Advanced Instruments Inc. Owner’s Manual GPR-3100 Oxygen Purity Analyzer Advanced Sensor Technology 24 Month Operating Life in 100% Oxygen Inherent Accuracy 0.1%, Resolution 00.01% Auto Ranging & Suppressed Range Capability Temperature Controlled & Barometric Compensationsy 2855 Metropolitan Place, Pomona, CA 91767 USA ♦ Tel: 909-392-6900, Fax: 909-392-3665, e-mail: info@aii2.com, www.aii2.
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Advanced Instruments Inc. 1 Introduction Thank You For Your Business 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 purity of oxygen gas containing innert gases such as nitrogen, helium or argon and/or other reactive gases such as hydrogen and gaseous hydrocarbon gases as minor contaminants.
Advanced Instruments Inc. 2 Quality Control Certification Date: Customer: Order No.
Advanced Instruments Inc. 3 Safety This section summarizes the essential generic precautions applicable to all analyzers. Additional precautions specific to individual analyzers 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.
Advanced Instruments Inc. 3 Safety 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.
Advanced Instruments Inc. Gas analysis solutions through advanced analyzer and sensor technology Technical Specifications Accuracy: < 1% of FS range at constant conditions; inherent accuracy of 0.
Advanced Instruments Inc. 5 Operation Principle of Operation The GPR-3100 oxygen analyzer incorporates an advanced galvanic fuel cell type sensor capable of measuring 100% oxygen on a suppressed range of 90-100% on a continuous basis It is the only electrochemical sensor based analyzer capable of this measurement. Background The production of pure oxygen has been confined to the production of medical grade oxygen (99.0%, typically specified at 99.5% or greater purity).
Advanced Instruments Inc. 5 Operation With the sensor and sample gas lines temperature controlled and the signal output of the sensor compensated for ambient pressure variations it was possible to measure oxygen in the suppressed range of 90-100% with less than +1% of full scale (+0.1% oxygen) accuracy. The calibration was checked periodically and found to be within +1% of full 1 0 0 .0 0 scale over the fourteen month test period 9 9 .
Advanced Instruments Inc. 5 Operation Sample System: The GPR-3100 is supplied with stainless steel flow housing, fittings and tubing along with an integral flow meter to provide optimum percentage range oxygen measurements. As a rule of thumb, the sample must be properly presented to the sensor to ensure an accurate measurement.
Advanced Instruments Inc. 5 Operation 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. An eductor jet pump is an alternative to a pump that is used in classified areas since it has no moving parts or to eliminate the maintenance associated with mechanical pumps. The eductor must be positioned downstream of the sample outlet.
Advanced Instruments Inc. 5 Operation Calibration and Accuracy Single Point Calibration: As previously described the galvanic oxygen sensor generates an electrical current sensor exhibiting 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. 5 Operation Graph C illustrates these 'worse case' specifications that are typically used to develop an analyzer's overall accuracy statement of +2% of full scale at constant temperature or +5% over the operating temperature range. QC testing is typically <+0.5% prior to shipment. Example: 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.
Advanced Instruments Inc. 5 Operation Installation The GPR-3100 Oxygen Analyzer consists of an electronic module, sensor housing and sample system housed in a 10.8”W x 7.5”H x 12.25”D enclosure suitable for panel mounting or 19” rack mounting with the optional panel. A 12”W x 12”H x 8”D wall mount configuration is also available. An integral temperature controlled heating system maintains the temperature of the sensor at a pre-set temperature and assures the stability not found in competitive analyzers.
Advanced Instruments Inc. 5 Operation Mounting the Analyzer: The GPR-3100’s 10.8”W x 7.5”H x 12.25”D configuration is designed for panel mounting directly to any flat vertical surface, wall or bulkhead plate with the appropriate cut out. To facilitate servicing the interior of the analyzer, position it approximately 5 feet off the floor. It can also be mounted in a standard 19” rack with an optional panel.
Advanced Instruments Inc. 5 Operation Gas Connections: The GPR-3100 is designed for positive pressure samples and requires connections for incoming sample and vent lines. Optional zero and span inlet ports are provided as part of the optional sample systems. Optional Span and Zero Inlet Ports Standard Sample and Vent Ports The user is responsible for making provision for introducing gases for calibration purposes. Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading.
