GPR-1000WP Pipe Weld Purge PPM Oxygen Analyzer

GPR-1000WP Pipe Weld Purge PPM Oxygen Analyzer
Pipe Weld Purge PPM Oxygen Analyzer
The all-new GPR-1000 WP Pipe Weld Purge PPM Oxygen Analyzer is designed specifically for pipe welding applications, and
features an innovative design and advanced long life electrochemical oxygen sensor that provide highly reliable trace ppm oxygen
readings in seconds! Additionally, the cost of ownership is 40% less than competitive analyzers!
The Fabricators & Manufacturers Association recommends the
following oxygen levels before welding commences to prevent
oxidation, discoloration, and coking that result in substandard
welds:
 Below 70 ppm in stainless steel welding
 Below 50 ppm in titanium welding
 Below 10 ppm in the semiconductor industry
In addition, the benefits of the improving the weld quality by
reducing the rest oxygen to trace ppm levels is driving the
standards lower in other industries such as aerospace,
pharmaceutical, dairy, brewery, chemical, and food processing.
WP
The GPR-1000 WP is capable of measuring oxygen levels to meet
all of the above requirements. In addition, the GPR-1000 WP offers
the following invaluable features:
Comes Online in Seconds (see reverse)


A built-in pump transports sample to the analyzer
The integral Bypass Valve maintains the oxygen
sensor at trace ppm oxygen levels, which enables the
GPR-1000 WP to come online in seconds from
Bypass Mode!
1 Week Typical Use on Overnight Charge

True portable analyzer with a heavy duty rechargeable
battery that provides one week of typical use on a
single overnight charge
Advanced Electrochemical Oxygen Sensor




Long expected life, requires no maintenance
Specific to oxygen
Unaffected by moisture or particulate matter
Replace the sensor like a battery
Additional Features:



GPR-1000 WP Weld Purge
Oxygen Analyzer
Can be used 24/7 while charging with an AC adapter
User friendly, menu-driven controls
Aluminum casing to withstand the rigors and abuse of
field work

Increases welder productivity and
reduces purge gas waste by
coming online in seconds!

Increases welder productivity with
a heavy duty rechargeable battery
that provides one week of typical use

Weld quality is enhanced by the
GPR-1000 WP’s ability to accurately
and reliably measure trace ppm
oxygen levels

Low cost of ownership and
unmatched performance!
2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: 909-392-6900, Fax: 909-392-3665, www.aii1.com, e-mail: [email protected]
Rev 10/15
* Subject to change without notice
Pipe Weld Purge PPM Oxygen Analyzer
Setup and Optional Accessory Kit:
Bypass Valve Operation:
Technical Specifications
Analysis Range:
0-100 PPM, 0-1%, 0-25%
Accuracy:
< 2% of FS range under constant conditions
Linearity:
±2% of full scale
Signal Output:
0-1V FS
Indicators:
LCD display, resolution 1 PPM;
LED indicates LOW BATT and CHARGE mode
Calibration:
Certified span gas with 500-800 ppm O2 or air
Sensor:
GPR-12-100-M PPM Oxygen Sensor
Expected Sensor Life:
24 months
Warranty:
12 months analyzer; 12 months sensor
2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: 909-392-6900, Fax: 909-392-3665, www.aii1.com, e-mail: [email protected]
Rev 10/15
* Subject to change without notice
Advanced Instruments Inc.
GPR-1000-WP
Portable PPM Oxygen Analyzer
Owner’s Manual
Revised June 2014
2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: 909-392-6900, Fax: 909-392-3665, e-mail: [email protected], www.aii2.com
Advanced Instruments Inc.
Table of Contents
Introduction
1
Quality Control Certification
2
Safety
3
Features & Specifications
4
Operation
5
Maintenance
6
Spare Parts
7
Troubleshooting
8
Warranty
9
Material Safety Data Sheets
10
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Advanced Instruments Inc.
1. Introduction
Your new oxygen analyzer incorporates an advanced electrochemical sensor specific to oxygen along with state-of-the-art
digital electronics designed to give you years of reliable precise oxygen measurements in a variety of industrial oxygen
applications. More importantly, it has been constructed as intrinsically safe in accordance with ATEX Directives 94/9/CE for use
in hazardous areas in zone 1 Group C and D when used in conjunction with the recommended operating instructions in this
manual. The analyzer meets the following area classification.
Analytical Industries, Inc.
dba Advanced Instruments Inc.
2855 Metropolitan Place, Pomona, CA 91767 USA
GPR-1200MS/1200/1200P/1100/1000/1000-WP/2000/2000P
0080
Serial No.:
Year of Manufacture:
INERIS 08ATEX0036
II 2 G
Ex ib IIB T4
Tamb +5⁰C to +45⁰C
WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD – SEE INSTRUCTIONS
The design also meets NEC intrinsic safety standards for use in Class 1, Division 1, Group C, D hazardous areas. Please refer
to Appendix A for information on making electrical connections that maintain the desired level of protection.
To obtain maximum performance from your new oxygen analyzer, please read and follow the guidelines provided in this
Owner’s Manual.
Every effort has been made to select the most reliable state of the art materials and components to design the analyzer for
superior performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer prior to
shipment for best performance. However, all electronic devices do require service from time to time. The warranty included
herein plus a staff of trained professional technicians to quickly service your analyzer is your assurance that we stand behind
every analyzer sold.
The serial number of this analyzer may be found on the inside as well as on the outside wall of the analyzer enclosure. You
should note the serial number in the space provided and retains this Owner’s Manual as a permanent record of your purchase,
for future reference and for warranty considerations.
Serial Number: _______________________
Advanced Instruments Inc. appreciates your business and pledges to make every effort to maintain the highest possible
quality standards with respect to product design, manufacturing and service.
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2. Quality Control Certification
Customer:
Order No.:
Model
GPR-1000-WP ATEX Portable PPM Oxygen Analyzer
Sensor
(
(
Accessories
) GPR-12-100 PPM Oxygen Sensor
) XLT-12-100 PPM Oxygen Sensor
Pass
S/N ____________________
S/N ____________________
Owner’s Manual
(
(
(
) PWRS-1002 9VDC Battery Charger/Adapter 110VAC
) PWRS-1003 9VDC Battery Charger/Adapter 220VAC
) PWRS-1008 9VDC Battery Charger/Adapter 12VDC Auto Cigarette Lighter
CONN-1034 Plug Mini Phone .141 dia. Black Handle
Configuration
Electronics
Test
Gas Phase
Test
A-1161-B-ATEX Rev C3 PCB
Software Version
B-3562 Battery Assembly
Range: 0-1000 PPM, 0-1%, 0-5%, 0-25%
Wetted parts: stainless steel, 4-way crossover valve
LED indicators: Low battery, charge
Electronic offset
Analog signal output 0-1V
Recovery from air to < 100 PPM in < 5 minutes
Baseline drift on zero gas < ± 2% FS over 24 hour period on 0-1000 PPM range
Noise level < ± 0.5% FS
Span adjustment within 10-50% FS
Final
Overall inspection for physical defects
Options
Notes
B-3653 Pump Assembly
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3. General Safety & Installation
Safety
This section summarizes the basic precautions applicable to all analyzers. Additional precautions specific to individual analyzer
are contained in the following sections of this manual. To operate the analyzer safely and obtain maximum performance follow
the basic guidelines outlined in this Owner’s Manual.
Caution: This symbol is used throughout the Owner’s Manual and alert the user to recommended safety and/or
operating guidelines.
Danger: This symbol is used throughout the Owner’s Manual to identify sources of immediate danger such as the
presence of hazardous voltages.
Electrostatic Discharge Hazard: This symbol is used to caution the user to take all necessary steps to avoid
generating electrostatic discharge.
Retain Instructions: The safety precautions and operating instructions found in the Owner’s Manual should be retained for
future reference.
Heed Warnings Follow Instructions: Follow all warnings on the analyzer, accessories (if any) and in this Owner’s Manual.
Observe all precautions and operating instructions. Failure to do so may result in personal injury or damage to the analyzer.
Heat: Situate and store the analyzer away from sources of heat.
