Analytical Industries Inc (AII) GPR-1500 IS-LD Operating Manual

Technical Specifications *

Accuracy: < 2% of FS range under constant conditions

cUL or ATEX Certified for Hazardous Areas

Analysis:

Application:

Approvals: Certified for use in hazardous areas - see lower right

Area Classification: Certified for use in hazardous areas - see lower right
Calibration:

Compensation: Barometric pressure (ATEX) and Temperature (UL)
Connections: 1/4" compression tube fittings

Controls:

Display:

Enclosure:

Flow: Not flow sensitive; recommended flow rate 1-2 SCFH
Linearity: ±2% of full scale

Pressure:

Power:
Response Time: 90% of final reading in < 2 minutes
Sample System: Unique liquid drain sensor manifold, 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: 4-20mA or 1-5V; optional Modbus RTU communication

Operating Range: 5ºC to 45ºC (GPR sensor); -10ºC to 45ºC (XLT)
Warranty: 12 months analyzer; 12 months sensor

Wetted Parts: Stainless steel

Optional Equipment

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, hydrocarbon, helium, hydro­gen, mixed and acid (CO2) gas streams

UL: United States: UL 1203, UL 913, UL 508
Canada: CAN/CSA C22.2 No. 30-M1986,
CAN/CSA C22.2 No. 157-92,
CAN/CSA C22.2 No. 14-10
ATEX: Directive 94/9/EC

1 month interval using certified span gas (preferred
for fastest online time) with O2 value approximating
80% of full scale range balance N2

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

Graphical LCD 2.75” x 1.375”; resolution 0.01 PPM;

displays real time ambient temperature and pressure
NEMA Type 3R for rain in outdoor applications (UL)

NEMA 4X (ATEX)

Inlet - regulate to 5-30 psig to deliver 1-2 SCFH flow
to transmitter; vent - atmospheric

18-24 VDC (cUL, ATEX Certified)

GPR-12-333-LD for non-acid (CO2) gas streams
XLT-12-333-LD for gases containing > 0.5% CO2

Drains Free Liquids

GPR-1500 IS-LD
PPM Oxygen Analyzer

Unique Liquid Drain Sensor Manifold

Full Featured 2-wire Loop Powered

PPM Oxygen Transmitter

Exia

UL Certified

File E343386

Class I, Division 1, Groups C and D

T4 T

ATEX Certified - Directive 94/9/EC

Examination Cert: INERIS 08ATEX0036

II 2 G
Ex d [ib] ib IIB T4 Gb

T

-20⁰C to +50⁰C

amb

-20⁰C to +50⁰C

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0080

Automated sample conditioning system (see other side)

* Specifications subject to change without notice

ISO 9001:2008 Certified

INTERTEK Certificate No. 485

2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: [phone], Fax: [phone], www.aii1.com, e-mail: [e-mail] Rev 9/15

Advanced Instruments Inc.

GPR-1500 IS LD

PPM OXYGEN ANALYZER

Revised September 2013

Owner's Manual

2855 Metropolitan Place, Pomona, California 91767 USA ♦ Tel: [phone], Fax: [phone]
www.aii1.com e-mail: [e-mail]

Introduction

1 Quality Control Certification

2

Safety

3 Features & Specificat io n s

4

Operation

5 Maintenance

6

Spare Parts

7 Troubleshooting

8

Warranty

9 Material Safety Data Sheets

10

Explosion Proofing Electrical Connections

Appendix A

H2S Scrubber, Sample System, Media MSDS

Appendix F Maintenance H2S Scrubber & Coalescing Filter

Appendix

G

Table of Contents

Advanced Instruments, Inc

The appendices referenced above are an integral part of the documentation, installation and maintenance of this analyzer
to comply with all applicable directives. It is important that users review these documents before proceeding.

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1. Introduction

Your new oxygen analyzer incorporates an advanced electrochemical sensor specific to oxygen along with state-of-the-art
digital electronics designed to give you years of reliable precise oxygen measurements in a variety of industrial oxygen
applications. More importantly, it has been constructed as explosion proof/intrinsically safe in accordanc e with Safety
Standards: UL 913 Seventh Edition, Referencing UL 60079-0:2005 and UL 60079-11:2009 and CSA C22.2 No. 157-92
Third Edition for use in Class I, Div 1, Groups C and D hazardous locations and the ATEX Directives 94/9/EC for zone 1
Group IIB.

Please refer to Appendix A for making electrical connections that maintains 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 mater ial s and com ponents, to design the analyz er for

superior performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer prior to
shipment for best performance.

However, modern electronic devices do require service from time to time. The warranty included herein plus a staff of
trained professional technicians to quickly service your transmitter is your assurance that we stand behind every
transmitter sold.

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

Serial Number: _______________________

Advanced Instruments Inc. appreciates your business and pledges to make every effort to maintain the highest possible
quality standards with respect to product design, manufacturing and service.

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

GPR-1500 IS/2500 IS LD

0080

Serial No.:
Year of Manufacture:
INERIS 08ATEX0036

II 2 G
Ex d [ib] ib IIB T4
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-20⁰C to +50⁰C

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WARNING: POTENTIAL ELECTROSTATIC CHARGING HA ZARD – SEE
INSTRUCTIONS

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3. General Safety & Installation

This section summar izes the essential precautions applicable to the GPR-1500 IS LD Oxygen Analyzer. Additional
precautions specific to individual transmitter are contained in the following sections of this manual. To operate the
transmitter safely and obtain maximum performance follow the basic guidelines outlined in this Owner’s Manual.

Caution: This symbol is used throughout the Owner’s Manual to Caution and alert the user to recommended
safety and/or operating guidelines.

Warning: This symbol is used throughout the Owner’s Manual to Warn and alert the user of the presence of
electrostatic discharge.

Danger: This symbol is used throughout the Owner’s Manual to identify sources of immediate Danger such as
the presence of hazardous voltages.

Read Instructions: Before operating the transmitter read the instructions.
Retain Instructions: The safety precautions and operating instructions found in the Owner’s Manual should be retained

for future reference.

Heed Warnings: Follow all warnings on the transmitter, accessories (if any) and in this Owner’s Manual.
Follow Instructions: Observe all precautions and operating instructions. Failure to do so may result in personal injury or

damage to the transmitter.

Analyzer label

WARNING – Potential Explosion Hazard: The devices are not intended for use in atmospheres or with sample gas
streams containing oxygen concentration greater than 21 percent by volume (ambient air) and are only intended
for use in gases or gas mixtures classified as Class I, Div 1, Groups C and D hazardous locations or in non­hazardous locations, when used in the United States or Canada.

4

2. Quality Control Certification

See analyzer packing slip/Instruction Manual that came with the analyzer for QC certificate

Advanced Instruments, Inc

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Advanced Instruments, Inc

Maintenance

Serviceability: Except for replacing the oxygen sensor, there are no parts inside the analyzer for the operator to service.
Only trained personnel with the authorization of their supervisor should conduct maintenance.

