Analytical Industries GPR-1600 MS User Manual

Download

Advanced Instruments Inc.

GPR-1600 MS

ppm Oxygen Analyzer

Owner’s Manual

2855 Metropolitan Place, Pomona, California 91767 USA ♦ Tel: 909-392-6900, Fax: 909-392-3665, e-mail: info@aii1.com

Table of Contents

Introduction 1 Quality Control Certification 2 Safety & Installation 3 Features & Specifications 4 Operation 5 Maintenance 6 Spare Parts 7 Troubleshooting 8 Warranty 9 Material Safety Data Sheets 10 Correlating reading - LCD display to 4-20mA output Appendix B

Advanced Instruments Inc.

1 Introduction

Your new oxygen analyzer is a precision piece of equipment designed to give you years of use in variety of industrial oxygen applications.

This analyzer is designed to measure the oxygen concentration in inert gases, gaseous hydrocarbons, hydrogen, and a variety of gas mixtures. In order to derive maximum performance from your new oxygen analyzer, please read and follow the guidelines provided in this Owner’s Manual.

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: _______________________ Every effort has been made to select the most reliable state of the art materials and components designed for superior

performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer 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.

Advanced Instruments Inc. appreciates your business and pledge to make effort to maintain the highest possible quality standards with respect to product design, manufacturing and service.

Advanced Instruments Inc.

2 Quality Control Certification

Date:

Model: GPR-1600MS ppm Oxygen Analyzer S/N _____________________ Sensor: GPR-12-2000MS ppm Oxygen Sensor S/N _____________________

Accessories: Owner’s Manual

Configuration: Ranges: 0-1 ppm, 0-10 ppm, 0-100 ppm, 0-1000 ppm

( ) Stainless steel sensor housing, manual flow control and bypass valves, ¼” compression

Temperature controlled heater system 85°F specify: ( ) 110VAC ( ) 220VAC ( ) Delete Power: 100/120/220/250 VAC (universal without temperature controlled heater systems) Enclosure: ( ) Std. panel mount (“T”) 7.5x10.8x12”; ( ) “TO” option 7.75x 7.75x12”

Test System start-up diagnostics satisfactory Auto/manual range Alarm relays activate/deactivate with changes in O2 concentration Alarm bypass Analog outputs: 4-20mA signal output Range ID: ( x ) 4-20mA or ( x ) 5x relay contacts reflects range changes Recovery from air to < 10 ppm in < 15 minutes Baseline drift on zero gas < ± 2% FS over 24 hour period Noise level < ± 1.0% FS Span adjustment within 10-50% FS Peak to peak over/under shoot < 0.5% FS Overall inspection for physical defects

Options Label analyzer “Oxygen Service” in accordance with P-1507 Rev-1; see certificate next page. Notes

Customer: Order No.:

CABL-1008 Power Cord TOOL-1001 5/16” Combination Wrench

A-1146-20 PCB Assembly Main / Display Software V. ______ ( ) A-1174 PCB Assy Power Supply / Interconnect, 4-20mA Range ID ( ) A-1174 PCB Assy Power Supply / Interconnect, 5x Relay Contacts Range ID

type fittings for sample inlet and vent ( ) Delete bypass valve from above (T and TO options) ( ) Sample, span, zero inlet solenoid valves

( ) Bezel for 19” rack mmount 19x12x12” option ( ) GPR-1600MS-W option general purpose wall mount 12x12x8” ( ) GPR-1600MS-W306 option general purpose panel mount 18.2x16x10”

Pass

Advanced Instruments Inc.

Certificate of Cleaning

Oxygen Service

Standard: Manufacturing Procedure No. P-1057 Rev-1,

Compressed Gas Association, Publication: G-4.1 Edition 4, Title: Cleaning Equipment for Oxygen Service, Published 1/1/1996 and related publications

Mfg. Item No.: GPR-1600MS Series Description: ppm Oxygen Analyzer

Serial No.: Customer: Purchase Order:

Quantity: 1 of Warranty Date: 12 months from ______________

The undersigned warrants on behalf of Manufacturer that the product identified above conforms to the manufacturing, testing and packaging criteria set forth by the ‘Standard’ specified above.

___________________________ ___________________________ ___________________________

Date:

______________ Place: Pomona, CA By print name: Signature: Title:

Advanced Instruments Inc.

3 Safety Guidelines

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.

Advanced Instruments Inc.

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 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 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. 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. 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-1600MS WITH AMBIENT 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 a control room or open area such as a landfill or bio-pond). The following is applicable to analyzers equipped with Pico-Ion UHP and MS oxygen sensors, also refer to the analyzer’s specifications.

Sample systems and flowing gas samples are generally required for applications involving oxygen measurements below 1% and 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.

A flow valve upstream (flow indicator positioned downstream) of the sensor is recommended as a means of controlling the flow rate of the sample gas, minimizing potential air leaks and providing optimum performance.

Caution: The superior performance characteristics of the Pico-Ion Series oxygen sensor include:

¾ LDL (lower detectable limit) b ¾ Excellent stability, ¾ Fast recovery from high oxygen upset conditions, ¾ 24 month operating life, ¾ No maintenance

Flow Rate: For optimum performance, a flow rate of 1 SCFH at 30 psig is recommended.

elow 10 ppb,

Advanced Instruments Inc.

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 4” 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 20-50 psig although the rating of the fitting itself is considerably higher.

Outlet Pressure: In positive pressure applications the vent pressure must be less than the inlet, preferably atmospheric. Application Pressure - Positive: 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 20-50 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 (vacuum should no exceed 4” water column) 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. 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 4” of water column pressure – unless done gradually ¾ Avoid excessive flow rates above 3 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, digital analyzers 50 watts without optional heaters. Optional 110V and 220V heaters AC powered heaters consume an additional 100-150 watts; DC powered digital analyzers consume 30 watts, 40 watts with the optional DC powered heater.

