Analytical Industries Inc (AII) GPR-1900 Operating Manual

Technical Specifications *

Accuracy: < 2% of FS range under constant conditions

Analysis:

Application:

Approvals: CE

Area Classification: General purpose

Alarms:

Calibration:

Compensation: Barometric pressure and temperature

Connections: 1/8" compression tube fittings

Controls:

Display:

Enclosure: Painted aluminum 6” x 4” x 4” panel mount

Flow: Not flow sensitive, 1-2 SCFH recommended

Linearity: > .995 over all ranges

Pressure:

Power: Universal; specify 100/120/220/240 VAC or 12-28 VDC

Range ID:

Recovery Time: 60 seconds in air to < 10 PPM in < 1 hr on N2 purge

Response Time: 90% of final FS reading < 10 seconds

Sample System: None

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 non-isolated or 1-5V

Temp. Range:

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

Two user configurable alarms: magnetic coil relays rated
3A at 100 VAC, field programmable alarm time delays,
alarm bypass for CAL and system fail alarm

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, alarm and system functions

Graphical LCD 5” x 2.75”; resolution .01 PPM; displays

real time ambient temperature and pressure

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

4-20mA non-isolated or 1-5V; option: relay contacts
(eliminates alarms)

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

5ºC to 45ºC (GPR), -10ºC to 45ºC (XLT sensor)

GPR-1900

PPM Oxygen Analyzer

Panel Mount Configuration for OEM Applications

Advanced Sensor Technology

 Unmatched Expected Life & Warranty
 Unmatched Recovery from Air to 10 PPM
 Extended Operating Range -20⁰C (-4⁰F)
 Excellent Compatibility with 0-100% CO
 Sensitivity < 0.5% FS Range
 Fast Response, No Maintenance

100-240 VAC or 12-28 VDC Power
2 Field Selectable Alarm Setpoints
Power and System Failure Alarms
5 Ranges Standard
Auto Ranging or Single Fixed
4-20 mA or 1-5V Signal Output
Range ID 4-20 mA, 1-5V, or Relay Contacts
Stainless Steel Wetted Parts

2

Warranty: 12 months analyzer; 12 months sensor

Wetted Parts: Stainless steel

Optional Equipment

Sample conditioning accessories - contact factory

* Specification subject to change without notice.

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

ISO 9001:2008 Certified

INTERTEK Certificate No. 485

Advanced Instruments Inc.

GPR-1900

ppm Oxygen Analyzer

Owner’s Manual

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

Table of Contents

Introduction 1
Quality Control Certification 2
Safety 3
Features & Specifications 4
Operation 5
Maintenance 6
Spare Parts 7
Troubleshooting 8
Warranty 9
Material Safety Data Sheets 10
Correlating reading - LCD display to 4-20mA output Appendix B

Advanced Instruments Inc.

1 Introduction

Your new oxygen analyzer is a precision piece of equipment designed to give you years of use in variety of industrial oxygen
applications.

This analyzer is designed to measure the oxygen concentration in inert gases, gaseous hydrocarbons, hydrogen, a variety of gas
mixtures and acid gases containing from 0-100% CO

In order to derive maximum performance from your new oxygen analyzer, please read and follow the guidelines provided in this
Owner’s Manual.

The serial number of this analyzer may be found on the inside the analyzer. 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: _______________________
Every effort has been made to select the most reliable state of the art materials and components designed for superior

performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer 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 analyzer is your assurance that we stand behind every analyzer sold.

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

(for CO

2

background, the XLT series sensor must be used) present.

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2 Quality Control Certification

Date:

Model: GPR-1900 ppm Oxygen Analyzer S/N _____________________
Sensor: ( ) GPR-12-333 ppm Oxygen Sensor

Accessories: Owner’s Manual

Configuration: Ranges: 0-10 ppm, 0-100 ppm, 0-1000 ppm, 0-1%, 0-25%

Power: ( ) 100/120/220/250 VAC

(GPR-1900R)
(GPR-1900W)

SS sensor housing and 1/8” compression type fittings for inlet and vent

Test System start-up diagnostics satisfactory
Auto/manual range
Alarm relays activate/deactivate with changes in O2 concentration
Alarm bypass
Analog outputs: 4-20mA signal output
4-20mA range ID reflects range changes
Recovery from air to < 10 ppm in < 60 minutes
Baseline drift on zero gas < ± 2% FS over 24 hour period
Noise level < ± 1.0% FS
Span adjustment within 10-50% FS
Peak to peak over/under shoot < 0.5% FS
Overall inspection for physical defects

Options
Notes

Customer: Order No.:

( ) XLT-12-333 ppm Oxygen Sensor S/N _____________________

CABL-1008 Power Cord

A-1161-1 PCB Assembly Micro / Display – Software V. ______
A-1162 PCB Assembly Power Supply / Interconnection

( ) 9-28 VDC non-loop
Enclosure: ( ) Panel mount 7W x 4”H x 4”D (panel cutout 6”W x 3”H)

( ) Panel mounted with rear cover for 19” rack 19x7x12”
( ) Door mounted for NEMA4 wall mount 12x12x8”

Pass

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3 Safety Guidelines

General

This section summarizes the essential precautions applicable to the GPR-1900 ppm Oxygen Analyzer. Additional precautions
specific to individual analyzer are contained in the following sections of this manual. To operate the analyzer safely and obtain
maximum performance follow the basic guidelines outlined in this Owner’s Manual.

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

Read Instructions: Before operating the analyzer 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 analyzer, 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 analyzer.

Pressure and Flow

Inlet Pressure: GPR-1900 Oxygen Analyzer is designed for flowing samples, equipped with 1/8” compression tube fitting
connections on the side of the sensor housing (unless otherwise indicated, either fitting can serve as inlet or vent) and are
intended to operate at positive pressure regulated to between 5-30 psig.

Outlet Pressure: The sample gas vent pressure should be atmospheric.

Installation

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.

Mounting: The analyzer is approved for indoor use, outdoor use requires mounting in a secondary enclosure with the
appropriate NEMA rating. Mount as recommended by the manufacturer.

Power: Supply power to the analyzer only as rated by the specification or markings on the analyzer enclosure. The wiring that
connects the analyzer to the power source should be installed in accordance with recognized electrical standards and so they
are not pinched particularly near the power source and the point where they attach to the analyzer. Never yank wiring to
remove it from an outlet or from the analyzer. The analyzer consumes approximately 30 watts of power.

Operating Temperature: The maximum operating temperature is 45º C on an intermittent basis.
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.

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Handling: Do not use force when using the 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 analyzer for the operator to service.
Only trained personnel with the authorization of their supervisor should conduct maintenance.

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

Troubleshooting: Consult the guidelines in Section 8 for advice on the common operating errors before concluding that your
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 electrical 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 analyzer is left unused for a long period of time.

4 Features & Specifications

Specifications are subject to change without notice. See last page for current specifications, this section left blank intentionally.

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5 Operations

Principle of Operation

The GPR-1900 ppm Oxygen Analyzer incorporates several advanced galvanic fuel cell type sensors for parts-per-million ppm
oxygen analysis. This model is configured for panel mounting and requires a 6”W x 3”H cutout with 4 holes for the studs located
on the back side of the analyzer’s front panel.

Optional mounting configurations include a 19” rack or wall mount enclosure with or without a sample system. Contact the
factory for additional information on options.

Advanced Galvanic Sensor Technology

The sensors function on the same principle and are specific for oxygen. They measure the partial pressure of oxygen from low
ppm to 100% levels in inert gases, gaseous hydrocarbons, helium, hydrogen, mixed gases, acid gas streams and ambient air.
Gas streams with acid gases like CO2 in the background in concentrations greater than 0.5% require the use of an XLT Series
oxygen sensor to maintain accuracy and reasonable sensor life.

Oxygen, the fuel for this electrochemical transducer, diffusing into the sensor 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 over all 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 an extremely versatile oxygen sensing
technology. 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. Another significant development involves expanding the operating temperature range for
percentage range sensors from -30°C to 50°C.

The GPR-1900 employs the GPR-12-333 or XLT-12-333 ppm oxygen sensor and a stainless steel sensor flow housing to provide
a very cost effective versatile ppm trace oxygen analyzer with four (4) standard ranges: 0-100 ppm, 0-1000 ppm, 0-1% for
analysis and 0-25% for air calibration (analysis is possible on this range provided the user can accept a drastic reduction in
expected sensor life). Under constant conditions the GPR-1900 is capable of analyzing 1 ppm or less.

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.

Additional features of the micro-processor based electronics include manual or auto ranging, isolated 4-20mA signal for signal
output and range ID. Whenever the analyzer is calibrated, a unique algorithm predicts and displays a message indicating a
‘weak sensor’ suggesting the sensor be replaced in the near future.

