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

2

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

2

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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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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Accuracy & Calibration

Single Point Calibration: As
previously descr ibed the galvanic oxygen
sensor generates an electrical cu r r en t
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 a ccur acy, 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 than +5%
(over the entire Operating Temperature Range of the analyzer) and generates an output function that is virtually
independent of temperature. There is essentially no error in measu rements if the analyzer cal ibr at io n an d 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 10-15º) produce < 2% error in measurements.

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

1) those producing 'percent of reading errors', as illustrated by Graph A below, such as +
compensation
illustrated by Graph B, such as +1-2% linearity errors in readout 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.

circuit due to tolerances in electronic components and 2) those producing 'percent of full scale errors',

5% error in temperature

Example: As illustrated by Graph A, any error due to the tolerances in the circuit, will increase with increasing oxygen
concentration if the analyzer calibration is done at lower end of the range, e.g., calibration with 20.9%, any error
would be multiplied by a factor of 4.78 (100/20.9) when used for measurements near 100% oxygen. Conversely, an

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error during a span adjustment at 100% of full scale range is reduced proportionately for measurements of lower
oxygen concentrations.

Mounting the Analyzer

Normally mounting a portable analyzer is not a consideration. However, the GPR-1200 analyzer can operate
continuously when connected to AC power using the factory provided battery charging adapter. The analyzer enclosure
is cast aluminum with four (4) holes in the bottom section specifically intended for wall mounting option.

Gas Connections

The GPR-1200 flow through configuration is designed for positive pressure samples and requires connections to
incoming sample and vent 1/8” diameter tube fittings. The user is responsible for making provision for calibration
gases, see Calibration section of the Analyzer Specification and Installing Span Gas below.

Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH
generate a backpressure on sensor and cause erroneous oxygen readings (because the 1/8” diameter of the integral
tubing cannot evacuate the sample gas at the higher flow rate quickly). A flow control valve upstream of the sensor
controls the flow rate of the sample gas which is displayed by the flow indicator downstream of the sensor. A flow

rate of 2 SCFH or 1liter per minute is recommended for optimum performance.
Note: For applications where the sample flow is ambient or at a slightly negative pressure (up to 40” of water column

pressure), either the optional integral sample pump or an external sample pump connected to the vent of the
analyzer should be used to draw the sample through the sensor housing.

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 it
(voiding the sensor warranty).

Caution: Before turning the sample pump ON, open the flow control valve completely. Failure to do so will draw
vacuum on the sensor and may cause permanent damage to the sensor.

Procedure

Caution: Do not change the factory setting until instructed to do so, leave the SAMPLE/BYPASS valve in the BYPASS
position.

1. Locate the sample inlet and vent fittings respectively on the right side of the analyzer.

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

3. Connect the 1/8” dia. metal vent line to the fitting designated VENT.

4. Connect the 1/8” dia. metal sample gas line to the fitting designated SAMPLE IN.

5. Set the flow rate to 2 SCFH
Caution: Open the flow control valve completely if using the optional integral or an external sampling pump (pump
positioned downstream of the sensor).

6. Allow ga s to flow throug h the analyzer for 3-5 minutes in the BYPASS mode to purge air trapped in the sample gas

line before switching the SAMPLE/BYPASS valve to SAMPE.

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Electrical Connections

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 when the battery voltage drops below a pre-determined value. A 9 V AC/DC adapter (with 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 battery will be fully charged within 8-10 hours. Th e anal yzer is designed to be fully operational
during the 8-10 hour charging cycle. When the adopter is connected to the analyzer, the battery charging process is
indicated by a second continuously lit LED.

CAUTION: The battery must be charged in a safe are only. Do not leave the charger connected to the
analyzer for more than 24 hours.

Charging Battery

Locate a source of AC power to meet the area classification, plug in the appropriate charging adapter to the outlet.
Connect the jack at the other end to the mating receptacle identified as CHARGE on the analyzer.

Analog Signal Output

A separate receptacle is provided for signal output. The analyzer signal output is 0-1 V full scale selected.
The signal output must be connected to an external recording device in accordance with local safety
directives.

Connect the lead wires from the external recording device to the male phone plug supplied with the analyzer. (Note:
Connect the positive lead to the center terminal of the male phone plug.)
Insert the male phone plug into the integral female OUTPUT jack located on the side of the enclosure.

Caution: Do not connect a recording device capable of generating a voltage greater than 12
VDC. A voltage greater than 18 V may blow the safety fuse on A-1161-B Rev C3 main signal
processing PCB. A blown fuse must be replaced with the recommended fuse only (see spare

parts list).

Installing the Oxygen Sensor

GPR-1200 Oxygen Analyzer is equipped with an integral oxygen sensor
that has been tested and calibrated by the manufacturer prior to shipment
and is fully operational from the shipping container. Should it be necessary
to install a new oxygen sensor, follow the procedure described below.

Note: All analyzer must be calibrated once the installation has been
completed and periodically th ereafter as described below.

Caution: DO NOT open/dissect the oxygen sensor. The sensor contains a
corrosive liquid electrolyte that could be harmful if touched or ingested,
refer to the Material Safety Data Sheet in section 10. 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.

