Concentration  
Set the expected CO pan gas concentration. This should be 80-90% of range of concentration range for which  
the analyzer’s analog output range is set.  
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3.6.2.4. Zero/Span Calibration  
To perform the zero/span calibration procedure, press:  
SAMPLE  
RANGE=0.0 PPm  
CAL  
CO= XX.XX  
Set the Display to show  
the STABIL test function.  
This function calculates  
the stability of the CO  
measurement.  
< TST TST >  
SETUP  
Toggle TST> button until ...  
SAMPLE  
STABIL= XXXX PPM  
CO=XX.XX  
SETUP  
< TST TST >  
CAL  
Allow zero gas to enter the sample port  
at the rear of the analyzer.  
Wait until STABIL  
falls below 0.5 ppm.  
This may take several  
minutes.  
SAMPLE  
STABIL= XXXX PPM  
CAL  
CO=XX.XX  
SETUP  
< TST TST >  
Press ENTR to changes  
the OFFSET & SLOPE  
values for the CO  
M-P CAL  
STABIL= XXXX PPM  
CO=XX.XX  
<TST TST> ZERO CONC  
EXIT  
measurements.  
Press EXIT to leave the  
calibration unchanged and  
return to the previous  
menu.  
M-P CAL  
STABIL= XXXX PPM  
CO=XX.XX  
<TST TST> ENTR  
CONC  
EXIT  
Allow span gas to enter the sample port  
at the rear of the analyzer.  
Wait until STABIL  
falls below 0.5 PPM.  
This may take several  
minutes.  
SAMPLE  
STABIL= XXXX PPM  
CAL  
CO=XX.XX  
SETUP  
< TST TST >  
The SPAN key now appears  
during the transition from  
zero to span.  
Press ENTR to changes  
the OFFSET & SLOPE  
values for the CO  
M-P CAL  
STABIL= XXXX PPM  
CO=XX.XX  
EXIT  
You may see both keys.  
If either the ZERO or SPAN  
buttons fail to appear see the  
Troubleshooting section for  
tips.  
<TST TST> ZERO SPAN CONC  
measurements.  
Press EXIT to leave the  
calibration unchanged and  
return to the previous  
menu.  
M-P CAL  
STABIL= XXXX PPM  
CONC  
CO=XX.XX  
EXIT  
<TST TST> ENTR  
M-P CAL  
STABIL= XXXX PPM  
CONC  
CO=XX.XX  
EXIT  
EXIT at this point  
returns to the  
SAMPLE menu.  
<TST TST> ENTR  
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3.6.3. O2 SENSOR CALIBRATION PROCEDURE  
If your GFC 7001E/EM is equipped with the optional O2 sensor, this sensor should be calibrated during  
installation of the instrument. See Section 9.7.1 for instructions.  
3.6.4. CO2 SENSOR CALIBRATION PROCEDURE  
If your GFC 7001E/EM is equipped with the optional CO2 sensor, this sensor should be calibrated during  
installation of the instrument. See Section 9.7.2 for instructions.  
The GFC 7001E/EM Analyzer is now ready for operation  
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 API.  
This information is vital to our efforts in continuously improving our service and our products.  
THANK YOU.  
.
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4. FREQUENTLY ASKED QUESTIONS  
4.1. FAQ’S  
The following is a list from the Teledyne’s Customer Service Department of the most commonly asked questions  
relating to the GFC 7001E/EM CO Analyzer.  
Q: 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 hold off period of more than 20 minutes).  
Once you adjust the setting in question to an allowable value, the ENTR key will re-appear.  
Q: Why is the ZERO or SPAN key not displayed during calibration?  
A: The GFC 7001E/EM disables certain these keys expected span or zero value entered by the users is too  
different from the gas concentration actually measured value at the time. This is to prevent the accidental  
recalibration of the analyzer to an out-of-range response curve.  
EXAMPLE: The span set point is 40 ppm but gas concentration being measured is only 5 ppm.  
For more information, see Sections 13.3.3 and 13.3.4.  
Q: How do I enter or change the value of my Span Gas?  
A: Press the CONC key found under the CAL or CALS buttons of the main SAMPLE display menus to enter  
the expected CO span concentration.  
See Section 3.6.2.3 or Zero/Span Calibration3.6.2.4 for more information.  
Q: Why does the analyzer not respond to span gas?  
A: Section 13.3.3 has some possible answers to this question.  
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’s Service Department  
for more information on this topic.  
Q: What do I do if the concentration on the instrument's front panel display does not match the value recorded or  
displayed on my data logger even if both instruments are properly calibrated?  
A: This most commonly occurs for one of the following reasons:  
A difference in circuit ground between the analyzer and the data logger or a wiring problem;  
A scale problem with the input to the data logger.  
The analog outputs of the GFC 7001E/EM can be manually adjusted to compensate for either or both of  
these effects, see Section 7.4.5;  
The analog outputs are not calibrated, which can happen after a firmware upgrade.  
Both the electronic scale and offset of the analog outputs can be adjusted (see Section 7.4.3).  
Alternately, use the data logger itself as the metering device during calibrations procedures.  
Q: How do I perform a leak check?  
A: See Section 12.3.3.  
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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 cm3/min  
10%. See Section 12.3.4.  
Q: How long does the IR source last?  
A: Typical lifetime is about 2-3 years.  
Q: Can I automate the calibration of my analyzer?  
A: Any analyzer with zero/span valve or IZS option can be automatically calibrated using the instrument’s  
AutoCal feature. The setup of this option is located in Section 9.4.  
Q: Can I use the IZS option to calibrate the analyzer?  
A: Yes. However, whereas this may be acceptable for basic calibration checks, the IZS option is not  
permitted as a calibration source in applications following US EPA protocols.  
To achieve highest accuracy, it is recommended to use cylinders of calibrated span gases in combination  
with a zero air source.  
Q: My analyzer has the optional, user-configurable analog output channels. How do I program and use them?  
A: Instructions for this can be found in Appendix E .  
Q: What is the averaging time for an GFC 7001E/EM?  
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 11.5.12 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  
Term  
10BaseT  
Description/Definition  
An Ethernet standard that uses twisted (“T”) pairs of copper wires to transmit at  
10 megabits per second (Mbps).  
100BaseT  
Same as 10BaseT except ten times faster (100 Mbps).  
APICOM  
ASSY  
cm3  
Name of a remote control program offered by Teledyne to its customers.  
Assembly.  
metric abbreviation for cubic centimeter. Same as the obsolete abbreviation “cc”.  
Chemical formulas that may be included in this document:  
CO2  
C3H8  
CH4  
H2O  
HC  
carbon dioxide  
propane  
methane  
water vapor  
general abbreviation for hydrocarbon  
nitric acid  
HNO3  
H2S  
NO  
hydrogen sulfide  
nitric oxide  
NO2  
nitrogen dioxide  
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Term  
Description/Definition  
NOX  
nitrogen oxides, here defined as the sum of NO and NO2  
NOy  
nitrogen oxides, often called odd nitrogen. The sum of NO, NO2 (NOX) plus other  
compounds such as HNO3 Definitions vary widely and may include nitrate (NO3), PAN,  
N2O and other compounds.  
NH3  
O2  
ammonia  
molecular oxygen  
ozone  
O3  
SO2  
sulfur dioxide  
DAS  
Data Acquisition System  
DIAG  
DHCP  
Diagnostics, the diagnostic settings of the analyzer.  
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  
DOM  
DOS  
Disk On Module, the analyzer’s central storage area for analyzer firmware,  
configuration settings and data This is a 44-pin IDE flash disk that can hold up to  
128MB.  
Disk Operating System  
DRAM  
Dynamic Random Access Memory  
Digital Research DOS  
DR-DOS  
Ethernet  
a standardized (IEEE 802.3) computer networking technology for local area  
networks (LANs), facilitating communication and sharing resources  
FLASH  
GFC  
flash memory is non-volatile, solid-state memory  
Gas Filter Correlation  
I2C bus  
a clocked, bi-directional, serial bus for communication between individual  
analyzer components  
IC  
Integrated Circuit, a modern, semi-conductor circuit that can contain many basic  
components such as resistors, transistors, capacitors etc in a miniaturized  
package used in electronic assemblies  
IP  
Internet Protocol  
IZS  
Internal Zero Span  
LAN  
Local Area Network  
LCD  
LED  
Liquid Crystal Display  
Light Emitting Diode  
LPM  
M/R  
Liters Per Minute  
Measure/Reference  
NDIR  
NIST-SRM  
Non-Dispersive Infrared.  
National Institute of Standards and Technology - Standard Reference Material.  
PC  
Printed Circuit Assembly, the PCB with electronic components, ready to use  
PC/AT  
Personal Computer / Advanced Technology.  
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Term  
Description/Definition  
PCB  
Printed Circuit Board, the bare board without electronic component.  
PLC  
PFA  
Programmable Logic Controller, a device that is used to control instruments  
based on a logic level signal coming from the analyzer  
Per-Fluoro-Alkoxy, an inert polymer. One of the polymers that du Pont markets  
as Teflon®  
PLD  
PLL  
Programmable Logic Device  
Phase Lock Loop  
PMT  
Photo Multiplier Tube, a vacuum tube of electrodes that multiply electrons  
collected and charged to create a detectable current signal  
P/N (or PN)  
PSD  
Part Number  
Prevention of Significant Deterioration  
PTFE  
Poly-Tetra-Fluoro-Ethylene, a very inert polymer material used to handle gases  
that may react on other surfaces One of the polymers that du Pont markets as  
Teflon®  
PVC  
Poly Vinyl Chloride, a polymer used for downstream tubing  
Rdg  
Reading.  
RS-232  
specification and standard describing a serial communication method between  
two devices, DTE (Data Terminal Equipment) and DCE (Data Circuit-terminating  
Equipment), using a maximum cable-length of 50 feet.  
RS-485  
specification and standard describing a binary serial communication method  
among multiple devices at a data rate faster than RS-232 with a much longer  
distance between the host and the furthest device.  
SAROAD  
SLAMS  
SLPM  
Storage and Retrieval of Aerometric Data.  
State and Local Air Monitoring Network Plan.  
Standard Liters Per Minute; liters per minute of a gas at standard temperature  
and pressure.  
STP  
Standard Temperature and Pressure.  
TCP/IP  
Transfer Control Protocol / Internet Protocol, the standard communications  
protocol for Ethernet devices.  
TEC  
USB  
Thermal Electric Cooler.  
Universal Serial Bus is a standard connection method to establish  
communication between peripheral devices and a host controller, such as a  
mouse and/or keyboard and a personal computer.  
VARS  
Z/S  
Variables, the variable settings of the analyzer.  
Zero / Span.  
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5. OPTIONAL HARDWARE AND SOFTWARE  
This includes a brief description of the hardware and software options available for the GFC 7001E/EM Gas  
Filter Correlation Carbon Monoxide Analyzer. For assistance with ordering these options please contact the  
Sales department of Teledyne Analytical Instruments at:  
TELEDYNE ELECTRONIC TECHNOLOGIES  
Analytical Instruments  
16830 Chestnut Street  
City of Industry, CA 91748  
Telephone: (626) 934-1500  
Fax: (626) 961-2538  
Web: www.teledyne-ai.com  
5.1. EXTERNAL PUMPS (OPTIONS 10A-10E, 11, 13)  
A variety of optional pumps are available for the GFC 7001E/EM Analyzer. The range of available pump options  
meets all typical AC power supply standards while exhibiting the same pneumatic performance.  
OPTION  
DESCRIPTION  
NUMBER  
10A  
10B  
10C  
10D  
10E  
11  
External Pump 115V @ 60 Hz  
External Pump 220V @ 50 Hz  
External Pump 220V @ 60 Hz  
External Pump 100V @ 50 Hz  
External Pump 100V @ 60 Hz  
Pumpless, external Pump Pack/Rack  
High Voltage Internal Pump 240V/50Hz  
13  
5.2. RACK MOUNT KITS (OPT 20 TO OPT 23)  
There are several options for mounting the analyzer in standard 19” racks. The slides are three-part extensions,  
one mounts to the rack, one mounts to the analyzer chassis and the middle part remains on the rack slide when  
the analyzer is taken out. The analyzer locks into place when fully extended and cannot be pulled out without  
pushing two buttons, one on each side.  
The rack mount brackets for the analyzer require that you have a support structure in your rack to support the  
weight of the analyzer. The brackets cannot carry the full weight of an analyzer and are meant only to fix the  
analyzer to the front of a rack, preventing it from sliding out of the rack accidentally.  
OPTION NUMBER  
DESCRIPTION  
Rack mount brackets with 26 in. chassis slides.  
Rack mount brackets with 24 in. chassis slides.  
Rack mount brackets only.  
20A  
20B  
21  
23  
Rack Mount for External Pump Pack (No Slides).  
Each of these options permits the analyzer to be mounted in a standard 19" x 30" RETMA rack.  
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5.3. CARRYING STRAP/HANDLE (OPT 29)  
The chassis of the GFC 7001E/EM Analyzer allows the user to attach a strap handle for carrying the instrument.  
The handle is located on the right side and pulls out to accommodate a hand for transport. When pushed in, the  
handle is nearly flush with the chassis, only protruding out about 9 mm (3/8”).  
Figure 5-1:  
GFC 7001E/EM with Carrying Strap Handle and Rack Mount Brackets  
Installing the strap handle prevents the use of the rack mount slides, although the rack mount brackets, Option  
21, can still be used.  
CAUTION  
GENERAL SAFETY HAZARD  
A fully configured GFC 7001E/EM with valve options weighs about 23 kg (51 pounds).  
To avoid personal injury we recommend two persons lift and carry the analyzer.  
Ensure to disconnect all cables and tubing from the analyzer before carrying it.  
5.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41)  
The current loop option adds isolated, voltage-to-current conversion circuitry to the analyzer’s analog outputs. It  
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,  
This option may be ordered separately for three of the analog outputs and can be installed as a retrofit.  
Figure 5-2 provides installation instructions and illustrates a sample combination of one current output and two  
voltage outputs configuration. Section 5.4.1 provides instructions for converting current loop analog outputs to  
standard 0-to-5 VDC outputs. Information on calibrating or adjusting these outputs can be found in Section  
7.4.3.5.  
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Figure 5-2:  
Current Loop Option Installed on the Motherboard  
5.4.1. CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD  
VOLTAGE OUTPUTS  
NOTE  
Servicing or handling of circuit components requires electrostatic discharge protection, i.e. ESD  
grounding straps, mats and containers. Failure to use ESD protection when working with electronic  
assemblies will void the instrument warranty.  
See Section 14 for more information on preventing ESD damage.  
To convert an output configured for current loop operation to the standard 0 to 5 VDC output operation:  
1. Turn off power to the analyzer.  
2. If a recording device was connected to the output being modified, disconnect it.  
3. Remove the top cover.  
Remove the screw located in the top, center of the front panel.  
Remove the screws on both sides that fasten the top cover to the unit.  
Slide the cover back and lift straight up.  
4. Remove the screw holding the current loop option to the motherboard.  
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5. Disconnect the current loop option PCA from the appropriate connector on the motherboard (see Figure  
5-2).  
6. Each connector, J19 and J23, requires two shunts. Place one shunt on the two left most pins and the  
second shunt on the two pins next to it (see Figure 5-2).  
6 spare shunts (P/N CN0000132) were shipped with the instrument attached to JP1 on the back of  
the instruments keyboard and display PCA.  
7. Reattach the top case to the analyzer.  
8. The analyzer is now ready to have a voltage-sensing, recording device attached to that output.  
9. Calibrate the analog output as described in Section 7.4.3.  
5.5. EXPENDABLES AND SPARES KITS (OPTIONS 42A, 45)  
Expendables Kit, Option 42A: one-year supply of replacement particulate filters (47mm diameter)  
Spares Kit, Option 45: spare parts for one unit  
5.6. CALIBRATION VALVES (OPTIONS 50A, 50B, 50E, 50H)  
The GFC 7001E/EM Gas Filter Correlation Carbon Monoxide Analyzer has a variety of available options  
involving various valves for controlling the flow of calibration gases. From an operational and software  
standpoint, all of the options are the same, only the source of the span and zero gases are different.  
5.6.1. GENERAL INFORMATION RELATED TO ALL VALVE OPTIONS  
5.6.1.1. Gas Flow Rate  
The minimum span gas flow rate required is 800 cm3/min; however, the US EPA recommends that there  
be an excess of flow at least 800 cm3/min of calibration gas.  
Zero air will be supplied at ambient pressure from the local atmosphere.  
5.6.1.2. Valve Control  
The state of the various valves included in these options can be controlled as follows:  
Manually from the analyzer’s front panel by using the SIGNAL I/O controls located under the DIAG Menu  
(see Section 7.3),  
By activating the instrument’s AutoCal feature (see Section 9.4),  
Remotely by using the external digital control inputs (see Section 9.3.3.3), or  
Remotely through the RS-232/485/Ethernet serial I/O ports (see Appendix A-6 for the appropriate  
commands).  
5.6.2. ZERO/SPAN VALVE (OPTION 50A)  
This valve option is intended for applications where:  
Zero air is supplied by a zero air generator like the Teledyne’s M701 and;  
Span gas is supplied by Gas Dilution Calibrator like the Teledyne’s M700E or M702.  
Internal zero/span and sample/cal valves control the flow of gas through the instrument, but because the  
generator and calibrator limit the flow of zero air and span gas, no shutoff valves are required.  
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5.6.2.1. Internal Pneumatics (OPT 50A)  
Figure 5-3:  
Internal Pneumatic Flow OPT 50A – Zero/Span Valves  
Table 5-1: Zero/Span Valve Operating States for Option 52  
MODE  
VALVE  
CONDITION  
Open to SAMPLE inlet  
Open to IZS inlet  
SAMPLE  
(Normal  
State)  
Sample/Cal  
Zero/Span  
Sample/Cal  
Zero/Span  
Open to ZERO/SPAN valve  
Open to IZS inlet  
ZERO CAL  
SPAN CAL  
Sample/Cal  
Zero/Span  
Open to ZERO/SPAN valve  
Open to PRESSURE SPAN inlet  
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5.6.2.2. Pneumatic Set Up (OPT 50A)  
See Figure 3-2 for the location of gas inlets and  
Figure 5-4:  
Pneumatic Connections – Option 50A: Zero/Span Calibration Valves  
SAMPLE GAS SOURCE:  
Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters  
long.  
Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure  
and ideally should equal ambient atmospheric pressure.  
In applications where the sample gas is received from a pressurized manifold, a vent must be placed on  
the sample gas before it enters the analyzer.  
CALIBRATION GAS SOURCES:  
A vent is required when an M700 is used with this option. However, if an M700E is used, a vent may or may not  
be required depending on how the M700E output manifold is configured.  
SPAN GAS:  
Attach a gas line from the source of calibration gas (e.g. a Teledyne’s M700E Dynamic Dilution  
Calibrator) to the SPAN inlet at 30 psig.  
ZERO AIR:  
Zero air is supplied via a zero air generator such as a Teledyne’s M701.  
An adjustable valve is installed in the zero air supply line to regulate the gas flow.  
5.6.2.3. Input Gas Venting  
The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed  
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These  
vents should be:  
At least 0.2m long;  
No more than 2m long and;  
Vented outside the shelter or immediate area surrounding the instrument.  
5.6.2.4. Exhaust Outlet  
Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:  
PTEF tubing; minimum O.D ¼”;  
A maximum of 10 meters long;  
Vented outside the analyzer’s enclosure.  
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5.6.3. ZERO/SPAN/SHUTOFF VALVE (OPTION 50B)  
This option requires that both zero air and span gas be supplied from external sources.  
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 ensures that the gas pressure of the span gas is reduced to ambient atmospheric  
pressure.  
A SHUTOFF valve preserves the span gas source when it is not in use.  
Zero gas is supplied by either an external scrubber or a zero air generator such as the Teledyne’s M701.  
5.6.3.1. Internal Pneumatics (OPT 50B)  
Figure 5-5:  
Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves  
Table 5-2: Zero/Span Valve Operating States for Option 50B  
MODE  
VALVE  
CONDITION  
Sample/Cal  
Zero/Span  
Open to SAMPLE inlet  
Open to IZS inlet  
Closed  
SAMPLE  
(Normal  
State)  
Shutoff Valve  
Sample/Cal  
Zero/Span  
Open to ZERO/SPAN valve  
Open to IZS inlet  
Closed  
ZERO CAL  
SPAN CAL  
Shutoff Valve  
Sample/Cal  
Zero/Span  
Open to ZERO/SPAN valve  
Open to SHUTOFF valve  
Shutoff Valve  
Open to PRESSURE SPAN Inlet  
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5.6.3.2. Pneumatic Set Up (OPT 50B)  
See Figure 3-2 for the location of gas inlets and outlets.  
Figure 5-6:  
Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves  
SAMPLE GAS SOURCE:  
Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters  
long.  
Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure  
and ideally should equal ambient atmospheric pressure.  
In applications where the sample gas is received from a pressurized manifold, a vent must be placed on  
the sample gas before it enters the analyzer.  
CALIBRATION GAS SOURCES:  
SPAN GAS:  
Attach a gas line from the pressurized source of calibration gas (e.g. a bottle of NIST-SRM gas) to the  
SPAN inlet at 30 psig.  
ZERO AIR:  
Zero air is supplied via a zero air generator such as a Teledyne’s M701.  
An adjustable valve is installed in the zero air supply line to regulate the gas flow.  
INPUT GAS VENTING:  
The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed  
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These  
vents should be:  
At least 0.2m long;  
No more than 2m long and;  
Vented outside the shelter or immediate area surrounding the instrument.  
A similar vent line should be connected to the VENT SPAN outlet on the back of the analyzer.  
EXHAUST OUTLET  
Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:  
PTEF tubing; minimum O.D ¼”;  
A maximum of 10 meters long;  
Vented outside the analyzer’s enclosure.  
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5.6.4. ZERO/SPAN VALVE WITH INTERNAL CO SCRUBBER (OPTION 50H)  
Option 50H is operationally and pneumatically similar to Option 50A above, except that the zero air is generated  
by an internal zero air scrubber. This means that the IZS inlet can simply be left open to ambient air.  
Internal zero/span and sample/cal valves control the flow of gas through the instrument, but because the  
generator and calibrator limit the flow of zero air and span gas no shutoff valves are required.  
5.6.4.1. Internal Pneumatics (OPT 50H)  
Figure 5-7:  
Internal Pneumatic Flow OPT 50H – Zero/Span Valves with Internal Zero Air Scrubber  
Table 5-3: Zero/Span Valve Operating States for Option 50H  
MODE  
VALVE  
CONDITION  
SAMPLE  
(Normal  
State)  
Sample/Cal  
Open to SAMPLE inlet  
Zero/Span  
Open to ZERO AIR scrubber  
Sample/Cal  
Zero/Span  
Sample/Cal  
Zero/Span  
Open to ZERO/SPAN valve  
Open to ZERO AIR scrubber  
Open to ZERO/SPAN valve  
Open to PRESSURE SPAN inlet  
ZERO CAL  
SPAN CAL  
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5.6.4.2. Pneumatic Set Up (OPT 50H)  
See Figure 3-2 for the location of gas inlets and outlets and span gas no shutoff valves are required.  
Figure 5-8:  
Pneumatic Connections – Option 50H: Zero/Span Calibration Valves  
SAMPLE GAS SOURCE:  
Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters  
long.  
Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-Hg above ambient pressure  
and ideally should equal ambient atmospheric pressure.  
In applications where the sample gas is received from a pressurized manifold, a vent must be placed on  
the sample gas before it enters the analyzer.  
CALIBRATION GAS SOURCES:  
SPAN GAS:  
Attach a gas line from the source of calibration gas (e.g. a Teledyne’s M700E Dynamic Dilution  
Calibrator) to the SPAN inlet.  
ZERO AIR:  
Zero air is supplied internally via a zero air scrubber that draws ambient air through the IZS inlet.  
INPUT GAS VENTING:  
The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed  
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These  
vents should be:  
At least 0.2m long;  
No more than 2m long and;  
Vented outside the shelter or immediate area surrounding the instrument.  
EXHAUST OUITLET  
Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:  
PTEF tubing; minimum O.D ¼”;  
A maximum of 10 meters long;  
Vented outside the analyzer’s enclosure.  
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5.6.5. ZERO/SPAN/SHUTOFF WITH INTERNAL ZERO AIR SCRUBBER  
(OPTION 50E)  
5.6.5.1. Internal Pneumatics (OPT 50E)  
Figure 5-9:  
Internal Pneumatic Flow OPT 50E – Zero/Span/Shutoff Valves with Internal Zero Air  
Scrubber  
Table 5-4: Zero/Span Valve Operating States for Option 50E  
Mode  
Valve  
Condition  
Sample/Cal  
Zero/Span  
Open to SAMPLE inlet  
Open to internal ZERO AIR scrubber  
Closed  
SAMPLE  
(Normal  
State)  
Shutoff Valve  
Sample/Cal  
Zero/Span  
Open to zero/span valve  
Open to internal ZERO AIR scrubber  
Closed  
ZERO CAL  
SPAN CAL  
Shutoff Valve  
Sample/Cal  
Zero/Span  
Open to ZERO/SPAN valve  
Open to SHUTOFF valve  
Shutoff Valve  
Open to PRESSURE SPAN inlet  
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5.6.5.2. Pneumatic Set Up (OPT 50E)  
See Figure 3-2 for the location of gas inlets and outlets.  
Figure 5-10:  
Pneumatic Connections – Option 50E: Zero/Span Calibration Valves  
SAMPLE GAS SOURCE:  
Attach a sample inlet line to the sample inlet port. The SAMPLE input line should not be more than 2 meters  
long.  
Maximum pressure of any gas at the sample inlet should not exceed 1.5 in-hg above ambient pressure  
and ideally should equal ambient atmospheric pressure.  
In applications where the sample gas is received from a pressurized manifold, a vent must be placed on  
the sample gas before it enters the analyzer.  
CALIBRATION GAS SOURCES:  
SPAN GAS:  
Attach a gas line from the pressurized source of calibration gas (e.g. a bottle of NIST-SRM gas) to the  
span inlet.  
Span gas can by generated by a M700E Dynamic Dilution Calibrator.  
ZERO AIR:  
Zero air is supplied internally via a zero air scrubber that draws ambient air through the IZS inlet.  
INPUT GAS VENTING:  
The zero air supply and sample gas line MUST be vented in order to ensure that the gases input do not exceed  
the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects. These  
vents should be:  
At least 0.2m long;  
No more than 2m long and;  
Vented outside the shelter or immediate area surrounding the instrument.  
A similar vent line should be connected to the VENT SPAN outlet on the back of the analyzer.  
EXHAUST OUITLET  
Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust line should be:  
PTEF tubing; minimum O.D ¼”;  
A maximum of 10 meters long;  
Vented outside the analyzer’s enclosure.  
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5.7. COMMUNICATION OPTIONS  
5.7.1. RS-232 MODEM CABLE (OPTION 60A)  
Table 5-5: GFC 7001E/EM Modem Cable Options  
OPTION NO.  
DESCRIPTION  
Shielded, straight-through DB-9F to DB-25M cable of about 1.8 m length.  
60A  
This cable is used to interface with older computers or code activated switches with  
a DB-25 serial connectors.  
Shielded, straight-through DB-9F to DB-9F cable of about 1.8 m length, which should fit  
most computers of recent build.  
60B  
60C  
CAT5 7’ cable, a shielded straight through cable, 2 meters in length, terminated with  
RJ45 connectors.  
For use with the GFC 7001E/EM Analyzer’s optional Ethernet Card (Option 63A).  
5.7.2. RS-232 MULTIDROP (OPTION 62)  
The multidrop option is used with RS232 and utilizes both DB-9 connectors on the rear panel to enable  
communications of up to eight analyzers with the host computer over a chain of RS-232 cables. It is subject to  
the distance limitations of the RS-232 standard.  
Figure 5-11:  
GFC 7001E/EM Multidrop Card Seated on CPU above Disk on Module  
The option consists of a small printed circuit assembly, which plugs into to the analyzer’s CPU card and is  
connected to the RS-232 and COM2 DB9 connectors on the instrument’s back panel via a cable to the  
motherboard.  
One OPT 62 and one OPT 60B are required for each analyzer along the multidrop network.  
See Section 8.2 for information regarding setting up a multidrop network for GFC 7001E/EM Analyzers.  
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5.7.3. ETHERNET (OPTION 63A)  
The ETHERNET option allows the analyzer to be connected to any Ethernet Local Area Network (LAN) running  
TCP/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.  
Maximum communication speed is limited by the RS-232 port to 115.2 kBaud.  
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.  
The option consists of a Teledyne’s designed Ethernet card (see Figure 5-12 and Figure 5-13), and a 7-foot long  
CAT-5 network cable, terminated at both ends with standard RJ-45 connectors.  
Figure 5-12:  
GFC 7001E/EM Ethernet Card  
Figure 5-13:  
GFC 7001E/EM Rear Panel with Ethernet Installed  
For more information on setting up and using this option, see Section 8.4.  
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5.7.4. ETHERNET + MULTIDROP (OPT 63C)  
This option allows the instrument to communicate on both RS-232 and ETHERNET networks simultaneously. It  
includes the following:  
RS-232 MULTIDROP (OPT 62)  
ETHERNET (OPT 63A)  
5.8. SECOND GAS SENSORS  
5.8.1. OXYGEN SENSOR (OPTION 65A)  
5.8.1.1. Theory of Operation - Paramagnetic measurement of O2  
The oxygen sensor used in the GFC 7001E/EM Analyzer utilizes the fact that oxygen is attracted into strong  
magnetic field while most other gases are not, to obtain fast, accurate oxygen measurements.  
The sensor’s core is made up of two nitrogen filled glass spheres, which are mounted on a rotating suspension  
within a magnetic field (see Figure 5-14). A mirror is mounted centrally on the suspension and light is shone  
onto the mirror that reflects the light onto a pair of photocells. The signal generated by the photocells is passed  
to a feedback loop, which outputs a current to a wire winding (in effect, a small DC electric motor) mounted on  
the suspended mirror.  
Oxygen from the sample stream is attracted into the magnetic field displacing the nitrogen filled spheres and  
causing the suspended mirror to rotate. This changes the amount of light reflected onto the photocells and  
therefore the output levels of the photocells. The feedback loop increases the amount of current fed into the  
winding in order to move the mirror back into its original position. The more O2 present, the more the mirror  
moves and the more current is fed into the winding by the feedback control loop.  
A sensor measures the amount of current generated by the feedback control loop which is directly proportional to  
the concentration of oxygen within the sample gas mixture.  
Figure 5-14:  
Oxygen Sensor - Principle of Operation  
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5.8.1.2. Operation within the GFC 7001E/EM Analyzer  
The oxygen sensor option is transparently integrated into the core analyzer operation. All functions can be  
viewed or accessed through the front panel, just like the functions for CO.  
The O2 concentration is displayed in the upper right-hand corner, alternating with CO concentration.  
Test functions for O2 slope and offset are viewable from the front panel along with the analyzer’s other test  
functions.  
O2 sensor calibration is performed via the front panel CAL function and is performed in a nearly identical  
manner as the standard CO calibration. See Section 9.7.1 for more details.  
Stability of the O2 sensor can be viewed via the front panel (see Section 9.7.1.3).  
The O2 concentration range is 0-100% (user selectable) with 0.1% precision and accuracy.  
The temperature of the O2 sensor is maintained at a constant 50° C by means of a PID loop and can be viewed  
on the front panel as test function O2 TEMP.  
The O2 sensor assembly itself does not have any serviceable parts and is enclosed in an insulated canister.  
5.8.1.3. Pneumatic Operation of the O2 Sensor  
Pneumatically, the O2 sensor draws a flow of 80 cm³/min in addition to the normal sample flow rate. It is  
separately controlled with its own critical flow orifice.  
Figure 5-15:  
GFC 7001E/EM – Internal Pneumatics with O2 Sensor Option 65A  
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5.9. CARBON DIOXIDE SENSOR (OPTION 67A)  
The optional CO2 sensor allows the GFC 7001E/EM to measure both CO and CO2 simultaneously. This option  
includes a CO2 sensor probe, a Logic PCA that conditions the probe output and issues a 0-5 VDC signal to the  
analyzer’s CPU that is used to compute the CO2 concentration.  
The GFC 7001E/EM receives this input, scales it based on the values of the CO2_SLOPE and CO2_OFFSET  
recorded during calibration (see Section 9.7.2).  
Figure 3-4 shows the location of the Sensor Probe and PCA within the GFC 7001E/EM.  
The CO2 sensor assembly itself does not have any serviceable parts and is enclosed in an insulated canister.  
5.9.1. CO2 SENSOR RANGES AND SPECIFICATIONS  
Table 5-6: CO2 Sensor - Available Ranges  
OPTION NO.  
RANGES  
ANALYZER MODEL(S)  
0-20%  
GFC 7001EM  
67A  
Table 5-7: CO2 Sensor Specifications  
Accuracy at 25˚C 0.02% CO + 2% of reading  
Linearity 0.5 % of full scale  
Typical Temperature Dependence -0.1% FS / ˚C  
Long Term Stability <+15 % FS / 2 years  
Response time 20 seconds  
Warm up time 5 minutes  
Power consumption 2.5 watts  
5.9.2. THEORY OF OPERATION  
5.9.2.1. NDIR measurement of CO2  
The optional CO2 sensor is a silicon based Non-Dispersive Infrared (NDIR) sensor. It uses a single-beam, dual  
wavelength measurement method.  
An infrared source at one end of the measurement chamber emits IR radiation into the sensor’s measurement  
chamber where light at the 4.7 μm wavelength is partially absorbed by any CO2 present. A special light filter  
called a Fabry-Perot Interferometer (FPI) is electronically tuned so that only light at the absorption wavelength of  
CO2 is allowed to pass and be detected by the sensor’s IR detector.  
A reference measurement is made by electronically shifting the filter band pass wavelength so that no IR at the  
CO2 absorption wavelength is let through.  
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Figure 5-16:  
CO2 sensor Theory of Operation  
The sensor computes the ratio between the reference signal and the measurement signal to determine the  
degree of light absorbed by CO2 present in the sensor chamber. This dual wavelength method the CO2  
measurement allows the instrument to compensate for ancillary effects like sensor aging and contamination.  
5.9.2.2. Operation within the GFC 7001E/EM Analyzer  
The CO2 sensor option is transparently integrated into the core analyzer operation. All functions can be viewed  
or accessed through the front panel, just like the functions for CO.  
The CO2 concentration is displayed in the upper right-hand corner, alternating with CO concentration.  
Test functions for CO2 slope and offset are viewable from the front panel along with the analyzer’s other  
test functions.  
CO2 sensor calibration is performed via the front panel CAL function and is performed in a nearly identical  
manner as the standard CO calibration. See Section 9.7.2 for more details.  
Stability of the CO2 sensor can be viewed via the front panel (see Section 9.7.2.3).  
The CO2 concentration range is 0-20%. See Section 9.7.2.1 for information on calibrating the CO2.  
5.9.2.3. Pneumatic Operation of the CO2 Sensor  
Pneumatically, the CO2 sensor is placed in line with the sample gas line between the particulate filter and the  
analyzer’s sample chamber. It does not alter the gas flow rate of the sample through the analyzer.  
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Figure 5-17:  
GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66  
5.9.2.4. Electronic Operation of the CO2 Sensor  
The CO2 PCA which is mounted to the rear side of the Relay Board Mounting Bracket controls the CO2 Sensor.  
It converts the sensor’s digital output to an analog voltage that is measured with the motherboard and draws 12  
VDC from the analyzer via the relay card from which converts to fit the power needs of the probe and its own  
onboard logic. It outputs a 0-5 VDC analog signal to the analyzer’s CPU via the motherboard that corresponds  
to the concentration of CO2 measured by the probe.  
Figure 5-18:  
CO2 Sensor Option PCA Layout and Electronic Connections  
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5.10. CONCENTRATION ALARM RELAY (OPTION 61)  
The Teledyne “E” series analyzers have an option for four (4) “dry contact” relays on the rear panel of the  
instrument. This relay option is different from and in addition to the “Contact Closures” that come standard  
on all TAI instruments. The relays have 3 pins that have connections on the rear panel (see Figure 5-19).  