- wipe away.

Advanced Instruments Inc.

4 Features & Specifications

Advanced Instruments Inc.

5 Operation

Principle of Operation

The GPR-1600MS ppm Oxygen Analyzers incorporates a proprietary Pico-Ion oxygen sensor. It is configured for panel mounting and requires a 7.5x10.8” (T configuration) cutout with 4 holes for the analyzer’s front panel. Optional configurations include a panel mount (TO configuration) 7.75x7.75” with cutout; 19” bezel for rack mounting either the T or TO; 12x12x8” wall mount enclosure; 18.2x16x10” panel mount configuration using the wall mount enclosure. Contact the factory for additional information on options. All configurations are tested and calibrated by the manufacturer prior to shipment. The GPR-1600MS analyzers and sensors are CE certified and manufactured under a Quality Assurance System certified by an independent agency to ISO 9001:2000 standards. However, the main feature remains the:

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.

Advanced Instruments Inc.

Oxygen, the fuel for this electrochemical transducer, 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.

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.

Additional features of the micro-processor based electronics include manual or auto ranging, auto-zero and auto-cal, isolated 420mA signal for signal output and range ID, separate relay contacts rated 30VDC max @ 1A are provided for the alarm feature and an optional range ID feature (auto-zero/auto-cal with relay contacts for Range ID is special order, so . Whenever the analyzer is calibrated, a unique algorithm predicts and displays a message indicating a ‘weak sensor’ suggesting the sensor be replaced in the near future.

Sample System

The sample must be properly presented to the sensor to ensure an accurate measurement. In standard form the GPR-1600MS is designed with a sample system that complements the performance capabilities of the Pico-Ion oxygen sensor and enables the user to isolate the sensor from exposure to high oxygen concentration 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 h igh oxygen levels when changing sample lines, during transport and during standby intervals making it ideal for mobile cart applications. 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 levels in a matter of minutes and provides users with a significant increase in productivity.

For ppb and ppm trace oxygen measurements, the sensor is exposed to sample gas that must flow or be drawn through the analyzer’s internal sample system. This unique sample system, when operated accordingly to the instructions in this Owner’s Manual, can significantly increase user productivity by minimizing the sensor’s exposure to ambient air or high oxygen concentrations which contribute to the significant amount of downtime associated with competitive analyzers.

The advantages of the bypass sample system include:

¾ Supplying the analyzer with the sensor it was qualified with. ¾ Isolating the sensor during transport, calibration and maintenance intervals when changing gas line connections. ¾ Isolating the sensor from exposure to high oxygen levels during upset conditions which extends sensor life. ¾ Purging the air (or high oxygen levels above 1,000 ppm) trapped in the gas lines following a process upset.

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 info@aii1.com

Advanced Instruments Inc.

Calibration & Accuracy Overview

Single Point Calibration: As previously described the galvanic oxygen sensor generates an electrical current proportional to the oxygen concentration in the sample gas. In the absence of oxygen the sensor exhibits an absolute zero, e.g. the sensor does not generate a current output in the absence of oxygen. Given these linearity and absolute zero properties, single point calibration is possible.

Pressure: Because sensors are sensitive to the partial pressure of oxygen in the sample gas their output is a function of the number of molecules of oxygen 'per unit volume'. Readouts in percent are permissible only when the total pressure of the sample gas being analyzed remains constant. The pressure of the sample gas and that of the calibration gas(es) must be the same (reality < 1-2 psi).

Temperature: The rate oxygen molecules diffuse into the sensor is controlled by a Teflon membrane otherwise known as an 'oxygen diffusion limiting barrier' and all diffusion processes are temperature sensitive, the fact the sensor's electrical output will vary with temperature is normal. This variation is relatively constant 2.5% per ºC. A temperature compensation circuit employing a thermistor offsets this effect with an accuracy of + independent of temperature. There is no error if the calibration and sampling are performed at the same temperature or if the measurement is made immediately after calibration. Lastly, small temperature variations of 10-15º produce < 1% error.

Accuracy:

producing 'percent of reading errors', illustrated by Graph A below, such as + of range resistors and the 'play' in the potentiometer used to make span adjustments and 2) those producing 'percent of full scale errors', illustrated by Graph B, such as + technology and the fact that other errors are 'spanned out' during calibration. Graph C illustrates these 'worse case' specifications that are typically used to develop an analyzer's overall accuracy statement of < 1% of full scale at constant temperature or < 5% over the operating temperature range. QC testing is typically < 0.5% prior to shipment.

Example 1: As illustrated by Graph A any error, play in the multi-turn span pot or the temperature compensation circuit, during a span adjustment at 20.9% (air) of full scale range would be multiplied by a factor of 4.78 (100/20.9) if used for measurements of 95-100% oxygen concentrations. Conversely, an error during a span adjustment at 100% of full scale range is reduced proportionately for measurements of lower oxygen concentrations.

In light of the above parameters, the overall accuracy of an analyzer is affected by two types of errors: 1) those

1-2% linearity errors in readout devices, which are really minimal due to today's

5% or better and generates an output function that is

5% temperature compensation circuit, tolerances

Advanced Instruments Inc.

Zero Calibration

In theory oxygen free sample gas. In reality

¾ Contamination or quality of the zero gas ¾ Minor leakage in the sample line connections ¾ Residual oxygen dissolved in the sensor’s electrolyte ¾ Tolerances of the electronic components

The Zero Offset capability of the analyzer is limited to 50% of lowest most sensitive range available with the analyzer. As part of our Quality Control Certification process, the zero capability of every ppm analyzer is qualified prior to shipment.

