Analytical Industries Inc (AII) GPR-1000 ATEX Operating Manual

Technical Specifications *

Accuracy: < 2% of FS range under constant conditions
Analysis Ranges:

Application:

Approvals: Certified for use hazardous areas - see lower right
Area Classification: Class I, Division 1, Groups C, D

Calibration:

Compensation: Temperature
Connections: 1/8" quick disconnect
Controls:

Display: Graphical LCD 2.75 x 1.375”; resolution 1 PPM
Enclosure: Painted aluminum NEMA 4X, 4 x 9 x 3", 8 lbs.
Flow: Not flow sensitive; recommended flow rate 2 SCFH

LED Indicators: LOW BATT (72 hr. warning); CHARGE mode
Linearity: > .995 over all ranges
Pressure:

0-1000 PPM, 0-1%, 0-25% (CAL) FS
Auto-ranging or manual lock on a single range

Oxygen analysis in inert, helium, hydrogen, mixed
and acid (CO2) gas streams

Max interval—3 months. Use certified span gas with
O2 content (balance N2) approximating 80% of full
scale for fast 20-30 minute recovery to online use.
Alternatively, air calibrate with clean source of com­pressed or ambient (20.9% O2) air on 0-25% range
and allow 60 minutes on zero gas to recover to 10
ppm. For optimum accuracy, calibrate one range
higher than the range of interest.

Water resistant keypad; menu driven range selection,
calibration and system functions

Inlet - regulate to 5-30 psig to deliver 2 SCFH flow;
vent - atmospheric

ATEX Certified for Hazardous Areas

GPR-1000 ATEX

Portable PPM O

Rechargeable Battery Powered

Analyzer

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Power: Rechargeable battery, 60 day cycle, 8 hrs with pump
Recovery Time: 60 sec in air to < 100 PPM in < 15 min on N2 purge
Response Time: 90% of final FS reading in 10 seconds

Sample System: None; Brass quick disconnect fittings
Sensitivity: < 0.5% of FS range

Sensor Model:

Sensor Life: 24 months in < 1000 PPM O2 at 25ºC and 1 atm
Signal Output: 0-1V FS

Temp. Range: 5ºC to 45ºC (GPR sensor), -10º to 45ºC (XLT sensor)
Warranty: 12 months analyzer; 12 months sensor

Wetted Parts: Brass connections; stainless steel optional

Optional Equipment

Carrying case with custom foam insert
Sample conditioning - pump, filter, scrubbers - contact factory

* Subject to change without notice.

GPR-12-100-M for non-acid (CO2) gas streams
XLT-12-100-M for gas mixture with > 0.5% CO2

Advanced Sensor Technology

 Fast Recovery to < 20 PPM from Exposure to Air
 Sensor Life, Warranty and Performance is Unmatched
 Excellent Compatibility in 0-100% CO
 Extended Operating Temperature –10⁰C

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Sensitivity 0.5% Full Scale

ATEX Certified - Directive 94/9/EC

Examination Cert: INERIS 10ATEX0020

II 2 G
Ex ib IIB T4

T

-20⁰C to +45⁰C

amb

0080

ISO 9001:2008 Certified

INTERTEK Certificate No. 485

2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: [phone], Fax: [phone], www.aii1.com, e-mail: [e-mail] Rev 10/15

Advanced Instruments Inc.

GPR-1000

Portable PPM Oxygen Analyzer

Owner’s Manual

2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: [phone], Fax: [phone], e-mail: [e-mail], www.aii2.com

Table of Contents

Introduction 1

Quality Control Certification 2

Safety 3

Features & Specifications 4

Operation 5

Maintenance 6

Spare Parts 7

Troubleshooting 8

Warranty 9

Material Safety Data Sheets 10

Advanced Instruments Inc.

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Advanced Instruments Inc.

1. Introduction

Your new oxygen analyzer incorporates an advanced electrochemical sensor specific to oxygen along with state-of-the-art
digital electronics designed to give you years of reliable precise oxygen measurements in a variety of industrial oxygen
applications. More importantly, it has been constructed as intrinsically safe in accordance with ATEX Directives 94/9/CE for use
in hazardous areas in zone 1 Group C and D when used in conjunction with the recommended operating instructions in this
manual. The analyzer meets the following area classification.

