Analytical Industries GPR-15 AXP User Manual

ATEX Certified Explosion Proof

Advanced Instruments Inc.

GPR-18MS / 18 / 28

Oxygen Analyzer

Owner’s Manual

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

Advanced Instruments Inc.

Table of Contents

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

Declaration of Conformity Appendix A
ATEX Certificate (English) 18MS / 18 / 28 Appendix B
ATEX Certificate (French) 18MS / 18 / 28 Appendix Bf
CE Certificate EN 61326 Minimum Immunity Appendix C
CE Certificate EN 61010-1 Safety Requirements Appendix D
ATEX Certificate Manufacturer’s Enclosure & Controllers Appendix E
Instructions Installation & Maintenance Enclosure & Controllers Appendix F
ATEX Certificate & Instructions Flame Arrestors Appendix G
Instructions Explosion Proof Electrical Connections Appendix H
Drawings Appendix I

The appendices referenced above are an integral part of the documentation, installation and maintenance of this ATEX certified
oxygen analyzer. It is important that users review these documents before proceeding.

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1 Introduction

Your new ATEX Certified Explosion Proof Oxygen Analyzer is a precision device designed to give you years of use. It has been
designed to incorporate several types of oxygen sensors enabling user’s to select an analysis range appropriate for their
application with the confidence of an ATEX certified analyzer system. Analysis ranges available with selected oxygen sensors:

GPR-18MS analyzes oxygen levels from 10 ppb (parts per billion) to 1,000 ppm (parts per million) and features the new “Pico­Ion” Sensor Technology developed exclusively by Advanced Instruments Inc.

GPR-18 analyzes oxygen levels from 100 ppb to 1% (10,000 ppm) and features the advanced galvanic type ppm oxygen sensor.
GPR-28 analyzes oxygen levels from 0.05% (500 ppm) to 95% and features the advanced galvanic type percent oxygen sensor.
Specifications of the individual analyzers and discussion of the sensors can be found in sections 4 and 5 .
These analyzers is designed to measure the oxygen concentration in inert gases, gaseous hydrocarbons, hydrogen and a variety

of gas mixtures. The galvanic sensors can be configured for measuring 0-100% oxygen concentration in CO2 and acid gases. 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; and, to design the analyzer
for superior performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer prior to
shipment for best performance.

However, 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. 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-18MS Explosion Proof ppm O2 Analyzer S/N ______________________

( ) GPR-18 Explosion Proof ppm O2 Analyzer S/N ______________________
( ) GPR-28 Explosion Proof O2 Analyzer S/N ______________________

Sensor: ( ) GPR-12-2000MS ppm Oxygen Sensor S/N ______________________

( ) GPR or ( ) XLT-12-333 ppm Oxygen Sensor S/N ______________________
( ) GPR-11-32 or ( ) XLT-11-24 Oxygen Sensor S/N ______________________

Approvals: ATEX certified Ex d IIB T6 or Ex d IIB+H2; certificate #INERIS07ATEX0025X

EN 61326 Minimum Immunity Test
EN 61010-1:2001 Low Voltage Directive (see Appendix A, B, C, D)

Accessories: Owner’s Manual
5/16 Open end wrench
Configuration: A-1107-M PCB Assembly Main / Display
A-1106-M PCB Assembly Power / Relay
Range: ( ) GPR-18MS 0-1 ppm, 0-10 ppm, 0-100 ppm, 0-1000 ppm

( ) GPR-18 0-10 ppm, 0-100 ppm, 0-1000 ppm, 0-25% (air calibration only)
( ) GPR-28 0-1%, 0-5%, 0-10%, 0-25%

Wetted parts: stainless steel ( ) Manual flow and bypass valves, flow indicator

( ) Manual flow meter (with integral metering valve)

Standard power: ( ) 100/110 VAC or ( ) 220/240 VAC
Heater system: ( ) 100/110 VAC or ( ) 220/240 VAC; controller set at 85° F