They are a Common (C), a Normally Open (NO), & a Normally Closed (NC) pin.  
Figure 5-19:  
Concentration Alarm Relay  
Alarm 1  
Alarm 2  
Alarm 3  
Alarm 4  
“System OK 2”  
“Conc 1”  
“Conc 2”  
“Range Bit”  
“Alarm 1” Relay  
Alarm 1 which is “System OK 2” (system OK 1, is the status bit) is in the energized state when the  
instrument is “OK” & there are no warnings. If there is a warning active or if the instrument is put into the “DIAG”  
mode, Alarm 1 will change states. This alarm has “reverse logic” meaning that if you put a meter across the  
Common & Normally Closed pins on the connector you will find that it is OPEN when the instrument is OK. This  
is so that if the instrument should turn off or loose power, it will change states & you can record this with a data  
logger or other recording device.  
“Alarm 2” Relay & “Alarm 3” Relay  
The “Alarm 2 Relay” on the rear panel, is associated with the “Concentration Alarm 1” set point in the  
software & the “Alarm 3 Relay” on the rear panel is associated with the “Concentration Alarm 2” set point in the  
software.  
Alarm 2 Relay  
Alarm 3 Relay  
Alarm 2 Relay  
Alarm 3 Relay  
CO Alarm 1 = xxx PPM  
CO2 Alarm 2 = xxx PPM  
CO Alarm 1 = xxx PPM  
CO2 Alarm 2 = xxx PPM  
The Alarm 2 Relay will be turned on any time the concentration set-point is exceeded & will return to its  
normal state when the concentration value goes back below the concentration set-point.  
Even though the relay on the rear panel is a NON-Latching alarm & resets when the concentration goes  
back below the alarm set point, the warning on the front panel of the instrument will remain latched until it is  
cleared. You can clear the warning on the front panel by either pushing the CLR button on the front panel or  
through the serial port.  
In instruments that sample more than one gas type, there could be more than one gas type triggering the  
Concentration 1 Alarm (“Alarm 2” Relay). For example, the GFC 7001EM instrument can monitor both CO &  
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CO2 gas. The software is flexible enough to allow you to configure the alarms so that you can have 2 alarm  
levels for each gas.  
CO Alarm 1 = 20 PPM  
CO Alarm 2 = 100 PPM  
CO2 Alarm 1 = 20 PPM  
CO2 Alarm 2 = 100 PPM  
In this example, CO Alarm 1 & CO2 Alarm 1 will both be associated with the “Alarm 2” relay on the rear panel.  
This allows you do have multiple alarm levels for individual gasses.  
A more likely configuration for this would be to put one gas on the “Alarm 1” relay & the other gas on the “Alarm  
2” relay.  
CO Alarm 1 = 20 PPM  
CO Alarm 2 = Disabled  
CO2 Alarm 1 = Disabled  
CO2 Alarm 2 = 100 PPM  
“Alarm 4” Relay  
This relay is connected to the “range bit”. If the instrument is configured for “Auto Range” & the  
instrument goes up into the high range, it will turn this relay on.  
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5.11. SPECIAL FEATURES  
5.11.1. DILUTION RATIO OPTION  
The Dilution Ratio Option is a software option that is designed for applications where the Sample gas is diluted  
before being analyzed by the GFC 7001E. 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 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 6.6.5.  
5.11.2. MAINTENANCE MODE SWITCH  
TAI’s instruments can be equipped with a switch that places the instrument in maintenance mode. When  
present, the switch is 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.  
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.  
5.11.3. SECOND LANGUAGE SWITCH  
TAI’s instruments can be equipped with a switch that activates an alternate set of display message in a language  
other than the instrument’s default language. To activate this feature, the instrument must have a specially  
programmed Disk-on-Module (DOM) containing the second language. Call Customer Service for this DOM.  
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Part II Operating Instructions  
Model GFC7001E Carbon Dioxide Analyzer  
PART II  
–
OPERATING INSTRUCTIONS  
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6. BASIC OPERATION  
The GFC 7001E/EM Analyzer is a computer-controlled analyzer with a dynamic menu interface that allows all  
major operations to be controlled from the front panel display and keyboard through user-friendly menus (a  
complete set of menu trees is located in Appendix A of this manual).  
This section includes step-by-step instructions for using the display/keyboard to set up and operate the GFC  
7001E/EM Analyzer's basic CO measurement features and functional modes.  
6.1. OVERVIEW OF OPERATING MODES  
The GFC 7001E/EM 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. If  
the analyzer is configured to measure more than one gas (e.g. CO along with O2 or CO2) the display will cycle  
through gas list.  
While in SAMPLE mode calibrations can be performed and TEST functions as well as WARNING messages can  
be examined. If any of the analyzer’s analog outputs are enabled, the current concentration value will be  
available at the analog output connector.  
The second most important operating mode is SETUP mode. This mode is used for performing certain  
configuration operations, such as programming the iDAS system or the configurable analog output channels, or  
setting up the analyzer’s serial communication channels (RS-232/RS-485/Ethernet). The SETUP mode is also  
used for performing various diagnostic tests during troubleshooting.  
Message Field  
Concentration Field  
Mode Field  
SAMPLE  
RANGE=50.00 PPM  
CO= XX.XX  
SETUP  
<TST TST> CAL  
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:  
Table 6-1:  
Analyzer Operating Modes  
MODE  
SAMPLE  
SAMPLE A  
M-P CAL  
EXPLANATION  
Sampling normally, flashing text indicates adaptive filter is on.  
Indicates that unit is in Sample Mode while AUTOCAL feature is active (Internal Span Only).  
This is the basic calibration mode of the instrument and is activated by pressing the CAL key.  
SETUP mode is being used to configure the analyzer. The gas measurement will continue during this  
process. The revision of the GFC 7001E/EM firmware being run will appear after the word “SETUP”  
SETUP [X.X]  
ZERO CAL [type] 1,2 & 3  
LO CAL [type] 2 & 3  
SPAN CAL [type] 1,2 & 3  
DIAG Mode  
Unit is performing ZERO calibration procedure.  
Unit is performing LOW SPAN (midpoint) cal check procedure.  
Unit is performing SPAN calibration procedure.  
One of the analyzer’s diagnostic modes is active (Section 7.3).  
[type:]  
1A: Initiated automatically by the AUTOCAL feature (Internal Span Only).  
2M: initiated manually by the user via the front panel controls.  
3R: initiated remotely through the COM ports or digital control inputs.  
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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 CO concentration and reporting this information to the user via the front panel display, the  
analog outputs and, if set up properly, the RS-232/RS-485/Ethernet ports.  
NOTE  
A value of “XXXX” displayed in the CO Concentration field means that the M/R ratio is invalid because  
CO REF is either too high (> 4950 mVDC) or too low (< 1250 VDC).  
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.  
A variety of TEST functions are available for viewing at the front panel whenever the analyzer is at the MAIN  
MENU. These functions provide information about the various functional parameters related to the analyzers  
operation and its measurement of gas concentrations. This information is particularly a performance problem  
during troubleshooting (see Section 13.1.2).  
To view these TEST functions, press,  
Figure 6-2:  
Viewing GFC 7001E/EM Test Functions  
NOTE  
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.  
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Table 6-2:  
DISPLAY TITLE UNITS  
Test Functions Defined  
MEANING  
PARAMETER  
Standard deviation of CO concentration readings. Data points are  
recorded every ten seconds using the last 25 data points. This  
PPB3, PPM  
STABIL  
UGM3, MGM function can be reset to show O2 or CO2 stability in instruments with  
those sensor options installed.  
Stability  
RANGE  
RANGE11  
RANGE21  
The full scale limit at which the reporting range of the analyzer is  
currently set. THIS IS NOT the Physical Range of the instrument.  
See Section 6.6.1 for more information.  
PPB, PPM,  
UGM, MGM  
Range  
O2 Range 1  
CO2 Range2  
O2 RANGE  
%
%
The range setting for the optional O2 Sensor.  
The range setting for the optional CO2 Sensor.  
CO2 RANGE  
The demodulated, peak IR detector output during the measure  
portion of the GFC Wheel cycle.  
CO MEAS  
CO REF  
MV  
MV  
CO Measure  
The demodulated, peak IR detector output during the reference  
portion of the GFC Wheel cycle.  
CO Reference  
The result of CO MEAS divided by CO REF. This ratio is the  
primary value used to compute CO concentration. The value  
displayed is not linearized.  
Measurement /  
Reference Ratio  
MR Ratio  
PRES  
-
The absolute pressure of the Sample gas as measured by a  
pressure sensor located inside the sample chamber.  
In-Hg-A  
Sample Pressure  
Sample Flow  
Sample mass flow rate as measured by the flow rate sensor in the  
sample gas stream.  
SAMPLE FL  
SAMP TEMP  
BENCH TEMP  
cm3/min  
C  
Sample  
Temperature  
The temperature of the gas inside the sample chamber.  
Optical bench temperature.  
Bench  
Temperature  
C  
Wheel  
Temperature  
WHEEL TEMP  
BOX TEMP  
GFC Wheel temperature.  
C  
C  
C  
The temperature inside the analyzer chassis.  
The current temperature of the O2 sensor measurement cell.  
Box Temperature  
O2 CELL TEMP3  
O2 Cell  
Temperature3  
Photo-detector  
Temp. Control  
Voltage  
The drive voltage being supplied to the thermoelectric coolers of the  
IR photo-detector by the sync/demod Board.  
PHT DRIVE  
mV  
The sensitivity of the instrument as calculated during the last  
calibration activity.  
SLOPE  
-
-
Slope  
Offset  
The overall offset of the instrument as calculated during the last  
calibration activity.  
OFFSET  
O2 Sensor  
Slope 1  
O2 SLOPE  
O2 OFFSET  
CO2 SLOPE  
-
-
-
O2 slope, computed during zero/span calibration.  
O2 offset, computed during zero/span calibration.  
CO2 slope, computed during zero/span calibration.  
O2 Sensor Offset 1  
CO2 Sensor  
Slope2  
CO2 Sensor  
Offset 2  
CO2 OFFSET  
-
CO2 offset, computed during zero/span calibration.  
The current time. This is used to create a time stamp on iDAS  
readings, and by the AUTOCAL feature to trigger calibration events.  
TIME  
-
Current Time  
1 Only appears when the optional O2 sensor is installed.  
2 Only appears when the optional CO2 sensor is installed.  
3 Only available on the GFC 7001E.  
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6.3. WARNING MESSAGES  
The most common instrument failures will be reported as a warning on the analyzer’s front panel and through the  
COMM ports. Section 13.1.1 explains how to use these messages to troubleshoot problems. Section 6.3 shows  
how to view and clear warning messages.  
Table 6-3:  
List of Warning Messages  
MESSAGE  
MEANING  
ANALOG CAL WARNING  
BENCH TEMP WARNING  
BOX TEMP WARNING  
CANNOT DYN SPAN2  
CANNOT DYN ZERO3  
CONC ALRM1 WARNING1  
CONC ALRM2 WARNING1  
CONFIG INITIALIZED  
DATA INITIALIZED  
The instrument’s A/D circuitry or one of its analog outputs is not calibrated.  
The temperature of the optical bench is outside the specified limits.  
The temperature inside the chassis is outside the specified limits.  
Remote span calibration failed while the dynamic span feature was set to turned on.  
Remote zero calibration failed while the dynamic zero feature was set to turned on.  
Concentration alarm 1 is enabled and the measured CO level is ≥ the set point.  
Concentration alarm 2 is enabled and the measured CO level is ≥ the set point.  
Configuration storage was reset to factory configuration or erased.  
iDAS data storage was erased.  
O2 CELL TEMP WARN2  
PHOTO TEMP WARNING  
REAR BOARD NOT DET  
RELAY BOARD WARN  
SAMPLE FLOW WARN  
SAMPLE PRESS WARN  
SAMPLE TEMP WARN  
SOURCE WARNING  
O2 sensor cell temperature outside of warning limits.  
The temperature of the IR photo detector is outside the specified limits.  
The CPU is unable to communicate with the motherboard.  
The firmware is unable to communicate with the relay board.  
The flow rate of the sample gas is outside the specified limits.  
Sample gas pressure outside of operational parameters.  
The temperature of the sample gas is outside the specified limits.  
The IR source may be faulty.  
SYSTEM RESET1  
The computer was rebooted.  
WHEEL TEMP WARNING  
The Gas Filter Correlation Wheel temperature is outside the specified limits.  
1 Alarm warnings only present when 0ptional alarm package is activated.  
2 Only enabled when the optional O2 Sensor is installed.  
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To view and clear warning messages:  
Figure 6-3:  
Viewing and Clearing GFC 7001E/EM WARNING Messages  
6.4. CALIBRATION MODE  
Press the CAL key to switch the GFC 7001E/EM into calibration mode. In this mode the user can, in conjunction  
with introducing zero or span gases of known concentrations into the analyzer, cause it to adjust and recalculate  
the slope (gain) and offset of the its measurement range. This mode is also used to check the current calibration  
status of the instrument.  
For more information about setting up and performing standard calibration operations or checks, see  
Section 9.  
For more information about setting up and performing EPA equivalent calibrations, see Section 10.  
If the instrument includes one of the available zero/span valve options, the SAMPLE mode display will also  
include CALZ and CALS keys. Pressing either of these keys also puts the instrument into calibration mode.  
The CALZ key is used to initiate a calibration of the analyzer’s zero point using internally generated zero air.  
The CALS key is used to calibrate the span point of the analyzer’s current reporting range using span gas.  
For more information concerning calibration valve options, see Section 5.6  
For information on using the automatic calibration feature (ACAL) in conjunction with the one of the calibration  
valve options, see Section 9.4.  
NOTE  
It is recommended that this span calibration be performed at 80-90% of full scale of the analyzer’s  
currently selected reporting range.  
EXAMPLES:  
If the reporting range is set for 0 to 50 ppm, an appropriate span point would be 40-45 ppm.  
If the of the reporting range is set for 0 to 1000 ppb, an appropriate span point would be 800-900 ppb.  
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6.5. 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).  
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.  
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.  
For a visual representation of the software menu trees, refer to Appendix A-1.  
The areas accessible under the SETUP mode are shown in Table 6-4 and Table 6-5:  
Table 6-4:  
Primary Setup Mode Features and Functions  
KEYPAD  
LABEL  
MANUAL  
SECTION  
MODE OR FEATURE  
DESCRIPTION  
Analyzer Configuration  
Lists key hardware and software configuration information  
6.5.1  
CFG  
Used to set up and operate the AutoCal feature.  
Only appears if the analyzer has one of the internal valve  
options installed.  
6.5.2  
and  
9.4  
Auto Cal Feature  
ACAL  
Internal Data Acquisition  
(iDAS)  
Analog Output Reporting  
Range Configuration  
Calibration Password Security  
Used to set up the iDAS system and view recorded data  
7.1  
6.6  
DAS  
Used to configure the output signals generated by the  
instruments Analog outputs.  
Turns the calibration password feature ON/OFF.  
RNGE  
6.5.3  
6.5.4  
PASS  
CLK  
Internal Clock Configuration  
Used to Set or adjust the instrument’s internal clock.  
See  
Table 6-5  
Advanced SETUP features  
This button accesses the instruments secondary setup menu.  
MORE  
Table 6-5:  
Secondary Setup Mode Features and Functions  
KEYPAD  
LABEL  
MANUAL  
SECTION  
MODE OR FEATURE  
DESCRIPTION  
Used to set up and operate the analyzer’s various serial  
channels including RS-232,RS-485, modem communication  
and/or Ethernet access.  
External Communication  
Channel Configuration  
COMM  
8.1  
Used to view various variables related to the instruments current  
operational status.  
System Status Variables  
VARS  
Changes made to any variable are not recorded in the  
instrument’s memory until the ENTR key is pressed.  
7.2  
Pressing the EXIT key ignores the new setting.  
Used to access a variety of functions that are used to configure,  
test or diagnose problems with a variety of the analyzer’s basic  
systems.  
Most notably, the menus used to configure the output signals  
generated by the instruments Analog outputs are located here.  
Used to turn the instrument’s two alarms on and off as well as  
set the trigger limits for each.  
System Diagnostic Features  
and  
Analog Output Configuration  
DIAG  
7.3  
7.5  
Alarm Limit Configuration1  
1
ALRM  
Alarm warnings only present when optional alarm package is activated.  
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6.5.1. SETUP CFG: CONFIGURATION INFORMATION  
Pressing the CFG key displays the instrument’s configuration information. This display lists the analyzer model,  
serial number, firmware revision, software library revision, CPU type and other information.  
Special instrument or software features or installed options may also be listed here.  
Use this information to identify the software and hardware installed in your GFC 7001E/EM Analyzer when  
contacting customer service.  
To access the configuration table, press:  
6.5.2. SETUP ACAL: AUTOMATIC CALIBRATION  
Instruments with one of the internal valve options installed can be set to automatically run calibration procedures  
and calibration checks. These automatic procedures are programmed using the submenus and functions found  
under the ACAL menu.  
A menu tree showing the ACAL menu’s entire structure can be found in Appendix A-1 of this manual.  
Instructions for using the ACAL feature are located in the Section 9.4 of this manual along with all other  
information related to calibrating the GFC 7001E/EM Analyzer.  
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6.5.3. SETUP PASS: PASSWORD FEATURE  
The GFC 7001E/EM provides password protection of the calibration and setup functions to prevent unauthorized  
adjustments. When the passwords have been enabled in the PASS menu item, the system will prompt the user  
for a password anytime a password-protected function (e.g., SETUP) is requested. This allows normal operation  
of the instrument, but requires the password (101) to access to the menus under SETUP. When PASSWORD is  
disabled (SETUP>OFF), any operator can enter the Primary Setup (SETUP) and Secondary Setup  
(SETUP>MORE) menus. Whether PASSWORD is enabled or disabled, a password (default 818) is required to  
enter the VARS or DIAG menus in the SETUP>MORE menu.  
Table 6-6:  
Password Levels  
PASSWORD  
LEVEL  
MENU ACCESS ALLOWED  
Null (000)  
Operation  
All functions of the MAIN menu: TEST, GEN, initiate SEQ , MSG, CLR  
Access to Primary and Secondary SETUP Menus when PASSWORD  
enabled  
101  
818  
Configuration/Maintenance  
Configuration/Maintenance  
Access to Secondary SETUP Submenus VARS and DIAG whether  
PASSWORD is enabled or disabled.  
To enable or disable passwords, press:  
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Example: If all passwords are enabled, the following keypad sequence would be required to enter the SETUP  
menu:  
NOTE  
The instrument still prompts for a password when entering the VARS and DIAG menus, even if  
passwords are disabled. It will display the default password (818) upon entering these menus.  
The user only has to press ENTR to access the password-protected menus but does not have to enter  
the required number code.  
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6.5.4. SETUP CLK: SETTING THE GFC 7001E/EM ANALYZER’S  
INTERNAL CLOCK  
6.5.4.1. Setting the internal Clock’s Time and Day  
The GFC 7001E/EM has a time of day clock that supports the DURATION step of the automatic calibration  
(ACAL) sequence feature, time of day TEST function, and time stamps on for the iDAS feature and most COMM  
port messages.  
To set the clock’s time and day, press:  
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6.5.4.2. Adjusting the Internal Clock’s Speed  
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.  
The CLOCK_AD variable is accessed via the VARS submenu: To change the value of this variable, press:  
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6.6. SETUP RNGE: ANALOG OUTPUT REPORTING RANGE  
CONFIGURATION  
6.6.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING  
RANGES  
Functionally, the GFC 7001E Family of CO Analyzers have one hardware PHYSICAL RANGE that is capable of  
determining CO concentrations between across a very wide array of values.  
Table 6-7:  
GFC 7001E Family Physical range by Model  
MODEL  
GFC 7001E  
GFC 7001EM  
RANGE  
0 – 1000 ppm  
0 – 5000 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 physical range.  
Because many applications use only a small part of the analyzer’s full physical range, this can create data  
resolution problems for most analog recording devices. For example, in an application where an GFC 7001E is  
being used to measure an expected concentration of typically less than 50 ppm CO, the full scale of expected  
values is only 4% of the instrument’s full 1000 ppm measurement range. Unmodified, the corresponding output  
signal would also be recorded across only 2.5% of the range of the recording device.  
The GFC 7001E/EM Analyzers solve 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 this REPORTING RANGE of the analog outputs is scaled, the physical range of the analyzer and the  
readings displayed on the front panel remain unaltered.  
NOTE  
Both the iDAS values stored in the CPU’s memory and the concentration values reported on the front  
panel are unaffected by the settings chosen for the reporting range(s) of the instrument.  
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6.6.2. ANALOG OUTPUT RANGES FOR CO CONCENTRATION  
The analyzer has several active analog output signals related accessible through a connector on the rear panel  
(see Figure 3-2).  
ANALOG OUT  
Only active if the Optional  
CO concentration  
CO2 or O2 Sensor is  
outputs  
Test Channel  
A1  
A2  
A3  
A4  
+
-
+
-
+
-
+
-
LOW range when DUAL  
HIGH range when DUAL  
mode is selected  
mode is selected  
Figure 6-4:  
Analog Output Connector Pin Out  
All four 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, A2 and A3 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 7.4.5).  
The A1 and A2 channels output a signal that is proportional to the CO concentration of the sample gas. Several  
modes are available which allow them to operate independently or be slaved together (See Section 6.6.3).  
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.  
Output A3 is only active if the CO2 or O2 sensor option is installed. In this case a signal representing the  
currently measured CO2 or O2 concentration is output on this channel.  
The output, labeled A4 is special. It can be set by the user (See Section 7.4.6) to output several of the test  
functions accessible through the <TST TST> keys of the units sample display.  
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6.6.3. REPORTING RANGE MODES  
The GFC 7001E/EM provides three analog output range modes to choose from.  
Single range (SNGL) mode sets a single maximum range for the analog output. If single range is selected  
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).  
Dual range (DUAL) allows the A1 and A2 outputs to be configured with different measurement spans as  
well as separate electronic signal levels.  
Auto range (AUTO) mode gives the analyzer to ability to output data via a low range and high range.  
When this mode is selected the analyzer 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 outputs (See Section 3.3.3).  
To select the Analog Output Range Type press:  
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:  
SNGL  
Range  
DUAL  
 Range1  
Range2  
AUTO  
Low Range  
High Range  
  
  
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6.6.3.1. RNGE MODE SNGL: Configuring the GFC 7001E/EM Analyzer for SINGLE Range  
Mode  
NOTE  
This is the default reporting range mode for the analyzer.  
When the single range mode is selected (SNGL), all analog CO concentration outputs (A1 and A2) are slaved  
together and set to the same reporting range limits (e.g. 500.0 ppb). The span limit of this reporting range can be  
set to any value within the physical range of the analyzer.  
Although both outputs share the same concentration reporting range, the electronic signal ranges of the analog  
outputs may still be configured for different values (e.g. 0-5 VDC, 0-10 VDC, etc; see Section 7.4.2)  
To select SNGL range mode and to set the upper limit of the range, press:  
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6.6.3.2. RNGE MODE DUAL: Configuring the GFC 7001E/EM Analyzer for DUAL Range  
Mode  
Selecting the 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 names 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:  
RANGE1: The range setting for the A1 output.  
RANGE2: The range setting for the A2 output.  
To select the DUAL range mode press following keystroke sequence  
.
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 LOW and HIGH ranges have separate slopes and offsets for computing CO  
concentrations.  
The two ranges must be independently calibrated.  
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To set the upper range limit for each independent reporting range, press:  
.
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6.6.3.3. RNGE MODE AUTO: Configuring the GFC 7001E/EM Analyzer for AUTO Range  
Mode  
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 CO2 concentration exceeds 98% of the low  
range span.  
The unit will return from high range back to low range once both the CO2 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 be replaced by two separate functions:  
RANGE1: The LOW range setting for all analog outputs.  
RANGE2: The HIGH range setting for all analog outputs.  
The high/low range status is also reported through the external, digital status bits (See Section 3.3.3).  
To set individual ranges press the following keystroke sequence.  
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SETUP X.X  
CFG DAS  
CLK MORE  
EXIT  
Avoid accidentally setting the  
range (  
) of the instrument  
with a higher span limit than the  
range (  
).  
SETUP X.X  
This will cause the unit to stay in  
the low reporting range perpetually  
and defeat the function of the  
range mode.  
SET UNIT DIL  
EXIT  
ENTR EXIT  
EXIT  
SETUP X.X  
SNGL DUAL  
DIL  
SETUP X.X  
SNGL DUAL AUTO  
The  
and  
ranges have separate  
slopes and offsets for  
computing the CO  
concentration.  
SETUP X.X  
MODE  
UNIT DIL  
EXIT  
The two ranges must  
be independently  
calibrated.  
SETUP X.X  
SETUP X.X  
discards the new  
setting.  
Toggle these keys to  
select the upper  
limit for the  
accepts the  
new setting.  
reporting range.  
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6.6.4. SETUP RNGE UNIT: SETTING THE REPORTING RANGE UNITS  
OF MEASURE  
The GFC 7001E/EM can display concentrations in parts per million (106 mols per mol, PPM) or milligrams per  
cubic meter (mg/m3, MG). Changing units affects all of the display, COMM port and iDAS values for all reporting  
ranges regardless of the analyzer’s range mode. To change the concentration units:  
NOTE  
In order to avoid a reference temperature bias, the analyzer must be recalibrated after every change in  
reporting units.  
NOTE  
Concentrations displayed in mg/m3 and ug/m3 use 0C@ 760 mmHg for Standard Temperature and  
Pressure (STP).  
Consult your local regulations for the STP used by your agency.  
(Example: US EPA uses 25C as the reference temperature).  
Once the Units of Measurement have been changed from volumetric (ppb or ppm) to mass units (µg/m3  
or mg/m3) the analyzer 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.  
This will also counteract any discrepancies between STP definitions.  
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6.6.5. SETUP RNGE DIL: USING THE OPTIONAL DILUTION RATIO  
FEATURE  
This feature is a optional software utility that allows the user to compensate for any dilution of the sample gas  
that may occur before it enters the sample inlet. Typically this occurs in continuous emission monitoring (CEM)  
applications where the sampling method used to remove the gas from the stack dilutes it.  
Using the dilution ratio option is a 4-step process:  
1. Select the appropriate units of measure (see Section 6.6.4).  
2. Select the reporting range mode and set the reporting range upper limit (see Section 6.6.3). Make sure  
that:  
The upper span limit entered for the reporting range is the maximum expected concentration of the  
UNDILUTED gas.  
3. Set the dilution factor as a gain (e.g., a value of 20 means 20 parts diluent and 1 part of sample gas):  
4. Calibrate the analyzer.  
Make sure that the calibration span gas is either supplied through the same dilution system as the  
sample gas or has an appropriately lower actual concentration.  
EXAMPLE: If the reporting range limit is set for 100 ppm and the dilution ratio of the sample gas is 20  
gain, either:  
a span gas with the concentration of 100 ppm can be used if the span gas passes through the same  
dilution steps as the sample gas, or;  
a 5 ppm span gas must be used if the span gas IS NOT routed through the dilution system.  
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7. ADVANCED FEATURES  
7.1. SETUP IDAS: USING THE DATA ACQUISITION SYSTEM  
(IDAS)  
The GFC 7001E/EM 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 GFC 7001E/EM 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 is stored in non-volatile  
memory and is retained even when the instrument is powered off. Data is stored in plain text format 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.  
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 offers APICOM, a program that provides a visual interface for remote  
or local setup, configuration and data retrieval of the iDAS. 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 manual.  
The GFC 7001E/EM is configured with a basic iDAS configuration, which is enabled by default. New data  
channels are also enabled by default at their creation, but all channels may be turned off for later or occasional  
use.  
Note  
iDAS operation is suspended whenever its configuration is edited using the analyzer’s front panel and  
therefore data may be lost. To prevent such data loss, it is recommended to use the APICOM graphical  
user interface for iDAS changes.  
Please be aware that all stored data will be erased if the analyzer’s Disk-on-Module or CPU board is  
replaced or if the configuration data stored there is reset.  
Since all changes to the configuration of the iDAS cause all of the existing data to be erased, it is  
recommended to download your stored data prior to making any changes.  
7.1.1. IDAS STATUS  
The green SAMPLE LED on the instrument front panel, which indicates the analyzer status, also indicates  
certain aspects of the iDAS status:  
Table 7-1: Front Panel LED Status Indicators for iDAS  
LED STATE  
IDAS STATUS  
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.  
Off  
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.  
Blinking  
On  
Sampling normally.  
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The iDAS can be disabled, as opposed to suspended, only by disabling or deleting its individual data channels.  
7.1.2. IDAS STRUCTURE  
The iDAS is designed around the feature of a “record”. A record is a single data point. The type of data  
recorded in a record is defined by two properties:  
PARAMETER type that defines the kind of data to be stored (e.g. the average of gas concentrations  
measured with three digits of precision). See Section 7.1.5.3.  
A TRIGGER event that defines when the record is made (e.g. timer; every time a calibration is performed,  
etc.). See Section 7.1.5.2.  
The specific PARAMETERS and TRIGGER events that describe an individual record are defined in a construct  
called a DATA CHANNEL (see Section 7.1.3). Each data channel is related one or more parameters with a  
specific trigger event and various other operational characteristics related to the records being made (e.g. the  
channels name, number or records to be made, time period between records, whether or not the record is  
exported via the analyzer’s RS-232 port, etc.).  
7.1.2.1. 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 50 data channels and each channel can  
contain one or more parameters. For each channel, the following are selected:  
One triggering event is selected.  
Up to 50 data parameters, which can be the shared between channels.  
Several other properties that define the structure of the channel and allow the user to make operational  
decisions regarding the channel.  
Table 7-2: iDAS Data Channel Properties  
DEFAULT  
PROPERTY  
DESCRIPTION  
SETTING RANGE  
SETTING  
Up to 6 letters or digits 1.  
NAME  
The name of the data channel.  
“NONE”  
Any available event  
(see Appendix A-5).  
TRIGGERING  
EVENT  
The event that triggers the data channel to measure  
and store the datum.  
ATIMER  
NUMBER AND  
LIST OF  
PARAMETERS  
Any available parameter  
(see Appendix A-5).  
A User-configurable list of data types to be  
recorded in any given channel.  
1
(COMEAS)  
000:00:01 to  
366:23:59  
(Days:Hours:Minutes)  
The amount of time between each channel data  
point.  
000:01:00  
(1 hour)  
REPORT PERIOD  
The number of reports that will be stored in the data  
file. Once the limit is exceeded, the oldest data is  
over-written.  
1 to 1 million, limited by  
available storage space.  
NUMBER OF  
RECORDS  
100  
Enables the analyzer to automatically report  
channel values to the RS-232 ports.  
RS-232 REPORT  
OFF  
ON  
OFF or ON  
OFF or ON  
OFF or ON  
CHANNEL  
ENABLED  
Enables or disables the channel. Allows a channel  
to be temporarily turned off without deleting it.  
Disables sampling of data parameters while  
CAL HOLD OFF  
OFF  
instrument is in calibration mode 2.  
1 More with APICOM, but only the first six are displayed on the front panel.  
2 When enabled records are not recorded until the DAS HOLD OFF period is passed after calibration mode. DAS HOLD OFF SET in  
the VARS menu (see Section Error! Reference source not found.).  
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7.1.3. 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.  
PNUMTC: Collects sample flow and sample pressure data at five-minute intervals and stores an 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 of CO measurements every time a zero or span calibration is  
performed and the result changes the value of the slope (triggering event: SLPCHG). The CO stability  
data to evaluate if the calibration value was stable are also stored.  
This data channel will store data from the last 200 calibrations and can be used to document analyzer  
calibration and is useful in the detection of the in slope and offset (instrument response) when  
performing predictive diagnostics as part of a regular maintenance schedule.  
The CALDAT channel collects data based on events (e.g. a calibration operation) rather than a timed  
interval and therefore does not represent any specific length of time. As with all data channels, a  
date and time stamp is recorded for every logged data point.  
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 COMM 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.  
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Triggering Events and Data Parameters/Functions for these default channels are:  
Figure 7-1:  
Default iDAS Channel Setup  
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7.1.4. SETUP DAS VIEW: VIEWING IDAS CHANNELS AND INDIVIDUAL  
RECORDS  
iDAS data and settings can be viewed on the front panel through the following keystroke sequence.  
Moves the VIEW backward 10 record  
SETUP X.X  
Moves the VIEW backward 1 records or channel  
CFG  
RNGE PASS CLK MORE  
EXIT  
EXIT  
EXIT  
Moves the VIEW forward 1 record or channel  
Moves the VIEW forward 10 records  
SETUP X.X  
Selects the previous parameter on the list  
Selects the next parameter on the list  
EDIT  
SETUP X.X  
SETUP X.X  
SETUP X.X  
EXIT  
SETUP X.X  
PREV  
EXIT  
<PRM PRM>  
EXIT  
EXIT  
SETUP X.X  
PREV  
SETUP X.X  
PV10 PREV  
EXIT  
SETUP X.X  
EXIT  
SETUP X.X  
PV10 PREV NX10 NEXT <PRM PRM>  
SETUP X.X  
PV10 PREV  
EXIT  
<PRM PRM>  
EXIT  
Continue pressing  
to view remaining  
iDAS channels  
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7.1.5. SETUP DAS EDIT: ACCESSING THE IDAS EDIT MODE  
iDAS configuration is most conveniently done through the APICOM remote control program. The following list of  
key strokes shows how to edit the iDAS using the front panel.  
When editing the data channels, the top line of the display indicates some of the configuration parameters.  
For example, the display line:  
0) CONC: ATIMER, 1, 800  
Translates to the following configuration:  
Channel No.: 0  
NAME: CONC  
TRIGGER EVENT: ATIMER  
PARAMETERS: One parameter is included in this channel  
EVENT: This channel is set up to store 800 records.  
To edit the name of a data channel, follow the above key sequence and refer to Section 7.1.5.1:  
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7.1.5.1. Editing iDAS Data Channel Names  
To edit the name of an iDAS data channel, follow the instruction shown in Section 7.1.5.1, then press:  
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7.1.5.2. Editing iDAS Triggering Events  
Triggering events define when and how the iDAS records a measurement of any given data channel. 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.  
EXITZR, EXITSP, and 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.  
WARNINGS: Some data may be useful when stored if one of several warning messages appears such as  
WTEMPW (GFC Wheel temperature warning). This is helpful for troubleshooting by monitoring when a  
particular warning occurrs.  
To edit the list of data parameters associated with a specific data channel, follow the instruction shown in Section  
7.1.5 then press:  
NOTE  
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Triggering events are firmware-specific and a complete list of Triggers for this model analyzer can be  
found in Appendix A-5.  
7.1.5.3. Editing iDAS Parameters  
Data parameters are types of data that may be measured and stored by the iDAS. For each 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 GFC 7001E/EM. iDAS parameters include things like CO concentration  
measurements, temperatures of the various heaters placed around the analyzer, pressures and flows of the  
pneumatic subsystem and other diagnostic measurements as well as calibration data such as stability, slope and  
offset.  
Most data parameters have associated measurement units, such as mV, ppb, cm³/min, etc., although some  
parameters have no units (e.g. SLOPE). 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 6.6.4.  
Note  
iDAS does not keep track of the units (i.e. PPM or PPB) of each concentration value therefore iDAS data  
files may contain concentrations data recorded in more than one the type of unit if the units of measure  
was changed during data acquisition.  
Each data parameter has user-configurable functions that define how the data are recorded.  
Table 7-3: iDAS Data Parameter Functions  
FUNCTION  
PARAMETER  
SAMPLE MODE  
EFFECT  
Instrument-specific parameter name.  
INST: Records instantaneous reading.  
AVG: Records average reading during reporting interval.  
SDEV: Records the standard deviation of the data points recorded during the reporting interval.  
MIN: Records minimum (instantaneous) reading during reporting interval.  
MAX: Records maximum (instantaneous) reading during reporting interval.  
PRECISION  
0 to 4: Sets the number of digits to the right decimal point for each record.  
Example: Setting 4; “399.9865 PPB”  
Setting 0; “400 PPB”  
STORE NUM  
SAMPLES  
OFF: Stores only the average (default).  