Liquid and Object Entry: The analyzer should not be immersed in any liquid. Care should be taken so that liquids are not
spilled into and objects do not fall into the inside of the analyzer.
Handling: Do not use force when using the connectors, switches and knobs. Before moving your analyzer be sure to
disconnect the wiring/power cord and any cables connected to the output terminals located on the analyzer.
Maintenance
Serviceability: Except for replacing the oxygen sensor, there are no parts inside the transmitter for the operator to service.
Only trained personnel with the authorization of their supervisor should conduct maintenance.
Oxygen Sensor: DO NOT open the sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if touched
or ingested, refer to the Material Safety Data Sheet contained in the Owner’s Manual appendix. Avoid contact with any liquid
or crystal type powder in or around the sensor or sensor housing, as either could be a form of electrolyte. Leaking sensors
should be disposed of in accordance with local regulations.
Troubleshooting: Consult the guidelines in Section 8 for advice on the common operating errors before concluding that your
transmitter is faulty. Do not attempt to service the transmitter beyond those means described in this Owner’s Manual.
Do not attempt to make repairs by yourself as this will void the warranty as per Section 10 and may result in electrical shock,
injury or damage. All other servicing should be referred to qualified service personnel.
Cleaning: The transmitter should be cleaned only as recommended by the manufacturer. Wipe off dust and dirt from the
outside of the unit with a soft damp cloth then dry immediately. Do not use solvents or chemicals.
Non-use Periods: Turn the power OFF when the analyzer is left unused for a long period of time.
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Installation
This analyzer has been constructed in compliance with the following EN directives
EN 60079-0 : 2006
EN 60079-1 : 2007
The analyzers must be used in accordance with the guidelines delineated in this instruction manual.
Gas Sample Stream: Ensure the gas stream composition of the application is consistent with the specifications and if in
doubt, review the application and consult the factory before initiating the installation.
Note: In natural gas applications such as extraction and transmission, a low voltage current is applied to the pipeline itself to
inhibit corrosion of the pipeline. As a result, electronic devices connected to the pipeline can be affected unless they are
adequately grounded.
Contaminant Gases: A gas scrubber and flow indicator with integral metering valve are required upstream of the analyzer
to remove any interfering gases such as oxides of sulfur and/or hydrogen sulfide that can interfere with measurement and
cause reduction in the expected life of the sensor. Consult factory for recommendations concerning the proper selection and
installation of components.
Expected Sensor Life: With reference to the published specification, the expected life of all oxygen sensors is predicated on
the basis of average oxygen concentration (<10,000 PPM for a PPM sensor or air for a % sensor), sample temperature of
77°F/25°C and sample pressure of 1 atmosphere in “normal” applications. Deviations from standard conditions will affect the
life of the sensor. As a rule of thumb sensor life is inversely proportional to changes in oxygen concentration, sample pressure
and temperature.
Accuracy & Calibration: Refer to section 5 Operation.
Materials: Assemble the necessary zero, sample and span gases and optional components such as valves, coalescing or
particulate filters and pumps as dictated by the application. Stainless steel tubing is essential for maintaining the integrity of
the gas stream for very low % or PPM O2 level analysis.
Operating Temperature: The sample must be sufficiently cooled before it enters the analyzer and any optional
components. A coiled 10 foot length of ¼” stainless steel tubing is sufficient to cool sample gases as high as 1,800 ºF to
ambient temperature. The recommended operating temperature is below 35 ºC. However, the analyzer may be operated at
temperature up to 45 ºC on an intermittent basis but the user is expected to accept a reduction in expected sensor life –as a
rule of thumb, for every degree ºC increase in temperature (above 25 ºC), the sensor life is reduced by approximately 2.5%.
Heat: Situate and store the analyzer away from direct sources of heat.
Liquid and Object Entry: The analyzer should not be immersed in any liquid. Care should be taken so that liquids are not
spilled into and objects do not fall into the inside of the analyzer.
Handling: Do not use force when using the switches, knobs or any other mechanical components. Before moving your
analyzer be sure to disconnect the wiring/power cord and any cables connected to the output terminals of the analyzer.
Sample Pressure and Flow
All electrochemical oxygen sensors respond to partial pressure changes in oxygen. The sensors are equally capable of
analyzing the oxygen content of a flowing sample gas stream or monitoring the oxygen concentration in ambient air (such as
a confined space in a control room or an open area around a landfill or bio-pond). The following is applicable to analyzers
equipped with fuel cell type oxygen sensors.
Inlet Pressure:
For the analyzers designed to measure oxygen in a flowing gas stream, the inlet sample pressure must
be regulated between 5-30 psig. Although the rating of the SS tubing and tube fittings/valves itself is considerably higher
(more than 100 psig), a sample pressure of 5-30 psig is recommended for ease of control of sample flow.
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Advanced Instruments Inc.
The analyzer is equipped with a Sample Inlet port. The sample gas must be connected to Sample Inlet port. There is no
sample flow control valve upstream of sensor, therefore, the user must install a Flow Meter upstream of Sample Inlet Port to
control sample flow rate (see below for the sample flow rate recommendation).
If the analyzer is equipped with optional sample pump, its speed is set at the factory to draw the recommended sample flow
to the sensor. Caution: in order to prevent the pump from drawing a vacuum on the sensor,
1.
Do not restrict the sample inlet port while the pump is running
2.
Use a 1/4 tube to bring sample to the analyzer
Outlet Pressure: In applications where sample pressure is positive, the sample must be vented to the atmosphere or
into a pipe at atmospheric pressure.
Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH may generate
a slight backpressure on the sensor resulting in erroneous oxygen readings.
Caution: Do not place your finger over the vent (it pressurizes the sensor) to test the flow indicator when gas is
flowing to the sensor. Removing your finger (the restriction) generates a vacuum on the sensor and may damage
the sensor (voiding the sensor warranty).
Application Pressure - Atmospheric or Slightly Negative: The GPR-1000-WP may be purchased
with an intrinsically safe integral sample pump, however, if the analyzer is not equipped with integral sample pump, an
external sample pump capable of pulling sample through the analyzer or high integrity leak free sample pump to push the
sample through the analyzer is recommended. However, the user must ensure that by using external pump, the intrinsic
safety of the analyzer is not compromised. Consult factory for recommendation.
Moisture & Particulates: Installation of a suitable coalescing or particulate filter is required to remove
condensation, moisture and/or particulates from the sample gas to prevent erroneous analysis readings and damage to the
sensor. Moisture and/or particulates do not necessarily damage the sensor. However, collection of moisture/particulate on the
sensing surface can block or inhibit the diffusion of sample gas into the sensor resulting in a reduction of sensor signal output
– and the appearance of a sensor failure. Consult the factory for recommendations concerning the proper selection and
installation of optional components.
Mounting: The analyzer is approved for indoor as well as outdoor use. However, avoid using the analyzer in an area
where direct sun might heat up the analyzer beyond the recommended operating temperature range.
Gas Connections: The Inlet and outlet vent gas lines are 1/8" compression type fittings. The sample inlet tubing must
be metallic, preferably SS. The sample vent line may be of SS or hard plastic tubing with low gas permeability.
Power: The analyzer is powered by an integral lead-acid rechargeable battery. The analyzer will continue to run for a
minimum of 30-60 days after the battery is fully charged or 8 hours with pump running.
WARRNING: THE ANALYZER BATTERY MUST BE CHARGED IN A SAFE AREA ONLY BY USING FACTORY PROVIDED WALL
PLUG-IN CHARGER.
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4. Features & Specifications
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5. Operation
Principle of Operation
The GPR-1000-WP portable oxygen analyzer incorporates a variety of PPM range advanced galvanic fuel cell type sensors. The
analyzer is configured in a general purpose NEMA 4 rated enclosure and meets the intrinsic safety ATEX Directive 94/9/EC for
use in Zone 1 Groups C and D hazardous areas.