Test – Electronics: LED indicators: range, alarms
4-20mA offset
Alarm relays activate/deactivate with changes in O2 concentration
Analog signal output 0-1V and 4-20mA
Range ID contacts (optional)
Test – Gas: Baseline drift on zero gas < ± 2% F.S. over 24 hour period
Noise level < ± 1.0% F.S.
Span adjustment within 10-50% F.S.
Peak to peak over / under shoot < 0.5% F.S.
Final: Overall inspection for physical defects; place SAMPLE/BYPASS valve in BYPASS position

Options:
Notes:

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3 General Safety & Installation

Safety

This section summarizes the basic precautions applicable to all analyzers. Additional precautions specific to individual analyzer
are contained in the following sections of this manual. To operate the analyzer safely and obtain maximum performance follow
the basic guidelines outlined in this Owner’s Manual.

Caution: This symbol is used throughout the Owner’s Manual 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 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 Instructions: Follow all warnings on the analyzer, accessories (if any) and in this Owner’s Manual.

Observe all precautions and operating instructions. Failure to do so may result in personal injury or damage to the analyzer.

Heat: Situate and store the analyzer away from sources of heat.
Liquid and Object Entry: The analyzer should not be immersed in any liquid. Care should be taken so that liquids are not

spilled into and objects do not fall into the inside of the analyzer.
Handling: Do not use force when using the switches and knobs. Before moving your analyzer be sure to disconnect the

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

Maintenance

Serviceability: Except for replacing the oxygen sensor, there are no parts inside the analyzer 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 this Owner’s Manual. 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
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 detailed by section 9, 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: Disconnect the power when the analyzer is left unused for a long period of time.

Installation

Gas Sample Stream: Ensure the gas stream composition of the application is consistent with the specifications and review the
application conditions before initiating the installation. Consult the factory to ensure the sample is suitable for analysis.
Contaminant Gases: A gas scrubber and flow indicator with integral metering valve are required upstream of the of the
analyzer to remove interfering gases such as oxides of sulfur and nitrogen or hydrogen sulfide that can produce false readings,
reduce the expected life of the sensor and void the sensor warranty if not identified at time of order placement. Installation of a
suitable scrubber is required to remove the contaminant from the sample gas to prevent erroneous analysis readings and

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damage to the sensor or optional components. Consult the factory for recommendations concerning the proper selection and
installation of components.

Expected Sensor Life: With reference to the publish specification located in section 4 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. As a rule of thumb sensor life is inversely proportional to changes in the parameters.
Deviations are outside the specifications and will affect the life of the sensor, with respect to Pico-Ion sensors avoid exposure to
oxygen levels above 1000 ppm. Failure to do will result in damage to the sensor.

Accuracy & Calibration: Refer to section 5 Operation, Calibration. Analyzers equipped with Pico-Ion oxygen sensors have a
maximum range of 0-1000 ppm reflecting its high signal output capability, DO NOT CALIBRATE THE GPR-18MS WITH AIR.

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.

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 1,800ºF to ambient. The
maximum operating temperature is 45º C on an intermittent basis unless the user is willing to accept a reduction in expected
sensor life – refer to analyzer specification - where expected sensor life is specified at an oxygen concentration less than 1000
ppm oxygen for ppm analyzers and air (20.9% oxygen) for percent analyzers, but in all instances at 25°C and 1 atmosphere of
pressure. Expected sensor varies inversely with changes in these parameters.

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 ambient air (such as a confined
space such in a control room or an open area such as a landfill or bio-pond). The following is applicable to analyzers

equipped with galvanic oxygen sensors, GPR-18 and GPR-28. With respect to analyzers equipped with Pico-Ion
oxygen sensors, GPR-18MS refer to the analyzer’s specifications in section 4.

Analyzers designed for in-situ ambient or area monitoring have no real inlet and vent pressure because the sensor is exposed
directly to the sample gas and intended to operate at atmospheric pressure, however, slightly positive pressure has minimal
effect on accuracy.

