Advanced Instruments GPR-2800 AIS S Manual (AIS)

Technical Specifications *

Accuracy: < 2% of FS range under constant conditions
Analysis: 0-25% O2 FS ranges
Application:

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

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

Oxygen analysis in hazardous ambient areas and con­fined spaces

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

UL or ATEX Certified for Hazardous Areas

Alarms:

Calibration:

Compensation: Barometric pressure and temperature
Connections: None

Controls:

Display:

Enclosure:

Flow:
Linearity: ±2% of full scale

Pressure:
Power:

Response Time: 90% of final reading in 10 seconds
Sample System: None

Sensitivity: < 0.5% of FS range
Sensor Model:

Sensor Life: 32 months
Signal Output: 4-20mA non-isolated or 1-5VDC

Operating Range:
Warranty: 12 months analyzer; 12 months sensor

Wetted Parts: N/A

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.

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

N/A, Ambient air monitoring only

Atmospheric
12-28 VDC (UL, ATEX Certified)

110-220 VAC (ATEX Certified)

GPR-11-32-4

5ºC to 45ºC

GPR-2800 AIS S

Ambient Oxygen Analyzer

Full Featured Ambient Oxygen Analyzer

Optional Modbus RTU Communication

Advanced Galvanic Sensor Technology

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

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-20⁰C to +50⁰C

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-20⁰C to +45⁰C

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0080

Optional Equipment

Modbus RTU Communication

* 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-2800 AIS-S ATEX
Ambient Oxygen Analyzer

Owner’s Manual

2855 Metropolitan Place, Pomona, California 91767 USA ♦ Tel: [phone], e-mail: [e-mail] Rev 11/14

Table of Contents

Introduction 1
Quality Control & Calibration Certification * 2
Safety 3
Features & Specifications * 4
Operation 5
Maintenance 6
Spare Parts 7
Troubleshooting 8
Warranty 9
Material Safety Data Sheets 10
Drawings A/R

Advanced Instruments Inc.

Explosion Proofing Electrical Connections Appendix A
Correlating readings – LCD display to 4-20mA signal output Appendix B

* Quality Control & Calibration Certification (separate page) 2
* Features & Specifications (separate page) 4

The appendices referenced above are an integral part of the documentation, installation and maintenance of this analyzer to
comply with all applicable directives. It is important that users review these documents before proceeding.

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1. Introduction

Your new Ambient Oxygen Analyzer i ncorpor ates an advanced electroc hemical sensor specific to O xygen along with state-of­the-art digital electronics designed to give you years of reli able precise measurements of Oxygen in a mbient environment or
confined spaces.

More importantly, it has been constructed as explosion proof/intrinsically safe in accordance with:

ATEX Directives 94/9/EC, INERIS 08ATEX0036, for use in hazardous areas in zone 1 Group C and D

EX d [ib] ib IIB T4
T amb -20°C to +50°C
WARNING: Potential electrostatic charging hazard - see instructions.

Safety Standards: EN 60079-0:2009
EN 60079-1:2007
EN 60079-11:2012
UL 913 Seventh Edition and CSA C22.2 No . 157- 92 Third Edition, for use in Class I, Div 1, Groups C and D

hazardous locations.

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 fo r

superior performance and minimal cost of ownership. 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 Analyzer is your assurance that we stand
behind every Analyzer 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 perma nent 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. General Safety & Installation

This section summarizes the essential precautions applicable to the GPR-2800 AIS-S Ambient Oxygen Anal yzer. Additional
precautions specific to individual Analyzer are co ntained in the following sections of this manual. To operate the Analyzer
safely and obtain maximum performance follow the basic guidelines outlined in this O wner’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 Analyzer read the instructions.
Retain Instructions: The safety precautions and operating instructions found in the Owner’s Manual should be

retained for future reference.

Heed Warnings: Follow all warnings on the Analyzer, 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 Analyzer.

Analyzer Label

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, when used in the United States or Canada.

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2. Quality Control & Calibration Certification

Attached as separate page following indices.

3. Maintenance

Serviceability: Except for replacing the Oxygen sensor, there are no parts inside the Analyzer for the operator to service.

WARNING- Substitution of Components May Impair Intrinsic Safety

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 cont act with
any liquid or crystal type powder in or around the se nsor 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 c ommon operati ng errors before conc lu ding th at

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 m ay result in electrical shock,

injury or damage. All other servicing should be referred to qualified service personnel.

Cleaning: The analyzer should be cle aned 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 Period: If the analyzer is equipped with a range switch advance the switch to the OFF positio n and disconnect

the power when the Analyzer is left unused for a long period of time.

