Teledyne Microscope & Magnifier GFC7000E User Manuals

Table of Contents

• 1. MGFC7000E DOCUMENTATION

  1
• 1.1. Using This Manual

  1
• 2. SPECIFICATIONS, APPROVALS AND WARRANTY

  5
• 2.1. Specifications

  5
• 2-1: Model GFC7000E Basic Unit Specifications

  5
• 2.2. CE Mark Compliance

  6
• 2.3. Warranty

  6
• 3. GETTING STARTED

  9
• 3.1. Unpacking and Initial Set Up

  9
• 3-1: Removal of Shipping Screws

  10
• 3.1.1. Electrical Connections

  11
• 3-2: Rear Panel Layout

  12
• 3-1: GFC7000E Analog Output Pin Outs

  13
• 3-2: GFC7000E Status Output Pin Outs

  14
• 3.1.2. Pneumatic Connections:

  15
• 3.1.2.1. Basic Pneumatic Connections

  15
• 3-3: GFC7000E Control Input Pin Outs

  15
• 3-3: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas

  16
• 3-4: Model GFC7000E Rear Panel Pneumatic Connections

  16
• 3-4: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator

  17
• 3.1.2.2. Connections with Internal Valve Options Installed

  19
• 3-5: Pneumatic Connections–MGFC7000E with Zero/Span/Shutoff Valves (OPT 50)

  19
• Zero Air Scrubber (OPT 51)

  19
• Pneumatic Connections–MGFC7000E with Zero/Span Valves (OPT 52)

  20
• Scrubber (OPT 53)

  20
• 3.2. Initial Operation

  21
• 3-9: Example of Pneumatic Set up for Multipoint Calibration of M360

  21
• 3.2.1. Startup

  22
• 3.2.2. Warm Up

  23
• 3-10: Front Panel Layout

  23
• 3-5: Front Panel Display During System Warm-Up

  23
• 3.2.3. Warning Messages

  24
• 3-6: Possible Warning Messages at Start-Up

  24
• 3.2.4. Functional Check

  25
• 3.3. Initial Calibration Procedure

  26
• 3-11: Assembly Layout

  30
• 3-12: Optical Bench Layout

  31
• 3-13: Internal Pneumatic Flow – Basic Configuration

  31
• 4. FREQUENTLY ASKED QUESTIONS

  33
• 4.1. FAQ’s

  33
• 4.2. Glossary

  34
• 5. OPTIONAL HARDWARE AND SOFTWARE

  37
• 5.1. Rack Mount Kits (Options 20a, 20b & 21)

  37
• 5.2. Current Loop Analog Outputs (Option 41)

  37
• 5-1: Current Loop Option Installed on the Motherboard

  37
• 5.3. Expendable Kits (Options 42C, 42D and 43)

  38
• 5.4. Calibration Valves Options

  38
• 5.4.1. Zero/Span/Shutoff Valve (Option 50)

  38
• 5-1: Zero/Span Valve Operating States for Options 50 & 51

  38
• 5-2: Internal Pneumatic Flow – Zero/Span/Shutoff Valves OPT 50 & 51

  39
• 5.4.2. Zero/Span/Shutoff with External CO2 Scrubber (Option 51)

  40
• 5.4.3. Zero/Span Valve (Option 52)

  40
• 5-2: Zero/Span Valve Operating States for Options 52 & 53

  40
• 5.4.4. Zero/Span Valve with External CO2 Scrubber (Option 53)

  41
• 5.5. Communication Options

  41
• 5.5.1. RS232 Modem Cable (Option 60)

  41
• 5-3: Internal Pneumatic Flow – Zero/Span OPT 52 & 53

  41
• 5.5.2. RS-232 Multidrop (Option 62)

  42
• 5.5.3. Ethernet (Option 63)

  42
• 5.6. Additional Manuals

  42
• 5.6.1. Printed Manuals (Option 70)

  42
• 5-4: GFC7000E Ethernet Card and rear panel With Ethernet Installed

  42
• 5.6.2. Manual on CD (Part number 045840200)

  43
• 5.7. Extended Warranty (Options 92 & 93)

  43
• 5.8. Dilution Ratio Option (Option ??)