Analytical Industries, Inc.
dba Advanced Instruments Inc
2855 Metropolitan Place, Pomona, CA 91767 USA

GPR-1200MS/1200/1200P/1100/1000/2000/2000P

0080

Serial No.:
Year of Manufacture:
INERIS 08ATEX0036

II 2 G
Ex ib IIB T4
T

WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD – SEE INSTRUCTIONS

The design also meets NEC intrinsic safety standards for use in Class 1, Division 1, Group C, D hazardous areas. Please refer
to Appendix A for information on making electrical connections that maintain the desired level of protection.

To obtain maximum performance from your new oxygen analyzer, please read and follow the guidelines provided in this
Owner’s Manual.

Every effort has been made to select the most reliable state of the art materials and components to design the analyzer for
superior performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer prior to
shipment for best performance. However, all electronic devices do require service from time to time. The warranty included
herein plus a staff of trained professional technicians to quickly service your analyzer is your assurance that we stand behind
every analyzer sold.

The serial number of this analyzer may be found on the inside as well as on the outside wall of the analyzer enclosure. You
should note the serial number in the space provided and retains this Owner’s Manual as a permanent record of your purchase,
for future reference and for warranty considerations.

Serial Number: _______________________
Advanced Instruments Inc. appreciates your business and pledges to make every effort to maintain the highest possible

quality standards with respect to product design, manufacturing and service.

-20⁰C to +50⁰C

amb

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2. Quality Control Certification

Model GPR-1000 ATEX Portable PPM Oxygen Analyzer S/N ____________________
Sensor ( ) GPR-12-100 PPM Oxygen Sensor

Accessories Owner’s Manual
( ) PWRS-1002 9VDC Battery Charger/Adapter 110VAC

CONN-1034 Plug Mini Phone .141 dia. Black Handle
FITN-1153 (3x) Plug Male Quick Disconnect Fittings

Configuration A-1161-B Rev C3 PCB

Range: 0-1000 PPM, 0-1%, 0-5%, 0-25%
Wetted parts: stainless steel/Brass

Electronics
Test

Electronic offset
Analog signal output 0-1V
Gas Phase

Test
Baseline drift on zero gas < ± 2% FS over 24 hour period on 0-1000 PPM range

Noise level < ± 0.5% FS
Span adjustment within 10-50% FS
Final Overall inspection for physical defects

Options B-3653 Pump Assembly
Notes

Customer: Order No.: Pass

( ) XLT-12-100 PPM Oxygen Sensor S/N ____________________

( ) PWRS-1003 9VDC Battery Charger/Adapter 220VAC
( ) PWRS-1008 9VDC Battery Charger/Adapter 12VDC Auto Cigarette Lighter

Software Version
B-3562 Battery Assembly

LED indicators: Low battery, charge

Recovery from air to < 100 PPM in < 5 minutes

_

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3. General Safety & Installation

Safety

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

Caution: This symbol is used throughout the Owner’s Manual 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.

Electrostatic Discharge Hazard: This symbol is used to caution the user to take all necessary steps to avoid
generating electrostatic discharge.

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 connectors, 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 transmitter for the operator to service.
Only trained personnel with the authorization of their supervisor should conduct maintenance.

Oxygen Sensor: DO NOT open the sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if touched
or ingested, refer to the Material Safety Data Sheet contained in the Owner’s Manual appendix. Avoid contact with any liquid
or crystal type powder in or around the sensor or sensor housing, as either could be a form of electrolyte. Leaking sensors
should be disposed of in accordance with local regulations.

Troubleshooting: Consult the guidelines in Section 8 for advice on the common operating errors before concluding that your
transmitter is faulty. Do not attempt to service the transmitter beyond those means described in this Owner’s Manual.

Do not attempt to make repairs by yourself as this will void the warranty as per Section 10 and may result in electrical shock,
injury or damage. All other servicing should be referred to qualified service personnel.

Cleaning: The transmitter should be cleaned only as recommended by the manufacturer. Wipe off dust and dirt from the
outside of the unit with a soft damp cloth then dry immediately. Do not use solvents or chemicals.
Non-use Periods: Turn the power OFF when the analyzer is left unused for a long period of time.

Installation

This analyzer has been constructed in compliance with the following EN directives
EN 60079-0 : 2006

EN 60079-1 : 2007

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Advanced Instruments Inc.

The analyzers must be used in accordance with the guidelines delineated in this instruction manual.
Gas Sample Stream: Ensure the gas stream composition of the application is consistent with the specifications and if in

doubt, review the application and consult the factory before initiating the installation.
Note: In natural gas applications such as extraction and transmission, a low voltage current is applied to the pipeline itself to

inhibit corrosion of the pipeline. As a result, electronic devices connected to the pipeline can be affected unless they are
adequately grounded.

