Analytical Industries Inc (AII) GPR-1100 ATEX Operating Manual

Technical Specifications *

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

0-10, 0-100, 0-1000 PPM, 0-1%, 0-25% (CAL) FS
Auto-ranging or manual lock on a single range

ATEX Certified for Hazardous Areas

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" NPT male quick disconnects

Controls:

Display: Graphical LCD 2.75 x 1.375”; resolution .01 PPM
Enclosure: Painted aluminum NEMA 4X, 4 x 9 x 3", 10 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:

Power: Rechargeable battery, 60 day cycle
Recovery Time: 60 sec in air to < 10 PPM in < 1 hour on N2 purge
Response Time: 90% of final FS reading in 10 seconds

Sample System: None; SS 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: Stainless steel

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

GPR-12-333 for non-acid (CO2) gas streams
XLT-12-333 for gas mixture with > 0.5% CO2

GPR-1100 ATEX

Portable PPM O

Rechargeable Battery Powered

Advanced Sensor Technology

 Fast Recovery to < 10 PPM from Exposure to Air
 Sensor Life, Warranty and Performance is Unmatched
 Excellent Compatibility in 0-100% CO
 Extended Operating Temperature –20⁰C

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 +50⁰C

amb

Analyzer

2

2

0080

Optional Equipment

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

* Subject to change without notice.

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

ISO 9001:2008 Certified

INTERTEK Certificate No. 485

Advanced Instruments Inc.

GPR-1100

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

Advanced Instruments Inc.

Table of Contents

Introduction 1

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

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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-1200P/1100/1000/2000P

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

Date:

Model GPR-1100 Portable PPM Oxygen Analyzer S/N ____________________
Sensor ( ) GPR-12-333 PPM Oxygen Sensor

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

CONN-1034 Plug Mini Phone .141 dia. Black Handle
FITN-1003 (3x) Plug Male Quick Disconnect Fittings
TOOL-1001 5/16 Combination Wrench

Configuration A-1161-C2-B1 PCB Assembly

Range: 0-10 ppm, 0-100 ppm, 0-1000 ppm, 0-25%
Wetted parts: stainless steel

Electronics Test LED indicators: Low battery, charge

Customer: Order No.:

( ) XLT-12-333 PPM Oxygen Sensor S/N ____________________

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

Electronic offset
Analog signal output 0-1V
Gas Phase Test Recovery from air to < 10 ppm in < 1 hour

Baseline drift on zero gas < ± 2% FS over 24 hour period on 0-10 ppm range
Noise level < ± 0.5% FS
Span adjustment within 10-50% FS
Final Overall inspection for physical defects

Options
Notes

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3. General Safety & Installation

Safety

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

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

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Installation

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

EN 60079-1 : 2004
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.

2

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

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Advanced Instruments Inc.

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.

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.
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-1100 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.

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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.

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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4. Features & Specifications

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5. Operation

Principle of Operation

The GPR-1100 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
and other acid gases (XLT series sensors only) and 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.

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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. 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.

Sample System

The GPR-1100 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

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Advanced Instruments Inc.

As illustrated above, the GPR-1100’s internal sample system includes:

¾ Female quick connect/disconnect fittings for the inlet and outlet and

¾ Stainless steel sensor housing with a metal clamp holding two sections together via a clamp and an

o-ring seal to prevent the leakage of air

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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Advanced Instruments Inc.

Accuracy & Calibration

Single Point Calibration: As
previously described the galvanic
oxygen sensor generates an electrical
current proportional to the oxygen
concentration in the sample gas.

Absolute Zero: 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 or PPM are
permissible only when the total pressure of the sample gas being analyzed remains constant. For optimum
accuracy, the pressure of the sample gas and that of the calibration gas must be the same (in reality, within
1-2 psig).

Temperature: The rate of diffusion of oxygen molecules into the sensor is controlled by a thin Teflon
membrane otherwise known as an 'oxygen diffusion limiting barrier'. All diffusion processes are temperature
sensitive, therefore, the fact that the sensor's electrical output varies with temperature is normal. This
variation, however, is relatively constant (2.5% increase per ºC increase in temperature).

A temperature compensation circuit employing a thermistor offsets this effect with an accuracy of better

5% (over the entire Operating Temperature Range of the analyzer) and generates an output function

than +
that is virtually independent of temperature. There is essentially no error in measurements if the analyzer
calibration and sampling are performed at the same temperature or if the measurement is made
immediately after analyzer calibration. Lastly, a small sample/ambient temperature variations (within 10­15º) produce < 2% error in measurements.

Accuracy:

types of errors: 1) those producing 'percent of reading errors', as illustrated by Graph A below, such as

5% error in temperature compensation circuit due to tolerances in electronic components and 2) those

+
producing 'percent of full scale errors', illustrated by Graph B, such as +
devices, which are generally very minimal due to today's advancements in technology and the fact that
these errors are 'spanned out' during calibration. Graph C illustrates these 'worse case' specifications that
are typically used to develop the analyzer's overall accuracy statement of < 1% of full scale at constant
temperature and pressure or < 5% over the operating temperature range. The error in QC testing is
typically < 0.5% prior to shipment of analyzers.

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

1-2% linearity errors in readout

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