  43
• 5.9. Maintenance Mode Switch (Option ??)

  43
• 5.10. Second Language Switch (Option ??)

  44
• 6. OPERATING INSTRUCTIONS

  45
• 6.1. Overview of Operating modes

  45
• 6-1: Front Panel Display

  45
• 6.2. Sample Mode

  46
• 6.2.1. Test Functions

  46
• 6-1: Analyzer Operating modes

  46
• 6-2: Test Functions Defined

  46
• 6.2.2. Warning Messages

  48
• 6-2 Viewing MGFC7000E TEST Functions

  48
• 6-3: List of Warning Messages

  49
• 6.3. Calibration Mode

  50
• 6.3.1. SETUP – PASS: Calibration Password Security

  50
• 6-3 Viewing and Clearing MGFC7000E WARNING Messages

  50
• 6.4. SETUP Mode

  52
• 6-4: Primary Setup Mode Features and Functions

  52
• 6-5: Secondary Setup Mode Features and Functions

  52
• 6.4.1. SETUP Mode Password Security

  53
• 6.5. SETUP – CFG: Viewing the Analyzer’s Configuration Information

  53
• 6.6. SETUP – CLK: Setting the Internal Time-of-Day Clock

  54
• 6.7. SETUP – RNGE: Analog Output Reporting Range Configuration

  56
• 6.7.1. Physical Range versus Analog Output Reporting Ranges

  56
• 6-4: Analog Output Connector Pin Out

  56
• 6.7.2. Reporting Range Modes

  57
• 6.7.3. Single Range mode (SNGL)

  58
• 6.7.4. Dual Range Mode (DUAL)

  60
• 6.7.5. Auto Range Mode (AUTO)

  61
• 6.7.6. Range Units

  62
• 6.7.7. Dilution Ratio

  63
• 6-6: Variable Names (VARS) Revision B.3

  64
• 6.9. SETUP – DIAG: Using the Diagnostics Functions

  66
• 6-7: GFC7000E Diagnostic (DIAG) Functions

  66
• 6.9.1. Accessing the Diagnostic Features

  67
• 6.9.2. Signal I/O

  67
• 6.9.3. Analog Output Step Test

  68
• 6.9.4. Analog I/O Configuration

  69
• 6-8: DIAG - Analog I/O Functions

  69
• 6-9: Analog Output Voltage Ranges

  69
• 6-10: Analog Output Current Loop Range

  70
• 6-11: Analog Output Pin Assignments

  70
• 6.9.4.1. Analog Output Signal Type and Range Span Selection

  71
• 6.9.4.2. Analog Output Calibration Mode

  71
• 6.9.4.3. Manual Analog Output Calibration and Voltage Adjustment

  73
• 6-12: Voltage Tolerances for Analog Output Calibration

  73
• 6-5: Setup for Calibrating Analog Voltage Outputs

  74
• 6.9.4.4. Current Loop Output Adjustment

  75
• 6-6: Setup for Calibrating Current Outputs

  75
• 6-13: Current Loop Output Calibration with Resistor

  76
• 6.9.4.5. AIN Calibration

  77
• 6.9.5. Electric Test

  77
• 6.9.6. Dark Calibration Test

  78
• 6.9.7. Pressure Calibration

  78
• 6.9.8. Flow Calibration

  80
• 6.9.9. Test Channel Output

  81
• 6-14: Test Parameters Available for Analog Output A3

  81
• 6.10.1. Analyzer ID Code

  82
• 6.10.2. COMM Port Default Settings

  83
• 6.10.3. COMM Port Cable Connections

  84
• 6.10.4. RS-485 Configuration of COM2

  84
• 6.10.5. DTE and DCE Communication

  85
• 6.10.6. COMM Port Communication Modes

  85
• 6-15: COM1 and COM2 DB-9 Pin Assignments

  85
• 6-16: COMM Port Communication modes

  86
• 6.10.7. COM Port Baud Rate

  88
• 6.10.8. COM Port Testing

  89
• 6.10.9. Ethernet Card Configuration

  89
• 6-17: Ethernet Status Indicators

  89
• 6.10.9.1. Ethernet Card COM2 Communication Modes and Baud Rate

  90
• 6.10.9.2. Configuring the Ethernet Interface Option using DHCP

  90
• 6-18: LAN/Internet Configuration Properties

  90
• 6.10.9.3. Manually Configuring the Network IP Addresses

  92
• 6.10.9.4. Changing the Analyzer’s HOSTNAME

  94
• 6-19: Internet Configuration Keypad Functions

  94
• 6-20: CO2 Concentration Alarm Default Settings

  95
• 6.12. SETUP – DAS: Using the Data Acquisition System (iDAS)

