Advanced Instruments Inc. GPR-18MS / 18 / 28 Explosion Proof 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.aii1.
Advanced Instruments Inc. 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 Instructions Explosion Proof Electrical Connections Appendix H Drawings Appendix I The appendices referenced above are an integral part of the documentation, installation and maintenance of this oxygen analyzer.
Advanced Instruments Inc. 1 Introduction Your new Explosion Proof Oxygen Analyzer is a precision device designed to give you years of use. It has been designed to incorporate several types of oxygen sensors enabling user’s to select an analysis range appropriate for their application with the confidence of an ATEX certified analyzer system.
Advanced Instruments Inc. 2 Quality Control Certification Date: Customer: Order No.
Advanced Instruments Inc.
Advanced Instruments Inc. 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.
Advanced Instruments Inc. Expected Sensor Life: With reference to the publish specification located in section 4 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. As a rule of thumb sensor life is inversely proportional to changes in the parameters.
Advanced Instruments Inc. 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. Caution: If the analyzer is equipped with a H2S scrubber as part of an optional sample conditioning system, inlet pressure must not exceed 30 psig.
Advanced Instruments Inc.
Advanced Instruments Inc.
Advanced Instruments Inc. 5 Operation Principle of Operation This ATEX Certified Explosion Proof Oxygen Analyzer is a precision device designed to give you years of use. It has been designed to incorporate several types of oxygen sensors enabling user’s to select an analysis range appropriate for their application with the confidence of an ATEX certified analyzer system.
Advanced Instruments Inc. Oxygen, the fuel for these electrochemical transducers, 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 four ranges and remains virtually constant over its useful life. The sensor requires no maintenance or electrolyte addition and is easily and safely replaced at the end of its useful life.
Advanced Instruments Inc. Electronics The signal generated by the sensor is processed by state of the art low design and integrated circuits. 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.
Advanced Instruments Inc. GPR-18MS GPR-18 The ¾ ¾ ¾ ¾ advantages of the bypass sample system include: Supplying the analyzer with the sensor it was qualified with. Isolating the sensor during transport, calibration and maintenance intervals when changing gas line connections. Isolating the sensor from exposure to high oxygen levels during upset conditions which extends sensor life. Purging the air (or high oxygen levels above 1,000 ppm) trapped in the gas lines following a process upset.
Advanced Instruments Inc. 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.
Advanced Instruments Inc. Mounting the Analyzer The oxygen analyzer consists of two PCB assemblies, sensor housing and sample system valves. An optional temperature controlled heater system enhances stability during low ppm measurements. In standard configuration the alarm controls are integral to prevent tampering, however, as illustrated below the alarm controls can be accessed externally with approved actuators. These components are packaged in a compact 8” x 8” x 8” wall mount enclosure.
Advanced Instruments Inc. Gas Connections The analyzers flow through configuration is designed for positive pressure samples and requires connection to 1/8” diameter tube fittings, see illustration, of the FLOW control valve (SAMPLE IN), SAMPLE/BYPASS valve (ppm analyzers only and flow indicator (SAMPLE OUT or VENT). The user is responsible for making provision for calibration gases, regulating the pressure and flow as described below in the Span Gas Preparation section.
Advanced Instruments Inc. Procedure: 1. Disconnect the AC power source before servicing the analyzer. 2. Insert the power cable through the user supplied approved conduit fitting on the left side of the analyzer. 3. Insert the output cable(s) through the user supplied approved conduit fittings on the right side of the analyzer. 4. Strip the ends of the wires approximately ¼ inch. 5. Remove the safety cover plate. 6.
Advanced Instruments Inc. Alarms The analyzer is equipped with two user adjustable alarms located on the interior panel attached to the front door. When activated the alarms trigger SPDT Form C, normally closed, non-latching relays @ 5A, 30VDC or 240VAC resistive. The alarms are fully adjustable by the two potentiometers accessible from the auxiliary panel on the inside of the door with a small bladed screwdriver.
Advanced Instruments Inc. Installing the Oxygen Sensor Analyzers are equipped with an integral oxygen sensor that is tested and calibrated by the manufacturer prior to shipment and is fully operational from the shipping container. Analyzers must be calibrated once the installation has been completed and periodically thereafter as described below. Should it be necessary to install the oxygen sensor – refer to section 6 Maintenance which covers replacing the oxygen sensor.
Advanced Instruments Inc. Establishing Power to the Electronics Establish power to the electronics by connecting the power cable to an appropriate source of AC power. The electronics are rated for a universal power input of 100-230 +/-10% VAC 50-60 Hz, unless the analyzer is equipped with the optional temperature controlled heater system. Ensure the voltage provided is appropriate for the heater.
Advanced Instruments Inc. Procedure: 1. Open the front door to access the DISPLAY SELECT slide switch located on the A-1107 PCB Assembly Main/Display. 2. Advance the selector switch to the ALM1 (high alarm) or ALM2 (low alarm). 3. The digital LED display will indicate the current alarm set point. 4. The alarm setpoint is expressed as a value. 5. Adjust the potentiometer a ½ a turn at a time to allow the electronic processing to catch up . . . until the display reads the desired alarm setpoint value.