Users interested in adding their own sample handling or conditioning system are encouraged to consult the factory to ensure all
applicable conditions are addressed to ensure proper operation of the analyzer. 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]

Sample System

The GPR-1900 is designed to be integrated into a larger analyzer system and provide users with maximum flexibility, and,
therefore is not equipped with a sample system. The sample must be properly presented to the sensor to ensure an accurate
measurement. Users interested in adding their own sample conditioning system should consult the factory. Advanced
Instruments Inc. offers a full line of sample handling, conditioning and expertise to meet your application requirements. Contact
us at 909-392-6900 or e-mail us at [e-mail]

.

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Advanced Instruments Inc.

However, for optimal performance after exposing the sensor to air or elevated oxygen levels in terms of:

1) bringing the analyzer back online, and,

2) maximizing the service life of the sensor by isolating the sensor
Advanced Instruments recommends the user employ one of the following ‘bypass sample system’ designs illustrated below.

Preference is given to the illustration on the left because it is the surest and simplest approach.

The ‘bypass sample system’ is optimal, however, it is not required. For example, deleting the 3-way valve from the illustration
on the right enables the user to isolate the sensor but lengthens the time required to bring the analyzer online. The bypass
feature diverts the flow of sample gas containing high concentrations of oxygen around the sensor – which when the valves are
operated properly remains in an atmosphere containing a low concentration of oxygen, less than 100-200 ppm. The source of
the atmosphere with the low concentration of oxygen can be either be a zero gas or sample gas is not important - only the
oxygen concentration is important. Without the bypass feature, the sensor still can be isolated but not as easily and the best the
user can do when connecting a new gas line is start the flow of sample gas (to purge the air trapped inside the line) several
minutes before connecting to the analyzer.

Calibration & Accuracy Overview

Single Point Calibration: As previously described
the galvanic 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 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 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(es) must be the same (reality < 1-2 psi).

Temperature: The rate 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 offsets this effect with an accuracy of +
independent of temperature. There is no error if the calibration and sampling are performed at the same temperature or if the
measurement is made immediately after calibration. Lastly, small temperature variations of 10-15º produce < 1% error.

5% or better and generates an output function that is

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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', illustrated by Graph A below, such as +
of range resistors and the 'play' in the potentiometer used to make span adjustments and 2) those producing 'percent of full
scale errors', illustrated by Graph B, such as +
technology and the fact that other errors are 'spanned out' during calibration.
Graph C illustrates these 'worse case' specifications that are typically used to develop an analyzer's overall accuracy statement
of < 1% of full scale at constant temperature or < 5% over the operating temperature range. QC testing is typically < 0.5%
prior to shipment.

Example 1: As illustrated by Graph A any error, play in the multi-turn span pot or the temperature compensation circuit,
during a span adjustment at 20.9% (air) of full scale range would be multiplied by a factor of 4.78 (100/20.9) if used for
measurements of 95-100% oxygen concentrations. Conversely, an error during a span adjustment at 100% of full scale range is
reduced proportionately for measurements of lower oxygen concentrations.

Zero Calibration: In theory
signal output when exposed to an oxygen free sample gas. In reality
sampling oxygen free sample gas due to contamination or quality of the zero gas; minor leakage in the sample line connections;
residual oxygen dissolved in the sensor’s electrolyte; and, tolerances of the electronic components. The Zero Offset capability of
the analyzer is limited to 50% of lowest most sensitive range available with the analyzer.
Recommendation 1: Zero calibration, see Determining True Zero Offset below, is recommended only
performing continuous analysis below 5% of the lowest most sensitive range available with a ppm analyzer, e.g. analysis below

0.5 ppm on the 10 ppm range, or below 0.1% (1000 ppm) with a percent analyzer. Note 1: Once the zero offset adjustment is
made, zero calibration is not required again until the sample system connections are modified, or, when installing a new oxygen
sensor. As a result, zero calibration is not practical and therefore not recommended for higher ranges or portable analyzers.

Determining True Zero Offset:
stable reading or horizontal trend on an external recording device. Note 2: 24 hours is required to assure the sensor has
consumed the oxygen that has dissolved into the electrolyte inside the sensor while exposed to air or percentage levels of
oxygen. For optimum accuracy, utilize as much of the actual sample system as possible.

Span Calibration: Involves adjusting the analyzer electronics to the sensor’s signal output at a given oxygen standard.
Regardless of the oxygen concentration of the oxygen standard used, a typical span calibration takes approximately 10 minutes.

Note 3: The amount time required to get the analyzer back on line for normal use is influenced by a.) the level of oxygen
analysis anticipated during normal operation (also determines the initial analyzer selection), and, b.) whether the sensor is new
or has been in service for at least two weeks.

General guidelines
oxygen content below the stated thresholds:

¾ measurements above 1000 ppm or 0.1% require less than 3 minutes
¾ measurements above 100 ppm (parts-per-million analyzer) require less than 10 minutes
¾ measurements below 10 ppm (part-per-million analyzer) require 20 minutes if the sensor has been in service at ppm

levels for at least two weeks, and, 60 minutes if the sensor is new assuming the zero/purge/sample gas has an oxygen
concentration below 1 ppm

for analyzers to come online following span calibration and exposure to a zero/purge/sample gas with an

, the electrochemical galvanic fuel cell type oxygen has an absolute zero meaning it produces no

Allow the analyzer approximately 24 hours to stabilize with flowing zero gas as evidenced by a

1-2% linearity errors in readout devices, which are really minimal due to today's

, expect the analyzer to generate an oxygen reading when

Recommendation 2: For 'optimum calibration accuracy' calibrate with a span gas approximating 80% of the full scale range
one or two ranges higher than the full scale range of interest (normal use) to achieve the effect illustrated on Graph A and
Example 1. Always calibrate at the same temperature and pressure of the sample gas stream.

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5% temperature compensation circuit, tolerances

for online analyzers

Advanced Instruments Inc.

Note 4: Calibrating with a span gas approximating 10% of the full scale range near the expected oxygen concentration of the
sample gas is acceptable but less accurate than ‘optimum calibration accuracy’ method recommended – the method usually
depends on the gas available. Calibrating at the same 10% of the full scale range for measurements at the higher end of the
range results in magnification of errors as discussed in Graph A and Example 1 and is not recommended. Of course the user can
always elect at his discretion to accept an accuracy error of +

Air Calibration:
calibrate the analyzer with ambient air (20.9% oxygen) and operate the analyzer within the stated accuracy spec on the lowest
most sensitive range available with the analyzer – there is no need to recalibrate the analyzer with span gas containing a lower
oxygen concentration. Except for Oxygen Purity Analyzers intended to measure elevated oxygen levels ranging from 50-100%
oxygen, calibrating either a ppm or percent analyzer with ambient air on the CAL or 0-25% range meets the 80% criteria
discussed in Recommedation 2.

Recommendation 3: Air calibrate the analyzer (with the exception of Oxygen Purity Analyzers intended to measure elevated
oxygen levels ranging from 50-100% oxygen) when operating a percent analyzer, installing and replacing a ppm oxygen sensor,
to verify the oxygen content of a certified span gas or when a certified span gas is not available to calibrate a ppm analyzer
(immediately following air calibration reintroduce a gas with a low oxygen concentration to expedite the return to ppm level
measurements as per Note 3).

Based on the inherent linearity of the electrochemical galvanic fuel cell type oxygen sensor enables the user to

2-3% of full scale range if no other span gas is available.

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Installation Considerations

Gas Sample Stream: Ensure the gas stream composition of the application is consistent with the specifications and review the
application conditions before initiating the installation. Consult the factory if necessary to ensure the sample is suitable for
analysis.

Note: In natural gas applications such as extraction and transmission, a low voltage current is applied to the pipeline itself to
inhibit corrosion. As a result, electronic devices can be affected unless adequately grounded.

Contaminant Gases: A gas scrubber and flow indicator with integral metering valve are required upstream of the analyzer to
remove interfering gases such as oxides of sulfur and nitrogen or hydrogen sulfide that can produce false readings, reduce the
expected life of the sensor and void the sensor’s warranty if not identified at time of order placement. Installation of a suitable
scrubber is required to remove the contaminant from the sample gas to prevent erroneous analysis readings and damage to the
sensor or optional components. Consult the factory for recommendations concerning the proper selection and installation of
components.

Expected Sensor Life: With reference to the publish specification located as the last page of this manual, the expected life of
all oxygen sensors is predicated on oxygen concentration (< 1000 ppm or air), temperature (77°F/25°C) and pressure (1
atmosphere) in “normal” applications. Deviations are outside the specifications and will affect the life of the sensor. As a rule of
thumb sensor life is inversely proportional to changes in the parameters.