Installation

This analyzer has been constructed in compliance with:

ATEX Directive 94/9/EC
EN 60079-0 : 2006
EN 60079-1 : 2004
EN 60079-11 : 2007

It must be installed in accordance with: EN 60079-14

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, when used in the United States or Canada.

Sampling Stream: The analyzer is designed to measure Oxygen in ambient air and hence has no sample stream

requirement.

Expected Sensor Life: With reference to the publish specification included as a separate page following the

appendices of this manual, the expected life of all Oxygen sensors is predicated on the rate at which the sensor's anode is
consumed at: temperature of 77°F/25°C; pressure of 1 atmosphere in ambient air (20.9% oxygen).

Deviations from these conditions will affect the life of the sensor (temperature higher than 77
atmospheric would cause a reduction in the sensor life).

0

C and pressure less than

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Accuracy and Calibration: Refer to section 5 Operation.

Material and Gases: A certified span gas is required for routine calibration (see details in Operation).

Operating 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 sens or

life is reduced by approximately 2.5%.

Heat: Install the analyzer away from direct sun and from any sour ce of heat. Situate and store the analyzer a way from direct

sources of heat.

Liquid and Solid Object Entry: The analyzer should not be immersed in any liquid. Care shou ld be taken so that

liquids are not spilled into and objects do not fall on or inside of the analyze r .

Handling: Do not use force when using/operating mechanical components. Before moving your analyzer be sure to

disconnect the wiring/power cord and any cables connected to the output terminals of the analyz er.

Sample Pressure

All electrochemical sensors respond to partial pressure changes in the gas of interest. The sensors are capable of analyzing
the Oxygen in ambient air (such as a confined space in a control room or an open area around a landfill or bio-pond) . The
following conditions are applicable to analyzers equipped with electrochemical sensors.

Analyzers designed for in-situ ambient or area monitoring have no real sample inlet and vent. The sensor is intended to
operate at atmospheric pressure and is exposed directly to the ambient measuring environment. The analyzer has a built-i n
barometric pressure sensor and the sensor output is automatically compensated for any atmospheric pressure changes.

Mounting of the Analyzer: The analyzer is approved for indoor as well as outdoor use. Ho wever, 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.

Gas Connections: None for normal operation. For calibration, a flow-through adapter with gas Inlet and outlet is

provided. A flow control valve is recommended to bring the span gas to sensor within the recommended flow rate (1-2 SCFH)

Power Requirement: Suppl y power to the analyzer only as rated by the specification or markings on the analyzer

enclosure. The GPR-2800AIS-S is powered by 12-28 VDC. The wiring that connects the anal yzer to the power source shoul d
be installed in accordance with recognized el ectrical st andar ds. Ensure that the analyzer case is properly grou nded and meets
the requirements for area classification where the analyzer is installed. Never yank wiring to remove it from a terminal
connection.

Power Consumption: The maximum power consumption is less than 7 Watts.

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4. Features & Specifications

Attached as separate page following indices.

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, when used in the United States or Canada.

5. Operation

Principle of Operation

The GPR-2800AIS-S Ambient Oxygen Analyzer incorporates an adv anced electrochemical sensor
very specific to Oxygen and generates an electrical signa l proportional to the amount of Oxygen
present in a gas.

The analyzer is configured in two sections. T he signal pr ocessing electronics a nd sensor are housed
in a general purpose (Type R3) rated enclosure. T he terminals of power input, signal output and the
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-fitting, explosion proof
packing fiber and sealing cement. Once connected, the i ntrinsic safety barriers limit the amo unt of power that
flows to and from the signal processing electronics effectively preventing an explosive condition.

The GPR-2800AIS-S meets the ATEX and cUL intrinsic safety standards required for use in Class I, Division 1, Group C, D
hazardous areas and carries the following area classification:

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Advanced Electrochemical Sensor Technology

All galvanic type sensors function on the same principle and are specif ic 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 req uires 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 a nd reliable quality. The expected life of our
new generation of percentage range sensors now range fr om 32 months to ten years with faster response times and greater
stability. Another significant development involves expandin g the operating temperature range for percentage range sensors
from -30°C to 50°C. Contact factory for more specific information about your application.

Electronics

The signal generated by the sensor is processed by state of the art lo w power micro-processor based digital circuitr y. The first
stage amplifies the signal. The second stage eliminates the low frequency nois e. The third stage employs a high frequency
filter and compensates for signal output variations caused by ambient temperature changes. The result is a ver y stable signal.
Sample oxygen is analyzed very accurately. Respo nse 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 rang es 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.

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Calibration and Accuracy Overview

Single Point Calibration: As previously described, the electrochemical 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.