ON: Stores the average and the number of samples in used to compute the value of the  
parameter. This property is only useful when the AVG sample mode is used. Note that the  
number of samples is the 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 GFC 7001E/EM provides about 40 parameters).  
However, the number of parameters and channels is ultimately limited by available memory.  
Data channels can be edited individually from the front panel without affecting other data channels. However,  
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.  
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To modify, add or delete a parameter, follow the instruction shown in Section 7.1.5 then press:  
NOTE  
When the STORE NUM SAMPLES feature is turned on, the instrument will store how many  
measurements were used to compute the AVG, SDEV, MIN or MAX  
value but not the actual measurements themselves.  
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7.1.5.4. Editing Sample Period and Report Period  
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 parameter in  
volatile memory. SAMPLE PERIOD is only used when the iDAS parameter’s sample mode is set for  
AVG, SDEV, MIN or MAX.  
The SAMPLE PERIOD 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.  
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 Period 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.  
To define the REPORT PERIOD, follow the instruction shown in Section 7.1.5 then press:  
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The SAMPLE PERIOD and REPORT PERIOD intervals are synchronized to the beginning and end of the  
appropriate interval of the instruments internal clock.  
If SAMPLE PERIOD were set for one minute the first reading would occur at the beginning of the next full  
minute according to the instrument’s internal clock.  
If the REPORT PERIOD 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 the 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.  
NOTE  
In AVG, SDEV, MIN or MAX sample modes (see Section 7.1.5.3), the settings for the Sample Period and  
the Report Period determine the number of data points used each time the parameter is calculated,  
stored and reported to the COMM ports.  
The actual sample readings are not stored past the end of the chosen report period.  
When the STORE NUM SAMPLES feature is turned on, the instrument will store how many  
measurements were used to compute the AVG, SDEV, MIN or MAX Value, but not the actual  
measurements themselves.  
7.1.5.5. Report Periods 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 stores  
them in volatile memory as part of the REPORT PERIOD currently active at the time of restart. At the end of this  
REPORT PERIOD PERIOD, only the sample readings taken since the instrument was turned back on will be  
included in any AVG, SDEV, MIN or MAX calculation.  
Also, the STORE NUM SAMPLES feature will report the number of sample readings taken since the instrument  
was restarted.  
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7.1.5.6. Editing the Number of Records  
The number of data records in the iDAS is limited to about a cumulative one million data points in all channels  
(one megabyte of space on the Disk-on-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. 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 cause the upload of an iDAS configuration with APICOM or a terminal program to fail, if the combined  
number of records would be exceeded. In this case, it is suggested to either try to determine what the maximum  
number of records available is using the front panel interface or use trial-and-error in designing the iDAS script or  
calculate the number of records using the DAS or APICOM manuals.  
To set the NUMBER OF RECORDS, follow the instruction shown in Section 7.1.5 then press:  
.
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7.1.5.7. RS-232 Report Function  
The 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 using the APICOM software.  
To enable automatic COMM port reporting, follow the instruction shown in Section 7.1.5 then press:  
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7.1.5.8. Enabling/Disabling the HOLDOFF Feature  
The iDAS HOLDOFF feature prevents data collection during calibration operations and at certain times when  
the quality of the analyzer’s CO measurements may not be certain (e.g. while the instrument is warming up). In  
this case, the length of time that the HOLDOFF feature is active is determined by the value of the internal  
variable (VARS), DAS_HOLDOFF.  
To set the length of the DAS_HOLDOFF period, see Section Error! Reference source not found..  
To enable or disable the HOLDOFF, follow the instruction shown in Section 7.1.5 then press:  
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7.1.5.9. The Compact Report Feature  
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.  
The COMPACT DATA REPORT 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.  
7.1.5.10. The Starting Date Feature  
This option allows the user 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 default condition), the  
iDAS ignores this setting and begins recording data as defined by the REPORT PERIOD setting.  
The STARTING DATE 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.  
7.1.6. DISABLING/ENABLING DATA CHANNELS  
Data channels can be temporarily disabled, which can reduce the read/write wear on the Disk-on-Chip.  
To disable a data channel, follow the instruction shown in Section 7.1.5 then press:  
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7.1.7. REMOTE IDAS CONFIGURATION  
7.1.7.1. iDAS Configuration Using APICOM  
Editing channels, parameters and triggering events as described in this can be performed via the APICOM  
remote control program using the graphic interface shown below. Refer to Section 8 for details on remote  
access to the GFC 7001E/EM Analyzer.  
Figure 7-2:  
APICOM User Interface for Configuring the iDAS  
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’s P/N 039450000) is included in the APICOM installation file, which can be downloaded at  
http://www.teledyne-ai.com/manuals/.  
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7.1.7.2. iDAS Configuration Using Terminal Emulation Programs  
Although Teledyne recommends the use of APICOM, the iDAS can also be accessed and configured through a  
terminal emulation program such as HyperTerminal (see example in Figure 7-3).  
To do this:  
All configuration commands must be created and edited off line (e.g. cut & pasted in from a text file or  
word processor) following a strict syntax (see below for example).  
The script is then uploaded via the instruments RS-232 port(s).  
Figure 7-3:  
iDAS Configuration Through a Terminal Emulation Program  
Both of the above steps are best started by:  
1. Downloading the default iDAS configuration.  
2. Getting familiar with its command structure and syntax conventions.  
3. Altering a copy of the original file offline.  
4. Uploading the new configuration into the analyzer.  
NOTE  
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.  
On the other hand, uploading an iDAS configuration script to the analyzer through its communication  
ports will ERASE ALL DATA, PARAMETERS AND CHANNELS and replace them with the new iDAS  
configuration.  
It is recommended that you download and backup all data and the original iDAS configuration before  
attempting any iDAS changes.  
Refer to the next section, 8. Remote Operation, for details on remote access to and from the GFC 7001E/EM  
Analyzer via the instrument’s COMM ports.  
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7.2. SETUP MORE VARS: INTERNAL VARIABLES (VARS)  
The GFC 7001E/EM 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  
redefined using the VARS menu.  
The following table lists all variables that are available within the 818 password protected level. See Appendix  
A-2 for a detailed listing of all of the GFC 7001E/EM variables that are accessible through the remote interface.  
Table 7-4: Variable Names (VARS)  
VARS  
DEFAULT  
VALUES  
ALLOWED  
VALUES  
NO.  
VARIABLE  
DESCRIPTION  
Changes the Internal Data Acquisition System (iDAS)  
HOLDOFF timer.  
May be set for  
intervals  
between  
0.5 – 20 min  
No data is stored in the iDAS channels during situations  
when the software considers the data to be questionable  
such as during warm-up or just after the instrument returns  
from one of its calibration modes to SAMPLE Mode.  
DAS_HOLD_OFF  
15 min.  
0
Allows the user to set the number of significant digits to the  
CONC_PRECISION right of the decimal point display of concentration and stability  
AUTO, 1, 2,  
3, 4  
AUTO  
OFF  
1
2
3
4
values.  
Dynamic zero automatically adjusts offset and slope of the  
CO response when performing a zero point calibration during  
an AutoCal (see Section 9.4).  
DYN_ZERO 1  
DYN_SPAN 1  
ON/OFF  
ON/OFF  
Dynamic span automatically adjusts the offsets and slopes of  
the CO response when performing a slope calibration during  
an AutoCal (see Section 9.4).  
OFF  
Adjusts the speed of the analyzer’s clock. Choose the +  
sign if the clock is too slow, choose the - sign if the clock is  
too fast.  
-60 to +60  
s/day  
CLOCK_ADJ  
STABIL_GAS2  
0 sec  
CO  
Selects which gas measurement is displayed when the STABIL  
test function is selected.  
CO; CO2 & O2  
5
1
Use of the DYN_ZERO and DYN_SPAN features are not allowed for applications requiring EPA equivalency.  
This VARS only appears if either the optional O2 or CO2 sensors are installed.  
2
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To access and navigate the VARS menu, use the following key sequence.  
Concentration display  
continuously cycles  
through all gasses.  
SETUP X.X  
CFG DAS RNGE PASS CLK  
EXIT  
SETUP X.X  
In all cases:  
discards the new  
setting.  
COMM  
DIAG  
EXIT  
EXIT  
accepts the  
new setting.  
SETUP X.X  
Toggle these  
keys to enter the  
correct  
SETUP X.X  
PREV  
JUMP  
PRNT EXIT  
SETUP X.X  
Toggle these keys to set  
the iDAS HOLDOFF time  
period in minutes  
SETUP X.X  
PREV  
(MAX = 20 minutes).  
JUMP  
JUMP  
PRNT EXIT  
PRNT EXIT  
SETUP X.X  
SETUP X.X  
Use these Keys to select  
the precision of the o33  
concentration display.  
SETUP X.X  
PREV  
Toggle this key to turn the  
Dynamic Zero calibration  
feature  
SETUP X.X  
PREV  
JUMP  
PRNT EXIT  
SETUP X.X  
Toggle this key to turn the  
Dynamic Span calibration  
feature  
PREV  
JUMP  
JUMP  
EDIT ENTR EXIT  
ENTR EXIT  
Enter sign and number of  
seconds per day the clock  
gains (-) or loses(+).  
SETUP X.X  
PREV  
PRNT EXIT  
SETUP X.X  
Use these keys to select  
which gas will be reported  
by the sTABIL test  
function.  
Press  
VARS; press  
for additional  
or  
to move back and  
forth throughout the list of  
VARS.  
(O2 is only available if the  
optional O2 sensor is  
installed)  
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7.3. SETUP MORE DIAG: USING THE DIAGNOSTICS  
FUNCTIONS  
A series of diagnostic tools is grouped together under the SETUPMOREDIAG menu, as these parameters  
are dependent on firmware revision (see Appendix A). 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  
of this manual.  
The various operating modes available under the DIAG menu are:  
Table 7-5: Diagnostic Mode (DIAG) Functions  
Front Panel Mode  
Indicator  
MANUAL  
SECTION  
DIAG SUBMENU  
SIGNAL I/O  
SUBMENU FUNCTION  
Allows observation of all digital and analog signals in  
the instrument. Allows certain digital signals such as  
valves and heaters to be toggled ON and OFF.  
DIAG I/O  
13.1.3  
When entered, the analyzer performs an analog  
ANALOG OUTPUT output step test. This can be used to calibrate a  
DIAG AOUT  
13.5.7.1  
chart recorder or to test the analog output accuracy.  
This submenu allows the user to configure the  
analyzer’s analog output channels, including  
choosing what parameter will be output on each  
ANALOG I/O  
channel. Instructions that appear here allow  
DIAG AIO  
7.4.1  
CONFIGURATION adjustment and calibration of the voltage signals  
associated with each output as well as calibration of  
the analog to digital converter circuitry on the  
motherboard.  
When activated, the analyzer performs an electrical  
test, which generates a voltage intended to simulate  
the measure and reference outputs of the  
SYNC/DEMOD board to verify the signal handling  
9.6.4  
13.5.6.2  
ELECTRICAL  
DIAG ELEC  
TEST  
and conditioning of these signals.  
Disconnects the preamp from synchronous  
DARK  
demodulation circuitry on the SYNC/DEMOD PCA to  
establish the dark offset values for the measure and  
reference channel.  
DIAG DARK  
CAL  
9.6.1  
CALIBRATION1  
PRESSURE  
Allows the user to calibrate the sample pressure  
sensor.  
DIAG PCAL  
DIAG FCAL  
DIAG TCHN  
9.6.2  
9.6.3  
7.4.6  
CALIBRATION1  
FLOW  
This function is used to calibrate the gas flow output  
signals of sample gas and ozone supply.  
CALIBRATION1  
TEST CHAN  
OUTPUT  
Selects one of the available test channel signals to  
output over the A4 analog output channel.  
1
These settings are retained after exiting DIAG mode.  
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7.3.1. ACCESSING THE DIAGNOSTIC FEATURES  
To access the DIAG functions press the following keys:  
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7.4. USING THE GFC 7001E/EM ANALYZER’S ANALOG  
OUTPUTS.  
The GFC 7001E/EM Analyzer comes equipped with four analog outputs.  
The first two outputs (A1 & A2) carry analog signals that represent the currently measured concentration  
of CO (see Section 6.6.2).  
The third output (A3) is only active if the analyzer is equipped with one of the optional 2nd gas sensors (e.g.  
O2 or CO2).  
The fourth output (A4) outputs a signal that can be set to represent the current value of one of several test  
functions (see Table 7-10).  
7.4.1. ACCESSING THE ANALOG OUTPUT SIGNAL CONFIGURATION  
SUBMENU  
The following lists the analog I/O functions that are available in the GFC 7001E/EM Analyzer.  
Table 7-6: DIAG - Analog I/O Functions  
OUTPUT  
CHANNEL  
MANUAL  
SECTION  
SUB MENU  
FUNCTION  
Initiates a calibration of the A1, A2, A3 and A4 analog output  
channels that determines the slope and offset inherent in the  
circuitry of each output.  
AOUT  
CALIBRATED  
7.4.3  
ALL  
These values are stored and applied to the output signals by  
the CPU automatically.  
Sets the basic electronic configuration of the A1 output (CO  
Concentration).  
There are four options:  
RANGE1: Selects the signal type (voltage or current loop)  
and level of the output.  
CONC_OUT_1  
A1  
REC OFS: Allows them input of a DC offset to let the user  
manually adjust the output level.  
7.4  
AUTO CAL: Enables / Disables the AOUT CALIBRATED  
feature.  
CALIBRATED: Performs the same calibration as AOUT  
CALIBRATED, but on this one channel only.  
CONC_OUT_2  
CONC_OUT_3  
Same as for CONC_OUT_1 but for analog channel A2.  
A2  
A3  
Same as for CONC_OUT_1 but for analog channel A3 but  
only if either the optional O2 or CO2 sensors are installed.  
Same as for CONC_OUT_1 but for analog channel A4  
TEST OUTPUT  
7.4.6  
7.4.7  
A4  
(TEST CHANNEL).  
AIN  
CALIBRATED  
Initiates a calibration of the A-to-D Converter circuit located on  
the Motherboard.  
N/A  
1
Any changes made to RANGE or REC_OFS require recalibration of this output.  
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To access the ANALOG I/O CONFIGURATION sub menu, press:  
Figure 7-4:  
Accessing the Analog I/O Configuration Submenus  
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7.4.2. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION  
In its standard configuration, each of the analog outputs is set to output a 0–5 VDC signals. Several other output  
ranges are available. Each range has is usable from -5% to + 5% of the rated span.  
Table 7-7: Analog Output Voltage Range Min/Max  
RANGE NAME  
RANGE SPAN  
0-100 mVDC  
0-1 VDC  
MINIMUM OUTPUT  
-5 mVDC  
MAXIMUM OUTPUT  
105 mVDC  
0.1V  
1V  
-0.05 VDC  
1.05 VDC  
5V  
0-5 VDC  
-0.25 VDC  
5.25 VDC  
10V  
0-10 VDC  
-0.5 VDC  
10.5 VDC  
The default offset for all VDC ranges is 0-5 VDC.  
CURR  
0-20 mA  
0 mA  
20 mA  
While 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 current ranges is 0 mA.  
Current outputs are available only on A1-A3.  
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To change the output type and range, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4)  
then press:  
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7.4.3. CALIBRATION OF THE ANALOG OUTPUTS  
Analog output calibration should to be carried out on first startup of the analyzer (performed in the factory as part  
of the configuration process) or whenever recalibration is required. The analog outputs can be calibrated  
automatically or adjusted manually.  
During automatic calibration, the analyzer tells the output circuitry to generate a zero mV signal and high-scale  
point signal (usually about 90% of chosen analog signal scale) then measures actual signal of the output. Any  
error at zero or high-scale is corrected with a slope and offset.  
Automatic calibration can be performed via the CAL button located inside The AOUTS CALIBRATION  
submenu. By default, the analyzer is configured so that calibration of analog outputs can be initiated as a group  
with the AOUT CALIBRATION command. The outputs can also be calibrated individually, but this requires the  
AUTOCAL feature be disabled.  
7.4.3.1. Enabling or Disabling the AutoCal for an Individual Analog Output  
To enable or disable the AutoCal feature for an individual analog output, elect the ANALOG I/O  
CONFIGURATION submenu (see Figure 7-4) then press:  
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7.4.3.2. Automatic Calibration of the Analog Outputs  
To calibrate the outputs as a group with the AOUTS CALIBRATION command, select the ANALOG I/O  
CONFIGURATION submenu (see Figure 7-4) then press:  
NOTE  
Before performing this procedure, make sure that the AUTO CAL for each analog output is enabled.  
(See Section 7.4.3.1)  
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NOTE:  
Manual calibration should be used for any analog output set for a 0.1V output range or in cases where  
the outputs must be closely matched to the characteristics of the recording device.  
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7.4.3.3. Individual Calibration of the Analog Outputs  
To use the AUTO CAL feature to initiate an automatic calibration for an individual analog output, select the  
ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press:  
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7.4.3.4. Manual Calibration of the Analog Outputs Configured for Voltage Ranges  
For highest accuracy, the voltages of the analog outputs can be manually calibrated.  
NOTE:  
The menu for manually adjusting the analog output signal level will only appear if the AUTO-CAL feature  
is turned off for the channel being adjusted (see Section 7.4.3.1).  
Calibration is performed with a voltmeter connected across the output terminals and by changing the actual  
output signal level using the front panel keys in 100, 10 or 1 count increments. See Figure 3-7 for pin  
assignments and diagram of the analog output connector.  
V
+DC Gnd  
Figure 7-5:  
Setup for Checking / Calibrating DCV Analog Output Signal Levels  
Table 7-8: Voltage Tolerances for the TEST CHANNEL Calibration  
MINIMUM  
ADJUSTMENT  
(1 count)  
FULL  
SCALE  
ZERO  
TOLERANCE  
SPAN  
TOLERANCE  
SPAN VOLTAGE  
0.1 VDC  
1 VDC  
±0.0005V  
±0.001V  
±0.002V  
±0.004V  
90 mV  
900 mV  
4500 mV  
4500 mV  
±0.001V  
±0.001V  
±0.003V  
±0.006V  
0.02 mV  
0.24 mV  
1.22 mV  
2.44 mV  
5 VDC  
10 VDC  
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To adjust the signal levels of an analog output channel manually, select the ANALOG I/O CONFIGURATION  
submenu (see Figure 7-4) then press:  
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7.4.3.5. Manual Adjustment of Current Loop Output Span and Offset  
A current loop option may be purchased for the A1, A2 and A3 analog outputs of the analyzer. This option  
places circuitry in series with the output of the D-to-A converter on the motherboard that changes the normal DC  
voltage output to a 0-20 milliamp signal (see Section 5.4).  
The outputs can be ordered scaled to any set of limits within that 0-20 mA range, however most current  
loop applications call for either 0-20 mA or 4-20 mA range spans.  
All current loop outputs have a +5% over range. Ranges whose lower limit is set above 1 mA also have a  
–5% under range.  
To switch an analog output from voltage to current loop, follow the instructions in Section 7.4.2 (select CURR  
from the list of options on the “Output Range” menu).  
Adjusting the signal zero and span levels of the current loop output is done by raising or lowering the voltage  
output of the D-to-A converter circuitry on the analyzer’s motherboard. This raises or lowers the signal level  
produced by the current loop option circuitry.  
The software allows this adjustment to be made in 100, 10 or 1 count increments. Since the exact amount by  
which the current signal is changed per D-to-A count varies from output-to-output and instrument-to-instrument,  
you will need to measure the change in the signal levels with a separate, current meter placed in series with the  
output circuit. See Figure 3-7 for pin assignments and diagram of the analog output connector.  
Figure 7-6:  
Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter  
CAUTION  
GENERAL SAFETY HAZARD  
Do not exceed 60 V peak voltage between current loop outputs and instrument  
ground.  
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To adjust the zero and span signal levels of the current outputs, select the ANALOG I/O CONFIGURATION  
submenu (see Figure 7-4) then press:  
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An alternative method for measuring the output of the Current Loop converter is to connect a 250 ohm 1%  
resistor across the current loop output in lieu of the current meter (see Figure 3-7 for pin assignments and  
diagram of the analog output connector). This allows the use of a voltmeter connected across the resistor to  
measure converter output as VDC or mVDC.  
V
+DC Gnd  
Figure 7-7:  
Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels  
In this case, follow the procedure above but adjust the output for the following values:  
Table 7-9: Current Loop Output Check  
Voltage across  
Resistor for 2-20 mA  
Voltage across  
Resistor for 4-20 mA  
% FS  
0
500 mVDC  
1000 mVDC  
5000 mVDC  
100  
5000 mVDC  
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7.4.4. TURNING AN ANALOG OUTPUT OVER-RANGE FEATURE ON/OFF  
In its default configuration, a ± 5% over-range is available on each of the GFC 7001E/EM Analyzer’s analog  
outputs. This over-range can be disabled if your recording device is sensitive to excess voltage or current.  
To turn the over-range feature on or off, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4)  
then press:  
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7.4.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT  
Some analog signal recorders require that the zero signal is significantly different from the baseline of the  
recorder in order to record slightly negative readings from noise around the zero point. This can be achieved in  
the GFC 7001E/EM by defining a zero offset, a small voltage (e.g., 10% of span).  
To add a zero offset to a specific analog output channel, select the ANALOG I/O CONFIGURATION submenu  
(see Figure 7-4) then press:  
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7.4.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4  
The test functions available to be reported are listed in Table 7-10:  
Table 7-10: Test Channels Functions available on the GFC 7001E/EM’s Analog Output  
TEST CHANNEL  
NONE  
DESCRIPTION  
ZERO  
FULL SCALE *  
TEST CHANNEL IS TURNED OFF.  
The demodulated, peak IR detector output  
during the measure portion of the GFC Wheel  
cycle.  
CO MEASURE  
CO REFERENCE  
SAMPLE PRESS  
0 mV  
0 mV  
0" Hg  
5000 mV  
5000 mV  
40 "Hg  
The demodulated, peak IR detector output  
during the reference portion of the GFC  
Wheel cycle.  
The absolute pressure of the Sample gas as  
measured by a pressure sensor located inside  
the sample chamber.  
Sample mass flow rate as measured by the  
flow rate sensor in the sample gas stream.  
SAMPLE FLOW  
SAMPLE TEMP  
0 cm3/m  
1000 cm 3/m  
The temperature of the gas inside the sample  
chamber.  
0C  
70C  
BENCH TEMP  
WHEEL TEMP  
Optical bench temperature.  
GFC Wheel temperature.  
0C  
70C  
0C  
70C  
The current temperature of the O2 sensor  
measurement cell.  
O2 CELL TEMP  
n
70C  
CHASSIS TEMP  
The temperature inside the analyzer chassis.  
0C  
70C  
The drive voltage being supplied to the  
thermoelectric coolers of the IR photo-  
detector by the Sync/Demod Board.  
PHT DRIVE  
0 mV  
5000 mV  
* Maximum test signal value at full scale of test channel output.  
Once a function is selected, the instrument not only begins to output a signal on the analog output, but also adds  
TEST to the list of test functions viewable via the front panel display.  
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To activate the TEST Channel and select CO MEASURE a function, press:  
SETUP X.X  
CFG DAS RNGE PASS CLK  
EXIT  
SETUP X.X  
COMM VARS  
EXIT  
EXIT  
SETUP X.X  
Toggle these  
keys to enter the  
correct  
DIAG  
PREV  
ENTR EXIT  
Continue pressing  
until ...  
DIAG  
PREV NEXT  
EXIT  
EXIT  
DIAG  
Toggle these keys to  
choose a mass flow  
controller TEST  
DIAG  
channel parameter.  
discards the new  
setting.  
PREV NEXT  
EXIT  
accepts the  
new setting.  
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7.4.7. AIN CALIBRATION  
This is the submenu to conduct a calibration of the GFC 7001E/EM Analyzer’s analog inputs. This calibration  
should only be necessary after major repair such as a replacement of CPU, motherboard or power supplies.  
To perform an analog input calibration, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4)  
then press:  
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7.5. SETUP MORE ALRM: USING THE GAS  
CONCENTRATION ALARMS  
The GFC 7001E/EM includes two CO concentration alarms if OPT 61 is installed on your instrument. Each  
alarm has a user settable limit, and is associated with a Single Pole Double Throw relay output accessible via the  
alarm output connector on the instrument’s back panel (See Section 3.3.3). 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 7-11: CO Concentration Alarm Default Settings  
ALARM  
alm1  
STATUS  
Disabled  
Disabled  
LIMIT SET POINT1  
100 ppm  
alm2  
300 ppm  
1Set points listed are for PPM. Should the reporting range units of measure be changed (See Section  
6.6.3) 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 ensure that the  
CAL or CALS button is pressed prior to introducing span gas into the analyzer.  
7.5.1. SETTING THE GFC 7001E CONCENTRATION ALARM LIMITS  
To enable either of the CO concentration alarms and set the limit points, press:  
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8. REMOTE OPERATION  
8.1. SETUP MORECOMM: USING THE ANALYSER’S  
COMMUNICATION PORTS  
The GFC 7001E/EM is equipped with two serial communication ports located on the rear panel (see 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 RS232 port can also be configured to operate in single or RS-232 multidrop mode (option 62; See  
Section 5.7.2 and 8.2).  
The COM2 port can be configured for standard RS-232 operation, half-duplex RS-485 communication or  
for access via an LAN by installing the Teledyne’s Ethernet interface card (option 63; See Section 5.7.3  
and 8.4).  
A Code-Activated Switch (CAS), can also be used on either port to connect typically between 2 and 16  
send/receive instruments (host computer(s) printers, data loggers, analyzers, monitors, calibrators, etc.) into one  
communications hub. Contact Teledyne sales for more information on CAS systems.  
8.1.1. RS-232 DTE AND DCE COMMUNICATION  
RS-232 was developed for allowing communications between Data Terminal Equipment (DTE) and Data  
Communication Equipment (DCE). Basic data terminals always fall into the DTE category whereas modems are  
always considered DCE devices.  
Electronically, the difference between the DCE and DTE 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.  
A switch located below the bottom DB-9 connector on the rear panel allows the user to switch between DTE (for  
use with data terminals) or DCE (for use with modems). Since computers can be either DTE or DCE, check your  
computer to determine which mode to use.  
8.1.2. 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.  
RS-232 RS-232 (fixed) DB-9 male connector.  
Baud rate: 19200 bits per second (baud).  
Data Bits: 8 data bits with 1 stop bit.  
Parity: None.  
COM2: RS-232 (configurable to RS 485), DB-9 female connector.  
Baud rate:115000 bits per second (baud).  
Data Bits: 8 data bits with 1 stop bit.  
Parity: None.  
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Female DB-9 (COM2)  
(As seen from outside analyzer)  
Male DB-9 (RS-232)  
(As seen from outside analyzer)  
TXD  
TXD  
GND  
GND  
RXD  
RXD  
1
2
3
4
5
1
2
3
4
5
6
7
8
9
6
7
8
9
CTS  
CTS  
RTS  
RTS  
(DTE mode)  
(DTE mode)  
RXD  
GND  
TXD  
1
2
3
4
5
6
7
8
9
RTS  
CTS  
(DCE mode)  
Figure 8-1:  
Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE)  
The signals from these two connectors are routed from the motherboard via a wiring harness to two 10-pin  
connectors on the CPU card, J11 (RS-232) and J12 (COM2).  
Figure 8-2:  
Default Pin Assignments for CPU COM Port connector (RS-232)  
Teledyne offers two mating cables, one of which should be applicable for your use.  
Part number WR000077, a DB-9 female to DB-9 female cable, 6 feet long. Allows connection of the serial  
ports of most personal computers. Also available as Option 60 (see Section 5.7.1).  
Part number WR000024, 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.  
NOTE  
Cables that appear to be compatible because of matching connectors may incorporate internal wiring  
that makes the link inoperable. Check cables acquired from sources other than Teledyne for pin  
assignments before using.  
To assist in properly connecting the serial ports to either a computer or a modem, there are activity indicators just  
above the RS-232 port. Once a cable is connected between the analyzer and a computer or modem, both the  
red and green LEDs should be on.  
If the lights are not lit, use small switch on the rear panel to switch it between DTE and DCE modes.  
If both LEDs are still not illuminated, make sure the cable properly constructed.  
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8.1.3. COMM PORT BAUD RATE  
To select the baud rate of either one of the COMM ports, press:  
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8.1.4. 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  
8-1. As modes are selected, the analyzer sums the mode ID numbers and displays this combined number on  
the front panel display. For example, if quiet mode (01), computer mode (02) and Multi-Drop-Enabled mode (32)  
are selected, the analyzer would display a combined MODE ID of 35.  
Table 8-1: COMM Port Communication Modes  
MODE1  
QUIET  
ID  
1
DESCRIPTION  
Quiet mode suppresses any feedback from the analyzer (such as warning messages) to  
the remote device and is typically used when the port is communicating with a computer  
program where such intermittent messages might cause communication problems.  
Such feedback is still available but a command must be issued to receive them.  
Computer mode inhibits echoing of typed characters and is used when the port is  
communicating with a computer operated control program.  
COMPUTER  
2
HESSEN  
PROTOCOL  
The Hessen communications protocol is used in some European countries. TAI P/N  
02252 contains more information on this protocol.  
16  
When turned on this mode switches the COMM port settings from  
E, 8, 1  
E, 7, 1  
RS-485  
8192  
2048  
1024  
●
NO PARITY; 8 data bits; 1 stop bit to EVEN PARITY; 8 data bits; 1 stop bit.  
When turned on this mode switches the COM port settings from  
●
NO PARITY; 8 DATA BITS; 1 stop bit to EVEN PARITY; 7 DATA BITS; 1 stop bit.  
Configures the COM2 Port for RS-485 communication. RS-485 mode has precedence  
over multidrop mode if both are enabled.  
When enabled, the serial port requires a password before it will respond (see Section  
8.1.7.5). If not logged on, the only active command is the '?' request for the help  
screen.  
SECURITY  
4
MULTIDROP  
PROTOCOL  
Multidrop protocol allows a multi-instrument configuration on a single communications  
channel. Multidrop requires the use of instrument IDs.  
32  
64  
ENABLE  
MODEM  
Enables to send a modem initialization string at power-up. Asserts certain lines in the  
RS-232 port to enable the modem to communicate.  
ERROR  
Fixes certain types of parity errors at certain Hessen protocol installations.  
CHECKING2  
128  
256  
XON/XOFF  
Disables XON/XOFF data flow control also known as software handshaking.  
HANDSHAKE2  
Enables CTS/RTS style hardwired transmission handshaking. This style of data  
transmission handshaking is commonly used with modems or terminal emulation  
protocols as well as by Teledyne Instrument’s APICOM software.  
HARDWARE  
HANDSHAKE  
8
HARDWARE  
Disables the HARDWARE FIFO (First In – First Out). When FIFO is enabled it improves  
data transfer rate for that COM port.  
512  
FIFO2  
COMMAND  
PROMPT  
Enables a command prompt when in terminal mode.  
4096  
1 Modes are listed in the order in which they appear in the  
SETUP MORE COMM COM[1 OR 2] MODE menu  
2 The default setting for this feature is ON. Do not disable unless instructed to by Teledyne’s Customer Service personnel.  
Note  
Communication Modes for each COMM port must be configured independently.  
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Press the following keys to select communication modes for a one of the COMM ports, such as the following  
example where RS-485 mode is enabled:  
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8.1.5. COMM 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 COMM 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:  
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8.1.6. MACHINE ID  
Each type of Teledyne’s analyzer is configured with a default ID code.  
The default ID code for the GFC 7001E/EM Analyzers is 300.  
The ID number is only important if more than one analyzer is connected to the same communications channel  
such as when several analyzers are:  
On the same Ethernet LAN (see Section 8.4);  
in a RS-232 multidrop chain (see Section 8.2) or;  
operating over a RS-485 network (See Section 8.3).  
If two analyzers of the same model type are used on one channel, the ID codes of one or both of the instruments  
needs to be changed.  
To edit the instrument’s ID code, press:  
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.  
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8.1.7. TERMINAL OPERATING MODES  
The GFC 7001E/EM 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 devices.  
The COMPUTER MODE is used when the analyzer is connected to a computer with a dedicated interface  
program.  
The 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  
8-2.  
8.1.7.1. Help Commands in Terminal Mode  
Table 8-2: Terminal Mode Software Commands  
COMMAND  
Control-T  
Function  
Switches the analyzer to terminal mode  
(echo, edit). If mode flags 1 & 2 are OFF,  
the interface can be used in interactive  
mode with a terminal emulation program.  
Control-C  
Switches the analyzer to computer mode  
(no echo, no edit).  
CR  
A carriage return is required after each  
command line is typed into the  
(carriage 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 being  
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  
Control-P  
Pauses the listing of commands.  
Restarts the listing of commands.  
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8.1.7.2. 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.  
All 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 Appendix A-6.  
[ID]  
is the machine identification number (Section 8.1.6). Example: the Command “? 700”  
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 700.  
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).  
Table 8-3: Teledyne’s Serial I/O Command Types  
COMMAND  
COMMAND TYPE  
Calibration  
Diagnostic  
C
D
L
Logon  
T
Test measurement  
Variable  
V
W
Warning  
8.1.7.3. Data Types  
Data types consist of integers, hexadecimal integers, floating-point numbers, Boolean expressions and text  
strings.  
Integer data: 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: Used for the same purposes as integers.  
They consist of the two characters “0x,” 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, 0x1, 0x12, 0x1234abcd are all valid hexadecimal integers.  
Floating-point number: 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.  
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For example, +1.0, 1234.5678, -0.1, 1 are all valid floating-point numbers.  
Boolean expressions: 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: Used to represent 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. When using these commands, you  
must type the entire name of the item; you cannot abbreviate any names.  
8.1.7.4. 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 (see Section  
8.1.4, Table 8-1).  
Status reports include warning messages, calibration and diagnostic status messages. Refer to Appendix A-3  
for a list of the possible messages, and this for information on controlling the instrument through the RS-232  
interface.  
General Message Format:  
All messages from the instrument (including 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 8-3.  
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,  
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.  
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8.1.7.5. COMM Port Password Security  
In order to provide security for remote access of the GFC 7001E/EM, a LOGON feature can be enabled to  
require a password before the instrument will accept commands. This is done by turning on the SECURITY  
MODE (Mode 4, Table 8-1.  
Once the SECURITY MODE is enabled, the following items apply.  
A password is required before the port will respond or pass on commands.  
If the port is inactive for one hour, it will automatically logoff, which can also be achieved with the LOGOFF  
command.  
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.  
If not logged on, the only active command is the '?' request for the help screen.  
The following messages will be returned at logon:  
LOGON SUCCESSFUL - Correct password given  
LOGON FAILED - Password not given or incorrect  
LOGOFF SUCCESSFUL - Connection terminated successfully  
To log on to the GFC 7001E/EM Analyzer with SECURITY MODE feature enabled, type:  
LOGON 940331  
NOTE  
940331 is the default password.  
To change the default password, use the variable RS-232_PASS issued as follows:  
V RS-232_PASS=NNNNNN  
Where N is any numeral between 0 and 9.  
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8.2. MULTIDROP RS-232 SET UP  
The RS-232 multidrop consists of a printed circuit assembly that is seated on the CPU card and is connected by  
a Y-ribbon cable from its J3 connector to the CPU’s COM1 and COM2 connectors. This PCA includes all  
circuitry required to enable your analyzer for multidrop operation. It converts the instrument’s RS232 port to  
multidrop configuration allowing up to eight Teledyne’s E-Series Analyzers to be connected to the same I/O port  
of the host computer.  
Because both of the DB9 connectors on the analyzer’s back panel are needed to construct the multidrop chain,  
COM2 is no longer available for separate RS-232 or RS-485 operation; however, with the addition of an Ethernet  
Option (Option 63A, See Section 5.7.3 and 8.4) the COM2 port is available for communication over a 10BaseT  
LAN.  
Figure 8-3:  
Location of JP2 on RS-232-Multidrop PCA (Option 62)  
Each analyzer or analyzer in the multidrop chain must have:  
One Teledyne’s Option 62 installed.  
One 6’ straight-through, DB9 male DB9 Female cable (Teledyne’s P/N WR0000101) is required for  
each analyzer.  
