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User Manual for Analytical Industries models including: GPR-18 MS Explosion Proof Oxygen Analyzers, GPR-18 MS, Explosion Proof Oxygen Analyzers, Proof Oxygen Analyzers, Oxygen Analyzers, Analyzers
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DocumentDocumentGPR-x8 Explosion-Proof Oxygen Analyzers User Manual PST-UM-3014-EN-3.1 Issue No. Description 01 Original document issued 02 Re-brand template Hazardous area information 03 Updated GPR-28: specifications 3.1 Updated specifications GPR-x8 Explosion Proof Oxygen Analyzers Date 01/2016 Author Initials PP 09/2023 FR 12/2023 FR 01/2024 NSF GPR-x8 Oxygen Analyzers For contact information, visit ProcessSensing.com Analytical Industries Inc (Aii) is part of the Process Sensing Technologies Group (PST). This document is the property of Process Sensing Technologies and may not be copied or otherwise reproduced, communicated to third parties, nor stored in any Data Processing System without the express written authorization of Process Sensing Technologies. ©2024 Process Sensing Technologies ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers Contents 1. Introduction Intended Use Technical Description & Labeling Theory of Operation 2. Essential Information Symbols Warnings, Cautions & Information 3. Installation Unpacking & Inspect Overview Sensors Available Operating Conditions Sample Systems Mounting Electrical Connections Gas Connections Establishing Power Installing the Oxygen Sensor 4. Calibration Overview Accuracy Calibration Gas Preparations Zero Calibration Span Calibration Sampling 5. Operation Overview Oxygen Display Display Mode Selection Oxygen Alarms: Description & Setup Power Failure Alarm Sensor Failure Alarm Signal Outputs Range ID Output Temperature Controlled Heater - (optional GPR-18 and GPR-28) - Heater Runaway Range Selection Standby 6. Maintenance Overview Sensor Replacement Analyzer Enclosure 7. Spare Parts 8. Trouble Shooting 9. Warranty 10. Safety Data Sheet GPR Series Oxygen Sensors XLT Series Oxygen Sensors A. Appendix Recommendations Cable Gland & Conduit Sealing ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 1. Introduction Your new oxygen analyzer is a precision device designed to give you years of measuring a wide range of oxygen concentrations. This analyzer features sensor technology devel- Technical Description Oxygen Analyzer oped exclusively by Analytical Industries Inc. For a discussion of the various analyzer's performance section 11 Specifications of this Instructions for Use. see Manufacturer: Analytical Industries Inc. Types: GPR-18 MS, GPR-18, GPR-28 The analyzers are designed to measure the oxygen concen- ATEX: Certificate: CML 23ATEX1357X tration in inert gases, gaseous hydrocarbons, hydrogen and a variety of gas mixtures. To obtain maximum performance from your new oxygen analyzer, please read and follow the guidelines provided in this Instructions for Use. Standards: EN IEC 60079-0:2018 EN 60079-1:2014 Marking: II 2 G Every effort has been made to select the most reliable state Ex db IIB or IIB+H2 T6 Gb of the art materials and components; and, to design the analyzer for superior performance and minimal cost of ownership. This analyzer was tested thoroughly by the manu- IECEx: Certificate: IECEx CML 23.0122X Standards: IEC 60079-0:2017 facturer prior to shipment for best performance. IEC 60079-1:2014 However, these 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. Marking: Ex db IIB or IIB+H2 T6 Gb Tamb = -20°C to +60°C UKEX: Certificate: CML 23 UKEX1358X The serial number of this analyzer may be found on the Standards: EN IEC 60079-0:2018 side the analyzer. 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. Marking: EN 60079-1:2014 II 2 G Ex db IIB or IIB+H2 T6 Gb Serial Number: _______________________ Flameproof Enclosure Analytical Industries Inc. appreciates your business and Manufacturer: Killark pledges to make every effort to maintain the highest possi- Type: EXB N34 cover, window and three buttons ble quality standards with respect to product design, manu- EXB N34 box, 3 holes ½"NPT, 2 holes ¾"NPT facturing and service. ATEX: Certificate: QPS 21ATEX0001U Intended Use The Explosion Proof Series of Oxygen Analyzers are designed with an explosion proof enclosure, flame arrestors, breather device, actuators and certified for use in hazardous areas as noted at the right. Standards: EN IEC 60079-0: 2018 EN 60079-1:2014 EN 60079-31: 2014 EN 60529:1992+A2:2013 Marking: II 2G Ex db IIB+H2 Gb *The equipment shall not have an internal source of release of oxygen or any other oxidizers in concentrations greater than that found in normal air (21%). II 2D Ex tb IIIC Db IP66 Ta= -50°C.. +70°C UKEX: Certificate: 3CT UKEX1002U GPR-18 MS: 10 PPB to 1000 PPM oxygen contamination in inert gases streams. Standards: EN IEC 60079-0: 2018 EN 60079-1:2014 EN IEC 60079-31: 2014 GPR-18: 50 PPB to 1% oxygen contamination in inert, hydrocarbon, He, H2, mixed, and acid (CO2) gas streams. Marking: II 2G Ex db IIB+H2 