WARNING- Substitution of Components May Impair Intrinsic Safety
Oxygen Sensor: DO NOT open the sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if

touched or ingested, refer to the Material Safety Data Sheet contained in the Owner’s Manual appendix. Avoid contact with
any liquid or crystal type powder in or around the sensor or sensor housing, as either could be a form of electrolyte.
Leaking sensors should be disposed of in accordance with local regulations.

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

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

Cleaning: The analyzer should be cleaned only as recommended by the manufacturer. Wipe off dust and dirt from the
outside of the unit with a soft damp cloth then dry immediately. Do not use solvents or chemicals.

Nonuse Periods: If the analyzer is equipped with a range switch advance the switch to the OFF position and disconnect
the power when the transmitter is left unused for a long period of time.

Installation

This analyzer has been constructed in compliance with

EN 60079-0 : 2006
EN 60079-1 : 2004
EN 60079-11 : 2007

For USA and Canada
UL 913, 7
CSA C22.2 No. 157-92
It must be installed in accordanc e with

EN 60079-14
For USA - NEC and Canada – CEC Standards

WARNING - Potential Explosion Hazard – See Warning in Section 4 – Features and Specifications

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 nitrogen or hydrogen sulfide that can interfere with
measurement and cause reduction in the expected life of the sensor. Consult the factory for recommendations concerning
the proper selection and installation of com pon ents.

Expected Sensor Life: With reference to the publish specification lo cate d at the last page of this manual, the

expected life of all oxygen sensors is predicated on oxygen concentration (< 1000 ppm for PPM sensor or air for %
sensor), temperature (77°F/25°C) and pressure (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 the
pressure and temperature.

Accuracy & Calibration: Refer to section 5 Operation.
Materials: Assemble the nece ssary zero, sa mpl e 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 low % or PPM O

th

Edition

level analysis.

2

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Advanced Instruments, Inc

Operating Temperature: The sample must be sufficiently cooled before it enters the analyzer and any

optional components. A coiled 10 foot length of ¼” stainless steel tubing is sufficient for cooling sample gases
as high as 1,800 ºF to ambient. 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 i s 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%.

Warning – Sample Stream entering unit must never exceed 50

0

C

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 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.

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.

Analyzers designed for in-situ ambient or area monitoring has no real sample inlet and vent. The sensor is exposed directly
to the sample gas and it is intended to operate at atmospheric pressure. The analyzer has a built-in pressure sensor and
the sensor output is automatically compensated for any atmospheric pressure changes.

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 consi der a bly
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 atmospheric pressure.

Note: The sensor may be used at a slight 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 be maintain ed at all times
including during the span calibration. This may be accomplished by using a back-pressure regulator at 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 (voidi ng
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 syst em,
inlet pressure must not exceed 30 psig.

Application Pressure - Atmospheric or Slightly Negative: For % oxygen measurements, an

optional external sample pump may be used upstream of the sensor to push the sample across the sensor and out to

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Advanced Instruments, Inc

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 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 meter ing
valve completely before turning the pump ON to avoid drawing a vacuum on the sensor and placing an undue
burden on the pump.

If pump loading is a consideration, a second throttle valve on the pump’s inlet side may be necessary to provide a bypass
path so the sample flow rate is within the above parameters.

Moisture & Particulates: Installation of a suitable coalescing or particulate filter is required to remove

condensation, moisture and/or particulates from the sample gas to prevent erroneous analysis readings and damage to the
sensor or other optional components. Moisture and/or particulates do not necessarily damage the sensor. However,
collection of moisture/part icu la te on the sensing surface can block or inhibit the diffusion of sample gas into the sensor
resulting in a reduction of sensor signal output – and the appearance of a sensor failure. Consult the factory for
recommendations concerning the pro per sel ect ion and in stal l ation 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 t he cleaning process is completed.

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

direct sun might heat up the analyzer beyond the recommended operating temperature range. If possible, install a small
hood over the analyzer for rain water drain and to prevent over-heat ing of analyz er .

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 l ow gas permeability.

Power: Supply power to the analyzer only as rated by the specification or markings on the analyzer enclosure. The

GPR-1500 IS LD is powered by 18-28 VDC supply. The wiring that connects the analyzer to the power source should be
installed in accordance with recognized electrical standards. Ensure that the analyzer case is properly grounded and
meets the requirements for area classification where the analyzer is installed. Never yank wiring to remove it from a
terminal connection.

The maximum power the analyzer consumes is no more than 1/4 Watts.

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4. Features & Specifications

Advanced Instruments, Inc

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Advanced Instruments, Inc

*WARNING - Potential Explosion Hazard : The devices are not intended for use in atmosphere or with sample gas

streams containing more than 21% oxygen (ambient air) and are only intended for use with or in gases or gas mixtures
classified as Class I, Div 1 Groups C and D hazardous location gases or in non-hazardous location s when used in the
United States or Canada.

**NOTE 1: Optional Sampling system shown is not part of UL/cUL Classification.

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5. Operation
Principle of Operation

The GPR-1500 IS LD Oxygen Analyzer incorporates a variety of advanced galvanic fuel cell type oxygen sensors. These
sensors are very specific to oxygen and generate an electrical signal proportional to the amount of oxygen present in a gas
stream. The selection of A particular type of sensor depends on the composition of the sample gas stream. Consult the
factory for recommendation.

The analyzer is configured in two sections. The signal processing electronics and sensor are housed in a general purpose
NEMA 4X rated enclosure. The terminals for incoming power, signal output and intrinsic safety barriers are mounted on a
PCB housed in an explosion proof enclosure.

The two sets of electronics are interconnected using an explosion proof Y-fitting, explosion proof packing fiber and sealing
cement – see Appendix A. Once connected, the intrinsic safety barriers limit the amount of power that flows to and from
the signal processing electronics effectively preventing an explosive condition. The analyzer design conforms to the ATEX
directive for equipment as intrinsically safe and has been approved by an independent body:

The analyzer carries the following area classification

II 2 G
Ex d [ib] ib IIB T4
T

For USA and Canada
UL 913, 7th Edition
CSA C22.2 No. 157-92

It must be installed in accordanc e with
EN 60079-14
For USA - NEC and Canada – CEC Standards

The GPR-1500 AIS also meets the intrinsic safety standards required for use in Class I, Division 1, Groups C, D hazardous
areas.

-20⁰C to +50⁰C

amb

WARNING: POTENTIAL ELECTROSTATIC CHARGING HA ZARD-SEE INSTRUCTION

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Advanced Instruments, Inc

Advanced Galvanic Sensor Technology

All galvanic type sensors function on the same principle and are specific to oxygen. They measure the partial pressure of
oxygen from low PPM to 100% levels in inert gases, gaseous hydrocarbons, helium, hydr ogen and mix ed gases.

Oxygen, the fuel for this electrochemical transducer, diffusing into the sensor, reacts electrochemically at the sensing
electrode to produce an electrical current output proportional to the oxygen concentration in the gas phase. The sensor’s
signal output is linear over all measuring ranges and remains virtually constant over its useful life. The sensor requires no
maintenance and is easily and safely replaced at the end of its useful life.