  96
• 6.12.1. iDAS Structure

  96
• 6-21: Front Panel LED Status Indicators for iDAS

  96
• 6.12.1.1. iDAS Channels

  97
• 6-22: iDAS Data Channel Properties

  97
• 6.12.1.2. iDAS Parameters

  98
• 6.12.1.3. iDAS Triggering Events

  98
• 6-23: iDAS Data Parameter Functions

  98
• 6.12.2. Default iDAS Channels

  99
• 6-7: Default iDAS Channels Setup

  101
• 6.12.2.1. Viewing iDAS Data and Settings

  103
• 6.12.2.2. Editing iDAS Data Channels

  104
• 6.12.2.3. Trigger Events

  105
• 6.12.2.4. Editing iDAS Parameters

  106
• 6.12.2.5. Sample Period and Report Period

  107
• 6.12.2.6. Number of Records

  109
• 6.12.2.7. RS-232 Report Function

  110
• 6.12.2.8. Compact Report

  111
• 6.12.2.9. Starting Date

  111
• 6.12.2.10. Disabling/Enabling Data Channels

  111
• 6.12.2.11. HOLDOFF Feature

  112
• 6.12.3. Remote iDAS Configuration

  113
• 6-8: APICOM user interface for configuring the iDAS.

  113
• 6-9: iDAS Configuration Through a Terminal Emulation Program

  114
• 6.13.1. Remote Operation Using the External Digital I/O

  115
• 6.13.1.1. Status Outputs

  115
• 6-10: Status Output Connector

  115
• 6.13.1.2. Control Inputs

  116
• 6-24: Status Output Pin Assignments

  116
• 6-25: Control Input Pin Assignments

  116
• 6.13.2. Remote Operation Using the External Serial I/O

  117
• 6.13.2.1. Terminal Operating Modes

  117
• 6-11: Control Inputs

  117
• 6.13.2.2. Help Commands in Terminal Mode

  118
• 6.13.2.3. Command Syntax

  118
• 6-26: Terminal Mode Software Commands

  118
• 6.13.2.4. Data Types

  119
• 6-27: Command Types

  119
• 6.13.2.5. Status Reporting

  120
• 6.13.2.6. Remote Access by Modem

  120
• 6.13.2.7. COM Port Password Security

  122
• 6.13.2.8. APICOM Remote Control Program

  122
• 6.13.3. Additional Communications Documentation

  123
• 6.13.4. Using the MGFC7000E with a Hessen Protocol Network

  123
• 6.13.4.1. General Overview of Hessen Protocol

  123
• 6-12: APICOM Remote Control Program Interface

  123
• 6-28: Serial Interface Documents

  123
• 6.13.4.2. Hessen COMM Port Configuration

  124
• 6.13.4.3. Activating Hessen Protocol

  124
• 6-29: RS-232 Communication Parameters for Hessen Protocol

  124
• 6.13.4.4. Selecting a Hessen Protocol Type

  125
• 6.13.4.5. Setting The Hessen Protocol Response Mode

  126
• 6.13.4.6. Hessen Protocol Gas ID

  126
• 6-30: Teledyne Instruments Hessen Protocol Response Modes

  126
• 6.13.4.7. Setting Hessen Protocol Status Flags

  127
• 6-31: Default Hessen Status Bit Assignments

  127
• 6.13.4.8. Instrument ID Code

  128
• 7. CALIBRATION PROCEDURES

  129
• 7.1. Before Calibration

  129
• 7.1.1. Zero Air and Span Gas

  129
• 7.1.2. Calibration Gas Traceability

  130
• 7.1.3. Data Recording Devices

  130
• 7.2. Manual Calibration without Zero/Span Valves

  130
• 7-1: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas

  130
• 7-2: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator

  131
• 7.3. Manual Calibration Checks

  133
• 7.4. Manual Calibration with Zero/Span Valves

  133
• Zero Air Scrubber (OPT 51)