To set up the network, for each instrument:  
1. With NO power to the instrument, remove its top cover and locate JP2 on the multidrop PCA, which is  
assembled with a shunt that jumpers Pins 21 22 (Error! Reference source not found.).  
2. Remove and store the shunt (place the shunt on one pin only) for all instruments in the network except  
the instrument that is to be the last: make sure a shunt is in place connecting Pins 21 22 for the last  
instrument.  
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Note: If you are adding an instrument to the end of a previously configured chain, remove the shunt  
between Pins 21 22 of JP2 on the multidrop PCA in the instrument that was previously the last  
instrument in the chain.  
3. Close the instrument.  
4. Using straight-through, DB9 male DB9 Female cable, interconnect the host and the analyzers as  
shown in Figure 8-4.  
5. BEFORE communicating from the host, power on the instruments and check that the Machine ID code is  
unique for each. (On the front panel menu, use SETUP>MORE>COMM>ID. Note that the default ID is  
typically the model number; to change the 4-digit identification number, press the key below the  
corresponding digit to be changed).  
NOTE  
Teledyne recommends setting up the first link, between the Host and the first instrument and testing it  
before setting up the rest of the chain.  
KEY:  
Host  
Female DB9  
RS-232 port  
Male DB9  
TAPI Analyzer  
Last  
INSTRUMENT  
COM2  
CALIBRATOR  
CALIBRATOR  
COM2  
COM2  
COM2  
RS-232  
RS-232  
RS-232  
RS-232  
Make Sure  
Jumper between  
JP2 pins 21  
22  
is installed.  
Figure 8-4:  
RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram  
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8.3. RS-485 CONFIGURATION OF COM2  
As delivered from the factory, COM2 is configured for RS-232 communications. This port can be reconfigured  
for operation as a non-isolated, half-duplex RS-485 port capable of supporting up to 32 instruments with a  
maximum distance between the host and the furthest instrument being 4000 feet. If you require full duplex or  
isolated operation, please contact Teledyne’s Customer Service.  
To reconfigure COM2 as an RS-485 port:  
Locate J32 and move the shunt from Pins 1 2 to Pins 3 4.  
Remove the connector from J12.  
Plug the RS-485 connector into J15.  
Figure 8-5:  
CPU RS-485 Setup  
When COM2 is configured for RS-485 operation the port uses the same female DB-9 connector on the back of  
the instrument as when COM2 is configured for RS-232 operation, however, the pin assignments are different.  
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Female DB-9 (COM2)  
(As seen from outside analyzer)  
RX/TX-  
GND  
RX/TX+  
1
2
3
4
5
6
7
8
9
(RS-485)  
Figure 8-6:  
Back Panel Connector Pin-Outs for COM2 in RS-485 Mode.  
The signal from this connector is routed from the motherboard via a wiring harness to a 3-pin connector on the  
CPU card, J15.  
Figure 8-7:  
CPU Connector Pin-Outs for COM2 in RS-485 Mode  
NOTE  
The DCE/DTE switch has no effect on COM2.  
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8.4. REMOTE ACCESS VIA THE ETHERNET  
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.  
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).  
The card has four LEDs that are visible on the rear panel of the analyzer, indicating its current operating status.  
Table 8-4: Ethernet Status Indicators  
LED  
LNK (green)  
ACT (yellow)  
TxD (green)  
RxD (yellow)  
FUNCTION  
ON when connection to the LAN is valid.  
Flickers on any activity on the LAN.  
Flickers when the RS-232 port is transmitting data.  
Flickers when the RS-232 port is receiving data.  
The Ethernet interface operates in ”polled” mode with a polling period that ranges from between 250 ms and 2  
seconds.  
When there is port activity, the polling rate is the minimum, 250 ms.  
When port activity is quiet, the polling rate lengthens to up to 2-seconds to reduce the burden on the  
instruments CPU.  
NOTE  
Commands should not be issued faster than twice a second for reliable operation.  
8.4.1. ETHERNET CARD COM2 COMMUNICATION MODES AND BAUD  
RATE  
The firmware on board the Ethernet card automatically sets the communication modes for the COM2 port. The  
baud rate is also automatically set at 115,200 kBaud.  
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8.4.2. CONFIGURING THE ETHERNET INTERFACE OPTION USING DHCP  
The Ethernet option for you GFC 7001E/EM uses Dynamic Host Configuration Protocol (DHCP) to configure its  
interface with your LAN automatically. This requires your network servers also be 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.  
NOTE  
It is a good idea to check the INET settings the first time you power up your analyzer after it has been  
physically connected to the LAN/Internet to make sure that the DHCP has successfully downloaded the  
appropriate information from you network server(s).  
The Ethernet configuration properties are viewable via the analyzer’s front panel.  
Table 8-5: LAN/Internet Configuration Properties  
PROPERTY  
DEFAULT STATE  
DESCRIPTION  
This displays whether the DHCP is turned ON or OFF.  
DHCP STATUS  
On  
Editable  
EDIT key  
disabled when  
DHCP is ON  
INSTRUMENT  
IP ADDRESS  
Configured by  
DHCP  
This string of four packets of 1 to 3 numbers each (e.g.  
192.168.76.55.) is the address of the analyzer itself.  
EDIT key  
disabled when  
DHCP is ON  
A string of numbers very similar to the Instrument IP address  
(e.g. 192.168.76.1.) that is the address of the computer used by  
your LAN to access the Internet.  
GATEWAY IP  
ADDRESS  
Configured by  
DHCP  
Also, a string of four packets of 1 to 3 numbers each (e.g.  
255.255.252.0) that defines that identifies the LAN to which the  
device is connected.  
All addressable devices and computers on a LAN must have the  
same subnet mask. Any transmissions sent devices with  
different subnet masks are assumed to be outside of the LAN  
and are routed through a different gateway computer onto the  
Internet.  
EDIT key  
disabled when  
DHCP is ON  
Configured by  
DHCP  
SUBNET MASK  
TSP listening port 1. This port is used for standard Ethernet  
communications. The number defines the terminal control port  
by which the instrument is addressed by terminal emulation  
software, such as Teledyne’s APICOM.  
Editable, but  
DO NOT  
CHANGE  
TCP PORT11  
TCP PORT21  
3000  
520  
TSP listening port 2. This port is reserved for the GFC  
7001E/EM Analyzer’s optional Modbus® capability. The number  
matches the default address specified by Modbus®  
specifications.  
Editable, but  
DO NOT  
CHANGE  
The name by which your analyzer appears when addressed by  
other computers on the LAN or via the Internet. While the  
default setting is the model type (e.g. GFC 7001E, etc.) the  
host name may be changed to fit customer needs.  
DEFAULT =  
Model Type  
HOST NAME  
ONLINE  
Editable  
Enables or disables the GFC 7001E/EM Analyzer’s two TCP  
Ports. The TCP ports are inactive when this is set to OFF.  
ON  
Editable  
1 DO NOT CHANGE the setting for this property unless instructed to by Teledyne’s Customer Service personnel.  
NOTE  
If the gateway IP, instrument IP and the subnet mask are all zeroes (e.g. “0.0.0.0”), the DCHP was not  
successful in which case you may have to configure the analyzer’s Ethernet properties manually.  
See your network administrator.  
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To view the above properties listed in Table 8-5, press:  
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8.4.3. MANUALLY CONFIGURING THE NETWORK IP ADDRESSES  
There are several circumstances when you may need to configure the interface settings of the analyzer’s  
Ethernet card manually. The INET submenu may also be used to edit the Ethernet card’s configuration  
properties.  
Your LAN is not running a DHCP software package;  
The DHCP software is unable to initialize the analyzer’s interface;  
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. start /low firmware.exe /y  
STEP 1: Turn DHCP OFF: While DHCP is turned ON, the ability to set the INSTRUMENT IP, GATEWAY IP and  
SUBNET MASK manually is disabled.  
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SAMPLE  
RANGE=50.0 PPM  
CO= XX.XX  
SETUP  
<TST TST> CAL  
SETUP X.X  
PRIMARY SETUP MENU  
CFG DAS RNGE PASS CLK MORE  
EXIT  
SETUP X.X  
SECONDARY SETUP MENU  
COMM VARS DIAG  
EXIT  
EXIT  
SETUP X.X  
COMMUNICATIONS MENU  
ID ADDR INET  
SETUP X.X  
ENTER PASSWORD:818  
ENTR EXIT  
8
1
8
SETUP X.X  
DHCP:ON  
<SET SET> EDIT  
EXIT  
SETUP X.X  
ON  
DHCP:ON  
Toggle this key  
to turn DHCP  
ENTR EXIT  
ENTR EXIT  
ON/OFF  
SETUP X.X  
OFF  
DHCP:OFF  
ENTR accepts  
the new setting  
EXIT ignores the  
new setting  
Continue to Step 2 Below  
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STEP 2: Configure the INSTRUMENT IP, GATEWAY IP and SUBNET MASK addresses by pressing:  
KEY  
[0]  
FUNCTION  
Press this key to cycle through the range of  
numerals and available characters (“0 – 9” & “ . ”)  
Moves the cursor one character to the left or  
right.  
<CH CH>  
INS  
Inserts a character before the cursor location.  
Deletes a character at the cursor location.  
DEL  
Some keys only appear as needed.  
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8.4.4. CHANGING THE ANALYZER’S HOSTNAME  
The HOSTNAME is the name by which the analyzer appears on your network.  
The default name for all Teledyne’s GFC 7001E Analyzers is GFC 7001E.  
The default name for all Teledyne’s GFC 7001EM Analyzers is GFC 7001EM.  
To change this name (particularly if you have more than one GFC 7001E/EM Analyzer on your network), press:  
KEY  
FUNCTION  
<CH  
CH>  
INS  
Moves the cursor one character to the left.  
Moves the cursor one character to the right.  
Inserts a character before the cursor location.  
Deletes a character at the cursor location.  
DEL  
Press this key to cycle through the range of  
numerals and characters available for  
insertion. 0-9, A-Z, space ’ ~ ! # $ % ^ & * (  
) - _ = +[ ] { } < >\ | ; : , . / ?  
[?]  
Accepts the new setting and returns to the  
previous menu.  
ENTR  
EXIT  
Ignores the new setting and returns to the  
previous menu.  
Some keys only appear as needed.  
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8.5. MODBUS SETUP  
The following set of instructions assumes that the user is familiar with MODBUS communications, and provides  
minimal information to get started. For additional instruction, please refer to the Teledyne MODBUS manual, PN  
06276. Also refer to www.modbus.org for MODBUS communication protocols.  
Minimum Requirements  
Instrument firmware with MODBUS capabilities installed.  
MODBUS-compatible software (TAI uses MODBUS Poll for testing; see www.modbustools.com)  
Personal computer  
Communications cable (Ethernet or USB or RS232)  
Possibly a null modem adapter or cable  
Actions  
Set Com Mode parameters  
Comm  
Ethernet:  
Using the front panel menu, go to SETUP – MORE – COMM – INET; scroll through the INET  
submenu until you reach TCP PORT 2 (the standard setting is 502), then continue to TCP  
PORT 2 MODBUS TCP/IP; press EDIT and toggle the menu button to change the setting to  
ON, then press ENTR. (Change Machine ID if needed: see “Slave ID”).  
RS232: Using the front panel menu, go to SETUP – MORE – COMM – COM2 – EDIT; scroll through the  
COM2 EDIT submenu until the display shows COM2 MODBUS RTU: OFF (press OFF to  
change the setting to ON. Scroll NEXT to COM2 MODBUS ASCII and ensure it is set to  
OFF. Press ENTR to keep the new settings. (If RTU is not available with your  
communications equipment, set the COM2 MODBUS ASCII setting to ON and ensure that  
COM2 MODBUS RTU is set to OFF. Press ENTR to keep the new settings).  
Slave ID  
A MODBUS slave ID must be set for each instrument. Valid slave ID’s are in the range of 1 to 247. If  
your analyzer is connected to a serial network (ie. RS-485), a unique Slave ID must be assigned to each  
instrument. To set the slave ID for the instrument, go to SETUP – MORE – COMM – ID. The default  
MACHINE ID is the same as the model number. Toggle the menu buttons to change the ID.  
Reboot analyzer  
For the settings to take effect, power down the analyzer, wait 5 seconds, and power up the analyzer.  
Make appropriate cable  
connections  
Connect your analyzer either:  
via its Ethernet or USB port to a PC (this may require a USB-to-RS232 adapter for your PC; if so, also  
install the sofware driver from the CD supplied with the adapter, and reboot the computer if required), or  
via its COM2 port to a null modem (this may require a null modem adapter or cable).  
Specify MODBUS software  
settings  
1. Click Setup / [Read / Write Definition] /.  
a. In the Read/Write Definition window (see example that follows) select a Function (what you wish  
(examples used here are for  
MODBUS Poll software)  
to read from the analyzer).  
b. Input Quantity (based on your firware’s register map).  
c. In the View section of the Read/Write Definition window select a Display (typically Float Inverse).  
d. Click OK.  
2. Next, click Connection/Connect.  
a. In the Connection Setup window (see example that follows), select the options based on your  
computer.  
b. Press OK.  
Read the Modbus Poll Register Use the Register Map to find the test parameter names for the values displayed (see example that follows  
If desired, assign an alias for each.  
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Example Read/Write Definition window:  
Example Connection Setup window:  
Example MODBUS Poll window:  
8.5.1. REMOTE ACCESS BY MODEM  
The GFC 7001E/EM can be connected to a modem for remote access. This requires a cable between the  
analyzer’s COMM port and the modem, typically a DB-9F to DB-25M cable (available from Teledyne with P/N  
WR0000024).  
Once the cable has been connected, check to make sure:  
The DTE-DCE is in the DCE position.  
The GFC 7001E/EM COMM port is set for a baud rate that is compatible with the modem,  
The modem is designed to operate with an 8-bit word length with one stop bit.  
The MODEM ENABLE communication mode is turned on (Mode 64, see Table 8-1).  
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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 Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0  
This string can be altered to match your modem’s initialization and can be up to 100 characters long.  
To change this setting press:  
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To initialize the modem press:  
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8.6. USING THE GFC 7001E/EM WITH A HESSEN PROTOCOL  
NETWORK  
8.6.1. 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.  
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. ‘s implementation supports both of these principal features.  
The Hessen protocol is not well defined, therefore while’s application is completely compatible with the protocol  
itself, it may be different from implementations by other companies.  
NOTE  
The following sections 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  
web site: http://www.teledyne-api.com/manuals/.  
8.6.2. HESSEN COMM PORT CONFIGURATION  
Hessen protocol requires the communication parameters of the GFC 7001E/EM Analyzer’s COMM ports to be  
set differently than the standard configuration as shown in Table 8-6.  
Table 8-6: RS-232 Communication Parameters for Hessen Protocol  
PARAMETER  
Baud Rate  
Data Bits  
Stop Bits  
Parity  
STANDARD  
HESSEN  
300 – 19200  
1200  
7
8
1
2
None  
Even  
Duplex  
Full  
Half  
To change the baud rate of the GFC 7001E/EM’s COMM ports, see Section 8.1.3.  
To change the rest of the COMM port parameters listed in the Table 8-6. Also see Section 8.1 and Table 8-1.  
Note  
Make sure that the communication parameters of the host computer are also properly set.  
Also, the instrument software has a 200 ms latency period 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.  
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8.6.3. ACTIVATING HESSEN PROTOCOL  
Once the COMM port has been properly configured, the next step in configuring the GFC 7001E/EM to operate  
over a Hessen protocol network is to activate the Hessen mode for COMM ports and configure the  
communication parameters for the port(s) appropriately.  
To activate the Hessen Protocol, press:  
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8.6.4. SELECTING A HESSEN PROTOCOL TYPE  
Currently there are two versions of Hessen Protocol in use. The original implementation, 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 1 and TYPE 2 download the Manual  
Addendum for Hessen Protocol from the Teledyne web site: http://www.teledyne-api.com/manuals/.  
To select a Hessen Protocol Type press:  
NOTE  
While Hessen Protocol Mode can be activated independently for COM1 and COM2 in the  
COMMUNICATIONS MENU, the TYPE selection affects both Ports.  
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8.6.5. SETTING THE HESSEN PROTOCOL RESPONSE MODE  
The Teledyne’s implementation of Hessen Protocol allows the user to choose one of several different modes of  
response for the analyzer.  
Table 8-7: Teledyne’s Hessen Protocol Response Modes  
MODE ID  
CMD  
MODE DESCRIPTION  
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.  
Responses from the instrument are always delimited with <STX> (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.  
BCC  
Responses from the instrument are always delimited with <CR> at the beginning and the  
end of the string, regardless of the command encoding.  
TEXT  
To select a Hessen response mode, press:  
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8.6.6. HESSEN PROTOCOL GAS LIST ENTRIES  
8.6.6.1. Gas List Entry Format and Definitions  
The GFC 7001E/EM Analyzer keeps a list of available gas types. Each entry in this list is of the following format.  
[GAS TYPE],[RANGE],[GAS ID],[REPORTED]  
WHERE:  
GAS TYPE = The type of gas to be reported (e.g. CO, CO2, O2, etc.).  
RANGE  
= The concentration range for this entry in the gas list. This feature permits the user to  
select which concentration range will be used for this gas list entry. The GFC 7001E/EM  
Analyzer has two ranges: RANGE1 or LOW & RANGE2 or HIGH (See Section 6.6.1).  
0 - The HESSEN protocol to use whatever range is currently active.  
1 - The HESSEN protocol will always use RANGE1 for this gas list entry.  
2 - The HESSEN protocol will always use RANGE2 for this gas list entry.  
3 - Not applicable to the GFC 7001E/EM Analyzer.  
GAS ID  
= An identification number assigned to a specific gas. In the case of the GFC 7001E/EM  
Analyzer in its base configuration, there is only one gas CO, and its default GAS ID is  
310. (Note: This ID number should not be modified).  
REPORT  
= States whether this list entry is to be reported or not reported when ever this gas type or  
instrument is polled by the HESSEN network. If the list entry is not to be reported this  
field will be blank.  
While the GFC 7001E/EM Analyzer is a single gas instrument that measures CO, it can have additional, optional  
sensors for CO2 or O2 installed. The default gas list entries for these three gases are:  
CO, 0, 310, REPORTED  
CO2, 0, 311, REPORTED  
O2, 0, 312, REPORTED  
These default settings cause the instrument to report the concentration value of the currently active range. If you  
wish to have just concentration value stored for a specific range, this list entry should be edited or additional  
entries should be added to the list.  
EXAMPLE: Changing the above CO gas list entry to read:  
CO, 2, 310, REPORTED  
would cause only the last CO reading while RANGE2 (HIGH) range was active to be recorded.  
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8.6.6.2. Editing or Adding HESSEN Gas List Entries  
To add or edit an entry to the Hessen Gas List, press:  
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8.6.6.3. Deleting HESSEN Gas List Entries  
To delete an entry from the Hessen Gas list, press:  
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8.6.7. SETTING HESSEN PROTOCOL STATUS FLAGS  
Teledyne’s 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 8-8: Default Hessen Status Flag Assignments  
DEFAULT BIT  
STATUS FLAG NAME  
ASSIGNMENT  
WARNING FLAGS  
SAMPLE FLOW WARNING  
BENCH TEMP WARNING  
SOURCE WARNING  
0001  
0002  
0004  
0008  
0010  
0020  
0040  
BOX TEMP WARNING  
WHEEL TEMP WARNING  
SAMPLE TEMP WARN  
SAMPLE PRESS WARN  
INVALID CONC  
0080  
(The Instrument’s Front Panel Display Will Show The  
Concentration As “Warnings”)  
OPERATIONAL FLAGS1  
Instrument OFF  
0100  
0200  
0400  
0400  
In MANUAL Calibration Mode  
In ZERO Calibration Mode4  
In O2 Calibration Mode (if O2 sensor installed )2,4  
In CO2 Calibration Mode (if CO2 sensor installed )2,4  
0400  
0800  
In SPAN Calibration Mode  
UNITS OF MEASURE FLAGS  
UGM  
MGM  
PPB  
PPM  
0000  
2000  
4000  
6000  
1000, 8000  
SPARE/UNUSED BITS  
UNASSIGNED FLAGS (0000)  
AZERO WARN2  
DCPS WARNING  
CANNOT DYN SPAN2  
CANNOT DYN ZERO3  
CONC ALARM 13  
REAR BOARD NOT DET  
SYNC WARNING1  
SYSTEM RESET1  
CONC ALARM 23  
1
These status flags are standard for all instruments and should probably not be  
modified.  
2
3
3
Only applicable if the optional internal span gas generator is installed.  
Only applicable if the analyzer is equipped with an alarm options.  
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.  
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To assign or reset the status flag bit assignments, press:  
<TST TST> CAL  
SETUP X.X  
CFG DAS RNGE PASS CLK  
EXIT  
SETUP X.X  
VARS DIAG  
EXIT  
EXIT  
SETUP X.X  
ID  
COM1 COM2  
SETUP X.X  
EDIT PRNT EXIT  
Continue pressing  
until ...  
Continue pressing  
until desired  
flag message is displayed  
SETUP X.X  
PREV NEXT  
PRNT EXIT  
SETUP X.X  
discards the  
new setting.  
The  
and  
keys move the cursor  
brackets “  
left and right along the  
bit string.  
accepts the  
new setting.  
Press the  
through the available character set:  
: Values of can also be set  
but are meaningless.  
key repeatedly to cycle  
deletes the  
character currently  
inside the cursor  
brackets.  
8.6.8. INSTRUMENT ID CODE  
Each instrument on a Hessen Protocol network must have a unique ID code. If more than one GFC 7001E/EM  
Analyzer is on the Hessen network, you will have to change this code for all but one of the GFC 7001E/EM  
Analyzer’s on the Hessen network (see Section 8.1.6).  
The default ID code for the GFC 7001E/EM Analyzers is 300.  
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8.7. APICOM REMOTE CONTROL PROGRAM  
APICOM is an easy-to-use, yet powerful interface program that allows the user to access and control any of  
Teledyne’s main line of ambient and stack-gas instruments from a remote connection through direct cable,  
modem or Ethernet. Running APICOM, a user can:  
Establish a link from a remote location to the GFC 7001E/EM through direct cable connection via RS-  
232 modem or Ethernet.  
View the instrument’s front panel and remotely access all functions that could be accessed when  
standing in front of the instrument.  
Remotely edit system parameters and set points.  
Download, view, graph and save data for predictive diagnostics or data analysis.  
Check on system parameters for trouble-shooting and quality control.  
APICOM is very helpful for initial setup, data analysis, maintenance and troubleshooting. Figure 8-8 shows  
example of APICOM’s main interface, which emulates the look and functionality of the instruments actual front  
panel.  
Figure 8-8:  
APICOM Remote Control Program Interface  
NOTE  
APICOM is included free of cost with the analyzer and the latest versions can also be downloaded for  
free at http://www.teledyne-api.com/man  
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9. CALIBRATION PROCEDURES  
This section contains a variety of information regarding the various methods for calibrating a GFC 7001E/EM as  
well as other supporting information. For information on EPA protocol calibration, please refer to Section 10.  
This section is organized as follows:  
SECTION 9.1 – BEFORE CALIBRATION  
This section contains general information you should know before about calibrating the analyzer.  
SECTION 9.2– MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE GFC 7001E/EM ANALYZER  
IN ITS BASE CONFIGURATION  
This section describes the procedure for checking the calibrating of the GFC 7001E/EM and calibrating the  
instrument with no zero/span valves installed or if installed, not operating.  
It requires that zero air and span gas is inlet through the SAMPLE port.  
Also included are instructions for selecting the reporting range to be calibrated when the GFC 7001E/EM  
Analyzer is set to operate in either the DUAL or AUTO reporting range modes.  
SECTION 9.3 – MANUAL CALIBRATION AND CAL CHECKS WITH VALVE OPTIONS INSTALLED  
This section describes:  
The procedure for manually checking the calibration of the instrument with optional zero/span valves  
option installed.  
The procedure for manually calibrating the instrument with zero/span valves.  
Instructions on activating the zero/span valves via the control in contact closures of the analyzers external  
digital I/O.  
SECTION 9.4 – AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL)  
This section describes the procedure for using the AutoCal feature of the analyzer to check or calibrate the  
instrument.  
The AutoCal feature requires that either the zero/span valve option or the internal span gas generator  
option be installed and operating. NOTE: This practice is not approved by the US EPA.  
SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS  
This section describes how to judge the effectiveness of a recently performed calibration.  
SECTION 9.6 – CALIBRATION OF GFC 7001E/EM ANALYZER’S ELECTRONIC SUBSYSTEMS  
This section describes how to perform calibrations of the GFC 7001E/EM Analyzer’s electronic systems,  
including:  
Dark Calibration of the optical bench.  
The pressure and flow sensors.  
SECTION 9.7 – CALIBRATION OF OPTIONAL GAS SENSORS  
This section describes how to perform calibrations of the various optional sensors available on the GFC  
7001E/EM Analyzers, including:  
The O2 Sensor, and;  
The CO2 Sensor.  
NOTE  
Throughout this section are various diagrams showing pneumatic connections between the GFC  
7001E/EM and various other pieces of equipment such as calibrators and zero air sources.  
These diagrams are only intended to be schematic representations of these connections and do not  
reflect actual physical locations of equipment and fitting location or orientation.  
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Contact your regional EPA or other appropriate governing agency for more detailed recommendations.  
9.1. BEFORE CALIBRATION  
The calibration procedures in this section assume that the range mode, analog range and units of measure have  
already been selected for the analyzer. If this has not been done, please do so before continuing (see Section  
6.6 for instructions).  
NOTE  
If any problems occur while performing the following calibration procedures, refer to Section 12 for  
troubleshooting tips.  
9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES  
Calibration of the GFC 7001E/EM Analyzer requires a certain amount of equipment and supplies. These include,  
but are not limited to, the following:  
Zero-air source.  
Span gas source.  
Gas lines - All Gas lines should be PTFE (Teflon), FEP, glass, stainless steel or brass.  
A recording device such as a strip-chart recorder and/or data logger (optional). For electronic  
documentation, the internal data acquisition system iDAS can be used.  
NOTE  
If any problems occur while performing the following calibration procedures, refer to Section 12 of this  
manual for troubleshooting tips.  
9.1.2. CALIBRATION GASES  
9.1.2.1. Zero Air  
Zero air or zero calibration gas is defined as a gas that is similar in chemical composition to the measured  
medium but without the gas to be measured by the analyzer.  
For the GFC 7001E/EM 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 -5C or less.  
If your application is not a measurement in ambient air, the zero calibration gas should be matched to the  
composition of the gas being measured.  
Pure nitrogen (N2) can be used as a zero gas for applications where CO is measured in nitrogen.  
If your analyzer is equipped with an external zero air scrubber option, it is capable of creating zero air from  
ambient air.  
For analyzers without the zero air scrubber, a zero air generator such as the Teledyne’s M701 can be used.  
Please visit the company website for more information.  
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9.1.2.2. Span Gas  
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 80-90% of the full measurement range. If Span Gas is sourced directly from a calibrated,  
pressurized tank, the gas mixture should be CO mixed with Zero Air or N2 at the required ratio.  
For oxygen measurements using the optional O2 sensor, we recommend a reference gas of 21% O2 in N2.  
For quick checks, ambient air can be used at an assumed concentration of 20.8%.  
Generally, O2 concentration in dry, ambient air varies by less than 1%.  
9.1.2.3. Traceability  
All 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.  
Table 9-1: NIST-SRMs Available for Traceability of CO Calibration Gases  
NIST-SRM  
1680b  
1681b  
2613a  
TYPE  
CO in N2  
NOMINAL CONCENTRATION  
500 ppm  
CO in N2  
1000 ppm  
CO in Zero Air  
CO in Zero Air  
O2 in N2  
20 ppm  
2614a  
2659a1  
45 ppm  
21% by weight  
4% by weight  
16% by weight  
2626a  
27452  
CO2 in N2  
CO2 in N2  
1 Used to calibrate optional O2 sensor.  
2 Used to calibrate optional CO2 sensor.  
NOTE  
It is generally a good idea to use 80% of the reporting range for that channel for the span point  
calibration.  
For instance if the reporting range of the instrument is set for 50.0 PPM, the proper span gas would be  
40.0 PPM  
9.1.3. DATA RECORDING DEVICES  
A strip chart recorder, data acquisition system or digital data acquisition system should be used to record data  
from the serial or analog outputs of the GFC 7001E/EM.  
If analog readings are used, the response of the recording system should be checked against a NIST  
traceable voltage source or meter.  
Data recording devices should be capable of bi-polar operation so that negative readings can be recorded.  
For electronic data recording, the GFC 7001E/EM provides an internal data acquisition system (iDAS),  
which is described in detail in Section 7.1  
APICOM, a remote control program, is also provided as a convenient and powerful tool for data handling,  
download, storage, quick check and plotting (see Section 8.4).  
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9.2. MANUAL CALIBRATION CHECKS AND CALIBRATION OF  
THE GFC 7001E/EM ANALYZER IN ITS BASE  
CONFIGURATION  
ZERO/SPAN CALIBRATION CHECKS VS. ZERO/SPAN CALIBRATION  
Pressing the ENTR key during the following procedure resets the stored values for OFFSET and SLOPE  
and alters the instrument’s Calibration.  
This should ONLY BE DONE during an actual calibration of the GFC 7001E/EM.  
NEVER press the ENTR key if you are only checking calibration.  
9.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION  
STEP ONE: Connect the Sources of Zero Air and Span Gas as shown below.  
Figure 9-1:  
Pneumatic Connections – Basic Configuration – Using Bottled Span Gas  
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Figure 9-2:  
Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator  
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9.2.2. PERFORMING A BASIC MANUAL CALIBRATION CHECK  
NOTE  
If the ZERO or SPAN keys are not displayed, the measurement made during is out of the allowable range  
allowed for a reliable calibration.  
See Section 12 for troubleshooting tips.  
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9.2.3. PERFORMING A BASIC MANUAL CALIBRATION  
The following section describes the basic method for manually calibrating the GFC 7001E/EM.  
If the analyzer’s reporting range is set for the AUTO range mode, a step will appear for selecting which range is  
to be calibrated (LOW or HIGH). Each of these two ranges MUST be calibrated separately.  
9.2.3.1. Setting the Expected Span Gas Concentration  
NOTE  
When setting expected concentration values, consider impurities in your span gas.  
The expected CO span gas concentration should be 80% of the reporting range of the instrument (see Section  
6.6.1).  
The default factory setting is 40 ppm. To set the span gas concentration, press:  
SAMPLE  
< TST  
RANGE=50.0PPM  
CO=XX.XX  
SETUP  
CAL  
MSG  
Only appears if either  
the O2 or CO2  
SAMPLE  
Sensors are installed.  
O2  
EXIT  
SAMPLE  
HIGH  
EXIT  
Only appears if the  
or  
range modes are selected.  
Use these keys to choose the  
appropriate range.  
M-P CAL  
RANGE=50.0PPM  
CO=XX.XX  
EXIT  
Repeat entire procedure for each  
range.  
<TST TST> ZERO SPAN  
ignores the new  
setting and returns to  
the previous display.  
The CO span concentration value is  
automatically default to  
4
.
If this is not the the concentration of  
the span gas being used, toggle  
these buttons to set the correct  
concentration of the CO  
accepts the new  
setting and returns to  
the  
calibration gas.  
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.  
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9.2.3.2. Zero/Span Point Calibration Procedure  
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9.3. MANUAL CALIBRATION WITH ZERO/SPAN VALVES  
There are a variety of valve options available on the GFC 7001E/EM for handling calibration gases (see Section  
5.6 for descriptions of each).  
Generally performing calibration checks and zero/span point calibrations on analyzers with these options  
installed is similar to the methods discussed in the previous sections of this section. The primary differences are:  
On instruments with Z/S valve options, zero air and span gas is supplied to the analyzer through other gas  
inlets besides the sample gas inlet.  
The zero and span calibration operations are initiated directly and independently with dedicated keys  
(CALZ & CALS).  
9.3.1. SETUP FOR CALIBRATION USING VALVE OPTIONS  
Each of the various calibration valve options requires a different pneumatic setup that is dependent on the exact  
nature and number of valves present.  
Figure 9-3:  
Pneumatic Connections – Option 50A: Zero/Span Calibration Valves  
Figure 9-4:  
Pneumatic Connections – Option 50B: Zero/Pressurized Span Calibration Valves  
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Figure 9-5:  
Pneumatic Connections – Option 51B: Zero/Span Calibration Valves  
Figure 9-6:  
Pneumatic Connections – Option 51C: Zero/Span Calibration Valves  
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9.3.2. MANUAL CALIBRATION CHECKS WITH VALVE OPTIONS  
INSTALLED  
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9.3.3. MANUAL CALIBRATION USING VALVE OPTIONS  
The following section describes the basic method for manually calibrating the GFC 7001E/EM Analyzer.  
If the analyzer’s reporting range is set for the DUAL or AUTO range modes, a step will appear for selecting  
which range is to be calibrated (LOW or HIGH).  
Each of these two ranges MUST be calibrated separately.  
9.3.3.1. Setting the Expected Span Gas Concentration  
NOTE  
When setting expected concentration values, consider impurities in your span gas.  
The expected CO span gas concentration should be 80% of the reporting range of the instrument (see Section  
6.6.1). The default factory setting is 40 ppm.  
To set the span gas concentration, press:  
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.  
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9.3.3.2. Zero/Span Point Calibration Procedure  
The zero and cal operations are initiated directly and independently with dedicated keys (CALZ & CALS).  
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9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure  
Contact closures for controlling calibration and calibration checks are located on the rear panel CONTROL IN  
connector. Instructions for setup and use of these contacts can be found in Section 3.3.4.  
When the appropriate contacts are closed for at least 5 seconds, the instrument switches into zero, or span  
calibration mode and any internal zero/span valves installed will be automatically switched to the appropriate  
configuration.  
The remote calibration contact closures may be activated in any order.  
It is 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 contact closures are being used in conjunction with the analyzer’s AutoCal (see Section 9.4) feature and the  
AutoCal attribute “CALIBRATE” is enabled, the GFC 7001E/EM will not recalibrate the analyzer until the contact  
is opened. At this point, the new calibration values will be recorded before the instrument returns to Sample  
Mode.  
If the AutoCal attribute “CALIBRATE” is disabled, the instrument will return to Sample Mode, leaving the  
instrument’s internal calibration variables unchanged.  
9.4. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL)  
The AutoCal system allows unattended periodic operation of the ZERO/SPAN valve options by using the GFC  
7001E/EM Analyzer’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 three separate sequences (SEQ1, SEQ2 and SEQ3). Each sequence can  
operate in one of three modes, or be disabled.  
Table 9-2: AUTOCAL Modes  
MODE NAME  
DISABLED  
ZERO  
ACTION  
Disables the Sequence.  
Causes the Sequence to perform a Zero calibration/check.  
Causes the Sequence to perform a Zero point calibration/check followed by a Span  
point calibration/check.  
ZERO-SPAN  
SPAN  
Causes the Sequence to perform a Span concentration calibration/check only.  
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For each mode, there are seven parameters that control operational details of the SEQUENCE (see Table 9-3).  
Table 9-3: AutoCal Attribute Setup Parameters  
ATTRIBUTE  
TIMER ENABLED  
STARTING DATE  
STARTING TIME  
ACTION  
Turns on the Sequence timer.  
Sequence will operate after Starting Date.  
Time of day sequence will run.  
Number of days to skip between each Sequence execution.  
DELTA DAYS  
If set to 7, for example, the AutoCal feature will be enabled once every  
week on the same day.  
Number of hours later each “Delta Days” Seq is to be run.  
If set to 0, the sequence will start at the same time each day. Delta  
Time is added to Delta Days for the total time between cycles.  
DELTA TIME  
This parameter prevents the analyzer from being calibrated at the same  
daytime of each calibration day and prevents a lack of data for one  
particular daytime on the days of calibration.  
Number of minutes the sequence operates.  
This parameter needs to be set such that there is enough time for the  
concentration signal to stabilize.  
The STB parameter shows if the analyzer response is stable at the end  
of the calibration.  