Ambient 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' . All diffusion processes are temperature sensitive, therefor e, the fact
that the sensor's electrical output will vary with temperature is normal. Unde r typical applications, this variation is relatively
constant and the measurement accuracy remains within the published s pecifications over the r ecommended operatin g rage of
temperature. The accuracy of +
measurement accuracy will be the highest if the calibration and sampling are performed at similar temperatures (a temperature
variation of 10 ºC may produce an error of >+/-2% of full scale).

Accuracy: In light of the above parameters, the overall accuracy of an analyzer is affected by two types of errors, 'percent

of reading errors', illustrated by Graph A below and the 'p ercent of full scale errors', illustrated by Graph B. The percent of
reading error is contributed by incorrect calibration procedure whereas the percent of full scale error is contributed by tolerance
in components and the measurement device. These errors are 'spanned out' during calibration, especially when span
calibration is done close to the top end of the measuring range followed by a zero calibration.

Graph C illustrates these 'worse case' specifications that are typicall y used to develop an overall accuracy statement of < 2%
of full scale at constant temperature or < 5% over the operating tempe rature range. The QC testing error at the factory is
typically < 1% of full scale.

Example 1: Graph A, percent of reading error, this error is more pronounced when a span adjustment is carried out at the
lower end of the scale. Conversely, an error during a span adj ustment cl ose to th e top end of the r ange would red uce t he error
proportionately for measurements near the bottom end of the range.

Graph B represents a constant error over the entire me asuring range. This error is generally associated with the measuring
e.g., LCD and or calibrating devices, e.g., current simulator or current/voltage measuring devices.

Graph C shows the overall accuracy of the measurement.

5% or better over an operating temperature range e.g., 5-45oC can be obtained. The

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Mounting of the Analyzer

The GPR-2800AIS-S consists of two interconnected
enclosures. This configuration is designed to be
mounted directly to any flat vertical surface, wall or
bulkhead plate by using eight (4) of the appropriate
screws.

To facilitate servicing the interior of the Analyzers,
secure the back plate to a vertical surface
approximately 5 feet from the floor or a level
accessible to service personnel. This requires the
user to supply four (4) additional proper size scre ws
and anchors.

Caution: Do not remove or discard the
gaskets from either the Ex enclosure or
the fiberglass enclosure. Failure to
reinstall either of the gaskets will void the

UL Type 3R rating and the immunity to RFI/EMI.
The Analyzer's design provides immunity from RFI/EMI by mainta ining a good conductive contact between the t wo halves of

the enclosures via a conductive gasket (the smaller enclosure containing signal processing electronics). The surfaces
contacting the conductive gasket are unpainted. Do not paint these areas. Painting will negate the RFI/EMI protection

See Section 4 – Specifications, for exclusions

Gas Connections

The GPR-2800AIS-S measures Oxygen in ambient air thus it does not require sample gas connections.
For calibration a flow through housing with gas inlet and vent is provided that mounts directly to the sensor. Use supplies the

flow control device to regulate span gas flow within the recommended range (1-2 SCFH). The user is responsible for
calibration gases and other required components, see below.

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Electrical Connections

The Incoming power, alarm relays, and signal output connections are made to terminal blocks mounted on a PCB located i n
the explosion proof enclosure.

Do not supply voltage above the noted value i n this
manual and noted near the power input terminal of
the analyzer.

The PCB in the explosion proof enclosure contains a
power limiting intrinsic safety barrier that limit the total power
available at the PCB electronics mounted in the general
purpose enclosure.

The GPR-2800 AIS-S meets the intrinsic safety standards required for use in Class I, Division 1, Group C, D hazardou s areas.
ATEX Directive 94/9/EC

II 2 G
Ex d ib IIB T4 Gb
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For USA and Canada, it conforms to: UL 913, 7

The A-1166 AIS PCB in the Ex enclosure contains five fuses, one plug-in (bro wn color) rated at 200 mA and the rest are
mounted on the PCB (after the DC voltage is regulated to lower safe value, these fuse meet barrier net work standard EN

50020).

-20⁰C to +50⁰C

amb

Avoid electrostatic discharge – Clean all surfaces with a
damp cloth only.

200 mA Fuse

th

Edition and CSA C22.2 No. 157-92

Power In Alarms Signal Out

Analyzer ground terminal must be connected to ground.

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Hazardous Area Installation

The GPR-2800AIS-S may be installed in a hazardous area when adhered to the recommended installation procedure
delineated above mentioned directives; see Installation section be ginning on page 5.

Power Input

A 12-28 VDC power supply with a shielded power cable is recommended. The po wer cable to the Ex enclosure must be
supplied through a conduit approved for us e in hazardous area. Secure the wires to the po wer input terminal block by using
the integral screws of the terminal block.