Procedure

1. Do not remove sensor from its original package until the analyzer is ready to accept sensor installation.

2. Make sure that a low PPM gas is flowing through the analyzer.

3. Set the sample flow rate between 1-2 SCFH

4. Loose n the nut a t the bottom of the sens or hous i ng with 5/16” wrench provided.

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Remove the two red ribbons
from sensor PCB

5. Twist the upper section of the sensor housing 90 degree and then pull it away.

6. Remove old sensor (if previously installed).

7. Remove the new sensor from the package (use a pair of scissors to cut the bag, do not use hands to tear the
bag)

8. Remove the two red ribbons from the two gold ring contact plate at the back of the sensor.

9. Insert the sensor into the upper section of the sensor housing with the contact plate facing toward the two
gold pins of the sensor housing. Hold the sensor and the housing in your hand while keeping the sensor
pushed against the sensor housing.

10. Check the oxygen reading; it should reach close to 20.0% (+7% -4%) indicating that the sensor has proper
signal output. At this time perform air calibration.

11. After air calibration, insert the sensor into the bottom section of the sensor housing, place the upper section
of the sensor housing and twist it 90 degree until it fits on the lower section of the sensor housing. Tighten
the nut (3/4 turn after figure tight).

Span Gas Preparation

Avoid contamination of the span gas cylinder when connecting the pressure regulator. Bleed the air filled regulator for
a couple of minutes before closing the vent valve of the pressure regulator (faster and more reliable method of purging
the regulator than simply allowing the span gas to flow through the regulator and the span gas line).

The following components/tools are required for setting a span gas cylinder:

1. Certified span gas cylinder with an oxygen concentration, balance nitrogen, approximating 80% of the full scale
range above the intended measuring range.

2. Use a Pressure Regulator to reduce span ga s pressure to between 5 and 30 psig.

3. Use flow meter (only if the analyzer is not equipped with a flow meter) and set the flow between 1-2 SCFH.

4. Use suitable fittings and 1/8” dia. metal tubing to connect the regulator to the inlet of the analyzer.

Procedure of Setting up a Span Gas Cylinder

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

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

3. Open slightly the cylinder valve.

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

5. Retighten the nut connecting the regulator to the cylinder

6. Adjust the regulator exit valve and slowly bleed the pressure regu lat o r .

7. Open the cylinder valve completely.

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

Caution: Do not exceed the recommended pressure. Excessive pressure would make flow adjustment more difficult.

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Establishing Power to the Analyzer

The analyzer is fully operational from the shipping container with the oxygen sensor installed and calibrated at the
factory prior to shipment. Once installed, we recommend the user allow the analyzer to stabilize for 10-15 minutes
before analyzing a sample gas.

Establish power to the analyzer electronics by pushing the red ON/OFF key. The digital display responds
instantaneously. When power is applied, the analyzer performs several diagnostic system status checks termed
“START-UP TEST” as illustrated below.

If equipped with an optional integral sampling pump, it is operated by
a separate toggle switch located on the front of the analyzer. When
using the sample pump, open the flow control valve completely.

Note: In the unlikely event, the LOW BATTERY warning LED comes
on when the analyzer is turned on – proceed immediately to section 6
Maintenance Battery.

The analyzer is supplied with a 9 V AC/DC adapter for recharging the
batteries or operating the analyzer continuously. The an al yzer’s
charging circuit a ccep t s only 9 VDC from any standard AC 110V or
220V adapter (with positive supply in the center of the female
charging jack). The electronic design enables the analyzer to remain
fully operable during the 8-10 hour charging cycle. However, the
analyzer must be charged in safe areas only.

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

START-UP TEST

ELECTRONICS – PASS
TEMP SENSOR – PASS
BAROMETRIC SENSOR – PASS

REV. 2.14

After self diagnostic tests, the analyzer turns itself into the sampling mode. And displays oxygen contents the sensor is
exposed to, the analysis range, the ambient temperature and pressure.

0.3 %

AUTO SAMPLING

1% RANGE

76 F 100 KPA

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MAIN MENU

MAIN MENU

Menu Navigation

The four (4) pushbuttons located on the front of the transmitter control all of the micro-processor functions:
Blue ENTER (select)

Yellow UP ARROW
Yellow DOWN ARROW
Green MENU (escape)

Main Menu

To access the MAIN MENU, press the MENU (ESC) key and the following screen will appear.

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION

This screen show various option available. You can use the UP and DOWN arrow key to move the cursor and highlight
the desired function. After moving the cursor to the desired function, you can press ENTER to get to that function.

Range Selection

The GPR-1200 analyzer is equipped with five (5) standard measuring ranges (see specification) and provides users
with a choice of sampling modes. By accessing the MAIN MENU, users may select either the AUTO SAMPLING
(ranging) or MANUAL SAMP LING (to lock on a single range) mode.

Note: For calibration purposes, use of the AUTO SAMPLE mode and ambient air (20.9% oxygen on the 0-25% range
which meets the 80% of FS recommendation described below) is recommended. However, the user can select the full
scale MANUAL SAMPLE RANGE for calibration as dictated by the accuracy of the analysis required – for exam ple, a
span gas with an 8% oxygen concentration in nitrogen would dictate the use of the 0-10% full scale range for
calibration and a 0-10% measuring range.

Auto Sampling
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE.
Press the ENTER key to select the highlighted menu option.
The display returns to the sampling mode:

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION

0.3%

AUTO SAMPLING

1% RANGE

76 F 100 KPA

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MAIN MENU

The display will shift to the next higher range when the oxygen reading exceeds 99.9% of the upper limit of the
current range. The display will shift to the next lower range when the oxygen reading drops to 85% of the upper limit
of the next lower range.