Advanced Galvanic Sensor Technology
All galvanic type sensors function on the same principle and are very specific to oxygen. They measure the partial pressure of
oxygen from low PPM to % levels in inert gases, gaseous hydrocarbons, helium, hydrogen, mixed gases, acid gas streams and
ambient air. Oxygen, the fuel for this electrochemical transducer, diffusing into the sensor and reacts chemically at the
sensing electrode to produce an electrical current output proportional to the oxygen concentration in the gas phase. The
sensor’s signal output is linear and remains virtually constant over its useful life. The sensor requires no maintenance and is
easily and safely replaced at the end of its useful life.
Proprietary advancements in the design and chemistry add significant advantages to an extremely versatile oxygen sensing
technology. Sensors for low PPM analysis recover from air to low PPM levels in minutes, exhibit longer life, extended operating
temperature range of -20°C to 50°C, excellent compatibility with CO2 and other acid gases (XLT series sensors only) and
reliable quality giving them a significant advantage over the competition.
The expected life of our new generation of percentage range sensors now range to five and ten years with faster response
times and greater stability. Other significant developments involve the first galvanic oxygen sensor capability of continuous
oxygen purity measurements and expanding the operating temperature range from -40°C to 50°C.
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Advanced Instruments Inc.
Electronics
The signal generated by the sensor is processed by state of the art low power micro-processor based digital circuitry. The first
stage amplifies the signal. The second stage eliminates the low frequency noise. The third stage employs a high frequency
filter and compensates for signal output variations caused by ambient temperature changes. The result is a very stable signal.
Sample oxygen is analyzed very accurately. Response time of 90% of full scale is less than 10 seconds (actual experience may
vary due to the integrity of sample line connections, dead volume and flow rate selected) on all ranges under ambient
monitoring conditions. Sensitivity is typically 0.5% of full scale low range. Oxygen readings may be recorded by an external
device via the 0-1V signal output jack.
Power is supplied by an integral rechargeable lead acid battery which provides enough power to operate the analyzer
continuously for approximately 60 days. An LED located on the front panel provides a blinking 72 hour warning to recharge
the battery. A 9 VAC adapter (positive pole located on the inside of the female connector) can be used to recharge the battery
from a 110V or 220V convenience outlet. The analyzer is designed to be fully operational during the 8-10 hour charging cycle
which is indicated by a second continuously lit CHARGE LED (only when the analyzer power is turned ON).
Sample System
The GPR-1000-WP is supplied with a 4-way Sample/Bypass valve. This valve when in Bypass mode, isolates the sensor from
ambient air and must be used when analyzer is not connected to a sample line or when sample is not flowing through the
analyzer. This valve in when in Sample mode allows the sample to enter the analyzer, pass through the sensor housing and
vent sample to atmosphere. The analyzer is shipped with the sensor pre-tested and installed but is isolated from the ambient
air by 4-way Sample/Bypass valve.
For PPM oxygen measurements, the sensor is exposed to the sample gas that must flow or be drawn through the analyzer’s
internal sample system. The sample flow must be controlled by using an external flow control device. Sample flow rate of 1-5
SCFH has no significant effect on the accuracy of the analyzer, however, for optimum performance, a flow rate of 1-2 SCFH is
recommended.
4-Way Sample/Bypass Valve
shown with 1/8" Sample IN
Compression Type Fitting
As illustrated above, the GPR-1000-WP’s internal sample system includes:
1.
2.
3.
4.
1/8" Compression type fittings for sample inlet and outlet
4-Way Sample/Bypass valve
Stainless steel sensor housing with a thread-in type sensor installation mechanism.
Optional intrinsically safe pump
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Advanced Instruments Inc.
The sample system with a 4-way Sample/Bypass valve is schematically shown below.
For positive sample pressure, install a metering valve before the 4-way valve
For sample pressure at ambient or slightly negative, install pump at the vent (but add a metering valve between the pump
and the Sample Vent)
Users interested in adding their own sample conditioning system should consult the factory. Advanced Instruments Inc. offers
a full line of sample handling, conditioning and expertise to meet your application requirements. Contact us at 909-392-6900
or e-mail us at [email protected]
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Accuracy & Calibration
Single Point Calibration: As previously described the
galvanic oxygen sensor generates an electrical current
proportional to the oxygen concentration in the sample
gas.
Absolute Zero: In the absence of oxygen the sensor
exhibits an absolute zero, e.g. the sensor does not
generate a current output in the absence of oxygen.
Given these linearity and absolute zero properties, single
point calibration is possible.
Pressure: Because sensors are sensitive to the partial
pressure of oxygen in the sample gas, their output is a
function of the number of molecules of oxygen 'per unit
volume'. Readouts in percent or PPM are permissible
only when the total pressure of the sample gas being
analyzed remains constant. For optimum accuracy, the
pressure of the sample gas and that of the calibration gas must be the same (in reality, within 1-2 psig).
Temperature: The rate of diffusion of oxygen molecules into the sensor is controlled by a thin Teflon membrane otherwise
known as an 'oxygen diffusion limiting barrier'. All diffusion processes are temperature sensitive, therefore, the fact that the
sensor's electrical output varies with temperature is normal. This variation, however, is relatively constant (2.5% increase per
ºC increase in temperature).
A temperature compensation circuit employing a thermistor offsets this effect with an accuracy of better than +5% (over the
entire Operating Temperature Range of the analyzer) and generates an output function that is virtually independent of
temperature. There is essentially no error in measurements if the analyzer calibration and sampling are performed at the
same temperature or if the measurement is made immediately after analyzer calibration. Lastly, a small sample/ambient
temperature variations (within 10-15º) produce < 2% error in measurements.
Accuracy: In light of the above parameters, the overall accuracy of an analyzer is affected by two types of errors: 1)
those producing 'percent of reading errors', as illustrated by Graph A below, such as +5% error in temperature compensation
circuit due to tolerances in electronic components and 2) those producing 'percent of full scale errors', illustrated by Graph B,
such as +1-2% linearity errors in readout devices, which are generally very minimal due to today's advancements in
technology and the fact that these errors are 'spanned out' during calibration. Graph C illustrates these 'worse case'
specifications that are typically used to develop the analyzer's overall accuracy statement of < 1% of full scale at constant
temperature and pressure or < 5% over the operating temperature range. The error in QC testing is typically < 0.5% prior to
shipment of analyzers.
Example: As illustrated by Graph A, any error due to the tolerances in the circuit, will increase with increasing oxygen
concentration if the analyzer calibration is done at lower end of the range, e.g., calibration with 20.9%, any error would be
multiplied by a factor of 4.78 (100/20.9) when used for measurements near 100% oxygen. Conversely, an error during a span
adjustment at 100% of full scale range is reduced proportionately for measurements of lower oxygen concentrations.
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Zero Calibration
In theory, the galvanic fuel cell type oxygen sensor exhibits an absolute zero, meaning it produces no signal output when
exposed to an oxygen free sample gas. In reality, however, the analyzer may generate an oxygen reading when sampling
supposedly a zero gas due to:
1.
2.
3.
4.
Contamination or quality of the zero gas
Minor leakage in the sample line connections
Residual oxygen dissolved in the sensor’s electrolyte
Tolerances of the electronic components
The Zero Offset feature of the analyzer allows the user to eliminate this offset. The extent of the zero offset, however, is
limited to 50% of the most sensitive range available with the analyzer.
As part of our Quality Control Certification process, the zero capability of every PPM analyzer is qualified prior to shipment.
Since the factory sample system conditions may differ from that of the user, no ZERO OFFSET adjustment is made to analyzer
at the factory.
Recommendations
Zero calibration is recommended only for analyzers performing continuous analysis below 5% of the most sensitive range
available with the analyzer, e.g. analysis below 0-5 PPM on the 100 PPM range.
Determining the true Zero Offset requires approximately 2-4 hours wait (after initial installation of sensor) to ensure that the
sensor has consumed all the dissolved oxygen in the electrolyte. Allow the analyzer to stabilize with a flowing zero gas as
evidenced by a stable reading or a horizontal trend on an external recording device.
Initiate the DEFAULT ZERO and DEFAULT SPAN procedures before performing either a ZERO or SPAN CALIBRATION.
Caution: Prematurely initiating the ZERO CALIBRATION function can result in negative readings near zero.
