Analytical Industries Inc (AII) GPR-2600 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: 1/4" compression tube fittings
Controls:

Data Acquisition:

Display:

Enclosure: Painted aluminum 7.5” x 10.8” x 12.25” panel mount
Flow: Not flow sensitive; recommended flow rate 2 SCFH

0-1%, 0-5%, 0-10%, 0-25% FS ranges
Auto-ranging or manual lock on a single range

Oxygen analysis in inert, helium, hydrogen, mixed and
acid (CO2) gas streams

Two adjustable form C relay contacts non-latching;
“weak sensor” indicator; power failure; system failure

Max interval—3 months. Air calibrate with clean source of
certified span gas, compressed, or ambient (20.9% O2)
air on 0-25% range.

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

Selectable data point intervals

Graphical LCD 5” x 2.75”; resolution .001%; displays real

time ambient temperature and pressure

GPR-2600

Oxygen Analyzer

Advanced Full Featured Process O2 Analyzer

Linearity: > .995 over all ranges
Pressure:

Power: Universal; specify 100 or 200 VAC for heater system
Range ID:

Response Time: 90% of final FS reading < 10 seconds
Sample System: Flow indicator and flow control

Sensitivity: < 0.5% of FS range
Sensor Model:

Sensor Life:

Signal Output: 4-20mA isolated, 0-1V, and 0-5V
Temp. Range:
Warranty: 12 months analyzer; 12 months sensor

Optional Equipment

19” rack, wall mounting, auto zero/cal, remote communication-contact factory

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

1-5V; Optional (1) 4-20mA non-isolated OR (2) relay
contacts w/ 4-20mA or 1-5V

GPR-11-32-4 for non-acid (CO2) gas streams
XLT-11-24-4 for gas mixture with > 0.5% CO2

GPR-11-32-4 32 months in air at 25ºC and 1 atm
XLT-11-24-4 24 months in air at 25ºC and 1 atm

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

Advanced Sensor Technology

 Unmatched Performance in O2 Analysis
 Unmatched 32 Month Expected Life
 Sensitivity < 0.5% FS Range
 Extended –10°C Operating Range

 Excellent Compatibility with 0-100% CO2

2 Field Selectable Alarm Setpoints
Auto Ranging or Single Fixed
Options: Temperature Control
Auto-Zero and Auto-Cal
Remote Communication via USB,
RS232, RS485

ISO 9001:2008 Certified

INTERTEK Certificate No. 485

* 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

GPR-2600 W

Advanced Sensor Technology

The sensor is the heart of any analyzer, thus sensor technology is the critical factor in analyzer performance. Advanced Instruments
focuses on optimizing the sensor to meet specific application needs and has produced the first real advancements in sensor technolo­gy in decades. All sensors are manufactured under an independently certified QA system that complies with ISO 9001:2008.

Advancements:

Innovative design, materials

Galvanic Oxygen Sensor

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

Control O2 reaction
Proprietary mfg process
Extend operating temperature
Insensitive to vibration
Compact inexpensive design

Performance:

Accuracy < + 1% FS
Sensitivity 0.5% FS (500 ppm)
Service life up to 10 yrs in air
5⁰C (GPR); -10⁰C (XLT) to 45⁰C
Linear pressure comp to 1 atm
No sensor maintenance

Advanced Instruments Inc.

GPR-2600

% Oxygen Analyzer

Revised February 05, 2015

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 & Installation 3

Features & Specifications 4

Operation 5

Maintenance 6

Spare Parts 7

Troubleshooting 8

Warranty 9

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Material Safety Data Sheets 10

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1. Introduction

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

This analyzer is designed to measure oxygen concentration in inert gases, gaseous hydrocarbons, hydrogen, and a
variety of gas mixtures. 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 retain 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.

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2. Quality Control Certification

Date:

Model: GPR-2600 % Oxygen Analyzer S/N _____________________

Customer: Order No.:

Pass

Sensor: ( ) GPR-11-32 PPM Oxygen Sensor

( ) XLT-11-24 PPM Oxygen Sensor S/N _____________________

Accessories: Owner’s Manual

CABL-1008 Power Cord
TOOL-1001 5/16” Combination Wrench

Configuration: Ranges: 0-1%, 0-5%, 0-10%, 0-25%

( ) Stainless steel sensor housing, manual flow control, 1/4" Tube

( ) Temperature controlled heater system 85°F specify: ( ) 110VAC (X ) 220VAC
Power: 100/120/220/250 VAC (universal without temperature controlled heater systems)
Enclosure: ( X ) Std. panel mount 7.5"x10".8x12"

Test System start-up diagnostics satisfactory
Auto/manual range
Alarm relays activate/deactivate with changes in O2 concentration
Alarm bypass
Analog outputs: 0-1 V DC, 0-5 VDC and output 4-20mA
Range ID: ( X ) 1-5 VDC or ( ) 5x relay contacts plus 1x common

Baseline drift on zero gas < ± 2% FS over 24 hour period
Noise level < ± 1.0% FS
Span calibration gas value
Span adjustment within 10-50% FS
Peak to peak over/under shoot < 0.5% FS
Overall inspection for physical defects

