Advanced Instruments GPR-2500 AIS-LD Manual (AIS-LD)

Technical Specifications *

Accuracy: < 2% of FS range under constant conditions
Analysis:

Application:

Approvals: Certified for use in hazardous areas - see lower right

Area Classification: Certified for use in hazardous areas - see lower right
Alarms:

Calibration:

Compensation:

Connections: 1/4" compression tube fittings
Controls:

Display:

Enclosure:

Flow: Not flow sensitive; recommended flow rate 1-2 SCFH
Linearity: ±1% of full scale
Pressure:

Power:

Response Time: 90% of final reading in < 2 minutes
Sample System: Unique liquid drain manifold and sensor, flow indicator

Sensitivity: < 0.5% of FS range
Sensor Model:

Sensor Life: 24 months in air at 25ºC and 1 atm
Signal Output:

Operating Range: -10ºC to 45ºC (GPR sensor); -10ºC to 45ºC (XLT)
Warranty: 12 months analyzer; 12 months sensor

Wetted Parts: Stainless steel

0-1%, 0-5%, 0-10%, 0-25% FS ranges; auto-ranging
or fixed single range

Oxygen analysis in inert, hydrocarbon, helium, hydro­gen, mixed and acid (CO2) gas streams

UL: United States: UL 1203, UL 913, UL 508
Canada: CAN/CSA C22.2 No. 30-M1986,
CAN/CSA C22.2 No. 157-92,
CAN/CSA C22.2 No. 14-10
ATEX: Directive 94/9/EC

Two user configurable alarms: magnetic coil relays
rated 3A at 100 VAC, programmable alarm delays,
alarm bypass for calibration and system fail alarm

Max interval—3 months. Air calibrate with clean source
of certified span gas, compressed, or ambient (20.9%
O2) air on 0-25% range.

Barometric pressure and temperature (ATEX)
Temperature (UL)

Water resistant keypad; menu driven range selection,
calibration and system functions

Graphical LCD 2.75” x 1.375”; resolution 0.001%;
displays real time ambient temperature and pressure

NEMA 3R for rain in outdoor applications (UL)
NEMA 4X (ATEX)

Inlet - regulate to 5-30 psig to deliver 1-2 SCFH flow;
vent - atmospheric

12-28 VDC (UL and ATEX Certified)
110-220 VAC (ATEX Certified)

GPR-11-32-LD; XLT-11-24-LD for gases containing
>0.5% CO2

4-20mA non-isolated or 1-5V; optional Modbus RTU
communication

UL or ATEX Certified for Hazardous Areas

Drains Free Liquids

GPR-2500 AIS-LD
Oxygen Analyzer

Unique Liquid Drain Sensor Manifold

Full Featured Oxygen Analyzer

Optional Modbus RTU Communication

Exia

UL Certified

File E343386

Class I, Division 1, Groups C and D

T4 T

ATEX Certified - Directive 94/9/EC

Examination Cert: INERIS 08ATEX0036

II 2 G
Ex d [ib] ib IIB T4 Gb

T

-20⁰C to +50⁰C

amb

-20⁰C to +50⁰C

amb

0080

Optional Equipment

Automated sample conditioning system (see other side)
GPR-11-32-LD sensor for non-acid (CO2) gas streams; 32 month life

* Specifications subject to change without notice

2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: [phone], Fax: [phone], www.aii1.com, e-mail: [e-mail] Rev 10/15

ISO 9001:2008 Certified

INTERTEK Certificate No. 485

Advanced Instruments Inc.

GPR-2500 AIS LD

% OXYGEN ANALYZER

Owner's Manual

Revised March 2015

2855 Metropolitan Place, Pomona, California 91767 USA ♦ Tel: [phone], Fax: [phone] ♦ www.aii1.com ♦ e-mail: [e-mail]

Advanced Instruments Inc.

