AII GPR-1500 AIS User manual

2855 Metropolitan Place, Pomona, CA 91767 USA ♦Tel: 909-392-6900, Fax: 909-392-3665, www.aii1.com, e-mail: [email protected] Rev 10/15

ISO 9001:2008 Certified

INTERTEK Certificate No. 485

GPR-1500 AIS

PPM Oxygen Analyzer

Full Featured PPM Oxygen Analyzer with

Optional Modbus RTU Communication and

Modular Natural Gas Sample Systems

Technical Specifications *

Accuracy: < 2% of FS range under constant conditions

Analysis: 0-10, 0-100, 0-1000 PPM, 0-1%, 0-25% (CAL) FS

Auto-ranging or manual lock on a single range

Application: Oxygen analysis in inert, hydrocarbon, helium, hydro-

gen, mixed and acid (CO2) gas streams

Approvals: Certified for use in hazardous areas - see lower right

UL: United States: UL 1203, UL 913, UL 508

Canada: CAN/CSA C22.2 No. 30-M1986,

CAN/CSA C22.2 No. 157-92,

CAN/CSA C22.2 No. 14-10

ATEX: Directive 94/9/EC

Area Classification: Certified for use in hazardous areas - see lower right

Alarms: Two user configurable alarms: magnetic coil relays

rated 3A at 100 VAC, programmable alarm delays,

alarm bypass for calibration and system fail alarm

Calibration: Max interval—3 months. Use certified span gas with

O2 content (balance N2) approximating 80% of full

scale for fast 20-30 minute recovery to online use.

Alternatively, air calibrate with clean source of com-

pressed or ambient (20.9% O2) air on 0-25% range

and allow 60 minutes on zero gas to recover to 10

ppm. For optimum accuracy, calibrate one range high-

er than the range of interest.

Compensation: Barometric pressure and temperature (ATEX)

Temperature (UL)

Connections: 1/8" compression tube fittings

Controls: Water resistant keypad; menu driven range selection,

calibration and system functions

Display: Graphical LCD 2.75” x 1.375”; resolution 0.01 PPM;

displays real time ambient temperature and pressure

Enclosure: NEMA Type 3R for rain in outdoor applications (UL)

NEMA 4X (ATEX)

Flow: Not flow sensitive; recommended flow rate 1-2 SCFH

Linearity: ±2% of full scale

Pressure: Inlet - regulate to 5-30 psig to deliver 1-2 SCFH flow;

vent - atmospheric

Power: 12-28 VDC (cUL and ATEX Certified)

110-220 VAC (ATEX Certified)

Response Time: 90% of final reading in 10 seconds

Sample System: Sample flow meter; options available, see other side

Sensitivity: < 0.5% of FS range

Sensor Model: XLT-12-333 for gases containing > 0.5% CO2

Sensor Life: 24 months in < 1000 PPM O2 at 25ºC and 1 atm

Signal Output: 4-20mA non-isolated or 1-5V; optional Modbus RTU

communication

Operating Range: 5ºto 45ºC (GPR sensor); -10ºC to 45ºC (XLT sensor)

Warranty: 12 months analyzer; 12 months sensor

Wetted Parts: Stainless steel

Optional Equipment

Sample conditioning systems (see back page) - Contact factory

GPR-12-333 sensor for non-acid (CO2) gas streams

* Specifications subject to change without notice

Exia

UL Certified

File E343386

Class I, Division 1, Groups C and D

T4 Tamb -20⁰C to +50⁰C

0080

ATEX Certified - Directive 94/9/EC

Examination Cert: INERIS 08ATEX0036

II 2 G

Ex d ib IIB T4 Gb

Tamb -20⁰C to +50⁰C

cUL & ATEX Certified for Hazardous Areas

Advanced Instruments Inc.