Inlet Pressure: Analyzers designed for flowing samples under positive pressure or pump vacuum (for samples at atmospheric
or slightly negative atmospheres) that does not exceed 14” water column are equipped with bulkhead tube fitting connections
on the side of the unit (unless otherwise indicated, either fitting can serve as inlet or vent) and are intended to operate at
positive pressure regulated to between 5-30 psig although the rating of the fitting itself is considerably higher. Caution: If the
analyzer is equipped with an optional H2S scrubber, inlet pressure must not exceed 30 psig.

Outlet Pressure: In positive pressure applications the vent pressure must be less than the inlet, preferably atmospheric.
Sample systems and flowing gas samples are generally required for applications involving oxygen measurements at a pressure

other than ambient air. 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. Flow Through Configuration: The sensor is exposed to sample gas that must flow or be
drawn through metal tubing inside the analyzer. The internal sample system includes 1/8” compression inlet and vent fittings, a
stainless steel sensor housing with an o-ring seal to prevent the leakage of air and stainless steel tubing.

Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH generate
backpressure and erroneous oxygen readings because the diameter of the integral tubing cannot evacuate the sample gas at
the higher flow rate. The direction the sample gas flows is not important, thus either tube fitting can serve as the inlet or v
just not simultaneously.

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.

ent –

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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.

Caution: If the analyzer is equipped with a H2S scrubber as part of an optional sample conditioning system, inlet pressure
must not exceed 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 analyzer 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 consideration, a second throttle valve on the pump’s inlet side may be
necessary to provide a bypass path so the sample flow rate is within the above parameters.

Recommendations to avoid erroneous oxygen readings and damaging the sensor:

¾ 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 (thus voiding
the sensor warranty).

¾ Assure there are no restrictions in the sample or vent lines
¾ Avoid drawing a vacuum that exceeds 14” of water column pressure – unless done gradually
¾ Avoid excessive flow rates above 5 SCFH which generate backpressure on the sensor.
¾ Avoid sudden releases of backpressure that can severely damage the sensor.
¾ Avoid the collection of liquids or particulates on the sensor, they block the diffusion of oxygen into the sensor
¾ If the analyzer is equipped with an optional integral sampling pump (positioned downstream of the sensor) and a flow

control metering valve (positioned upstream of the sensor), completely open the flow control metering valve to avoid
drawing a vacuum on the sensor and placing an undue burden on the pump.

Moisture & Particulates: Installation of a suitable coalescing or particulate filter is required to remove condensation, moisture
and/or particulates from the sample gas to prevent erroneous analysis readings and damage to the sensor or optional
components. Moisture and/or particulates do not necessarily damage the sensor, however, collection on the sensing surface can
block or inhibit the diffusion of sample gas into the sensor resulting in a reduction of sensor signal output – and the appearance
of a sensor failure when in fact the problem is easily remedied by blowing on the front of the sensor. Consult the factory for
recommendations concerning the proper selection and installation of components.

Moisture and/or particulates generally can be removed from the sensor by opening the sensor housing and either blowing on
the sensing surface or gently wiping or brushing the sensing surface with damp cloth. Caution: Minimize the exposure of ppm
sensors to air during this cleaning process. Air calibration followed by purging with zero or a gas with a low ppm oxygen
concentration is recommended following the cleaning process. Moisture and/or particulates generally can be removed from the
sample system by flowing the purge gas through the analyzer at a flow rate of 4.5-5 SCFH for an hour.
Mounting: The analyzer is approved for indoor use, outdoor use requires optional enclosures, consult factory. Mount as
recommended by the manufacturer.

Gas Connections: Inlet and outlet vent gas lines for ppm analysis require 1/8” or ¼” stainless steel compression fittings; hard
plastic tubing with a low permeability factor can be used percentage range measurements.

Power: Supply power to the analyzer only as rated by the specification or markings on the analyzer enclosure. The wiring that
connects the analyzer to the power source should be installed in accordance with recognized electrical standards. Ensure that is
properly grounded and meets the requirements for area classification. Never yank wiring to remove it from a terminal
connection. AC powered analog analyzers consume 5 watts. Optional 110V and 220V heaters AC powered heaters consume an
additional 100-150 watts.