Proprietary advancements in design and chemistry add significant advantages to this extremely versatile oxygen sensing
technology. Sensors recover from air to low % levels in seconds, exhibit longer life and reliable quality. The expected life of
our new generation of percentage range sensors now range from 32 months to ten years with faster response times and
greater stability. Another significant development involves expanding the operating temperature range for percentage
range sensors from -30°C to 50°C. Contact factory for more specific information about your application.

NOTE- Check the product label for safe operating conditions

The PPM sensors recover from an upset condition to low PPM level in a matter of few minutes. These sensors show
excellent stability over its useful life.

Electronics

The signal generated by the sensor is processed by state of the art low power micro-proce ssor ba sed 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 scal e is less than 10 second s
(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 of the low range. Oxygen readings
may be recorded by an external device via the 4-20 mA or 1-5V signal output.

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Sample System

See Section 4, Features and Specification, Note 1 for exclusions.
The standard GPR-1500 IS-LD is supplied with a sample flow-through sensor housing that allows the moisture to separate

when the sample enters the sensor housing thus providing the user with hassle free sample analysis despite the presence
of liquid in the sample gas; see section 2 QC Certification for additional opti onal equip ment or dered .

The GPR-1500 IS-LD is generally supplied with a sample flow control valve and a flow meter and sample/span selection
valve. Users interested in adding their own sample conditioni ng syst em should co nsu lt factory. Advanced Instruments Inc.
offers a full range of sample handl ing, con ditioning and expertise to meet your applicat ion r equire me nts. Conta ct us at 909­392-6900 or e-mail us at

[e-mail].

Calibration & Accuracy Overview

Single Point Calibration: A s prev ious ly descri bed the
galvanic type oxygen sensor generates an electrical
current proportional to the oxygen concentration in the
sample gas. In the absence of oxygen the sensor
exhibits an absolute zero, e.g. the sensor do es 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 sensitiv e to the

partial pressure of oxygen in the sample gas, their
output is a function of the number of molecules of
oxygen 'per unit volume'. Readouts in percent are
permissible only when the total pressure of the sample
gas being analyzed remains constant. The pressure of
the sample gas and that of the calibration gas must be
the same.

Temperature: The rate at which oxygen molecules diffuse into the sensor is controlled by a Teflon membrane

otherwise known as an 'oxygen diffusion limiting barrier' and all diffusion processes are temperature sensitive, the fact the
sensor's electrical output will vary with temperature is normal. This variation is relatively constant (2.5% per ºC). A
temperature compensation circuit employing a thermistor and a network of resisters offsets this effect with an accuracy of

5% or better over a wide operating temperature range e.g., 5-45 oC can be obtained thus the signal output remains

+
virtually independent of ambient temperature. There is extremely low error in measurement if the calibration and sampling
are performed at similar temperatures (within +/- 5 ºC. Conversely, a temperature variation of 10 ºC may produce an err or
of < 2% of full scale.

Accuracy: In light of the above parameters, the overall accuracy of an analyzer is affected by two types of errors: 1)

'percent of reading errors', illustrated by Graph A below, is contributed by the temperature compensation
in the thermistor value, variation in temperature coefficient of the thermistor, tolerances in resistors values and the
accuracy in the measuring devices, e.g., LCD dis play and 2) 'percent of full scale errors', illustrated by Graph B, such as1­2% offset errors in readout and calibration devices. Other errors are 'spanned out' during calibration, especially when
analyzer is calibrated close to the top end of the measuring range.

Graph C illustrates these 'worse case' specifications that are typically used to develop an overall accuracy statement of <
1% of full scale at constant temperature or < 5% over the operating temperature range. The QC testing error is typically <

0.5% prior to shipment of analyzer from the factory.

circuit (tolerance

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Advanced Instruments, Inc

Example 1: As illustrated by Graph A, any error during a span adjustment at lower end of the scale, e.g., 20.9% (air) on a
100% full scale range, would be multiplied by a factor of 4.78 (100/20.9) when making measurements close to 100% O2.
Conversely, an error during a span adjustment close to the top end of the range, e.g., at 100% is reduced proportionately
for measurements of oxygen concentrations near the bottom end of the range.

Graph B represents a constant error over the entire measuring range. This error is generally associated with the measuring
e.g., LCD and or calibrating devices, e.g., current si mul ator o r curre nt/v olta ge mea suri ng devices.

Potential Explosion Hazard – See warning in Section 4 – Features and Specifications

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Mounting the Transmitter

The GPR-1500 IS-LD analyzer consists of two interconnected enclosures. This configuration is designed to be mounted
directly to any flat vertical surface, wall or bulkhead plate by using four (4) of the appropriate mounting holes on the back
panel..

To facilitate servicing the interior of the transmitters, secure the back plate to a vertical surface approximately 5 feet from
the floor or a level accessible to service personnel. This requires the user to supply four (4) additional proper size screws
and anchors.

Caution: Do not remove or discard the gaskets from either the Ex enclosure or the fiberglass enclosure .
Failure to reinstall either of the gaskets will void the NEMA 4, UL Type 3R rating and the immunity to RFI/EMI.

The transmitters design provides immunity from RFI /EMI by maintaining a good conductive contact between
the two sections of the enclosures containing the main electronic signal processing PCB/display via a conductive gasket
(the smaller enclosure inside the fiber glass enclosure) The surfaces contacting the conductive gasket are unpainted. Do
not paint these areas. Painting will negate the RFI/EMI protection.

Note: The transmitter and sample system are mounted to a back panel 15-3/4”H x 15-3/4”W with four mounting holes.
Mount the entire panel to any vertical flat surface.

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Gas Connections

See Section 4 – Features an d Specifi cat io n s, for excl usions if any

The GPR-1500 IS-LD with its standard flow through configuration is designed for positive pressure samples and requires
connections for incoming sample and outgoing vent lines. Span inlet ports is offered as part of the sample system. The
user is responsible for calibration gases and other required component s, see bel ow.

Procedure

Caution: Do not change the factory setting until instructed to do in this manual.

1. Regulate the sample pressure as described in “Pressure and Flow” section above.

2. Connect a ¼” vent line to the compressi on fitting to be used for venting the sample.

3. Connect a ¼” sample line to the compres sio n fitting marked SAMPLE on the analyzer.

4. Connect the SPAN gas lines to the SPAN port of the analyzer

5. Set the SAMPLE and SPAN gas pressure between 5-30 psig. Set the Sample and Span flow within 2 PSIG

6. Select Span gas and allow it to flow through the analyzer (by setting the three-way Sensor/Vent valve to Sensor and

set the flow rate 1- 2 SCFH. This will also set the flow rate of the Sample as well (the sample containing liquid is not
directed through the flow meter to avoid damage to flow meter).

7. After setting the flow rate, switch the Senor/Vent valve to Sensor and Sample/Span valve to Sample

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Electrical Connections

Incoming power/signal output connections are
made to terminal block mounted on a PCB located
in the explosion proof enclosure.

