Analytical Industries Inc (AII) Weld Purge Operating Manual

Pipe Weld Purge PPM Oxygen Analyzer

The all-new GPR-1000 WP Pipe Weld Purge PPM Oxygen Analyzer is designed specifically for pipe welding applications, and

features an innovative design and advanced long life electrochemical oxygen sensor that provide highly reliable trace ppm oxygen

readings in seconds! Additionally, the cost of ownership is 40% less than competitive analyzers!

The Fabricators & Manufacturers Association recommends the
following oxygen levels before welding commences to prevent
oxidation, discoloration, and coking that result in substandard

welds:

 Below 70 ppm in stainless steel welding
 Below 50 ppm in titanium welding

 Below 10 ppm in the semiconductor industry

In addition, the benefits of the improving the weld quality by
reducing the rest oxygen to trace ppm levels is driving the
standards lower in other industries such as aerospace,

pharmaceutical, dairy, brewery, chemical, and food processing.
The GPR-1000 WP is capable of measuring oxygen levels to meet

all of the above requirements. In addition, the GPR-1000 WP offers
the following invaluable features:

WP

Comes Online in Seconds

(see reverse)

 A built-in pump transports sample to the analyzer

 The integral Bypass Valve maintains the oxygen

sensor at trace ppm oxygen levels, which enables the

GPR-1000 WP to come online in seconds from
Bypass Mode!

1 Week Typical Use on Overnight Charge

 True portable analyzer with a heavy duty rechargeable

battery that provides one week of typical use on a

single overnight charge

Advanced Electrochemical Oxygen Sensor

 Long expected life, requires no maintenance
 Specific to oxygen
 Unaffected by moisture or particulate matter
 Replace the sensor like a battery

Additional Features:

 Can be used 24/7 while charging with an AC adapter
 User friendly, menu-driven controls

 Aluminum casing to withstand the rigors and abuse of

field work

GPR-1000 WP Weld Purge

Oxygen Analyzer

 Increases welder productivity and

reduces purge gas waste by

coming online in seconds!

 Increases welder productivity with

a heavy duty rechargeable battery

that provides one week of typical use

 Weld quality is enhanced by the

GPR-1000 WP’s ability to accurately

and reliably measure trace ppm

oxygen levels

 Low cost of ownership and

unmatched performance!

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

* Subject to change without notice

Pipe Weld Purge PPM Oxygen Analyzer

Bypass Valve Operation:

Setup and Optional Accessory Kit:

Technical Specifications

Analysis Range: 0-100 PPM, 0-1%, 0-25%
Accuracy: < 2% of FS range under constant conditions
Linearity: ±2% of full scale
Signal Output: 0-1V FS
Indicators: LCD display, resolution 1 PPM;

Calibration: Certified span gas with 500-800 ppm O2 or air
Sensor: GPR-12-100-M PPM Oxygen Sensor
Expected Sensor Life: 24 months
Warranty: 12 months analyzer; 12 months sensor

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

LED indicates LOW BATT and CHARGE mode

* Subject to change without notice

Advanced Instruments Inc.

GPR-1000-WP

Portable PPM Oxygen Analyzer

Owner’s Manual

Revised June 2014

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

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

Advanced Instruments Inc.

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Advanced Instruments Inc.

1. Introduction

Your new oxygen analyzer incorporates an advanced electrochemical sensor specific to oxygen along with state-of-the-art
digital electronics designed to give you years of reliable precise oxygen measurements in a variety of industrial oxygen
applications. More importantly, it has been constructed as intrinsically safe in accordance with ATEX Directives 94/9/CE for use
in hazardous areas in zone 1 Group C and D when used in conjunction with the recommended operating instructions in this
manual. The analyzer meets the following area classification.

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

GPR-1200MS/1200/1200P/1100/1000/1000-WP/2000/2000P

0080

Serial No.:
Year of Manufacture:
INERIS 08ATEX0036

II 2 G
Ex ib IIB T4
T

WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD – SEE INSTRUCTIONS

The design also meets NEC intrinsic safety standards for use in Class 1, Division 1, Group C, D hazardous areas. Please refer
to Appendix A for information on making electrical connections that maintain the desired level of protection.