CAUTION: Check the Quality Control & Calibration Certification, Section 2, attached as a separate page following
the appendices for the proper power requirement. Incorrect power will severely damage the analyzer

Output Connections

The Analyzer has two adjustable alarms, one power fail alarm and 4-20 mA or 1-5 VDC signal output connections.

CAUTION: T he 4-20mA circuit does not require external power. Supplying external power to the 4-20 mA signa l
output connector will permanently damage the PCB.

The HI and LOW alarms are user configurable. The relays are rated at 1A @ 230 VAC.

CAUTION: Do not e xceed the recommended rating of the relays. Excessive power throu gh the relays can severely damage
the relays and the PCB.

Power 12-28 VDC

PCB A-1166
Alarm Relays and 4-20 mA Signal PCB A-1161
Explosion proof enclosure Fiber Glass enclosure

There are total five wire connections between the Ex enclosure and the fiber glass enclosure but for simplicity, only two
connections are shown.

Procedure

1. Unscrew the cone shaped cover from the EX enclosure.

2. Separate the shielding from the wires of the cables.

3. Strip the end of wires no greater than 1/4"

4. Insert the stripped end of wires into the appropriate slots of the terminal block

5. Ensure the positive and negative terminals of the power supply are connected to the appr opriate terminals of the

6. Tighten the screws and ensure the wires are properly secured.

7. Connect the shielding of the cable to the ground screw inside of the enclosure.

200 mA fuse

terminal block as marked.

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8. Follow the same procedure and establish alarm relays and 4-20 mA signal connections with appropriate
terminals

9. Replace the cover.

Note: The male and female power terminals snap together, making it diffic ult to detach them when connecting the shield to the
ground. However, after connecting the shield, ensure that the male terminal is fully inserted and secured into the female
terminal block.

Installation of Oxygen Sensor

The sensor housing is threaded and screws directly into the bottom section of the fiber glass enclosure.

Caution: DO NOT dissect the sensor. The sensor contains a corrosive liquid el ectrolyte 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 h ousing, as either co uld be a form
of electrolyte. Leaking sensors should be disposed off in a manner similar to that of a common battery in

accordance with local regulations.

Should the Analyzer come without sensor installed or need to install a new sensor, follow the procedure below.

1. Turn the power to analyzer OFF.

2. Remove the two (2) clamps securing the right side corners and open the door of the fiber glass enclosure.

3. Remove the connector cable from the top of the sensor by gently squeezing the ta b attached to the co nnector toward the
connector itself, pulling the connector up and away from the jack.

Avoid electrostatic discharge – touch a metal surface with your bare hand before contacting the sensor.
Clean all surfaces with a damp cloth only

4. Unscrew the sensor by turn the sensor anti clockwise.

5. Remove the new sensor from the bag.

6. Screw the new sensor in to the sensor housing until finger tight.

7. Align the tab on the connector with the registration slot of the jack and push into the sensor until firmly seated. .

Sensor shown with connector cable
half inserted into mating jack

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Span Gas Requirement

The GPR-2800AIS-S must be calibrated with a mixture of O xygen approximating 20.9 % and the balance Nitrogen from either
a known clean source of air (ambient or compressed) or a certif ied span gas balance air or nitrogen. User is res ponsible to
provide means of calibration gas.

Establishing Power to Electronics

Once the two power input wires of the shielded cable ar e properly connected to the terminals inside the Ex enclosure as
described above, connect the other end of the t wo wires to a suitable 12-28 VDC po wer source such as a b attery, PLC, DCS,
etc. The digital display responds instantaneously. The Analyzer performs several self-diagnostic system status checks termed
as “START-UP TEST” as illustrated below:

After self diagnostic tests, the analyzer turns itself into the sampling mode and disp lays the Oxygen concentration the sensor
is exposed to, the analysis range, the ambient temperature and pressure, High and Low alarm set points.

REV 2.40

76 F 97 Kpa
LO 1 19.5% HI 20.0%

Menu Navigation

The four (4) pushbuttons located on the front of the Analyzer control 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.

This screen shows various options available. You can use the UP a nd DOWN arrow key to move the cursor and highli ght the
desired function. After moving the cursor to the desired function, press ENTER to access that function.

START-UP TEST

ELECTRONICS – PASS
TEMP SENSOR – PASS
BAROMETRIC SENSOR – PASS

21.0%

Auto Sampling
0-25% Range

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS
ALARM BYPASS

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Range Selection

The GPR-2800 AIS-S is equipped with four (4) standard me asuring ranges. B y accessing the MAIN MENU, users may sel ect
either the AUTO SAMPLING (ranging) or MANUAL SAMPLING (to lock on a single range) mode.

Note: The GPR-2800 AIS-S is shipped with the range manually locked on the 0-25% range.

Auto Sampling

1. Access the MAIN MENU by pressing the MENU key.

2. Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE.