Once the zero offset adjustment has been made, further zero calibration is normally not required unless substantial changes in
the sample system connections are made or a new sensor is installed.
Span Calibration
Span Calibration involves adjusting the analyzer electronics gain to match with the sensor’s signal output at a given oxygen
standard. After span calibration, the analyzer output will reflect accurately the oxygen content in a sample gas. The signal
output may drift with changes in the ambient temperature. Maximum drift from calibration temperature is approximately
0.11% of reading per °C change in temperature.
The frequency of calibration varies with the application conditions, the degree of accuracy required by the application and the
Quality Assurance Protocol requirements of the user. However, the interval between span calibrations should not
exceed beyond three (3) months.
Recommendation, General
The interval between span calibrations should not exceed three (3) months.
Initiate the DEFAULT ZERO and DEFAULT SPAN procedures before performing either a ZERO or SPAN CALIBRATION. This
procedure clears up previous calibration data from the analyzer internal memory.
Always calibrate analyzer close to the normal operating temperature and pressure of the sample gas.
For optimum calibration accuracy, calibrate with a span gas approximating 50-80% of the full scale range of analysis or one
range above the range of interest. This will “narrow the error” when moving downscale (close to zero) as illustrated by Graph
A in the Accuracy & Calibration section.
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Advanced Instruments Inc.
Air Calibration
The inherent linearity of the galvanic fuel cell type oxygen sensor enables the user to calibrate the analyzer with ambient air
(20.9% oxygen) and operate the analyzer within the stated accuracy spec on the lowest most sensitive range available with
the analyzer. After air calibration, though acceptable but it is not necessary to recalibrate the analyzer with a low PPM oxygen
span gas.
When installing or replacing a new sensor (PPM or percent), a quick air calibration is always recommended to verify that the
new sensor has the proper output and is ready to use.
In order to perform air calibration, remove the sensor from its bag. Remove the Molex connector (shorting the negative and
positive terminals of the sensor)
Remove the Molex
connector
Connect the sensor with the sensor cable and hold the sensor in your hand for a couple of minutes to allow the sensor to
stabilize with ambient air.
Check the oxygen reading; with factory default span setting, it should reach close to 20.9% (+7% -4%) indicating that the
sensor has proper signal output. At this time perform air calibration (see detailed procedure later in this manual).
Hold the sensor in your hand in air
and perform air calibration
After air calibration, screw the sensor in the sensor housing and immediately allow the sample or zero gas to flow through the
sensor housing.
Mounting the Analyzer
Normally mounting a portable analyzer is not a consideration. However, the GPR-1000 analyzer can operate continuously
when connected to AC power using the factory provided battery charging adapter. The analyzer enclosure is cast with four (4)
holes in the bottom section specifically intended for wall mounting option.
Gas Connections
The GPR-1000-Wp flow through configuration is designed for positive pressure samples and requires a connection to Sample
IN tube fitting connector. The Sample Vent is also 1/8" tube fittings connector; this may be connected to a vent pipe or allow
the sample to vent to atmosphere.
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Note: The user is responsible for making provision for calibration gases, see Calibration section above.
1/8" Compression
Fittings for Sample IN
Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH may generate
a backpressure on sensor and cause erroneous oxygen readings.
For positive sample pressure, a flow control valve upstream of the analyzer is highly recommended ( see below sample system
schematic with optional metering valve). For optimum performance, a flow rate of 1- 2 SCFH or 0.5 – 1 liter per minute is
recommended.
For applications where the sample flow is ambient or at a slightly negative pressure (up to 40” of water column pressure), the
analyzer may be purchased with an optional internally mounted sample pump, otherwise, an external sample pump connected
to the vent of the analyzer should be used to draw the sample through the sensor housing.
Caution: When using an external pump to draw the sample through, open the flow control valve completely. Failure to do so
will draw vacuum on the sensor and may cause permanent damage to the sensor.
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Electrical Connections
Power is supplied by an integral rechargeable lead acid battery which provides enough power to operate the analyzer
continuously for approximately 30-60 days. A LOW BATTERY LED located on the front panel provides a blinking 72 hour
warning to recharge the battery when the battery voltage drops below a pre-determined value. A 9 V AC/DC adapter (with
positive pole located on the inside of the female connector) can be used to recharge the battery from 110V or 220V
convenience outlet. The battery will be fully charged within 8-10 hours. The analyzer is designed to be fully operational during
the 8-10 hour charging cycle. When the adopter is connected to the analyzer, the battery charging process is indicated by a
second continuously lit CHARGE LED (only when the analyzer power is turned ON).
Caution: The battery must be charged in a safe are only. Do not leave the charger connected to the analyzer for more than
24 hours
Charging Battery
Locate a source of AC power in a safe area, plug in the charging adapter supplied to the AC outlet.
Connect the female jack of the charger to the mating male receptacle identified as CHARGE on the analyzer.
Analog Signal Output
A separate receptacle is provided for signal output. The analyzer signal output is 0-1 V full scale selected. The
signal output must be connected to an external recording device in accordance with local safety directives.
Connect the lead wires from the external recording device to the male phone plug supplied with the analyzer.
(Note: Connect the positive lead to the center terminal of the male phone plug.)
Insert the male phone plug into the integral female OUTPUT jack located on the side of the enclosure.
Caution: Do not connect a recording device capable of generating a voltage greater than 12 VDC. A voltage
greater than 18 V may blow the safety fuse on A-1161-B Rev C3 main signal processing PCB. A blown fuse must
be replaced with the recommended fuse only.
Side of analyzer: signal
output and battery
charging connectors
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Installing the Oxygen Sensor
GPR-1000-WP Oxygen Analyzer is equipped with an integral oxygen sensor that has been tested and calibrated by the
manufacturer prior to shipment and is fully operational from the shipping container. Should it be necessary to install a new
oxygen sensor, refer to section “6 Maintenance” for further instructions.
The analyzer must be calibrated once the installation has been completed and periodically thereafter as described below.
Unscrew the old sensor and screw
in the new sensor finger tight
Caution: DO NOT open/dissect the oxygen sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if
touched or ingested, refer to the Material Safety Data Sheet in section 10. Avoid contact with any liquid or crystal type powder
in or around the sensor or sensor housing, as either could be a form of electrolyte. Leaking sensors should be disposed of in
accordance with local regulations.
Procedure
1.
2.
3.
4.
5.
6.
7.
8.
Do not remove sensor from its original package until the analyzer is ready to accept sensor installation.
Make sure that a low PPM gas is flowing through the analyzer.
Set the sample flow rate between 1-2 SCFH
Remove old sensor (if previously installed).
Remove the new sensor from the package (use a pair of scissors to cut the bag, do not use hands to tear the bag)
Remove the Molex connector at the back of the sensor. Connect the sensor to the sensor cable. While holding the sensor
in your hand, perform a quick air calibration (see above).
Check the oxygen reading; it should reach close to 20.0% (+7% -4%) indicating that the sensor has proper signal
output. At this time perform air calibration.
After air calibration, screw the sensor back in to the sensor housing and allow the sample gas to flow
Analyzer Trending
After sensor installation is complete, the analyzer will respond to the oxygen concentration in the sample gas and will slowly
trend down. Within 5-10 minutes, the analyzer will trend down to low PPM values; typically less than 100 PPM and eventually
start displaying the true oxygen value in the sample gas. Complete purge down from the time of sensor installation may take
a few hours.
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Establishing Power to Analyzer
The analyzer power is provided by an integral lead-acid rechargeable battery mounted inside of the analyzer. The analyzer is
fully operational from the shipping container with the oxygen sensor installed and calibrated at the factory prior to shipment.
Once installed, we recommend the user allow the analyzer to stabilize for 10-15 minutes before analyzing a sample gas (this
will remove any residual oxygen that might have trapped in the sample system during installation).
Establish power to the analyzer electronics by pushing the red ON/OFF key. The digital display responds instantaneously.
When power is applied, the analyzer performs several diagnostic system status checks termed “START-UP TEST” as illustrated
below.