DURATION  
This parameter is logged with calibration values in the iDAS.  
Enable to do a calibration – Disable to do a cal check only.  
CALIBRATE  
This setting must be OFF for analyzers used in US EPA applications and  
with internal span gas generators installed and functioning.  
LOW calibrates the low range, HIGH calibrates the high range. Applies only  
to auto and remote range modes; this property is not available in single and  
independent range modes.  
RANGE TO CAL  
NOTE  
The CALIBRATE attribute (formerly called “dynamic calibration”) must always be set to OFF for  
analyzers used in US EPA controlled applications that have internal span gas generators option  
installed.  
Calibration of instruments used in US EPA related applications should only be performed using external  
sources of zero air and span gas with an accuracy traceable to EPA or NIST standards and supplied  
through the analyzer’s sample port.  
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The following example sets sequence #2 to do a zero-span calibration every other day starting at 2:15 PM on  
September 4, 2008, lasting 15 minutes, without calibration. This will start ½ hour later each iteration.  
Table 9-4: Example AutoCal Sequence  
MODE AND  
ATTRIBUTE  
VALUE  
COMMENT  
SEQUENCE  
Define Sequence #2  
2
Select Zero and  
Span Mode  
MODE  
ZERO-SPAN  
ON  
TIMER ENABLE  
STARTING DATE  
Enable the timer  
Start after  
Sept 4, 2008  
Sept. 4, 2008  
First Span starts at  
2:15 PM  
STARTING TIME  
DELTA DAYS  
DELTA TIME  
DURATION  
14:15  
2
Do Sequence #2  
every other day  
Do Sequence #2 ½  
hr later each day  
00:30  
30.0  
ON  
Operate Span valve  
for 15 min  
Calibrate at end of  
Sequence  
CALIBRATE  
NOTE  
The programmed STARTING_TIME must be a minimum of 5 minutes later than the real time clock for  
setting real time clock (See Section 6.5.4).  
Avoid setting two or more sequences at the same time of the day. Any new sequence that is initiated  
whether from a timer, the COM ports or the contact closure inputs will override any sequence that is in  
progress.  
NOTE  
With CALIBRATE turned ON, the state of the internal setup variables DYN_SPAN and DYN_ZERO is set  
to ON and the instrument will reset the slope and offset values for the CO response each time the  
AutoCal program runs.  
This continuous readjustment of calibration parameters can often mask subtle fault conditions in the  
analyzer. It is recommended that, if CALIBRATE is enabled, the analyzer’s test functions, slope and  
offset values be checked frequently to assure high quality and accurate data from the instrument.  
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9.4.1. SETUP ACAL: PROGRAMMING AND AUTO CAL SEQUENCE  
NOTE  
If at any time an illegal entry is selected, (for example: Delta Days > 366) the ENTR key will disappear  
from the display.  
To program the example sequence shown in Table 9-4, press:  
SAMPLE  
RANGE = 50.0 PPM  
CO=XX.XX  
SETUP  
< TST TST > CAL CALZ CZLS  
SETUP X.X  
CFG ACAL DAS RNGE PASS CLK MORE EXIT  
SETUP X.X SEQ 1) DISABLED  
NEXT MODE  
EXIT  
EXIT  
SETUP X.X SEQ 2) DISABLED  
PREV NEXT MODE  
SETUP X.X MODE: DISABLED  
NEXT  
ENTR EXIT  
ENTR EXIT  
SETUP X.X MODE: ZERO  
PREV NEXT  
SETUP X.X MODE: ZERO–SPAN  
PREV NEXT  
ENTR EXIT  
SETUP X.X SEQ 2) ZERO–SPAN, 1:00:00  
PREV NEXT MODE SET  
EXIT  
SETUP X.X TIMER ENABLE: ON  
SET> EDIT  
EXIT  
SETUP X.X STARTING DATE: 01–JAN–07  
<SET SET> EDIT  
EXIT  
SETUP X.X STARTING DATE: 01–JAN–02  
0
4
SEP  
0
8
ENTR EXIT  
Toggle keys to set  
Day, Month & Year:  
Format : DD-MON-YY  
CONTINUE NEXT PAGE  
With STARTING TIME  
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CONTINUED FROM PREVIOUS PAGE -  
STARTING DATE  
SETUP X.X STARTING DATE: 04–SEP–08  
<SET SET> EDIT  
EXIT  
EXIT  
SETUP X.X STARTING TIME:00:00  
<SET SET> EDIT  
Toggle keys to set  
time:  
SETUP X.X STARTING TIME:00:00  
Format : HH:MM  
1
4
: 1  
5
ENTR EXIT  
This is a 24 hr clock . PM  
hours are 13 – 24.  
Example 2:15 PM = 14:15  
SETUP X.X STARTING TIME:14:15  
<SET SET> EDIT  
EXIT  
SETUP X.X DELTA DAYS: 1  
<SET SET> EDIT  
EXIT  
ENTR EXIT  
EXIT  
SETUP X.X DELTA DAYS: 1  
Toggle keys to set  
number of days between  
procedures (1-365).  
0
0
2
SETUP X.X DELTA DAYS:2  
<SET SET> EDIT  
SETUP X.X DELTA TIME00:00  
<SET SET> EDIT  
EXIT  
Toggle keys to set  
delay time for each  
iteration of the sequence:  
HH:MM  
SETUP X.X DELTA TIME: 00:00  
0
0
:3  
0
ENTR EXIT  
(0 – 24:00)  
SETUP X.X DELTA TIME:00:30  
<SET SET> EDIT  
EXIT  
CONTINUE NEXT PAGE  
With DURATION TIME  
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CONTINUED FROM PREVIOUS PAGE  
DELTA TIME  
SETUP X.X DURATION:15.0 MINUTES  
<SET SET> EDIT  
EXIT  
ENTR EXIT  
EXIT  
Toggle keys to set  
duration for each iteration  
of the sequence:  
Set in Decimal minutes  
from 0.1 – 60.0.  
SETUP X.X DURATION 15.0MINUTES  
3
0
.0  
SETUP X.X DURATION:30.0 MINUTES  
<SET SET> EDIT  
SETUP X.X CALIBRATE: OFF  
<SET SET> EDIT  
EXIT  
ENTR EXIT  
EXIT  
SETUP X.X CALIBRATE: OFF  
ON  
Toggle key  
Between Off and  
ON.  
SETUP X.X CALIBRATE: ON  
<SET SET> EDIT  
Display show:  
SEQ 2) ZERO–SPAN, 2:00:30  
SETUP X.X SEQ 2) ZERO–SPAN, 2:00:30  
EXIT returns  
to the SETUP  
Menu.  
Sequence  
Delta Time  
Delta Days  
MODE  
PREV NEXT MODE SET  
EXIT  
9.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected  
If the GFC 7001E/EM Analyzer is set for either the Dual or Auto reporting range modes, the following three steps  
will appear at the beginning of the AutoCal setup routine:  
SETUP X.X  
<SET  
RANGE TO CAL: LOW  
EDIT  
EXIT  
SETUP X.X  
RANGE TO CAL: LOW  
RANGE TO CAL: HIGH  
LOW HIGH  
ENTR SETUP  
SETUP X.X  
<SET  
EDIT  
EXIT  
EXIT  
SETUP X.X SEQ 2) ZERO–SPAN, 2:00:30  
EXIT returns to the  
PRIMARY SETUP  
Menu.  
PREV NEXT MODE SET  
NOTE  
In order to automatically calibrate both the HIGH and LOW ranges, you must set up a separate sequence  
for each.  
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9.5. CO 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 curve 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 (see Section 3.5.4 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 below and frequently compare them to those values  
on the Final Test and Validation Sheet that came attached to your manual, which should not be significantly  
different. If they are, refer to the troubleshooting Section 12.  
Table 9-5: Calibration Data Quality Evaluation  
FUNCTION  
SLOPE  
MINIMUM VALUE  
0.700  
OPTIMUM VALUE  
MAXIMUM VALUE  
1.000  
0.000  
1.300  
0.500  
OFFS  
-0.500  
These values should not be significantly different from the values recorded on the Teledyne’s Final Test and Validation  
Data Sheet that was shipped with your instrument.  
If they are, refer to the troubleshooting Section 12.  
The default iDAS configuration records all calibration values in channel CALDAT as well as all calibration check  
(zero and span) values in its internal memory.  
Up to 200 data points are stored for up to 4 years of data (on weekly calibration checks) and a lifetime  
history of monthly calibrations.  
Review these data to see if the zero and span responses change over time.  
These channels also store the STABIL value (standard deviation of CO concentration) to evaluate if the  
analyzer response has properly leveled off during the calibration procedure.  
Finally, the CALDAT channel also stores the converter efficiency for review and documentation.  
If your instrument has either an O2 or CO2 sensor option installed these should be calibrated as well.  
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9.6. CALIBRATION OF THE GFC 7001E/EM’S ELECTRONIC  
SUBSYSTEMS  
9.6.1. 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 one 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=50.0 PPM  
CO= XX.XX  
SETUP  
<TST TST> CAL  
SETUP X.X  
PRIMARY SETUP MENU  
CFG DAS RNGE PASS CLK MORE  
EXIT  
SETUP X.X  
SECONDARY SETUP MENU  
COMM VARS DIAG  
EXIT  
SETUP X.X  
ENTER PASSWORD  
8
1
8
ENTR EXIT  
DIAG  
SIGNAL I/O  
PREV NEXT  
ENTR EXIT  
Continue pressing NEXT until ...  
DIAG OPTIC  
DARK CALIBRATION  
PREV NEXT  
ENTR EXIT  
DIAG DARK  
VIEW CAL  
CO DARK CALIBRATION  
EXIT  
Calibration runs automatically  
Offset for CO REF signal  
DIAG DARK  
REF DARK OFFSET: 0.0mV  
DIAG DARK  
DARK CAL 1% COMPLETE  
EXIT  
EXIT  
EXIT  
Offset for CO MEAS signal  
DIAG DARK  
MEAS DARK OFFSET: 0.0mV  
DIAG DARK  
DARK CALIBRATION ABORTED  
EXIT  
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9.6.2. 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 CO concentration calculation for changes in atmospheric pressure and is stored in  
the CPU’s memory as the test function PRES (also viewable via the front panel).  
NOTE  
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.  
To cause the analyzer to measure and record a value for PRES, press.  
SETUP X.X  
CFG DAS RNGE PASS CLK  
EXIT  
SETUP X.X  
COMM VARS  
EXIT  
EXIT  
SETUP X.X  
ENTR  
until ...  
Continue pressing  
DIAG  
PREV NEXT  
EXIT  
EXIT  
DIAG PCAL  
DIAG PCAL  
discards the  
new setting.  
accepts the  
new setting.  
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9.6.3. FLOW CALIBRATION  
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 COMM 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  
Section 12.3.4 for more details). Once the flow meter is attached and is measuring actual gas flow, press:  
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9.6.4. ELECTRICAL TEST CALIBRATION  
To run the Electrical Test, see Section 13.5.6.2. For Electrical Test calibration the 929 password must be used:  
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9.7. CALIBRATION OF OPTIONAL SENSORS  
9.7.1. O2 SENSOR CALIBRATION PROCEDURE  
9.7.1.1. O2 Calibration Setup  
The pneumatic connections for calibrating are as follows:  
Figure 9-7:  
O2 Sensor Calibration Set Up  
O2 SENSOR ZERO GAS: Teledyne recommends using pure N2 when calibration the zero point of your O2  
sensor option.  
O2 SENSOR SPAN GAS: Teledyne recommends using 20.8% O2 in N2 when calibration the span point of your  
O2 sensor option (See Table 3-7).  
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9.7.1.2. Set O2 Span Gas Concentration  
Set the expected O2 span gas concentration.  
This should be equal to the percent concentration of the O2 span gas of the selected reporting range (default  
factory setting = 20.8%; the approximate O2 content of ambient air).  
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9.7.1.3. Activate O2 Sensor Stability Function  
To change the stability test function from CO concentration to the O2 sensor output, press:  
NOTE  
Use the same procedure to reset the STB test function to CO when the O2 calibration procedure is  
complete.  
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9.7.1.4. O2ZERO/SPAN CALIBRATION  
To perform the zero/span calibration procedure:  
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9.7.2. CO2 SENSOR CALIBRATION PROCEDURE  
9.7.2.1. CO2 Calibration Setup  
The pneumatic connections for calibrating are as follows  
Figure 9-8:  
CO2 Sensor Calibration Set Up  
CO2 SENSOR ZERO GAS: Teledyne recommends using pure N2 when calibration the zero point of your CO2  
sensor option.  
CO2 SENSOR SPAN GAS: Teledyne recommends using 16% CO2 in N2 when calibration the span point of your  
CO2 sensor option (Table 3-7) is 20%.  
9.7.2.2. Set CO2 Span Gas Concentration:  
Set the expected CO2 span gas concentration.  
This should be equal to the percent concentration of the CO2 span gas of the selected reporting range (default  
factory setting = 12%).  
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9.7.2.3. Activate CO2 Sensor Stability Function  
To change the stability test function from CO concentration to the CO2 sensor output, press:  
NOTE  
Use the same procedure to reset the STB test function to CO when the CO2 calibration procedure is  
complete.  
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9.7.2.4. CO2 Zero/Span Calibration  
To perform the zero/span calibration procedure:  
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10. EPA CALIBRATION PROTOCOL  
10.1. CALIBRATION REQUIREMENTS  
If the GFC 7001E is to be used for EPA SLAMS monitoring, it must be calibrated in accordance with the  
instructions in this section.  
The USEPA strongly recommends that you obtain a copy of the publication Quality Assurance Handbook for Air  
Pollution Measurement Systems Volume 2: Part 1, Ambient (abbreviated, Q.A. Handbook Volume II). This  
manual can be purchased from:  
USEPA Order Number: EPA454R98004; or NTIS Order Number: PB99 129876.  
National Technical Information Service (phone 800-553-6847) or Center for Environmental Research  
Information or the U.S. Government Printing Office at http://www.gpo.gov. The Handbook can also be  
located on line by searching for the title at http://www.epa.gov.  
Special attention should be paid to Section 2.6 of that which covers CO analyzers of this type.  
Specific regulations regarding the use and operation of ambient CO analyzers can be found in  
Reference 1 at the end of this Section.  
A bibliography and references relating to CO monitoring are listed in Section 10.6.  
10.1.1. CALIBRATION OF EQUIPMENT - GENERAL GUIDELINES  
In general, calibration is the process of adjusting the gain and offset of the GFC 7001E against some recognized  
standard. In this section the term dynamic calibration is used to express a multipoint check against known  
standards and involves introducing gas samples of known concentration into the instrument in order to adjust the  
instrument to a predetermined sensitivity and to produce a calibration relationship.  
This relationship is derived from the instrumental response to successive samples of different known  
concentrations. As a minimum, three reference points and a zero point are recommended to define this  
relationship.  
All monitoring instrument systems are subject to some drift and variation in internal parameters and cannot be  
expected to maintain accurate calibration over long periods of time. Therefore, it is necessary to dynamically  
check the calibration relationship on a predetermined schedule. Zero and span checks must be used to  
document that the data remains within control limits. These checks are also used in data reduction and  
validation.  
Calibration can be done by either diluting high concentration CO standards with zero air or using individual tanks  
of known concentration. Details of documentation, forms and procedures should be maintained with each  
analyzer and also in a central backup file as described in Section 2.6.2 of the Quality Assurance Handbook.  
The reliability and usefulness of all data derived from any analyzer depends primarily upon its state of calibration.  
To ensure accurate measurements of the CO levels:  
1. The analyzer must be calibrated at the time of installation and recalibrated as necessary.  
2. In order to insure that high quality, accurate measurement information is obtained at all times, the  
analyzer must be calibrated prior to use.  
3. Calibrations should be carried out at the field-monitoring site.  
4. The analyzer should be in operation for at least several hours (preferably overnight) before calibration  
so that it is fully warmed up and its operation has stabilized.  
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5. If the instrument will be used on more than one range, it should be calibrated separately on each  
applicable range.  
6. Calibration documentation should be maintained with each analyzer and also in a central backup file.  
7. The true values of the calibration gases used must be traceable to NIST-SRMs See Table 3-7.  
10.1.2. CALIBRATION EQUIPMENT, SUPPLIES, AND EXPENDABLES  
The measurement of CO in ambient air requires a certain amount of basic sampling equipment and  
supplemental supplies. The Quality Assurance Handbook Section 2.6 contains information about setting up the  
appropriate systems.  
10.1.2.1. Data Recording Device  
Either a strip chart recorder, data acquisition system, digital data acquisition system should be used to record the  
data from the Mode; GFC 7001E RS-232 port or analog outputs. If analog readings are being used, the  
response of that system should be checked against a NIST referenced voltage source or meter. Data recording  
device should be capable of bi-polar operation so that negative readings can be recorded.  
10.1.2.2. Spare Parts and Expendable Supplies  
In addition to the basic equipment described in the Q.A. Handbook, it is necessary to maintain an inventory of  
spare parts and expendable supplies. Section Error! Reference source not found. describes the parts that  
require periodic replacement and the frequency of replacement. Appendix B of this Technical Manual contains a  
list of spare parts and kits of expendables supplies.  
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Table 10-1: Matrix for Calibration Equipment & Supplies  
ACTION IF  
REQUIREMENTS ARE NOT  
MET  
EQUIPMENT &  
SUPPLIES  
SPECIFICATION  
REFERENCE  
Compatible with output  
signal of analyzer; min.  
chart width of 150 mm (6 in)  
is recommended  
Recorder  
Return equipment to supplier  
Sample line and  
manifold  
Constructed of PTFE or  
glass  
Check upon receipt  
Return equipment to supplier  
Return equipment/ supplies  
to supplier or take corrective  
action  
Q.A. Handbook1 Vol II Part 1 , App 15,  
Sec. 4.4 & 5.4  
Calibration equipment  
Instruments designated as  
reference or equivalent have  
been determined to meet  
these acceptance criteria.  
Noise = 0.5 ppm  
Lower detectable  
limit=1.0 ppm  
Detection limit  
40 CFR, Pt 53.20 & 232  
Analyzed against NIST-SRM;  
Obtain new working  
standard and check for  
traceability  
Working standard CO  
cylinder gas  
Traceable to NIST-SRM  
40 CFR, Pt 50, App C; para.  
3.13  
Clean dry ambient air, free  
of contaminants that cause 40 CFR, Pt 50, App C; para.  
detectable response with  
the CO analyzer.  
Obtain air from another  
source or regenerate.  
Zero air  
3.23  
Q.A. Handbook1 Vol II Part 1 , App 15,  
Table A-5 & A-6  
Record form  
Revise forms as appropriate  
Q.A. Handbook1 Vol II Part 1 ,  
Must not be the same as  
used for calibration  
Locate problem and correct  
or return to supplier  
Audit equipment  
App 15,  
Sec. 4.4 & 5.4  
10.1.3. RECOMMENDED STANDARDS FOR ESTABLISHING TRACEABILITY  
To assure data of desired quality, two considerations are essential:  
The measurement process must be in statistical control at the time of the measurement.  
The systematic errors, when combined with the random variation in the measurement process, must result  
in a suitably small uncertainty.  
Evidence of good quality data includes documentation of the quality control checks and the independent audits  
of the measurement process by recording data on specific forms or on a quality control chart and by using  
materials, instruments, and measurement procedures that can be traced to appropriate standards of reference.  
To establish traceability, data must be obtained routinely by repeat measurements of standard reference  
samples (primary, secondary and/or working standards). More specifically, working calibration standards must  
be traceable to standards of higher accuracy, such as those listed in Table 3-7.  
Cylinders of working gas traceable to NIST-SRMs (called EPA Protocol Calibration Gas) are also commercially  
available (from sources such as Scott Specialty Gases, etc.). See Table 3-7 for a list of appropriate SRMs.  
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10.1.4. CALIBRATION FREQUENCY  
To ensure accurate measurements of the CO concentrations, calibrate the analyzer at the time of installation,  
and recalibrate it:  
No later than three months after the most recent calibration or performance audit which indicate the  
analyzer’s calibration to be acceptable.  
When there is an interruption of more than a few days in analyzer operation.  
When any repairs have taken place which might affect its calibration.  
After a physical relocation of the analyzer.  
When any other indication (including excessive zero or span drift) of possible significant inaccuracy of the  
analyzer exists.  
Following any of the activities listed above, the zero and span should be checked to determine if a calibration is  
necessary.  
Table 10-2: Activity Matrix for Quality Assurance Checks  
Frequency and method of  
Characteristic  
Acceptance limits  
Action if requirements are not met  
measurement  
Mean temperature between  
22oC and 28oC (72o and 82oF),  
daily fluctuations not greater  
than ±2oC  
Mark strip chart for the affected time  
period  
Check thermograph chart  
weekly for variations greater  
than ±2oC (4oF)  
Shelter temperature  
Repair or adjust temperature control  
No moisture, foreign material,  
leaks, obstructions; sample line Weekly visual inspection  
connected to manifold  
Sample introduction  
system  
Clean, repair, or replace as needed  
Adequate ink & paper  
Replenish ink and paper supply  
Adjust time to agree with clock; note on  
chart  
Legible ink traces  
Recorder  
Weekly visual inspection  
Correct chart speed and range  
Correct time  
TEST measurements at  
nominal values  
2. GFC 7001E in Sample Mode  
Analyzer operational  
settings  
Weekly visual inspection  
Adjust or repair as needed  
Zero and span within tolerance Level 1 zero/span every 2  
limits as described in weeks; Level 2 between Level  
Find source of error and repair  
After corrective action, re-calibrate  
analyzer  
Analyzer operational  
check  
Subsection 9.1.3 of Sec. 2.0.9 1 checks at frequency desired  
(Q.A. Handbook Vol II4)  
analyzer by user  
Assess precision as described  
in Sec. 2.0.8 and Subsection  
3.4.3 (Ibid.)  
Every 2 weeks, Subsection  
3.4.3 (Ibid.)  
Precision check  
.
Calc, report precision, Sec. 2.0.8 (Ibid.)  
10.1.5. LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS  
Essential to quality assurance are scheduled checks for verifying the operational status of the monitoring system.  
The operator should visit the site at least once each week. It is recommended Level 1 zero and span check  
conducted on the analyzer every two weeks. Level 2 zero and span checks should be conducted at a frequency  
desired by the user. Definitions of these terms are given in Error! Reference source not found..  
To provide for documentation and accountability of activities, a checklist should be compiled and then filled out  
by the field operator as each activity is completed.  
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Table 10-3: Definition of Level 1 and Level 2 Zero and Span Checks  
(Q.A. Handbook1 Vol II, Part1, Section 12.3 & 12.4)  
LEVEL 1 ZERO AND SPAN CALIBRATION  
LEVEL 2 ZERO AND SPAN CHECK  
A Level 1 zero and span calibration is a simplified, two-  
point analyzer calibration used when analyzer linearity  
does not need to be checked or verified. (Sometimes  
when no adjustments are made to the analyzer, the  
Level 1 calibration may be called a zero/span check, in  
which case it must not be confused with a Level 2  
zero/span check.) Since most analyzers have a reliably  
linear or near-linear output response with concentration,  
they can be adequately calibrated with only two  
concentration standards (two-point concentration).  
Furthermore, one of the standards may be zero  
concentration, which is relatively easily obtained and  
need not be certified. Hence, only one certified  
concentration standard is needed for the two-point (Level  
1) zero and span calibration. Although lacking the  
advantages of the multipoint calibration, the two-point  
zero and span calibration--because of its simplicity--can  
be (and should be) carried out much more frequently.  
Also, two-point calibrations are easily automated.  
Frequency checks or updating of the calibration  
relationship with a two-point zero and span calibration  
improves the quality of the monitoring data by helping to  
keep the calibration relationship more closely matched to  
any changes (drifts) in the analyzer response.  
A Level 2 zero and span check is an "unofficial" check of  
an analyzer's response. It may include dynamic checks  
made with uncertified test concentrations, artificial  
stimulation of the analyzer's detector, electronic or other  
types of checks of a portion of the analyzer, etc.  
Level 2 zero and span checks are not to be used as a  
basis for analyzer zero or span adjustments, calibration  
updates, or adjustment of ambient data. They are  
intended as quick, convenient checks to be used  
between zero and span calibrations to check for possible  
analyzer malfunction or calibration drift. Whenever a  
Level 2 zero or span check indicates a possible  
calibration problem, a Level 1 zero and span (or  
multipoint) calibration should be carried out before any  
corrective action is taken.  
If a Level 2 zero and span check is to be used in the  
quality control program, a "reference response" for the  
check should be obtained immediately following a zero  
and span (or multipoint) calibration while the analyzer's  
calibration is accurately known. Subsequent Level 2  
check responses should then be compared to the most  
recent reference response to determine if a change in  
response has occurred. For automatic Level 2 zero and  
span checks, the first scheduled check following the  
calibration should be used for the reference response. It  
should be kept in mind that any Level 2 check that  
involves only part of the analyzer's system cannot  
provide information about the portions of the system not  
checked and therefore cannot be used as a verification  
of the overall analyzer calibration.  
10.2. ZERO AND SPAN CHECKS  
A system of Level 1 and Level 2 zero span checks is recommended. These checks must be conducted in  
accordance with the specific guidance given in Section 12 of the QA Handbook Vol II Part 11. It is recommended  
that Level 1 zero and span checks be conducted every two weeks. Level 2 checks should be conducted in  
between the Level 1 checks at a frequency desired by the user. Span concentrations for both levels should be  
between 70 and 90% of the measurement range.  
Zero and span data are to be used to:  
1. Provide data to allow analyzer adjustment for zero and span drift;  
2. Provide a decision point on when to calibrate the analyzer;  
3. Provide a decision point on invalidation of monitoring data.  
Items 1 and 2 are described in detail in Subsection 9.1.3 of Section 2.0.9 (Q.A. Handbook Vol II4). Item 3 is  
described in Subsection 9.1.4 of the same section.  
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Refer to the Troubleshooting and Repair (see Section 13) of this manual if the instrument is not within the  
allowed variations.  
10.2.1. ZERO/SPAN CHECK PROCEDURES  
The Zero and Span calibration can be checked in a variety of different ways. They include:  
Manual Zero/Span Check - Zero and Span can be checked from the front panel keyboard. The procedure  
is in Section 9.3 of this manual.  
Automatic Zero/Span Checks - After the appropriate setup, Z/S checks can be performed automatically  
every night. See Section 9.3 of this manual for setup and operation procedures.  
If using the AutoCal feature to perform a calibration check, set the CALIBRATE parameter to NO.  
Zero/Span checks via remote contact closure = Zero/Span checks can be initiated via remote contact  
closures on the rear panel. See Section 9.3.3.3 of this manual.  
Zero/Span via RS-232 port - Z/S checks can be controlled via the RS-232 port. See Section 9.3.3.3 and  
Appendix A-6 of this manual for more details.  
10.2.2. PRECISION CHECK  
A periodic check is used to assess the data for precision. A one-point precision check must be carried out at  
least once every 2 weeks on each analyzer at a CO concentration between 8.0 ppm and 10.0 ppm.  
The analyzer must be operated in its normal sampling mode, and the precision test gas must pass through all  
filters, scrubbers, conditioners, and other components used during normal ambient sampling.  
The standards from which precision check test concentrations are obtained must be traceable to NIST-SRM.  
Those standards used for calibration or auditing may be used.  
To perform a precision check during the instrument set up, the sources of zero air and sample gas and  
procedures should conform to those described in Section Error! Reference source not found. for analyzers  
with no valve options or with an IZS valve option installed and Section 9.3.1 for analyzers with Z/S options  
installed with the following exception:  
Connect the analyzer to a precision gas that has a CO concentration between 8.0 ppm and 10.0 ppm. If a  
precision check is made in conjunction with a zero/span check, it must be made prior to any zero or span  
adjustments.  
Record this value.  
Information from the check procedure is used to assess the precision of the monitoring data; see CFR 40 CFR  
585 for procedures for calculating and reporting precision.  
10.3. PRECISIONS CALIBRATION  
Calibration must be performed with a calibrator that meets all conditions specified in QA Handbook1 Vol II Part 1,  
App 15, Sec. 4.4 & 5.4. The user should be sure that all flow meters are calibrated under the conditions of use  
against a reliable standard. All volumetric flow rates should be corrected to 25oC (77oF) and 760 mm-Hg  
(29.92in–Hg). Make sure the calibration system can supply the range of the concentration at a sufficient flow  
over the whole range of concentration that will be encountered during calibration.  
All operational adjustments to the GFC 7001E should be completed prior to the calibration. The following  
software features must be set into the desired state before calibration.  
If the instrument will be used for more than one range, it should be calibrated separately on each  
applicable range.  
Automatic temperature/pressure compensation should be enabled. See Section 6.6.  
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Alternate units, make sure ppm units are selected for EPA monitoring. See Section 6.6.4.  
The analyzer should be calibrated on the same range used for monitoring.  
10.3.1. PRECISION CALIBRATION PROCEDURES  
To perform a precision calibration during the instrument set up, the input sources of zero air and sample gas and  
procedures should conform to those described in Section Error! Reference source not found. for analyzers  
with no valve options or with an IZS valve option installed and Section 9.3 for analyzers with Z/S options  
installed.  
10.4. AUDITING PROCEDURE  
An audit is an independent assessment of the accuracy of data. Independence is achieved by having the audit  
made by an operator other than the one conducting the routine field measurements and by using audit standards  
and equipment different from those routinely used in monitoring. The audit should be a true assessment of the  
measurement process under normal operations without any special preparation or adjustment of the system.  
Routine quality control checks conducted by the operator are necessary for obtaining and reporting good quality  
data, but they are not considered part of the auditing procedure. Audits are recommended once per quarter, but  
frequency may be determined by applicable regulations and end use of the data.  
Refer to The Q.A. Handbook1 Volume II, Part 1 Section 16 (for a more detailed description).  
10.4.1. CALIBRATION AUDIT  
A calibration audit consists of challenging the GFC 7001E/EM with known concentrations of CO. The difference  
between the known concentration and the analyzer response is obtained, and an estimate of the analyzer's  
accuracy is determined.  
The recommended audit schedule depends on the purpose for which the monitoring data are being collected.  
For example, Appendix A, 40 CFR 585 requires that each analyzer in State and Local Air Monitoring Network  
Plan (SLAMS) be audited at least once a year. Each agency must audit 25% of the reference or equivalent  
analyzers each quarter. If an agency operates less than four reference or equivalent analyzers, it must randomly  
select analyzers for reauditing so that one analyzer will be audited each calendar quarter and each analyzer will  
be audited at least once a year.  
Appendix B, 40 CFR 585 requires that each Prevention of Significant Deterioration (PSD) reference or equivalent  
analyzer be audited at least once a sampling quarter. Results of these audits are used to estimate the accuracy  
of ambient air data.  
10.4.2. DATA REDUCTION AUDIT  
A data reduction audit involves transcribing analyzer data and determining if the collected data is within the  
control limits, generally 2 ppm between the analyzer response and the audit value. The resulting values are  
recorded on the SAROAD form. If data exceeds 2 ppm, check all of the remaining data in the 2-week period.  
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10.4.3. SYSTEM AUDIT/VALIDATION  
A system audit is an on-site inspection and review of the quality assurance activities used for the total  
measurement system (sample collection, sample analysis, data processing, etc.); it is an appraisal of system  
quality.  
Conduct a system audit at the startup of a new monitoring system and periodically (as appropriate) as significant  
changes in system operations occur.  
10.5. DYNAMIC MULTIPOINT CALIBRATION PROCEDURE  
10.5.1. LINEARITY TEST  
In order to record the instrument’s performance at a predetermined sensitivity and to derive a calibration  
relationship, a minimum of three reference points and one zero point uniformly spaced covering 0 to 90 percent  
of the operating range are recommended to define this relationship.  
The analyzer's recorded response is compared with the known concentration to derive the calibration  
relationship.  
To perform a precision check during the instrument set up, the sources of zero air and sample gas should conform to  
those described in Section 9.1.2.  
Follow the procedures described in Section 9.3 for calibrating the zero points.  
For each mid point:  
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SAMPLE  
A1:CONC1=50 PPM  
CO = XXXX  
SETUP  
Set the Display to show the  
COSTB test function.  
This function calculates the  
stability of the CO  
< TST TST > CAL  
measurement.  
SAMPLE  
CO STB=XXXX PPB  
CO=XXXX  
SETUP  
< TST TST > CAL  
ACTION:  
Allow calibration gas diluted to proper concentration for  
Midpoint N to enter the sample port  
SAMPLE  
COSTB=XXXX PPB  
CO=XXXX  
SETUP  
Wait until  
STABIL falls  
below 0.2 PPM  
(for M300E).  
< TST TST > CAL CALZ CALS  
This may take  
several minutes.  
Record the CO  
reading as  
displayed on the  
instrument’s front  
panel.  
SPAN CAL M  
A1:CONC1=50 PPM  
CO = XXXX  
< TST TST > ZERO SPAN CONC  
EXIT  
Press EXIT to  
Return to the  
Main SAMPLE  
Display.  
ACTION:  
Allow Calibration Gas diluted to  
proper concentration for  
Midpoint N+1 to enter the sample  
port.  
Plot the analyzer responses versus the corresponding calculated concentrations to obtain a calibration  
relationship. Determine the best-fit straight line (y = mx + b) determined by the method of least squares.  
After the best-fit line has been drawn, determine whether the analyzer response is linear. To be considered  
linear, no calibration point should differ from the best-fit line by more than 2% of full scale.  
If carried out carefully, the checks described in this section will provide reasonable confidence that the GFC  
7001E is operating properly. Checks should be carried out at least every 3 months as the possibility of  
malfunction is always present.  
If the linearity error is excessive and cannot be attributed to outside causes, check the GFC 7001E system for:  
Sample pressure higher than ambient – pressurized sample gas  
Leaks  
Correct flow  
Miscalibrated span gas tanks or bad zero gas  
Miscalibrated sample pressure transducer  
Failed IR detector, GFC Wheel or Sync/Demod Board  
Contaminated optical bench or sample lines  
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10.6. REFERENCES  
1
Quality Assurance Handbook for Air Pollution Measurement Systems Volume II: Part 1 - Ambient Air Quality  
Monitoring Program Quality System Development - EPA-454/R-98-004 - August 1998. United States  
Environmental Protection Agency - Office of Air Quality Planning and Standards  
2
3
CFR Title 40: Protection of Environment - PART 53—AMBIENT AIR MONITORING REFERENCE AND  
EQUIVALENT METHODS:  
- 53.20 General provisions.  
- 53.23 Test procedures.  
CFR Title 40: Protection of Environment - PART 50—NATIONAL PRIMARY AND SECONDARY AMBIENT  
AIR QUALITY STANDARDS: Appendix C to Part 50—Measurement Principle and Calibration Procedure for  
the Measurement of Carbon Monoxide in the Atmosphere (Non-Dispersive Infrared Photometry)  
4
5
Quality Assurance Handbook for Air Pollution Measurement Systems - Volume II, Ambient Air Specific  
Methods, EPA-600/4-77-027a, 1977.  
CFR Title 40: Protection of Environment - AMBIENT AIR QUALITY SURVEILLANCE  
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Part III Technical Information  
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PART III  
–
TECHNICAL INFORMATION  
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Theory of Operation  
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11. THEORY OF OPERATION  
The GFC 7001E/EM Gas Filter Correlation Carbon monoxide Analyzer is a microprocessor-controlled analyzer  
that determines the concentration of carbon monoxide (CO) in a sample gas drawn through the instrument. It  
requires that the sample and calibration gases 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 CO 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 7.1) as well as reported to the user via a vacuum  
florescent display or a variety of digital and analog signal outputs.  
11.1. MEASUREMENT METHOD  
11.1.1. BEER’S LAW  
The basic principle by which the analyzer works is called the Beer-Lambert Law or Beer’s Law. It defines how  
light of a specific wavelength is absorbed by a particular gas molecule over a certain distance. The  
mathematical relationship between these three parameters is:  
I = Io e-αLc  
Equation 11-1  
Where:  
Io  
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 GFC 7001E/EM, Carbon Monoxide (CO).  
α
is the absorption coefficient that tells how well CO absorbs light at the specific wavelength of interest.  