Contaminant Gases: A gas scrubber and flow indicator with integral metering valve are required upstream of the analyzer
to remove any interfering gases such as oxides of sulfur and/or hydrogen sulfide that can interfere with measurement and
cause reduction in the expected life of the sensor. Consult factory for recommendations concerning the proper selection and
installation of components.

Expected Sensor Life: With reference to the published specification, the expected life of all oxygen sensors is predicated on
the basis of average oxygen concentration (<10,000 PPM for a PPM sensor or air for a % sensor), sample temperature of
77°F/25°C and sample pressure of 1 atmosphere in “normal” applications. Deviations from standard conditions will affect the
life of the sensor. As a rule of thumb sensor life is inversely proportional to changes in oxygen concentration, sample pressure
and temperature.

Accuracy & Calibration: Refer to section 5 Operation.
Materials: Assemble the necessary zero, sample 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 very low % or PPM O

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 to cool sample gases as high as 1,800 ºF to
ambient temperature. The recommended operating temperature is below 35 ºC. However, the analyzer may be operated at
temperature up to 45 ºC on an intermittent basis but the user is expected to accept a reduction in expected sensor life –as a
rule of thumb, for every degree ºC increase in temperature (above 25 ºC), the sensor life is reduced by approximately 2.5%.

Heat: Situate and store the analyzer away from direct 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, knobs or any other mechanical components. Before moving your

analyzer be sure to disconnect the wiring/power cord and any cables connected to the output terminals of the analyzer.

level analysis.

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Sample Pressure and 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 in a control room or an open area around a landfill or bio-pond). The following is applicable to analyzers
equipped with fuel cell type oxygen sensors.

Inlet Pressure: For the analyzers designed to measure oxygen in a flowing gas stream, the inlet sample pressure must

be regulated between 5-30 psig. Although the rating of the SS tubing and tube fittings/valves itself is considerably higher
(more than 100 psig), a sample pressure of 5-30 psig is recommended for ease of control of sample flow.
The analyzer is equipped with two gas ports. Either port can be connected to SAMPLE gas inlet. If the analyzer is equipped
with optional sample pump, pay attention to the SAMPLE IN and SAMPLE OUT ports.

Caution: If the analyzer is equipped with an optional H2S scrubber, sample inlet pressure must not exceed 30 psig.

Outlet Pressure: In applications where sample pressure is positive, the sample must be vented to an exhaust pipe at a

pressure less than the inlet pressure so that the sample gas can flow through the sensor housing. Ideally, the sample must be
vented to the atmosphere or into a pipe at atmospheric pressure.

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Note: The sensor may be used at a slightly positive pressure (e.g., when sample is vented to a common exhaust where the
pressure might be higher than 1 atmosphere). However, the pressure at the sensor must remain constant at all times
including during the span calibration. This may be accomplished by using a back-pressure regulator at the vent line of the
analyzer. Caution: A sudden change in pressure at the sensor may result in the sensor electrolyte leakage.

Use only the male “quick disconnect” fittings provided with the analyzer for bringing the sample gas in and venting it out.
Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH may generate

a slight backpressure on the sensor resulting in erroneous oxygen readings.

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).

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. If a separate flow control valve and a flow indicator is
used, position flow control valve upstream of the sensor and position a flow indicator downstream of the sensor. If necessary,
a pressure regulator 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: The GPR-1000 may be purchased with

an intrinsically safe integral sample pump, however, if the analyzer is not equipped with integral sample pump, an external
sample pump capable of pulling sample from atmosphere to a pressure down to ~ 40 inches of water column is
recommended. However, the user must ensure that by using external pump, the intrinsic safety of the analyzer is not
compromised.

Positioning of a Sampling Pump: For low % oxygen measurements, an optional external sample pump may

be used upstream of the sensor to push the sample across the sensor and out to atmosphere. For low PPM 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. However, if the sample pump can pull/push more than 5 SCFH, a flow control valve must be
used to control the sample flow. The flow control valve must be positioned in such a way that it does not generate any
vacuum on the sensor.

Caution: If the analyzer is equipped with a flow indicator with integral metering valve or a metering flow control
valve upstream of the sensor and the pump is installed downstream of sensor- open the metering valve
completely before turning the pump ON 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.