To obtain maximum performance from your new oxygen analyzer, please read and follow the guidelines provided in this
Owner’s Manual.

Every effort has been made to select the most reliable state of the art materials and components to design the analyzer for
superior performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer prior to
shipment for best performance. However, all electronic devices do require service from time to time. The warranty included
herein plus a staff of trained professional technicians to quickly service your analyzer is your assurance that we stand behind
every analyzer sold.

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

Serial Number: _______________________

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

+5⁰C to +45⁰C

amb

.

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Advanced Instruments Inc.

2. Quality Control Certification

Model GPR-1000-WP ATEX Portable PPM Oxygen Analyzer S/N ____________________

Sensor ( ) GPR-12-100 PPM Oxygen Sensor

Accessories Owner’s Manual

( ) PWRS-1002 9VDC Battery Charger/Adapter 110VAC

CONN-1034 Plug Mini Phone .141 dia. Black Handle

Configuration A-1161-B-ATEX Rev C3 PCB

Range: 0-1000 PPM, 0-1%, 0-5%, 0-25%
Wetted parts: stainless steel, 4-way crossover valve

Electronics
Test

Electronic offset
Analog signal output 0-1V
Gas Phase

Test

Baseline drift on zero gas < ± 2% FS over 24 hour period on 0-1000 PPM range
Noise level < ± 0.5% FS
Span adjustment within 10-50% FS

Final Overall inspection for physical defects

Options B-3653 Pump Assembly
Notes

Customer: Order No.: Pass

( ) XLT-12-100 PPM Oxygen Sensor S/N ____________________

( ) PWRS-1003 9VDC Battery Charger/Adapter 220VAC
( ) PWRS-1008 9VDC Battery Charger/Adapter 12VDC Auto Cigarette Lighter

Software Version
B-3562 Battery Assembly

LED indicators: Low battery, charge

Recovery from air to < 100 PPM in < 5 minutes

_

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3. General Safety & Installation

Safety

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

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

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

Electrostatic Discharge Hazard: This symbol is used to caution the user to take all necessary steps to avoid
generating electrostatic discharge.

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 connectors, switches and knobs. Before moving your analyzer be sure to
disconnect the wiring/power cord and any cables connected to the output terminals located on the analyzer.

Maintenance

Serviceability: Except for replacing the oxygen sensor, there are no parts inside the transmitter for the operator to service.
Only trained personnel with the authorization of their supervisor should conduct 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
transmitter is faulty. Do not attempt to service the transmitter beyond those means described in this Owner’s Manual.

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

Cleaning: The transmitter should be cleaned only as recommended by the manufacturer. Wipe off dust and dirt from the
outside of the unit with a soft damp cloth then dry immediately. Do not use solvents or chemicals.
Non-use Periods: Turn the power OFF when the analyzer is left unused for a long period of time.

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Advanced Instruments Inc.

Installation

This analyzer has been constructed in compliance with the following EN directives

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

The analyzers must be used in accordance with the guidelines delineated in this instruction manual.

Gas Sample Stream: Ensure the gas stream composition of the application is consistent with the specifications and if in
doubt, review the application and consult the factory before initiating the installation.

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

Contaminant Gases: A gas scrubber and flow indicator with integral metering valve are required upstream of the analyzer
to remove any interfering gases such as oxides of sulfur and/or hydrogen sulfide that can interfere with measurement and
cause reduction in the expected life of the sensor. Consult factory for recommendations concerning the proper selection and
installation of components.

Expected Sensor Life: With reference to the published specification, the expected life of all oxygen sensors is predicated on
the basis of average oxygen concentration (<10,000 PPM for a PPM sensor or air for a % sensor), sample temperature of
77°F/25°C and sample pressure of 1 atmosphere in “normal” applications. Deviations from standard conditions will affect the
life of the sensor. As a rule of thumb sensor life is inversely proportional to changes in oxygen concentration, sample pressure
and temperature.

Accuracy & Calibration: Refer to section 5 Operation.