Options

Notes

A-1146-10 PCB Assembly Main / Display Software V. ______
( ) A-1146-10 PCB Power Supply / Interconnect, 1-5V Range ID
( ) A-1174-10 PCB Power Supply / Interconnect, 5x Relay Contacts Range ID

fittings for sample inlet and vent
( ) Delete sample/bypass valve from above (T and TO options)
( ) Sample, span, zero inlet solenoid valves

( ) Bezel for 19” rack mount 19"x12"x12” option
( ) GPR-2600-W option general purpose wall mount 12"x12"x8”
( ) GPR-2600-W306 option general purpose panel mount 18.2"x16"x10”

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3. Safety Guidelines

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

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

Danger: This symbol is used throughout the Owner’s Manual to identify sources of immediate
DANGER

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 Instructions: Follow all warnings on the analyzer, accessories (if any) and in this Owner’s

Manual. Observe all precautions and operating instructions. Failure to do so may result in personal injury or damage
to the analyzer.

Heat: Situate and store the analyzer away from sources of heat.
Liquid and Object Entry: The analyzer should not be immersed in any liquid. Care should be taken so that liquids

are not spilled into and objects do not fall into the inside of the analyzer.
Handling: Do not use force when using the 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.

such as the presence of hazardous voltages.

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 this Owner’s Manual. 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 detailed by section 9, 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: Disconnect the power when the analyzer is left unused for a long period of time.

Installation Consideration

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

Expected Sensor Life

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and alert the user to

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With reference to the publish specification located in section 4 of this manual, the expected life of sensor is
predicated on the basis of oxygen concentration at 21%,, temperature (77°F/25°C) and pressure (1 atmosphere). As
a rule of thumb sensor life is inversely proportional to changes in these parameters.

Materials
Assemble the necessary zero, sample and span gases and optional components such as valves, coalescing or
particulate filters, and pumps as dictated by the application; stainless steel tubing is essential for maintaining the
integrity of the gas stream of low %O2 (<0.05%) measurements.

Operating Temperature

The sample must be sufficiently cooled before it enters the analyzer and any optional components. A coiled 10 foot
length of ¼” stainless steel tubing is sufficient for cooling sample gases as high as 1,800ºF to ambient. The
maximum recommended operating temperature is 45º C. On an intermittent basis, unless the user is willing to accept
a reduction in expected sensor life – refer to analyzer specification, the analyzer may be operated at 50 degree
temperatures above 25
temperature. As an example, if the analyzer is continuously operated at 35
reduced by ~25%.

Pressure and Flow

All electrochemical oxygen sensors respond to partial pressure changes in oxygen in a gas stream.
A sample system and flowing gas samples are generally required for applications involving oxygen measurements in
a gas mixture.

To analyze a gas stream, the gas must flow or be drawn through the sensor housing. The internal sample system of
the analyzer may include a flow control (please check the QC sheet to ensure the included sample system), a flow
indicator and al sensor housing with an o-ring seal.

Inlet Pressure

Analyzers designed for flowing samples under positive pressure requires sample pressure between 5-30 PSIG. This
pressure range is recommended for ease in controlling the sample flow with the integral flow control valve. Sample
pressure up to 100 PSIG is acceptable but will cause difficulty in setting the flow rate.

Outlet Pressure

In positive sample pressure applications, the sample must be vented to ambient air or in a vent with pressure less
than 40 inches of water.

If the sample is vented to a line at pressure above ambient, a back pressure regulated set at no greater
1-2 PSIG must be installed on the downstream of the sensor to ensure a constant pressure on the
sensor.

Flow Rate

Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH may
generate a backpressure on the sensor and cause erroneous oxygen readings. A flow rate of 2 SCFH or 1 liter per
minute is recommended for optimum performance.

Recommendations to avoid erroneous oxygen readings and damaging the sensor

1. 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.

2. Assure there are no restrictions in the sample or vent lines.

3. Avoid excessive flow rate, flow rate above 5 SCFH may generate backpressure on the sensor.

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

5. Avoid the collection of liquids or particulates on the sensor,
sensor - wipe away any liquid and particulate with a damped cloth only.

Moisture & Particulates

Installation of a suitable coalescing and/or particulate filter is required to remove liquid condensates, and/or
particulates from the sample gas to prevent clogging of the sampling system. Moisture and/or particulates do not
necessarily damage the sensor itself but collection of moisture/particulate on the sensing surface can block or inhibit

o

C, the user can expect a reduction in sensor life of ~ 2.5% per degree increase in

6

o

C, the expected sensor life will be

they block the diffusion of oxygen into the

o

C. At

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the diffusion of sample gas into the sensor thus resulting in a reduction of sensor signal output – and the appearance
of a sensor failure. Consult factory for recommendations concerning the proper selection of coalescing/particulate
filters.

Mounting

The standard analyzer is approved for indoor use only. Outdoor use requires optional enclosures, consult factory.
Mount analyzer as recommended in this manual.