For example, if the transmitter is reading 1% on the 0-10% range and an upset occurs, the display will shift to the 0­25% range when the oxygen reading exceeds 9.9%. Conversely, once the upset condition is corrected, the display will
shift back to the 0-10% range when the oxygen reading drops to 8.5%.
Manual Sampling
Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight MANUAL SAMPLE.
Press the ENTER key to select the highlighted menu option.
The following display appears:

AUTO SAMPLE

MANUAL SAMPLE

CALIBRATION

Advance the reverse shade cursor using the ARROW keys to highlight the desired MANUAL RANGE.
Press the ENTER key to select the highlighted menu option.
The following display appears with the range se lected and oxygen concentration of the sample gas:

MANUAL RANGE

25%

1%

1000 PPM
100 PPM
10 PPM

>>>

>>>

25%
1%
1000 PPM
100 PPM
10 PPM

76 F 100 KPA

MANUAL RANGE

0.3%

MANUAL SAMPLING

1% RANGE

If the oxygen value goes above the 1%, display will not shift to the next higher range. Instead, when the oxygen
reading exceeds 110% of the upper limit of the current range, an OVER RANGE warning will be displayed.

1.25 %

OVERRANGE

MANUAL SAMPLING

1% RANGE

76 F 100 KPA

Once the OVER RANGE warning appears the user must advance the transmitter to the next higher range.
NOTE: With oxygen reading above 110% of the selected range, the analog signal output will increase but will freeze at
a maximum value of 1.2 V. After the oxygen reading falls below the full scale range, the voltage signal will become
normal.

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Calibration of Analyzer

The electrochemical oxygen sensors generate an electrical current that is linear or proportional to the oxygen
concentration in a sample gas. In the absence of oxygen the sensor exhibits an absolute zero, i.e., the sensor does
not generate a current output in the absence of oxygen. Given the properties of linearity and an absolute zero, a single
point calibration is possible.

The analyzer is equipped with “Zero Offset” feature. However, as described below, zero calibration is recommended
only when the application (or user) demands optimum accuracy of below 5% of the most sensitive or lowest range
available on the analyzer. For example, if the user requires analysis of a sample gas below 0.5 PPM, zero calibration is
highly recommended.

Span calibration, in one of the forms described below, is necessary to adjust the analyzer sensitivity for accurate
measurements of oxygen. As a rule of thumb, zero calibration should be carried out after span calibration.

Zero Offset

Despite the absolute zero inherent in the electrochemical oxygen sensors, the reality is that analyzers may display an
oxygen reading even when sampling a zero gas (oxygen free gas) due to:

1. Contamination or questionable quality of the zero gas

2. Minor leakage in the sample line connections

3. Residual oxygen dissolved in the sensor’s electrolyte

4. Tolerances of the electronic components

The maximum zero offset of every analyzer is checked prior to shipment. However, due to the fact that the factory
sample system conditions differ from that of the user, no ZERO OFFSET adjustment is made at the factory

Span Calibration

Involves periodically, see Intervals section below, checking and/or adjusting the electronics to the sensor’s signal
output at a given oxygen standard. The frequency of calibration varies with the application, e.g., the degree of
accuracy required by the application and the quality assurance protocol of the user. However, the interval between

span calibrations should not exceed three (3) months.
Note: Regardless of the oxygen concentration of the standard used, the span calibration process takes approximately

10-15 minutes. However, the time required to bring analyzer back on-line (within 0.01% of original value) after span
calibration can vary, see Online Recovery Time below.

Considerations

When it comes to the calibration of oxygen analyzers utilizing an electrochemical oxygen sensor, circumstances vary
widely from the ideal conditions that exist at the factory to a variety of differing circumstances users encounter in the
field. The following describes the most common factor s an d reasons that influence the calibration procedures.

All electrochemical sensor based analyzers require periodic calibration, e.g. weekly intervals to a 3 month maximum, to
ensure accuracy and ascertain the integrity of the sensor. Although, the sensor signal remains relatively constant
throughout the useful life of the sensor, some components in a gas stream, e.g., sulfides, can adversely affect the
sensor causing the sensor to loose its sensitivity with time. Hence it is highly recommended to verify/adjust the
sensitivity of the sensor by performing span calibration.

For optimum accuracy, calibrate the analyzer at or close to the temperature and pressure of the sample gas
The priority users place on getting or keeping an analyzer online is “the” most significant factor involved in calibration
and troubleshooting issues. The time it takes an analyzer to come down to a specific level after exposure to high O2
concentrations or air is significantly different if a sensor is being installed than if the sensor had been in-service at low
oxygen levels for more than 1 week

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Sensor

Recovery from Calibration

In-service Calibration Recovery

PPM Fuel
Cell

The above times assume the introduction of a zero gas (low level of oxygen in nitrogen) after span calibration.
When purging the analyzer to lower ranges and calibrating with a span gas, observe the following guideline.
If the oxygen reading reaches less than 2% of the intended calibration range, enter the value of the span gas. If the

oxygen reading is greater than 2% of the calibration range, add the O2 reading to the value of the span gas (the
impact of the offset on accuracy is minor but the addition allows the oxygen sensor to continue to purge down and
avoid negative readings after calibration).

Air to 0.1% < 30 seconds
Air to 0.01% <2 min

2 minute exposure to
Air to 10 PPM < 60 min

Similar

Less than 30 min

Zero Calibration

Typical offset from a PPM analyzer is less than 0.5 PPM. Therefore, for most applications, a Zero calibration is not
required. However, ZERO calibration option has been provided to allow the user to measure oxygen concentration at
the very low levels (less than 0.5 PPM) with great precision. As described below, accomplishing either objective places
a degree of responsibility on the user.