However, because the factory sample system conditions differ from that of the user, no ZERO OFFSET adjustment is made to analyzer by the factory

Recommendations:

¾ ZERO CALIBRATION is recommended only

¾ Determining the true ZERO CALIBRATION adjustment requires approximately 24 hours to assure the galvanic fuel cell

¾ Always calibrate at the same temperature and pressure of the sample gas stream. ¾ Caution: Prematurely initiating the ZERO CALIBRATION function can result in negative readings near zero. ¾ ZERO CALIBRATION should precede SPAN CALIBRATION. ¾ If a ZERO CALIBRATION adjustment is made during initial installation, it is normally not required again until the sample

¾ If a ZERO CALIBRATION adjustment has NOT been made as described above, perform the DEFAULT ZERO and DEFAULT

¾ ZERO CALIBRATION is not practical and not recommended for portable analyzers or measurements on higher ranges.

Span Calibration

Span Calibration involves adjusting the transmitter electronics to the sensor’s signal output at a given oxygen standard. Maximum drift from calibration temperature is approximately 0.11% of reading per °C. The frequency of calibration varies with the application conditions, the degree of accuracy required by the application and the quality requirements of the user. However, the interval between span calibrations should not exceed three (3) months.

Note: Regardless of the oxygen concentration of the standard used, the span calibration process takes approximately 10 minutes, however, the time required to bring a ppm analyzer back on-line can vary depending on a combination of factors and assumes exposure to a zero/purge/sample gas** with an oxygen content below the stated thresholds immediately after span calibration:

, the galvanic fuel cell type oxygen has an absolute zero meaning it produces no signal output when exposed to an

, expect the analyzer to generate an oxygen reading when sampling a zero gas due to:

for online analyzers performing continuous analysis below 5% of the lowest most sensitive range available with a ppm analyzer, e.g. analysis below 0.05 ppm on the 0-1 ppm range, 0.5 ppm on the 10 ppm range, or below 0.1% (1000 ppm) with a percent analyzer.

sensor has consumed the oxygen that has dissolved into the electrolyte inside the sensor while exposed to air or percentage levels of oxygen. After allowing the analyzer to stabilize with flowing zero gas (evidenced by a stable reading or horizontal trend on an external recording device) perform the DEFAULT ZERO function before the ZERO CALIBRATION function. For optimum accuracy, utilize as much of the actual sample system as possible.

system connections are modified or a new oxygen sensor is installed. Therefore the DEFAULT ZERO function is recommended only when performing a ZERO CALIBRATION and during troubleshooting and should not be repeated before routine subsequent SPAN CALIBRATION

SPAN functions when troubleshooting an analyzer and before SPAN CALIBRATION.

However, satisfying these users that the zero offset is acceptable for their application without the 24 hour wait can be accomplished by introducing a zero gas (or sample gas with a low ppm oxygen concentration) to the analyzer. Unless the zero gas is contaminated or there is a significant leak in the sample connections, the analyzer should read less than 100 ppm oxygen within 10 minutes after being placed on zero gas thereby indicating it is operating normally.

Advanced Instruments Inc.

* Refer to analyzer specifications for comparable data on the Pico-Ion UHP and MS oxygen sensors. Recommendations General:

¾ The interval between SPAN CALIBRATION should not exceed three (3) months. ¾ Always calibrate at the same temperature and pressure of the sample gas stream. ¾ If a ZERO CALIBRATION adjustment is made during initial installation, it is normally not required again until the sample

¾ If a ZERO CALIBRATION adjustment has NOT been made as described above, perform the DEFAULT ZERO and DEFAULT

SPAN functions when troubleshooting an analyzer and before SPAN CALIBRATION.

¾ Caution: Prematurely initiating the SPAN CALIBRATION function before the analyzer reading has stabilized can result in

erroneous readings. This is especially true when installing a new sensor that must adjust to the difference in oxygen concentrations. It should take about 2 minutes for the sensor to equilibrate in ambient air from storage packaging.

¾ For 'optimum SPAN CALIBRATION accuracy' use a span gas approximating 80% of the full scale range higher range than

the range of interest (normal use) to achieve the effect of “narrowing the error” by moving downscale as illustrated by Graph A in the Accuracy & Calibration section.

¾ SPAN CALIBRATION with a span gas approximating 5-10% of the full scale range near the expected oxygen concentration

of the sample gas is acceptable but less accurate than ‘optimum SPAN CALIBRATION accuracy’ method recommended – the method usually depends on the gas available.

¾ SPAN CALIBRATION at the same 5-10% of the full scale range for measurements at the higher end of the range (example:

calibrating an Oxygen Purity Analyzer in air at 20.9% oxygen with the intention of measuring oxygen levels of 50-100%) results in the effect of “expanding the error” by moving upscale as illustrated by Graph A and Example 1 in the Accuracy & Calibration section above and is not recommended. Of course the user can always elect at his discretion to accept an accuracy error of +

Recommendations Air Calibration:

¾ Do not calibrate an analyzer employing the Pico-Ion UHP or MS sensor, or, an oxygen purity sensor with air.

2-3% of full scale range if no other span gas is available.

Mounting the Analyzer

The standard GPR-1600MS is designed to be panel mounted and requires a cutout that accommodates the enclosure and 4 mounting bolts. The design also lends itself to 19” rack mounting with an optional bezel or wall mount enclosures as illustrated below.

Procedure:

1. The GPR-1600MS is designed for panel mounting directly to any flat vertical surface, wall or bulkhead plate with the appropriate cut out and four ¼” diameter holes for insertion of the mounting studs located on the back side of the front panel.