3. Press the ENTER key to select the highlighted menu option.

The display returns to the sampling mode:

4. 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 ran ge when the Oxygen reading drops to 85% of the next
lower range.

Manual Sampling

1. Access the MAIN MENU by pressing the MENU key.

2. Advance the reverse shade cursor using the ARROW keys to highlight MANUAL SAMPLE.

3. Press the ENTER key to select the highlighted menu option and the following display a ppears:

4. Advance the reverse shade cursor using the ARROW keys to highlight the desired MANUAL RANGE.

5. Press the ENTER key to select the highlighted menu optio n and the following display appears with the range
selected and oxygen concentration of the sample gas:

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS
ALARM BYPASS

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE

CALIBRATION
CONFIG ALARMS
BYPASS ALARMS

21.0%

Manual Sampling
0-25% Range

76 F 97 Kpa
LO1 19.5% HI 20.0%

MANUAL RANGE

21.0%

Manual Sampling
0-25% Range

1 %
5 %
10 %
25 %

76 F 97 Kpa
LO1 19.5% HI 20.0%

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6. If the value of Oxygen goes above the full scale range sele c t ed, the dis play will not shift to the next higher range.
Instead, when the Oxygen reading exceeds 125% of the upper limit of the current range, an OVER RANGE
warning will be displayed.

7. Once the OVER RANGE warning appears the user must advance the Analyzer to the next higher range.

8. NOTE: With Oxygen reading above 125% of the selected rang e, the mA signal output will increase but will freeze
at a maximum value of 24 mA. After the sample reading falls below the full scale range, the mA signal will
become normal.

Calibration

The electrochemical Oxygen sensors gener ate an electrical current that is linear or proportional to the Oxygen concentratio n
in a sample gas. In the absence of Oxygen the sensor exhibits an absolute zero , i.e., the sensor does not gener ate a current
output in the absence of Oxygen. Given the properties of linearity and an absolute zero, a single point calibration is po ssible.

Zero Calibration
sensitive or lowest range available. Inasmuch as the GP R-2800 AIS-S is designed for ambient Oxygen measurements the
zero calibration section of the software is not applicable, except for one function, has been omitted from this manual.

Span Calibration, as described below, is necessary to adjust the analyzer sensitivity for accu rate measurements of Oxygen.

Zero Calibration - Default Zero

This function eliminates any previous zero calibration and displays the actual signal output of the sensor and should be
performed prior to Span Calibration. To perform Default Zero,

The following display appears and after 3 seconds the system returns to the SAMPLING mode:

is recommended only when the application (or user) demands optimum accuracy of below 5% of the most

1. Access the MAIN MENU by pressing the MENU key.

2. Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.

3. Press the ENTER key to select the highlighted menu option and the following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

4. Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT ZERO.

5. Press the ENTER key to select the highlighted menu option.

FACTORY
DEFAULTS
SET

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN

DEFAULT ZERO

OUTPUT SPAN
OUTPUT ZERO

CALIBRATION

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Span Calibration

Involves periodically checking and/or adjusting th e electronics to the sensor’s signal output at a given Oxygen standard. The
frequency of calibration varies with the application, e.g., the de gree of accuracy required by the application and the quality
assurance protocol of the user. However, the interval between span calibrations should not exceed 1 month.

Note: Regardless of the value of the standard used, the span calibration process takes approximately 10-15 minutes.

Span Calibration - Default Span

This function should be performed immediately following the Zero Calibrat ion - Default Zero (describe d above) and pri or to the
actual Span Calibration, see menu below right.

This function eliminates all previous calibr atio n d ata stored in the mem ory and the sensiti vit y of the se ns or is reset to the v alue
based on the average output of the sensor at a specific Oxygen conce ntration. For example, with factory default settings,
when a span gas is introduced, the micro-processor will display a n Oxygen reading within 30-50% of the span gas value,
indicating that the sensor output is within the specified limit.

1. Access the MAIN MENU by pressing the MENU key.

2. Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.

3. Press the ENTER key to select the highlighted menu option and the following display a ppears:

4. Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT SPAN.

5. Press the ENTER key to select the highlighted menu option and the following displays appear and after 3
seconds the system returns to the SAMPLING mode:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

FACTORY
DEFAULTS
SET

SPAN CALIBRATE
ZERO CALIBRATE

DEFAULT SPAN

DEFAULT ZERO
OUTPUT SPAN

OUTPUT ZERO

76 F 97 Kpa
LO 19.5 % HI 20.0%

CALIBRATION

21.0%

Auto Sampling
0-25% Range

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Span Calibration

This procedure assumes a span gas under positive pressure.