Determining the true offset requires the user to wait (see Online Recovery Time section) until the analyzer reading is
no longer trending downward (best evidenced by a constant horizontal trend on an external recording device.

The zero offset adjustment is limited to 50% of the most sensitive range of the analyzer. At the factory,
each analyzer is QC tested to confirm that the maximum offset is less than 50% of the most sensitive range available.
Should you observe a zero offset more than 50% of the lowest range, check the sample system for any possible leaks,
integrity of the zero gas and, assure that the analyzer has been given enough time to stabilize on zero gas before
initiating the “ZERO CALIBRATION”.

Caution: If adequate time is not allowed for the analyzer to establish the true baseline and a ZERO calibration is
performed, the analyzer will in all probability display a negative reading in the sample mode after a certain period of
time. If a negative reading is seen, perform ZERO calibration again.

Zero Calibration Procedu re

Zero calibration should carried out after the span calibration and once performed should not have to be repeated with
subsequent span calibrations. Normally, zero calibrations are performed when a new sensor is installed or changes are
made in the sample system connections.

The maximum zero calibration adjustment permitted is 50% of the lowest full scale analysis range available.
Accordingly, the analyzer’s ZERO has not been adjusted prior to shipment because the factory conditions are different
from the application condition at the user’s installation.

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

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

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

The following displays appear:

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MAIN MENU

OUTPUT ZERO

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

>>>

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

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

The following displays appear:

0.15 PPM

ZERO

CALIBRTION

ENTER TO CALIBRATE

MENU TO ABORT

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE

DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN

6. Wait until the analyzer reading stabilizes (depending on the history of the sensor, it may take a few minutes to
several hours) and then press the ENTER key to calibrate (or MENU key to abort).

7. If the offset is less than 50% of the lowest range, by pressing ENTER will pass the calibration and the analyzer will
return to the Sample mode. On the other hand, if the offset is above 50%, pressing ENTER will fail calibration and
the analyzer will return to Sample mode without completing the Zero calibration.

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

PASSED

CALIBRATION

OR

FAILED

CALIBRATION

Default Zero

This feature will eliminate any previous zero calibration adjustment and display the actual signal output of the sensor
at a specified oxygen concentration. For example, assuming a zero gas is introduced, the display above 0.00 PPM will
reflect an actual zero offset. This feature allows the user to ensure that the accumulative zero offset never exceeds
50% of the lowest range limit. To perform Default Zero,
Access the MAIN MENU by pressing the MENU key.

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

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

The following displays appear:

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MAIN MENU

OUTPUT ZERO

MAIN MENU

OUTPUT ZERO

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

>>>

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

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

The following display appears and after 3 seconds the system returns to the SAMPLING mode:

FACTORY

DEFAULTS

SET

0.5 PPM

76 F 100 KPA

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN

DEFAULT ZERO

OUTPUT SPAN

AUTO SAMPLING

10 PPM RANGE

Analog Output with Zero O 2

In rare instances the 0-1 V signal output may not agree with the reading displayed on the LCD. This feature enables
the user to adjust the 0V signal output when the LCD displays 00.00. Note: Adjust the 1V signal output with the
OUTPUT SPAN option described below.

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

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

3. Press the ENTER key to select the highlighted menu option and the following displays appear:

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

>>>

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

5. Press the ENTER key to select the highlighted menu option and the following display appears:

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN

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100.0

095.0

Hold the sensor pressed against the

OUTPUT ZERO OFFSET
PRESS UP OR DOWN
TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN

6. The default setting of 100 illustrates no adjustment to the analog output signal. Compute the adjustment value as
described in Appendix B or consult the factory. The true adjustment value must be determined empirically by trial
and error. Adjust the initial value to above 100 to increase the analog signal value or decrease it below 100 to
decrease the analog signal.

OUTPUT ZERO OFFSET
PRESS UP OR DOWN
TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN

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

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

9. Repeat the OUTPUT ZERO OFFSET routine until the output is 0.00V.

10. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key. After adjustment, the
system returns to the SAMPLING mode.

Span Calibration Procedure
Air Calibration

This procedure requires only a source of clean ambient air and removal of the sensor from its flow housing.

1. Access the interior of the analyzer by removing the 4 clamps securing the door of the analyzer.

Caution: Do not remove the gaskets from the enclosure. Failure to reinstall the gasket will void the NEMA rating.

2. Remove the sensor from the sensor housing. Hold the sensor pushed inside of the upper sensor housing with your
hand while exposing the sensor to ambient air.

3. Advance the cursor on the MAIN MENU to SAMPLE and press ENTER to accept the selection.

4. From the above SAMPLE menu advance the cursor to AUTO RANGING and press ENTER.

5. Analyzer will return to the MAIN MENU and display the oxygen concentration which should a p proximate 20.9%
oxygen.

6. Wait approximately 2 minutes to ensure the reading is s ta ble.

7. Using the menus below, advance the cursor on the MAIN MENU to SPAN and press ENTER to accept the selection.

contact pins inside the housing

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MAIN MENU

76 F 100 KPA

MAIN MENU

OUTPUT ZERO

8. From the SPAN menu advance the cursor to Calibrate and press ENTER to select.

9. Follow the menus below to enter and accept the 20.9% span value.

10. The analyzer returns to the SAMPLE mode after accepting calibration.

11. Replace the sensor in the housing – tighten the clamp by turning the bolt (finger tight plus 3/4) turn.

12. Close the door of the enclosure, ensure that the gasket is in place to maintain NEMA 4 rating and lock the door by
using (4) screws.