Advanced Instruments Inc. 5 Operation Procedure: Caution: Do not change the factory setting until instructed to do in this manual. 1. Regulate the pressure and flow of the incoming sample and zero/span calibration gas(es) as described in Controlling Pressure & Flow above. 2. Connect the ¼” vent line to the compression fitting labeled VENT. 3. Connect the 1/8” sample line to the fitting labeled SAMPLE. 4. Connect the 1/8” ZERO and SPAN gas lines as labeled, if equipped with optional sample system(s). 5.
Advanced Instruments Inc. 5 Operation Output Connections As illustrated above the sensor, alarm relays and signal output connections are hard wired to screw type terminal blocks located at the rear of the analyzer. 1. Use a small bladed screwdriver to loosen the appropriate terminal screws as illustrated above. 2. Strip the wires of the cable no more than 3/16 inch. 3.
Advanced Instruments Inc. 5 Operation 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. Weak Sensor Indicator A 5V output with negative ground is provided when the sensor is operational.
Advanced Instruments Inc. 5 Operation Installing the Oxygen Sensor The GPR-3100 is equipped with an integral oxygen sensor that is fully operational from the shipping container with the oxygen sensor installed, tested and calibrated by the manufacturer prior to shipment. However, for a variety of reasons it may be necessary to ship the oxygen sensor separately. Caution: DO NOT open the oxygen sensor.
Advanced Instruments Inc. 5 Operation Installing Span Gas 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 Span gas cylinder with an oxygen concentration described in the Calibration section below. ¾ Regulator to reduce pressure to between 5 and 30 psig.
Advanced Instruments Inc. 5 Operation Establishing Power to the Electronics: Once the power cord is connected into to the power entry module at the rear of the enclosure as illustrated above, connect the plug end to the appropriate AC outlet. When power is applied to the analyzer, the analyzer performs diagnostic status checks and the 5” x 2.75” graphical LCD displays the following: Note: After establishing power to the analyzer, place the SENSOR BYPASS SWITCH (SW1) in the ON position.
Advanced Instruments Inc. 5 Operation Operating the Menu Driven Controls – The appendix details the entire menu layout and functional operation of the GPR-1600 when equipped with either the standard bypass or optional zero and span inlets sample systems with manual valves. 1. The menu options at the upper left corner are as simple and straightforward as possible. 2. The current MODE of the analyzer is indicated at the top center of the LCD. 3.
Advanced Instruments Inc. 5 Operation Range Selection: The analyzer display defaults to the sampling mode when 30 seconds elapses without user interface. The GPR-3100 analyzer provides four (4) standard ranges and gives users 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.
Advanced Instruments Inc. 5 Operation 4. Press the ENTER key when F-C starts flashing on the display 5. Press INDEX to exit the SECURE MENU Part of the optional temperature controlled heater system is a heater runaway protection circuit that protects the electronics in the event the temperature controller should fail and thereby allowing the heater to runaway damaging the interior of the analysis unit.
Advanced Instruments Inc. 5 Operation Calibration - General Guideline Zeroing the analyzer is recommended for oxygen measurements requiring accuracy greater than +/0.5% oxygen and when the analysis is carried out on 0-100% range. The ZERO OFFSET is not required if the analysis is carried out on the suppressed ranges. Caution: Do not attempt to calibrate the unit in the atmosphere air (20.9% oxygen) and use the analyzer for either elevated or high purity oxygen measurements.
Advanced Instruments Inc. 5 Operation consume the oxygen that has dissolved into the electrolyte inside the sensor (while exposed to air or percentage levels of oxygen). However, finding the true zero offset (and waiting 24 hours) is not always necessary particularly in the case of applications requiring higher level oxygen measurements. But, being absolutely precise and correct requires time.
Advanced Instruments Inc. 5 Operation span calibration again for up to 3 months under “normal” application conditions as described in the published specifications. In standard configuration, the GPR-3100 can be calibrated by exposing the sensor to the readily available cost effective and reliable 20.9% (209,000 ppm) oxygen concentration of ordinary atmospheric air or a certified span gas with an oxygen concentration of 80-100% of full scale range balance nitrogen.
Advanced Instruments Inc. 5 Operation 16. The analyzer returns to the SAMPLE mode after 30 seconds. 17. 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. 18. Disconnect the span gas line and replace it with the purged sample gas line. 19. Wait 10-15 minutes to ensure the reading is stable and proceed to sampling. 20. Once calibrated, the analyzer is ready for Sampling.