Optimum Accuracy: Determine if Zero Calibration is recommended for your application. If it is Zero Calibration should
precede Span Calibration and both should be repeated after the analyzer has been allowed to stabilize, typically 24-36 hours
after installation. For Span Calibration use a certified span gas with an oxygen content (balance nitrogen) approximating 80% of
the next higher full scale range above the intended measuring range is recommended for optimum accuracy, see Calibration
and Accuracy.

Assuming the initial zero is performed according to the procedure described herein, the analyzer should not require Zero
Calibration again until the either the sensor is replaced or a change is made to the sample system or gas lines, and, it should
not require Span Calibration again for up to 3 months under “normal” application conditions as described in the published
specifications. One of the unique features of analyzers based on the electrochemical galvanic fuel cell type oxygen sensor is the
fact that it can be field calibrated at the user’s discretion to whatever standard of certified span gas the user elects to use.

Zero Calibration: In theory
reality, expect the analyzer to generate an oxygen reading when sampling oxygen free sample gas due to contamination or
quality of the zero gas; minor leakage in the sample line connections; residual oxygen dissolved in the sensor’s electrolyte; and,
tolerances of the electronic components.

Zero calibration, see Determining True Zero Offset below, is recommended only
analysis below 5% of the lowest most sensitive range available with a ppm analyzer, e.g. analysis below 0.5 ppm on the 10 ppm
range, or below 0.1% (1000 ppm) with a percent analyzer. Note: Once the zero offset adjustment is made, zero calibration is
not required again until the sample system connections are modified, or, when installing a new oxygen sensor. As a result, zero
calibration is not practical and therefore not recommended for higher ranges or portable analyzers.

Determining True Zero Offset:
stable reading or horizontal trend on an external recording device. Note: 24 hours is required to assure the sensor has
consumed the oxygen that has dissolved into the electrolyte inside the sensor while exposed to air or percentage levels of
oxygen. For optimum accuracy, utilize as much of the actual sample system as possible.

Span Calibration: Involves adjusting the analyzer electronics to the sensor’s signal output at a given oxygen standard, e.g. a
certified span gas with an oxygen content (balance nitrogen) approximating 80% of the next higher full scale range above the
intended measuring range is recommended for optimum accuracy, see Calibration and Accuracy.

Recommendation:
ambient air (20.9% oxygen) and operate the analyzer within the stated accuracy spec on the lowest most sensitive range
available with the analyzer – there is no need to recalibrate the analyzer with span gas containing a lower oxygen
concentration. Calibrating either a ppm or percent analyzer with ambient air (with the exception of Oxygen Purity Analyzers

Based on the inherent linearity of the galvanic oxygen sensor enables the user to calibrate the analyzer with

, the oxygen sensor produces no signal output when exposed to an oxygen free sample gas. In

for online analyzers performing continuous

Allow the analyzer approximately 24 hours to stabilize with flowing zero gas as evidenced by a

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Advanced Instruments Inc.

intended to measure elevated oxygen levels ranging from 50-100% oxygen) on the CAL or 0-25% range meets the 80% criteria
discussed above.

Air calibrate the analyzer (with the exception of Oxygen Purity Analyzers intended to measure elevated oxygen levels ranging
from 50-100% oxygen) when operating a percent analyzer, installing and replacing a ppm oxygen sensor, to verify the oxygen
content of a certified span gas or when a certified span gas is not available to calibrate a ppm analyzer (immediately following
air calibration reintroduce a gas with a low oxygen concentration to expedite the return to ppm level measurements).

Materials: Assemble the necessary zero, purge 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 ppm and percentage range (above or below ambient air) analysis; hardware for mounting.

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 1,800ºF to ambient.

Pressure & 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 such in a control room or an open area such as a landfill or bio-pond).

Sample systems and/or flowing gas samples are generally required for applications involving oxygen measurements at levels
other than ambient air and when the pressure exceeds ambient. In these situations, the use of stainless steel tubing and fittings
is critical to maintaining the integrity of the gas stream to be sampled and the inlet pressure must always be higher than the
pressure at the outlet vent which is normally at atmospheric pressure. The sensor is exposed to sample gas that must flow or
be drawn through metal tubing via 1/8” compression inlet and vent fittings, a stainless steel sensor housing with an o-ring seal
to prevent the leakage of air and stainless steel tubing.

Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH generate
backpressure and erroneous oxygen readings because the diameter of the integral tubing cannot evacuate
the sample gas at the higher flow rate. The direction the sample gas flows is not important, thus either
tube fitting can serve as the inlet or vent – just not simultaneously.

A flow indicator with an integral metering valve upstream of the sensor is recommended as a means of
controlling the flow rate of the sample gas. A flow rate of 2 SCFH or 1 liter per minute is recommended for
optimum performance.

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). To avoid generating a vacuum on the sensor (as
described above) during operation, always select and install the vent fitting first and remove the vent
fitting last.

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. To reduce the possibility of leakage for low
ppm measurements, position a metering needle valve upstream of the sensor to control the flow rate and position a flow
indicator downstream of the sensor. If necessary, a pressure regulator (with a metallic diaphragm is recommended for optimum
accuracy, the use of diaphragms of more permeable materials may result in erroneous readings) upstream of the flow control
valve should be used to regulate the inlet pressure between 5-30 psig.

Application Pressure - Atmospheric or Slightly Negative: For accurate ppm range 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.

Caution: If the analyzer is equipped with an optional flow indicator with integral metering valve or a metering flow control
valve upstream of the sensor - open the metering valve completely to avoid drawing a vacuum on the sensor and placing an
undue burden on the pump. If pump loading is a consideration, a second throttle valve on the pump’s inlet side may be
necessary to provide a bypass path so the sample flow rate is within the above parameters.

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Recommendations to avoid erroneous oxygen readings and damaging the sensor:

¾ 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).

¾ Assure there are no restrictions in the sample or vent lines
¾ Avoid drawing a vacuum that exceeds 14” of water column pressure – unless done gradually
¾ Avoid excessive flow rates above 5 SCFH which generate backpressure on the sensor.
¾ Avoid sudden releases of backpressure that can severely damage the sensor.
¾ Avoid the collection of liquids or particulates on the sensor, they block the diffusion of oxygen into the sensor
¾ 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.

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 optional
components. Moisture and/or particulates do not necessarily damage the sensor, however, collection 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 when in fact the problem is easily remedied by blowing on the front of the sensor. Consult the factory for
recommendations concerning the proper selection and installation of components.

Gas Connections: Inlet and outlet vent gas lines for ppm analysis require 1/8” or ¼” stainless steel compression fittings; hard
plastic tubing with a low permeability factor can be used percentage range measurements.

Power Connection: Locate the appropriate source of to meet the analyzer or analyzer requirements, ensure that is properly
grounded and meets the area classification.

Mounting the Analyzer & Sensor

The GPR-1900 consists of a six (6) foot insulated cable which
connects the sensor to the rear of the electronics module, a
long life maintenance free oxygen sensor and a stainless steel
sensor housing equipped with 1/8” diameter stainless steel
compression fittings.

The compact design also lends itself to optional mounting
configuration such as a standard 19” rack or wall mount
enclosures, both of which can be equipped with optional
sample system components. Contact the factory for additional
information.

Procedure:

1. The GPR-1900 front panel measures 7”W x 4”H x 4.5”D.
This compact configuration is designed for panel
mounting directly to any flat vertical surface, wall or
bulkhead plate with the appropriate 6”W x 3”H cut out
and four ¼” diameter holes for insertion of the mounting studs located on the back side of the front panel.

2. When mounting the analyzer position it approximately 5 feet off the floor for viewing purposes and allow sufficient room for
access to the terminal connections at the rear of the enclosure.

3. Note: The proximity of the analyzer to the sample point and use of optional sample conditioning components have an
impact on sample lag time.

4. Position the sensor housing along any flat surface. The bracket attached to the sensor housing is fabricated with two 6/32
mounting holes. The oxygen sensor is not position sensitive but it is recommended to orient the sensor housing with the
upper section identified by the interconnection cable facing the ceiling.

5. Connect the four wires of the cable, following the color coding above the terminal block, at the rear of the analyzer.

6. Attach the flow housing to the mounting position determine above.

7. Do not install the sensor at this time, see below.

.

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Gas Connections

The GPR-1900 with its standard flow through configuration is designed for positive pressure samples and requires connections
for incoming sample and outgoing vent lines. The user is responsible for calibration gases and the required components, see
below. Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH generate
backpressure and erroneous oxygen readings because the diameter of the integral tubing cannot evacuate the sample gas at
the higher flow rate. A flow indicator with an integral metering valve upstream of the sensor is recommended as a means of
controlling the flow rate of the sample gas. A flow rate of 2 SCFH or 1 liter per minute is recommended for optimum
performance.