13. Proceed to sampling.

Span Gas Calibration

This procedure assumes a span gas under positive pressure and is recommended for a transmitter without an optional
sampling pump, which if installed downstream of the sensor should be placed in the OFF position and disconnected so
the vent is not restricted during calibration.
To assure an accurate calibration, the temperature and pressure of the span gas must closely approximate the sample
conditions.
For calibration purposes, use of the AUTO SAMPLE mode is recommended.

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

2. Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE.

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

The following displays appear:

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION

4. Return to the MAIN MENU by pressing the MENU key.

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

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

7. Repeat to select SPAN CALIBRATE

The following displays appear:

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

8. After selecting the SPAN CALIBRATION, enter appropriate span gas value.

9. Assure there are no restrictions in vent line.

10. Regulate the Span gas pressure, as described above at 5-30 psig, and set gas flow 1-2 SCFH flow rate.

11. If the span gas line is not already connected, connect the span gas to the sample inlet or span inlet (if equ ipped
with a separate span inlet).

After selecting the span menu, the following display appears:

0.3 PPM

AUTO SAMPLING

10 PPM RANGE

>>>

24

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN

Advanced Instruments Inc.

GAS CONCENTRATION

000.00 PPM

PERCENT

PPM

12. Select PERCENT or PPM option. After gas concentration selection, following menu appears to enter the actual span
gas value.

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

>>>

13. By using the UP or DOWN arrow keys, enter the appropriate digit where the cursor is blinking

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

15. Repeat until the complete span value has been entered.

16. In the example above, a span value of 09.00 PPM has been entered.

17. After the span value has been entered, the analyzer will prompt to press the ENTER key to accept SPAN
CALIBRATION.

Caution: Allow the span gas to flow until the analyzer reading has stabilized before accepting calibration.
The wait time will vary depending on the amount of oxygen introduced to the sensor when the sample and span gas
lines were switched

18. After successful calibration, the analyzer will display a message “Passed Calibration” and return to the Sample
mode.

NOTE: The analyzer is allowed to accept calibration when O2 reading is within 50% of the span gas value. If the O2
reading is outside of this limit, by pressing ENTER to accept calibration will result in “Failed Calibration” and return to
the Sample mode without completing Span calibration. After pressing ENTER either of the following two messages will
be displayed.

PASSED

CALIBRATION

OR

09.00 PPM

SPAN

CALIBRATION

ENTER TO CALIBRATE

MENU TO ABORT

FAILED

CALIBRATION

If the calibration is unsuccessful, return to the SAMPLING mode with span gas flowing through the ana lyze r and retry
calibration befor e concluding that the analyzer is defective.
Before disconnecting the span gas line and connecting the sample gas line (if the analyzer is not equipped with a
SPAN/SAMPLE vale option), flow the sample gas for 1-2 minutes to purge the air inside the sample line and then
disconnect th e span gas line and r eplace it with th e purged sampl e gas line.

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MAIN MENU

OUTPUT ZERO

MAIN MENU

OUTPUT ZERO

Default Span

The software will set the SPAN adjustment based on the average output of the oxygen at a specific oxygen
concentration. For example, with factory default settings, when a span gas is introduced, the micro-processor will
display oxygen reading within +
limits. This feature allows the user to check the sensor’s signal output without removing it from the sensor housing.

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

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

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

The following display appears:

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

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

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

The following displays appear and after 3 seconds the system returns to the SAMPLING mode:

FACTORY

DEFAULTS

50% of the span gas value, indicating that the sensor output is within the specified

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE

DEFAULT SPAN

DEFAULT ZERO
OUTPUT SPAN

AUTO SAMPLING

10 PPM RANGE

SET

>>>

76 F 100 KPA

0.1 PPM

Analog Output Adjustment at known O

In rare instances the 0-1V signal output may not agree to the reading displayed by the LCD. This feature enables the
user to adjust the 0-1V signal output should the LCD display not agree. Note: Adjust the 0.0V signal output with the
OUTPUT ZERO option described above.

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

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

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

The following displays appear:

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

>>>

26

2

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO

OUTPUT SPAN

Advanced Instruments Inc.

100.0

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

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

The following display appears

OUTPUT SPAN OFFSET
PRESS UP OR DOWN
TO CHANGE VALUE
ENTER TO SAVE
MENU TO RETURN

6. Compute the adjustment value as described in Appendix B or consult the factory. The true adjustment value must
be determined empirically by trial and error. Adjust the initial adjustment value for additional percent errors.

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

8. Press the ARROW keys to enter the OUTPUT SPAN OFFSET value.

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

10. Save the adjustment by pressing the ENTER key or abort by pressing the MENU key

Note: The number 100 is the default value. With OUTPUT SPAN set at 100, no adjustment is made to the 1V signal.
To increase the 1V signal increase the OUTPUT SPAN above 100. To decrease the 1V signal, decrease the OUTPUT
SPAN below 100.

Sampling a Gas

GPR-1200 Oxygen Analyzer requires a positive pressure to flow the sample gas across the sensor to measure the
oxygen concentration in a sample gas. If a positive sample pressure is not available see the option of using a sample
pump as described above.