Gb II 2D Ex tb IIIC Db IP66 Ta= -50°C.. +70°C GPR-28: IECEx: Certificate: IECEx QPS 17.0013U 0.05% to 21% oxygen measurements in inert, hydrocar- Standards: IEC 60079-0:2017 Edition: 7.0 bon, He, H2, mixed and acid (CO2) gas streams. IEC 60079-1:2014-06 Edition: 7.0 IEC 60079-31:2013 Edition: 2.0 Marking: Ex db IIB+H2 T6 Gb Ex tb IIIC Db IP66 Tamb = -20°C to +60°C Volume : 13L Maximum power dissipated: 93W ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 1. Introduction Flame Arrestors and Breather Manufacturer: Michell Instruments Type: FA-2-A Flame Arrestors and BR-2-A Breathers ATEX: Certificate: CML 20ATEX1302U Standard: EN IEC 60079-0:2018 EN 60079-1:2014 EN 60079-31:2014 Marking: II 2 G D Ex db IIB+H2 T6 Gb Ex tb IIIC T85°C Db Ts= -40°C to +60°C IP6X UKEX: Certificate: CML 21UKEX1086U Standard: EN 60079-0:2018 EN 60079-1:2014 EN 60079-31:2014 Marking: Group II 2 G D Ex db IIB+H2 T6 Gb Ex tb IIC T85°C Db Tamb -40°C to +60°C IP6X Containment system with limited release (presence of fittings) Description: The sample gas is completely confined inside 1/8" stainless steel tubing with Swagelok type ferrule and ring compression fittings and tightened to Swagelok's instructions, until exiting the enclosure. Inlet pressure: specified regulated to 5-30 psig. Flowrate: sample gas entering the enclosure: 1-2 SCFH Test realized according to annex G of EN 60079-0:2018 / IEC 60079-0:2017 for certification. Cable gland Analytical Industries does not supply the cable gland. It is the responsibility of the user to install a cable gland that complies with local regulations. A unique label reflecting the sample above is permanently affixed to the enclosure to identify every analyzer. IECEx: Certificate: IECEx CML 20.0168U Standards: EC 60079-0:2017 Edition: 7.0 IEC 60079-1:2014-06 Edition: 7.0 IEC 60079-31:2013 Edition 2 Marking: Ex db IIB+H2 T6 Gb Ex tb IIIC T85°C Db Tamb -40°C to +60°C IP6X The flame arrestors do not include any polymeric or elastomeric materials. The analyzer must be installed in accordance with: EN 60079-14:2014; IEC 60079-14:2013 EN 60079-17:2014; IEC 60079-17:2013 ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 1. Introduction Theory of Operation Sensitivity, stability and recovery time are improved while These analyzers consist of two PCB assemblies, sample system including sample flow control valve and flow meter, sensor housing, and, incorporate a variety of advanced significantly reducing the temperature dependence of the sensor's signal output which contributes to excellent long term stability. electrochemical galvanic fuel cell type sensors for PPB, PPM and % range oxygen measurements. GPR-18: Measures 50 PPB to 1% oxygen contamination in inert, hydrocarbon, He, H2, mixed, and acid (CO2) gas An optional temperature controlled heater system is availa- streams. Proprietary advancements in design and chemis- ble that enhances the stability of the oxygen reading and is try add significant advantages to an extremely versatile recommended for outdoor installations or when ambient oxygen sensing technology. temperatures vary regularly. These PPM oxygen sensors exhibit superior accuracy and In standard configuration the alarm controls are integral to stability, recover from exposure to air to PPM levels in the main PCB and cannot accessed from the outside of ana- minutes with a longer life and warranty period. The XLT lyzer (to prevent tampering with alarm set points) version offers an extended operating range of -20°C to 50° C and excellent compatibility for measuring PPM oxygen * The analyzer shall not have an internal source of release levels in applications involving natural gas and beverage of oxygen or any other oxidizers in concentrations greater grade CO2 containing up to 100% CO2. than 21%. GPR-28: 0.05% to 21% oxygen measurements in inert, Sensor Technology hydrocarbon, He, H2, mixed and acid (CO2) gas streams. Oxygen enters the sensor, simultaneously oxidizes the anode and reduces the cathode to produce a linear electrical Proprietary advancements aid in the transition from PPM to low percentage range measurements to 21% oxygen. current signal output proportional to the oxygen concentra- tion in the gas phase. In addition to superior accuracy and stability, the percent Advanced sensor technology permeates the range of oxygen sensors which are: specific to oxygen with superior accuracy generate a signal output that is both linear over all rang- oxygen sensor offer the longest life and extended temperature range in the industry. The XLT version also offer an extended operating range of -20°C to 50°C and excellent compatibility for measuring oxygen levels in applications containing varying concentrations of CO2. es and virtually constant over its life time exhibits superior stability and fast response time requires no maintenance or electrolyte additions easily replaced in the field like a battery offer the best warranty and service in the industry Signal Processing Electronics The signal generated by the sensor is processed by an integrated electronic circuit. 