1. Attach the flow-through sensor housing to the sensor.

2. Connect 1/4" tubing from the span gas to the inlet of the flow-through sensor housing.

3. Connect a 1/4" tubing to vent of the sensor housing to vent the span gas to a safe location.

4. Set the span gas flow 1-2 SCFH.

5. For calibration purposes, use AUTO SAMPLE mode.

1. Access the MAIN MENU by pressing the MENU key.

2. Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE.

3. Press the ENTER key to select the highlighted menu option and the following displays appear:

4. Return to the MAIN MENU by pressing the MENU key.

5. Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.

6. Press the ENTER key to select the highlighted menu option.

7. Repeat to select SPAN CALIBRATE and the following displays appear:

8. After selecting the SPAN CALIBRATION, the
following display appears:

9. Press the ENTER key to advance the underline cursor right or press the MENU ke y to advance the underline
cursor left to reach to the desired digit of the alarm value.

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS

BYPASS ALARMS

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS
BYPASS ALARMS

21.0%

Auto Sampling
0-25% Range

76 F 97 Kpa
LO 19.5 % HI 20.0%

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN

OUTPUT ZERO

000.00%
PRESS UP OR DOWN

TO CHANGE VALUE
ENTER TO SAVE
MENUE TO ABORT

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10. Repeat until the complete sp an value has been entered and press ENTER. The following display will appear
showing the real time Oxygen concentration..

11. Press the ENTER key to accept SPAN CALIBRATION. 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 o nly when the Oxygen read ing is within 50% of the span gas value. If the
Oxygen reading is outside of this limit, by pressing ENT ER to acc ept calibration will result in “FAILED CALIBRAT ION” and the
analyzer will return to the Sample mode without completing Span calibration.

If span calibration is unsuccessful, repeat calibration, make sure the reading stabilizes a nd reach es within 30-50% of the span
gas value (after factory default span setting) before pressing ENTER to accept calibration.

PASSED CALIBRATION

Setting Alarms

The analyzer is equipped with two programmable alarm re lays. The two alarms set points are user adjustable and can be set
either as LOW/HIGH, LOW/LOW or HIGH/HIGH.

Setting Alarm Delays

Alarm delay option allows the user to ignore the alarm should a sudden short spike in the oxygen reading occurs.

Setting Alarm Bypass

The alarms bypass feature allows the user to bypass the alarm during trouble shooting/repa ir or test run. However, once the
alarm bypass is selected, alarm will remain disabled even if the oxygen reading is over/under th e alarm set point. The alarm
will re-arm itself only after the fault condition has been reverted.

The alarms are automatically disabled during SPAN/ZERO calibration.
The relays are rated at 1A @ 230V.
CAUTION; When using these relays, do not exceed the recommended rating.

20.9%

SPAN
CLAIBRATION
ENTER TO CALIBRATE
MENU TO ABORT

FAILED CALIBRATION

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Adjustment of 20 mA Analog Output

In rare instances the 4-20mA signal output may not agree to the reading displaye d by the LCD. This feature enables t he user
to adjust the 4-20mA signal output should the LCD display and signal output does not match.

Note: Adjust the 4mA signal output with the OUTPUT ZERO option described above.

1. Access the MAIN MENU by pressing the MENU key.

2. Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.

3. Press the ENTER key to select the highlighted menu option and the following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO

OUTPUT SPAN

4. Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT SPAN.

5. Press the ENTER key to select the highlighted menu option and the following display a ppears

6. The default setting of 100 illustrates no adj ustment to the analog output signal. Adjust the initial value to above
100 to increase the 20 mA analog signal value or decrease it below 100 to decrease the 20 mA analog signal.

7. Press the ENTER key to advance the underline cursor right or press the MENU ke y 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 desired digit. After entering the digit press ENTER and the 20 mA signal will
adjust to the new value.

9. If the 20 mA signal still does not match with 20 mA signal, repeat steps 7 through 8 the 20 mA matches with the
display..

10. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key and the

system returns to the SAMPLING mode.

100.0
OUTPUT SPAN OFFSET
PRESS UP OR DOWN

TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN

Sampling

GPR-2800 AIS-S Ambient Oxygen Analyzer is design to measure Oxygen concentrat ion in ambient air and hence does not
require any sampling system. When powered, the analyzer will immediately start to analyze the ambient air and will display the
real time Oxygen concentration in air.

Standby

The analyzer has no special storage re quirements. The sensor should remain connected to the electronics during storage
periods.

Store the analyzer with 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.

CALIBRATION

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6. Maintenance

Generally, replacing the sensor periodically is the extent of the maintenance requireme nts of this analyzer.
Serviceability: Except for replacing the 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.