Caution: Do not place your finger over the fitting designated as the vent (it pressurizes the sensor) or 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).

Procedure:

1. Caution: Do not change the factory setting until instructed.

2. Designate the female quick disconnect fittings, right side of the analyzer, as inlet and vent respectively.

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

4. Install one mating male vent fitting into the female quick disconnect fitting designated as the VENT – connection of 1/8”
dia. metal vent line (requires an 1/8” male NPT to tube adapter) is optional.

5. Connect the second mating male fitting to 1/8” dia. metal sample line using a 1/8” male NPT to tube adapter.

6. Connect the third mating male fitting to 1/8” dia. metal span gas line using a 1/8” male NPT to tube adapter.

7. Install either the sample or span mating male fitting into the female quick disconnect fitting designated as SAMPLE.

8. Set the flow rate to 2 SCFH (open the flow control valve completely if using an external sampling pump positioned
downstream of the sensor).

9. Allow gas to flow through the analyzer for 3-5 minutes and proceed to Calibration or Sampling.

Electrical Connections:

The appropriate AC or DC power requirement must specified be
specified at order placement.

Incoming power for the 100-250V AC powered analyzers is
supplied through a universal power entry module. A standard
computer type power cord (P/N A-1008) is required for the
universal power entry module. DC power cable must be supplied
by the user. A well grounded insulated power cable is
recommended to avoid noise resulting from unwanted
interference. Power consumption is approximately 30 watts.

Filtered terminal blocks are provided for power failure, set point
alarm relays and signal output connections. The PCB also
includes a transformer to power the relays, a sensor bypass
switch for troubleshooting the electronics

Caution: Integral 4-20mA converters are internally powered
and do not require external power. DO NOT supply any voltage
to any of the terminals for 4-20mA signal output and range ID or

the 4-20mA converters will be damaged.
Caution: To assure proper grounding, connect the 4-20mA

signal output to the external device (PLC, DCS, etc.) before attempting any zero or span adjustments.
Procedure:

1. As illustrated above the sensor, power and alarm relays and signal output connections are hard wired to screw type
terminal blocks located at the rear of the analyzer.

2. Use a small bladed screwdriver to loosen the appropriate terminal screws as illustrated above.

3. Strip the wires of the cable no more than 3/16 inch.

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4. To connect to an active relay or “fail safe”, connect the live cable to the common terminal C and the secondary cable to the
normally open NO terminal.

5. To break the connection upon relay activation, connect the secondary cable to the normally closed NC terminal.

6. Insert the stripped end of the cables into the appropriate terminal slots assuring no bare wire remains exposed that could
come in contact with the back panel of the analyzer enclosure.

7. Tighten the terminal screws to secure the wires of the cable.

Danger: While connecting the cables to the relay terminals, ensure there is no voltage on the cables to prevent electric shock
and possible damage to the analyzer. Caution: Assure the stripped wire ends of the cable are fully inserted into the terminal
slots and do not touch each other or the back panel of the analyzer enclosure.

Alarm Relays

Alarm 1 and Alarm 2 represent two threshold type alarms that can be configured in the field from the analyzer’s menu driven
LCD display as follows:

¾ Establish independent set points
¾ Either Hi or Lo
¾ Either On or Off (enabled or disabled)
¾ Both temporarily defeated using a user entered ‘timeout’ period (normally minutes)

The alarm set point represents a value. When the oxygen reading exceeds (high alarm) or falls below (low alarm) the alarm set
point, the relay is activated and the LCD displays the alarm condition. When activated the alarms trigger SPDT Form C non­latching relays @ 5A, 30VDC or 240VAC resistive. To prevent chattering of the relays, a 2% hysteresis is added to the alarm set
point. This means that the alarm will remain active until the oxygen reading has fallen 2% below the alarm set point (high
alarm) or risen 2% above the alarm set point (low alarm) after the alarm was activated. Aside from being totally defeated in the
Alarm Bypass mode, the timeout feature is useful while replacing the oxygen sensor or during calibration when the oxygen
reading might well rise above the alarm set point and trigger a false alarm.

Note: When making connections the user must decide whether to configure/connect Alarm 1 and Alarm 2 in failsafe mode
(Normally Open – NO – where the alarm relay de-energizes and closes in an alarm condition) or non-failsafe mode (Normally
Closed – NC – where alarm relay energizes and opens in an alarm condition).

Power Failure Alarm

A dry contact rated at 30VDC @ 1A is provided as a power failure alarm that activates when power supplied to the analyzer’s
circuits is unacceptable. The contact is normally closed but opens when the power to the analyzer is switched off or interrupted
and cannot be disabled.

4-20mA Signal Output and Range ID

The analyzer provides a 4-20mA full scale fully isolated ground signals for external recording devices. The integral IC on the
main PCB provides 4-20mA fully isolated signals for output and range ID. The 4-20mA current output is obtained by connecting
the current measuring device between the positive and negative terminals labeled OUTPUT 4-20mA. To check the signal output
of the 4-20mA E/I integrated circuit connect an ammeter as the measuring device and confirm the output is within +
4mA. A finer adjustment of the zero offset of the 4-20mA converter can be provided by a potentiometer mounted on the main
PCB Assembly. Consult factory for instructions

For range ID the output of 4mA, 8mA, 12mA, 16mA, 20mA correspond to the most sensitive to least sensitive analysis range.

Caution:

voltage to any of the two terminals of the 4-20mA converter.

The integral 4-20mA converters are internally powered and do not require external power. DO NOT supply any

0.1mA of

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Installing the Oxygen Sensor

The GPR-1900 Oxygen Analyzer is equipped with an external oxygen sensor. They have been tested and calibrated by the
manufacturer prior to shipment and are fully operational from the shipping containers. The sensor has not been installed at the
factory and it will be necessary to install the sensor in the field. Caution: Review procedure before proceeding, mainly 2 and 9.

Caution: DO NOT open 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 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 manner similar to that of a common battery in accordance with local regulations.

Procedure:

1. The sensor has not been installed at the factory (in standard configuration there are no valves to isolate the sensor) and it
will be necessary to install the sensor in the field.

2. As described above the following steps should already be completed:
a) Secure the sensor housing bracket with two 6/32 mounting screws, in the preferred
position the upper section with the interconnection cable should be facing the ceiling;
b) connect the gas lines;
c) electrical connections.

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

2. Purge the oxygen trapped in the newly connected gas lines for 3-5 minutes.

3. Flow zero gas or sample gas with a low ppm oxygen concentration to the analyzer at the
predetermined flow rate of 2 SCFH.

4. Using the 5/16 wrench supplied loosen but do not remove the clamp bolt located under the sensor housing, see photo.

5. Rotate the upper section of the sensor housing 90º to disengage from the clamp.

6. Remove the upper section by pulling it straight up and place it on a smooth surface.

7. Select the AUTO RANGING option from the SAMPLE menu with gas flowing to the analyzer.

8. Remove the oxygen sensor from the bag and remove the red shorting device (including the gold ribbon) from the PCB
located at the rear of the sensor.

9. Minimize the time the sensor is exposed to ambient air.

10. Immediately place the sensor in the bottom section of the sensor housing with the PCB facing up.

11. Immediately place the upper section of the sensor housing over the sensor, gently push the upper section downward and
rotate 90º to engage the clamp.

12. Finger tighten the clamp bolt and then tighten it one full turn with the 5/16 wrench to securely lock the two sections of the
sensor housing.

13. The analyzer will OVER RANGE for a short period of time as indicated by the graphical LCD display.

14. Wait until the display shows a meaningful oxygen reading and begins to approach the expected oxygen content of the
sample gas.

Span Gas Preparation

A percent analyzer such as the GPR-1900 may be reliable calibrated with the known 20.9% oxygen content of ambient air and
operated confidently at the lowest levels of the most sensitive analysis range. However, the GPR-1900 may be calibrated with
span gas at the user’s discretion.

Caution: Do not contaminate the span gas cylinder when connecting the regulator. Bleed the air filled regulator (faster and
more reliable than simply flowing the span gas) before attempting the initial calibration of the instrument.

Required components:
¾ Certified span gas cylinder with an oxygen concentration, balance nitrogen, approximating 80% of the full scale range

above the intended measuring range.

¾ Regulator to reduce pressure to between 5 and 30 psig.
¾ Flow meter to set the flow between 1-5 SCFH,
¾ Suitable fittings and 1/8” dia. 4-6 ft. in length of metal tubing to connect the regulator to the flow meter inlet
¾ Suitable fitting and 1/8” dia. 4-6 ft. in length of metal tubing to connect from the flow meter vent to tube fitting designated

SAMPLE IN on the GPR-1900.

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Procedure:

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 regulator.