2. When mounting the analyzer position it approximately 5 feet off the floor for viewing purposes and allow sufficient room for access to the terminal connections at the rear of the enclosure.

Advanced Instruments Inc.

3. Note: The proximity of the analyzer to the sample point and use of optional sample conditioning components have an impact on sample lag time.

Mounting GPR-1600MS:

Mounting GPR-1600MS-W Option:

Advanced Instruments Inc.

Mounting GPR-1600MS-W-306 Option:

Advanced Instruments Inc.

Gas Connections

The GPR-1600MS with its standard flow through configuration is designed for positive pressure samples and requires connections for incoming sample and outgoing vent lines, see illustrations above. The user is responsible for calibration gases and the required components, see below. Flow rates of 1-3 SCFH cause no appreciable change in the oxygen reading. 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 1 SCFH is recommended for optimum performance.

Caution: Do not place your finger over the fitting designated as the vent (it pressurizes the sensor) or 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).

Procedure:

1. Caution: Do not change the factory setting until instructed.

2. Regulate the pressure and flow as described in Pressure & Flow above.

3. Install the sample out or vent line connection to the 1/8” dia. fitting labeled SAMPLE VENT.

4. Install the incoming sample or span gas line to the 1/8” dia. fitting labeled SAMPLE IN.

5. Set the flow rate to 1 SCFH (open the flow control valve completely if using an external sampling pump positioned downstream of the sensor).

6. Allow gas to flow through the analyzer for 3-5 minutes and proceed to Calibration or Sampling.

Advanced Instruments Inc.

Electrical Connections

The appropriate AC power requirement must specified be specified at order placement if the analyzer is to be equipped with the temperature control heater system. Incoming power for the 100-250V AC powered analyzers is supplied through a universal power entry module. A standard computer type power cord (P/N A-1008) is required for the universal power entry module. A well grounded insulated power cable is recommended to avoid noise resulting from unwanted interference.

Power consumption is approximately 150-200 watts with the temperature control heater system and 30 watts without. Caution: Integral 4-20mA converters are internally powered and do not require external power. DO NOT supply any voltage to

any of the terminals for 4-20mA signal output and range ID or the 4-20mA converters will be damaged. Caution: To assure proper grounding, connect the 4-20mA signal output to the external device (PLC, DCS, etc.) before

attempting any zero or span adjustments.

Optional Range ID:

The standard 4-20mA output used for range indentification, as described below, can be replaced by eliminating the alarms feature and using the relay contacts associated with the alarms to provide a single common and four (4) normally open relay contacts that close when the related range is active. The dry contacts are rated at 30VDC @ 1A and powering them is not required if the PLC can distinguish contact closure via continuity check.

Advanced Instruments Inc.

Procedure:

1. As illustrated above the sensor, power and alarm relays and signal output connections are hard wired to screw type terminal blocks located at the rear of the analyzer.

2. Use a small bladed screwdriver to loosen the appropriate terminal screws as illustrated above.

3. Strip the wires of the cable no more than 3/16 inch.

4. To connect to an active relay or “fail safe”, connect the live cable to the common terminal C and the secondary cable to the normally open NO terminal.

5. To break the connection upon relay activation, connect the secondary cable to the normally closed NC terminal.

6. Insert the stripped end of the cables into the appropriate terminal slots assuring no bare wire remains exposed that could come in contact with the back panel of the analyzer enclosure.

7. Tighten the terminal screws to secure the wires of the cable.

Danger: While connecting the cables to the relay terminals, ensure there is no voltage on the cables to prevent electric shock and possible damage to the analyzer. Caution: Assure the stripped wire ends of the cable are fully inserted into the terminal slots and do not touch each other or the back panel of the analyzer enclosure.

Interconnections for the optional wall mount enclosure pictured below.

Advanced Instruments Inc.

Alarms Alarm 1 and Alarm 2 represent two threshold type alarms that can be configured in the field from the analyzer’s menu driven LCD display as follows:

¾ Establish independent set points ¾ Either Hi or Lo ¾ Either On or Off (enabled or disabled) ¾ Both temporarily defeated using a user entered ‘timeout’ period (normally minutes)

The alarm set point represents a value. When the oxygen reading exceeds (high alarm) or falls below (low alarm) the alarm set point, the relay is activated and the LCD displays the alarm condition. When activated the alarms trigger SPDT Form C nonlatching relays @ 5A, 30VDC or 240VAC resistive. To prevent chattering of the relays, a 2% hysteresis is added to the alarm set point. This means that the alarm will remain active until the oxygen reading has fallen 2% below the alarm set point (high alarm) or risen 2% above the alarm set point (low alarm) after the alarm was activated. Aside from being totally defeated in the Alarm Bypass mode, the timeout feature is useful while replacing the oxygen sensor or during calibration when the oxygen reading might well rise above the alarm set point and trigger a false alarm.

Note: When making connections the user must decide whether to configure/connect Alarm 1 and Alarm 2 in failsafe mode (Normally Open – NO – where the alarm relay de-energizes and closes in an alarm condition) or non-failsafe mode (Normally Closed – NC – where alarm relay energizes and opens in an alarm condition).

Note: Selection of the optional Range ID configuration utilizes the alarms relays contacts thereby eliminating the alarms feature.

Power Failure Alarm

A dry contact rated at 30VDC @ 1A is provided as a power failure alarm that activates when power supplied to the analyzer’s circuits is unacceptable. The contact is normally closed but opens when the power to the analyzer is switched off or interrupted and cannot be disabled.

