GPR-1200 Portable ppm Oxygen Analyzer Owner’s Manual 2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: 909-392-6900, Fax: 909-392-3665, e-mail: info@aii1.com, www.aii.
Table of Contents Introduction 1 Quality Control Certification 2 Safety 3 Specifications 4 Operation 5 Maintenance 6 Spare Parts 7 Troubleshooting 8 Warranty 9 10 Material Safety Data Sheets Appendix C – Pump Options 1 Introduction Your new portable oxygen analyzer incorporates an advanced electrochemical sensor specific to oxygen along with state-of-theart digital electronics designed to give you years of reliable precise oxygen measurements in variety of industrial oxygen applications.
2 Quality Control Certification Date: Customer: Order No.: Model GPR-1200 Portable ppm Oxygen Analyzer S/N ____________________ Sensor ( ( S/N ____________________ Accessories ) GPR-12-333 ppm Oxygen Sensor ) XLT-12-333 ppm Oxygen Sensor Owner’s Manual ( ) PWRS-1002 9VDC Battery Charger/Adapter 110VAC ( ) PWRS-1003 9VDC Battery Charger/Adapter 220VAC ( ) PWRS-1008 9VDC Battery Charger/Adapter 12VDC Auto Cigarette Lighter CONN-1034 Plug Mini Phone .141 dia.
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 to Caution and alert the user to recommended safety and/or operating guidelines.
Installation 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 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.
drawn through metal tubing inside the analyzer. The internal sample system includes 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.
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.
4 Specifications * Accuracy: < 1% of FS range under constant conditions Analysis Ranges: 0-10 ppm, 0-100, 0-1000 ppm, 0-1% plus 0-25% FS range for air calibration; auto-ranging or lock on single range Application: Analyze oxygen concentrations from 100 ppb to 1% in inert, hydrocarbon, helium, hydrogen, mixed and acid (CO2) gas streams Approvals: CE, Intrinsic Safety (pending, void with optional general purpose sampling pump) Area Classification: Meets standards for Class 1, Division 1, Group C, D h
5 Operation Principle of Operation The GPR-1200 portable oxygen analyzer incorporates a variety of ppm range advanced galvanic fuel cell type sensors. The analyzer is configured in a general purpose NEMA 4 rated enclosure and meets the intrinsic safety standards required for use in Class 1, Division 1, Groups A, B, C, D hazardous areas. Two integral sampling pump options are available – one that meets the intrinsic safety standards and a less expensive option for general purpose service.
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.
Accuracy & Calibration Single Point Calibration: As previously described the galvanic oxygen sensor generates an electrical current proportional to the oxygen concentration in the sample gas. Absolute Zero: In the absence of oxygen the sensor exhibits an absolute zero, e.g. the sensor does not generate a current output in the absence of oxygen. Given these linearity and absolute zero properties, single point calibration is possible.
Mounting the Analyzer Normally mounting a portable analyzer is not a consideration. However, the analyzer enclosure is cast with four (4) holes in the bottom section specifically intended for wall mounting. The GPR-1200 analyzer can operate continuously when connected to AC power using the appropriate charging adapter. Gas Connections The GPR-1200 flow through configuration is designed for positive pressure samples and requires connections to incoming sample and vent 1/8” diameter tube fittings.
Installing the Oxygen Sensor GPR-1200 Portable ppm Oxygen Analyzer is equipped with an integral oxygen sensor that has been tested and calibrated by the manufacturer prior to shipment and is fully operational from the shipping container. Should it be necessary to install the oxygen sensor – see section 6 Maintenance which covers replacing the oxygen sensor. Caution: All analyzer must be calibrated once the installation has been completed and periodically thereafter as described below.
Establishing Power to the Electronics The analyzer is fully operational from the shipping container with the oxygen sensor installed and calibrated at the factory prior to shipment. Once installed, we recommend the user allow the analyzer to stabilize for 10-15 minutes and then recalibrate the device as instructed below. Establish power to the analyzer electronics by pushing the red ON/OFF key. The digital display responds instantaneously.
Menu Navigation The 1. 2. 3. 4. 5. five (5) pushbuttons located on the front of the analyzer operate the micro-processor: Blue ENTER (select) Yellow UP ARROW Yellow DOWN ARROW Green MENU (escape) Red ON/OFF Main Menu Access the MAIN MENU by pressing the MENU key: MAIN MENU AUTO SAMPLE MANUAL SAMPLE CALIBRATION Range Selection The analyzer is equipped with five (5) standard measuring ranges (see specification) and provides users with a choice of sampling modes.
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 to highlight MANUAL SAMPLE. 3.
Zero Calibration In theory, the galvanic fuel cell type oxygen has an absolute zero meaning it produces no signal output when exposed to an oxygen free sample gas.
MAIN MENU AUTO SAMPLE MANUAL SAMPLE CALIBRATION 4. 5. 6. CALIBRATION SPAN CALIBRATE ZERO CALIBRATE DEFAULT SPAN DEFAULT ZERO OUTPUT SPAN OUTPUT ZERO >>> Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT ZERO. Press the ENTER key to select the highlighted menu option. The following display appears and after 3 seconds the system returns to the SAMPLING mode: 3.3PPM FACTORY DEFAULTS SET AUTO SAMPLING 10 PPM RANGE 24.