Advanced Instruments Inc. 5 Operation To avoid damaging the sensor or sample system observe the following guidelines: 1. Drawing a vacuum on the sensor by pressurizing the analyzer: Results when sample gas flows into the analyzer, builds up within the analyzer sample system because the SHUT OFF valve is closed or the outlet vent is restricted, and, is suddenly released when the blockage is removed. This sudden release of backpressure draws a vacuum on the sensor. 2.
Advanced Instruments Inc. 6 Maintenance 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. 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.
Advanced Instruments Inc. 7 Spare Parts Recommended spare parts for the GPR-3100 % High Purity O2 Analyzer include: Item No.
Advanced Instruments Inc. 8 Troubleshooting Symptom Possible Cause Recommended Action Reading does not reflect expected values Sensor was not calibrated at the pressure, flow rate and temperature anticipated in the sample gas stream Recalibrate the analyzer Oxygen reading drifts toward zero or significant number of turns of the span control adjustment is required to calibrate the analyzer. Indication sensor is nearing the end of its useful life Replace sensor, see Section 6 Maintenance.
Advanced Instruments Inc. 9 Warranty What is covered: Any defect in material and workmanship from normal use in accordance with the Owner’s Manual. This warranty applies to all analyzers purchased worldwide. Advanced Instruments Inc. reserves the right in it’s sole discretion to invalidate this warranty if the serial number does not appear on the analyzer. For how long: One year from shipment by manufacturer or purchase from a distributor with proof of purchase.
Advanced Instruments Inc. 9 Warranty What is not covered: 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 attachment not provided with the analyzer; fire, flood, or acts of God; or other failure to follow the Owner’s Manual.
Advanced Instruments Inc. 10 Material Safety Data Sheet (MSDS) Product Identification Product Name Oxygen Sensor Models CAD, GPR, PSR, SAF, 67013 Synonyms Galvanic Fuel Cell, Electrochemical Transducer 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.
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Advanced Instruments Inc. 10 Material Safety Data Sheet (MSDS) Symptoms Eye contact - burning sensation. Skin contact - soapy slick feeling. Medical Conditions Aggravated None Carcinogenic Reference Data NTP Annual Report on Carcinogens - not listed LARC Monographs - not listed OSHA - not listed Other Lead is listed as a chemical known to the State of California to cause birth defects or other reproductive harm. Emergency First Aid Ingestion Do not induce vomiting. Give plenty of cold water.
Advanced Instrtuments Inc. 5 Operation - Appendix A * MAIN MENU Sample Sample Span Zero Alarm System Auto Range 75F 101 Kpa 99.55 % 90 to 100 % 02/10/2004 17:32:48 MAIN MENU Sample SAMPLE * Sample System 90 to 100 % 02/10/2004 17:32:48 Sample Span Zero 99.55 % Alarm * MAIN MENU Sample Manual Ranging Zero Auto Range 75F 101 Kpa Sample * Auto Ranging (default) Span 99.
Advanced Instrtuments Inc. 5 Operation - Appendix A * MAIN MENU Sample Sample Span Zero Alarm System Auto Range 75F 101 Kpa 99.55 % 90 to 100 % 02/10/2004 17:32:48 MAIN MENU Sample SPAN Sample Zero Alarm System Auto Range 75F 101 Kpa Sample * Factory Default (1) * Span 99.
Advanced Instrtuments Inc. 5 Operation - Appendix A * MAIN MENU Sample Sample Span Zero Alarm System Auto Range 75F 101 Kpa 99.55 % 90 to 100 % 02/10/2004 17:32:48 MAIN MENU Sample ZERO Sample 99.
Advanced Instrtuments Inc. 5 Operation - Appendix A * MAIN MENU Sample Sample Span Zero Alarm System Auto Range 75F 101 Kpa MAIN MENU Sample Span Zero * Alarm System Auto Range 75F 101 Kpa 99.55 % 90 to 100 % 02/10/2004 17:32:48 Sample 99.
Advanced Instrtuments Inc. 5 Operation - Appendix A * MAIN MENU Sample Sample Span Zero Alarm System Auto Range 75F 101 Kpa 5_ops_3100_menu 99.
Advanced Instrtuments Inc. 5 Operation - Appendix A * MAIN MENU Sample Sample Span Zero Alarm System Auto Range 75F 101 Kpa MAIN MENU Sample Span Zero Alarm * System Auto Range 75F 101 Kpa 99.55 % 90 to 100 % 02/10/2004 17:32:48 Sample 99.
Advanced Instrtuments Inc. 5 Operation - Appendix A * MAIN MENU Sample Sample Span Zero Alarm System Auto Range 75F 101 Kpa 99.
