Analytical Industries Inc (AII) GPR-1200, GPR-1200P 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" compression tube fittings
Controls:

Display: Graphical LCD 2.75 x 1.375”; resolution .01 PPM
Enclosure: Painted aluminum NEMA 4X, 8.6 x 9 x 3", 12 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, 8 hrs with pump

0-10, 0-100, 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-1200 ATEX

Portable PPM O

Rechargeable Battery Powered

Integral stainless steel bypass sample system
significantly increases user productivity. The
bypass valve isolates the sensor from high
oxygen levels when changing sample lines.

Analyzer

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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: Flow control and sample/bypass valves; flow indicator
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: 5º to 45ºC (GPR sensor), -10º to 45ºC (XLT sensor)
Warranty: 12 months analyzer; 12 months sensor

Wetted Parts: Stainless steel

Optional Equipment

Carrying case with custom foam insert
Sample conditioning - pump, 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

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

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 –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

Advanced Instruments Inc.

GPR-1200/1200P

Portable PPM Oxygen Analyzer

Owner’s Manual

Revised May 2014

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

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

Table of Contents

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1. Introduction

Your new oxygen analyzer incorporates an advanced electrochemical sensor specific to oxygen along with state-of-the­art 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

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 en c l o su r e.
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.

+5⁰C to +45⁰C

amb

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Date:

Customer: Order No.:

Pass

Model

GPR-1200 ATEX 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

TOOL-1001 5/16 Combination Wrench

Configuration

A-1161-B Rev C3 PCB

B-3346 Sample Pump

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

Electronics Test

LED indicators: Low battery, Battery charge
Analog signal output 0-1V Full scale

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

2. Quality Control Certification

( ) 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

Software Version
A-3878 Battery Assembly

Electronic offset set

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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 Manua l .

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 el ec t r o static discharg e.

Retain Instructions: The safety precautions and operating instructions found i n the Owner’s Ma nual s houl d 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 mai nt e na nce.

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. Leaki ng sensors shou ld 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 : 2007
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 fittings/valves itself is

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considerably higher (more than 100 psig), a sample pressure of 5-30 psig is recommended for ease of control of
sample flow.
The analyzer equipped with a sample system has designated SAMPLE and VENT ports. Connect SAMPLE gas to
SAMPLE and the vent to the VENT ports only.

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.

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-1200P is equipped with

integral sample pump. The pump is capable of pulling sample from atmosphere to a pressure down to 40 inches of
water column. For analyzer without a sample pump, external sample pump may be deployed. However, user must
ensure that by using external pump, the intrinsic safety of the analyzer is not compromised.

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

may be used upstream of t h e sen so r to push the sample across the sensor and out to atmosphere. For 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 t h e 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 sur face can block or i nhibit the diffusion of sample gas into the sensor

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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 1/8” or ¼” stainless steel compression type tube

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 without the pump. If the pump is used, the battery will
continue to power the pump for up to 8 hours.
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-1200 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. The integral sampling pump (GPR-1200P) meets the
intrinsic safety standards.

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 l ow 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
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.

and other acid gases (XLT

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Advanced Instruments Inc.

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 sign al 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 wa rni ng to
recharge the battery. A 9VAC 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-1200 is supplied with a unique bypass sample system which enables the user to isolate the sensor from
exposure to high oxygen concentration which results in a substantial increase is user productivity. However the sample
must be properly presented to the sensor to ensure an accurate measurement.

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. This unique sample system, when operated according 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.

As illustrated above, the GPR-1200’s internal sample system includes:

 1/8” tube fittings for the inlet and outlet

 Flow control metering valve

 A 4-way sample/bypass valve to purge lines and isolate the sensor

 Stainless steel sensor housing with an o-ring seal to prevent the leakage of air

 Flow indicator common to bypass and sample lines

 Optional sample pump to draw sample through the analyzer (not shown in the above flow schematic).

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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