11.2. MEASUREMENT FUNDAMENTALS  
In the most basic terms, the GFC 7001E/EM 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 a number of times (see Figure 11-1).  
The total length that the reflected light travels is directly related to the intended sensitivity of the instrument. The  
lower the concentrations the instrument is designed to detect, the longer the light path must be in order to create  
detectable levels of attenuation.  
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Lengthening the absorption path is accomplished partly by making the physical dimension of the reaction cell  
longer, but primarily by adding extra passes back and forth along the length of the chamber.  
Table 11-1: Absorption Path Lengths for GFC 7001E and GFC 7001EM  
TOTAL  
ABSORPTION LIGHT  
PATH  
TOTAL NUMBER OF  
REFLECTIVE PASSES  
MODEL  
DISTANCE BETWEEN MIRRORS  
GFC 7001E  
32  
8
437.5 mm  
312.5 mm  
14 Meters  
2.5 Meters  
GFC 7001EM  
Band-Pass Filter  
Sample Chamber  
IR  
Source  
Photo-Detector  
IR Beam  
Figure 11-1:  
Measurement Fundamentals  
Upon exiting the sample cell, the beam shines through a band-pass filter that allows only light at a wavelength of  
4.7 µm to pass. Finally, the beam strikes a solid-state photo-detector that converts the light signal into a  
modulated voltage signal representing the attenuated intensity of the beam.  
11.2.1. GAS FILTER CORRELATION  
Unfortunately, water vapor absorbs light at 4.7 µm too. To overcome the interfering effects of water vapor the  
GFC 7001E/EM adds another component to the IR light path called a Gas Filter Correlation (GFC) Wheel.  
Measurement Cell  
(Pure N2)  
Reference Cell  
(N2 with CO)  
Figure 11-2:  
GFC Wheel  
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11.2.1.1. The 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 4.7 µm IR radiation creating two airtight cavities. Each cavity is mainly filled with  
composed gases. One cell is filled with pure N2 (the measurement cell). The other is filled with a combination of  
N2 and a high concentration of CO (the reference cell).  
IR unaffected by N2 in Measurement Cell  
∆ H  
IR is affected by CO in Reference Cell  
M
IR  
Source  
Photo-Detector  
R
GFC Wheel  
Figure 11-3:  
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 in the gas filter wheel strips the beam of most of the IR at 4.7μm. When the light  
beam is exposed to the measurement cell, the N2 in the filter wheel does not absorb IR light. This causes a  
fluctuation in the intensity of the IR light striking the photo-detector which results in the output of the detector  
resembling a square wave.  
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11.2.1.2. The Measure Reference Ratio  
The GFC 7001E/EM determines the amount of CO in the sample chamber by computing the ratio between the  
peak of the measurement pulse (CO MEAS) and the peak of the reference pulse (CO REF).  
If no gases exist in the sample chamber that absorb light at 4.7μm, 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 this  
additional attenuation is greater. This causes CO MEAS to be more sensitive to the presence of CO in the  
sample chamber than CO REF and the ratio between them (M/R) to move closer to 1:1 as the concentration of  
CO in the sample chamber increases.  
IR unaffected by N2 in Measurement Cell of  
the GDC Wheel and no additional CO in the  
Sample Chamber  
CO MEAS  
CO REF  
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 11-4:  
Effect of CO in the Sample on CO MEAS & CO REF  
Once the GFC 7001E/EM 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 calibration SLOPE and  
OFFSET values to produce the CO concentration which is then normalized for changes in sample pressure.  
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Interference and Signal to Noise Rejection:  
If an interfering gas, such as H2O 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.  
M/R  
is Shifted  
IR shining through both cells is  
affected equally by interfering  
gas in the Sample Chamber  
Figure 11-5:  
Effects of Interfering Gas on CO MEAS & CO REF  
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 case, GFC rejects the effects of interfering gases and so that the analyzer responds only to the  
presence of CO.  
To improve the signal-to-noise 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 ratio.  
The IR Signal as the Photo-  
Detector sees it after being  
chopped by the GFC Wheel  
CO MEAS  
CO REF  
Figure 11-6:  
Chopped IR Signal  
11.2.1.3. Summary Interference Rejection  
The basic design of the GFC 7001E/EM rejects most of this interference at a 300:1 ratio. The two primary  
methods used to accomplish this are:  
The 4.7μm band pass filter just before the IR sensor which allows the instrument to only react to IR  
absorption in the wavelength affected by CO.  
Comparison of the measure and reference signals and extraction of the ratio between them.  
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11.3. PNEUMATIC OPERATION  
CAUTION  
GENERAL SAFETY HAZARD  
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 12-1.  
Procedures for correctly performing leak checks can be found in Section 12.3.3.  
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.  
By placing the pump down stream from the sample chamber several problems are avoided.  
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.  
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.  
INSTRUMENT CHASSIS  
GFC Motor Heat Sync  
GFC Wheel  
Housing  
SAMPLE  
PRESSURE  
SENSOR  
FLOW  
SENSOR  
Sample Gas  
Flow Control  
Figure 11-7:  
Internal Pneumatic Flow – Basic Configuration  
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11.4. FLOW RATE CONTROL  
To maintain a constant flow rate of the sample gas through the instrument, the GFC 7001E/EM uses a special  
flow control assembly located in the exhaust gas line just before the pump. In instruments with the O2 sensor  
installed, a second flow control assembly is located between the O2 sensor assembly and the pump. These  
assemblies consist of:  
A critical flow orifice.  
Two o-rings: Located just before and after the critical flow orifice, the o-rings seal the gap between the  
walls of assembly housing and the critical flow orifice.  
A spring: Applies mechanical force needed to form the seal between the o-rings, the critical flow orifice and  
the assembly housing.  
11.4.1.1. 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 pump draws  
the gas through the orifice.  
As the pressure on the downstream side of the orifice (the pump side) continues to drop, the speed that the gas  
flows through 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.  
CRITICAL  
FLOW  
ORIFICE  
AREA OF  
LOW  
AREA OF  
HIGH  
PRESSURE  
PRESSURE  
Sonic  
Shockwave  
O-RINGS  
SPRING  
FILTER  
Figure 11-8:  
Flow Control Assembly & Critical Flow Orifice  
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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 the gas molecules move at the speed of sound and  
pass through the orifice. Because the flow rate of gas through the orifice is only related to the minimum 2:1  
pressure differential and not absolute pressure, the flow rate of the gas is also unaffected by degradations in  
pump efficiency due to age.  
The critical flow orifice used in the GFC 7001E/EM is designed to provide a flow rate of 800 cc/min.  
11.4.2. PARTICULATE FILTER  
The GFC 7001E/EM 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 12-1.  
11.4.3. PNEUMATIC SENSORS  
11.4.3.1. 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 Section 11.4.3.2 and Figure 3-4  
11.4.3.2. 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 N2, but can be calibrated to operate with samples consisting of other gases  
such as CO. This sensor is mounted to a printed circuit board with the Sample Pressure Sensor on the sample  
chamber (see Section 11.4.3.1 and Figure 3-4).).  
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11.5. ELECTRONIC OPERATION  
11.5.1. OVERVIEW  
Figure 11-9 shows a block diagram of the major electronic components of the GFC 7001E/EM.  
At the heart of the analyzer is a microcomputer/CPU that controls various internal processes, interprets data,  
makes calculations, and reports results using specialized firmware developed by Teledyne. 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 motherboard.  
The motherboard collects data, performs signal conditioning duties and routes 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 CO in the sample gas. This analog signal is transformed into two, pre-amplified, DC voltages  
(CO MEAS and CO REF) by a synchronous demodulator printed circuit assembly. CO MEAS and CO REF are  
converted into digital data by a unipolar, analog-to-digital converter, located on the motherboard.  
A variety of sensors report the physical and operational status of the analyzer’s major components, again  
through the signal processing capabilities of the motherboard. 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:  
Through the analyzer’s keyboard and vacuum florescent display over a clocked, digital, serial I/O bus  
(using a protocol called I2C);  
RS-232 & RS-485 Serial I/O channels;  
Via an optional Ethernet communications card:  
Various analog and current analog outputs, and  
Several sets of Digital I/O channels.  
Finally, the CPU issues commands via a series of relays and switches (also over the I2C bus) located on a  
separate printed circuit assembly to control the function of key electromechanical devices such as heaters,  
motors and valves.  
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Analog Outputs  
A1  
A2  
Back Panel  
Connectors  
Optional  
4-20 mA  
Control Inputs:  
COM1 COM2  
A3  
A4  
1 – 8  
Status Outputs:  
1 – 6  
Optional  
Ethernet  
Interface  
Analog  
Outputs  
(D/A)  
External  
Digital I/O)  
PC 104  
CPU Card  
A/D  
Converter(  
V/F)  
RS–232  
or RS-485  
Power-Up  
Circuit  
Disk On  
Chip  
RS – 232  
MOTHER  
BOARD  
Flash Chip  
Box  
Temp  
PC 104 Bus  
Zero/Span  
Valve  
Options  
Thermistor  
Interface  
Internal  
Digital I/O  
I2C  
Bus  
PUMP  
Sensor Inputs  
SAMPLE  
TEMP  
Optional  
O2 Sensor  
C
O
C
O
RELAY  
BOARD  
Sample Flow  
& Pressure  
Sensors  
Keyboard &  
Display  
CPU Status  
M
E
A
S
R
E
F
LED  
BENCH  
TEMP  
Optional  
CO2  
Sensor  
TEC Control  
IR  
Source  
PHT  
WHEEL  
TEMP  
Photo-  
detector  
SYNC  
DEMOD  
Drive  
Detector  
Output  
GFC  
Motor  
GFC  
Wheel  
O2 SENSOR  
TEMP  
Optical  
Bench  
(optional)  
Schmidt  
Trigger  
Wheel  
Heater  
Segment Sensor  
Bench Heater  
M / R Sensor  
Figure 11-9:  
GFC 7001E/EM Electronic Block Diagram  
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11.5.2. CENTRAL PROCESSING UNIT (CPU)  
The CPU for the E-Series instruments is a low power (5 VDC, 360mA MAX), high performance, Vortex86SX-  
based microcomputer running MS-DOS; its operation and assembly are compliant with the PC/104 Standard.  
The CPU is installed on the motherboard located inside the rear panel. It supports both RS-232 and RS-485  
serial I/O.  
The CPU includes two types of non-volatile data storage: a Disk-on-Module and an embedded flash chip.  
DISK-ON-MODULE (DOM)  
While technically an EEPROM, the DOM,is a 44-pin IDE flash drive with a storage capacity up to 128 MB. It is  
used to store the operating system for the computer, the Teledyne’s Firmware, and most of the operational data  
generated by the analyzer’s internal data acquisition system (iDAS - See Section 7.1).  
FLASH CHIP  
Another, smaller EEPROM is the flash chip embedded in the CPU, which is used to store critical calibration and  
configuration data. Storing these key data on a separate, less heavily accessed chip significantly decreases the  
chance of the data being corrupted.  
In the unlikely event that the flash chip should fail, the analyzer will continue to operate with just the DOM.  
However, all configuration information will be lost, requiring the unit to be recalibrated.  
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11.5.3. OPTICAL BENCH & GFC WHEEL  
Electronically, in the case of the optical bench for the GFC 7001E Analyzer, GFC Wheel and associated  
components do more than simply measure the amount of CO present in the sample chamber. A variety of other  
critical functions are performed here as well.  
11.5.3.1. Temperature Control  
Because the temperature of a gas affects its density resulting in the amount of light absorbed by that gas, it is  
important to reduce the effect of fluctuations in ambient temperature on the GFC 7001E’s measurement of CO  
for the GFC 7001E Analyzer. 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 48C (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 68C. A cartridge heater 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 instrument.  
11.5.3.2. IR Source  
The light used to detect CO in the sample chamber is generated by an element heated to approximately 1100oC  
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.  
11.5.3.3. 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 range 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.  
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KEY:  
Detection Beam shining  
through MEASUREMENT  
side of GFC Wheel  
Detection Beam shining  
through REFERENCE side  
of GFC Wheel  
IR Detection Ring  
Segment Sensor Ring  
M/R Sensor Ring  
Figure 11-10: GFC Light Mask  
M/R SENSOR  
This emitter/detector assembly produces a signal that 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  
Light from this emitter/detector pair shines through a portion of the mask that is divided into the same number of  
segments as the IR detector ring. It is used by the 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  
Pulses  
MR Sensor  
Pulses  
Figure 11-11: Segment Sensor and M/R 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.  
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11.5.3.4. 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 electrical 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 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 detector’s resistance and raising the output voltage.  
11.5.4. SYNCHRONOUS DEMODULATOR (SYNC/DEMOD) ASSEMBLY  
11.5.4.1. 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. CO MEAS and CO 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.  
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.  
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56V  
Bias  
CO MEAS  
Variable  
Gain Amp  
Sample &  
Dark  
Switch  
Pre Amp  
Photo-  
detector  
Signal  
Conditioner  
Hold  
Circuits  
TEC Control  
PHT DRIVE  
E-Test  
Generator  
CO Reference  
Signal  
Conditioner  
(x4)  
Thermo-Electric  
Cooler  
Control Circuit  
E Test A Gate  
E Test B Gate  
Dark Test Gate  
Measure Gate  
Compact  
Programmable  
Logic Device  
Measure Dark Gate  
Reference Gate  
Reference Dark Gate  
Phase Lock Warning  
M/R Sensor  
From GFC  
Wheel  
Segment  
Sensor  
Segment Clock  
X1 Reference  
E Test Control  
Phase  
Lock  
Loop  
x10  
From CPU  
via Mother  
Board  
10  
Dark Switch  
Control  
X10 Clock  
M/R  
Segment  
Status LED  
Status LED  
Phase Lock  
Figure 11-12: GFC 7001E/EM Sync/Demod Block Diagram  
11.5.4.2. 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 sync/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-hold circuits that capture various voltage  
levels found in the amplified detector signal needed to determine the value of CO MEAS and CO 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 as shown in Figure 11-9.  
The four sample and hold circuits are:  
Table 11-2: Sync DEMOD Sample and Hold Circuits  
Active When:  
Designation  
IR BEAM PASSING THROUGH  
MEASUREMENT cell of GFC Wheel  
MEASUREMENT Cell of GFC Wheel  
REFERENCE cell of GFC Wheel  
REFERENCE cell of GFC Wheel  
Segment Sensor Pulse is:  
Measure Gate  
Measure Dark Gate  
Reference Gate  
HIGH  
LOW  
HIGH  
LOW  
Reference Dark Gate  
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Timing for activating the Sample and Hold Circuits is provided by a Phase Lock Loop (PLL) circuit. 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 & Hold  
Active  
Detector  
Output  
Sample & Hold  
Inactive  
Figure 11-13: Sample & Hold Timing  
11.5.4.3. Sync/Demod Status LED’s  
The following two status LED’s located on the sync/demod board provide additional diagnostic tools for checking  
the GFC Wheel rotation.  
Table 11-3: Sync/Demod Status LED Activity  
LED  
Function  
Status OK  
Fault Status  
D1  
M/R Sensor Status  
LED flashes approximately  
2/second  
LED is stuck  
ON or OFF  
D2  
Segment Sensor  
Status  
LED flashes approximately  
6/second  
LED is stuck  
ON or OFF  
See Section 13.1.4.2 for more information.  
11.5.4.4. Photo-Detector Temperature Control  
The sync/demod board also contains circuitry that controls the IR photo-detector’s Thermal Electric Coolers  
(TEC). A drive voltage, PHT DRIVE, is supplied to the coolers by the sync/demod board which is adjusted by the  
sync/demod board based on a return signal called TEC control which alerts the sync/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> until it  
appears on the display.  
11.5.4.5. Dark Calibration Switch  
This switch initiates the Dark Calibration procedure. When initiated by the user (See Section 9.6.1 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 sync/demod board circuitry.  
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11.5.4.6. 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 7.4 for more details).  
11.5.5. 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 I2C bus, interprets these  
digital instructions and activates its various switches and relays appropriately.  
11.5.5.1. 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 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.  
11.5.5.2. 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.  
11.5.5.3. 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.  
11.5.5.4. IR Source  
The relay board supplies a constant 11.5VDC to the IR Source. Under normal operation the IR source is always  
on.  
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11.5.5.5. 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. They are listed on Table 11-4.  
Table 11-4: Relay Board Status LED’s  
LED  
COLOR  
FUNCTION  
STATUS WHEN LIT  
STATUS WHEN UNLIT  
Cycles On/Off Every 3 Seconds under direct control of the  
analyzer’s CPU.  
D1  
RED  
Watch Dog Circuit  
D2  
D3  
D4  
YELLOW  
YELLOW  
YELLOW  
Wheel Heater  
Bench Heater  
Spare  
HEATING  
HEATING  
N/A  
NOT HEATING  
NOT HEATING  
N/A  
Sample/Cal Gas  
Valve Option  
Valve Open to CAL GAS  
FLOW  
D5  
D6  
GREEN  
GREEN  
Valve Open to SAMPLE Gas Flow  
Valve Open to ZERO GAS FLOW  
Zero/Span Gas  
Valve Option  
Valve Open to SPAN GAS  
FLOW  
Shutoff Valve  
Option  
Valve Open to CAL GAS  
FLOW  
Valve CLOSED to CAL GAS  
FLOW  
D7  
D8  
GREEN  
GREEN  
IR SOURCE  
Source ON  
Source OFF  
DC VOLTAGE TEST  
POINTS  
STATUS LED’s  
RELAY PCA  
PN 04135  
Figure 11-14: Location of relay board Status LED’s  
11.5.5.6. I2C Watch Dog Circuitry  
Special circuitry on the relay board monitors the activity on the I2C bus and drives LED D1. Should this LED  
ever stay ON or OFF for 30 seconds, the watch dog circuit will automatically shut off 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.  
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11.5.6. MOTHERBOARD  
This printed circuit assembly provides a multitude of functions including, A/D conversion, digital input/output, PC-  
104 to I2C translation, temperature sensor signal processing and is a pass through for the RS-232 and RS-485  
signals.  
11.5.6.1. 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, CO MEAS, CO REF, 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 GFC 7001E/EM is used in uni-  
polar mode with a +5 V full scale. The converter includes a 1% over and under-range. This allows signals from  
–0.05 V to +5.05 V to be fully converted.  
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 values to compute the converter’s offset and slope and uses these factors for  
subsequent conversions.  
See Section 7.4.3 for instructions on performing this calibration.  
11.5.6.2. 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.  
11.5.6.3. Thermistor Interface  
This circuit provides excitation, termination and signal selection for several negative-coefficient, thermistor  
temperature sensors located inside the analyzer. They are as follows:  
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 the CO  
concentration value.  
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BENCH TEMPERATURE SENSOR  
This thermistor is attached to the sample chamber housing. It reports the current temperature of the chamber  
housing to the CPU as part of the bench heater control loop.  
WHEEL TEMPERATURE SENSOR  
This thermistor is attached to the heatsink on the GFC Wheel motor assembly. It 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 motherboard. It measures the analyzer’s internal 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 13.1.2).  
11.5.6.4. Analog Outputs  
The analyzer comes equipped with four analog outputs: A1, A2, A3 and A4. The type of data and electronic  
performance of these outputs are configurable by the user (see Section 7.4).  
OUTPUT LOOP-BACK  
All 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.  
11.5.6.5. Internal Digital I/O  
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 sync/demod board that initiate the ELECTRICAL TEST and  
DARK CALIBRATION procedures.  
11.5.6.6. External Digital I/O  
This External Digital I/O performs two functions.  
STATUS OUTPUTS  
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 3.3.3).  
CONTROL INPUTS  
By applying +5VDC power supplied from an external source such as a PLC or Data logger (See Section 3.3.4),  
Zero and Span calibrations can be initiated by contact closures on the rear panel.  
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11.5.7. I2C DATA BUS  
An I2C data bus is used to communicate data and commands between the CPU and the keyboard/display  
interface and the relay board. I2C 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 I2C. 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 I2C 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 I2C circuitry to specific values until the CPU boots and the instrument software can establish control.  
11.5.8. POWER SUPPLY/ CIRCUIT BREAKER  
The analyzer operates on 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 11-13, 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 VDC for logic and  
analog circuitry. All DC voltages are distributed via the relay board.  
CAUTION  
GENERAL SAFETY HAZARD  
Should the AC power circuit breaker trip, investigate and correct the condition causing  
this situation before turning the analyzer back on.  
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Figure 11-15: Power Distribution Block Diagram  
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11.5.9. COMMUNICATION INTERFACE  
The analyzer has several ways to communicate to the outside world. 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 RS-232 & RS-485 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.  
COMM A  
Male  
RS–232 ONLY  
RS-232 or RS–485  
COMM B  
CPU  
Female  
Mother  
Board  
Control Inputs:  
ETHERNET  
OPTION  
1 – 6  
Status Outputs:  
1 – 8  
PC/104 BUS  
Analog Outputs  
KEYBOARD  
A1  
A2  
A3  
A4  
Optional  
4-20 mA  
I2C BUS  
I2C BUS  
RELAY  
BOARD  
FRONT PANEL DISPLAY  
Figure 11-16: Interface Block Diagram  
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11.5.10. FRONT PANEL INTERFACE  
The most commonly used method for communicating with the GFC 7001E/EM Analyzer is via the instrument’s  
front panel which includes a set of three status LED’s, a vacuum florescent display and a keyboard with 8 context  
sensitive keys.  
Figure 11-17: GFC 7001E/EM Front Panel Layout  
11.5.10.1. Analyzer Status LED’s  
Three LED’s are used to inform the user of the instrument’s basic operating status. They are listed on Table  
11-5 as follows:  
Table 11-5: Front Panel Status LED’s  
NAME  
COLOR  
STATE  
Off  
DEFINITION  
Unit is not operating in sample mode, iDAS is disabled.  
On  
Sample Mode active; Front Panel Display being updated, iDAS data being stored.  
SAMPLE  
Green  
Blinking  
Unit is operating in sample mode, front panel display being updated, iDAS hold-off  
mode is ON, iDAS disabled  
Off Auto Cal disabled  
On Auto Cal enabled  
CAL  
Yellow  
Red  
Blinking Unit is in calibration mode  
Off CO warnings exist  
Blinking Warnings exist  
FAULT  
11.5.10.2. Keyboard  
A row of eight keys just below the vacuum florescent display (see Figure 11-15) 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 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.  
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11.5.10.3. 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 11-17):  
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 are dynamic, context sensitive and software driven.  
11.5.10.4. Keyboard/Display Interface Electronics  
I2C to Relay Board  
Key Press  
Detect  
Display Data  
Decoder  
Display  
Controller  
Display Power  
Watchdog  
Keypad  
Decoder  
I2C Interface  
Serial  
Data  
From 5 VDC  
Power Supply  
Optional  
Maintenance  
LED  
Sample LED  
(Green)  
Maint.  
Switch  
2nd Lang.  
Switch  
Cal LED  
(Yellow)  
2 x 40 CHAR. VACUUM  
FLUORESCENT DISPLAY  
Fault LED  
(Red)  
KEYBOARD  
FRONT PANEL  
Beeper  
Figure 11-18: Keyboard and Display Interface Block Diagram  
The keyboard/display interface electronics of the GFC 7001E/EM 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 handled by way of the  
instrument’s I2C bus. The 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.  
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KEYPAD DECODER  
Each key on the front panel communicates with a decoder IC via a separate analog line. When a 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 I2C interface chip.  
KEY-DEPRESS-DETECT CIRCUIT  
This circuit flips the state of one of the inputs to the I2C interface chip causing it to send an interrupt signal to the  
CPU  
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I2C INTERFACE CHIP  
This IC performs several functions:  
Using a dedicated digital status bit, it sends an interrupt signal alerting the CPU that new data from the  
keyboard is ready to send.  
Upon acknowledgement by the CPU that it has received the new keyboard data the I2C interface chip  
resets the key-depress-detect flip-flop.  
In response to commands from the CPU, it turns the front panel status LEDs on and off and activates the  
beeper.  
Informs the CPU when the optional maintenance and second language switches have been opened or  
closed (see Section 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 Section 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 WATCH DOG  
The GFC 7001E Analyzer’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 brownout watch dog 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  
I2C LINK TO THE RELAY PCA  
While the CPU’s I2C 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.  
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11.5.11. SOFTWARE OPERATION  
The GFC 7001E/EM Gas Filter Correlation Carbon Monoxide Analyzer has at its heart a high performance, 386-  
based microcomputer running MS-DOS. Inside the DOS shell, special software developed by Teledyne  
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.  
DOS Shell  
API FIRMWARE  
Analyzer Operations  
Calibration Procedures  
Configuration Procedures  
Autonomic Systems  
Memory Handling  
IDAS Records  
Calibration Data  
System Status Data  
PC/104 BUS  
Diagnostic Routines  
ANALYZER  
HARDWARE  
Interface Handling  
Sensor input Data  
Display Messages  
Measurement  
Algorithm  
Keypad  
Analog Output Data  
RS232 & RS485  
External Digital I/O  
PC/104 BUS  
Linearization Table  
Figure 11-19: Basic Software Operation  
11.5.12. ADAPTIVE FILTER  
The GFC 7001E/EM software processes the CO MEAS and CO 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 GFC 7001E/EM averages over a set number of samples, where each sample  
is 0.2 seconds. This 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 conditions 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.  
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11.5.13. CALIBRATION - SLOPE AND OFFSET  
Calibration of the analyzer is performed exclusively in software.  
During instrument calibration (see Section 9) 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 are available for viewing from the  
from the front panel (see Section 3.5.4).  
11.5.14. MEASUREMENT ALGORITHM  
Once the IR photo-detector signal is demodulated into CO MEAS and CO REF by the sync/demod board and  
converted to digital data by the motherboard, the GFC 7001E/EM analytical software calculates the ratio  
between CO MEAS and CO REF. This value is compared to a look-up table that 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 CO 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.  
11.5.15. TEMPERATURE AND PRESSURE COMPENSATION  
Changes in pressure can have a noticeable, effect on the CO concentration calculation. To account for this, the  
GFC 7001E/EM software includes a feature which allows the instrument to compensate for the CO calculations  
based on changes in ambient pressure.  
The TPC feature multiplies the analyzer’s CO 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 CO concentration is decreased.  
11.5.16. 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-volatile 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 analyzers. New data parameters and triggering events can be added to the instrument  
as needed.  
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 Section  
7.1.  
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12. MAINTENANCE SCHEDULE & PROCEDURES  
Predictive diagnostic functions, including data acquisition records, failure warnings and test functions built into the  
analyzer, allow the user to determine when repairs are necessary without performing 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 lifetime. Repairs and  
troubleshooting are covered in Section Error! Reference source not found. of this manual.  
12.1. MAINTENANCE SCHEDULE  
Table 12-1 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 12-1) must be performed  
following certain of the maintenance procedure listed below.  
See Sections 9.3 and 9.4 for instructions on performing checks.  
CAUTION  
GENERAL SAFETY HAZARD  
Risk of electrical shock. Disconnect power before performing any of the following  
operations that require entry into the interior of the analyzer.  
CAUTION  
QUALIFIED PERSONNEL  
The operations outlined in this section are to be performed by qualified maintenance  
personnel only.  
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Table 12-1: GFC 7001E/EM Maintenance Schedule  
CAL  
DATE PERFORMED  
ITEM  
ACTION  
FREQ  
CHECK MANUAL  
REQ’D  
Particulate  
Filter  
Weekly or As  
Needed  
Replace  
No  
No  
Weekly or after  
any  
Maintenance or  
Repair  
Verify Test  
Functions  
Record and  
Analyze  
Pump  
Diaphragm  
Replace  
Annually  
Annually  
Yes  
No  
Perform Flow  
Check  
Check Flow  
Annually or  
after any  
Maintenance or  
Repair  
Perform  
Leak Check  
Verify Leak  
Tight  
No  
Yes if  
cleaned  
Pneumatic  
lines  
Examine and  
Clean  
As Needed  
As Needed  
Only if  
cover  
Cleaning  
Clean  
removed  
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Table 12-2: GFC 7001E/EM Test Function Record  
DATE RECORDED  
OPERATING  
MODE*  
FUNCTION  
ZERO CAL  
ZERO CAL  
ZERO CAL  
SPAN CAL  
SAMPLE  
STABILITY  
CO MEAS  
MR RATIO  
PRES  
PHT DRIVE  
SLOPE  
SAMPLE  
AFTER WARM-  
UP  
SPAN CAL  
ZERO CAL  
OFFSET  
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12.2. 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 12-3 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 12-3: Predictive uses for Test Functions  
FUNCTION  
STABILITY  
CONDITION  
BEHAVIOR  
INTERPRETATION  
Pneumatic Leaks – instrument & sample system  
Detector deteriorating  
Zero Cal  
Increasing  
Source Aging  
CO MEAS  
Zero Cal  
Zero Cal  
Decreasing  
Increasing  
Detector deteriorating  
Optics getting dirty or contaminated  
Source Aging  
Detector deteriorating  
Contaminated zero gas (H2O)  
Source Aging  
Detector deteriorating  
GFC Wheel Leaking  
Pneumatic Leaks  
Decreasing  
Increasing  
MR RATIO  
Contaminated zero gas (CO)  
Source Aging  
Pneumatic Leaks – instrument & sample system  
Calibration system deteriorating  
GFC Wheel Leaking  
Span Cal  
Sample  
Source Aging  
Calibration system deteriorating  
Decreasing  
Pneumatic Leak between sample inlet and Sample Cell  
Change in sampling manifold  
Increasing > 1”  
Dirty particulate filter  
Pneumatic obstruction between sample inlet and  
Sample Cell  
PRES  
Decreasing > 1”  
Increasing  
Obstruction in sampling manifold  
Mechanical Connection between IR-Detector and  
Sample Cell deteriorating  
IR-Photodetector deteriorating  
Any, but with  
Bench Temp at  
48°C  
PHT DRIVE  
OFFSET  
SLOPE  
See MR Ratio - Zero Cal Decreasing above  
Increasing  
Decreasing  
Increasing  
Decreasing  
Zero Cal  
Span Cal  
See MR Ratio - Zero Cal Increasing above  
See MR Ratio - Span Cal Decreasing above  
See MR Ratio – Span Cal Increasing above  
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12.3. MAINTENANCE PROCEDURES  
The following procedures are to be performed periodically as part of the standard maintenance of the GFC  
7001E.  
12.3.1. REPLACING THE SAMPLE PARTICULATE FILTER  
The particulate filter should be inspected often for signs of plugging or contamination. We recommend that the  
filter and the wetted surfaces of the filter housing are handled as little as possible when you change the filter. 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 GFC 7001E Analyzer’s hinged front panel and unscrew the knurled retaining ring on the filter  
assembly.  
Figure 12-1:  
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.  
12.3.2. REBUILDING THE SAMPLE PUMP  
The diaphragm in the sample pump periodically wears out and must be replaced. A sample rebuild kit is  
available – see label on pump 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.  
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12.3.3. PERFORMING LEAK CHECKS  
Leaks are the most common cause of analyzer malfunction; Section 12.3.3.1 presents a simple leak check  
procedure. Section 12.3.3.2 details a more thorough procedure.  
12.3.3.1. 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 pressure has stabilized, scroll through the TEST menu, note the  
SAMPLE PRESSURE reading.  
4. If the reading is < 10 in-Hg, the pump is in good condition and there are no large leaks.  
5. Check the sample gas flow. If the flow is <10 cm3/min and stable, there are no large leaks in the  
instrument’s pneumatics.  
12.3.3.2. 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 P/N 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 with a shutoff valve and pressure gauge.  
CAUTION  
GENERAL SAFETY HAZARD  
Do not use bubble solution with vacuum applied to the analyzer. The solution may  
contaminate the instrument. Do not exceed 15 PSIG pressure.  
6. Turn OFF power to the instrument.  
7. Install a leak checker or tank of gas as described above on the sample inlet at the rear panel.  
8. 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.  
9. 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.  
10. 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.  
11. 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.  
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12.3.4. PERFORMING A SAMPLE FLOW CHECK  
CAUTION  
GENERAL SAFETY HAZARD  
Always use a separate calibrated flow meter capable of measuring flows in the 0 – 1000  
cm3/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. Attach the Flow Meter to the sample inlet port on the rear panel. Ensure that the inlet to the Flow Meter  
is at atmospheric pressure.  
2. Sample flow should be 800 cm3/min 10%.  
3. Once an accurate measurement has been recorded by the method described above, adjust the  
analyzer’s internal flow sensors (See Section 9.6.3).  
Low flows indicate blockage somewhere in the pneumatic pathway, typically a plugged sintered filter or critical  
flow orifice in one of the analyzer’s flow control assemblies. High flows indicate leaks downstream of the Flow  
Control Assembly.  
12.3.5. CLEANING THE OPTICAL BENCH  
The GFC 7001E/EM sensor assembly and optical bench are complex and delicate. Disassembly and cleaning is  
not recommended. Please check with the factory before disassembling the optical bench.  
12.3.6. CLEANING EXTERIOR SURFACES OF THE GFC 7001E/EM  
If necessary, the exterior surfaces of the GFC 7001E/EM can be cleaned with a clean damp cloth. Do not  
submerge any part of the instrument in water or cleaning solution.  
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13. TROUBLESHOOTING & REPAIR  
This contains a variety of methods for identifying the source of performance problems with the analyzer. Also  
included in this are procedures that are used in repairing the instrument.  
NOTE  
QUALIFIED PERSONNEL  
The operations outlined in this section must be performed by qualified maintenance  
personnel only.  
CAUTION  
GENERAL SAFETY HAZARD  
Risk of electrical shock. Some operations need to be carried out with the  
instrument open and running.  
Exercise caution to avoid electrical shocks and electrostatic or mechanical  
damage to the analyzer.  
Do not drop tools into the analyzer or leave those after your procedures.  
Do not shorten or touch electric connections with metallic tools while operating  
inside the analyzer.  
Use common sense when operating inside a running analyzer.  
13.1. GENERAL TROUBLESHOOTING  
The GFC 7001E/EM Carbon Monoxide Analyzer has been designed so that problems can be rapidly detected,  
evaluated and repaired. During operation, it continuously performs diagnostic tests and provides the ability to  
evaluate its key operating parameters without disturbing monitoring operations.  
A systematic approach to troubleshooting will generally consist of the following five steps:  
1. Note any WARNING MESSAGES and take corrective action as necessary.  
2. Examine the values of all TEST functions and compare them to factory values. Note any major  
deviations from the factory values and take corrective action.  
3. Use the internal electronic status LED’s to determine whether the electronic communication channels are  
operating properly.  
Verify that the DC power supplies are operating properly by checking the voltage test points on the relay  
PCA.  
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 PCA.  
4. SUSPECT A LEAK FIRST!  
Customer service data indicate that the majority of all problems are eventually traced to leaks in the  
internal pneumatics of the analyzer or the diluent gas and source gases delivery systems.  
Check for gas flow problems such as clogged or blocked internal/external gas lines, damaged seals,  
punctured gas lines, a damaged / malfunctioning pumps, etc.  
5. Follow the procedures defined in Section 13.5 to confirm that the analyzer’s vital functions are working  
(power supplies, CPU, relay PCA, keyboard, PMT cooler, etc.).  
See Figure 3-4 for the general layout of components and sub-assemblies in the analyzer.  
See the wiring interconnect diagram and interconnect list in Appendix D.  
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13.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES  
The most common and/or serious instrument failures will result in a warning message being displayed on the  
front panel. Table 13-1 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 specific failures referenced by the warnings. In this case, it is recommended that  
proper operation of power supplies (See Section 13.5.2), the relay board (See Section 13.5.5), and the A/D  
Functions (see Section Error! Reference source not found.) 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  
BENCH TEMP WARNING  
CO = XXX.0  
TEST 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:  
Figure 13-1:  
Viewing and Clearing Warning Messages  
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Table 13-1: Warning Messages - Indicated Failures  
WARNING  
MESSAGE  
FAULT CONDITION  
POSSIBLE CAUSES  
Bad bench heater  
Bad bench temperature sensor  
Bad relay controlling the bench heater  
Entire relay board is malfunctioning  
I2C bus malfunction  
The optical bench temp is  
BENCH TEMP  
WARNING  
controlled at 48 2 °C.  