Advanced Instruments Inc. Calibration The electrochemical oxygen sensors manufactured by Analytical Industries Inc. (dba Advanced Instruments) generate an electrical current that is linear or 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 properties of linearity and an absolute zero, single point calibration is possible.
Advanced Instruments Inc. Zero Calibration Offset Adjustment Capability: Designed to facilitate precise analysis below 5% of the most sensitive or lowest range available on the analyzer, this feature enables users’ to compensate for background offsets, as defined above, of up to 50% of the most sensitive or lowest full scale range available on the analyzer and bring analyzers online faster. As described below, accomplishing either objective places a degree of responsibility on the user.
Advanced Instruments Inc. The above times assume the introduction of a purge gas, the lower of the available zero or sample (if known and constant) gas, with a ppm level O2 concentration less than 0.5 ppm is introduced to the analyzer following span calibration to purge (accelerate the reaction of) the O2 that has dissolved into the electrolyte inside the sensor. If zero gas is not available, substitute the sample gas and expect slightly longer recovery time.
Advanced Instruments Inc. Span Calibration Adjustments: Prematurely initiating the SPAN CALIBRATION function (when ZERO CALIBRATION has not been performed) before the analyzer reading has stabilized can result in erroneous readings as follows: When purging an analyzer to lower ranges for span gas calibration: If the oxygen reading reaches less than 2% of the intended calibration range, enter the value of the span gas.
Advanced Instruments Inc. 7. With your other hand remove the oxygen sensor, place it in the upper section of the sensor housing ensuring the PCB contacts the two gold pins and use your thumb to hold the sensor and upper section of the sensor housing together. 8. The sensor is now exposed to ambient air, connected to the analyzer electronics and ready for calibration. 9. With the sensor exposed to ambient air – allow the reading to stabilize before adjusting the SPAN actuator/potentiometer. 10.
Advanced Instruments Inc. Application Pressure - Atmospheric or Slightly Negative: For accurate ppm range oxygen measurements, an optional integral sampling pump is positioned downstream of the sensor to draw the sample from the process, by the sensor and out to atmosphere.
Advanced Instruments Inc. 6 Maintenance With exception of components related to optional equipment and charging the battery of portable analyzers, cleaning the electrical contacts when replacing the sensor is the extent of the maintenance requirements of this analyzer as there are no serviceable parts in the analyzer given the nature of the solid state electronics and sensor. Serviceability: Except for replacing the oxygen sensor, there are no parts inside the analyzer for the operator to service.
Advanced Instruments Inc. 7 Spare Parts Recommended spare parts for the GPR-18MS Explosion Proof ppm Oxygen Analyzer: Item No. Description GPR-12-2000MS ppm Oxygen Sensor Other spare parts: Item No. Description IC-1007 Amplifier E/I Converter 4-20mA Isolated CTRL-1004 Controller Temperature Proportional A-3290 Flow Indicator 1/4” FNPT SS Glass Viton O-rings 2x10” FUSE-1001 Fuse 3A 240V .25 x 1.25” FUSE-1002 Fuse Holder 3A 240V .25 x 1.
Advanced Instruments Inc. Recommended spare parts for the GPR-18 Explosion Proof ppm Oxygen Analyzer: Item No. Description GPR-12-333 ppm Oxygen Sensor XLT-12-333 ppm Oxygen Sensor Other spare parts: Item No. Description IC-1007 Amplifier E/I Converter 4-20mA Isolated CTRL-1004 Controller Temperature Proportional A-3290 Flow Indicator 1/4” FNPT SS Glass Viton O-rings 2x10” FUSE-1001 Fuse 3A 240V .25 x 1.25” FUSE-1002 Fuse Holder 3A 240V .25 x 1.
Advanced Instruments Inc. Recommended spare parts for the GPR-28 % O2 Analyzer include: Item No. GPR-11-32 XLT-11-24 Description Oxygen Sensor Oxygen Sensor Other spare parts: Item No. Description IC-1007 Amplifier E/I Converter 4-20mA Isolated CTRL-1004 Controller Temperature Proportional FMTR-1002 Flow Meter SS ¼” FNPT Ports Viton O-Rings 5 SCFH Scale FUSE-1001 Fuse 3A 240V .25 x 1.25” FUSE-1002 Fuse Holder 3A 240V .25 x 1.
Advanced Instruments Inc.
Advanced Instruments Inc.
Advanced Instruments Inc.
Advanced Instruments Inc.
Advanced Instruments Inc. 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.
Advanced Instruments Inc. 10 MSDS – Material Safety Data Sheet Product Identification Product Name Synonyms Manufacturer Emergency Phone Number Preparation / Revision Date Notes Oxygen Sensor Series - PSR, GPR, AII, XLT Electrochemical Sensor, Galvanic Fuel Cell Analytical Industries Inc., 2855 Metropolitan Place, Pomona, CA 91767 USA 909-392-6900 January 1, 1995 Oxygen sensors are sealed, contain protective coverings and in normal conditions do not present a health hazard.
Advanced Instruments Inc. Disposal Health Hazard Information Primary Route(s) of Entry Exposure Limits Ingestion Eye Skin Inhalation Symptoms Medical Conditions Aggravated Carcinogenic Reference Data Other Special Protection Ventilation Requirements Eye Hand Respirator Type Other Special Protection Special Precautions Precautions Transportation In accordance with federal, state and local regulations.