  134
• Pneumatic Connections–MGFC7000E with Zero/Span Valves (OPT 52)

  135
• Scrubber (OPT 53)

  135
• 7.5. Manual Calibration Checks with Zero/Span Valves

  137
• 7.5.1. Zero/Span Calibration on Auto Range or Dual Ranges

  137
• 7.5.2. Use of Zero/Span Valves with Remote Contact Closure

  138
• 7.6. Automatic Zero/Span Cal/Check (AutoCal)

  139
• 7-1: AUTOCAL Modes

  139
• 7-2: AutoCal ATTRIBUTE Setup Parameters

  139
• 7.6.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected

  142
• 7.7. Calibration Quality

  142
• 7-3: Calibration Data Quality Evaluation

  142
• 8. EPA PROTOCOL CALIBRATION

  143
• 9. MAINTENANCE SCHEDULE & PROCEDURES

  145
• 9.1. Maintenance Schedule

  145
• 9-1: GFC7000E Maintenance Schedule

  146
• 9-2: GFC7000E Test Function Record

  147
• 9.2. Predicting Failures Using the Test Functions

  148
• 9.3. Maintenance Procedures

  148
• 9-3: Predictive uses for Test Functions

  148
• 9.3.1. Replacing the Sample Particulate Filter

  149
• 9-1: Sample Particulate Filter Assembly

  149
• 9.3.2. Rebuilding the Sample Pump

  150
• 9.3.3. Performing Leak Checks

  150
• 9.3.3.1. Vacuum Leak Check and Pump Check

  150
• 9.3.3.2. Pressure Leak Check

  150
• 9.3.4. Performing a Sample Flow Check

  151
• 9.3.5. Cleaning the Optical Bench

  151
• 9.3.6. Cleaning Exterior Surfaces of the MGFC7000E

  151
• 10. THEORY OF OPERATION

  153
• 10.1. Measurement Method

  153
• 10.1.1. Beer’s Law

  153
• 10.1.2. Measurement Fundamentals

  154
• 10.1.3. Gas Filter Correlation

  154
• 10-1: Measurement Fundamentals

  154
• 10-2: GFC Wheel

  155
• 10-3: Measurement Fundamentals with GFC Wheel

  155
• 10-4: Affect of CO2 in the Sample on CO2 MEAS & CO2 REF

  156
• 10-5: Effects of Interfering Gas on CO2 MEAS & CO2 REF

  157
• 10-6: Chopped IR Signal

  157
• 10.1.4. Ambient CO2 Interference Rejection

  158
• 10.2. Pneumatic Operation

  158
• 10.2.1. Sample Gas Flow

  159
• 10.2.1.1. Critical Flow Orifice

  159
• 10-7: Internal Pneumatic Flow – Basic Configuration

  159
• 10.2.1.2. Sample Pressure Sensor

  160
• 10.2.1.3. Sample Flow Sensor

  160
• 10-8: Flow Control Assembly & Critical Flow Orifice

  160
• 10.2.1.4. Valve Options

  161
• 10.2.2. Purge Gas Pressure and Flow Control

  161
• 10.3. Electronic Operation

  161
• 10.3.1. Overview

  161
• 10-9: GFC7000E Electronic Block Diagram

  162
• 10.3.2. CPU

  163
• 10.3.3. Optical Bench & GFC Wheel

  163
• 10.3.3.1. Sample Gas and GFC Temperature Control

  163
• 10.3.3.2. IR Source

  164
• 10.3.3.3. GFC Wheel

  164
• 10-10: GFC Light Mask

  164
• 10.3.3.4. IR Photo-Detector

  165
• 10.3.4. Synchronous Demodulator (Sync/Demod) Assembly

  165
• 10.3.4.1. Overview

  165
• 10-11: Segment Sensor and M/R Sensor Output