The analyzer is supplied with a 9 V AC/DC adapter for recharging the batteries or operating the analyzer continuously. The
analyzer’s charging circuit accepts only 9 VDC from any standard AC 110V or 220V adapter (with positive supply in the center
of the female charging jack). The electronic design enables the analyzer to remain fully operable during the 8-10 hour
charging cycle. However, the analyzer must be charged in safe area only.
Once the power to the electronics is established, the digital display responds instantaneously; the analyzer performs several
diagnostic system status checks termed “START-UP TEST” as illustrated below:
START-UP TEST
ELECTRONICS – PASS
TEMP SENSOR – PASS
BAROMETRIC SENSOR – PASS
REV. 2.37
After self diagnostic tests, the analyzer turns itself into the sampling mode. And displays oxygen contents the sensor is
exposed to, the analysis range, the ambient temperature and pressure.
0.30%
AUTO SAMPLING
1% RANGE
76 F
100 KPA
Menu Navigation
The four (4) pushbuttons located on the front of the transmitter control all of the micro-processor functions:
Blue ENTER (select)
Yellow UP ARROW
Yellow DOWN ARROW
Green MENU (escape)
Main Menu
To access the MAIN MENU, press the MENU (ESC) key and the following screen will appear.
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MAIN MENU
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
This screen show various option available. You can use the UP and DOWN arrow key to move the cursor and highlight the
desired function. After moving the cursor to the desired function, you can press ENTER to get to that function.
Range Selection
The GPR-1000-WP analyzer is equipped with five (4) standard measuring ranges (see specification) and provides users with a
choice of sampling modes. By accessing the MAIN MENU, users may select either the AUTO SAMPLING (ranging) or MANUAL
SAMPLING (to lock on a single range) mode.
Auto Sampling
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE.
Press the ENTER key to select the highlighted menu option.
The display returns to the sampling mode:
MAIN MENU
0.3%
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
AUTO SAMPLING
1% RANGE
76 F
100 KPA
The display will shift to the next higher range when the oxygen reading exceeds 99.9% of the upper limit of the current
range. The display will shift to the next lower range when the oxygen reading drops to 85% of the upper limit of the next
lower range.
For example, if the analyzer is reading 0.1% on the 0-1% range and an upset occurs, the display will shift to the 0-25% range
when the oxygen reading exceeds 0.99%. Conversely, once the upset condition is corrected, the display will shift back to the
0-1% range when the oxygen reading drops to 0. 85%.
Manual Sampling
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight MANUAL SAMPLE.
Press the ENTER key to select the highlighted menu option.
The following display appears:
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MAIN MENU
MANUAL RANGE
>>>
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
4.
5.
25%
1%
1000 PPM
100 PPM
Advance the reverse shade cursor using the ARROW keys to highlight the desired MANUAL RANGE.
Press the ENTER key to select the highlighted menu option.
The following display appears with the range selected and oxygen concentration of the sample gas:
MANUAL RANGE
0.3%
25%
1%
1000 PPM
100 PPM
MANUAL SAMPLING
1% RANGE
>>>
76 F
100 KPA
If the oxygen value goes above the 1%, display will not shift to the next higher range. Instead, when the oxygen reading
exceeds 110% of the upper limit of the current range, an OVER RANGE warning will be displayed.
1.25%
OVERRANGE
MANUAL SAMPLING
1% RANGE
76 F
100 KPA
Once the OVER RANGE warning appears the user must advance the transmitter to the next higher range.
NOTE: With oxygen reading above 110% of the selected range, the analog signal output will increase but will freeze at a
maximum value of 1.2 V. After the oxygen reading falls below the full scale range, the voltage signal will become normal.
Calibration of Analyzer
The electrochemical oxygen sensors generate an electrical current that is linear or proportional to the oxygen concentration
in a sample gas. In the absence of oxygen the sensor exhibits an absolute zero, i.e., the sensor does not generate a current
output in the absence of oxygen. Given the properties of linearity and an absolute zero, a single point calibration is possible.
As described below, zero calibration is recommended only when the application (or user) demands optimum accuracy of below
5% of the most sensitive or lowest range available on the analyzer. Span calibration, in one of the forms described below, is
necessary to adjust the analyzer sensitivity for accurate measurements of oxygen. As a rule of thumb, zero calibration should
be carried out after span calibration.
Zero Offset
Despite the absolute zero inherent in the electrochemical oxygen sensors, the reality is that analyzers may display an oxygen
reading even when sampling a zero gas (oxygen free gas) due to:
1.
2.
3.
Contamination or questionable quality of the zero gas
Minor leakage in the sample line connections
Residual oxygen dissolved in the sensor’s electrolyte
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4.
Tolerances of the electronic components
The maximum zero offset of every analyzer is checked prior to shipment. However, due to the fact that the factory sample
system conditions differ from that of the user, no ZERO OFFSET adjustment is made at the factory
Span Calibration
Involves periodically, see Intervals section below, checking and/or adjusting the electronics to the sensor’s signal output at a
given oxygen standard. The frequency of calibration varies with the application, e.g., the degree of accuracy required by the
application and the quality assurance protocol of the user. However, the interval between span calibrations should not exceed
three (1) months.
Zero Calibration
Typical offset from a PPM analyzer is less than 0.5 PPM. Therefore, for most applications, a Zero calibration is not required.
However, ZERO calibration option has been provided to allow the user to measure oxygen concentration at the very low levels
(less than 5 PPM, e.g., for analyzer with 0-100 PPM low range) with great precision.
The zero offset adjustments is limited to 50% of the most sensitive range of the analyzer. At factory, analyzer is QC tested to
confirm that the maximum offset is less than 50% of the most sensitive range available. Should you observe a zero offset
more than 50% of the lowest range, check sample system for any possible leaks, integrity of the zero gas and assure that the
analyzer has been given enough time to stabilize on zero gas before initiating the “ZERO CALIBRATION”.
Caution: If adequate time is not allowed for the analyzer to establish the true baseline and a ZERO calibration is performed,
the analyzer will in all probability display a negative reading in the sample mode after a certain period of time. If a negative
reading is seen, perform ZERO calibration again.
Zero Calibration Procedure
At the factory, each analyzer is QC tested to confirm that the maximum offset is less than 50% of the most sensitive range
available. Should you observe a zero offset more than 50% of the lowest range, check the sample system for any possible
leaks, integrity of the zero gas and, assure that the analyzer has been given enough time to stabilize on zero gas before
initiating the “ZERO CALIBRATION”.
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.
The following displays appear
MAIN MENU
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
4.
5.
CALIBRATION
>>>
SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO
Advance the reverse shade cursor using the ARROW keys to highlight ZERO CALIBRATE.
Press the ENTER key to select the highlighted menu option.
The following displays appear:
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5 PPM
ZERO
CALIBRTION
ENTER TO CALIBRATE
MENU TO ABORT
6.
7.
Wait until the analyzer reading stabilizes (depending on the history of the sensor, it may take a few minutes to several
hours) and then press the ENTER key to calibrate (or MENU key to abort).
If the offset is less than 50% of the lowest range, by pressing ENTER will pass the calibration and the analyzer will return
to the Sample mode. On the other hand, if the offset is above 50%, pressing ENTER will fail calibration and the analyzer
will return to Sample mode without completing the Zero calibration.
Both the Zero Calibration and Span Calibration functions result in the following displays:
PASSED
CALIBRATION
OR
FAILED
CALIBRATION
Default Zero
This feature will eliminate any previous zero calibration adjustment and display the actual signal output of the sensor at a
specified oxygen concentration. For example, assuming a zero gas is introduced, the display above 0.00 PPM will reflect an
actual zero offset. This feature allows the user to ensure that the accumulative zero offset never exceeds 50% of the lowest
range limit. To perform Default Zero,
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.
The following displays appear
MAIN MENU
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
4.
5.
CALIBRATION
>>>
SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO
Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT ZERO.
Press the ENTER key to select the highlighted menu option.
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The following display appears and after 3 seconds the system returns to the SAMPLING mode:
0 PPM
FACTORY
DEFAULTS
SET
AUTO SAMPLING
1000 PPM RANGE
76 F
100 KPA
Analog Output with Zero O2
In rare instances the 0-1 V signal output may not agree with the reading displayed on the LCD. This feature enables the user
to adjust the 0V signal output when the LCD displays 00.00. Note: Adjust the 1V signal output with the OUTPUT SPAN option
described below.