GPR-1500AIS

PPM

OXYGEN

ANALYZER

Shown with optional Sampling System

Owner'sManual

Revised August 2013

2855 Metropolitan Place, Pomona, California 91767 USA ♦Tel: 909-392-6900, Fax: 909-392-3665, e-mail:

info@aii1.com

Advanced Instruments, Inc

TableofContents

Introduction

Quality Control Certification

Safety

Features & Specifications

Operation

Maintenance

Spare Parts

Troubleshooting

Warranty

Material Safety Data Sheets

Drawings

A/R

Explosion Proofing Electrical Connections

Appendix

Correlating readings – LCD display to 4-20mA signal

output

Appendix B

H2S Scrubber, Sample System, Media MSDS

Appendix

Maintenance H2S Scrubber & Coalescing Filter

Appendix

The appendices referenced above are an integral part of the documentation, installation and maintenance of this analyzer

to comply with all applicable directives. It is important that users review these documents before proceeding.

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 explosion proof/intrinsically safe in accordance with Safety

Standards: UL 913 Seventh Edition, Referencing UL 60079-0:2005 and UL 60079-11:2009 and CSA C22.2 No. 157-92

Third Edition for use in Class I, Div 1, Groups C and D hazardous locations and the ATEX Directives 94/9/EC for zone 1

Group IIB.

Please refer to Appendix A for making electrical connections that maintains 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, 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 transmitter is your assurance that we stand behind every

transmitter sold.

The serial number of this analyzer may be found on the inside 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.

Analytical Industries Inc.

dba Advanced Instruments Inc.

2855 Metropolitan Place, Pomona, CA 91767 USA

GPR-1500 AIS/2500 AIS

0080

Serial No.:

Year of Manufacture:

INERIS 08ATEX0036

II 2 G

Ex d ib IIB T4 Gb

Tamb -20⁰C to +50⁰C

WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD – SEE

INSTRUCTIONS

Advanced Instruments, Inc

3.GeneralSafety&Installation

This section summarizes the essential precautions applicable to the GPR-1500 AIS Oxygen Analyzer. Additional

precautions specific to individual transmitter are contained in the following sections of this manual. To operate the

transmitter 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.

Warning: This symbol is used throughout the Owner’s Manual to Warn and alert the user of the presence of

electrostatic discharge.

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

the presence of hazardous voltages.

Read Instructions: Before operating the transmitter 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 all warnings on the transmitter, accessories (if any) and in this Owner’s Manual.

Follow Instructions: Observe all precautions and operating instructions. Failure to do so may result in personal injury or

damage to the transmitter.

Analyzer label ULc

WARNING – Potential Explosion Hazard: The devices are not intended for use in atmospheres or with sample gas

streams containing oxygen concentration greater than 21 percent by volume (ambient air) and are only intended

for use in gases or gas mixtures classified as Class I, Div 1, Groups C and D hazardous locations or in non-

hazardous locations, when used in the United States or Canada.

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2. Quality Control Certification

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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.

WARNING- Substitution of Components May Impair Intrinsic Safety

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 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 per Section 10 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: If the analyzer is equipped with a range switch advance the switch to the OFF position and disconnect

the power when the transmitter is left unused for a long period of time.

Installation

This analyzer has been constructed in compliance with

EN 60079-0 : 2009

EN 60079-1 : 2007

EN 60079-11 : 2012

For USA and Canada

UL 913, 7th Edition

CSA C22.2 No. 157-92

It must be installed in accordance with

EN 60079-14

For USA - NEC and Canada – CEC Standards

WARNING - Potential Explosion Hazard – See Warning in Section 4 – Features and Specifications

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 nitrogen or hydrogen sulfide that can interfere with

measurement and cause reduction in the expected life of the sensor. Consult the factory for recommendations concerning

the proper selection and installation of components.

ExpectedSensor Life:With reference to the publish specification located at the last page of this manual, the

expected life of all oxygen sensors is predicated on oxygen concentration (< 1000 ppm for PPM sensor or air for %

sensor), temperature (77°F/25°C) and pressure (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 the

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 low % or PPM O2level analysis.