Table of Contents

Introduction 1 Quality Control Certification 2 Safety 3 Features & Specificatio ns 4 Operation 5 Maintenance 6 Spare Parts 7 Troubleshooting 8 Warranty 9 Material Safety Data Sheets 10

Explosion Proofing Electrical Connections Appendix A

The appendices referenced above are an integral part of the documentation, installation and maintenance of this analyzer
to comply with all applicabl e directives. It is importan t that users review thes e do cuments before proceeding.

2

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 explosion proof/intrinsically safe in accord anc e wit h Safety
Standards: UL 913 Seventh Edition, Referencing UL 60079-0:2005 and UL 60079-11:2009 and CSA C22.2 No. 157-92
Third Edition for use in Class I, Div 1, Groups C and D hazardous locations and the ATEX Directives 94/9/EC for zone 1
Group IIB.

Please refer to Appendix A for making electrical connections that maintains 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 mater ial s and com ponents, to design the analyzer for

superior performance and minimal co st of owner ship. This analyzer was tested thoroughly by the manufacturer prior to
shipment for best performance.

However, modern electronic devices do require service from time to time. The warranty included herein plus a staff of
trained professional technicians to quickly service your transmitter is your assurance that we stand behind every
transmitter sold.

The serial number of this analyzer may be found on the inside 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.

Analytical Industries Inc.
dba Advanced Instruments Inc.
2855 Metropolitan Place, Pomona, CA 91767 USA

GPR-2500 AIS/2500 AIS LD

0080

Serial No.:
Year of Manufacture:
INERIS 08ATEX0036

II 2 G
Ex d [ib] ib IIB T4 Gb
T

-20⁰C to +50⁰C

amb

WARNING: POTENTIAL ELECTROSTATIC CHARGING HA ZARD – SEE
INSTRUCTIONS

3

Advanced Instruments Inc.

2. Quality Control Certification

See analyzer packing slip/Instruction Manual that came with the analyzer for QC certificate

4

Advanced Instruments Inc.

3. General Safety & Installation

This section summarizes the essential precautions applicable to the GPR-2500 AIS LD Oxygen Analyzer. Additional
precautions specific to the individual transmitter is contained in the following sections of this manual. To operate the
transmitter safely and obtain maximum performance foll ow the basi c guideli nes outli ned in this Owne r’s Manual.

Caution: This symbol is used throughout the Owner’s Manual to Caution and alert the user to recommended
safety and/or operating guidelines.

Warning: This symbol is used throughout the Owner’s Manual to Warn and alert the user of the presence of
electrostatic discharge.

Danger: This symbol is used throughout the Owner’s Manual to identify sources of immediate Danger such
as the presence of hazardous voltages.

Read Instructions: Before operating the transmitter read the instructions.
Retain Instructions: The safety precautions and operating instructions found i n the Owner’s Ma nual s houl d be reta ined

for future reference.

Heed Warnings: Follow all warnings on the transmitter, accessories (if any) and in this Owner’s Manual.
Follow Instructions: Observe all precautions and operating instructions. Failure to do so may result in personal injury or

damage to the transmitter.

Analyzer label

WARNING – Potential Explosion Hazard: The devices are not intended for use in atmospheres or with sample gas
streams containing oxygen concentration greater than 21 percent by volume (ambient air) and are only intended
for use in gases or gas mixtures classified as Class I, Div 1, Groups C and D hazardous locations or in non­hazardous locations, when used in the United States or Canada.

5

Advanced Instruments Inc.

Maintenance

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 mai nt e na nce.

WARNING- Substitution of Components May Impair Intrinsic Safety
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 for m of el ec t r o lyte.
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 analyzer is faulty. Do not attempt to service the analyzer 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 analyzer 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.

Nonuse Periods: If the analyzer is equipped with a range switch advance the switch to the OFF position and disconnect
the power when the transmitter is left unused for a long period of time.

Installation

This analyzer has been constructed in compliance with:

EN 60079-0 : 2009
EN 60079-1 : 2007
EN 60079-11 : 2012

For USA and Canada
UL 913, 7
CSA C22.2 No. 157-92

It must be installed in accordance with :

EN 60079-14
For USA - NEC and Canada – CEC Standards

WARNING - Potential Explosion Hazard – See Warning in Section 4 – Features and Specifications

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 nitrogen or hydrogen sulfide that can interfere with
measurement and cause reduction in the expected life of the sensor. Consult the factory for recommendations concerning
the proper selection and installation of components.