The analyzer is configured for panel mounting and requires a 7.5x10.8” cutout with 4 holes for the analyzer’s front
panel. Optional configurations include a panel mount with 7.75x7.75” cutout; 19” bezel for rack mounting, 12x12x8”
wall mount enclosure (GPR-2600W).

Gas Connections

Sample Inlet and Sample Vent gas lines require 1/8” or ¼” stainless steel compression fittings connection; hard
plastic tubing with a low gas permeability factor may be used for measurements of oxygen above 0.1%.

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. Ensure that the analyzer enclosure is properly grounded and meets the requirements
of recommended local electrical standards.

Never yank wiring to remove it from a terminal connection.

Analyzers consume a maximum of 30 watts, without the optional heaters. With optional 110 VAC or
220 VAC heaters installed, the maximum power consumption is 230 watts.

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4. Features & Specifications

5. Operation

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5. Operation

Principle of Operation

The GPR-2600 Oxygen Analyzers incorporates a variety of % range advanced galvanic fuel cell type sensors. The
analyzer is configured for panel mounting and requires a 7.5"x10.8” cutout with 4 holes for the analyzer’s front
panel. Optional configuration; 19” bezel for rack mounting, 12"x12"x8" wall mount enclosure (GPR-2600W),

18.2"x16"x10” panel mount configuration (GPR-2600W-306) using the wall mount enclosure. Contact the factory for
additional information on options. All configurations are tested and calibrated by the manufacturer prior to shipment.

The GPR-2600 series analyzers and sensors conform to CE standards and are manufactured under a Quality
Assurance System, certified by an independent agency, in accordance with ISO 9001:2008 standards.

Advance Galvanic Sensor Technology

All galvanic sensors function on the same principle and are specific to oxygen. They measure the partial pressure of
oxygen ranging from low PPM to 100% levels in inert gases, gaseous hydrocarbons, helium, hydrogen, mixed gases
and acid gas streams. Oxygen, the fuel for this electrochemical transducer, diffuses into the sensor and

reacts chemically at the sensing electrode to produce an electrical current output proportional to the
oxygen concentration in the gas phase. The sensor’s signal output is linear over all measuring ranges and

remains virtually constant over its useful life. The sensor requires no maintenance and is easily and safely replaced at
the end of its useful life.

Electronics

The signal generated by the sensor is processed by state of the art low powered micro-processor based digital
circuitry. The first stage amplifies and converts the electrical current into voltage signal. The second stage eliminates
the low frequency noise. The third stage employs a high frequency filter and compensates for the sensor’s signal
output variations caused by ambient temperature variations. The result is a very stable sensor signal.

Sensor’s response time of 90% of a “step change” is less than 10-30 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 of the lowest range of analysis.

Additional features of the micro-processor based electronics include manual or auto ranging, auto-zero and auto-cal,
isolated 4-20mA signal for signal output, optional 4-20 mA as range ID, separate relay contacts rated 30 VDC max @
1A or 110/220 VAC @ 5A are provided for the alarm feature. Optional range ID contacts are rated at 30 VDC @1A.

Whenever the analyzer is span calibrated, a unique algorithm predicts and displays a message indicating a ‘weak
sensor’ (if the sensor output has fallen below a certain level), suggesting the sensor be replaced in the near future.

Sample System

For accurate measurements, the sample gas must be properly presented to the sensor. In standard form, the GPR­2600 is equipped with a sample system that complements the performance capabilities of the advanced oxygen
sensor. The sample system includes a flow meter and or flow meter with flow control valve

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]

for your specific requirements.

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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 the 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'. For best accuracy, the
pressure of the sample gas and that of the calibration
gas must be the same (in reality within 2-5 psi) so
that when the SAMPLE/SPAN gases are switched, the
gas flow rate would not drastically change.

Temperature: The rate at which oxygen molecules diffuse into the sensor is controlled by a Teflon membrane
otherwise known as an 'oxygen diffusion limiting barrier. The fact that all diffusion processes are temperature
sensitive, the sensor's electrical output also varies with temperature. This variation is relatively constant (2.5% per
ºC change in temperature). A temperature compensation circuit employing a thermistor offsets this effect with an

5% or better (over the operating temperature range of the analyzer) and generates an output signal

accuracy of
that is virtually independent of small ambient temperature variation. To minimize error in oxygen measurement, the
calibration of the analyzer should be carried out as close as possible to the temperature during sampling. A small
temperature variation of ~10º F will produce < 2% error.

Accuracy:

1) 'Percent of reading errors', illustrated by Graph A below, such as +
compensation

2) 'Percent of full scale errors', illustrated by Graph B, such as +
tolerances in the electronic components, which are really minimal due to today's 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 < 1% prior to shipment.

Example 1: As illustrated by Graph A any error during a span adjustment, e.g., at 20.9% (air) of full scale range
would be multiplied by a factor of 4.78 (100/20.9) when used for measurements of 95-100% oxygen concentrations.
Conversely, an error during span adjustment at 100% of full scale range will be reduced proportionately for
measurements of lower oxygen concentrations. Refer to the Calibration section for additional details.

+

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

5% inherited error in the temperature

circuit due to the tolerances of the resistors and thermistor.

1-2% linearity errors generally associated with

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