Do not supply voltage more than specified in this
manual and noted near the power input terminal of the
analyzer.

The PCB in the explosion proof enclosure contains a power
limiting intrinsic safety barrier that limit the total power
available at the PCB electronics mounted in the general
purpose enclosure.

With proper insulation of the incoming pow er (see Appendix
A), this configuration of the GPR-1500 IS-LD conforms to the
ATEX directives for equipments for use in hazardous area. The
analyzer meets the following area classification:

II 2 G
Ex d [ib] ib IIB T4
T

The GPR-1500 AIS also meets the intrinsic safety standards required for use in Class I, Division 1, Group C, D hazardous
areas.

UL 913 Seventh Edition, Referencing UL 60079-0:2005 and UL 60079-11:2009 and CSA C22.2 No. 157-92 Third Edition
for use in Class I, Div 1, Groups C and D hazardous locations

The A-1166 IS PCB in the Ex enclosure contains two f use s, one plug-in (brown color) rated at 200 mA and the second
mounted on the PCB (after the DC voltage is regulated to a lower safe value, this fuse meets barrier network standard EN

50020).

Analyzer ground terminal must
be connected to a ground

-20⁰C to +50⁰C

amb

Avoid electrostatic discharge – Clean all surfaces with a damp cloth only.

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Hazardous Area Installation

The GPR-1500 IS-LD may be installed in a hazardous area with proper insulation of the incoming power, see Appendix A.
A 18-28 VDC power supply with a shielded power cable is recommended. The power cable to the Ex enclosure must be
supplied through a conduit approved for use in hazardous area. Se cure the wires to the power input terminal block by
using the integral screws of the terminal block. Do not substitute terminal scr ew s.

CAUTION: Check the QC and the analyzer label for the proper power requirement. Incorrect power will
severely damage the analyzer

Power In/Signal Output Connections

The analyzer has one terminal for power in and 4-20 mA loop connections.

Power Source
18-28 VDC

Power IN, 4-20 mA Signal loop Signal Processing

Explosion Proof Fiber Glass
Enclosure Enclosure

NOTE: There are three interconnecting wires between the explosion proof enclosure and the fiber glass enclosure, for
Clarity, only two wires are shown.

Procedure

Power requirements consist of a 18-28 VDC power supply.

1. Unscrew the cone shaped cover from the Ex enclosure.

2. Strip the end of wires no greater than 1/4 inch

3. Loosen the two screws of the terminal block. Insert the stripped end of the wires into the terminal block. Ensure the

positive and negative terminals of the power cable are connected to the terminals of the terminal block as marked.

4. Connect the Ground to the ground screw outside the enclosure.

5. Replace the cover.

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Installing the Oxygen Sensor

The GPR-1500 IS-LD Oxygen Analyzer is equipped with a SS flow-through sensor housing. This housing offers ease of
replacement of sensor. The sensor simply screws into the sensor flow-through adaptor. After screwing the sensor into the
housing, remove the Molex connector on top of the sensor and connect the sensor cable to the sensor.

Caution: All analyzers must be

calibrated once the installation has been
completed and periodically thereafter as described
below. Following the initial installation and
calibration, allow the transmitters to stabilize for 12­24 hours and re-calibrate the transmitter with a
certified span gas.

Caution: DO NOT dissect the oxygen

sensor. The sensor contains a corrosive

liquid electrolyte that cou ld be harmf ul if
touched or ingested, refer to the Material Safety
Data Sheet contained in the Owner’s Manual
appendix. Avoid contact with any liquid or crystal
type powder in or around the sensor or sensor
housing, as either could be a form of electrolyte.
Leaking sensors should be disposed off in a
manner similar to that of a common battery in
accordance with local regulations.

Avoid electrostatic discharge – Clean all
surfaces with a damp cloth only.

Procedure

1. Remove the two (2) clamps securing the right

side corners and open the door of the fiber
glass enclosure.

2. Remove the sensor cable from the sensor (if

the sensor has been previously installed)

3. Remove the old sensor (if previously installed) from the sensor housing

4. Remove the oxygen sensor from the bag.

5. Immediately screw the sen sor into the sen sor flow through adaptor.

6. Remove the Molex connector with red shorting wire from the sensor

7. Connect the sensor cable to the sensor

8. You may choose the option to "air calibrate" the sensor at this time (see details in "calibration") to ensure that the

analyzer accepts the air calibration and that the sensor output is within the recommended limits.

9. The analyzer electronics will respond immediately and display the oxygen contents (in air or flowing sample)

10. The sensor will trend down from air to low PPM levels within a few minutes.

11. Allow sensor to stabilize for a few hours and re-check the calibration with a span gas if required.

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Span Gas Preparation

See Section 4 – Features an d Specifi cat io n s, for excl usions if any
Note: The GPR-1500 IS-LD can be calibrated by using ambient air. However, it can also be calibrated by using a certified

span gas. Air calibration can be achieved right after installing the sensor in the housing. Subsequent calibration, where the
sensor has been exposed to a sample gas, air calibration can be achieved by either removing the sensor from the sensor
housing or by pushing the air through the sensor housing.

Caution: Do not contaminate the span gas cylinder when installi ng the pressure regulator on the span gas

cylinder. Further, bleed the air filled regulator and span gas tubing before connecting the span gas to the
analyzer and attempting the initial calibration. A three way purge valve is highly recommended to purge the span line
before allowing the span gas to flow through the sensor housing.

Required Components

1. Certified span gas cylinder with an oxygen concentration, balance nitrogen, approximating 80% of the full scale of t he

measuring range or one range above the intended measuring range.

2. A pressure regulator to set the span gas press ure between 5-30 psig (set Span gas pressure with 2 PSIG of the

Sample gas).

3. Suitable tube fittings and a 4-6 ft. length of metal tubing to connect the pressure regulator to the analyzer Span inlet

4. A three way valve to purge the Span gas line before allowing the span gas to enter the the sensor housing.

Procedure

1. With the span gas cylinder valve closed, install the pressure 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 regula tor.

7. Open the cylinder valve completely.

8. Set the pressure between 5-30 psig using the pressure regulator’s control knob. The Span gas pressure should be

within 2 PSIG of the Sample pressure to ensure that when switching Span to Sample, the flow rate will be very similar
to that with Span gas.

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Advanced Instruments, Inc

REV.S1010.1.17

.

76 F 100 KPA

Establishing Power to Electronics

Once the two wires of the power cable are properly connected to the terminals inside the Ex enclosure as described
above, connect the other end of the two wires to a suitable 18-24 VDC power supply such as a battery, PLC, DCS, etc.

The digital display responds instantaneously. When power is applied, the transmitter performs several self-diagnostic
system status checks termed as “START-UP TEST” as illustrated below:

START-UP TEST

ELECTRONICS – PASS

TEMP SENSOR – PASS

BAROMETRIC SENSOR – PASS

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.

20

AUTO SAMPLING
25% RANGE

9 %

Menu Navigation

The four (4) pushbuttons located on the front of the transmitter control the micro-processor funct ion s:
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.