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option and the following displays appear:
MAIN MENU
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
4.
5.
CALIBRATION
>>>
SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO
Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT ZERO.
Press the ENTER key to select the highlighted menu option and the following display appears:
100.0
OUTPUT ZERO OFFSET
PRESS UP OR DOWN
TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN
6.
The default setting of 100 illustrates no adjustment to the analog output signal. Compute the adjustment value as
described in Appendix B or consult the factory. The true adjustment value must be determined empirically by trial and
error. Adjust the initial value to above 100 to increase the analog signal value or decrease it below 100 to decrease the
analog signal.
095.0
OUTPUT ZERO OFFSET
PRESS UP OR DOWN
TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN
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7.
Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to
reach to the desired digit of the OUTPUT ZERO OFFSET value.
8. Press the ARROW keys to enter the OUTPUT ZERO OFFSET value.
9. Repeat the OUTPUT ZERO OFFSET routine until the output is 0.00V.
10. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key. After adjustment, the system
returns to the SAMPLING mode.
Span Calibration Procedure
Air Calibration
This procedure requires only a source of clean ambient air and removal of the sensor from its flow housing.
1. Access the interior of the analyzer by removing the 4 clamps securing the door of the analyzer.
Caution: Do not remove the gaskets from the enclosure. Failure to reinstall the gasket will void the NEMA rating.
2. Remove the sensor from the sensor housing. Hold the sensor pushed inside of the upper sensor housing with your hand
while exposing the sensor to ambient air.
Hold the sensor with the sensor
cable connected to the sensor
3.
4.
5.
6.
7.
8.
Advance the cursor on the MAIN MENU to SAMPLE and press ENTER to accept the selection.
From the above SAMPLE menu advance the cursor to AUTO RANGING and press ENTER.
Analyzer will return to the MAIN MENU and display the oxygen concentration which should approximate 20.9% oxygen.
Wait approximately 2 minutes to ensure the reading is stable.
Using the menus below, advance the cursor on the MAIN MENU to SPAN and press ENTER to accept the selection.
From the SPAN menu advance the cursor to Calibrate and press ENTER to select.
Follow the menus below to enter and accept the 20.9% span value.
The analyzer returns to the SAMPLE mode after accepting calibration.
Replace the sensor in the housing – tighten the clamp by turning the bolt (finger tight plus 3/4) turn.
Close the door of the enclosure, ensure that the gasket is in place to maintain NEMA 4 rating and lock the door by using (4)
screws. Proceed to sampling.
Span Gas Calibration
This procedure assumes a span gas under positive pressure. Analyzer with an optional sampling pump, switch OFF the pump
before connecting a span gas to Sample IN connector. Set the span gas flow between 1-2 SCFH
To assure an accurate calibration, the temperature and pressure of the span gas must match closely with the sample
conditions. For calibration purposes, set the analyzer to AUTO SAMPLE.
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE.
Press the ENTER key to select the highlighted menu option.
The following displays appear:
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MAIN MENU
30 PPM
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
AUTO SAMPLING
1000 PPM RANGE
76 F
4.
5.
6.
7.
100 KPA
Return to the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.
Repeat to select SPAN CALIBRATE
The following displays appear:
MAIN MENU
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
8.
9.
10.
11.
CALIBRATION
>>>
SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO
After selecting the SPAN CALIBRATION, enter appropriate span gas value.
Assure there are no restrictions in vent line.
Regulate the Span gas pressure, as described above at 5-30 psig, and set gas flow 1-2 SCFH flow rate.
If the span gas line is not already connected, connect the span gas to the sample inlet or span inlet (if equipped with a
separate span inlet).
After selecting the span menu, the following display appears:
GAS CONCENTRATION
PERCENT
PPM
12. Select PERCENT or PPM option. After gas concentration selection, following menu appears to enter the actual span gas
value.
850 PPM
PRESS UP OR DOWN
850 PPM
>>>
TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN
SPAN
CALIBRATION
ENTER TO CALIBRATE
MENU TO ABORT
13. By using the UP or DOWN arrow keys, enter the appropriate digit where the cursor is blinking
14. Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to
reach to the desired digit of the alarm value.
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15. Repeat until the complete span value has been entered. In the example above, a span value of 09.00 PPM has been
entered.
16. After the span value has been entered, the analyzer will prompt to press the ENTER key to accept SPAN CALIBRATION.
Caution: Allow the span gas to flow until the analyzer reading has stabilized before accepting calibration.
The wait time will vary depending on the amount of oxygen introduced to the sensor when the sample and span gas lines
were switched
17. After successful calibration, the analyzer will display a message “Passed Calibration” and return to the Sample mode.
NOTE: The analyzer is allowed to accept calibration when O2 reading is within 50% of the span gas value. If the O2 reading
is outside of this limit, by pressing ENTER to accept calibration will result in “Failed Calibration” and return to the Sample
mode without completing Span calibration. After pressing ENTER either of the following two messages will be displayed.
PASSED
CALIBRATION
OR
FAILED
CALIBRATION
If the calibration is unsuccessful, return to the SAMPLING mode with span gas flowing through the analyzer and retry the
calibration before concluding that the analyzer is defective.
Before disconnecting the span gas line and connecting the sample gas line (if the analyzer is not equipped with a
SPAN/SAMPLE vale option), flow the sample gas for 1-2 minutes to purge the air inside the sample line before connecting it to
the sample input port. Disconnect the span gas line and replace it with the purged sample gas line.
Default Span
The software will set the SPAN adjustment based on the average output of the oxygen at a specific oxygen concentration. For
example, with factory default settings, when a span gas is introduced, the micro-processor will display oxygen reading within
+50% of the span gas value, indicating that the sensor output is within the specified limits. This feature allows the user to
check the sensor’s signal output without removing it from the sensor housing.
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.
The following display appears
MAIN MENU
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
4.
5.
CALIBRATION
>>>
SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO
Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT SPAN.
Press the ENTER key to select the highlighted menu option.
The following displays appear and after 3 seconds the system returns to the SAMPLING mode
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11 PPM
FACTORY
DEFAULTS
SET
AUTO SAMPLING
1000 PPM RANGE
76 F
100 KPA
Analog Output Adjustment at known O2
In rare instances the 0-1V signal output may not agree to the reading displayed by the LCD. This feature enables the user to
adjust the 0-1V signal output should the LCD display not agree. Note: Adjust the 0.0V signal output with the OUTPUT ZERO
option described above.
1.
2.
3.
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.
The following displays appear
MAIN MENU
AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
4.
5.
CALIBRATION
>>>
SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO
Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT SPAN.
Press the ENTER key to select the highlighted menu option.
The following display appears
100.0
OUTPUT SPAN OFFSET
PRESS UP OR DOWN
TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN
6.
Compute the adjustment value as described in Appendix B or consult the factory. The true adjustment value must be
determined empirically by trial and error. Adjust the initial adjustment value for additional percent errors.
7. Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to
reach to the desired digit of the OUTPUT SPAN OFFSET value.
8. Press the ARROW keys to enter the OUTPUT SPAN OFFSET value.
9. Repeat steps 9 and 10 until the complete OUTPUT SPAN OFFSET value has been entered.
10. Save the adjustment by pressing the ENTER key or abort by pressing the MENU key
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Note: The number 100 is the default value. With OUTPUT SPAN set at 100, no adjustment is made to the 1V signal. To
increase the 1V signal increase the OUTPUT SPAN above 100. To decrease the 1V signal, decrease the OUTPUT SPAN below
100.
Sampling a Gas
After successful span calibration, the GPR-1000-WP Oxygen Analyzer is ready for analyzing a sample gas; connect the sample
gas connection to the Sample IN, turn the Sample/Bypass valve to Sample and let the sample flow at the recommended flow
rate. The analyzer will respond to the oxygen contents in the sample gas and display the actual oxygen contents in the sample
gas.
Standby
The analyzer has no special storage requirements.
The sensor should remain connected to the analyzer PCB during storage periods.