Expected Sensor Life: With reference to the publish specification, the expected life of all oxygen sensors is predi c a ted
on the basis of typical oxygen concentration (air for % sensor), temperature (77°F/25°C) and pressure (1 atmosphere) in

th

Edition

6

Advanced Instruments Inc.

“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 the 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 low % 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 for cooling sample gases as high as 1,800 ºF
to ambient. 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%.

Warning – Sample Stream entering unit must never exceed 50

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 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 analy zer .

0

C

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.

The analyzer equipped with a sample system has designated SAMPLE and VENT ports. Connect SAMPLE gas to SAMPLE
and the vent to the VENT ports only.

Outlet Pressure: In applications where sample pressure is positive, the sample must be vented to an exhaust pipe at a
pressure less than the inlet pressure so that the sample gas can flow through the sensor housing. Ideally, the sample must
be vented to atmospheric pressure.

Note: The sensor may be used at a slight positive pressure (e.g., when sample is vented to a common exhaust where the
pressure might be higher than 1 atmosphere). However, the pressure at the sensor must be maintained at all times
including during the span calibration. This may be accomplished by using a back-pressure regulator at vent line of the
analyzer. The back-pressure regulated must be set less than 2 PSIG. For higher back-pressure requirements, consult
factory.

Caution: A sudden change in pressure at the sensor may result in the sensor electrolyte leakage.
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 - Positive: A flow indicator with integral metering valve positioned upstream of the sensor is
recommended for controlling the sample flow rate between 1-2 SCFH. If necessary, a pressure regulator upstream of the

7

Advanced Instruments Inc.

flow control valve should be used to regulate the inlet pressure between 5-30 psi g. Though the analyzer is designed to
handle inlet pressure up to 100 PSIG, 5-30 PSIG pressure range is recommended only for ease of control of sample flow.

Application Pressure - Atmospheric or Slightly Negative: For % oxygen measurements, an optional external sample
pump may be used upstream of the sensor to push the sample across the sensor and out to atmosphere or an eductor
pump downstream of the sensor to pull the sample across the sensor. If the sample pump can pull/push more than 5
SCFH, a flow meter with control valve must be used to control the sample flow. The flow control valve must be positioned
in such a way that it does not generate any vacuum on the sensor.

Caution: If the analyzer is equipped with a flow indicator with integral metering valve or a metering flow
control valve upstream of the sensor and the pump is installed downstream of sensor- open the metering valve

completely before turning the pump ON to avoid drawing a vacuum on the sensor and placing an undue

burden on the pump.

Mounting: The analyzer is approved for indoor as well as outdoor use. However, avoid mounting in an area where direct
sun might heat up the analyzer beyond the recommended operating temperature range. If possible, install a small hood
over the analyzer for rain water drain and to prevent over-heating of analyzer. If the ambient temperature is

expected to fall below -18 degree C (0 degree F), install the analyzer within an heated enclosure.

Gas Connections: The Inlet and outlet vent gas lines require 1/8” or ¼” stainless steel compression type tube 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: Supply power to the analyzer only as rated by the specification or markings on the analyzer enclosure. The GPR­2500 AIS LD is powered by 12-28 VDC supply. The wiring that connects the analyzer to the power source should be
installed in accordance with recognized electrical standards. Ensure that the analyzer case is properly grounded and meets
the requirements for area classification where the analyzer is installed. Never yank wiring to remove it from a terminal
connection.

The maximum power the analyzer consumes is no more than 7 Watts.

8

Advanced Instruments Inc.

4. Features & Specifications

9

Advanced Instruments Inc.