MAIN MENU

SELECT RANGE

CALIBRATION
VIEW HISTORY
SYSTEM OPTIONS

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.

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30.0 PPM

76 F 100 KPA

.

76 F 100 KPA

Range Selection

The GPR-1500 IS-LD transmitter is equipped with five (5) standard measur ing 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 SAMPLING (to lock on a single range) mode.

Note: For calibration purposes, use the AUTO SAMPLE mode; calibration with ambient air (20.9% oxygen), select the 0­25% range. However, the user can select the full scale MANUAL SAMPLE RANGE for calibration as dictated by the
accuracy of the analysis required – for example, a span gas with 50- 80 PPM oxygen concentration in nitrogen would
dictate the use of 0-100 PPM full scale range for calibration and 0-100 PPM measuring range.

Auto/ Manual Sampling

Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight SELECT RANGE and press ENTER
The display will show *AUTO and the actual range of analysis. Press the ENTER to select MANUAL RANGE and advance

the cursor to the desired RANGE and press ENTER or press ESC to stay in AUTO RANGE mode.
The following display appears:

The display returns to the sampling mode:

MAIN MENU

SELECT RANGE

CALIBRATION
VIEW HISTORY
SYSTEM OPTIONS

AUTO SAMPLING
100 PPM RANGE

With AUTO RANGE option, 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 15% of the
current range.

For example, if the transmitter is reading 5 PPM on 0-10 PPM range and an upset occurs, the display will shift to 0-100
PPM range when oxygen reading exceeds 9.99 PPM. Conversely, once the upset condition is corrected, the display will
shift back to 0-10 PPM range when oxygen reading drops to 8.5 PPM.

Pressing SELECT RANGE and then pressing ENTER will toggle between AUTO and MANUAL sampling

NOTE: W hen MANUAL range is selected and If oxygen value goes above the selected range, display will not shift to the
next higher range. Instead, when oxygen reading exceeds 110% of the upper limit of the current range, an OVER RANGE
warning will be displayed.

12

MANUAL SAMPLING
10 PPM RANGE

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 mA signal output will increase but will freeze at a

maximum value of 24 mA. After the oxygen reading falls below the full scale range, the mA signal will become normal.

22

5 PPM

OVER RANGE

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OUTPUT SIMULATE

Analyzer Calibration

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 Calibration” 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 may
be required.

Span calibration, it is necessary to adjust the analyzer sensitivity for accurate measurements of oxygen by using a
standardized (certified) oxygen or by using ambient air (20.9%).

Zero Calibration

Ideally, with no oxygen, the sensor should have zero signal but in reality, the analyzer may display oxygen reading with a
sample gas containing no oxygen (zero gas). Under such circumstance, it may be necessa ry to perform a Zero calibra t io n
to remove any offset with oxygen free sample gas. The maximum zero offset correction is limited to a maximum of 10% of
the lowest (most sensitive) range for positive zero offset and 10% of the lowest range for negative zero offset. If the zero
offset is greater than 10% of the lowest range, there might be a leak in the sample system or near end of life oxygen
sensor. Therefore, take corrective measures before proceeding for zero calibration.

Zero calibration could be carried out before or after the span calibration. Normally, zero calibrations are performed when a
new sensor is installed or changes are made in the sample system connections. Allow the ZERO gas to flow through the
analyzer and wait until the signal has dropped to a low value and is stable.

Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.

The following displays appear:

MAIN MENU

SELECT RANGE

CALIBRATION

VIEW HISTORY
SYSTEM OPTIONS

>>>

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE

DEFAULT SPAN
DEFAULT ZERO
OUTPUT CALIBRATE

Advance the reverse shade cursor using the ARROW keys to highlight ZERO CALIBRATE.
Press the ENTER key to select the highlighted menu option.

The following displays appear:

0.15 PPM

ZERO CALIBRATION
WAIT FOR STEADY RDG
ENTER TO CALIBRATE
MENU TO ABORT

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Advanced Instruments, Inc

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 zero calibrate (or MENU key to abort zero calibration).

If the offset is less than 10% 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 10%, pressing ENTER will fail calibration and the analyzer
will return to Sample mode without completing the Zero calibration.

After pressing ENTER, both the Zero Calibrate and Span Calibrate functions result in the following displays:

PASSED

CALIBRATION

OR

FAILED

CALIBRATION

and the analyzer returns to the sampling mode.

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Advanced Instruments, Inc

OUTPUT SIMULATE

0.25

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. This feature allows the user to ensure that the accumulative zero offset never exceeds
10% of the lowest range limit. To perform Default Zero,

Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.
The following displays appear:

MAIN MENU

SELECT RANGE

CALIBRATION

VIEW HISTORY
SYSTEM OPTIONS

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

>>>

>>>

76 F 97 KPA

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN

DEFAULT ZERO

OUTPUT CALIBRATE

PPM

AUTO SAMPLING

10 PPM RANGE

Analyzer Calibration-Span Calibration
Air Calibration

This procedure requires only a source of clean ambient air and removal of the sensor from its flow housing.
Access the interior of the analyzer by removing the 4 clamps securing the door of the analyzer enclosure.

Caution: Do not remove the gaskets from the enclosure. Failure to do so will void the NEMA rating.
Remove the sensor from the screw-in sensor housing or push the air through the analyzer SAMPLE IN thus exposing the

sensor to ambient air.
Advance the cursor on the MAIN MENU to CALIBRATE and press ENTER.
Advance the cursor to SPAN CALIBRATION and press ENTER

The following displays appear:

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Advanced Instruments, Inc

OUTPUT SIMULATE

MAIN MENU

SELECT RANGE

CALIBRATION

VIEW HISTORY
SYSTEM OPTIONS

>>>

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT CALIBRATE

GAS CONCENTRATION
2

0.09%

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

>>>

20.01%

SPAN CALIBRATION

WAIT FOR STEADY RDG

ENTER TO CALIBRATE

MENU TO ABORT

By using the UP or DOWN arrow keys, enter the appropriate digit where the cursor is blinking
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 gas value.
Repeat until complete span value has been entered.
In the example above, a span value of 20.09% has been entered.
After the span value has been entered, the analyzer will display the actual oxygen reading and prompt to press the ENTER

key to accept SPAN CALIBRATION or MENU to escape.

Caution: Allow the analyzer reading to stabilized before accepting calibration.
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 an acceptable range. If the O2 reading is
outside of this limit, by pressing ENTER to accept calibration will result in “Failed Calibration” and the analy z er w ill return to
Sample mode without completing Span calibration. After pressing ENTER either of the following two messages will be
displayed and the analyzer will return to SAMPLE mode.

PASSED

CALIBRATION

OR

FAILED

CALIBRATION

Span Gas Calibration

This procedure assumes a span gas under positive pressure. Connect the span gas to the analyzer Span input port and
set the span gas flow 1-2 SCFH (purge the Span gas line before allowing the span gas to flow through sensor housing).