- wipe away.

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4 Features & Specifications

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5 Operation

Principle of Operation

This ATEX Certified Explosion Proof Oxygen Analyzer is a precision device designed to give you years of use. It has been
designed to incorporate several types of oxygen sensors enabling user’s to select an analysis range appropriate for their
application with the confidence of an ATEX certified analyzer system. Analysis ranges available with selected oxygen sensors:

GPR-18MS analyzes oxygen levels from 10 ppb (parts per billion) to 1,000 ppm (parts per million) and features the new “Pico­Ion” Sensor Technology developed exclusively by Advanced Instruments Inc.
GPR-18 analyzes oxygen levels from 100 ppb to 1% (10,000 ppm) and features the advanced galvanic type ppm oxygen sensor.
GPR-28 analyzes oxygen levels from 0.05% (500 ppm) to 95% and features the advanced galvanic type percent oxygen sensor.

Breakthrough Sensor Technology:

A breakthrough sensor technology measures the partial pressure of oxygen from less than 10 ppb to 1000 ppm level in inert
gases, gaseous hydrocarbons, helium, hydrogen and mixed gas streams. The “Pico-Ion” sensor design and chemistry have been
combined to produce a significant advancement in oxygen sensor technology.

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Oxygen, the fuel for these electrochemical transducers, 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 four
ranges and remains virtually constant over its useful life. The sensor requires no maintenance or electrolyte addition and is
easily and safely replaced at the end of its useful life.

Advanced Galvanic ppm 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 1% levels in inert gases, gaseous hydrocarbons, helium, hydrogen, mixed gases, acid gas streams and ambient air.
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, excellent compatibility
with CO

Advanced Galvanic Percent Sensor Technology

The sensors function on the same principle and are specific for oxygen. They measure the partial pressure of oxygen from low
percent levels (0.05%) to 100% levels in inert gases, gaseous hydrocarbons, helium, hydrogen, mixed gases, acid gas streams
and ambient air.

Proprietary advancements in design and chemistry add significant advantages to an extremely versatile oxygen sensing
technology. Extending 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 the first galvanic oxygen sensor
capability of continuous oxygen purity measurements and expanding the operating temperature range from -40°C to 50°C,
excellent compatibility with CO
competition.

and acid gases (XLT series) and reliable quality giving them a significant advantage over the competition.

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and acid gases (XLT series) and reliable quality giving them a significant advantage over the

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Electronics

The signal generated by the sensor is processed by state of the art low design and integrated circuits. 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 an
isolated 4-20mA and 0-1V signal output jack.

Sample oxygen is analyzed very accurately. Overall performance is enhanced by an optional temperature controlled heater
system that controls the temperature around the sensor. Response time of 90% of full scale is less than 20 seconds on the 0-1
ppm range and on higher ranges (actual experience may vary due to the integrity of sample line connections, dead volume and
flow rate selected).

Power for the on-line analyzers is supplied by an integral power supply. Connections of the appropriate AC line voltage are hard
wired to screw type terminal blocks. Power requirements related to 100/110VAC and 220/230VAC heaters must be specified at
order placement.

Sample Systems

The sample must be properly presented to the sensor to ensure an accurate measurement. The GPR-18MS and GPR-18 are
designed with a sample system consisting of stainless steel and glass wetted parts,a uniquely designed leak tight sensor
housing that has been proven capable of less than 1 ppb oxygen measurements (using the Pico-Ion sensor) and a bypass
sample system that complements the performance (fast recovery from exposure to high oxygen levels) capabilities of the sensor
and enables the user to isolate the sensor from exposure to high oxygen concentrations which results is a substantial increase is
user productivity.

This bypass feature has two important features: one, the sensor can be isolated from exposure to high oxygen levels when
changing sample lines, during transport and during standby intervals; and, two, it enables the user to purge newly connected
gas lines of the oxygen trapped inside. The result is an analyzer that comes on-line at ppb or ppm levels in a matter of minutes
and provides users with a significant increase in productivity.

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