Materials: Assemble the necessary zero, sample and span gases and optional components such as valves, coalescing or

particulate filters and pumps as dictated by the application. Stainless steel tubing is essential for maintaining the integrity of
the gas stream for very low % or PPM O

Operating Temperature: The sample must be sufficiently cooled before it enters the analyzer and any optional
components. A coiled 10 foot length of ¼” stainless steel tubing is sufficient to cool sample gases as high as 1,800 ºF to
ambient temperature. The recommended operating temperature is below 35 ºC. However, the analyzer may be operated at
temperature up to 45 ºC on an intermittent basis but the user is expected to accept a reduction in expected sensor life –as a
rule of thumb, for every degree ºC increase in temperature (above 25 ºC), the sensor life is reduced by approximately 2.5%.

Heat: Situate and store the analyzer away from direct sources of heat.

Liquid and Object Entry: The analyzer should not be immersed in any liquid. Care should be taken so that liquids are not

spilled into and objects do not fall into the inside of the analyzer.

Handling: Do not use force when using the switches, knobs or any other mechanical components. Before moving your
analyzer be sure to disconnect the wiring/power cord and any cables connected to the output terminals of the analyzer.

level analysis.

2

Sample Pressure and Flow

All electrochemical oxygen sensors respond to partial pressure changes in oxygen. The sensors are equally capable of
analyzing the oxygen content of a flowing sample gas stream or monitoring the oxygen concentration in ambient air (such as
a confined space in a control room or an open area around a landfill or bio-pond). The following is applicable to analyzers
equipped with fuel cell type oxygen sensors.

Inlet Pressure: For the analyzers designed to measure oxygen in a flowing gas stream, the inlet sample pressure must

be regulated between 5-30 psig. Although the rating of the SS tubing and tube fittings/valves itself is considerably higher
(more than 100 psig), a sample pressure of 5-30 psig is recommended for ease of control of sample flow.

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Advanced Instruments Inc.

The analyzer is equipped with a Sample Inlet port. The sample gas must be connected to Sample Inlet port. There is no
sample flow control valve upstream of sensor, therefore, the user must install a Flow Meter upstream of Sample Inlet Port to

control sample flow rate (see below for the sample flow rate recommendation).

If the analyzer is equipped with optional sample pump, its speed is set at the factory to draw the recommended sample flow
to the sensor. Caution: in order to prevent the pump from drawing a vacuum on the sensor,

1. Do not restrict the sample inlet port while the pump is running

2. Use a 1/4 tube to bring sample to the analyzer

Outlet Pressure: In applications where sample pressure is positive, the sample must be vented to the atmosphere or

into a pipe at atmospheric pressure.

Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates above 5 SCFH may generate
a slight backpressure on the sensor resulting in erroneous oxygen readings.

Caution: Do not place your finger over the vent (it pressurizes the sensor) to test the flow indicator when gas is
flowing to the sensor. Removing your finger (the restriction) generates a vacuum on the sensor and may damage
the sensor (voiding the sensor warranty).

Application Pressure - Atmospheric or Slightly Negative: The GPR-1000-WP may be purchased

with an intrinsically safe integral sample pump, however, if the analyzer is not equipped with integral sample pump, an
external sample pump capable of pulling sample through the analyzer or high integrity leak free sample pump to push the
sample through the analyzer is recommended. However, the user must ensure that by using external pump, the intrinsic
safety of the analyzer is not compromised. Consult factory for recommendation.

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. Moisture and/or particulates do not necessarily damage the sensor. However, collection of moisture/particulate on the
sensing surface can block or inhibit the diffusion of sample gas into the sensor resulting in a reduction of sensor signal output
– and the appearance of a sensor failure. Consult the factory for recommendations concerning the proper selection and
installation of optional components.

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

where direct sun might heat up the analyzer beyond the recommended operating temperature range.

Gas Connections: The Inlet and outlet vent gas lines are 1/8" compression type fittings. The sample inlet tubing must

be metallic, preferably SS. The sample vent line may be of SS or hard plastic tubing with low gas permeability.

Power: The analyzer is powered by an integral lead-acid rechargeable battery. The analyzer will continue to run for a

minimum of 30-60 days after the battery is fully charged or 8 hours with pump running.

WARRNING: THE ANALYZER BATTERY MUST BE CHARGED IN A SAFE AREA ONLY BY USING FACTORY PROVIDED WALL

PLUG-IN CHARGER.