NOTE: Box temperature typically runs ~7oC warmer than ambient  
temperature.  
Poor/blocked ventilation to the analyzer.  
Stopped exhaust-fan  
BOX TEMP  
WARNING  
Box Temp is  
< 5 °C or > 48 °C.  
Ambient temperature outside of specified range  
Measured concentration value is too high or low.  
Concentration slope value to high or too low  
CANNOT DYN  
SPAN  
Dynamic Span operation failed  
Dynamic Zero operation failed  
Measured concentration value is too high.  
Concentration offset value to high.  
CANNOT DYN  
ZERO  
Failed disk on chip  
User erased data  
CONFIG  
INITIALIZED  
Configuration and Calibration data  
reset to original Factory state.  
Failed disk on chip  
User cleared data  
DATA INITIALIZED  
Data Storage in iDAS was erased  
Warning only appears on serial I/O com port(s)  
Front panel display will be frozen, blank or will not respond.  
Failed keyboard  
The CPU is unable to Communicate  
with the Front Panel Display  
/Keyboard  
FRONT PANEL  
WARN  
I2C bus failure  
Loose connector/wiring  
Failed IR photo-detector  
Failed sync/demod board  
IR photo-detector improperly attached to the sample chamber  
Bench temp too high.  
PHOTO TEMP  
WARNING  
PHT DRIVE is  
>4800 mVDC  
Motherboard not detected on power  
up.  
Warning only appears on serial I/O com port(s)  
Front panel display will be frozen, blank or will not respond.  
Massive failure of motherboard  
REAR BOARD NOT  
DET  
I2C bus failure  
Failed relay board  
Loose connectors/wiring  
RELAY BOARD  
WARN  
The CPU cannot communicate with  
the Relay Board.  
Failed sample pump  
Blocked sample inlet/gas line  
Dirty particulate filter  
Leak downstream of critical flow orifice  
Failed flow sensor/circuitry  
SAMPLE FLOW  
WARN  
Sample flow rate is < 500 cm3/min  
or > 1000 cm3/min.  
If sample pressure is < 10 in-hg:  
Blocked particulate filter  
Blocked sample inlet/gas line  
Sample Pressure is <10 in-Hg or  
> 35 in-Hg  
Failed pressure sensor/circuitry  
SAMPLE PRES  
WARN  
Normally 29.92 in-Hg at sea level  
decreasing at 1 in-Hg per 1000 ft of  
altitude (with no flow – pump  
disconnected).  
If sample pressure is > 35 in-hg:  
Pressurized sample gas. Install vent  
Blocked vent line on pressurized sample/zero/span gas supply  
Bad pressure sensor/circuitry  
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Table 13-1: Warning Messages – Indicated Failures (cont.)  
WARNING  
MESSAGE  
FAULT CONDITION  
POSSIBLE CAUSES  
Ambient temperature outside of specified range  
Failed bench heater  
SAMPLE TEMP  
WARN  
Sample temperature is < 10oC or >  
100oC.  
Failed bench temperature sensor  
Relay controlling the bench heater  
Failed relay board  
I2C bus  
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:  
Occurs when CO Ref is <1250  
mVDC or >4950 mVDC.  
SOURCE WARNING  
SYSTEM RESET  
IR source  
Relay board  
I2C bus  
Either of these conditions will result  
in an invalid M/R ratio.  
IR photo-detector  
This message occurs at power on. If you have not cycled the power  
on your instrument:  
Failed +5 VDC power,  
Fatal error caused software to restart  
Loose connector/wiring  
The computer has rebooted.  
Blocked cooling vents below GFC Assembly. Make sure that  
adequate clear space beneath the analyzer.  
Analyzer’s top cover removed  
Wheel heater  
The filter wheel temperature is  
WHEEL TEMP  
WARNING  
controlled at 68 2 °C  
Wheel temperature sensor  
Relay controlling the wheel heater  
Entire relay board  
I2C bus  
13.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS  
Besides being useful as predictive diagnostic tools, the test 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 Section Error! Reference source not found.).  
The acceptable ranges for these test functions are listed in the “Nominal Range” column of the analyzer Final  
Test and Validation Data Sheet (GFC 7001E, P/N 04307 and GFC 7001EM, P/N 04311) shipped with the  
instrument. Values outside these acceptable ranges indicate a failure of one or more of the analyzer’s  
subsystems. 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.  
NOTE:  
A worksheet has been provided in Appendix C to assist in recording the value of these test functions.  
This worksheet also includes expected values for the various test functions.  
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The following table contains some of the more common causes for these values to be out of range.  
Table 13-2: Test Functions - Indicated Failures  
TEST  
FUNCTIONS  
(As Displayed)  
INDICATED FAILURE(S)  
Time of day clock is too fast or slow.  
To adjust, see Section 6.5.4.  
TIME  
Battery in clock chip on CPU board may be dead.  
Incorrectly configured measurement range(s) could cause response problems with a Data logger or chart  
recorder attached to one of the analog output.  
RANGE  
STABIL  
If the Range selected is too small, the recording device will over range.  
If the Range is too big, the device will show minimal or no apparent change in readings.  
Indicates noise level of instrument or CO concentration of sample gas (see Section 13.4.2 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 (see Section 13.5.6.1).  
If the value displayed is too low or constantly changing and the CO REF is OK:  
Failed multiplexer on the mother board  
Failed sync/demod board  
Loose connector or wiring on sync/demod board  
If the value displayed is too low or constantly changing and the CO REF is bad:  
GFC Wheel stopped or rotation is too slow  
Failed sync/demod board IR source  
Failed IR source  
CO MEAS  
&
CO REF  
Failed relay board  
Failed I2C bus  
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.  
Failed sync/demod board  
MR Ratio  
When the analyzer is sampling zero air and the ratio is too high:  
Zero air is contaminated  
Failed IR photo-detector  
See Table 13-1 for SAMPLE PRES WARN.  
PRES  
Check for gas flow problems (see Section 13.2).  
SAMPLE FL  
SAMPLE TEMP should be close to BENCH TEMP. Temperatures outside of the specified range or oscillating  
temperatures are cause for concern.  
SAMP TEMP  
BENCH  
TEMP  
Bench temp control improves instrument noise, stability and drift. Temperatures outside of the specified range  
or oscillating temperatures are cause for concern. Table 13-1 for BENCH TEMP WARNING.  
WHEEL  
TEMP  
Wheel temp control improves instrument noise, stability and drift. Outside of set point or oscillating  
temperatures are causes for concern. See Table 13-1 for WHEEL TEMP WARNING.  
If the box temperature is out of range, check fan in the power supply module. Areas to the side and rear of  
instrument should allow adequate ventilation. See Table 13-1 for BOX TEMP WARNING.  
BOX TEMP  
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Table 13-2:  
Test Functions - Indicated Failures (cont.)  
TEST  
FUNCTIONS  
(As Displayed)  
INDICATED FAILURE(S)  
If this drive voltage is out of range it may indicate one of several problems:  
A poor mechanical connection between the photodetector, its associated mounting hardware and the  
absorption cell 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 WARNING or BOX TEMP WARNING.  
Values outside range indicate  
Contamination of the zero air or span gas supply  
Instrument is Miscalibrated  
Blocked gas flow  
Contaminated or leaking GFC Wheel (either chamber)  
Faulty IR photo-detector  
SLOPE  
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  
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13.1.3. DIAG SIGNAL I/O: USING THE DIAGNOSTIC SIGNAL I/O  
FUNCTION  
The signal I/O diagnostic mode allows access to the digital and analog I/O in the analyzer. Some of the digital  
signals can be controlled through the keyboard. These signals, combined with a thorough understanding of the  
instruments Theory of Operation (found in Section Error! Reference source not found.), are useful for  
troubleshooting in three ways:  
The technician can view the raw, unprocessed signal level of the analyzer’s critical inputs and outputs.  
Many of the components and functions that are normally under algorithmic control of the CPU can be  
manually exercised.  
The technician can directly control the signal level Analog and Digital Output signals.  
This allows the technician to observe systematically the effect of directly controlling these signals on the  
operation of the analyzer. The following flowchart shows 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.  
Figure 13-2:  
Example of Signal I/O Function  
NOTE  
Any I/O signals changed while in the signal I/O menu will remain in effect ONLY until signal I/O menu is  
exited. The Analyzer regains control of these signals upon exit.  
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See Appendix A-4 for a complete list of the parameters available for review under this menu  
13.1.4.  
INTERNAL ELECTRONIC STATUS LED’S  
Several LED’s are located inside the instrument to assist in determining if the analyzer’s CPU, I2C bus and relay  
board, GFC Wheel and the sync/demodulator board are functioning properly.  
13.1.4.1. CPU Status Indicator  
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. 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.  
Motherboard  
P/N 04069  
CPU Status LED  
Figure 13-3:  
CPU Status Indicator  
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13.1.4.2. Sync Demodulator Status LED’s  
Two LED’s located on the Sync/Demod Board and are there to make it obvious that the GFC Wheel is spinning  
and the synchronization signals are present:  
Table 13-3: Sync/Demod Board Status Failure Indications  
LED  
D1  
FUNCTION  
FAULT STATUS  
INDICATED FAILURE(S)  
GFC Wheel is not turning  
M/R Sensor on Opto-Pickup Board failed  
Sync/Demod Board failed  
M/R Sensor Status  
(Flashes slowly)  
LED is stuck  
ON or OFF  
JP 4 Connector/Wiring faulty  
Failed/Faulty +5 VDC Power Supply (PS1)  
GFC Wheel is not turning  
Segment Sensor on Opto-Pickup Board failed  
Sync/Demod Board failed  
Segment Sensor  
Status  
LED is stuck  
ON or OFF  
D2  
JP 4 Connector/Wiring faulty  
(Flashes quickly)  
Failed/Faulty +5 VDC Power Supply (PS1)  
D1 – M/R Sensor Status  
JP4 Connector to Opto-Pickup  
Board  
D2 – Segment Sensor Status  
Figure 13-4:  
Sync/Demod Board Status LED Locations  
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13.1.4.3. Relay Board Status LED’s  
There are eight LED’s located on the Relay Board. The most important of which is D1, which indicates the  
health of the I2C bus. If D1 is blinking the other faults following LED’s can be used in conjunction with DIAG  
menu signal I/O to identify hardware failures of the relays and switches on the relay (see Section 13.1.3 and  
Appendix D).  
Table 13-4: I2C Status LED Failure Indications  
LED  
FUNCTION  
FAULT STATUS  
INDICATED FAILURE(S)  
Failed/Halted CPU  
I2C bus Health  
(Watch Dog  
Circuit)  
Continuously ON  
or  
Continuously OFF  
Faulty Motherboard, Keyboard or Relay Board  
D1  
(Red)  
Faulty Connectors/Wiring between Motherboard,  
Keyboard or Relay Board  
Failed/Faulty +5 VDC Power Supply (PS1)  
DC VOLTAGE TEST  
POINTS  
STATUS LED’s  
RELAY PCA  
PN 04135  
Figure 13-5:  
Relay Board Status LEDs  
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Table 13-5:  
Relay Board Status LED Failure Indications  
SIGNAL I/O PARAMETER  
ACTIVATED BY VIEW RESULT  
LED  
FUNCTION  
DIAGNOSTIC TECHNIQUE  
Voltage displayed should change. If not:  
Failed Heater  
D2  
Yellow  
Wheel Heater  
WHEEL_HEATER WHEEL_TEMP  
BENCH_HEATER BENCH_TEMP  
Faulty Temperature Sensor  
Failed AC Relay  
Faulty Connectors/Wiring  
Voltage displayed should change. If not:  
Failed Heater  
D3  
Yellow  
Bench Heater  
Spare  
Faulty Temperature Sensor  
Failed AC Relay  
Faulty Connectors/Wiring  
D4  
Yellow  
N/A  
N/A  
N/A  
N/A  
Sample/Cal Valve should audibly change states. If  
not:  
Failed Valve  
D5  
Green  
Sample/Cal Gas  
Valve Option  
Failed Relay Drive IC on Relay Board  
Failed Relay Board  
CAL_VALVE  
Faulty +12 VDC Supply (PS2)  
Faulty Connectors/Wiring  
Zero/Span Valve should audibly change states. If  
not:  
Failed Valve  
D6  
Green  
Zero/Span Gas  
Valve Option  
Failed Relay Drive IC on Relay Board  
Failed Relay Board  
SPAN_VALVE  
N/A  
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  
D7  
Green  
Shutoff Valve  
Option  
SHUTOFF_VALVE N/A  
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  
D8  
Green  
IR SOURCE  
IR_SOURCE  
CO_MEASURE  
Failed IR Photo-Detector  
Failed Sync/Demod Board  
Faulty Connectors/Wiring  
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13.2. GAS FLOW PROBLEMS  
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 independent flow meter to perform a  
flow check as described in Section 12.3.4. If this test shows the flow to be correct, check the pressure sensors  
as described in Section 13.5.6.6.  
The GFC 7001E/EM has one main gas flow path. With the IZS or zero/span valve option installed, there are  
several subsidiary paths but none of those are displayed on the front panel or stored by the iDAS.  
With the O2 sensor option installed, third gas flow controlled with a critical flow orifice is added, but this flow is not  
measured or reported.  
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 crucial to confirm the actual flow rate without relying on the analyzer’s  
flow display. The use of an independent, external flow meter to perform a flow check as described in Section  
12.3.4 is essential.  
The flow diagrams found in a variety of locations within this manual depicting the GFC 7001E/EM in its standard  
configuration and with options installed can help in trouble-shooting flow problems. For your convenience they  
are collected here.  
13.2.1. GFC 7001E/EM INTERNAL GAS FLOW DIAGRAMS  
Figure 13-6:  
GFC 7001E/EM – Basic Internal Gas Flow  
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Figure 13-7:  
Internal Pneumatic Flow OPT 50A – Zero/Span Valves (OPT 50A & 50B)  
Figure 13-8:  
Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves  
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Figure 13-9:  
Internal Pneumatic Flow OPT 51B – Zero/Span Valves with Internal Zero Air Scrubber  
Figure 13-10: Internal Pneumatic Flow OPT 51C – Zero/Span/Shutoff w/ Internal Zero Air Scrubber  
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Figure 13-11: GFC 7001E/EM – Internal Pneumatics with O2 Sensor Option 65  
Figure 13-12: GFC 7001E/EM – Internal Pneumatics with CO2 Sensor Option 66  
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13.2.2. TYPICAL SAMPLE GAS FLOW PROBLEMS  
13.2.2.1. 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. If the pump is operating but the unit reports no gas flow, perform a flow check as described in Section  
12.3.4.  
3. If no independent flow meter is available:  
Disconnect the gas lines from both the sample inlet and the exhaust outlet on the rear panel of the  
instrument.  
Make sure that the unit is in basic SAMPLE Mode.  
Place a finger over an Exhaust outlet on the rear panel of the instrument.  
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 analyzer. Check to make sure that:  
All calibrators/generators are turned on and working correctly.  
Gas bottles are not empty or low.  
Valves, regulators and gas lines are not clogged or dirty.  
13.2.2.2. Low Flow  
1. Check if the pump diaphragm is in good condition. If not, rebuild the pump (see Section 12.3.2). Check  
the Spare Parts List for information on pump rebuild kits.  
2. Check for leaks as described in Section 12.3.3. 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 12.3.1).  
4. Check for partially plugged pneumatic lines, or valves. Clean or replace them.  
5. Check for plugged or dirty critical flow orifices. Replace them.  
6. If an IZS option is installed in the instrument, press CALZ and CALS. If the flow increases then suspect  
a bad sample/cal valve.  
13.2.2.3. 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,  
replace the critical flow orifice(s) inside the sample flow control assembly.  
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13.2.2.4. Displayed Flow = “Warnings”  
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  
2. A flow obstruction upstream or downstream of the flow sensor  
3. Bad Flow Sensor Board  
4. Bad pump  
To determine which case is causing the flow problem, 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.  
13.2.2.5. 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 cm3/min, adjust  
the calibration of the flow measurement as described in Section 12.3.4.  
13.2.2.6. 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 in-Hg for a pump that is in good condition. The pump  
needs rebuilding if the reading is above 10 in-Hg. If the test function SAMP FL is greater than 10 cm3/min there  
is a leak in the pneumatic lines.  
13.3. CALIBRATION PROBLEMS  
13.3.1. MISCALIBRATED  
There are several symptoms that can be caused by the analyzer being miscalibrated. This 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 GFC 7001E Analyzer’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 an independent  
lab.  
2. Contaminated zero gas. Excess H2O 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.  
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13.3.2. NON-REPEATABLE ZERO AND SPAN  
As stated earlier, leaks both in the GFC 7001E/EM 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 12.3.3. Don’t forget to consider  
pneumatic components in the gas delivery system outside the GFC 7001E/EM such as:  
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 the instrument passes a leak check, perform a flow check (see Section 12.3.4) to make sure  
adequate sample is being delivered to the sensor assembly.  
3. A failing IR photo-detector may be at fault. Check the CO MEAS and CO 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.  
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.  
13.3.3. INABILITY TO SPAN – NO SPAN KEY  
1. Confirm that the carbon monoxide span gas source is 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 12.3.3.  
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 CONC submenu of the Sample Displays.  
4. Check to make sure that there is no ambient air or zero air leaking into span gas line.  
13.3.4. INABILITY 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 12.3.3.  
3. If the analyzer has had zero/span valve options, the CO scrubber may need maintenance.  
4. Check to make sure that there is no ambient air leaking into zero air line.  
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13.4. 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 provides an itemized list of the  
most common dynamic problems with recommended troubleshooting checks and corrective actions.  
13.4.1. 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 GFC  
7001E/EM will perform poorly.  
13.4.1.1. 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 DIAG Menu (See Section 7.3).  
This parameter will vary with ambient temperature, but at ~30oC (6-7° 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  
13.4.1.2. 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 heater elements by measuring between pin 2 and 4 (~76 Ohms), and  
pin 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 I2C bus 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.  
CAUTION  
ELECTRICAL SHOCK HAZARD  
Hazardous Voltages are present during this test  
3. If the relay has failed there should be 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.  
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At room temperature it should have approximately 30K Ohms resistance; near the 48oC set point it should  
have ~12K ohms.  
13.4.1.3. GFC Wheel Temperature  
Like the bench heater above there are three possible causes for the GFC Wheel temperature to have failed.  
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 I2C bus 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.  
CAUTION  
ELECTRICAL SHOCK HAZARD  
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.  
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.  
5. Unplug the connector labeled “Wheel”, and measure the resistance of the thermistor. The resistance  
near the 68°C set point is ~5.7k ohms.  
13.4.1.4. IR Photo-Detector TEC Temperature  
If the PHT DRIVE test parameter described in Table 12-3 is out of range there are 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 the PHT DRIVE 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.  
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13.4.2. 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 GFC 7001E/EM Final Test and Validation Data  
Sheet,P/N 04271 shipped with the unit from Teledyne).  
1. The most common cause of excessive noise is leaks. Leak check and flow check the instrument  
described in Section 12.3.3 and 12.3.4.  
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 CO REFERENCE signal.  
3. Sync/Demod Board failure. There are many delicate, high impedance parts on this board. Check the  
CO MEAS and CO 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.  
5. Also check the SIGNAL I/O parameter PHT DRIVE.  
After warm-up, and at 25oC ambient, if PHT DRIVE < 4800 mV, the cooler is working properly.  
If PHT DRIVE is > 4800 mV there is a malfunction.  
6. The +5 and 15 VDC voltages in the GFC 7001E/EM 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.  
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13.5. SUBSYSTEM CHECKOUT  
The preceding 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 describes  
how to determine individually determine if a certain component or subsystem is actually the cause of the problem  
being investigated.  
13.5.1. AC MAINS CONFIGURATION  
The analyzer is correctly configured for the AC mains voltage in use if:  
1. The Sample Pump is running.  
2. The GFC Wheel motor is spinning. LED’s D1 & D2 (located on the sync/demod PCA) should be  
flashing.  
3. If incorrect power is suspected, check that the correct voltage and frequency is present at the line input  
on the rear panel.  
If the unit is set for 230 VAC and is plugged into 115VAC, or 100VAC the sample pump will not start,  
and the heaters will not come up to temperature.  
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.  
13.5.2. 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 the following table.  
Table 13-6:  
DC Power Test Point and Wiring Color Codes  
NAME  
Dgnd  
+5V  
TEST POINT#  
TP AND WIRE COLOR  
1
2
3
4
5
6
7
Black  
Red  
Agnd  
+15V  
-15V  
Green  
Blue  
Yellow  
Purple  
Orange  
+12R  
+12V  
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A voltmeter should be used to verify that the DC voltages are correct per the values in the table below, and an  
oscilloscope, in AC mode, with band limiting turned on, can be used to evaluate if the supplies are producing  
excessive noise (> 100 mV p-p).  
Table 13-7:  
DC Power Supply Acceptable Levels  
CHECK RELAY BOARD TEST POINTS  
FROM TEST POINT TO TEST POINT  
POWER  
SUPPLY VOLTAGE  
ASSY  
MIN V  
MAX V  
NAME  
Dgnd  
#
1
3
3
3
1
6
6
NAME  
+5  
#
2
PS1  
PS1  
PS1  
PS1  
PS1  
PS2  
PS2  
+5  
+15  
4.8  
5.25  
16V  
Agnd  
+15  
4
13.5  
-15  
Agnd  
-15V  
5
-14V  
-0.05  
-0.05  
11.75  
-0.05  
-16V  
0.05  
0.05  
12.5  
0.05  
Agnd  
Chassis  
+12  
Agnd  
Dgnd  
Chassis  
+12V  
Dgnd  
1
Dgnd  
N/A  
7
+12V Ret  
+12V Ret  
Dgnd  
1
13.5.3. I2C BUS  
Operation of the I2C bus can be verified by observing the behavior of DS6 and DS7 on the motherboard and 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 I2C bus is operating properly if:  
DS6 and DS7 on the motherboard are flashing at least once every 2 seconds and D1 on the relay board is  
flashing, or;  
D1 is not flashing but pressing a key on the front panel results in a change to the display.  
13.5.4. KEYBOARD/DISPLAY INTERFACE  
The front panel keyboard, display and Keyboard Display Interface PCA (P/N 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:  
1. The vacuum fluorescent display is good if on power-up a “-“ character is visible on the upper left hand  
corner of the display.  
2. The CPU Status LED, DS5, is flashing, see Section 13.1.4.1.  
3. 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.  
4. 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:  
One or more of the keys is bad,  
The interrupt signal between the Keyboard Display interface and the motherboard is broken, or  
The Keyboard Display Interface PCA is bad.  
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13.5.5. RELAY BOARD  
The relay board PCA (P/N 04135) can be most easily checked by observing the condition of the its status LED’s  
on the relay board, as described in Section 13.1.4.3, and the associated output when toggled on and off through  
signal I/O function in the diagnostic menu, see Section 13.1.3.  
1. If the front panel display responds to key presses and 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.  
2. 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 be easily replaced.  
The table below lists the control device associated with a particular function:  
Table 13-8:  
Relay Board Control Devices  
CONTROL  
DEVICE  
K1  
FUNCTION  
IN SOCKET  
Wheel Heater  
Bench Heater  
Spare AC Control  
IZS Valves  
Yes  
Yes  
Yes  
Yes  
No  
K2  
K3  
U4  
IR Source Drive  
U5  
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.  
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13.5.6. SENSOR ASSEMBLY  
13.5.6.1. Sync/Demodulator Assembly  
To verify that the Sync/Demodulator Assembly is working, follow the procedure below:  
1. Verify that D1 and D2 are flashing.  
If not check the opto pickup assembly, Section 13.5.6.3 and the GFC Wheel drive, Section 13.5.6.4.  
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, P/N 04216). If good  
then the sync/demod board is bad.  
2. Verify that the IR source is operating, Section 13.5.6.5.  
3. With the analyzer connected to zero air, measure between TP11 (measure) and analog ground, and  
TP12 (reference) and analog ground.  
If they are similar to values recorded on the factory data sheet then there is likely a problem with the  
wiring or the A/D converter.  
If they are not then either the sync demodulator board or the IR-photodetector are bad. See Section  
13.4.1.4 for problems with the IR-photodetector TEC drive.  
13.5.6.2. Electrical 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. (See Section 9.6.4 to calibrate Electrical Test).  
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13.5.6.3. Opto Pickup Assembly  
Operation of the opto pickup PCA (P/N 04088) can be verified with a voltmeter. Measure the AC and DC voltage  
between digital ground on the relay board, or keyboard and TP2 and TP4 on the sync pickup PCA. For a  
working board, with the GFC motor spinning, they should read 2.4 ±0.1 VAC and 2.5 ±0.15 VDC.  
Further confirmation that the pickups and motor are operating properly can be obtained by measuring the  
frequency at TP2 and TP4 using a frequency counter, a digital voltmeter with a frequency counter, or an  
oscilloscope per Table 13-9.  
Table 13-9:  
Opto Pickup Board Nominal Output Frequencies  
Nominal Measured Frequency  
AC Mains Freq.  
TP2  
25  
TP4  
300  
360  
50 Hz  
60 Hz  
30  
13.5.6.4. 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.  
2. Verify that 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.  
3. If there is power to the motor and the frequency select jumper is properly set then the motor is likely  
bad.  
See Section 13.6.2 for instructions on removing and replacing the GFC assembly that the motor is  
bolted to.  
13.5.6.5. 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.  
2. 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 ± 0.25 VDC.  
If not, then there is a problem with either the wiring, the relay board, or the +12V power supply.  
3. 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.  
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13.5.6.6. Pressure/Flow Sensor Assembly  
The pressure/flow sensor PCA, located on the top of the absorption bench, 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. For Pressure related problems:  
Measure the voltage across C1 it should be 5 ± 0.25 VDC.  
If not then the board is bad.  
Measure the voltage across TP4 and TP1.  
With the sample pump disabled it should be 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.  
2. 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.  
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.  
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13.5.7. MOTHERBOARD  
13.5.7.1. 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 reference voltages and input signals that can be easily  
measured with a voltmeter.  
3. Use the Signal I/O function (see Section 13.1.3 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.  
4. 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, P/N 04215 and interconnect list,  
P/N 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.  
13.5.7.2. Test Channel / Analog Outputs Voltage  
The ANALOG OUTPUT submenu, located under the SETUP MORE DIAG menu is used to verify that the  
GFC 7001E/EM Analyzer’s analog outputs are working properly. The test generates a signal on functioning  
outputs simultaneously as shown in the following table.  
Table 13-10: Analog Output Test Function - Nominal Values Voltage Outputs  
FULL SCALE OUTPUT OF VOLTAGE RANGE  
(see Section 7.4.2)  
100MV  
1V  
5V  
10V  
STEP  
%
0
NOMINAL OUTPUT VOLTAGE  
1
2
3
4
5
6
0
0
0
1
2
3
4
5
0
2
20  
40  
60  
80  
100  
20 mV  
40 mV  
60 mV  
80 mV  
100 mV  
0.2  
0.4  
0.6  
0.8  
1.0  
4
6
8
10  
For each of the steps the output should be within 1% of the nominal value listed in the table below except for the  
0% step, which should be within 0mV ±2 mV. Make sure you take into account any offset that may have been  
programmed into channel (see Section 7.4.5).  
If one or more of the steps fails to be within these ranges, it is likely that there has been a failure of either or both  
of the DACs and their associated circuitry on the motherboard. To perform the test connect a voltmeter to the  
output in question and perform an analog output step test as follows:  
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13.5.7.3. 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 described in Section 7.4.3.4 and then  
perform an analog output step test as described in Section 13.5.7.2.  
For each step the output should be within 1% of the nominal value listed in the table below.  
Table 13-11: Analog Output Test Function - Nominal Values Voltage Outputs  
OUTPUT RANGE  
2 -20  
4 -20  
NOMINAL OUTPUT VALUES  
STEP  
%
0
CURRENT  
2 mA  
5.6  
V(250 OHMS)  
CURRENT  
V(250 OHMS)  
1
2
3
4
5
6
0.5V  
1.4  
2.3  
3.2  
4.1  
5
4
1
20  
40  
60  
80  
100  
7.2  
1.8  
2.6  
3.4  
4.2  
5
9.2  
10.4  
13.6  
16.8  
20  
12.8  
16.4  
20  
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13.5.7.4. Status Outputs  
The procedure below can be used to test the Status outputs:  
1. Connect a jumper between the “D“ pin and the “” pin on the status output connector.  
2. Connect a 1000 ohm resistor between the “+” pin and the pin for the status output that is being tested.  
3. Connect a voltmeter between the “” pin and the pin of the output being tested (see table below).  
Under the DIAGSIGNAL I/O menu (see Section 13.1.3), 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 0 volts for ON and 5 volts for OFF.  
Table 13-12: Status Outputs Check  
PIN (LEFT TO RIGHT)  
STATUS  
SYSTEM OK  
CONC VALID  
HIGH RANGE  
ZERO CAL  
SPAN CAL  
DIAG MODE  
SPARE  
1
2
3
4
5
6
7
8
SPARE  
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13.5.7.5. Control Inputs – Remote Zero, Span  
The control input bits can be tested by the following procedure:  
1. Connect a jumper from the +5 pin on the Status connector to the U on the Control In connector.  
2. 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.  
3. 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.  
4. In each case, the GFC 7001E/EM should return to Sample Mode when the jumper is removed.  
13.5.8. CPU  
There are two major types of failures associated with the CPU board: complete failure and a failure associated  
with the Disk-On-Module on the CPU board. If either of these failures occurs, 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:  
The vacuum fluorescent display shows a dash in the upper left hand corner.  
The CPU Status LED, DS5, is not flashing. See Section 13.1.4.1.  
There is no activity from the primary RS-232 port on the rear panel even if “? <ret>” is pressed.  
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 (the vacuum fluorescent display “freezes”) then it is  
likely that the DOM has been corrupted.  
13.5.9. RS-232 COMMUNICATIONS  
13.5.9.1. General RS-232 Troubleshooting  
Teledyne 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.  
Problems with RS-232 connections usually center around 4 general areas:  
1. Incorrect cabling and connectors. See Section 3.3 for connector and pin-out information.  
2. The BAUD rate and protocol are incorrectly configured. See Section 8.1.3.  
3. If a modem is being used, additional configuration and wiring rules must be observed. See Section 8.2  
4. Incorrect setting of the DTE-DCE Switch. Ensure that switch is set correctly. See Section 8.1.1.  
5. Verify that cable (P/N 03596) that connects the serial COM ports of the CPU to J12 of the motherboard  
is properly seated.  
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13.5.9.2. Troubleshooting Analyzer/Modem or Terminal Operation  
These are the general steps for troubleshooting problems with a modem connected to a Teledyne 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 8.1.1.  
3. Check to make sure the set up command is correct. See Section 8.2.  
4. Verify that the Ready to Send (RTS) signal is at logic high. The GFC 7001E/EM 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 8.2.  
6. Use the RS-232 test function to send “w” characters to the modem, terminal or computer. See Section  
8.2.  
7. Get your terminal, modem or computer to transmit data to the analyzer (holding 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 P/N 013500000.  
13.5.10. THE OPTIONAL CO2 SENSOR  
There are Two LED’s located on the CO2 sensor PCA.  
Figure 13-13: Location of Diagnostic LED’s onCO2 Sensor PCA  
Normal Operation: V8 is not lit – V9 is Blinking  
Error State: Both LED’s are blinking.  
Check to make sure that the cable to the CO2 probe is properly connected.  
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13.6. REPAIR PROCEDURES  
This contains procedures that might need to be performed on rare occasions when a major component of the  
analyzer requires repair or replacement.  
13.6.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY  
The critical flow orifice is housed in the flow control assembly (Teledyne P/N 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  
it does, or the filter needs replacement 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 3-4.  
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 below.  
5. Replace the o-rings (P/N OR0000001) and the sintered filter (P/N FL0000001).  
6. If replacing the critical flow orifice itself (P/N 000941000), make sure that the side with the colored  
window (usually red) is facing upstream to the flow gas flow.  
7. Apply new Teflon® tape to the male connector threads.  
8. Re-assemble in reverse order.  
9. After reconnecting the power and pneumatic lines, flow check the instrument as described in Section  
12.3.4.  
Pneumatic Connector, Male 1/8”  
(P/N FT_70  
Spring  
(P/N HW_20)  
Sintered Filter  
(P/N FL_01)  
Critical Flow Orifice  
(P/N 00094100)  
Make sure it is placed with the  
jewel down)  
O-Ring  
(P/N OR_01)  
Purge Housing  
(P/N 000850000)  
Figure 13-14: Critical Flow Restrictor Assembly Disassembly  
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13.6.2. 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.  
3. Open the instrument’s hinged front panel.  
4. Locate the GFC Wheel/motor assembly. See Figure 3-4.  
5. Unplug the following electronic components:  
The GFC Wheel housing temperature sensor  
GFC Wheel heater  
GFC Wheel motor power supply  
SOURCE ASSEMBLY  
SYNCHRONOUS MOTOR  
THERMISTOR  
HEATER  
SAFETY SHIELD  
Figure 13-15: Opening the GFC Wheel Housing  
6. Remove the three (3) screws holding the opto-pickup printed circuit assembly to the GFC Wheel  
housing.  
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7. Carefully remove the opto-pickup printed circuit assembly.  
Opto-Pickup  
Figure 13-16: Removing the Opto-Pickup Assembly  
8. Remove the four (4) screws holding the GFC Wheel motor/heat sink assembly to the GFC Wheel  
housing.  
9. Carefully remove the GFC Wheel motor/heat sink assembly from the GFC Wheel housing.  
GFC WHEEL HOUSING  
Figure 13-17: Removing the GFC Wheel Housing  
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10. Remove the one (1) screw fastening the GFC Wheel/mask assembly to the GFC motor hub.  
11  
12  
Figure 13-18: Removing the GFC Wheel  
11. Remove the GFC Wheel/mask assembly.  
12. Follow the previous steps in reverse order to put the GFC Wheel/motor assembly back together.  
13.6.3. CHECKING AND ADJUSTING THE SYNC/DEMODULATOR, CIRCUIT  
GAIN (CO MEAS)  
13.6.3.1. Checking the Sync/Demodulator Circuit Gain  
The GFC 7001E/EM Analyzers will operate accurately as long as the sync/demodulator circuit gain is properly  
adjusted. To determine if this gain factor is correct:  
1. Make sure that the analyzer is turned on and warmed up.  
2. Set the analyzer display to show the STABIL or CO STB test function.  
3. Apply Zero Air to Sample Inlet of the analyzer.  
4. Wait until the stability reading falls below 1.0 ppm.  
5. Change the analyzer display to show the CO MEAS  
The value of CO MEAS must be > 2800 mV and < 4800 mV for the instrument to operate correctly.  
Optimal value for CO MEAS is 4500 mV ± 300 mV. If it is not, adjust the value.  
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13.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain  
To adjust the sync/demodulator circuit gain:  
1. Make sure that the analyzer is turned on and warmed up.  
2. Set the analyzer display to show the STABIL or CO STB test function.  
3. Apply Zero Air to Sample Inlet of the analyzer.  
4. Wait until the stability reading falls below 1.0 ppm.  
5. Change the analyzer display to show the CO MEAS.  
6. Remove the Sync/Demod Housing  
Remove the two mounting screws.  
Carefully lift the housing to reveal the sync/demod PCA.  
Housing Mounting  
Screws  
Sync/Demod  
PCA Housing  
Optical Bench  
Figure 13-19: Location of Sync/Demod Housing Mounting Screws  
7. Adjust potentiometer VR1 until CO MEAS reads 4500 mV ± 300 mV  
VR1  
Adjustment Made Here  
Figure 13-20: Location of Sync/Demod Gain Potentiometer  
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13.6.4. DISK-ON-MODULE REPLACEMENT PROCEDURE  
Replacing the Disk-on-Module (DOM) will cause loss of all DAS data; it also may cause loss of some instrument  
configuration parameters unless the replacement DOM carries the exact same firmware version. Whenever  
changing the version of installed software, the memory must be reset. Failure to ensure that memory is reset can  
cause the analyzer to malfunction, and invalidate measurements. After the memory is reset, the A/D converter  
must be re-calibrated, and all information collected in Step 1 below must be re-entered before the instrument will  
function correctly. Also, zero and span calibration should be performed.  