NOTE: To assure an accurate calibration, the temperature and pressure of the span gas must closely approximate with the
sample conditions.

For calibration purposes, use of AUTO SAMPLE mode is recommended.
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.

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OUTPUT SIMULATE

The following displays appear:

MAIN MENU

SELECT RANGE

CALIBRATION

VIEW HISTORY
SYSTEM OPTIONS

>>>

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT CALIBRATE

GAS CONCENTRATION
8

5.0 PPM

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

>>>

87.4 PPM

SPAN CALIBRATION

WAIT FOR STEADY RDG

ENTER TO CALIBRATE

MENU TO ABORT

By using UP or DOWN arrow keys, enter the appropriate digit where the cursor is blinking
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 gas value.
Repeat until complete span gas value has been entered.
In the example above, a span value of 85.0 PPM has been entered.
After the span value has been entered, the analyzer will display the actual oxygen reading and prompt to press the ENTER

key to accept SPAN CALIBRATION or MENU key to escape.
Caution: Allow the analyzer reading to stabilized before accepting calibration.
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 an acceptable range. If O2 reading is
outside of this limit, by pressing ENTER to accept calibration will result in “Failed Calibration” and analyzer will return to the
Sample mode without completing Span calibration. After pressing ENTER either of the following two messages will be
displayed and the analyzer will return to SAMPLE mode.

PASSED

CALIBRATION

OR

FAILED

CALIBRATION

Default Span

This feature eliminates previous span calibration data and sets the analyzer sensitivity based on the average output of
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 +
within specified limits. This feature allows the user to check sensor’s signal output at a specified oxygen concentration
without removing it from the sensor housing.

Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION.
Press the ENTER key to select the highlighted menu option.

27

30-50% of the span gas value, indicating that the sensor output is

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OUTPUT SIMULATE

5.10 PPM

The following display appears:

MAIN MENU

SELECT RANGE

CALIBRATION

VIEW HISTORY
SYSTEM OPTIONS

>>>

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE

DEFAULT SPAN

DEFAULT ZERO
OUTPUT CALIBRATE

Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT SPAN.
Press the ENTER key to select the highlighted menu option.
The following displays appear and the system returns to the SAMPLING mode and displays current oxygen reading .

FACTORY

DEFAULTS

SET

AUTO SAMPLING

10 PPM RANGE

76 F 100 KPA

Analog Output ChecK- Output Simulate

This feature allows the user to simulate the electronics and the signal output. A known current is added to the analyzer
electronics internally to generate an equivalent analog signal output. This feature allows the user to check all
interconnections from the analyzer to the signal output recording device before installation of sensor thus preventing the
user to open the sensor bag before comple ting satisfactory analyzer installation. To simulate signal output

Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION and then select OUTPUT

SIMULATE.
Press the ENTER key to select the highlighted menu option.
The following displays appear:

MAIN MENU

SELECT RANGE

CALIBRATION

VIEW HISTORY
SYSTEM OPTIONS

28

>>>

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT CALIBRATE

OUTPUT SIMULATEI

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ADJUST

OUTPUT SIMULATE

OUTPUT SIMULATE

PRESS UP OR DOWN TO

OUTPUT ENTER/MENU TO RETURN

0% SPAN

4.00 mA

Pressing UP or DOWN key will increase or decrease the output by 5% of the full scale signal each time. Check the output
on the external recording device or voltmeter/ammeter. The output on the external recording would be the % of the full
scale signal selected, for example, 0% will represent 4.00 mA, 25% value will represent 8 mA and 50% span value will
represent 12.0 mA of the 4-20 mA full scale. After SIMULATION is complete, press ENTER/MENU key to return to
SAMPLE mode.

Note: To perform "Calibrate-Output Simulation", an external recording device must be connected between the negative
terminal of the power source and negative terminal of the transmitter.

Analog Output ChecK- Output Calibrate

In certain cases, the full scale analog may not match with full scale display. This feature allows the user to adjust the
electronics so that the full scale display matches with full scale analog signal output. To calibrate full scale signal output

Access the MAIN MENU by pressing the MENU key.
Advance the reverse shade cursor using the ARROW keys to highlight CALIBRATION and then select OUTPUT

SIMULATE.
Press the ENTER key to select the highlighted menu option.
The following displays app ear:

MAIN MENU

SELECT RANGE

CALIBRATION

VIEW HISTORY
SYSTEM OPTIONS

>>>

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO

OUTPUT CALIBRATEI

OUTPUT SPAN

20.0 mA ADJUST

PRESS UP OR DOWN TO ADJUST

OUTPUT ENTER/MENU TO RETURN

Pressing UP or DOWN key will increase or decrease the full scale output signal each time. Check the output on the
external recording device or voltmeter/ammeter. Repeat this step until the out equals the full scale analog signal expected,
for example 20 mA in the present case. After OUTPUT CALIBRATION is complete, press ENTER/MENU key to return to
SAMPLE mode.

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Sampling a Gas

GPR-1500 IS-LD Oxygen Analyzer requires a positive pressure to flow a sample gas across the sensor to measure oxygen
concentration in a sample gas. If a positive sample pressure is not available, install a high quality external sample pump to
push the sample through the analyzer; see the option of using a sample pump as described above.

Procedure

Following calibration, the analyzer will return to the SAMPLE mode and ready for sampling any gas.
Select the desired sampling mode - auto or manual – as described abov e.
Use a suitable tubing to transport sample gas to the analyzer
The main consideration is to eliminate any air leaks which can affect oxygen measurements.
For sample gases under positive pressure, the user must provide a means of controlling the inlet pressure as

recommended.
With continuous drain feature of the analy z er, a sample gas loaded with any type of liquid can be analyzed. The liquid from

sample gas will fall due to gravity and leave the sensor housing whereas the gas will separate and migrate to the sensor's
sensing surface. The sensor is mounted in such a way that liquid from sample gas will not accumulate on the sensing
surface of sensor.

NOTE: Assure that sample is adequately vented for optimum response and recovery – and safety.

View History

This feature allows the user to view
Maximum PPM O2
Minimum PPM O2
Average PPM O2
Maximum ambient temperature
Number of days the sensor has been in service (at the time of installation and first calibration, the user must enter YES to

confirm "new sensor") and
Number of days since the last calibration was done.

System Options

This features allows the user to

1. Set security; password protected operation

2. Define ranges; choose a range between two ranges, for example, 200 PPM full scale instead of 1000 PPM full
scale.

3. Display signal below 0.00; Negative signal, YES or NO.

4. Displays MODBUS COMM menu

Security

PASSCODE LOCK- Prevents un-authorized access to the analyzer menu options. Selecting PASSCODE LOCK will put
the analyzer in Sample Mode and accessing the menus will require a valid passcode.

To enter pass code, from SYSTEN OPTIONS menu, select SECURITY, select PASSCODE LOCK and then enter four digit
PASS CODE, numeral numbers only and press ENTER. Then select AUTO LOCK option and enter the number of minutes
after which access to MENU options will be locked (access allowed only after entering the PASS CODE).