7. Open the cylinder valve completely.

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

9. Caution: Do not exceed the recommended flow rate. Excessive flow rate could cause the backpressure on the sensor

and may result in erroneous readings and permanent damage to the sensor.

Establishing Power to the Electronics:

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. 1.61

Note: The analyzer display defaults to the sampling mode when 30 seconds elapses without user interface.
Note: At installation expect the range to default to 25% range, thereafter, 100 ppm range but only if properly isolated.

3.3PPM

AUTO SAMPLING
100 PPM RANGE

24.5 C
LO1 2 PPM 10 PPM HI2

Menu Navigation

The four (4) pushbuttons located on the front of the analyzer operate the
micro-processor:

1. blue ENTER (select)

2. yellow UP ARROW

3. yellow DOWN ARROW

4. green MENU (escape)

Main Menu

Access the MAIN MENU by pressing the MENU key:

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MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS
BYPASS ALARMS

Range Selection

The GPR-1900 analyzer is equipped with four (4) 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
SAMPLING (to lock on a single range) mode.

Note: For calibration purposes, use of the AUTO SAMPLE mode 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 optimal accuracy, a span gas
with an 800 ppm oxygen concentration with the balance nitrogen would dictate the use of the 0-1000 ppm full scale range for
calibration for analysis below 100 ppm, whereas, 80 ppm span gas is acceptable but not “optimal”, see Calibration & Accuracy.

Auto Sampling:

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.

4. The display returns to the sampling mode:

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS
BYPASS ALARMS

The display will shift to the next higher range when the oxygen reading (actually the sensor’s signal output) 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 analyzer is reading 1% on the 0-10% range and an upset occurs, the display will shift to the 0-25% range
when the oxygen reading exceeds 9.9%. Conversely, once the upset condition is corrected, the display will shift back to the 0­10% range when the oxygen reading drops to 8.5%.

Manual Sampling:

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

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

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

4. The following display appears:

3.3PPM

AUTO SAMPLING

24.5 C
LO1 2 PPM 10 PPM HI2

100 PPM RANGE

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MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE

CALIBRATION
CONFIG ALARMS
BYPASS ALARMS

>>>

MANUAL RANGE

25%
1%
1000 ppm

100 ppm

5. Advance the reverse shade cursor using the ARROW keys to highlight the desired MANUAL RANGE.

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

7. The following displays appears with the range selected and oxygen concentration of the sample gas:

MANUAL RANGE

25%
1%
1000 ppm

100 ppm

>>>

3.3PPM

AUTO SAMPLING
100 PPM RANGE

24.5 C
LO1 2 PPM 10 PPM HI2

8. The display will not shift automatically. Instead, when the oxygen reading (actually the sensor’s signal output) exceeds
110% of the upper limit of the current range an OVER RANGE warning will be displayed.

9. Once the OVER RANGE warning appears the user must advance the analyzer to the next higher range via the menu and
keypad Press MENU, select MANUAL SAMPLING, press ENTER, select the appropriate MANUAL RANGE and press ENTER
again.

Alarms

The CONFIG ALARMS features a system that can be configured in the field. Two field adjustable alarm relays with dry contacts
operate independently of one another which means the alarms can be set-up as:

¾ HI and LO
¾ LO and LO, LO,
¾ HI and HI,HI

Additional feature includes delaying the activation of the local audible alarm and relay contacts for up 99 minutes to enable
users to distinguish between transient occurrences and true upset conditions which is particularly useful on remote applications
without affecting the 4-20mA signal output. The local audible alarm can be silenced or disabled as well without affecting the 4­20mA signal output.

Note: A separate feature, BYPASS ALARMS described below, enables the user to disable the local audible alarm and relay
contacts during calibration or servicing. The alarms are enabled when the alarm condition is corrected.

Set Alarm Values:

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

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

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

4. The following displays appears:

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MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1

SET ALARM 2
SET ALARM DELAY
ALARM 1 HI/LO
ALARM 2 HI/LO
ALARMS AUDIBLE/SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the SET ALARM 1 option.

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

7. The following displays appears with PERCENT as the default alarm value :

MAIN MENU

SET ALARM 1

SET ALARM 2
SET ALARM DELAY
ALARM 1 HI/LO
ALARM 2 HI/LO
ALARMS AUDIBLE/SILENT

>>>

GAS CONCENTRATION

PERCENT

PPM

8. Advance the reverse shade cursor using the ARROW keys to highlight the desired option.

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

10. Note: The PERCENT alarm value is entered with one decimal, the PPM alarm value is entered as an integer.

GAS CONCENTRATION

PERCENT

PPM

>>>

01.0

SET ALARM 1 VALUE

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

GAS CONCENTRATION

PERCENT

PPM

>>>

002

SET ALARM 1 VALUE

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

11. 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.

12. Press the ARROW keys to enter the alarm value.

13. Repeat steps 11 and 12 until the complete span value has been entered.

14. Note: If an alarm is set as a PERCENT value and subsequently changed to a PPM value, the PERCENT value is not retained
and is reset to 00.0. This holds if the alarm was first set as PPM value and then changed to a PERCENT value.

15. Save the alarm value by pressing the ENTER key or abort by pressing the MENU key.

16. The system returns to the SAMPLING mode and displays:

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3.3PPM

AUTO SAMPLING
100 PPM RANGE

24.5 C

LO1 2 PPM 10 PPM HI2

Repeat the steps above to set the ALARM 2 value:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1

SET ALARM 2

SET ALARM DELAY
ALARM 1 HI/LO
ALARM 2 HI/LO
ALARMS AUDIBLE/SILENT

Set Alarm Delay:

Once the values for ALARM 1 and ALARM 2 have been entered, the user may elect to delay the activation of the local alarms
and relay contacts for up to 99 minutes. This feature allows users to distinguish between transient occurrences and true upset
conditions. This feature can be particularly useful on remote applications without affecting the 4-20mA signal output.

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

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

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

4. The following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1
SET ALARM 2

SET ALARM DELAY

ALARM 1 HI/LO
ALARM 2 HI/LO
ALARMS AUDIBLE/SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the SET ALARM DELAY.

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

7. The following displays appear with last alarm delay value :

MAIN MENU

SET ALARM 1
SET ALARM 2

SET ALARM DELAY

ALARM 1 HI/LO
ALARM 2 HI/LO
ALARMS AUDIBLE/SILENT

>>>

99

DELAY IN MINUTES

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

8. 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.

9. Press the ARROW keys to enter the alarm value.

10. Repeat steps 17 and 18 until the complete span value has been entered.

11. Save the alarm value by pressing the ENTER key or abort by pressing the MENU key.

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12. The system returns the SAMPLING mode and displays:

3.3PPM

AUTO SAMPLING

24.5 C
LO1 2 PPM 10 PPM HI2

Set HI/LO Alarms:

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

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

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

4. The following displays appears:

100 PPM RANGE

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

MAIN MENU

SET ALARM 1
SET ALARM 2
SET ALARM DELAY

ALARM 1 HI/LO

ALARM 2 HI/LO
ALARMS AUDIBLE/SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the ALARM 1 option, which appears as either ALARM
1 HI or ALARM 1 LO.

6. Press the ENTER key to toggle and change the displayed setting. After 3 seconds, the system returns to SAMPLING mode.

3.3PPM

AUTO SAMPLING

24.5 C

LO1 2 PPM 10 PPM HI2

100 PPM RANGE

7. Repeat steps 1 through 6 for the ALARM 2 HI/LO setting.

Set Local Alarms:

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

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

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

4. The following displays appears:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION

CONFIG ALARMS

BYPASS ALARMS

>>>

21

MAIN MENU

SET ALARM 1
SET ALARM 2
SET ALARM DELAY
ALARM 1 HI/LO
ALARM 2 HI/LO

ALARMS AUDIBLE/SILENT

Advanced Instruments Inc.

5. Advance the reverse shade cursor using the ARROW keys to highlight the ALARMS AUDIBLE/SILENT option, which appear
as either ALARMS AUDIBLE or ALARMS SILENT.

6. Press the ENTER key to toggle and change the displayed setting. After 3 seconds, the system returns to SAMPLING mode.

3.3PPM

AUTO SAMPLING

24.5 C
LO1 2 PPM 10 PPM HI2

Bypass Alarms:

This feature, separate from CONFIG ALARMS above, enables the user to disable the local audible alarm and relay contacts
during calibration or servicing. The alarms are enabled when the alarm condition is corrected.

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

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

3. The following displays appears:

4. Press the ENTER key to bypass and disable both the local audible alarm and relay contacts. After 3 seconds, the system
returns to SAMPLING mode.

Note: The appropriate alarm setting will alternately reverse shades indicating the alarm condition exists but the BYPASS
ALARMS feature has disabled the local audible alarm and relay contact. The alarms are enabled when the alarm condition is
corrected.