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 other optional components. Moisture and/or particulates do not necessarily damage the sensor. However, collection
of moisture/particulate 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. Consult the factory for recommendations
concerning the proper selection and installation of optional 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 after the cleaning process is completed.

Mounting: The analyzer is approved for indoor as well as outdoor use. However, avoid using the analyzer in an area

where direct sun might heat up the analyzer beyond the recommended operating temperature range.

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Gas Connections: The Inlet and outlet vent gas lines require quick disconnect stainless steel fittings. The sample inlet

tubing must be metallic, preferably SS. The sample vent line may be of SS or hard plastic tubing with low gas permeability.

Power: The analyzer is powered by an integral lead-acid rechargeable battery. The analyzer will continue to run for a

minimum of 30-60 days after the battery is fully charged.
WARRNING: THE ANALYZER BATTERY MUST BE CHARGED IN A SAFE AREA ONLY BY USING FACTORY PROVIDED WALL
PLUG-IN CHARGER.

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Advanced Instruments Inc.

4. Features & Specifications

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Advanced Instruments Inc.

5. Operation

Principle of Operation

The GPR-1000 portable oxygen analyzer incorporates a variety of PPM range advanced galvanic fuel cell type sensors. The
analyzer is configured in a general purpose NEMA 4 rated enclosure and meets the intrinsic safety ATEX Directive 94/9/EC for
use in Zone 1 Groups C and D hazardous areas.

Advanced Galvanic Sensor Technology

All galvanic type sensors function on the same principle and are very specific to oxygen. They measure the partial pressure of
oxygen from low PPM to % 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 and 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 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 the design and chemistry add significant advantages to an extremely versatile oxygen sensing
technology. Sensors for low PPM analysis recover from air to low PPM levels in minutes, exhibit longer life, extended operating
temperature range of -20°C to 50°C, excellent compatibility with CO
reliable quality giving them a significant advantage over the competition.

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. Other significant developments involve the first galvanic oxygen sensor capability of continuous
oxygen purity measurements and expanding the operating temperature range from -40°C to 50°C.

and other acid gases (XLT series sensors only) and

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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.

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Advanced Instruments Inc.

Sample oxygen is analyzed very accurately. Response time of 90% of full scale is less than 10 seconds (actual experience may
vary due to the integrity of sample line connections, dead volume and flow rate selected) on all ranges under ambient
monitoring conditions. Sensitivity is typically 0.5% of full scale low range. Oxygen readings may be recorded by an external
device via the 0-1V signal output jack.

Power is supplied by an integral rechargeable lead acid battery which provides enough power to operate the analyzer
continuously for approximately 60 days. An LED located on the front panel provides a blinking 72 hour warning to recharge
the battery. A 9 VAC adapter (positive pole located on the inside of the female connector) can be used to recharge the battery
from a 110V or 220V convenience outlet. The analyzer is designed to be fully operational during the 8-10 hour charging cycle
which is indicated by a second continuously lit CHARGE LED (only when the analyzer power is turned ON).

Sample System

The GPR-1000 is supplied with two female quick connect fittings. Without the mating male quick disconnect fittings inserted,
the female fittings lock themselves thus preventing the ambient air from seeping into the sensor housing. The analyzer is
shipped with the sensor pre-tested and installed but is isolated from the ambient air by the self-locking female fittings and is
ready for immediate operation.

Caution: Do not insert the male quick connect fittings into the female fittings unless the provision for the sample gas to flow
through the sensor housing is established. Further, before connecting the sample gas inlet fitting, ensure that the vent line is
open. Failure to do so will generate a pressure on the sensor. Sudden release of pressure (by inserting the male fittings in the
vent line) may cause the sensor electrolyte leakage thus voiding sensor warranty.

For PPM oxygen measurements, the sensor is exposed to the sample gas that must flow or be drawn through the analyzer’s
internal sample system. The sample flow must be controlled by using an external flow control device. Sample flow rate of 1-5
SCFH has no significant effect on the accuracy of the analyzer, however, for optimum performance, a flow rate of 1-2 SCFH is
recommended.

Female quick disconnect
fittings

As illustrated above, the GPR-1000’s internal sample system includes:

1. Female quick connect/disconnect fittings for the inlet and outlet and

2. Stainless steel sensor housing with a thread-in type sensor installation mechanism.

3. Optional intrinsically safe pump

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Advanced Instruments Inc.

Users interested in adding their own sample conditioning system should consult the factory. 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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