In the vent the PASS CODE is lost, enter the factory default PASS CODE 2855 to access the MENU and then renter the
new PASS CODE.

Choosing the option to display negative number will allow the user to see the display below 0.00 but the output will not go
below 3.80 mA.

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Standby

The transmitter has no special storage requirements.
The sensor should remain mounted in the sensor housing and connected to the electron ic s during storage periods. Before

turning the sample gas OFF, ensure that sample/bypass valve (if analyzer equipped) is at the BYPASS position. This will
keep the sensor isolated from ambient air and would be ready to use again when required with very short down time.

NOTE: Under isolated conditions, some oxygen will diffuse into the sample system/sensor housing and the sensor out will
slowly climb up but after 2-3 hours, it will reach a plato, generally less than 400 PPM

Store the transmitter with power OFF at a safe location and away from any direct heating source.
If storing for an extended period of time, protect the analyzer from dust, heat and moisture.

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Item No.

Description

GPR-12-333-LD

Oxygen Sensor, for measuring O2 in inert gases

containing CO2

Item No.

Description

6. Maintenance

Generally, replacing oxygen sensor is the extent of the maintenance requirements of this transmitter.
Serviceability: Except for replacing oxygen sensor, there are no parts inside the transmitter for the operator to service.

Only trained personnel with the authorization of their supervisor should conduct maintenance.

7. Spare Parts

Recommended spare parts for the GPR-1500 AIS Oxygen Analyzer:

XLT-12-333-LD Oxygen Sensor, for measuring O2 in gases

Other spare parts:

The Factory must be
consulted for any other
questions/maintenance

32

Symptom

Possible Cause

Recommended Action

Sensor nearing end of life

pressure and temperature of sample)

8. Troubleshooting

Advanced Instruments, Inc

Slow recovery

High O
after installing
or replacing sensor

reading

2

At installation, defective
sensor

Air leak in sample system
connection(s)

Abnormality in zero gas
Damaged in service -

prolonged exposure to air,
electrolyte leak

Analyzer calibrated before
sensor stabilized caused by:

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

2) Air leak in sample
system connection(s)

3) Abnormality in zero gas

Replace sensor if recovery unacceptable

reading fails to reach 10% of lowest

or O

2

range
Leak test the entire sample system: Vary

the flow rate, if the O
inversely with the change in flow rate
indicates an air leak - correct source of
leak

Qualify zero gas (using portable
transmitter)

Replace sensor

Replace sensor

Allow O
making the span/calibration ad just men t

Continue purge with zero gas

Leak test the entire sample system
(above)

Qualify zero gas (using portable
transmitter)

reading to stabilize before

2

reading changes

2

High O2 reading
Sampling

Response time slow

O

reading doesn’t

2

agree to expected

values

O

2

Erratic O2 reading

Flow rate exceeds limits
Pressurized sensor
Improper sensor selection

Air leak, dead legs, distance
of sample line, low flow rate,
volume of optional filters and
scrubbers

Pressure and temperature of
the sample is different than
span gas

Abnormality in gas

Change in sample pressure

Correct pressure and flow rate
Remove restriction on vent line
Replace GPR sensor with XLT sensor

when CO2 or acid gases are present

Leak test (above), reduce dead volume or
increase flow rate

Calibrate the transmitter (calibrate at
pressure and temperature of sample)

Qualify the gas (use a portable analyzer as
a second check)

Calibrate the transmitter (calibrate at

33

or
No O2 reading

Dirty electrical contacts in
upper section of sensor
housing

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 interference
gases

Unauthorized maintenance
Sensor nearing end of life

Advanced Instruments, Inc

Clean contacts with alcohol (minimize
exposure time of MS sensor to ambient air
to extent possible)

Replace sensor and return sensor to the
factory for warranty determination

Upper section of sensor housing: Clean
contacts with water, wipe contacts with
clean paper towel and flush system and
sensor housing with dry gas

Sensor: Replace if leaking and return it to
the factory for warranty determination

Wipe with lint free towel or flow dry sample
or zero gas for 2-3 hours to flush out
condensation

Consult factory for recommendation.

Replace sensor and install scrubber

Consult factory.
Replace sensor

Erratic O

reading

2

or
Negative O2 reading
or
No O

reading

2

accompanied by
electrolyte leakage

34

Pressurizing the sensor by
flowing gas to the sensor with
the vent restricted or SHUT
OFF valve closed and
suddenly removing the
restriction draws a vacuum
on the sensor

or
partially opened valves

upstream of the analyzer
when using a pump
downstream of the analyzer
to draw sample from a
process at atmospheric
pressure or under a slight
vacuum. Placing a vacuum
on the sensor in excess 10”
of water column is strongly
discouraged.

A premature adjustment of
the ZERO OFFSET is a
common problem

Zero the transmitter. If not successful
replace the sensor

Avoid drawing a vacuum on the sensor, a
pressurized sensor may not leak but still
produce negative readings.

From MAIN MENU select DEFAULT ZERO

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9. Warranty

The design and manufacture of GPR Series oxygen transmitters/analyzers, monitors and oxygen sensors are performed
under a certified Quality Assurance System that conforms to established standards and incorporates stat e 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 monitor, analyzers and sensor 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 analyzer 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 option, replace 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 analyzer; affixing of any attachment not provided with the analyzer
or other failure to follow the Owner’s Manual. Some states and provinces do not allow limitations 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 with the analyzer; fire, flood, or acts 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 7:30 AM and 5:00 PM Pacific Time
Monday thru Thursday or 8:00 AM to 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
Tel: [phone]

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.

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Advanced Instruments, Inc

Product Identification

Product Name

Oxygen Sensor Series - PSR, GPR, AII, XLT

Synonyms

Electrochemical Sensor, Galvanic Fuel Cell

Manufacturer

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

Emergency Phone Number

909-392-6900

Preparation / Revision Date

January 1, 1995

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

Family

General Requirements

Use

Potassium Hydroxide or Acetic Acid - electrolyte, Lead - anode

Handling

Rubber or latex gloves, safety glasses

Storage

Indefinitely

Physical Properties

Boiling Point Range

KOH = 100 to 115° C or Acetic Acid = 100 to 117° 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

odor

Fire and Explosion Data

Flash and Fire Points

Not applicable

Flammable Limits

Not flammable

Extinguishing Method

Not applicable

Procedures

10. MSDS – Material Safety Data Sheet

Notes Oxygen sensors are sealed, contain protective coverings and in normal conditions do not

Chemical (Synonym) and

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

Appearance and Odor Aqueous solutions: KOH = Colorless, odorless or Acetic Acid = Colorless, vinegar-like

Special Fire Fighting

Not applicable

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Hazards

Reactivity Data

Stability

Stable

Instability

Incompatibility

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

Products

Conditions to Avoid

KOH = None or Acetic Acid = Heat

Spill or Leak

time).

Disposal

In accordance with federal, state and local regulations.