100 PPM RANGE

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS

BYPASS ALARMS

3.3PPM

AUTO SAMPLING

24.5 C
LO1 2 PPM 10 PPM HI2

100 PPM RANGE

Installation & Start-up is now complete . . . proceed to Calibration

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Zero Calibration

In theory
analyzer to generate an oxygen reading when sampling oxygen free sample gas due to:

¾ Contamination or quality of the zero gas
¾ Minor leakage in the sample line connections
¾ Residual oxygen dissolved in the sensor’s electrolyte
¾ Tolerances of the electronic components

Recommendation: Zero calibration is recommended only for online analyzers intended for continuous precise measurements
below 5 ppm on the 0-100 ppm range and then only when the sample system connections are modified and when installing a
new oxygen sensor. It is not practical on higher ranges or portable analyzers for the following reasons:

1. Determining the true zero offset reguires

2. Thus it is not practical to find the true zero offset particularly in the case of applications requiring higher level oxygen

3. Caution: Prematurely zeroing the analyzer can cause a negative reading in both the ZERO and SAMPLE modes.

4. Satisfying users that the zero offset is reasonably acceptable for their application can be accomplished much quicker.

Procedure:

Zero calibration should precede 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.

Refer to Span Calibration below for the detailed procedure. Differences include the displays illustrated below, substituting a
suitable zero gas for the span gas and the time required to determine the true zero offset of specific oxygen sensor, analyzer
and sample system combination.

The maximum zero calibration adjustment permitted is 50% of the lowest full scale 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.

4. The following displays appear:

, the oxygen sensor produces no signal output when exposed to an oxygen free sample gas. In reality, expect the

the user allow the analyzer approximately 24 hours to stabilize with flowing zero
gas as evidenced by a stable reading with no downward trend on an external recording device. Note: Approximately 24-36
hours is required to assure the sensor has consumed the oxygen that has dissolved into the electrolyte inside the sensor
while exposed to air or percentage levels of oxygen. For optimum accuracy, utilize as much of the actual sample system as
possible.

measurements because of the low offset value, normally 50% of the most sensitive analysis range, is not material to the
accuracy of higher level measurements. Nor is it practical to zero a portable analyzer every time it is moved from one
sample point to another.

Unless the zero gas is contaminated or there is a significant leak in the sample connections, the analyzer should read less
than 1000 ppm oxygen within 2-3 minutes after being placed on zero gas thereby indicating it is operating normally.

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

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

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

7. The following displays appear:

>>>

23

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE

DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO

Advanced Instruments Inc.

0.000 PPM

ZERO
CALIBRTION
ENTER TO CALIBRATE
MENU TO ABORT

8. Press the ENTER key to calibrate or MENU key to abort and return to SAMPLING mode.

9. Allow approximately 60 seconds for the calibration process while the processor determines whether the signal output or
reading has stabilized within 50% of the full scale low range.

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

PASSED

CALIBRATION

Default Zero:

The software will eliminate any previous zero calibration adjustment and display the actual the signal output of the sensor at
any specific oxygen concentration. For example, assuming a zero gas is introduced, the display will reflect an oxygen reading
representing basically the zero calibration adjustment as described above. This feature allows the user to test the sensor’s signal
output without removing it from the sensor housing.

Procedure:

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.

4. The following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

OR

>>>

FAILED

CALIBRATION

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN

DEFAULT ZERO

OUTPUT SPAN
OUTPUT ZERO

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

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

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

FACTORY

DEFAULTS

SET

24

3.3PPM

AUTO SAMPLING
100 PPM RANGE

24.5 C
LO1 2 PPM 10 PPM HI2

Advanced Instruments Inc.

Output Zero:

In rare instances the 4-20mA signal output may not agree to the reading displayed by the LCD. This feature enables the user to
adjust the 4mA signal output when the LCD displays 00.00. Compute the adjustment value as described in Appendix B or
consult the factory.

Note: Adjust the 20mA signal output with the OUTPUT SPAN option described below. The true adjustment value must be
determined empirically by trial and error. Adjust the initial adjustment value for additional percent errors.

Procedure:

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.

4. The following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

>>>

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

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

7. The following display appears

100.0

OUTPUT ZERO OFFSET

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

8. Compute the adjustment value as described in Appendix B. Note: The true adjustment value must be determined
empirically by trial and error. Adjust the initial adjustment value for additional percent errors.

090.0

OUTPUT ZERO OFFSET

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

9. 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.

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

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

12. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key.

13. The system returns to the SAMPLING mode.

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN

OUTPUT ZERO

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Advanced Instruments Inc.

Span Calibration

Maximum drift from calibration temperature is approximately 0.11% of reading per °C. The analyzer has been calibrated at the
factory. However, in order to obtain reliable data, the analyzer must be calibrated at the initial start-up and periodically
thereafter. The maximum calibration interval recommended is approximately 3 months, or as determined by the user’s
application.

Calibration involves adjusting the analyzer electronics to the sensor’s signal output at a given oxygen standard, e.g. a certified
span gas with an oxygen content (balance nitrogen) approximating 80% of the next higher full scale range above the intended
measuring range is recommended for optimum accuracy, see Calibration and Accuracy.

Recommendation – based on the inherent linearity of the galvanic oxygen sensor air calibrate the analyzer as described
below when installing and replacing the oxygen sensor (exception UHP and MS versions of the Pico Ion Sensor); or, to verify the
oxygen content of a certified span gas; or, when a certified span gas is not available (immediately following air calibration
reintroduce a gas with a low oxygen concentration to expedite the return to ppm level measurements).

Caution: Prematurely initiating the SPAN CALIBRATION key before the galvanic fuel cell sensor based analyzer reading has
stabilized can result in erroneous readings.

For example, to assure an accurate air calibration when installing a new ppm oxygen sensor from its packaged oxygen free
atmosphere allow the oxygen sensor 2-3 minutes to reach equilibrium with the oxygen content of the ambient air surrounding it
before pressing the SPAN CALIBRATE key. A ppm oxygen sensor that has not been allowed to reach equilibrium will generate a
lower current output than a ppm oxygen sensor that has reached equilibrium. Pressing the SPAN CALIBRATE key before the
ppm oxygen sensor has reached equilibrium forces the micro-processor to prematurely read the (erroneous low) current output
of the ppm oxygen sensor and introduce larger (erroneous) than required electronic gain adjustment and display (also
erroneous) CALIBRATION SUCCESSFUL message to the user. The error will become evident when a zero gas with a low oxygen
concentration is introduced into the ppm analyzer to purge it down below 10 ppm. The analyzer reading may stop and appear
to stabilize as high as 1800 ppm – giving the user the (erroneous) impression there is a problem with the ppm oxygen sensor
when in fact the problem lies with the user’s failure to follow the recommended calibration procedure.

Required components: Refer to Installing Span Gas section above.

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

2. Regulator to reduce pressure to between 5 and 30 psig.

3. Flow meter to set the flow between 1-5 SCFH,

4. Suitable fittings and a 4-6 ft. in length of 1/8” dia. metal tubing to connect the regulator to the flow meter inlet

5. Suitable fitting and a 4-6 ft. in length of 1/8” dia. metal tubing to connect to the flow meter vent

6. 1/8” male NPT to tube adapter fitting to connect the 1/8” dia. metal tubing from the flow meter vent to the mating male
fitting supplied with the GPR-1900.

Procedure:

The user must ascertain that the oxygen reading (actually the sensor’s signal output) has reached a stable value within the
limits entered below before entering the span adjustment. Failure to do so will result in an error.

This procedure assumes a span gas under positive pressure and is recommended for a analyzer 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. 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 an 80 ppm
oxygen concentration with the balance nitrogen would dictate the use of the 0-100 ppm full scale range for calibration and a 0­10 ppm measuring range. Select as described above.

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.

4. The following displays appear:

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Advanced Instruments Inc.

MAIN MENU

AUTO SAMPLE

MANUAL SAMPLE
CALIBRATION
CONFIG ALARMS
BYPASS ALARMS

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

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

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

8. Repeat to select SPAN CALIBRATE

9. The following displays appear:

3.3PPM

AUTO SAMPLING
100 PPM RANGE

24.5 C

LO1 2 PPM 10 PPM HI2

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

10. Assure there are no restrictions in vent line.

11. Regulate the pressure and control the flow rate as described above at 5-30 psig and a 2 SCFH flow rate.

12. Allow the span gas to flow for 1-2 minutes to purge the air trapped in the span gas line.

13. Disconnect the sample gas line and install the purged span gas line.

14. Caution: Allow the span gas to flow and wait until the reading is stable before proceedin g with calibration.
The wait time will vary depending on the amount oxygen introduced to the sensor when the gas lines were switched.