Switch the analyzer Sample/Bypass valve to BYPASS mode before disconnecting sample gas connection
Store the analyzer with the power OFF at a safe location and away from a direct heating source.
If storing for an extended period of time, protect the analyzer from dust, heat and moisture.
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6. Maintenance
With exception of components related to optional equipment and charging the battery of portable analyzers, cleaning the
electrical contacts when replacing the sensor is the extent of the maintenance requirements of this analyzer as there are no
serviceable parts in the analyzer given the nature of the solid state electronics and sensor.
Serviceability: Except for replacing the oxygen sensor, there are no parts inside the analyzer for the operator to service.
Only trained personnel with the authorization of their supervisor should conduct maintenance.
Sensor Replacement
Periodically, the oxygen sensor will require replacement. The operating life is determined by a number of factors that are
influenced by the user and therefore difficult to predict. The Features & Specifications define the normal operating conditions
and expected life of the standard sensor utilized by the GPR-1000 Series analyzer.
Unscrew the old sensor and
screw in the new sensor finger
tight
Caution: DO NOT open the oxygen sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if touched
or ingested, refer to the Material Safety Data Sheet contained in the Owner’s Manual.
When necessary, install the sensor as described in section 5 of this manual.
Charging Battery
Charging the battery requires a common 9VDC adapter (positive pole located inside the female connector) supplied with the
analyzer and a convenience outlet. The analyzer’s charging circuit accepts 9VDC from any standard AC 110V or 220V adapter.
The electronic design enables the analyzer to remain fully operable during the 8-10 hour charging cycle.
Procedure
1.
2.
3.
Unless the analyzer is to be operated while charging, turn the analyzer OFF when charging the battery for the shortest
charging cycle.
Connect the appropriate 9VDC adapter supplied with the analyzer to an 110V or 220V outlet.
Insert the male phone plug from the 9VDC adapter into the integral female CHARGE jack located on the bottom of the
enclosure.
The analyzer is designed to operate in the charging mode, however, operating the analyzer in hazardous or
explosive atmospheres while charging the battery IS NOT recommended despite the intrinsically safe
design.
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Service
A single charge is sufficient to operate the GPR-1200 analyzer continuously for a period of 60 days, 1 day when operating the
optional integral sampling pumps continuously.
Battery Warning LED Indicators
An LED indicator located on the front panel will light continuously during the CHARGE cycle.
A second LED (LOW BATTERY) indicator located on the front panel provides a blinking 72 hour warning when battery voltage
drops below a certain level. Operating the analyzer beyond this 72 hour may permanently damage the battery (a drained out
battery will never recharge). If the battery does not charge in 10-24 hour period, replace the battery.
7. Spare Parts
Recommended spare parts for the GPR-1000 Series Portable Oxygen Analyzer:
Item No.
Description
GPR-12-100-M
PPM Oxygen Sensor
XLT-12-100-M
PPM Oxygen Sensor for gases containing CO2
Other spare parts:
Item No.
Description
B-3652
Battery Assembly for analyzer with integral sample pump
A-3666
Battery Assembly for analyzer without integral sample pump
A-3377
Housing Flow Adaptor Stainless Steel
MTR-1010
Meter Digital Panel LCD Backlight
A-1161-B GP Rev C3
PCB Assembly Main / Display general purpose area analyzer
A-1161-B-ATEX Rev C3
PCB Assembly Main / Display ATEX
PWRS-1002
Power Source Plug-in 9VDC 110V Battery Charger
PWRS-1003
Power Source Plug-in 9VDC 220V Battery Charger
B-3653
Pump Assembly Intrinsically Safe
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8. Troubleshooting
Symptoms
Slow recovery
High O2 reading in
Sampling
Possible Cause
Recommended Actions
At installation, defective sensor
Replace sensor if recovery unacceptable or O2
reading fails to reach 10% of lowest range
Air leak in sample system connection(s)
Leak test the entire sample system:
Vary the flow rate, if the O2 reading changes
inversely with the change in flow rate indicates an
air leak - correct source of leak
Abnormality in zero gas
Qualify zero gas (using portable analyzer)
Damaged in service - prolonged
exposure to air, electrolyte leak
Replace sensor
Sensor nearing end of life
Replace sensor
Flow rate exceeds limits
Correct pressure and flow rate
Remove restriction on vent line/ open SHUT OFF
valve completely
Pressurized sensor
Improper sensor selection
Replace GPR/PSR sensor with XLT sensor when
CO2 or other acid gases are present
Abnormality in sample gas
Qualify sample gas independently by using a
second analyzer
Response time slow
Air leak, dead legs, longer distance of
sample line, low flow rate, high volume
of optional filters and scrubbers
Leak test sample system bringing sample gas to
analyzer, reduce dead volume and/or increase
sample flow rate
O2 reading doesn’t
agree with expected
O2 values
Pressure and temperature of the sample
may be different than the span gas used
for calibration
Calibrate the analyzer (calibrate close to the
pressure and temperature of the sample gas)
Abnormality in the sample gas
Qualify sample gas independently
Test sensor signal output independent
from analyzer
Remove sensor from housing. Using a volt-meter
set to uA, apply the (+) lead to the outer pin and
the (-) lead to the second pin of the Molex
connector on the sensor, measure the output in
air (expected value 290-400 uA). If no current
signal, replace sensor, otherwise contact factory.
Abrupt changes in sample pressure
Regulate sample gas pressure and flow. Clean
contacts with alcohol (minimize exposure time of
Erratic O2 reading or
No O2 reading
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sensor to ambient air to extent possible)
Replace sensor and return damaged sensor to the
factory for warranty determination
Damaged sensor
Corroded solder joints on sensor PCB
from corrosive sample or electrolyte
leakage from sensor
Corroded spring loaded contact in upper
section of sensor housing from liquid in
sample or electrolyte leakage from
sensor
Wipe sensor and sensor housing and sensor with
a damped towel.
Liquid covering sensing area
Replace GPR series sensor with XLT sensor when
CO2 or other acid gases are present, consult
factory
Improper sensor selection
Presence of other interference gases
Replace sensor and install H2S scrubber
Replace sensor, obtain authorized service
Replace sensor
Presence of sulfur gases
Unauthorized maintenance
Sensor nearing end of life
Erratic O2 reading or
Negative O2 reading
or
No O2 reading
possibly accompanied
by electrolyte leakage
Clean spring loaded contacts in upper
section of sensor housing with a damped
cloth. If electrolyte leakage from sensor
is evident, replace sensor and return
leaking sensor to the factory for
warranty determination
Pressurizing the sensor by flowing gas to
the sensor with: the vent restricted or
SHUT OFF valve closed and the suddenly
removing the restriction draws a vacuum
on the sensor or partially opening the
valves upstream of the analyzer when
using a pump downstream of the
analyzer to draw sample from a process
at atmospheric pressure or a slight
vacuum
A pressurized sensor may not leak but
still can produce negative readings.
Re-Zero the analyzer. If not successful replace the
sensor
Avoid drawing a vacuum on the sensor
Remove restriction from vent line/open shut off
valve completely
Replace a leaking sensor
Placing a vacuum on the sensor in
excess 40” of water column is strongly
discouraged. The front sensing
membrane is only 5/8 mil thick, heat
sealed to the sensor body and is subject
to tearing when vacuum is suddenly
applied.
A premature ZERO OFFSET of analyzer is
a common problem
From MAIN MENU select DEFAULT ZERO and
perform a zero calibration again
Sensor output outside the recommended
range
Replace sensor
Zero offset beyond the limit permitted
Perform DEFAULT ZERO, wait until the analyzer
reading falls below 50% of the most sensitive
range and perform zero calibration again
Low Battery
Charge battery, if unsuccessful, replace battery
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Advanced Instruments Inc.
Fails span calibration
Integrity of span gas
Verify span gas
Sensor end of its useful life
Replace sensor
Fails Zero calibration
Integrity of zero gas
Attempted premature calibration
Verify integrity of zero gas
Wait and allow the analyzer reading to stabilize
and re-zero the analyzer
Analyzer does not
power up
Weak battery
Replace battery
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Advanced Instruments Inc.