Health Hazard Information

Primary Route(s) of Entry

Ingestion, eye and skin contact

OSHA PEL 10 % (TWA), Lead - OSHA PEL .05 mg/cubic meter

or Acetic Acid = Oral LD50 (RAT) = 6620 mg/kg

Eye

Electrolyte is corrosive and eye contact could result 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

Monographs - not listed; OSHA - not listed

other reproductive harm.

Information

Ventilation Requirements

None

Eye

Safety glasses

Hand

Rubber or latex gloves

Respirator Type

Not applicable

Other Special Protection

None

Special Precautions

Transportation

Unusual Fire and Explosion

Advanced Instruments, Inc

Not applicable

Conditions Contributing to

Hazardous Decomposition

None

KOH = None or Acetic Acid = Emits toxic fumes when heated

Steps if material is released Sensor is packaged in a sealed plastic bag, check the sensor inside for electrolyte

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

Exposure Limits Potassium Hydroxide - ACGIH TLV 2 mg/cubic meter or Acetic Acid - ACGIH TLV /

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

Carcinogenic Reference Data KOH and Acetic Acid = NTP Annual Report on Carcinogens - not listed; LARC

Other Lead is listed as a chemical known to the State of California to cause birth defects or

Special Protection

Precautions

37

Do not remove the sensor’s protective Teflon and PCB coverings. Do not
probe the sensor with sharp objects. Wash hands thoroughly after handling.
Avoid contact with eyes, skin and clothing.

Empty sensor body may contain hazardous residue.
Not applicable

Appendix A

Electrical connections require an approved explosion
proof sealing fitting and packing around wires and
cables (for incoming power for the analyzer electronics
and 4-20mA signal output) coming into and out of the
explosion proof enclosure that houses the power
supply/signal output PCB.

Full compliance with hazardous area electrical code
requires the user to supply glands, fittings and/or
conduit commensurate with the level of protection or
classification desired. To maintain the ATEX
certification of this unit, the user must install ATEX
approved components according to ATEX directives.
To meet US and Canada requirements for use in Class
I, Division 1, Groups C, D hazardous areas, the user
must install the appropriate components according to
the NEC standards (US) or CEC standards (Canada).

Note: The following instruction is supplied from

information and data supplied by a reputable enclosure
manufacturer which we believe is reliable and is given
in good faith. Since the methods of application and
conditions under which our products are put to use are
beyond our control, we are not able to guarantee the
application and/or use of same. The user assumes all
risks and liability in connection with the application and
use of our products.

Advanced Instruments, Inc

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Advanced Instruments, Inc

Directions for use of Explosion Proof Packing Fiber ( non-asbestos )

For use as packing at the hub of sealing fittings, tamp packing fiber between and around conductors where they enter
fitting to prevent leakage of the liquid cement. Leave enough space in the fitting for length equivalent to the inside
diameter of the conduit but, not less then 5/8”.

Caution: Avoid getting in eyes or breathing dust
Use barrier cream, gloves and long sleeve shirts if dust or fiber is

irritating.

Prolonged contact may cause lung, eye or skin irritation. Directions for use

Explosion Proof Sealing Cement: Tamp packing fiber between and around

conductors where they enter the sealing fitting to prevent
leakage of liquid cement. Make sure conducto rs ar e not in
contact with each other or with the wall of fitting. Leav e space in
the fitting for a sealing length equivalent to the thread size of the

conduit seal but not less than 5/8”
Fill the marked shipping container with clean cold water to the “water line”

[35 ml to be precise].
Caution: Do not exceed the required amount of water.

Gradually pour cement from the plastic bag into the water and stir thoroughly for proper mixture. Fill fitting
completely within five (5) minutes after mixing, then tamp with blunt stick to expel any air bubbles. Close up

any opening in the fitting to insure integrity of the seal. Fittings requiring more than 10 oz. of cement must be
filled from a single mixture of cement and water. DO NOT POUR IN STAGES.
Water-mix sealing compound should not be poured or installed at temperature below 40F (4C). Maintain temperature at or
above 40F for at least 72 hours after pouring. CSA certified when used with any CSA certified sealing fitting. Ada co No. 1
sealing cement must be used as a part of any Adalet UL listed fitting.

Caution: At least five threads must engage on all fill plugs .
Caution: Prolonged breathing or ingestion may cause internal obstruction, seek medical care.

Do not get into eyes or on skin – if cement touches eyes or skin, flush with water for 15 minutes.
Large amounts on skin when hardening may cause skin burn.
Use adequate ventilation.

To reorder sealing cement kit, specify P/N ENCL-1071-KIT

Allow cement at least 72 hours to cure.

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Advanced Instruments, Inc

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Advanced Instruments, Inc

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Advanced Instruments, Inc

Appendix G

Maintenance – H2S Scrubber

Servicing any of the H2S scrubbers will depend on several factors as illustrated in Appendix F and include: the (average)
H2S concentration, volume of scrubber media and flow rate through the scrubber (often times maximizing the service lif e
means longer system response time) see Appendix F.

Required equipment:

1. 2x 7/16” open end wrenches

2. 1x 9/16” open end wrench

3. 1x 1” open end or adjustable wrench

Procedure:

Separate the top connection to the scrubber using a 7/16” and the 9/16” open end wrenches on the two top nuts.
Hold the second nut with the 9/16” open end wrench.
With one of the 7/16” open end wrenches turn the top nut counter clockwise until the fitting disengages.
Separate the bottom connection to the scrubber using both 7/16” open end wrenches.
Hold the nut at the bottom of the scrubber with a 7/16” open end wrench.
With the other 7/16” open end wrench turn the nut below counter clockwise until the fitting disengages.
Carefully, remove the stainles s tubing from the top and bottom of the scrubber.
Carefully pull the scrubber from its mounting clip which is attached to the back panel.
Once the scrubber is free, hold the scrubber with one hand and using the 1” open end or adjustable wrench with the other

hand, turn the 1” nut counter clockwise and remove the 1” nut from the scr ubber.
There is no need to remove the 7/16” fitting at the bottom of the scrubber.
With the 1” nut removed, empty the spent media through the opening.
Fill the scrubber with fresh media (should be rich purple in color).
Reverse the above steps to re-assemble and install the scrubber .

Maintenance – Coalescing Filter

Servicing the coalescing filter (P/N FLTR-1002-2) depends on the cleanliness and moisture content of the sample and
maintenance intervals.

Required equipment:

Channel locks
Damp rag
Lubricant (a thin coat applied to the o-ring after cleaning helps ensure a tight seal and extend o-ring life)

Procedure:

Unscrew the clear polycarbonate bowl by turning it counter clockwise.
Note: It is probably stuck tight – use a damp rag to grip if removing by hand or to prevent damage to the bowl if using the

channel locks.
The bowl seals to the head section with an o-ring, do not lose the o-ring.
The filter element screws into the head section, carefully turn it counter clockwise and remove it from the head.
Using the damp cloth, clean the inside of the bowl and the o-ring before reassembling – apply a very thin coat of lubricant

to the o-ring.
Reverse the above steps to re-assemble the filter.

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