5. Operation

Principle of Operation

The GPR-2500 AIS LD Oxygen Analyzer incorporates the GPR-11-32-LD or XLT-11-24-LD advanced galvanic fuel cell type
oxygen sensors. These sensors are very specific to oxygen and generate an electrical signal proportional to the amount of
oxygen present in a gas stream. The selection of a particular type of sensor depends on the composition of the sample gas
stream. Consult factory for recommendation.

The analyzer is configured in two sections. The signal processing electronics and sensor are housed in a general purpose
NEMA 4X rated enclosure. The terminals for incoming power, signal output and intrinsic safety barriers are mounted on a
PCB housed in an explosion proof enclosure.

The two sets of electronics are interconnected using an explosion proof Y-fit t i n g, expl osion proof packing fiber and sealing
cement – see Appendix A. Once connected, the intrinsic safety barriers limit the amount of power that flows to and from
the signal processing electronics effectively preventing an explosive condition. The analyzer design conforms to the ATEX
and UL directive for equipment as intrinsically safe and has been approved by an independent body:

The analyzer carries the following area classification

II 2 G
Ex d [ib] ib IIB T4 Gb
T

For USA and Canada
UL 913, 7th Edition
CSA C22.2 No. 157-92

It must be installed in accordance with
EN 60079-14
For USA - NEC and Canada – CEC Standards

The GPR-2500 AIS also meets the intrinsic safety standards required for use in Class I, Division 1, Groups C, D hazardous
areas.

-20⁰C to +50⁰C

amb

WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD-SEE INSTRUCTION

Advanced Galvanic Sensor Technology

All galvanic type sensors function on the same principle and are specific to oxygen. They measure the partial pressure of
oxygen from low PPM to 100% levels in inert gases, gaseous hydrocarbons, helium, hydrogen and mixed gases.

Oxygen, the fuel for this electrochemical transducer, diffusing into the sensor, reacts electrochemically 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 over all measuring ranges 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 design and chemistry add significant advantages to this extremely versatile oxygen sensing
technology. Sensors recover from air to low % levels in seconds, exhibit longer life and reliable quality. The expected life
of our new generation of percentage range sensors now range from 32 months to ten years with faster response times

10

Advanced Instruments Inc.

and greater stability. Another significant development involves expanding the operating temperature range for percentage
range sensors from -20°C to 50°C. Contact factory for more specific information about your appl ica ti on.

NOTE- Check the product label for safe operating conditions

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 2 minutes (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 of the low range. Oxygen readings may be
recorded by an external device via the 4-20 mA or 1-5V signal output.

Sample System

See Section 4, Features and Specification, Note 1 for exclusions.
The standard GPR-2500 AIS-LD is supplied with a sample flow-through sensor housing that allows the

moisture/condensable liquids to separate when the sample enters the sensor housing thus providing the user with hassle
free sample analysis despite the presence of liquid in the sample gas; see section 2 QC Certification for additional optional
equipment ordered.

The GPR-2500 AIS-LD is generally supplied with a sample flow control valve and a flow meter and sample/span selection
valve. Users interested in adding their own sample conditioning system should consult factory. Advanced Instruments Inc.
offers a full range of sample handling, conditioning and expertise to meet your application requirements. Contact us at
909-392-6900 or e-mail us at [e-mail].

Calibration & Accuracy Overview

Single Point Calibration: As previously described
the galvanic type oxygen sensor generates an electrical
current proportional to the oxygen concentration in the
sample gas. 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 are permissible only when
the total pressure of the sample gas being analyzed
remains constant. The pressure of the sample gas and
that of the cal i bration gas must be the same.

Temperature: The rate at which oxygen molecules
diffuse into the sensor is controlled by a Teflon membrane otherwise known as an 'oxygen diffusion limiting barrier' and all
diffusion processes are temperature sensitive, the fact the sensor's electrical output will vary with temperature is normal.
This variation is relatively constant (2.5% per ºC). A temperature compensation circuit employing a thermistor and a
network of resisters offsets this effect with an accuracy of +

o

45

C can be obtained thus the signal output remains virtually independent of ambient temperature. There is extremely

11

5% or better over a wide operating temperature range e.g., 5-