9. Warranty
The design and manufacture of Advanced Instruments Inc. oxygen analyzers and oxygen sensors are performed under a
certified Quality Assurance System that conforms to established standards and incorporates state of the art materials and
components for superior performance and minimal cost of ownership. Prior to shipment every analyzer is thoroughly tested by
the manufacturer and documented in the form of a Quality Control Certification that is included in the Owner’s Manual
accompanying every analyzer. When operated and maintained in accordance with the Owner’s Manual, the units will provide
many years of reliable service.
Coverage
Under normal operating conditions, the analyzers and sensors are warranted to be free of defects in materials and
workmanship for the period specified in accordance with the most recent published specifications, said period begins with the
date of shipment by the manufacturer. The manufacturer information and serial number of this analyzer are located on the
rear of the analyzer. Advanced Instruments Inc. reserves the right in its sole discretion to invalidate this warranty if the serial
number does not appear on the analyzer.
If your Advanced Instruments Inc. monitor, analyzer and/or oxygen sensor is determined to be defective with respect to
material and/or workmanship, we will repair it or, at our option, replace it at no charge to you. If we choose to repair your
purchase, we may use new or reconditioned replacement parts. If we choose to replace your Advanced Instruments Inc.
analyzer, we may replace it with a new or reconditioned one of the same or upgraded design. This warranty applies to all
monitors, analyzers and sensors purchased worldwide. It is the only one we will give and it sets forth all our responsibilities.
There are no other express warranties. This warranty is limited to the first customer who submits a claim for a given serial
number and/or the above warranty period. Under no circumstances will the warranty extend to more than one customer or
beyond the warranty period.
Limitations
Advanced Instruments Inc. will not pay for: loss of time; inconvenience; loss of use of your Advanced Instruments Inc.
analyzer or property damage caused by your Advanced Instruments Inc. analyzer or its failure to work; any special, incidental
or consequential damages; or any damage resulting from alterations, misuse or abuse; lack of proper maintenance;
unauthorized repair or modification of the analyzer; affixing of any attachment not provided with the analyzer or other failure
to follow the Owner’s Manual. Some states and provinces do not allow limitations on how an implied warranty lasts or the
exclusion of incidental or consequential damages, these exclusions may not apply.
Exclusions
This warranty does not cover installation; defects resulting from accidents; damage while in transit to our service location;
damage resulting from alterations, misuse or abuse; lack of proper maintenance; unauthorized repair or modification of the
analyzer; affixing of any label or attachment not provided with the analyzer; fire, flood, or acts of God; or other failure to
follow the Owner’s Manual.
Service
For service related questions, call Advanced Instruments Inc. at 909-392-6900 between 8:00am and 5:30pm Pacific Time
Monday thru Thursday or before 12:00 pm on Friday (or e-mail [email protected]). Trained technicians will assist you in
diagnosing the problem and arrange to supply you with the required parts. You may obtain warranty service by returning you
analyzer, postage prepaid to:
Advanced Instruments Inc.
2855 Metropolitan Place
Pomona, Ca 91767 USA
Be sure to pack the analyzer securely. Include your name, address, telephone number, and a description of the operating
problem. After repairing or, at our option, replacing your Advanced Instruments Inc. analyzer, we will ship it to you at no cost
for parts and labor.
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Advanced Instruments Inc.
10. MSDS – Material Safety Data Sheet
Product Identification
Product Name
Synonyms
Manufacturer
Emergency Phone Number
Preparation / Revision Date
Notes
Oxygen Sensor Series - PSR, GPR, AII, XLT
Electrochemical Sensor, Galvanic Fuel Cell
Analytical Industries Inc., 2855 Metropolitan Place, Pomona, CA 91767 USA
909-392-6900
January 1, 1995
Oxygen sensors are sealed, contain protective coverings and in normal conditions do not
present a health hazard. Information applies to electrolyte unless otherwise noted.
Specific Generic Ingredients
Carcinogens at levels > 0.1%
Others at levels > 1.0%
CAS Number
Chemical (Synonym) and
Family
None
Potassium Hydroxide or Acetic Acid, Lead
Potassium Hydroxide = KOH 1310-58-3 or Acetic Acid = 64-19-7, Lead = Pb 7439-92-1
Potassium Hydroxide (KOH) – Base or Acetic Acid (CH3CO2H) – Acid, Lead (Pb) – Metal
General Requirements
Use
Handling
Storage
Potassium Hydroxide or Acetic Acid - electrolyte, Lead - anode
Rubber or latex gloves, safety glasses
Indefinitely
Physical Properties
Boiling Point Range
Melting Point Range
Freezing Point
Molecular Weight
Specific Gravity
Vapor Pressure
Vapor Density
pH
Solubility in H2O
% Volatiles by Volume
Evaporation Rate
Appearance and Odor
KOH = 100 to 115° C or Acetic Acid = 100 to 117° C
KOH -10 to 0° C or Acetic Acid – NA, Lead 327° C
KOH = -40 to -10° C or Acetic Acid = -40 to -10° C
KOH = 56 or Acetic Acid – NA, Lead = 207
KOH = 1.09 @ 20° C, Acetic Acid = 1.05 @ 20° C
KOH = NA or Acetic Acid = 11.4 @ 20° C
KOH – NA or Acetic Acid = 2.07
KOH > 14 or Acetic Acid = 2-3
Complete
None
Similar to water
Aqueous solutions: KOH = Colorless, odorless or Acetic Acid = Colorless, vinegar-like
odor
Fire and Explosion Data
Flash and Fire Points
Flammable Limits
Extinguishing Method
Special Fire Fighting Procedures
Unusual Fire and Explosion
Hazards
Not
Not
Not
Not
Not
applicable
flammable
applicable
applicable
applicable
Reactivity Data
Stability
Conditions Contributing to
Instability
Incompatibility
Hazardous Decomposition
Products
Conditions to Avoid
Stable
None
Steps if material is released
Sensor is packaged in a sealed plastic bag, check the sensor inside for electrolyte
leakage. If the sensor leaks inside the plastic bag or inside an analyzer sensor housing
do not remove it without rubber or latex gloves and safety glasses and a source of
water. Flush or wipe all surfaces repeatedly with water or wet paper towel (fresh each
time).
Spill or Leak
KOH = Avoid contact with strong acids or Acetic Acid = Avoid contact with strong bases
KOH = None or Acetic Acid = Emits toxic fumes when heated
KOH = None or Acetic Acid = Heat
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Advanced Instruments Inc.
Disposal
In accordance with federal, state and local regulations.
Health Hazard Information
Primary Route(s) of Entry
Exposure Limits
Ingestion
Eye
Skin
Inhalation
Symptoms
Medical Conditions Aggravated
Carcinogenic Reference Data
Other
Ingestion, eye and skin contact
Potassium Hydroxide - ACGIH TLV 2 mg/cubic meter or Acetic Acid - ACGIH TLV / OSHA
PEL 10 ppm (TWA), Lead - OSHA PEL .05 mg/cubic meter
Electrolyte could be harmful or fatal if swallowed. KOH = Oral LD50 (RAT) = 2433
mg/kg or Acetic Acid = Oral LD50 (RAT) = 6620 mg/kg
Electrolyte is corrosive and eye contact could result in permanent loss of vision.
Electrolyte is corrosive and skin contact could result in a chemical burn.
Liquid inhalation is unlikely.
Eye contact - burning sensation. Skin contact - soapy slick feeling.
None
KOH and Acetic Acid = NTP Annual Report on Carcinogens - not listed; LARC
Monographs - not listed; OSHA - not listed
Lead is listed as a chemical known to the State of California to cause birth defects or
other reproductive harm.
Special Protection
Ventilation Requirements
Eye
Hand
Respirator Type
Other Special Protection
None
Safety glasses
Rubber or latex gloves
Not applicable
None
Special Precautions
Precautions
Transportation
Do not remove the sensor’s protective Teflon and PCB coverings. Do not
probe the sensor with sharp objects. Wash hands thoroughly after handling.
Avoid contact with eyes, skin and clothing.
Empty sensor body may contain hazardous residue.
Not applicable
36
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