7. Spare Parts

Recommended spare parts for the GPR-2800 AIS-S Ambient Oxygen Analyzer:

Item No. Description

GPR-11-32-4

Other spare parts:

The Factory must be consulted for any other spare parts and questions related to maintenance

Oxygen Sensor (inert gas atmospheres)

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8. Troubleshooting

Symptom Possible Cause Recommended Action

Slow settling

 At Installation, defective

sensor

 Damaged in service -

electrolyte leakage

 Sensor nearing end of

useful life

Replace sensor

Replace sensor

Replace sensor

High Oxygen reading
after installing
or replacing sensor

Slow response time

Oxygen reading doesn’t agree
to expected values

Erratic or no Oxygen reading

 Calibrated before sensor

stabilized

 Sensor surface clogged by

liquid/moisture condensation

 Varying ambient

temperature and pressure

 Error in calibration

 Sudden Changes in ambient

temperature and/or pressure

 Loose sensor cable

 Liquid covering sensing

area

 Sensor nearing end of life

Allow Oxygen reading to stabilize before
performing calibration

Clean front end of sensor with blowing air

Calibrate at pressure and temperature that is
average of temperature and pressure cycle in 24
hours

Repeat calibration

Calibrate at mean temperature and pressure during
a 24 hours period

Secure connector firmly by fully inserting the jack
into its mating socket on the sensor

Clean frond end of sensor with blowing air
.
Replace sensor

Cannot span calibrate

 Incorrect span gas
 Span flow rate too high
 Incorrect sensor
 Sensor nearing end of life

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Check span gas with a secondary analyzer
Set span gas flow within recommended range
Replace sensor
Replace sensor

Advanced Instruments Inc.

9. Warranty

The design and manufacture of GPR Series Anal yz ers and sensors are pe rformed und er a certifi ed Qual it y Assurance S ystem
that conforms to established standards and incorporates state of the art materials an d components for superior performance
and minimal cost of ownership. Prior to shipment every analyzer is thoroughl y 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 Analyzer, anal yzers and sensor are warranted to be free of defects in materia ls and
workmanship for the period specified in acc ordance with the most recent pu blished specifications, said p eriod begins with the
date of shipment by the manufacturer. The manufacturer information and serial number of this analyz er a re locate d on t he 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. Analyzer, 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
Analyzers, analyzers and sensors purchased worldwide. It is the only one we will give and it sets forth all our respons ibilities.
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 c ircumstances 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, mis use or ab use; lack of prop er maintena nce; u naut horiz ed
repair or modification of the analyzer; affixin g 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 last s 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; unauthoriz ed repair or modification of the
analyzer; affixing of any label or attachment not provided with the an alyzer; fire, flood, or acts of God; or other failure to follow
the Owner’s Manual.

Service

Call Advanced Instruments Inc. at 909-392-6900 (or e-mail [e-mail]) between 7:30 AM and 5:00 PM Pacific Time
Monday thru Thursday or 8:00 AM to 12:00 pm on Friday. Trained techni cians will assist you in diagnosing the proble m 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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10. MSDS – Material Safety Data Sheet

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Appendix A

Explosion Proofing Electrical Connections

Electrical connections require an approved explosion proof sealing fitting and packing around wires and cables (for incoming
power for the analyzer electronics and 4-20mA signal output) coming into and o ut of the explosio n proof enclos ure that house s
the power supply/signal output PCB.

Compliance with hazardous area electrical code requires the user to supply glands, fittings and/or conduit commensurate with
the level of protection or classification desired.

To maintain the ATEX certification of this unit, the user must install ATEX approved com pon ents accor ding to AT EX directives .
To meet US and Canada requirements for use in Class I, Division 1, Groups C, D hazardous areas, the user must install the
appropriate components according to the NEC standards (US) or CEC standards (Cana da).

Note: The following instruction is supplied from information and data supplied by a repu table enclosure manufacturer which

we believe is reliable and is given in good fai th. Since the me thods of application and conditions under which our products ar e
put to use are beyond our control, we are not able to guarantee the application a nd/or use of same. The user assumes all
risks and liability in connection with the application and use of our products.

Directions for use of Explosion Proof Packing Fiber ( non-asbestos )

For use as packing at the hub of sealing fittings, tamp packing fiber bet ween and aroun d conductors where they enter fitting to
prevent leakage of the liquid cement. Leave enough space in the fitting for length e quivalent to the inside diameter of the
conduit but, not less than 5/8”.

Caution: Avoid contact may cause lung, eye or skin irritation. Us e adequate ventilation, prolonge d breathing or
ingestion may cause internal obstruction, seek medical car e. Use protective gl oves, long sleev e and m ask if dust
or fiber is irritating. Contact with eyes or skin may cause skin burn, flush with water for 15 minutes.