ENTER TO SAVE MENU TO RETURN 7. 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. 090.0 OUTPUT ZERO OFFSET PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN 8.
¾ Always calibrate at the same temperature and pressure of the sample gas stream. ¾ For 'optimum calibration accuracy' calibrate with a span gas approximating 80% of the full scale range one or a higher range than the full scale range of interest (normal use) to achieve the effect of “narrowing the error” by moving downscale as illustrated by Graph A in the Accuracy & Calibration section.
3.3 PPM FACTORY DEFAULTS SET AUTO SAMPLING 10 PPM RANGE 24.5 C Procedure Span Calibration: This procedure assumes the span gas is under positive pressure. Caution: The user must ascertain that the oxygen reading (actually the sensor’s signal output) has reached a stable value before initiating the SPAN CALIBRATE function. Failure to do so will result in an error. For calibration purposes, use of the AUTO SAMPLE mode is recommended.
CALIBRATION MAIN MENU AUTO SAMPLE MANUAL SAMPLE CALIBRATION 17. 18. 19. 20. >>> SPAN CALIBRATE ZERO CALIBRATE DEFAULT SPAN DEFAULT ZERO OUTPUT SPAN OUTPUT ZERO Press the ENTER key to select the SPAN CALIBRATE option. Note: A span gas concentration above 1000 ppm dictates the selection of the PERCENT option. Advance the reverse shade cursor using the ARROW keys to highlight the desired GAS CONCENTRATION. Press the ENTER key to select the highlighted menu option. GAS CONCENTRATION PERCENT PPM 21.
30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. Disconnect the span gas line. Connect a purge gas line of either zero or sample gas with a low oxygen concentration. Allow the purge gas to flow for 1-2 minutes to purge the air trapped in the span gas line. Place the SAMPLE/BYPASS valve in the SAMPLE position. Allow the purge gas to flow in order to purge the sensor of the oxygen trapped inside from the calibration gas and bring the analyzer online to desired the measurement range.
8. Remember steps #29-30 and #32-33 do not apply because for air calibration the SAMPLE/BYPASS valve should already be in the SAMPLE position. 9. Perform step #31. 10. Skip to step #34 and perform the remainder of the procedure. Output Span Accuracy due to manufacturer tolerances may result in a slight difference between the LCD display and the 0-1V analog output. However, the difference is less than 0.25% of range and falls well below the specified accuracy of the analyzer.
9. 10. 11. 12. Press the ARROW keys to enter the OUTPUT SPAN OFFSET value. Repeat until the complete OUTPUT SPAN OFFSET value has been entered. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key. The system returns to the SAMPLING mode. Sampling The sensor is exposed to sample gas that must flow or be drawn through the analyzer’s internal sample system.
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 5. Assure there are no restrictions in the sample gas lines – inlet or vent. 6. For sample gases under positive pressure the user must provide a means of regulating the inlet pressure between 5-30 psig, the analyzer is equipped with a FLOW VALVE to set the flow rate at the recommended 2 SCHF. 7.
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. 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.
7 Spare Parts Recommended spare parts for the GPR-1200 Series Portable Oxygen Analyzer: Item No. Description GPR-12-333 ppm Oxygen Sensor XLT-12-333 ppm Oxygen Sensor Other spare parts: Item No.
8 Troubleshooting Symptom Possible Cause Recommended Action Slow recovery At installation – extended exposure to air Continue purging sensor with preferably N2 zero gas or sample gas with low ppm oxygen concentration At installation – sensor housing not properly tightened Check and tighten bolt in center of bottom section of sensor housing, purge sensor as above Replace sensor if recovery unacceptable or O2 reading fails to reach 10% of lowest range High O2 reading after installing replacing sensor
Symptom Possible Cause Recommended Action Erratic O2 reading or No O2 reading Test sensor independent from analyzer Remove sensor from housing. Using a volt-meter set to uA output; apply the (+) lead to the outer ring of the sensor PCB and the (-) lead to the center circle to obtain the sensor’s output in air. Contact factory with result. Sensors without PCB use mV setting.
9 Warranty The design and manufacture of Advanced Instruments Inc. oxygen analyzers and oxygen sensors are performed under a certified Quality Assurance System that conforms to established standards and incorporates state of the art materials and components for superior performance and minimal cost of ownership.
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 Oxygen sensors are sealed, contain protective coverings and in normal conditions do not present a health hazard.
Incompatibility KOH = Avoid contact with strong acids or Acetic Acid = Avoid contact with strong bases Hazardous Decomposition Products KOH = None or Acetic Acid = Emits toxic fumes when heated Conditions to Avoid KOH = None or Acetic Acid = Heat Spill or Leak Steps if material is released Sensor is packaged in a sealed plastic bag, check the sensor inside for electrolyte leakage.