15. Press the ENTER key to select the SPAN CALIBRATE option.

16. Note: A span gas concentration above 1000 ppm dictates the selection of the PERCENT option.

17. Advance the reverse shade cursor using the ARROW keys to highlight the desired GAS CONCENTRATION.

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

GAS CONCENTRATION

PERCENT

PPM

>>>

CALIBRATION

SPAN CALIBRATE

ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO

19. The following displays appear:

000.00 PPM

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

20. 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.

21. Press the ARROW keys to enter the alarm value.

>>>

27

080.00 PPM

SPAN
CALIBRATION
ENTER TO CALIBRATE
MENU TO ABORT

Advanced Instruments Inc.

22. Repeat steps 20 and 21 until the complete SPAN value has been entered.

23. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key.

24. Allow approximately 60 seconds for the calibration process while the processor determines whether the signal output or
reading has stabilized within 60% of the full scale low range. Both the Zero Calibrate and Span Calibrate functions result in
the following displays:

25. If the calibration is successful, the analyzer returns to the SAMPLING mode after 30 seconds.

26. If the calibration is unsuccessful, return to the SAMPLING mode with span gas flowing through the analyzer, make sure the
reading stabilizes and repeat the calibration before concluding the equipment is defective.

27. Before disconnecting the span gas line and connecting the sample gas line, restart if necessary the flow of sample gas and
allow it to flow for 1-2 minutes to purge the air inside the line.

28. For ppm sensors disconnect the span gas line and replace it with a purged, see above, zero or low oxygen content gas line
to purge the sensor down to the desired analysis range as quickly as possible.

29. Wait until the reading is stable and proceed to sampling.

Default Span

The software will set the SPAN adjustment based on the average oxygen reading (actually the sensor’s signal output) at any
specific oxygen concentration. For example, when a span gas is introduced, the micro-processor will display an oxygen reading
within +
sensor housing.

Procedure:

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.

4. The following displays appears:

50% of the span gas value. This feature allows the user to test the sensor’s signal output without removing it from the

PASSED

CALIBRATION

OR

FAILED

CALIBRATION

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

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

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

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

FACTORY

DEFAULTS

SET

>>>

28

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE

DEFAULT SPAN

DEFAULT ZERO
OUTPUT SPAN
OUTPUT ZERO

3.3PPM

AUTO SAMPLING
100 PPM RANGE

24.5 C
LO1 2 PPM 10 PPM HI2

Advanced Instruments Inc.

Output Span:

In rare instances the 4-20mA signal output may not agree to the reading displayed by the LCD. This feature enables the user to
adjust the 20mA signal output should the LCD display not agree.

Note: Adjust the 4mA signal output with the OUTPUT ZERO option described above.

Procedure:

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.

4. The following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

CONFIG ALARMS
BYPASS ALARMS

>>>

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO

OUTPUT SPAN

OUTPUT ZERO

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

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

7. The following display appears

100.0

OUTPUT SPAN OFFSET

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

8. 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.

099.0

OUTPUT SPAN OFFSET

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

9. 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.

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

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

12. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key.

13. The system returns to the SAMPLING mode.

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Advanced Instruments Inc.

Sampling

GPR-1900 Oxygen Analyzer requires positive pressure to flow the sample gas by the sensor to measure the oxygen
concentration in a sample gas. See Sample System and Pressure & Flow at the beginning of Section 5 Operations. To assure
optimal performance: connect gas lines with metal tubing, quality compression type fittings to minimize leaks, follow pressure
and flow recommendations and avoid exposing the sensor to air and high oxygen concentrations for prolonged periods of time
(this does not include the 5 minutes it should take to air calibrate the analyzer once a week).

Note: Prematurely initiating the ZERO CALIBRATION procedure can cause the analyzer to display a negative reading in both
the ZERO and SAMPLE modes. Prematurely initiating the SPAN CALIBRATION procedure can cause erroneously high offsets and
inaccurate readings.

Procedure:

Following calibration the analyzer returns to the SAMPLE mode after 30 seconds.

1. Select the desired sampling mode - auto or if manual, the range that provides maximum resolution – as described above.

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

3. The main consideration is to eliminate air leaks which can affect oxygen measurements above or below the 20.9% oxygen
concentration in ambient air - ensure the sample gas tubing connections fit tightly into the 1/8” male NPT to tube adapter,
and, the NPT end is taped and securely tightened into the mating male quick disconnect fittings which mate with the
female fittings on the analyzer

4. Assure there are no restrictions in the sample line.

5. For sample gases under positive pressure the user must provide a means of controlling the inlet pressure between 5-30
psig and the flow of the sample gas between 1-5 SCFH, a flow rate of 2 SCHF is recommended

6. For sample gases under atmospheric or slightly negative pressure an optional sampling pump is recommended to draw the
sample into the analyzer. Generally, no pressure regulation or flow control device is involved.

7. Caution: If the analyzer is equipped with an optional sampling pump and is intended for use in both positive and
atmospheric/slightly negative pressure applications where a flow meter valve is involved – ensure the valve is completely
open when operating the sampling pump. Refer to the Pressure & Flow section above.

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

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

To avoid erroneous oxygen readings and damaging the sensor:

¾ 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).

¾ Assure there are no restrictions in the sample or vent lines
¾ Avoid drawing a vacuum that exceeds 14” of water column pressure – unless done gradually
¾ Avoid excessive flow rates above 5 SCFH which generate backpressure on the sensor.
¾ Avoid sudden releases of backpressure that can severely damage the sensor.
¾ Avoid the collection of particulates, liquids or condensation collect on the sensor that cou ld block the diffusion of oxygen

into the sensor.

¾ 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.

Standby

¾ The analyzer has no special storage requirements.
¾ The sensor should remain connected during storage periods.
¾ Store the analyzer with the power OFF.
¾ If storing for an extended period of time protect the analyzer, cable and sensor from dust, heat and moisture.

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Advanced Instruments Inc.

6 Maintenance

There are no moving parts in the analyzer given the modular nature of the electronics and sensor. Cleaning the electrical
contacts when replacing the sensor is the extent of the maintenance requirements of this analyzer. 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.

Sensor Replacement:

Periodically, the oxygen sensor will require replacement. The operating life is determined by a number of factors that are
influenced by the user and therefore difficult to predict. The sections dealing with Specification and Installation Considerations
define the normal operating conditions and expected life of the standard sensor utilized by the GPR-1900 analyzer. As a general
guideline, expected sensor life is inversely proportional to changes in oxygen concentration, pressure and temperature.

Caution: DO NOT open 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 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.

Procedure:

1. Remove the four (4) screws securing the analyzer’s front panel.

2. Caution: Do not discard the gaskets from the enclosure.

3. Using the 5/16 wrench supplied loosen but do not remove the clamp bolt located in the
center of the housing with the elbows attached.

4. Rotate the upper section of the sensor housing 90º to disengage from the clamp.

5. Remove the upper section by pulling it straight up and place it on a smooth surface.

6. Remove the old oxygen sensor and dispose of it as you would a battery.

7. Remove the new oxygen sensor from the shipping bag.

8. Remove the red label and the gold ribbon from the PCB at the rear of the sensor.

9. Caution: Minimize the time the sensor is exposed to ambient air.

10. Place the new sensor in the bottom section of the sensor housing with the PCB facing up.

11. Place the upper section of the sensor housing over the sensor.

12. Span Calibrate the analyzer in 20.9% ambient air, once the reading stabilizes – see above.

13. Gently push the upper section downward and rotate 90º to engage the clamp.

14. Finger tighten the clamp bolt and one full turn with the 5/16 wrench to compressed the o-ring seal.

Connect zero gas or low oxygen content sample gas line to purge the sensor of oxygen.

7 Spare Parts

Recommended spare parts for the GPR-1900 Oxygen Analyzer include:

Item No. Description

GPR-12-333 ppm Oxygen Sensor
XLT-12-333 ppm Oxygen Sensor (CO2 background gas)

Other spare parts:

A-1004-1-36 Housing Sensor Stainless Steel
A-1016-A Housing Sensor Bottom Assembly Stainless Steel
B-2762-A-1-36 Housing Sensor Upper Assembly Stainless Steel
MTR-1011 Meter Digital Panel LCD Backlight
ORNG-1007 O-ring 3/32 x 1-3/8 x 1-9/16 Viton
A-1161-A1 PCB Assembly Main / Display
A-1162-AC PCB Assembly AC Power Supply / Interconnection
A-1162-DC PCB Assembly AC Power Supply / Interconnection

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Advanced Instruments Inc.