4-20mA Signal Output

The analyzer provides a 4-20mA full scale fully isolated ground signals for external recording devices. The integral IC on the main PCB provides 4-20mA fully isolated signals for output and range ID. The 4-20mA current output is obtained by connecting the current measuring device between the positive and negative terminals labeled OUTPUT 4-20mA. To check the signal output of the 4-20mA E/I integrated circuit connect an ammeter as the measuring device and confirm the output is within + 4mA. A finer adjustment of the zero offset of the 4-20mA converter can be provided by a potentiometer mounted on the main PCB Assembly. Consult factory for instructions

Range ID

For range ID the output of 4mA, 8mA, 12mA, 16mA, 20mA correspond to the most sensitive to least sensitive analysis range. The standard 4-20mA output used for range indentification, as described below, can be replaced by eliminating the alarms

feature and using the relay contacts associated with the alarms to provide a single common and four (4) normally open relay contacts that close when the related range is active. The dry contacts are rated at 30VDC @ 1A and powering them is optional as some PLCs can distinguish contact closure via continuity check.

Caution:

voltage to any of the two terminals of the 4-20mA converter.

The integral 4-20mA converters are internally powered and do not require external power. DO NOT supply any

0.1mA of

Advanced Instruments Inc.

Temperature Controlled Heater System with Runaway Protection Circuit

The standard GPR-1600MS Series analyzer is equipped with the heater system in anticipation of very low ppm (high ppb) oxygen analysis. However, in controlled environments or higher levels analysis the user may elect to delete the heater system. If the analyzer is equipped with an optional temperature controlled heater system, open the front door of the analyzer to access it. This unit is a PID controller which operates between 0-99°F. The controller is programmed to maintain the temperature at 75-85°F.

Caution: Do not change this setting. A higher temperature setting may drastically reduce sensor life and possibly cause damage to the electronic circuitry of both the controller and the analyzer.

Warning:

temperature controller, the controller tunes itself to eliminate and/or minimize the over/under shoot of temperature from the set point.

It is recommended that at initial start-up, when replacing the oxygen sensor or when trouble shooting, turn off the power to the heater or set the temperature set point at 60°F (to turn the heater off) to prevent overheating the analyzer.

Changing the display value from °F to °C:

1. Push the UP ARROW and ENTER buttons down for 5 seconds to access the SECURE MENU

2. Press INDEX to advance to the F-C MENU

3. Select °C or °F by pressing the UP ARROW key

4. Press the ENTER key when F-C starts flashing on the display

5. Press INDEX to exit the SECURE MENU

Heater Runaway Protection

Part of the optional temperature controlled heater system is a heater runaway protection circuit that protects the electronics in the event the temperature controller should fail and thereby allowing the heater to runaway damaging the interior of the analysis unit.

The runaway protection is provided by a J2 type device positioned between the temperature controller and the heater. This device cuts of power to the heater if the temperature inside the analysis unit exceeds 70°C. Should the J2 device cut power to the heater, correct the problem and reset the runaway protector device by exposing it to 0°C for a few minutes (a refrigerator freezer will do).

Keep the front door securely fastened closed when the temperature controller is ON. When power is applied to the

Installing the Oxygen Sensor

The GPR-1600MS Oxygen Analyzer is equipped with an external oxygen sensor that has been tested and calibrated by the manufacturer prior to shipment and is fully operational from the shipping containers. The sensor has not been installed at the factory and it will be necessary to install the sensor in the field. Caution: Review procedure before proceeding, mainly 2 and

Caution: DO NOT open the oxygen sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if touched or ingested, refer to the Material Safety Data Sheet contained in the Owner’s Manual 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 manner similar to that of a common battery in accordance with local regulations.

Procedure:

1. The sensor has not been installed at the factory (in standard configuration there are no valves to isolate the sensor) and it will be necessary to install the sensor in the field.

2. As described above the following steps should already be completed: a) Secure the sensor housing bracket with two 6/32 mounting screws, in the preferred position the upper section with the interconnection cable should be facing the ceiling; b) connect the gas lines; c) electrical connections.

1. Caution: Do not change the factory settings until instructed to do in this manual.

Advanced Instruments Inc.

2. Purge the oxygen trapped in the newly connected gas lines for 3-5 minutes.

3. Flow zero gas or sample gas with a low ppm oxygen concentration to the analyzer at the predetermined flow rate of 1 SCFH.

4. Using the 5/16 wrench supplied loosen but do not remove the clamp bolt located under the sensor housing, see photo.

5. Rotate the upper section of the sensor housing 90º to disengage from the clamp.

6. Remove the upper section by pulling it straight up and place it on a smooth surface.

7. Select the AUTO RANGING option from the SAMPLE menu with gas flowing to the analyzer.

8. Remove the oxygen sensor from the bag and remove the red shorting device (including the gold ribbon) from the PCB located at the rear of the sensor.

9. Minimize the time the sensor is exposed to ambient air.

10. Immediately place the sensor in the bottom section of the sensor housing with the PCB facing up.

11. Immediately place the upper section of the sensor housing over the sensor, gently push the upper section downward and rotate 90º to engage the clamp.

12. Finger tighten the clamp bolt and then tighten it one full turn with the 5/16 wrench to securely lock the two sections of the sensor housing.

13. The analyzer will OVER RANGE for a short period of time as indicated by the graphical LCD display.

14. Wait until the display shows a meaningful oxygen reading and begins to approach the expected oxygen content of the sample gas.

Span Gas Preparation

The GPR-1600MS must be calibrated with a certified span gas with an oxygen value below 1000 ppm. See the Accuracy & Calibration section above for recommendations. Exposure to ambient air beyond the time it takes to install the sensor can delay the calibration process and if long enough damage the sensor.