Directions for use of Explosion Proof Sealing Cement:

1. Water-mix sealing compound should not be poured or installed at temperature below 40F (4C).

2. Maintain temperature at or above 40F for at least 72 hours after pouring.

3. CSA certified when used with any CSA certified sealing fitting.

4. Adaco No. 1 sealing cement must be used as a part of any Adalet UL listed fitting.

5. Tamp packing fiber between and around conductors at entry to the sealing fitting to prevent leakage of liquid cement.

6. Make sure conductors are not in contact with each other or with the wall of fitting.

7. Leave space in the fitting for a sealing length equivalent to the thread size of the conduit seal but not less than 5/8”.

8. Fill the marked shipping container with clean cold water to the “water line” [35 ml to be precise].

9. Do not exceed the required amount of water.

10. Gradually pour cement from the plastic bag into the water and stir thoroughly for proper mixture.

11. Fill fitting completely within five (5) minutes after mixing, then tamp with blunt stick to expel any air bubbles.

12. Close up any opening in the fitting to insure integrity of the seal.

13. Fittings requiring more than 10 oz. of cement must be filled from a single mixture of cement and water.
DO NOT POUR IN STAGES.

14. Allow cement at least 72 hours to cure.

15. Caution: At least five threads must engage on all fill plugs.

To reorder sealing cement kit, specify P/N ENCL-1071-KIT

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Advanced Instruments Inc.

Appendix B

Matching - LCD Display with 4-20mA Output

In rare instances the 4-20mA signal output may n ot agree with the reading displayed on the LCD. The Output Zero and Output
Span features enable the user to adjust the 4mA and 20 mA signal output matching with the reading displayed b y the LCD.

For optimum accuracy make two separate adjustments as follows:

1. OUTPUT ZERO feature: To adjust the 4mA signal output and requires zero gas.

2. OUTPUT SPAN feature: To adjust the 20mA signal output and requires span gas near full range.
Note: In the field or in the absence of the preferred gases, use the OUTPUT SPAN feature and adju st the 20mA signal output

using the span gas available.

Procedure – regardless of type of adjustment:

1. When you select OUTPUT ZERO OR OUTPUT SPAN, the microprocessor defaults to 100% to start.

2. The “actual” 4-20mA signal output will be adjusted to the “theoretical” value of the LCD display.

3. Adjustment general rule:
a) If the actual 4-20mA value < the theoretical LCD value, the adjustment value will be > 100%.
b) If the actual 4-20mA value > the theoretical LCD value, the adjustment value will be < 100%.

4. Convert the “actual” reading of the LCD display to the “theoretical” 4-20mA as follows:
a) Divide the “actual” (% or percent) LCD reading by the value of the span gas available.
b) Multiply 16mA (20mA – 4mA) times the “result of a.”
c) Add 4mA plus the “result of b.” to obtain the “theoretical” 4-20mA signal output value.

5. Adjustment value: Divide the theoretical by the actual 4-20mA values and multiply by 100.

6. Enter the adjustment value via OUTPUT ZERO or OUTPUT SPAN routines described below.

Adjust 4 mA with Zero O

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

2

>>>

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN

OUTPUT ZERO

CALIBRATION

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Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT ZERO.
Press the ENTER key to select the highlighted menu option.
The following display appears:

100.0
OUTPUT ZERO OFFSET
PRESS UP OR DOWN

TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN

Enter the calculated adjustment value
NOTE: Once the initial adjustment is made and checked at the PLC it may be necessary to fine tune the initial a djustment by

repeating. Any additional percent error must be added or subtracted from the initial adjustment value

000.0
OUTPUT ZERO OFFSET
PRESS UP OR DOWN

TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN

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 adjustment OUTPUT ZERO OFFSET value.

Press the ARROW keys to enter each the numerical value of each digit of the adjustment OUTPUT ZERO OFFSET value.
Repeat until the complete OUTPUT ZERO OFFSET value has been entered.
Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key.
The system returns to the SAMPLING mode.

Adjust 20 mA at known Oxygen Concentration

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

>>>

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO

OUTPUT SPAN

OUTPUT ZERO

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Advance the reverse shade cursor using the ARROW keys to highlight OUTPUT 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

Enter the calculated adjustment value, refer to example described above.
Note: Once the initial adjustment is made and check ed at the PLC it may be necessary to fine tune the initial adjustment by

repeating. Any additional percent error must be added or subtracted from the initial adjustment value

064.0
OUTPUT SPAN OFFSET
PRESS UP OR DOWN

TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN

.
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 adjustment OUTPUT SPAN OFFSET value.
Press the ARROW keys to enter the numerical value of each digit of the OUTPUT SPAN OFFSET value.
Repeat until the complete OUTPUT SPAN OFFSET value has been entered.
Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key.
The system returns to the SAMPLING mode.

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