Analytical Industries GPR-1535 GB User Manual

Advanced Instruments Inc.

GPR-1535 GB

PPM Oxygen Transmitter

Owner’s Manual

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

Table of Contents

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

Advanced Instruments Inc.

1 Introduction

Your new oxygen transmitter incorporated 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 variety of industrial oxygen
applications. To obtain maximum performance from your new oxygen transmitter, 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 transmitter for
superior performance and minimal cost of ownership. This transmitter 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 transmitter may be found on the inside the transmitter. 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

Date: Customer: Order No.: Pass

Model GPR-1535 GB PPM Oxygen Transmitter S/N ________________

Sensor

Accessories
Configuration

Range(s): 0-10 PPM, 0-100 PPM, 0-1000 PPM, 0-1%, 0-25% (air calibration only)
Power: 12-24V DC two wire loop power
Barometric pressure compensation

( ) GPR-12-100-M ppm Oxygen Sensor
( ) XLT-12-100-M ppm Oxygen Sensor S/N___________________

Owner’s Manual
( ) A-1161-L1 PCB Assembly, Main / Display Software Ver. __________

A-1182 PCB Assembly, Interconnection
( ) BARR-1001 Barrier, Intrinsic Safety (ATEX Intrinsic Safety Certified)

B-3170 Glove Box Housing Assembly

Test - Electronics Default zero (without sensor)
Default span @ 600uA or 300uA
Analog signal output 4-20mA full scale
Test - Gas Phase Calibrates with adequate span adjustment within 10-50% FS
Baseline drift on zero gas < ± 2% FS over 24 hour period
Noise level < ± 1.0% FS
Span adjustment within 10-50% FS
Final Overall inspection for physical defects

Options
Notes

When operated in conjunction with the manufacturer’s recommended optional intrinsic safety barriers the GPR-1535 GB meets
the intrinsic safety standards required for use in Class 1, Division 1, Groups C, D hazardous areas.

The GPR-1535 GB is also available in a version, requiring optional intrinsic safety barriers, that has been certified to ATEX
Directive 94/9/EC, Ex II 1 G Ex ia IIB T4 Tamb -20⁰C to + 50⁰C

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Advanced Instruments Inc.

3 Safety

General

This section summarizes the essential precautions applicable to the GPR-1500AIS ppm Oxygen Transmitter. Additional
precautions specific to individual transmitter are contained in the following sections of this manual. To operate the transmitter
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 to Caution 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.

Read Instructions: Before operating the transmitter 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 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.

Pressure and Flow

Inlet Pressure: GPR-1535 GB PPM Oxygen Transmitter is designed for measuring the controlled atmosphere inside a glove
box. Calibration requires a flowing sample using the Glove Box Housing Assembly (refer to photo section 4 Specification) which
is equipped with 1/8” tube fitting connections and are intended to operate at positive pressure regulated to between 5-30 psig.

Outlet Pressure: The sample gas vent pressure should be atmospheric.

Installation

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.

Mounting: The transmitter is approved for indoor use. Mount as recommended by the manufacturer.
Power: Supply power to the transmitter only as rated by the specification or markings on the transmitter enclosure. The wiring

that connects the transmitter to the power source should be installed in accordance with recognized electrical standards and so
they are not pinched particularly near the power source and the point where they attach to the transmitter. Never yank wiring
to remove it from a terminal connection. Power consumption is 30 watts, 40 watts with the optional DC powered heater.

Operating Temperature: The maximum operating temperature is 45º C on an intermittent basis unless the user is willing to
accept a dramatic reduction in expected sensor life – refer to analyzer specification where expected sensor life is specified at
less than 1000 ppm oxygen at 25°C and 1 atmosphere of pressure.

Heat: Situate and store the transmitter away from sources of heat.
Liquid and Object Entry: The transmitter 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 transmitter.
Handling: Do not use force when using the switches and knobs. Before moving your transmitter be sure to disconnect the

wiring/power cord and any cables connected to the output terminals located on the transmitter.

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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.

Nonuse Periods: If the transmitter 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.

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4 Features & Specifications

Specifications and pricing are subject to change without notice. See last page for current specifications.

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5 Operation

Principle of Operation

The GPR-1535 GB incorporates a variety of ppm range advanced galvanic fuel cell type sensors. The transmitter is configured in
a general purpose NEMA 4 rated enclosure and meets the intrinsic safety standards required for use in Class 1, Division 1,
Groups C, D hazardous areas when operated in conjunction with the manufacturer’s recommended intrinsic safety barriers.