Caution: Do not contaminate the span gas cylinder when connecting the regulator. Bleed the air filled regulator (faster and more reliable than simply flowing the span gas) before attempting the initial calibration of the instrument.

Required components:

¾ Certified span gas cylinder with an oxygen concentration, balance nitrogen, approximating 80% of the full scale range

above the intended measuring range.

¾ Regulator to reduce pressure to 30 psig. ¾ Flow meter to set the flow between 1 SCFH, ¾ Suitable fittings and 1/8” dia. 4-6 ft. in length of metal tubing to connect the regulator to the flow meter inlet ¾ Suitable fitting and 1/8” dia. 4-6 ft. in length of metal tubing to connect from the flow meter vent to tube fitting designated

SAMPLE IN on the GPR-1600MS.

Procedure:

1. With the span gas cylinder valve closed, install the regulator on the cylinder.

2. Open the regulator’s exit valve and partially open the pressure regulator’s control knob.

3. Open slightly the cylinder valve.

4. Loosen the nut connecting the regulator to the cylinder and bleed the pressure regulator.

5. Retighten the nut connecting the regulator to the cylinder

6. Adjust the regulator exit valve and slowly bleed the pressure regulator.

7. Open the cylinder valve completely.

8. Set the pressure between 5-30 psig using the pressure regulator’s control knob.

9. Caution: Do not exceed the recommended flow rate. Excessive flow rate could cause the backpressure on the sensor

and may result in erroneous readings and permanent damage to the sensor.

Establishing Power to the Electronics:

Once the power to the electronics is established, the digital display responds instantaneously. When power is applied, the analyzer performs several diagnostic system status checks termed “START-UP TEST” as illustrated below:

Advanced Instruments Inc.

START-UP TEST

ELECTRONICS – PASS TEMP SENSOR – PASS BAROMETRIC SENSOR – PASS

REV. 1.61

Note: The analyzer display defaults to the sampling mode when 30 seconds elapses without user interface. Note: At installation expect the range to default to 25% range, thereafter, 100 ppm range but only if properly isolated.

3.3PPM

AUTO SAMPLING

24.5 C LO1 2 PPM 10 PPM HI2

Menu Navigation

The four (4) pushbuttons located on the front of the analyzer operate the micro-processor:

1. blue ENTER (select)

2. yellow UP ARROW

3. yellow DOWN ARROW

4. green MENU (escape)

Main Menu

Access the MAIN MENU by pressing the MENU key:

10 PPM RANGE

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE CALIBRATION CONFIG ALARMS BYPASS ALARMS

Range Selection

The GPR-1600MS analyzer is equipped with four (4) standard measuring ranges (see specification) and provides users with a choice of sampling modes. By accessing the MAIN MENU, users may select either the AUTO SAMPLING (ranging) or MANUAL SAMPLING (to lock on a single range) mode.

Advanced Instruments Inc.

Note: For calibration purposes, use of the AUTO SAMPLE mode is recommended. However, the user can select the full scale MANUAL SAMPLE RANGE for calibration as dictated by the accuracy of the analysis required – for optimal accuracy, a span gas with an 800 ppm oxygen concentration with the balance nitrogen would dictate the use of the 0-1000 ppm full scale range for calibration for analysis below 100 ppm, whereas, 80 ppm span gas is acceptable but not “optimal”, see Calibration & Accuracy.

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.

4. The display returns to the sampling mode:

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE CALIBRATION CONFIG ALARMS BYPASS ALARMS

The display will shift to the next higher range when the oxygen reading (actually the sensor’s signal output) exceeds 99.9% of the upper limit of the current range. The display will shift to the next lower range when the oxygen reading drops to 85% of the upper limit of the next lower range.

For example, if the analyzer is reading 1% on the 0-10% range and an upset occurs, the display will shift to the 0-25% range when the oxygen reading exceeds 9.9%. Conversely, once the upset condition is corrected, the display will shift back to the 010% range when the oxygen reading drops to 8.5%.

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.

4. The following display appears:

3.3PPM

AUTO SAMPLING

24.5 C LO1 2 PPM 10 PPM HI2

10 PPM RANGE

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE

CALIBRATION CONFIG ALARMS BYPASS ALARMS

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

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

7. The following displays appears with the range selected and oxygen concentration of the sample gas:

MANUAL RANGE

1000 ppm 100 ppm

10 ppm

1 ppm

>>>

MANUAL RANGE

1000 ppm 100 ppm

10 ppm

1 ppm

3.3PPM

AUTO SAMPLING

10 PPM RANGE

24.5 C LO1 2 PPM 10 PPM HI2

Advanced Instruments Inc.

8. The display will not shift automatically. Instead, when the oxygen reading (actually the sensor’s signal output) exceeds 110% of the upper limit of the current range an OVER RANGE warning will be displayed.

9. Once the OVER RANGE warning appears the user must advance the analyzer to the next higher range via the menu and keypad Press MENU, select MANUAL SAMPLING, press ENTER, select the appropriate MANUAL RANGE and press ENTER again.

Alarms

The CONFIG ALARMS features a system that can be configured in the field. Two field adjustable alarm relays with dry contacts operate independently of one another which means the alarms can be set-up as:

¾ HI and LO ¾ LO and LO, LO, ¾ HI and HI,HI

Additional feature includes delaying the activation of the local audible alarm and relay contacts for up 99 minutes to enable users to distinguish between transient occurrences and true upset conditions which is particularly useful on remote applications without affecting the 4-20mA signal output. The local audible alarm can be silenced or disabled as well without affecting the 420mA signal output.