1. Document all analyzer parameters that may have been changed, such as range, auto-cal, analog  
output, serial port and other settings before replacing the DOM  
2. Turn off power to the instrument, fold down the rear panel by loosening the mounting screws.  
3. When looking at the electronic circuits from the back of the analyzer, locate the Disk-on-Module in the  
right most socket of the CPU board.  
4. The DOM should carry a label with firmware revision, date and initials of the programmer.  
5. Remove the nylon fastener that mounts the DOM over the CPU board, and lift the DOM off the CPU. Do  
not bend the connector pins.  
6. Install the new Disk-on-Module, making sure the notch at the end of the chip matches the notch in the  
socket.  
7. It may be necessary to straighten the pins somewhat to fit them into the socket. Press the DOM all the  
way in and reinsert the offset clip.  
8. Close the rear panel and turn on power to the machine.  
9. If the replacement DOM carries a firmware revision, re-enter all of the setup information.  
13.7. TECHNICAL ASSISTANCE  
If this manual and its troubleshooting / repair sections do not solve your problems, technical assistance may be  
obtained from:  
TELEDYNE ELECTRONIC TECHNOLOGIES  
Analytical Instruments  
16830 Chestnut Street  
City of Industry, CA 91748  
Telephone: (626) 934-1500  
Fax: (626) 961-2538  
Web: www.teledyne-ai.com  
Before you contact Teledyne Customer service, fill out the problem report form in Appendix C, which is also  
available online for electronic submission at http://www.teledyne-api.com/forms/.  
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14. A PRIMER ON ELECTRO-STATIC DISCHARGE  
Teledyne 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.  
14.1. 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 make 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 the other.  
Materials  
Makes  
Contact  
Materials  
Separate  
+
+
+
+
PROTONS = 3  
ELECTRONS = 2  
PROTONS = 3  
ELECTRONS = 4  
PROTONS = 3  
ELECTRONS = 3  
PROTONS = 3  
ELECTRONS = 3  
NET CHARGE = -1  
NET CHARGE = +1  
NET CHARGE = 0  
NET CHARGE = 0  
Figure 14-1:  
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 cannot 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 StyrofoamTM pellets during shipment can also build  
hefty static charges.  
Table 14-1: Static Generation Voltages for Typical Activities  
MEANS OF GENERATION  
Walking across nylon carpet  
Walking across vinyl tile  
Worker at bench  
65-90% RH  
1,500V  
250V  
10-25% RH  
35,000V  
12,000V  
6,000V  
100V  
Poly bag picked up from bench  
1,200V  
20,000V  
Moving around in a chair padded  
with urethane foam  
1,500V  
18,000V  
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14.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE  
Damage to components occurs when these static charges come into contact with an electronic device. Current  
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 14-1 with the those shown in the Table 14-2, 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 14-2: Sensitivity of Electronic Devices to Damage by ESD  
DAMAGE SUSCEPTIBILITY VOLTAGE  
RANGE  
DEVICE  
DAMAGE BEGINS  
OCCURRING AT  
CATASTROPHIC  
DAMAGE AT  
MOSFET  
VMOS  
10  
30  
100  
1800  
100  
NMOS  
60  
GaAsFET  
EPROM  
60  
2000  
100  
100  
140  
150  
190  
200  
300  
300  
300  
500  
500  
500  
JFET  
7000  
500  
SAW  
Op-AMP  
2500  
3000  
2500  
3000  
7000  
500  
CMOS  
Schottky Diodes  
Film Resistors  
This Film Resistors  
ECL  
SCR  
1000  
2500  
Schottky TTL  
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 a sensitive device or 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.  
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14.3. 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 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 someone walking up  
to a workbench.  
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  
prevent discharges from static fields built up on other things, like you and your clothing, from discharging  
through the instrument and damaging it.  
14.4. 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.  
14.4.1. GENERAL RULES  
Only handle or work on all electronic assemblies at a properly set up ESD station. Setting up an ESD safe  
workstation 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.  
Protective Mat  
Wrist Stra  
Ground Point  
Figure 14-2:  
Basic anti-ESD Workbench  
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For technicians that work in the field, special lightweight and portable anti-ESD kits are available from most  
suppliers of ESD 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 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.  
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 through it.  
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 an ESD sensitive 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.  
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14.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND  
MAINTENANCE  
14.4.2.1. Working at the Instrument 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.  
Use a 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 induced 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 finished work and closed the case of the analyzer.  
14.4.2.2. Working at an Anti-ESD Work Bench  
When working on an instrument of an electronic assembly while it is resting on a anti-ESD workbench:  
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 workstation 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 workstation.  
Lay the bag or bin on the workbench surface.  
Before opening the container, wait several seconds for any static charges on the outside surface of the  
container to be bled away by the workstation’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.  
Only lay tools or ESD-sensitive devices and assemblies on the conductive surface of your workstation.  
Never lay them down on any non-ESD preventative surface.  
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.  
6. Disconnecting your wrist strap is always the last action taken before leaving the workbench.  
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14.4.2.3. Transferring Components from Rack to Bench and Back  
When transferring a sensitive device from an installed Teledyne analyzer to an anti-ESD workbench or back:  
1. Follow the instructions listed above for working at the instrument rack and workstation.  
2. Never carry the component or assembly without placing it in an anti-ESD bag or bin.  
3. Before using the bag or container allow any surface charges on it to dissipate:  
If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a  
ground point.  
If you are at an anti-ESD workbench, lay the container down on the conductive work surface.  
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.  
Folding the open end over isolates the component(s) inside from the effects of static fields.  
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:  
Connect your wrist strap to ground.  
If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a  
ground point.  
If you are at a anti-ESD workbench, lay the container down on the conductive work surface  
In either case wait several seconds  
7. Open the container.  
14.4.2.4. Opening Shipments from Teledyne’ 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 ships all electronic components and assemblies in properly  
sealed anti-ESD containers.  
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:  
Always unpack shipments from Teledyne Customer Service by:  
1. Opening the outer shipping box away from the anti-ESD work area.  
2. Carry the still sealed anti-ESD bag, tube or bin to the anti-ESD work area.  
3. Follow steps 6 and 7 of Section 14.4.2.3 above when opening the anti-ESD container at the work station.  
4. Reserve the anti-ESD container or bag to use when packing electronic components or assemblies to be  
returned to Teledyne.  
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14.4.2.5. Packing Components for Return to Teledyne’s Customer Service  
CAUTION – Avoid Warranty Invalidation  
Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing instructions  
and Return Merchandise Authorization (RMA) procedures when returning parts for repair or calibration  
may void your warranty. For anti-ESD handling and packing instructions please refer to “Packing  
Components for Return to Teledyne’s Customer Service” in the Primer on Electro-Static Discharge  
section of this manual, and for RMA procedures please contact TAI Customer Service at (626) 934-  
1500.  
Always pack electronic components and assemblies to be sent to Teledyne’s Customer Service in anti-ESD bins,  
tubes or bags.  
CAUTION  
ESD Hazard  
DO NOT use pink-poly bags.  
NEVER allow any standard plastic packaging materials to touch the electronic  
component/assembly directly.  
This includes, but is not limited to, plastic bubble-pack, Styrofoam peanuts,  
open cell foam, closed cell foam, and adhesive tape.  
DO NOT use standard adhesive tape as a sealer. Use ONLY anti-ESD tape.  
Never carry the component or assembly without placing it in an anti-ESD bag or bin.  
1. Before using the bag or container allow any surface charges on it to dissipate:  
If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a  
ground point.  
If you are at an anti-ESD workbench, lay the container down on the conductive work surface.  
In either case wait several seconds.  
2. Place the item in the container.  
3. Seal the container. If using a bag, fold the end over and fastening it with anti-ESD tape.  
Folding the open end over isolates the component(s) inside from the effects of static fields.  
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.  
NOTE  
If you do not already have an adequate supply of anti-ESD bags or containers available, Teledyne’s  
Customer Service department will supply them (see Section 13.7 for contact information).  
Follow the instructions listed above for working at the instrument rack and workstation.  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
Index  
AZERO, 182  
6
B
60 Hz, 38  
Baud Rate, 175  
Beer-Lambert law, 23  
BENCH TEMP, 87, 271  
BENCH TEMP WARNING, 49, 88, 182, 269  
Bench Temperature  
Control, 240  
BENCH_HEATER, 277  
BOX TEMP, 49, 87, 182, 271, 285  
BOX TEMP WARNING, 49, 88, 182, 269  
brass, 44, 186, 285  
A
Absorption Path Lengths, 230  
AC Power 60 Hz, 38  
address. See company address, See company  
address  
AIN, 146  
ALRM, 90, 147  
ANALOG CAL WARNING, 49, 88  
Analog Inputs, 146  
Analog Outputs, 39, 63, 90, 97, 98, 127, 294,  
C
295  
CAL Key, 57, 89  
CALDAT, 109  
Calibration  
AIN, 146  
Analog Ouputs, 31, 90, 136  
Analog Outputs  
AIN CALIBRATION, 146  
CONC1, 51  
CONC2, 51  
Configuration & Calibration, 90, 130, 132, 133, 134,  
136, 138, 140, 142, 143, 146  
Automatic, 31, 90, 136  
Manual-Current Loop, 139, 141  
Manual-Voltage, 137  
Electrical Connections, 39  
Electronic Range Selection, 100, 131  
Output Loop Back, 248  
Over-Range Feature, 142  
Pin Assignments, 39  
Recorder Offset, 143  
Reporting Range, 52, 90  
Test Channel, 144  
Current Loop, 139, 141  
Voltage, 137  
Initial Calibration  
Basic Configuration, 51  
Calibration Checks, 188, 195  
Calibration Gasses, 186  
Span Gas, 24, 32, 45, 57, 66, 68, 70, 72, 191, 196  
Dilution Feature, 106  
Standard Reference Materials (SRM’s)  
CO Span Gas, 43  
Zero Air, 24, 32, 45, 64, 66, 68, 70, 72, 186  
CALS Key, 57, 89, 193  
CALZ Key, 89, 193  
CANNOT DYN SPAN, 49, 88, 182, 269  
CANNOT DYN ZERO, 49, 88, 182, 269  
Carbon Monoxide, 23, 25, 64, 226  
Carrying Strap/Handle, 62  
CATS 7 cable, 73  
CLOCK_ADJ, 96, 125  
BENCH TEMP, 144  
CHASSIS TEMP, 144  
CO MEASURE, 144  
CO REFERFENCE, 144  
NONE, 144  
O2 CELL TEMP, 144  
PHT DRIVE, 144  
SAMPLE FLOW, 144  
SAMPLE PRESS, 144  
SAMPLE TEMP, 144  
WHEEL TEMP, 144  
User Configurable, 58  
CO Concentration Alarms, 147  
CO MEAS, 87, 205, 232, 233, 237, 242, 243,  
247, 256, 257, 262, 263, 271, 284, 287, 291,  
302, 303  
CO REF, 86, 87, 205, 232, 233, 237, 242, 243,  
247, 256, 257, 271, 284, 287, 291  
CO2, 40, 42, 43, 51, 56, 77, 78, 79, 85, 87, 103,  
125, 129, 179, 182, 185, 187, 204, 213, 214,  
215, 222, 298  
AOUT Calibration Feature, 133  
APICOM, 23, 24, 107, 109, 119, 123, 152, 184,  
187, 263  
and Ethernet, 164, 165  
and iDAS System, 108, 112, 117, 119, 120, 122, 123  
Interface Example, 184  
Software Download, 123, 184  
ATIMER, 108, 112, 114  
AutoCal, 58, 64, 85, 87, 90, 133, 185, 198, 199,  
200, 222  
CO2 OFFSET, 87  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
CO2 Sensor, 40, 42, 43, 56, 77, 78, 87, 182,  
187, 213, 214  
Calibration  
Procedure, 215  
Setup, 213  
Span Gas Concentration, 213  
Troubleshoting, 298  
CO2 Sensor Option  
Pneumatic Set Up for Calibration, 213  
CO2 SLOPE, 87  
COMM Ports, 42, 150, 152, 159, 175  
and iDAS System, 120  
Baud Rate, 151  
DATA INITIALIZED, 49, 88, 269  
DB-25M, 73, 172  
DB-9F, 73, 172  
DC Power, 41  
DCPS, 182  
Default Settings  
COMM Ports, 150  
Ethernet, 165  
Hessen Protocol, 178, 182  
iDAS System, 108  
VARS, 125  
DHCP, 42, 47, 50, 165  
DIAG AIO, 127  
COM1, 177  
DIAG AOUT, 127  
DIAG ELEC, 127  
DIAG FCAL, 127  
DIAG I/O, 127  
COM2, 73, 74, 149, 152, 160, 163, 164, 177  
Communication Modes, 152, 164  
DCE & DTE, 149  
Machine ID, 155, 161  
Parity, 152, 175  
DIAG Mode, 85  
RS232, 73, 160  
DIAG OPTIC, 127  
DIAG TCHN, 127  
Diagnostic Menu (DIAG), 26, 90, 92, 94, 294  
Ain Calibrated, 129, 146  
RS-485, 153  
testing, 154  
COMM PORTS  
Default Settings, 150  
company address, 61, 304  
CONC, 109, 112  
CONC ALRM1 WARNING, 88, 182  
CONC ALRM2 WARNING, 88, 182  
CONC Key, 57, 125  
Analog I/O  
Aout Calibration Configuration, 129  
AOUT Calibration Configuration, 134  
AOUTCalibrated Configuration, 133  
Conc_Out_1, 129  
Conc_Out_2, 129  
Conc_Out_3, 129  
CONC VALID, 40, 296  
Analog I/O Configuration, 127, 130, 132, 133, 134, 136,  
138, 140, 142, 143, 146  
ANALOG OUTPUT (Step Test), 294  
Analog Output Step Test, 127  
Dark Calikbration, 127  
Electrical Test, 127  
Flow Calibration, 127  
Pressure Calibration, 127  
SIGNAL I/O, 127, 273  
Test Chan Ouptut, 127  
CONC_PRECISION, 125  
CONC1, 51  
CONC2, 51  
Concentration Field, 31, 48  
CONFIG INITIALIZED, 49, 88, 269  
Contact, 310  
Continuous Emission Monitoring (CEM), 106  
Control Inputs, 41, 85, 248, 297  
Pin Assignments, 41  
Test Output, 129  
Control InputS  
Electrical Connections, 41  
Dilution Ratio, 82, 106  
Set Up, 53  
CPU, 47, 49, 73, 77, 79, 88, 91, 96, 97, 107,  
Disk –on-Module, 239  
129, 146, 150, 160, 164, 205, 206, 237, 239,  
242, 245, 246, 247, 248, 249, 251, 253, 254,  
255, 256, 267, 269, 271, 273, 274, 276, 289,  
Display Precision, 125  
DUAL, 99, 101, 102, 185  
DYN_SPAN, 125  
DYN_ZERO, 125  
Dynamic Span, 125  
Dynamic Zero, 125  
297  
Analog to Digital Converter, 49, 88, 129  
Status LED, 274  
Critical Flow Orifice, 76, 109, 235, 236, 265,  
266, 269, 278, 282, 299  
Current Loop Outputs, 63, 139, 141  
Manual Calibration, 139  
E
EEPROM  
Disk on Chip, 117  
Electric Test, 291  
Electric Test Switch, 245  
Electrical Connections, 38–42  
AC Power, 38, 61  
D
Dark Calibration, 185, 205, 244, 248  
DAS_HOLD_OFF, 125  
data acquisition. See iDAS System  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
Analog Outputs, 39, 98  
GFC Wheel, 46, 230, 231, 240, 241, 243, 244, 245,  
263, 270, 271, 272, 274, 275, 291, 292, 300, 301,  
302  
Current Loop, 139  
Voltage Ranges, 137  
Control InputS, 41  
Heater, 245, 249  
Ethernet, 42, 50, 74, 75, 160, 164  
Ethernet, 23, 26  
Modem, 172  
Multidrop, 42  
Serial/COMM Ports, 42, 150  
Status Outputs, 39  
Light Mask, 233, 241, 242  
Motor, 245, 246, 248, 288, 292, 300, 301  
Temperature, 49, 87, 88, 144, 286  
GFC Wheel Troubleshooting, 300  
Schmidt Triggers, 241  
Temperature Control, 240  
Electrical Test, 127  
Electro-Static Discharge, 26, 309  
Enable TCP Ports, 165  
ENTR Key, 25, 90, 94, 119, 188  
Environmental Protection Agency(EPA), 26, 43,  
Gas Inlets  
Pressure Span, 32  
Sample, 32  
Span2, 32  
Gas Outlets  
Exhaust, 32, 46, 66, 68, 70, 72  
Vent, 32  
58  
Calibration, 89  
EPA Calibration, 26  
EPA Equivalency, 25  
Gateway IP Address, 165, 167, 169  
GFC Wheel, 23  
Ethernet, 23, 47, 155, 164, 165  
and Multidrop, 75  
Baud Rate, 164  
H
Hessen Flags  
Internal Span Gas Generator, 182  
Configuration, 164–70  
Manual, 167  
Property Defaults, 165  
using DHCP, 165  
Hessen Protocol, 152, 175, 177, 178, 182  
Activation, 176  
DHCP, 42, 47, 50, 165  
Enable TCP Ports, 165  
Gateway IP Address, 165, 167, 169  
Hostname, 165  
and Reporting Ranges, 179  
Default Settings, 178  
Download Manual, 175  
Gas List, 180, 181  
GAS LIST, 179  
HOSTNAME, 170  
Instrument IP Address, 165, 167, 169  
Subnet Mask, 165, 167, 169  
TCP Port 1, 165  
ID Code, 183  
Latency Period, 175  
response Mode, 178  
Setup Parameters, 175  
Status Flag  
TCP Port 2, 165  
Exhaust Gas, 32, 235  
Exhaust Gas Outlet, 32, 46, 66, 68, 70, 72  
EXIT Key, 90  
Default Settings, 182  
Modes, 182  
Unassigned Flags, 182  
Unused Bits, 182  
EXITZR, 114  
External Pump, 61  
Warnings, 182  
Status Flags, 182  
types, 177  
HIGH RANGE  
REMOTE, 41  
Hold Off Period, 57  
HOSTNAME, 165, 170  
F
FEP, 44, 186  
Final Test and Validation Data Sheet, 50, 51,  
204, 287  
Flash Chip, 239  
Front Panel, 31, 74  
Concentration Field, 31, 48  
Display, 31, 48, 127, 144  
Keypad Definition Field, 31  
Message Field, 31  
Mode Field, 31, 48  
Status LED’s, 31, 48  
FRONT PANEL WARN, 49, 269  
I
I2C bus, 237, 245, 246, 249, 253, 254, 255,  
269, 270, 271, 274, 276, 285, 286, 289  
Power Up Circuit, 249  
I2c Link To The Relay Pca, 255  
iDAS System, 26, 31, 48, 49, 51, 85, 87, 88,  
90, 97, 105, 107–24, 125, 187, 199, 204,  
229, 239, 252, 257, 263, 269, 278  
and APICOM, 123, 124  
G
and RS-232, 124  
and Terminal Emulation Programs, 124  
Channel Names, 113  
Gas Filter Correlation, 23, 29, 61, 229, 230,  
231, 240, 245, 249, 256, 270, 301, 302  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
Channels, 108, 110, 124  
K
CALDAT, 109  
CONC, 109  
Keyboard/Display Interface Electronics, 253  
PNUNTC, 109  
Display Controller, 255  
Compact Data Report, 122  
HOLD OFF, 48, 108, 121, 125  
Holdoff Period, 57  
Number of Records, 108, 119  
Parameters, 108, 115, 124  
CONC, 112  
Display Data Decoder, 255  
I2C Interface Chip, 255  
Key-Depress-Detect Circuit, 254  
Keypad Decoder, 254  
Troubleshooting, 289  
Watch Dog:, 255  
NXCNC1, 112  
PMTDET, 108  
Keypad Definition Field, 31  
Precision, 115  
Report Period, 108, 118, 122  
Sample Mode  
L
AVG, 115, 116, 117, 118  
INST, 115, 116, 117, 118  
MAX, 115  
LO CAL A [type], 85  
Local Area Network (LAN), 42, 50, 74, 155,  
160, 164, 165, 167  
MIN, 115, 116, 117, 118  
SDEV, 115, 116, 117, 118  
Sample Period, 118  
Starting Date, 122  
M
Store Number of Samples, 115, 116, 118  
Triggerning Events, 108, 114  
ATIMER, 108, 112, 114  
EXITZR, 114  
M320E, 230  
M320EU, 230  
Machine ID, 155, 161  
Maintenance Schedule, 109  
Measure Reference Ratio, 232  
SLPCHG, 109, 114  
WTEMPW, 114  
Infrared Radiation (IR), 23, 49, 51, 58, 77, 87,  
88, 144, 205, 225, 229, 230, 231, 232, 233,  
240, 241, 242, 243, 244, 245, 246, 247, 249,  
257, 263, 269, 270, 271, 272, 277, 284, 286,  
290, 291, 292  
Instrument IP Address, 165, 167, 169  
Interferents, 51  
Internal Pneumatics  
Basic Model 300E/EM, 278  
Menu Keys  
CAL, 57, 89  
CALS, 57, 89, 193  
CALZ, 89, 193  
CONC, 57, 125  
ENTR, 25, 90, 94, 119, 188  
EXIT, 90  
MENUS  
AUTO, 99, 103, 185  
DUAL, 99, 101, 102, 185  
SNGL, 52, 99, 100  
Basic Model 300E/EM with CO2 Sensor Option, 79  
M300E/EM  
Message Field, 31  
Modbus, 26, 165  
Mode Field, 31, 48  
Modem, 73, 172  
Troubleshooting, 298  
Basic Configuration, 36  
M300E/EM WITH OPTIONAL CO2 SENSOR, 281  
M300E/EM WITH OPTIONAL O2 SENSOR, 281  
M300E/EM with Zero/Span Valves, 65, 279  
M300E/EM with Zero/Span Valves with Internal  
Scrubber, 69, 280  
Motherboard, 49, 129, 139  
M300E/EM with Zero/Span/Shutoff and Internal  
Scrubber Option, 280  
M300E/EM with Zero/Span/Shutoff Valves, 67, 279  
M300E/EM with Zero/Span/Shutoff valves and Internal  
Scrubber Option, 71  
M-P CAL, 85  
MR Ratio, 87, 262, 263, 271, 287  
Multidrop, 42, 73, 75, 152, 155, 160, 161, 175  
Internal Pump, 28, 44, 47, 109, 206, 234, 235,  
236, 249, 264, 265, 269, 282, 283, 288, 293,  
299  
Internal Span Gas Generator  
AutoCal, 199  
Warning Messages, 49  
Internal Zero Air (IZS), 28, 32, 42, 65, 67, 69,  
N
National Institute of Standards and Technology  
(NIST)  
Standard Reference Materials (SRM), 43  
CO, 43  
NXCNC1, 112  
71, 222, 223, 282, 290  
Gas Flow Problems, 278  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
M300E/EM with Zero/Span Valves with Internal  
Scrubber, 70, 194  
M300E/EM with Zero/Span/Shutoff and Internal  
Scrubber Option, 72, 194  
M300E/EM with Zero/Span/Shutoff Valves, 68, 193  
PNUMTC, 109  
Predictive Diagnostics, 184  
Using iDAS System, 109  
PRES, 87, 262, 263, 265, 271  
Pressure Span Inlet, 32  
PRESSURE SPAN inlet, 65  
PTEF, 46, 66, 68, 70, 72  
O
O2, 27, 39, 40, 43, 56, 75, 76, 85, 87, 88, 98,  
125, 129, 144, 179, 182, 185, 187, 204, 209,  
210, 211, 235, 278  
O2 CELL TEMP, 87  
O2 CELL TEMP WARNING, 88  
O2 OFFSET, 87  
O2 sensor, 39, 40, 43, 56, 76, 87, 88, 98, 144,  
182, 187, 209, 211, 235, 278  
O2 SENSOR, 211  
CALIBRATION  
PTFE, 28, 44, 186, 219, 264  
Pump  
Sample, 61  
Procedure, 212  
SETUP, 209  
Span Gas Concentration, 210  
O2 Sensor Option  
Pneumatic Set Up for Calibration, 209  
O2 SLOPE, 87  
OFFSET, 87, 139, 143, 188, 262, 263, 272  
Operating Modes, 127  
Calibration Mode, 182  
Calibration Mode  
R
Rack Mount, 61  
RANGE, 87, 129, 179, 271  
RANGE1, 87, 179  
AUTO, 103  
RANGE2, 87, 179  
AUTO, 103  
LO CAL A [type], 85  
M-P CAL, 85  
SPAN CAL [type], 85  
ZERO CAL [type], 85  
DIAG Mode, 85  
REAR BOARD NOT DET, 49, 88, 182, 269  
Rear Panel, 32  
Analog Outputs, 98  
Basic M200E, 32  
Diagnostic Mode (DIAG), 127  
SAMPLE A1, 85  
Recorder Offset, 143  
Sample Mode, 31, 85, 125, 198  
Secondaru Setup, 90  
SETUP [X.X], 85  
Optic Test, 127  
Optical Bench, 240, 247, 248, 266  
Layout, 35  
Relay Board  
Status LED's, 276  
Troubleshooting, 290  
RELAY BOARD WARN, 49, 88, 269  
relay PCA, 49  
Reporting Range, 52, 89, 90, 97, 100, 101, 103  
Optional Sensors  
Configuration, 90, 97  
Dilution Feature, 106  
Modes, 106  
CO2  
INTERNAL PNEUMATICS, 281  
O2  
AUTO, 103  
DUAL, 101  
INTERNAL PNEUMATICS, 281  
SNGL, 100  
Upper Span Limit, 100, 102, 106  
RJ45, 73  
RS-232, 23, 26, 28, 42, 64, 73, 74, 75, 85, 86,  
108, 120, 122, 124, 149, 150, 152, 155, 158,  
159, 160, 161, 162, 164, 175, 184, 218, 222,  
P
Particulate Filter, 78, 82, 236, 263, 264, 269  
PHOTO TEMP WARNING, 49, 88, 269  
Photometer  
Temperature Limits, 49  
237, 239, 247, 251, 297, 298  
Activity Indicators, 150  
DCE – DTE Switch, 32  
DCE & DTE, 149  
RS-485, 27, 74, 85, 149, 152, 153, 155, 160,  
162, 163, 237, 239, 247, 251  
PHT DRIVE, 87, 262, 263, 272  
PMT Preamp PCA, 127  
PMTDET, 108  
Pneumatic Set Up, 42  
Basic Model 300E/EM  
Bottled Gas, 44, 188  
Gas Dilution Calibrator, 45, 189  
Calibration  
M300E/EM with CO2 Sensor, 213  
M300E/EM with O2 Sensor, 209  
Calibration Gases, 42  
S
Safety Messages  
Electric Shock, 36, 38, 285, 286  
General, 36, 38, 42, 44, 62, 139, 267  
M300E/EM with Zero/Span Valves, 66, 193  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
Qualiified Personnel, 267  
Standard Temperature and Pressure, 105  
Status LED's, 246  
CO2 Sensor, 298  
SAMPLE A1, 85  
SAMPLE FL, 87, 271  
Sample Flow Sensor, 236  
CPU, 274  
Relay Board, 276  
Sync/Demod Board, 275, 288  
Status Outputs, 103, 248  
Electrical Connections, 39  
Pin Assignments, 40  
Subnet Mask, 165, 167, 169  
SYNC, 182  
SAMPLE FLOW WARN, 49, 88, 182, 269  
Sample Gas Line, 45, 66, 68, 70, 72  
SAMPLE INLET, 32  
Sample Mode, 31, 47, 85, 125, 198, 220, 297  
SAMPLE PRESS WARN, 49, 88, 182, 269  
Sample Pressure Sensor, 236  
SAMPLE TEMP, 87, 88, 182, 271, 285  
SAMPLE TEMP WARN, 49, 88, 182  
Schmidt Triggers, 241  
Scubber  
Zero Air, 186  
Sensor Inputs, 247, 293  
Bench Temperature, 248  
Box Temperature, 248  
Sync/Demod Board, 205, 242, 243, 244, 248,  
257, 269, 270, 271, 291  
Photo-Detector Temperature Control, 244  
Status LED’s, 275, 288  
Troubleshooting, 291, 302, 303  
System  
Default Settings, 108  
SYSTEM OK, 40, 296  
CO Measure And Reference, 247  
Sample Pressure And Flow, 247  
Sample Temperature, 247  
Thermistor Interface, 247  
Wheel Temperature, 248  
SYSTEM RESET, 49, 88, 182  
T
TCP Port 1, 165  
TCP Port 2, 165  
Teledyne Contact Information  
Technical Assistance, 304  
Website  
Hessen Protocol Manual, 175  
Software Downloads, 123  
Terminal Mode, 156  
Command Syntax, 157  
Computer mode, 152, 156  
INTERACTIVE MODE, 156  
SERIAL I/O  
BENCH_HEATER, 285  
CO_MEASURE, 287  
CO_REFERENCE, 287  
PHT_DRIVE, 286, 287  
WHEEL_HEATER, 286  
Serial I/O Ports  
Modem, 172  
Multidrop, 42, 73, 75, 152, 155, 160, 161  
RS-232, 26, 42, 73, 74, 75, 90, 108, 120, 122, 184  
RS-485, 74, 152  
Test Channel, 127, 129, 144  
BENCH TEMP, 144  
CHASSIS TEMP, 144  
CO MEASURE, 144  
CO REFERENCE, 144  
NONE, 144  
O2 CELL TEMP, 144  
PHT DRIVE, 144  
SAMPLE FLOW, 144  
SAMPLE PRESS, 144  
SAMPLE TEMP, 144  
WHEEL TEMP, 144  
Test Function  
RANGE, 129, 179  
Test Functions, 86, 129, 144, 294, 295  
BENCH TEMP, 87, 271  
BOX TEMP, 49, 87, 182, 271, 285  
CO MEAS, 87, 262, 263, 302, 303  
CO REF, 87  
CO2 OFFSET, 87  
CO2 SLOPE, 87  
Defined, 87  
MR Ratio, 87, 262, 263, 271, 287  
O2 CELL TEMP, 87  
O2 OFFSET, 87  
O2 SLOPE, 87  
OFFSET, 87, 188, 262, 263, 272  
SETUP [X.X], 85  
Shutoff Valve  
Span Gas, 67  
SLOPE, 87, 188, 262, 263, 272  
SLPCHG, 109, 114  
SNGL, 52, 99, 100  
SOURCE WARNING, 49, 88, 182  
SPAN CAL, 40, 65, 67, 69, 71, 85, 185, 262,  
296, 297  
Remote, 41  
SPAN CAL [type], 85  
Span Gas, 24, 32, 43, 45, 46, 51, 57, 64, 66,  
67, 68, 69, 70, 72, 89, 106, 147, 182, 185,  
187, 191, 193, 196, 199, 210, 213, 225, 265,  
269, 272, 282, 283, 284  
Dilution Feature, 106  
Standard Reference Materials (SRM’s) )  
CO Span Gas, 43  
Span2 Inlet, 32  
Specifications, 25, 27  
STABIL, 87, 262, 263, 271, 287, 302, 303  
STABIL_GAS, 125  
stainless steel, 44, 186  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
PHT DRIVE, 87, 262, 263, 272  
W
PRES, 87, 262, 263, 265, 271  
RANGE, 87, 179, 271  
RANGE1, 87, 179  
AUTO, 103  
RANGE2, 87, 179  
Warm-up Period, 48  
Warnings, 48  
ANALOG CAL WARNING, 49, 88  
AZERO, 182  
AUTO, 103  
BENCH TEMP WARNING, 182  
BENCH TEMP WARNING, 49, 88, 269  
BOX TEMP WARNING, 49, 88, 182, 269  
CANNOT DYN SPAN, 49, 88, 182, 269  
CANNOT DYN ZERO, 49, 88, 182, 269  
CONC ALRM1 WARNING, 88, 182  
CONC ALRM2 WARNING, 88, 182  
CONFIG INITIALIZED, 49, 88, 269  
DATA INITIALIZED, 49, 88, 269  
DCPS, 182  
SAMPLE FL, 87, 271  
SAMPLE TEMP, 87, 88, 182, 271, 285  
SLOPE, 87, 188, 262, 263, 272  
STABIL, 87, 262, 263, 271, 287, 302, 303  
TIME, 87, 200, 271  
WHEEL TEMP, 87, 271  
TIME, 87, 200, 271  
U
FRONT PANEL WARN, 49, 269  
O2 CELL TEMP WARNING, 88  
PHOTO TEMP WARNING, 49, 88, 269  
REAR BOARD NOT DET, 49, 88, 182, 269  
RELAY BOARD WARN, 49, 88, 269  
SAMPLE FLOW WARN, 49, 88, 182, 269  
SAMPLE PRESS WARN, 49, 88, 182, 269  
SAMPLE TEMP WARN, 49, 88, 182  
SOURCE WARNING, 49, 88, 182  
SYNC, 182  
Units of Measurement, 52, 105, 106  
Volumetric Units vs Mass Units, 105  
V
Valve Options, 32, 195, 245  
Calibration Using, 193, 196  
Internal Span Gas Generator  
AutoCal, 199  
Hessen Flags, 182  
Warning Messages, 49  
Shutoff Valve  
SYSTEM RESET, 49, 88, 182  
Wheel temp WARNING, 49  
WHEEL TEMP WARNING, 88, 182  
Warranty, 25  
Span Gas, 67  
Watch Dog Circuit, 246, 255  
web address, 61, 304  
WHEEL TEMP, 87, 271  
WHEEL TEMP WARNING, 49, 88, 182  
WTEMPW, 114  
Zero/Span, 284  
Zero/Span Valve w/ Internal Scrubber, 284  
Zero/Span Valves  
Internal Pneumatics, 65, 279  
Pneumatic Set Up, 66, 193  
Zero/Span Valves with Internal Scrubber  
Internal Pneumatics, 69, 280  
Pneumatic Set Up, 70, 194  
Zero/Span with Remote Contact Closure, 198  
Zero/Span/Shutoff Valves  
Internal Pneumatics, 67, 279  
Pneumatic Set Up, 68, 193  
Zero/Span/Shutoff Valves with Internal Scrubber  
Internal Pneumatics, 71, 280  
Pneumatic Set Up, 72, 194  
Z
Zero Air, 24, 32, 42, 43, 45, 46, 51, 58, 64, 66,  
67, 68, 69, 70, 71, 72, 89, 185, 186, 193,  
199, 217, 222, 223, 224, 225, 263, 271, 272,  
282, 283, 284, 287, 291  
ZERO CAL, 40, 41, 65, 67, 69, 71, 85, 262,  
VARS Menu, 90, 92, 94, 96, 108, 121, 125  
Variable Default Values, 125  
Variable Names  
296, 297  
Remote, 41  
ZERO CAL [type], 85  
CLOCK_ADJ, 125  
Zero/Span Valves, 198  
Internal Pneumatics, 65, 279  
Pneumatic Set Up, 66, 193  
Zero/Span Valves with Internal Scrubber  
Internal Pneumatics, 69, 280  
CONC_PRECISION, 125  
DAS_HOLD_OFF, 125  
DYN_SPAN, 125  
DYN_ZERO, 125  
STABIL_GAS, 125  
Pneumatic Set Up, 70, 194  
Vent Outlet, 32  
Ventilation Clearance, 37  
Venting, 46, 66, 68, 70, 72  
Exhaust Line, 46, 66, 68, 70, 72  
Sample Gas, 46, 66, 68, 70, 72  
Span Gas, 46, 66, 68, 70  
Zero/Span/Shutoff Valves  
Internal Pneumatics, 67, 279  
Pneumatic Set Up, 68, 193  
Zero/Span/Shutoff Valves with Internal  
Scrubber  
Internal Pneumatics, 71, 280  
Pneumatic Set Up, 72, 194  
Zero Air, 46, 66, 68, 70  
Teledyne Analytical Instruments  
319  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
Teledyne Analytical Instruments  
320  
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Index  
Model GFC7001E Carbon Dioxide Analyzer  
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321  
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