Procedure

Following calibration, the analyzer will return to the SAMPLE mode.

1. Select the desired sampling mode - auto or manual – as described above.

2. Use metal tubing to transport the sample gas to the analyzer

3. The main consideration is to eliminate any air leaks which can affect oxygen measurements.

4. For sample gases under positive pressure, the user must provide a means of controlling the inlet pressure
between 5-30 psig.

5. For sample gases under atmospheric or slightly negative pressure, an optional sampling pump is recommended to
push the sample through the sensor housing. Generally, when using a pump, no pressure regulation or flow
control device is involved. However, a flow meter upstream of analyzer is recommended to ensure that the sample
flow is adequate.

6. Assure the sample is adequately vented for optimum response and recovery – and safety.

7. Allow the oxygen reading to stabilize for approximately 10 minutes at each sample point.

8. Avoid drawing a vacuum that exceeds 14” of water column pressure – up to 40 “if done gradually

9. Avoid flow rates above 5 SCFH which may generate backpressure on the sensor.

10. Avoid sudden releases of backpressure that can severely damage the sensor.

11. Avoid the collection of particulates, liquids or condensation on the sensor that could block the diffusion of oxygen
into the sensor.

12. 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.

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Standby

The transmitter has no special storage requirements.
The sensor should remain connected during storage periods.
Store the transmitter with the power OFF at a safe location and away from a direct heating source.
If storing for an extended period of time protect the analyzer from dust, heat and moisture.

6. Maintenance

With exception of components related to optional equipment and charging the battery of portable analyzers, cleaning
the electrical contacts when replacing the sensor is the extent of the maintenance requirements of this analyzer as
there are no serviceable parts in the analyzer given the nature of the solid state electronics and sensor.

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 superv isor s hould conduct ma i ntenance.

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Item No.

Description

GPR-12-333

PPM Oxygen Sensor

XLT-12-333

PPM Oxygen Sensor

Item No.

Description

B-3652

Battery Assembly for Analyzer with Integral Pump
A-1004-3-14

Housing Sensor Stainless Steel Upper section wi th out sensor cable

A-1016-A-1

Housing Sensor Stainless Steel Bottom Assembly

B-2762-A-3-14

Housing Sensor Upper Assembly Stainless Steel

MTR-1010

Meter Digital Panel LCD

ORNG-1007

O-ring 3/32 x 1-3/8 x 1-9/16 Viton

A-1161-B-Gp -1 Rev C3

PCB Assembly Main / Display
PWRS-1002

Power Source Plug-in 9VDC 110V Battery Charger

PWRS-1003

B-3653

Power Source Plug-in 9VDC 220V Battery Charger

Pump Assembly Optional

7. Spare Parts

Recommended spare parts for the GPR-1200 Series Portable Oxygen Analyzer:

Other spare parts:

A-3666

A-1161-B-ATEX-1 Rev C3

A-3666
A-3625

Battery Assembly for Analyzer without Integral Pump

PCB Assembly Main / Display ATEX

Battery Assembly ATEX
Battery Assembly ATEX with Pump

29

Symptoms

Possible Cause

Recommended Actions

Slow recovery

At installation, defective sensor

Replace sensor if recovery

High O2 reading after

Analyzer calibrated before sensor

Allow O2 reading to stabili ze before making
High O2 reading

Flow rate exceeds limits

Correct pressure and flow rate

Response time slow

Air leak, dead legs, longer distance of

Leak test sample system bringing sample

8. Troubleshooting

Advanced Instruments Inc.

installing or replacing
sensor

Air leak in sample system connection(s)

Abnormality in zero gas

Damaged in service - prolonged
exposure to air, electrolyte leakage

Sensor nearing end of life

stabilized caused by:

1) Prolonged exposure to ambient air,
worse if sensor was left in air un-
shorted

2) Air leak in sample system
connection(s)

3) Abnormality in zero gas

unacceptable or O2 reading fails to
reach 10% of lowest range

Leak test the entire sample system:
Vary the flow rate, if the O2 reading
changes inversely with the change
in flow rate indicates an air leak ­correct source of leak
Qualify zero gas (using portable
analyzer)

Replace sensor

Replace sensor

any calibration adjustment
Continue purge with zero gas

Leak test the entire sample system (above)
Qualify zero gas (using portable analyzer)

Sampling

Pressurized sensor

Improper sensor selection

Abnormality in sample gas

sample line, low flow rate, high volume
of optional filters and scrubbers

30

Remove restriction on vent line or open
SHUT OFF valve completely

Replace GPR/PSR sensor with XLT sensor
when CO

Qualify sample gas independently

gas to analyzer, reduce dead volume and/or
increase sample flow rate

or acid gases are present

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Advanced Instruments Inc.

O2 reading doesn’t

Pressure and temperature of the

Calibrate the analyzer (calibrate close to the

Erratic O2 reading or No

Test sensor signal output independent

Sensor nearing end of life

Remove sensor from housing. Using a volt-

Replace sensor

agree with expected O
values

O2 reading

2

sample may be different than the span
gas used for calibration

Abnormality in the sample gas

from analyzer

Abrupt changes in sample pressure

Corroded solder joints on sensor PCB
from corrosive sample or electrolyte
leakage from sensor
Corroded spring loaded contact in upper
section of sensor housing from liquid in
sample or electrolyte leakage from
sensor

Liquid covering sensing area

Improper sensor selection
Presence of other interference gases

Presence of sulfur gases
Unauthorized maintenance

pressure and temperature of the sample
gas)

Qualify sample gas independently

meter set to uA output; apply the (+) lead
to the outer ring of the sensor PCB and the
(-) lead to the center circle to obtain the
sensor’s output in air (expected value 400­900 uA). If no current signal, replace
sensor, otherwise contact factory.