Note: A separate feature, BYPASS ALARMS described below, enables the user to disable the local audible alarm and relay contacts during calibration or servicing. The alarms are enabled when the alarm condition is corrected.

Note: If the “Range ID with Relay Contacts” option is specified, the alarm feature is eliminated, see above. Set Alarm Values:

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

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

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

4. The following displays appears:

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1

SET ALARM 2 SET ALARM DELAY ALARM 1 HI/LO ALARM 2 HI/LO ALARMS AUDIBLE/SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the SET ALARM 1 option.

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

7. The following displays appears with PERCENT as the default alarm value :

MAIN MENU

SET ALARM 1

SET ALARM 2 SET ALARM DELAY ALARM 1 HI/LO ALARM 2 HI/LO ALARMS AUDIBLE/SILENT

>>>

GAS CONCENTRATION

PERCENT

PPM

8. Advance the reverse shade cursor using the ARROW keys to highlight the desired option.

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

10. Note: The PERCENT alarm value is entered with one decimal, the PPM alarm value is entered as an integer.

Advanced Instruments Inc.

GAS CONCENTRATION

PERCENT

PPM

>>>

GAS CONCENTRATION

PERCENT

PPM

>>>

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

12. Press the ARROW keys to enter the alarm value.

13. Repeat steps 11 and 12 until the complete span value has been entered.

14. Note: If an alarm is set as a PERCENT value and subsequently changed to a PPM value, the PERCENT value is not retained and is reset to 00.0. This holds if the alarm was first set as PPM value and then changed to a PERCENT value.

15. Save the alarm value by pressing the ENTER key or abort by pressing the MENU key.

16. The system returns to the SAMPLING mode and displays:

01.0

SET ALARM 1 VALUE

PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN

002

SET ALARM 1 VALUE

PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN

3.3PPM

AUTO SAMPLING

24.5 C

LO1 2 PPM 10 PPM HI2

10 PPM RANGE

Repeat the steps above to set the ALARM 2 value:

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

Set Alarm Delay:

Once the values for ALARM 1 and ALARM 2 have been entered, the user may elect to delay the activation of the local alarms and relay contacts for up to 99 minutes. This feature allows users to distinguish between transient occurrences and true upset conditions. This feature can be particularly useful on remote applications without affecting the 4-20mA signal output.

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

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

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

4. The following displays appear:

>>>

MAIN MENU

SET ALARM 1

SET ALARM 2

SET ALARM DELAY ALARM 1 HI/LO ALARM 2 HI/LO ALARMS AUDIBLE/SILENT

Advanced Instruments Inc.

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1 SET ALARM 2

SET ALARM DELAY

ALARM 1 HI/LO ALARM 2 HI/LO ALARMS AUDIBLE/SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the SET ALARM DELAY.

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

7. The following displays appear with last alarm delay value :

MAIN MENU

SET ALARM 1 SET ALARM 2

SET ALARM DELAY

ALARM 1 HI/LO ALARM 2 HI/LO ALARMS AUDIBLE/SILENT

>>>

DELAY IN MINUTES

PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN

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

9. Press the ARROW keys to enter the alarm value.

10. Repeat steps 17 and 18 until the complete span value has been entered.

11. Save the alarm value by pressing the ENTER key or abort by pressing the MENU key.

12. The system returns the SAMPLING mode and displays:

3.3PPM

AUTO SAMPLING

24.5 C LO1 2 PPM 10 PPM HI2

10 PPM RANGE

Set HI/LO Alarms:

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

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

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

4. The following displays appears:

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1 SET ALARM 2 SET ALARM DELAY

ALARM 1 HI/LO

ALARM 2 HI/LO ALARMS AUDIBLE/SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the ALARM 1 option, which appears as either ALARM 1 HI or ALARM 1 LO.

6. Press the ENTER key to toggle and change the displayed setting. After 3 seconds, the system returns to SAMPLING mode.

Advanced Instruments Inc.

3.3PPM

AUTO SAMPLING

24.5 C

LO1 2 PPM 10 PPM HI2

7. Repeat steps 1 through 6 for the ALARM 2 HI/LO setting.

Set Local Alarms:

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

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

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

4. The following displays appears:

10 PPM RANGE

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1 SET ALARM 2 SET ALARM DELAY ALARM 1 HI/LO ALARM 2 HI/LO

ALARMS AUDIBLE/SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the ALARMS AUDIBLE/SILENT option, which appear as either ALARMS AUDIBLE or ALARMS SILENT.

6. Press the ENTER key to toggle and change the displayed setting. After 3 seconds, the system returns to SAMPLING mode.

3.3PPM

AUTO SAMPLING

24.5 C LO1 2 PPM 10 PPM HI2

10 PPM RANGE

Bypass Alarms:

This feature, separate from CONFIG ALARMS above, enables the user to disable the local audible alarm and relay contacts during calibration or servicing. The alarms are enabled when the alarm condition is corrected.

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

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

3. The following displays appears:

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE CALIBRATION CONFIG ALARMS

BYPASS ALARMS

Advanced Instruments Inc.

4. Press the ENTER key to bypass and disable both the local audible alarm and relay contacts. After 3 seconds, the system returns to SAMPLING mode.

Note: The appropriate alarm setting will alternately reverse shades indicating the alarm condition exists but the BYPASS ALARMS feature has disabled the local audible alarm and relay contact. The alarms are enabled when the alarm condition is corrected.