  165
• 10.3.4.2. Signal Synchronization and Demodulation

  166
• 10-12: GFC7000E Sync / Demod Block Diagram

  166
• 10.3.4.3. Phase Lock Warning

  167
• 10.3.4.4. Sync/Demod Status LED’s

  167
• 10-13: Sample & Hold Timing

  167
• 10.3.4.5. Photo-Detector Temperature Control

  168
• 10.3.4.6. Dark Calibration Switch

  168
• 10.3.4.7. Electric Test Switch

  168
• 10.3.5. Relay Board

  168
• 10-1: Sync/Demod Status LED Activity

  168
• 10.3.5.1. Status LED’s

  169
• 10-2: Relay Board Status LED’s

  169
• 10.3.5.2. I C Watch Dog Circuitry

  170
• 10.3.6. Mother Board

  170
• 10.3.6.1. A to D Conversion

  170
• 10-14: Location of relay board Status LED’s

  170
• 10.3.6.2. Sensor Inputs

  171
• 10.3.6.3. Thermistor Interface

  171
• 10.3.6.4. Analog Outputs

  172
• 10.3.6.5. Internal Digital I/O

  172
• 10.3.6.6. External Digital I/O

  173
• 10.3.7. I2C Data Bus

  173
• 10.3.8. Power Supply/ Circuit Breaker

  173
• 10-15: Power Distribution Block Diagram

  174
• 10.4.1. Front Panel Interface

  175
• 10.4.1.1. Analyzer Status LED’s

  175
• 10-16: Interface Block Diagram

  175
• 10-17: MGFC7000E Front Panel Layout

  175
• 10.4.1.2. Keyboard

  176
• 10.4.1.3. Display

  176
• 10-3: Front Panel Status LED’s

  176
• 10.4.1.4. Keyboard/Display Interface Electronics

  177
• 10-18: Keyboard and Display Interface Block Diagram

  177
• 10.5.1. Adaptive Filter

  179
• 10.5.2. Calibration - Slope and Offset

  179
• 10-19: Basic Software Operation

  179
• 10.5.3. Measurement Algorithm

  180
• 10.5.4. Temperature and Pressure Compensation

  180
• 10.5.5. Internal Data Acquisition System (iDAS)

  180
• 11. TROUBLESHOOTING & REPAIR PROCEDURES

  183
• 11.1.1. Interpreting WARNING Messages

  184
• 11-1: Viewing and Clearing Warning Messages

  184
• 11-1: Warning Messages - Indicated Failures

  185
• 11.1.2. Fault Diagnosis with TEST Functions

  186
• 11-2: Test Functions - Indicated Failures

  187
• 11.1.3. Using the Diagnostic Signal I/O Function

  188
• 11.1.4. Internal Electronic Status LED’s

  189
• 11.1.4.1. CPU Status Indicator

  189
• 11-2: Example of Signal I/O Function

  189
• 11.1.4.2. Sync Demodulator Status LED’s

  190
• 11-3: CPU Status Indicator

  190
• 11-3: Sync/Demod Board Status Failure Indications

  190
• 11.1.4.3. Relay Board Status LED’s

  191
• 11-4: Sync/Demod Board Status LED Locations

  191
• 11-5: Relay Board Status LEDs

  191
• 11-4: I2C Status LED Failure Indications

  191
• 11.1.5. Gas Flow Problems

  192
• 11-5: Relay Board Status LED Failure Indications

  192
• 11.1.6. Typical Sample Gas Flow Problems

  193
• 11.1.6.1. Flow is Zero

  193
• 11.1.6.2. Low Flow

  193
• 11.1.6.3. High Flow

  194
• 11.1.6.4. Displayed Flow = “XXXX”