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 ambi- ent temperature changes. GPR-18 MS: Measures 10 PPB to 1000 PPM oxygen con- tamination in inert, hydrocarbon, He, H2 and mixed gases The result is a very stable signal. Sample oxygen is ana- streams. It is based on a proprietary design, the Pico-IonTM lyzed very accurately. Response time of 90% of full scale is oxygen sensor which is specific to oxygen and produces a less than 30 seconds (actual experience may vary due to current signal output 80x greater than conventional electro- the integrity of sample line connections, dead volume and chemical fuel cells and equal to Coulometric wet cells. flow rate selected) on all ranges under ambient monitoring conditions. Sensitivity is typically 0.5% of full scale low The Pico-Ion sensor features a proprietary sensing range. The measured Oxygen value can be transmitted for electrode that generates the 80x increase in signal external use via an isolated 4-20mA and 0-1V signal outoutput and a unique gas delivery path that mini- put. mizes the amount of unreacted oxygen that can dissolve into the electrolyte and slow offline recov- Overall performance is enhanced by an optional tempera- ery time. ture controlled heater system that controls the tempera- ture around the sensor at a pre-set temperature. Connections of the appropriate AC line voltage should be hard wired to screw type terminal blocks. Power requirement related to the optional heater system is specific to 100/110VAC or 220/230VAC, supply power as indicated near the power input terminal. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 2. Essential Information This section summarizes the general precautions and operating information for the Explosion Proof Series Oxygen Analyzers that must be observed to prevent damage to the analyzer and injury to the operator. The remaining sections provide specific additional instructions for optimizing the analyzer's performance in inert sample gases. Analytical Industries Inc. will not be responsible for damages resulting from the installation or operation of the analyzer in a manner not consistent with these Instructions for Use. * The analyzer shall not have an internal source of release of oxygen or any other oxidizers in concentrations greater than 21%. ProcessSensing.com 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 the Instructions for Use. Serviceability: See section 6 Maintenance. While none of the components are serviceable in themselves, see Section 7 Spare Parts is provided in the unlikely event a component fails and has to be replaced. Please review section 9 Warranty, DO NOT attempt to service the analyzer or replace component parts on your own, consult the factory or a factory trained service technician. GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Unpack & Inspect Operating Conditions 1.Examine the condition of the packaging, remove the con- tents identified below and inspect. Temperature of the sample gas must be within the rec- Oxygen Analyzer Instructions for Use (e-copy on thumb drive) ommended operating range specified in section 11 before it enters the analyzer. Quality Control & Calibration Certification (sec 12) Chart Recording of Qualification Test Hot sample gases can easily be cooled to ambient temperature by using a coiled 10 foot (3m) length 2.Verify the contents against the packing slip. of ¼" stainless steel tubing. On an intermittent 3.Open the analyzer door, remove any shipping materials basis, the analyzer may be operated at 122°F (50 and inspect with particular attention to components °C). that may have come loose during transport. 4.Report any apparent damage or missing items to the car- Sample Inlet Pressure rier and factory immediately (+1 909-392-6900 or in- The analyzers are designed for flowing samples under pos- fo@aii1.com). DO NOT proceed if damage is noted. itive pressure as standard. An optional Sample pump can be specified for negative pressure applications. See section Overview 11 Specifications. The following sections provide key information about the sensors, influence of operating conditions, sample system requirements, mounting the analyzer, electrical connections, gas connections, establishing power to the analyzer If the analyzer is equipped with an optional H2S scrubber and or a coalescing filter, inlet sample pressure must not exceed 30 PSIG. and installing the oxygen sensor. For sampling gases at near atmospheric pressure Install in accordance with ATEX Directives and IECEx Scheme: or under slight vacuum an external sample pump can be used to either push or draw the sample gas from the process, move it through the analyz- EN 60079-14:2014; IEC 60079-14:2013 er for analysis and to vent. EN 60079-17:2014; IEC 60079-17:2013 The positioning of the sample pump either up- Sensors The GPR series sensor is available with all analyzers and 1. recommended for all inert and hydrocarbon gas streams, whereas, the XLT series sensor is available only with the stream or downstream of the analyzer requires making an informed decision: The rate at which air (oxygen) leaks into the pump should be empirically determined. GPR-18 and GPR-28 analyzers and is recommended for 2. The user's accuracy requirements must be assessed in background gases with more than 0.5% CO2 on a continual light of the actual leak rate of the sample pump. basis. 