3.3PPM

AUTO SAMPLING

24.5 C LO1 2 PPM 10 PPM HI2

Installation & Start-up is now complete . . . proceed to Calibration

Zero Calibration

In theory oxygen free sample gas. In reality

¾ Contamination or quality of the zero gas ¾ Minor leakage in the sample line connections ¾ Residual oxygen dissolved in the sensor’s electrolyte ¾ Tolerances of the electronic components

However, because the factory sample system conditions differ from that of the user, no ZERO OFFSET adjustment is made to analyzer by the factory

Recommendations:

¾ ZERO CALIBRATION is recommended only

¾ Determining the true ZERO CALIBRATION adjustment requires approximately 24 hours to assure the galvanic fuel cell

, the galvanic fuel cell type oxygen has an absolute zero meaning it produces no signal output when exposed to an

most sensitive range available with a ppm analyzer, e.g. analysis below 0.05 ppm on the 0-1 ppm range, 0.5 ppm on the 10 ppm range, or below 0.1% (1000 ppm) with a percent analyzer.

system connections are modified or a new oxygen sensor is installed. Therefore the DEFAULT ZERO function is

10 PPM RANGE

, expect the analyzer to generate an oxygen reading when sampling a zero gas due to:

for online analyzers performing continuous analysis below 5% of the lowest

Advanced Instruments Inc.

recommended only when performing a ZERO CALIBRATION and during troubleshooting and should not be repeated before routine subsequent SPAN CALIBRATION.

¾ If a ZERO CALIBRATION adjustment has NOT been made as described above, perform the DEFAULT ZERO and DEFAULT

SPAN functions when troubleshooting an analyzer and before SPAN CALIBRATION.

¾ ZERO CALIBRATION is not practical and not recommended for portable analyzers or measurements on higher ranges.

Procedure:

After allowing the analyzer reading to stabilize on good quality zero gas as described above, perform the ZERO CALIBRATION function as follows:

1. Assembly the required components as described under Installing Span (applies to zero) Gas section above.

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

3. The following display appears:

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS BYPASS ALARMS

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

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

6. The following display appears:

CALIBRATION SPAN CALIBRATE ZERO CALIBRATE DEFAULT SPAN

DEFAULT ZERO

OUTPUT SPAN OUTPUT ZERO

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

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

9. The following display (below left) appears and after 3 seconds the system returns to the SAMPLING mode:

FACTORY

DEFAULTS

SET

10. Repeat steps 1 through 4 above.

3.3PPM

AUTO SAMPLING

10 PPM RANGE

24.5 C LO1 2 PPM 10 PPM HI2

Advanced Instruments Inc.

CALIBRATION SPAN CALIBRATE ZERO CALIBRATE

DEFAULT SPAN

DEFAULT ZERO OUTPUT SPAN OUTPUT ZERO

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

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

13. The following display (below left) appears and after 3 seconds the system returns to the SAMPLING mode:

FACTORY

DEFAULTS

SET

14. Repeat steps 1 through 4 above.

CALIBRATION SPAN CALIBRATE

ZERO CALIBRATE

DEFAULT SPAN DEFAULT ZERO OUTPUT SPAN

OUTPUT ZERO

3.3PPM

AUTO SAMPLING

10 PPM RANGE

24.5 C LO1 2 PPM 10 PPM HI2

15. Advance the reverse shade cursor using the ARROW keys to highlight ZERO CALIBRATE.

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

17. The following displays appear:

0.000 PPM

ZERO CALIBRATION ENTER TO CALIBRATE MENU TO ABORT

18. Press the ENTER key to calibrate or MENU key to abort and return to SAMPLING mode.

19. Allow approximately 60 seconds for the calibration process while the processor determines whether the signal output or reading has stabilized within 50% of the full scale low range.

20. Both the Zero Calibrate and Span Calibrate functions result in the following displays:

PASSED

CALIBRATION

FAILED

CALIBRATION

Advanced Instruments Inc.

Default Zero:

The software will eliminate any previous zero calibration adjustment and display the actual the signal output of the sensor at any specific oxygen concentration. For example, assuming a zero gas is introduced, the display will reflect an oxygen reading representing basically the zero calibration adjustment as described above. This feature allows the user to test the sensor’s signal output without removing it from the sensor housing.

The DEFAULT ZERO function is recommended before performing the initial zero calibration or when troubleshooting the analyzer.

Output Zero:

In rare instances the 4-20mA signal output may not agree to the reading displayed by the LCD. This feature enables the user to adjust the 4mA signal output when the LCD displays 00.00. Compute the adjustment value as described in Appendix B or consult the factory.

Note: Adjust the 20mA signal output with the OUTPUT SPAN option described below. The true adjustment value must be determined empirically by trial and error. Adjust the initial adjustment value for additional percent errors.

Procedure:

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.

4. The following displays appear:

MAIN MENU

AUTO SAMPLE MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS BYPASS ALARMS

>>>

CALIBRATION

SPAN CALIBRATE ZERO CALIBRATE DEFAULT SPAN DEFAULT ZERO OUTPUT SPAN

OUTPUT ZERO

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

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

7. The following display appears

100.0

OUTPUT ZERO OFFSET

PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN

8. Compute the adjustment value as described in Appendix B. Note: The true adjustment value must be determined empirically by trial and error. Adjust the initial adjustment value for additional percent errors.

090.0

OUTPUT ZERO OFFSET

PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN

Advanced Instruments Inc.

9. Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to reach to the desired digit of the OUTPUT ZERO OFFSET value.

10. Press the ARROW keys to enter the OUTPUT ZERO OFFSET value.

11. Repeat steps 9 and 10 until the complete OUTPUT ZERO OFFSET value has been entered.

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

13. The system returns to the SAMPLING mode.

Span Calibration

* Refer to analyzer specifications for comparable data on the Pico-Ion UHP and MS oxygen sensors. Recommendations General:

Advanced Instruments Inc.

routine subsequent SPAN CALIBRATION.