  194
• 11.1.6.5. Actual Flow Does Not Match Displayed Flow

  194
• 11.1.6.6. Sample Pump

  194
• 11.1.7. Poor or Stopped Flow of Purge Gas

  194
• 11.2.1. Miss-Calibrated

  195
• 11.2.2. Non-Repeatable Zero and Span

  195
• 11.2.3. Inability to Span – No SPAN Key

  196
• 11.2.4. Inability to Zero – No ZERO Key

  196
• 11.3.1. Temperature Problems

  197
• 11.3.1.1. Box or Sample Temperature

  197
• 11.3.1.2. Bench Temperature

  197
• 11.3.1.3. GFC Wheel Temperature

  198
• 11.3.1.4. IR Photo-Detector TEC Temperature

  198
• 11.3.2. Excessive Noise

  198
• 11.4.1. AC Mains Configuration

  199
• 11.4.2. DC Power Supply

  200
• 11.4.3. I2C Bus

  200
• 11-6: DC Power Test Point and Wiring Color Codes

  200
• 11-7: DC Power Supply Acceptable Levels

  200
• 11.4.4. Keyboard/Display Interface

  201
• 11.4.5. Relay Board

  201
• 11-8: Relay Board Control Devices

  201
• 11.4.6. Sensor Assembly

  202
• 11.4.6.1. Sync/Demodulator Assembly

  202
• 11.4.6.2. Opto Pickup Assembly

  202
• 11-9: Opto Pickup Board Nominal Output Frequencies

  202
• 11.4.6.3. GFC Wheel Drive

  203
• 11.4.6.4. IR Source

  203
• 11.4.6.5. Pressure/Flow Sensor Assembly

  203
• 11.4.7. Motherboard

  204
• 11.4.7.1. A/D Functions

  204
• 11.4.7.2. Analog Outputs: Voltage

  204
• 11.4.7.3. Analog Outputs: Current Loop

  204
• 11-10: Analog Output Test Function - Nominal Values Voltage Outputs

  204
• 11.4.7.4. Status Outputs

  205
• 11.4.7.5. Control Inputs – Remote Zero, Span

  205
• 11-11: Analog Output Test Function - Nominal Values Current Outputs

  205
• 11-12: Status Outputs Check

  205
• 11.4.8. CPU

  206
• 11.4.9. RS-232 Communications

  206
• 11.4.9.1. General RS-232 Troubleshooting

  206
• 11.4.9.2. Troubleshooting Analyzer/Modem or Terminal Operation

  207
• 11.5.1. Repairing Sample Flow Control Assembly

  207
• 11-6: Critical Flow Restrictor Assembly Disassembly

  208
• 11.5.2. Removing/Replacing the GFC Wheel

  209
• 11-7: Opening the GFC Wheel Housing

  209
• 11.5.3. Disk-On-Chip Replacement Procedure

  210
• 11-8: Removing the GFC Wheel

  210
• 12. A PRIMER ON ELECTRO-STATIC DISCHARGE

  213
• 12-1: Triboelectric Charging

  213
• 12.2. How Electro-Static Charges Cause Damage

  214
• 12-1: Static Generation Voltages for Typical Activities

  214
• 12-2: Sensitivity of Electronic Devices to Damage by ESD

  214
• 12.4. Basic Principles of Static Control

  216
• 12.4.1. General Rules

  216
• 12-2: Basic anti-ESD Work Station

  216
• 12.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance

  218
• 12.4.2.1. Working at the Instrument Rack

  218
• 12.4.2.2. Working at a Anti-ESD Work Bench

  218
• 12.4.2.3. Transferring Components from Rack To Bench and Back

  219
• Customer Service.

  219
• A-1: Basic Sample Display Menu

  223
• A-2: Sample Display Menu - Units with Z/S Valve or IZS Option installed

  224
• A-3: Primary Setup Menu (Except iDAS)

  225
• A-4: Primary Setup Menu (iDAS)

  226
• A-5: Secondary Setup Menu (COMM & VARS)

  227
• A-6: Secondary Setup Menu (COMM Menu with Ethernet Card)

  228
• A-7: Secondary Setup Menu (COMM Menu with HESSEN)

  229
• A-8: Secondary Setup Menu (DIAG)

  230
• A-1: GFC7000E Setup Variables, Revision E.0

  231
• A-2: GFC7000E Warning Messages, Revision E.0

  238
• A-3: GFC7000E Test Functions, Revision E.0

  239
• A-4: GFC7000E Signal I/O Definitions, Revision E.0

  240
• A-5: GFC7000E DAS Trigger Events, Revision E.0

  243
• A-6: GFC7000E iDAS Functions, Revision E.0

  244
• A-7: Terminal Command Designators, Revision E.0

  245
• D-1: List of Included Electronic Schematics

  251