Advanced Galvanic Sensor Technology:

The sensors function on the same principle and are specific for oxygen.
They measure the partial pressure of oxygen from low ppm to 100%
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 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 over all 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 an extremely versatile oxygen sensing technology.
Sensors for low ppm analysis recover from air to ppm levels in minutes,
exhibit longer life and reliable quality. 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. Another significant
development involves expanding the operating temperature range for
percentage range sensors from -30°C to 50°C.

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.

A 4-20mA signal output is provided from a two-wire 12-28VDC loop power source such as a PLC and is represented on full scale
oxygen readings to an external device. When operated in conjunction with the manufacturer’s recommended optional intrinsic
safety barriers the GPR-1535 GB meets the intrinsic safety standards required for use in Class 1, Division 1, Groups C, D
hazardous areas.

The GPR-1535 GB is also available in a version, requiring optional intrinsic safety barriers, that has been certified to ATEX
Directive 94/9/EC, Ex II 1 G Ex ia IIB T4 Tamb -20⁰C to + 50⁰C

Sample System:

The GPR-1535 GB is supplied with a unique Glove Box Housing Assembly that also includes a mounting bracket for sampling
(see photo section 4 Specifications) and flow housing with valves for calibration.

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 [e-mail]

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Advanced Instruments Inc.

Installation Considerations

Gas Sample Stream: Ensure the gas stream or composition of the controlled atmosphere of the application is consistent with
the specifications and review the application conditions before initiating the installation. Consult the factory if necessary to
ensure the sample is suitable for analysis.

Expected Sensor Life: With reference to the publish specification located as the last page of this manual, the expected life of
all oxygen sensors is predicated on oxygen concentration (< 1000 ppm or air), temperature (77°F/25°C) and pressure (1
atmosphere) in “normal” applications. Deviations are outside the specifications and will affect the life of the sensor. As a rule of
thumb sensor life is inversely proportional to changes in the parameters.

Materials: Assemble the necessary zero, purge 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 ppm and percentage range (above or below ambient air) analysis; hardware for mounting.

Temperature: The sample or atmosphere must be controlled within the operating temperature parameters in section 4
Specifications. Note: Operating the sensor above the nominal specification of 25⁰C or 77⁰F has an exponential affect on sensor
life, 2.5% per ⁰C.

Pressure & 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 a controlled atmosphere.

Sample systems and/or flowing gas samples are generally required for applications involving oxygen measurements or
calibration below ambient air to maintain the integrity of the sample. In these situations, the use of stainless steel tubing and
fittings is critical to maintaining the integrity of the gas stream to be sampled and the inlet pressure must always be higher than
the pressure at the outlet vent which is normally at atmospheric pressure.

A flow indicator with an integral metering valve upstream of the sensor is recommended as a means of controlling the flow rate
of the sample gas. A flow rate of 2 SCFH or 1 liter per minute is recommended for optimum performance.

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). To avoid generating a vacuum on the sensor (as described above) during operation, always select and install
the vent fitting first and remove the vent fitting last.

Application Pressure - Positive: A flow indicator with integral metering valve positioned upstream of the sensor is
recommended for controlling the sample flow rate between 1-5 SCFH. To reduce the possibility of leakage for low ppm
measurements, position a metering needle valve upstream of the sensor to control the flow rate and position a flow indicator
downstream of the sensor. If necessary, a pressure regulator (with a metallic diaphragm is recommended for optimum
accuracy, the use of diaphragms of more permeable materials may result in erroneous readings) upstream of the flow control
valve should be used to regulate the inlet pressure between 5-30 psig.

Application Pressure - Atmospheric or Slightly Negative: For accurate ppm range oxygen measurements, an optional
external sampling pump should be positioned downstream of the sensor to draw the sample from the process, by the sensor
and out to atmosphere. A flow meter is generally not necessary to obtain the recommended flow rate with most sampling
pumps.

Caution: If the transmitter is equipped with an optional flow indicator with integral metering valve or a metering flow control
valve upstream of the sensor - open the metering valve completely to avoid drawing a vacuum on the sensor and placing an
undue burden on the pump.

If pump loading is a c
so the sample flow rate is within the above parameters.

onsideration, a second throttle valve on the pump’s inlet side may be necessary to provide a bypass path

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