8 Troubleshooting

Symptom Possible Cause Recommended Action

Slow recovery or

High O
after installing
or replacing sensor

High O
Sampling

Response time slow Air leak, dead legs, distance of sample line,

O
agree to expected O
values

reading

2

reading

2

reading doesn’t

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
Sensor nearing end of life

Analyzer calibrated before sensor stabilized
caused by:

1) Prolonged exposure to ambient air, worse
if sensor was unshorted

2) Air leak in sample system connection(s)

3) Abnormality in zero gas

Flow rate exceeds limits
Pressurized sensor
Improper sensor selection

low flow rate, volume of optional filters and
scrubbers

Pressure and temperature of the sample is
different than span gas

2

Abnormality in gas

32

Replace sensor if recovery unacceptable or O
reading fails to reach 10% of lowest range
Leak test the entire sample system: Vary the flow
rate, if the O
change in flow rate indicates an air leak - correct
source of leak
Qualify zero gas (using portable analyzer)
Replace sensor

Replace sensor

Allow O
span/calibration adjustment
Continue purge with zero gas

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

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

or acid gases are present

CO

2

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

Calibrate the analyzer (calibrate at pressure and
temperature of sample)
Qualify the gas (use a portable analyzer)

reading changes inversely with the

2

reading to stabilize before making the

2

2

Advanced Instruments Inc.

Symptom Possible Cause Recommended Action

Erratic O

reading

2

or

reading

No O

2

Erratic O

reading

2

or
Negative O

reading

2

or

reading

No O

2

accompanied by
electrolyte leakage

Change in sample pressure

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

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 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.
Placing a vacuum on the sensor in excess 4”
of water column is strongly discouraged.

A premature adjustment of the ZERO OFFSET
potentiometer is a common problem

Sensors without PCB use mV setting.
Calibrate the analyzer (calibrate at pressure and
temperature of sample)

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 alcohol, flow sample or zero gas for 2-3 hours
to flush sample system and sensor housing
Sensor: Replace if leaking and return it to the
factory for warranty determination

Wipe with alcohol and lint free towel or flow sample
or zero gas for 2-3 hours to flush
Replace GPR/PSR sensor with XLT sensor when CO
or acid gases are present. Consult factory.

Replace sensor and install scrubber
Consult factory.
Replace sensor

Zero the analyzer. 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

2

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Advanced Instruments Inc.

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Advanced Instruments Inc.

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Advanced Instruments Inc.

9 Warranty

The design and manufacture of GPR Series oxygen analyzers, monitors 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 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 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

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.

36

Advanced Instruments Inc.

10 MSDS Material Safety Data Sheet

Product Identification

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 Oxyg en sensors are sealed, conta in protective coverings and in normal conditions d o not present a

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 (CH

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
Melting Point Range
Freezing Point
Molecular Weight KOH = 56 or Acetic Acid – NA, Lead = 207
Specific Gravity
Vapor Pressure
Vapor Density KOH – NA or Acetic Acid = 2.07
pH KOH > 14 or Acetic Acid = 2-3
Solubility in H
% Volatiles by Volume None
Evaporation Rate Similar to water

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

O Complete

2

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

health hazard. Information applies to electrolyte unless otherwise noted.

H) – Acid, Lead (Pb) – Metal

3CO2

KOH = 100 to 115° C or Acetic Acid = 100 to 117° C
KOH -10 to 0° C or Acetic Acid – NA, Lead 327° C
KOH = -40 to -10° C or Acetic Acid = -40 to -10° C

KOH = 1.09 @ 20° C, Acetic Acid = 1.05 @ 20° C
KOH = NA or Acetic Acid = 11.4 @ 20° C

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Advanced Instruments Inc.

Spill or Leak

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

Disposal

Health Hazard Information

Primary Route(s) of Entry Ingestion, eye and skin contact
Exposure Limits Potassium Hydroxide - ACGIH TLV 2 mg/cub ic meter or Acetic Acid - ACGIH TLV / OSHA PEL 10

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

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. S kin contact - soapy slick feeling.
Medical Conditions Aggravated None
Carcinogenic Reference Data KOH and Acetic Acid = NTP An nual Report on Carcinogens - not listed; LARC Monographs - not

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

Special Protection Information

Ventilation Requirements None
Eye Safety glasses
Hand Rubber or latex gloves
Respirator Type Not applicable
Other Special Protection None

Special Precautions

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

Transportation Not applicable

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 time).

In accordance with federal, state and local regulations.

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

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

listed; OSHA - not listed

reproductive harm.

sharp objects. Wash hands thoroughly after handling. Avoid contact with eyes, skin and clothing.
Empty sensor body may contain hazardous residue.

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Advanced Instruments Inc.

Appendix B

Correlating Readings - LCD Display and 4-20mA Output

In rare instances the 4-20mA signal output may not agree to the reading displayed by the LCD. The Output Zero and Output
Span features enable the user to adjust the 4mA signal output to correlate with the reading displayed by the LCD.

For optimum accuracy make two separate adjustments as follows:

1. OUTPUT ZERO feature: To adjust the 4mA signal output and requires zero gas.

2. OUTPUT SPAN feature: To adjust the 20mA signal output and requires span gas near full range.

In the field or in the absence of the preferred gases, use the OUTPUT SPAN feature and adjust the 20mA signal output using
the span gas available.

Procedure – regardless of type of adjustment:

1. The microprocessor defaults to 100% to start.

2. The “actual” 4-20mA signal output will be adjusted to the “theoretical” value of the LCD display.

3. Adjustment general rule:

a) If the actual 4-20mA value < the theoretical LCD value, the adjustment value will be > 100%.
b) If the actual 4-20mA value > the theoretical LCD value, the adjustment value will be < 100%.

4. Convert the “actual” reading of the LCD display to the “theoretical” 4-20mA as follows:

a) Divide the “actual” (ppm or percent) LCD reading by the value of the span gas available.
b) Multiply 16mA (20mA – 4mA) times the “result of a.”
c) Add 4mA plus the “result of b.” to obtain the “theoretical” 4-20mA signal output value.

5. Adjustment value: Divide the theoretical by the actual 4-20mA values and multiply by 100.

6. Enter the adjustment value via OUTPUT ZERO or OUTPUT SPAN routines described below.

Example: Analyzer reading is 60 ppm oxygen (100 ppm range) on 84 ppm span gas, 4-20mA signal output at PLC is 24mA
Solution: a) Use OUTPUT SPAN feature to make the adjustment.

b) Adjustment will be < 100% (default value of OUTPUT SPAN feature).
c) 13.6mA is the “theoretical” 4-20mA converted from the “actual” reading of the LCD.
60 ppm divided by 84 ppm = 0.71 or 71%
16mA multiplied by 0.71 = 11.36mA
4mA plus 11.36mA = 15.36mA “theoretical” 4-20mA signal output value
d) 15.36mA divided by 24mA the “actual” 4-20mA value = 64.0 adjustment value
e) Enter 64.0 via OUTPUT SPAN procedure below.

Output Zero

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

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

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

10. The following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

>>>

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO
OUTPUT SPAN

OUTPUT ZERO

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

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

13. The following display appears:

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Advanced Instruments Inc.

100.0

OUTPUT ZERO OFFSET

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

14. Enter the calculated adjustment value. Note: Once the initial adjustment is made and checked at the PLC it may be
necessary to fine tune the initial adjustment by repeating. Any additional percent error must be added or subtracted from
the initial adjustment value

000.0

OUTPUT ZERO OFFSET

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

15. 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 adjustment OUTPUT ZERO OFFSET value.

16. Press the ARROW keys to enter each the numerical value of each digit of the adjustment OUTPUT ZERO OFFSET value.

17. Repeat until the complete OUTPUT ZERO OFFSET value has been entered.

18. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key.

19. The system returns to the SAMPLING mode.

Output Span

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

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

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

23. The following displays appear:

MAIN MENU

AUTO SAMPLE
MANUAL SAMPLE

CALIBRATION

24. Advance the reverse shade cursor using the ARROW keys to highlight OUTPUT SPAN.

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

26. The following display appears:

100.0

OUTPUT SPAN OFFSET

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

>>>

CALIBRATION

SPAN CALIBRATE
ZERO CALIBRATE
DEFAULT SPAN
DEFAULT ZERO

OUTPUT SPAN

OUTPUT ZERO

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Advanced Instruments Inc.

27. Enter the calculated adjustment value, refer to example described above. Note: Once the initial adjustment is made and
checked at the PLC it may be necessary to fine tune the initial adjustment by repeating. Any additional percent error must
be added or subtracted from the initial adjustment value

064.0

OUTPUT SPAN OFFSET

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

.

28. 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 adjustment OUTPUT SPAN OFFSET value.

29. Press the ARROW keys to enter the numerical value of each digit of the OUTPUT SPAN OFFSET value.

30. Repeat until the complete OUTPUT SPAN OFFSET value has been entered.

31. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key.

32. The system returns to the SAMPLING mode.

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