Analytical Industries GPR-2600 User Manual

Advanced Instruments Inc.

GPR-2600 Series

Oxygen Analyzer

Owner’s Manual

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

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

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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.

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2 Quality Control Certification

Date:

Model: GPR-2600 ppm Oxygen Analyzer S/N _____________________

Customer: Order No.:

Pass

Sensor: ( ) GPR-12-333 ppm Oxygen Sensor

( ) XLT-12-333 ppm Oxygen Sensor S/N _____________________

Accessories: Owner’s Manual

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

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
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: Signal output 4-20mA
Range ID: ( ) 4-20mA or ( ) 5x relay contacts plus 1x common
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 calibration gas value
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

A-1146-40 PCB Assembly Main / Display Software V. ______
( ) A-1174-40 PCB Assy Power Supply / Interconnect, 4-20mA Range ID
( ) A-1174-40C 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-2600-W option general purpose wall mount 12x12x8”

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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-2600 Series
Description: 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:

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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.

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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. Avoid exposure to oxygen levels near 100% for an
extended period of time.

Accuracy & Calibration: Refer to section 5 Operation. The 0-25% range is provided not only as a measuring range but for
the purpose of air calibration which is the recommended method of calibration. Optionally, the analyzer can be calibrated with a
certified span gas or compressed instrument air at the user’s discretion. Note: The oxygen sensor’s inherent linearity and
absolute zero properties facilitates single point calibration.

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).

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.

Sample systems and flowing gas samples are generally required for applications involving oxygen measurements at oxygen
concentrations and pressures 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.

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 corrosion resistant or stainless steel sensor housing with an o-ring
seal to prevent the leakage of air and stainless steel tubing.

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 co
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.

lumn are equipped with bulkhead tube fitting connections

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Outlet Pressure: In positive pressure applications the vent pressure must be less than the inlet, preferably atmospheric.
Flow Rate: 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
vent – just not simultaneously.

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

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.

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- wipe away.

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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.

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4 Features & Specifications

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5 Operation

Principle of Operation

The GPR-2600 ppm Oxygen Analyzers incorporates a a variety of ppm range advanced galvanic fuel cell type sensors and 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 (GPR-2600W). Contact the factory for additional information on options. All
configurations are tested and calibrated by the manufacturer prior to shipment. The GPR-2600 analyzers and sensors are CE
certified and manufactured under a Quality Assurance System certified by an independent agency to ISO 9001:2000 standards.

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. 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.

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.

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 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-2600 is
designed with a sample system that enables the user to control the flow rate via a flow meter positioned upstream of the
sensor. The sensor is exposed to sample gas that must flow or be drawn through the analyzer’s internal sample system.

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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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:

1) those producing 'percent of reading errors', illustrated by Graph A below, such as +
tolerances 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 +
are really minimal due to today's 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.

Refer to the Calibration section for additional details.

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

5% or better and generates an output function that is

5% temperature compensation circuit,

1-2% linearity errors in readout devices, which

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Mounting the Analyzer

The standard GPR-2600 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-2600 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.

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-2600:

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Mounting GPR-2600-W Option:

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Gas Connections

The GPR-2600 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 components described below. Flow rates of 1-5
SCFH cause no appreciable change in the oxygen reading. A flow valve upstream (flow indicator
downstream) of the sensor is recommended as a means of controlling the flow rate of the sample
gas. A flow rate of 2 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.

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