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Advanced Instruments Inc.

4. Features & Specifications

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Advanced Instruments Inc.

5. Operation

Principle of Operation

The GPR-1000-WP portable oxygen analyzer incorporates a variety of PPM range advanced galvanic fuel cell type sensors. The
analyzer is configured in a general purpose NEMA 4 rated enclosure and meets the intrinsic safety ATEX Directive 94/9/EC for
use in Zone 1 Groups C and D hazardous areas.

Advanced Galvanic Sensor Technology

All galvanic type sensors function on the same principle and are very specific to oxygen. They measure the partial pressure of
oxygen from low PPM to % levels in inert gases, gaseous hydrocarbons, helium, hydrogen, mixed gases, acid gas streams and
ambient air. Oxygen, the fuel for this electrochemical transducer, diffusing into the sensor and reacts chemically at the
sensing electrode to produce an electrical current output proportional to the oxygen concentration in the gas phase. The
sensor’s signal output is linear and remains virtually constant over its useful life. The sensor requires no maintenance and is
easily and safely replaced at the end of its useful life.

Proprietary advancements in the design and chemistry add significant advantages to an extremely versatile oxygen sensing
technology. Sensors for low PPM analysis recover from air to low PPM levels in minutes, exhibit longer life, extended operating
temperature range of -20°C to 50°C, excellent compatibility with CO
reliable quality giving them a significant advantage over the competition.

The expected life of our new generation of percentage range sensors now range to five and ten years with faster response
times and greater stability. Other significant developments involve the first galvanic oxygen sensor capability of continuous
oxygen purity measurements and expanding the operating temperature range from -40°C to 50°C.

and other acid gases (XLT series sensors only) and

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Advanced Instruments Inc.

Electronics

The signal generated by the sensor is processed by state of the art low power micro-processor based digital circuitry. The first
stage amplifies the signal. The second stage eliminates the low frequency noise. The third stage employs a high frequency
filter and compensates for signal output variations caused by ambient temperature changes. The result is a very stable signal.
Sample oxygen is analyzed very accurately. Response time of 90% of full scale is less than 10 seconds (actual experience may
vary due to the integrity of sample line connections, dead volume and flow rate selected) on all ranges under ambient
monitoring conditions. Sensitivity is typically 0.5% of full scale low range. Oxygen readings may be recorded by an external
device via the 0-1V signal output jack.

Power is supplied by an integral rechargeable lead acid battery which provides enough power to operate the analyzer
continuously for approximately 60 days. An LED located on the front panel provides a blinking 72 hour warning to recharge
the battery. A 9 VAC adapter (positive pole located on the inside of the female connector) can be used to recharge the battery
from a 110V or 220V convenience outlet. The analyzer is designed to be fully operational during the 8-10 hour charging cycle
which is indicated by a second continuously lit CHARGE LED (only when the analyzer power is turned ON).

Sample System

The GPR-1000-WP is supplied with a 4-way Sample/Bypass valve. This valve when in Bypass mode, isolates the sensor from
ambient air and must be used when analyzer is not connected to a sample line or when sample is not flowing through the
analyzer. This valve in when in Sample mode allows the sample to enter the analyzer, pass through the sensor housing and
vent sample to atmosphere. The analyzer is shipped with the sensor pre-tested and installed but is isolated from the ambient
air by 4-way Sample/Bypass valve.

For PPM oxygen measurements, the sensor is exposed to the sample gas that must flow or be drawn through the analyzer’s
internal sample system. The sample flow must be controlled by using an external flow control device. Sample flow rate of 1-5
SCFH has no significant effect on the accuracy of the analyzer, however, for optimum performance, a flow rate of 1-2 SCFH is
recommended.

As illustrated above, the GPR-1000-WP’s internal sample system includes:

1. 1/8" Compression type fittings for sample inlet and outlet

2. 4-Way Sample/Bypass valve

3. Stainless steel sensor housing with a thread-in type sensor installation mechanism.

4. Optional intrinsically safe pump

4-Way Sample/Bypass Valve
shown with 1/8" Sample IN
Compression Type Fitting

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