Regulate sample gas pressure and flow.
Clean contacts with alcohol (minimize
exposure time of sensor to ambient air to
extent possible)
Replace sensor and return damaged sensor
to the factory for warranty determination

Clean spring loaded contacts in upper
section of sensor housing with a damped
cloth. If electrolyte leakage from sensor is
evident, replace sensor and return leaking
sensor to the factory for warranty
determination

Wipe sensor and sensor housing and sensor
with a damped t ow el.

Replace GPR series sensor with XLT sensor
when CO
consult factory

Replace sensor and install H2S scrubber
Replace sensor, obtain authorized service

or other acid gases are pr esent,

2

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Advanced Instruments Inc.

power up

battery

Erratic O2 reading or
Negative O2 reading or
No O

reading

2

possibly accompanied
by electrolyte leakage

Fails Span Calibration

Fails Zero Calibration

Analyzer does not

Pressurizing the sensor by flowing
gas to the sens or with:
the vent restricted or
SHUT OFF valve closed and the
suddenly removing the
restriction draws a vacuum on the
sensor or
partially opening the valves
upstream of the analyzer when
using a pump downstream of the
analyzer to draw sample from a
process at atmospheric pressure or
a slight vacuum

A pressurized sensor may not leak
but still can produce negative
readings.

Placing a vacuum on the sensor in
excess 40” of water column is
strongly discouraged. The front
sensing membrane is only 5/8 mil
thick, heat sealed to the sensor
body and is subject to tearing when
vacuum is suddenly applied.

A premature ZERO OFFSET of
analyzer is a common cause

Sensor output beyond
recommended range

Zero offset beyond the permitted
range

Sensor output of spec, span gas
incorrect

Zero offset beyond acceptable limit,
contaminated zero ga s

Low battery

Zero the analyzer. If not successful replace
the sensor

Avoid drawing a vacuum on the sensor

From MAIN MENU select DEFAULT ZERO and
perform a zero calibration again. If
unsuccessful, replace sensor

Replace sensor

Perform DEFAULT ZERO, wait until the offset
is less than 50% of the lowest range,
perform zero calibration again

Check integrity of span gas, if OK, replace
sensor

Check integrity of zero gas, wait until zero
offset falls below the acceptable limit

Charge battery, if unsuccessful, replace

32

Advanced Instruments Inc.

9. Warranty

The design and manufacture of Advanced Instruments Inc. oxygen analyzers and oxygen sensors are performed under
a certified Quality Assurance System that conforms to established standards and incorporates state of the art materials
and components for superior performance and minimal cost of ownership. Prior to shipment every analyzer is
thoroughly tested by the manufacturer and documented in the form of a Quality Control Certification that is included in
the Owner’s Manual accompanying every analyzer. When operated and maintained in accordance with the Owner’s
Manual, the units will provide many years of reliable service.

Coverage

Under normal operating conditions, the analyzers and sensors are warranted to be free of defects in materials and
workmanship for the period specified in accordance with the most recent published specifications, said period begins
with the date of shipment by the manufacturer. The manufacturer information and serial number of this analyze r are
located on the rear of the analyzer. Advanced Instruments Inc. reserves the right in its sole discretion to invalidate this
warranty if the serial number does not appear on the analyzer.

If your Advanced Instruments Inc. monitor, analyzer and/or oxygen sensor is determined to be defective with respect
to material and/or workmanship, we will repair it or, at our opti on, r eplace it at no charge to you. If we choose to
repair your purchase, we may use new or reconditioned replacement parts. If we choose to replace your Advanced
Instruments Inc. analyzer, we may replace it with a new or reconditioned one of the same or upgraded design. This
warranty applies to all monitors, analyzers and sensors purchased worldwide. It is the only one we will give and it sets
forth all our responsibilities.

There are no other express warranties. This warranty is limited to the first customer who submits a claim for a given
serial number and/or the above warranty period. Under no circumstances will the warranty extend to more than one
customer or beyond the warranty period.

Limitations

Advanced Instruments Inc. will not pay for: loss of time; inconvenience; loss of use of your Advanced Instruments Inc.
analyzer or property damage caused by your Advanced Instruments Inc. analyzer or its failure to work; any special,
incidental or consequential damages; or any damage resulting from alterations, misuse or abuse; lack of proper
maintenance; unauthorized repair or modification of the analyze r ; affixing of any atta chment not p rov ided with t he
analyzer or other failure to follow the Owner’s Manual. Some states and provinces do not allow limitati ons on how an
implied warranty lasts or the exclusion of incidental or consequential damages, these exclusions may not apply.

Exclusions

This warranty does not cover installation; defects resulting from accidents; damage while in transit to our service
location; damage resulting from alterations, misuse or abuse; lack of proper maintenance; unauthorized repair or
modification of the analyzer; affixing of any label or attachment not provided wi th the analyz e r; fire, flood , or a cts of
God; or other failure to follow the Owner’s Manual.