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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 1,800 ºF to ambient. 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%.

Warning – Sample Stream entering unit must never exceed 50 0C

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 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.

SamplePressureandFlow

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.

Analyzers designed for in-situ ambient or area monitoring has no real sample inlet and vent. The sensor is exposed directly

to the sample gas and it is intended to operate at atmospheric pressure. The analyzer has a built-in pressure sensor and

the sensor output is automatically compensated for any atmospheric pressure changes.

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.

The analyzer equipped with a sample system has designated SAMPLE and VENT ports. Connect SAMPLE gas to

SAMPLE and the vent to the VENT ports only.

Caution: If the analyzer is equipped with an optional H2S scrubber, sample inlet pressure must not exceed 30

psig.

Outlet Pressure:In applications where sample pressure is positive, the sample must be vented to an exhaust pipe at

a pressure less than the inlet pressure so that the sample gas can flow through the sensor housing. Ideally, the sample

must be vented to atmospheric pressure.

Note: The sensor may be used at a slight positive pressure (e.g., when sample is vented to a common exhaust where the

pressure might be higher than 1 atmosphere). However, the pressure at the sensor must be maintained at all times

including during the span calibration. This may be accomplished by using a back-pressure regulator at vent line of the

analyzer. Caution: A sudden change in pressure at the sensor may result in the sensor electrolyte leakage.

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 - Positive:A flow indicator with integral metering valve positioned upstream of the

sensor is recommended for controlling the sample flow rate between 1-5 SCFH. If a separate flow control valve and a flow

indicator is used, position flow control valve upstream of the sensor and position a flow indicator downstream of the sensor.

If necessary, a pressure regulator 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.

Application Pressure - Atmospheric or Slightly Negative: For % oxygen measurements, an

optional external sample pump may be used upstream of the sensor to push the sample across the sensor and out to

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atmosphere. For PPM oxygen measurements, an optional external sampling pump should be positioned downstream of

the sensor to draw the sample from the process, by the sensor and out to atmosphere. A flow meter is generally not

necessary to obtain the recommended flow rate with most sampling pumps. However, if the sample pump can pull/push

more than 5 SCFH, a flow control must be used to control the sample flow. The flow control valve must be positioned in

such a way that it does not generate any vacuum on the sensor.

Caution: If the analyzer is equipped with a flow indicator with integral metering valve or a metering flow

control valve upstream of the sensor and the pump is installed downstream of sensor- open the metering

valve completely before turning the pump ON to avoid drawing a vacuum on the sensor and placing an undue

burden on the pump.

If pump loading is a consideration, a second 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.

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 other optional components. 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.

Moisture and/or particulates generally can be removed from the sensor by opening the sensor housing and either blowing

on the sensing surface or gently wiping or brushing the sensing surface with damp cloth. Caution: Minimize the exposure

of PPM sensors to air during this cleaning process. Air calibration followed by purging with zero or a gas with a low PPM

oxygen concentration is recommended after the cleaning process is completed.

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

direct sun might heat up the analyzer beyond the recommended operating temperature range. If possible, install a small

hood over the analyzer for rain water drain and to prevent over-heating of analyzer.

Gas Connections: The Inlet and outlet vent gas lines require 1/8” or ¼” stainless steel compression type tube

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: Supply power to the analyzer only as rated by the specification or markings on the analyzer enclosure. The

GPR-1500 AIS is powered by 12-28 VDC supply. The wiring that connects the analyzer to the power source should be

installed in accordance with recognized electrical standards. Ensure that the analyzer case is properly grounded and

meets the requirements for area classification where the analyzer is installed. Never yank wiring to remove it from a

terminal connection.

The maximum power the analyzer consumes is no more than 7 Watts.

Advanced Instruments, Inc

4.Features&Specifications

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