Service

Call Advanced Instruments Inc. at 909-392-6900 (or e-mail [e-mail]) between 8:00am and 5:30pm Pacific Time
Monday thru Thursday or before 12:00 pm on Friday. Trained technicians will assist you in diagnosing the problem and
arrange to supply you with the required parts. You may obtain warranty service by returning you analyzer, postage
prepaid to:

Advanced Instruments Inc.
2855 Metropolitan Place
Pomona, Ca 91767 USA

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Advanced Instruments Inc.

Be sure to pack the analyzer securely. Include your name, address, telephone number, and a description of the
operating problem. After repairing or, at our option, replacing your Advanced Instruments Inc. analyzer, we will ship it
to you at no cost for parts and labor.

34

Advanced Instruments Inc.

Product Identif ication

Product Name

Oxygen Sensor Series - PSR, GPR, AII, XLT

Synonyms

Electrochemical Sensor, Galvanic Fuel Cell

Manufacturer

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

Emergency Phone Number

909-392-6900

Preparation / Revision Date

January 1, 1995

Notes

Oxygen sensors are sealed, contain protective coverings and in normal conditions do not
present a health hazard. Information applies to electrolyte unless otherwise noted.

Specific Generic Ingredients

Carcinogens at levels > 0.1%

None

Others at levels > 1.0%

Potassium Hydroxide or Acetic Acid, Lead

CAS Number

Potassium Hydroxide = KOH 1310-58-3 or Acetic Acid = 64-19-7, Lead = Pb 7439-92-1

Chemical (Synonym) and
Family

Potassium Hydroxide (KOH) – Base or Acetic Acid (CH3CO2H) – Acid, Lead (Pb) – Metal

General Requirements

Use

Potassium Hydroxide or Acetic Acid - electrolyte, Lead - anode

Handling

Rubber or latex gloves, safety glasses

Storage

Indefinitely

Physical Propertie s

Boiling Point Range

KOH = 100 to 115° C or Acetic Acid = 100 to 11 7° C

Melting Point Range

KOH -10 to 0° C or Acetic Acid – NA, Lead 327° C

Freezing Point

KOH = -40 to -10° C or Acetic Acid = -40 to -10° C

Molecular Weight

KOH = 56 or Acetic Acid – NA, Lead = 207

Specific Gravity

KOH = 1.09 @ 20° C, Acetic Acid = 1.05 @ 20° C

Vapor Pressure

KOH = NA or Acetic Acid = 11.4 @ 20° C

Vapor Density

KOH – NA or Acetic Acid = 2.07

pH

KOH > 14 or Acetic Acid = 2-3

Solubility in H2O

Complete

% Volatiles by Volume

None

Evaporation Rate

Similar to water

Appearance and Odor

Aqueous solutions: KOH = Colorless, odorless or A cetic Acid = Colorless, vinegar-like
odor

Fire and Explosion Data

Flash and Fire Points

Not applicable

Flammable Limits

Not flammable

Extinguishing Method

Not applicable

Special Fire Fighting Procedures

Not applicable

Unusual Fire and Explosion
Hazards

Not applicable

Reactivity Data

Stability

Stable

Conditions Contributing to
Instability

None
Incompatibility

KOH = Avoid contact with strong acids or Acetic Acid = Avoid contact with strong bases

Hazardous Decomposition
Products

KOH = None or Acetic Acid = Emits toxic fumes when heated
Conditions to Avoid

KOH = None or Acetic Acid = Heat

Spill or Leak

Steps if material is released

Sensor is packaged in a sealed plastic bag , check the sensor inside for electrolyte

water. Flush or wipe all surfaces repeatedly with water or wet paper towel (fresh each

10. MSDS – Material Safety Data Sheet

leakage. If the sensor leaks inside the plastic bag or inside an analyzer sensor housing
do not remove it without rubber or latex gloves and safety glasses and a source of

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Advanced Instruments Inc.

time).

Disposal

In accordance with federal, state and local regulations.

Health Hazard Inform ation

Primary Route(s) of Entry

Ingestion, eye and skin contact

Exposure Limits

Potassium Hydroxide - ACGIH TLV 2 mg/cubic meter or Acetic Acid - ACGIH TLV / OSHA
PEL 10 ppm (TWA), Lead - OSHA PEL .05 mg/cubic meter

Ingestion

Electrolyte could be harmful or fatal if swallowed. KOH = Oral LD50 (RAT) = 2433
mg/kg or Acetic Acid = Oral LD50 (RAT) = 6620 mg/kg

Eye

Electrolyte is corrosive and eye contact could r e sult in permanent loss of vision.

Skin

Electrolyte is corrosive and skin contact could result in a chemical burn.

Inhalation

Liquid inhalation is unlikely.

Symptoms

Eye contact - burning sensation. Skin contact - soapy slick feeling.

Medical Conditions Aggravated

None

Carcinogenic Reference Data

KOH and Acetic Acid = NTP Annual Report on Carcinogens - not listed; LARC
Monographs - not listed; OSHA - not listed

Other

Lead is listed as a chemical known to the State of Califor nia to cause birth defects or
other reproductive harm.

Special Protectio n

Ventilation Requirements

None

Eye

Safety glasses

Hand

Rubber or latex glove s

Respirator Type

Not applicable

Other Special Protection

None

Special Precautio ns

Precautions

Do not remove the sensor’s protective Teflon and PCB coverings. Do not

Empty sensor body may contain hazardous residue.

Transportation

Not applicable

probe the sensor with sharp objects. Wash hands thoroughly after handling.
Avoid contact with eyes, skin and clothing.

36