3. If the sample pump has a low enough leak rate to Avoid prolonged exposure to air or high O2 levels. meet the user's accuracy requirements (a) position the pump upstream of the analyzer to draw the sample GPR-12-2000 MS2 PPB oxygen sensors are susceptible to damage from prolonged exposure to > 1000 PPM O2. and push it through the analyzer, (b) the analyzer's flow control device upstream of the sensor regulates the flowrate of the sample, a point that is critical to GPR-12-333 PPM sensors last 4-6 months in prolonged exposure to air but generate a > 1-2 PPM O2 offset in the reading on zero gas. XLT-12-333 PPM sensors expire the GPR-18 MS, (c) the possibility of damaging the oxygen sensor is minimized, (d) this approach is the exception rather than the rule. after 5-7 days in air. 4. To meet the user's accuracy requirements or inability GPR-11-32 and XLT-11-24 % sensors are not adversely affected by exposure to ambient air. to confirm the actual leak rate of the sample pump position the pump downstream of the analyzer as the safest approach to obtaining reliable measurements. See section 11 Specifications for the expected life of an oxygen sensor which is inversely proportional to changes in the oxygen concentration and pressure and exponential (2.54%/ C) to sample temperature, e.g. if an analyzer is continuously operated at 35 C, expect the sensor life to be DO NOT use a sample pump downstream of the GPR-18 MS. Using a sample pump downstream of the GPR-18 MS will damage the sensor. If a sample pump is used it must be suitable for the application and the area of installation. reduced by ~30%. GPR-18 and GPR-28 use an adjustable valve to control the flow rate. When a pump is positioned downstream of the analyzer, the adjustable valve MUST BE COMPLETELY OPEN to avoid drawing a vacuum directly on and permanently damaging the oxygen sensor. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Sample Vent Pressure Mounting In positive sample pressure applications, the sample must be vented to ambient or in a vent line with pressure less The analyzers are packaged in an aluminum wall mount than the sample inlet pressure. enclosure with dimensions of 13.25" x 17.25" x 10.75" which carries ATEX / IECEx certifications and IP66 rating. If the sample is vented to a line at a pressure above or below ambient, a back-pressure regulator must be installed Only authorized trained personnel should install downstream of the oxygen sensor and set at least 1 PSIG this analyzer. Installation must comply with local, higher that the line pressure of the vent to ensure a con- state, country regulations and the ATEX standards stant pressure on the sensor. identified above. When employing a back-pressure regulator to DO NOT connect electrical power until overcome a higher vent line pressure, e.g. venting the analyzer is properly mounted. a sample to a flare line, (a) set the back-pressure gradually to avoid drawing a vacuum on the sen- The analyzer is designed for mounting on a flat vertical sor and (b) calibrate the analyzer after the back- surface (mount approximately 5 feet above the floor) by pressure regulator has been set. bolting the mounting feet attached to the rear of the en- closure the mounting surface using 1/2" or M12 diameter Sample System steel bolt and washers Sample Gas Stream: Ensure that the sample gas composition and application conditions are consistent with the specifications of the analyzer. If in doubt, consult factory to ensure the analyzer is suitable for specific gas analysis. Inspect and clean the machined surfaces of both the bottom base and the hinged cover of the enclosure. The sealing surfaces must be inspected and free of nicks, dirt or any foreign particle build -up that would prevent a proper seal. Closing the enclosure: Material and Components The analyzers can be specified and supplied with a sample 1. 2. handling system. However, if the analyzer was purchased without a sample handling system, the user may be required to install the necessary sample handling components. 3. 4. 5. 6. Wipe the sealing surfaces with a clean lint-free cloth. Apply a light coating of Killark "LUBG" lubricant to the sealing surfaces. Close the hinged cover and mate to enclosure base. Install the bolts thru the cover into enclosure base. Finger tighten bolts. Torque all bolts to 30 ft/lbs. When designing a sample system, use of stainless steel tubing, fittings and valves is essential for maintaining the integrity of the sample gas stream. After installation, the unit must be inspected regularly to verify the enclosure mounting bolts are tight and in good condition, the cover bolts are torqued to 30 ft/lbs., conduit/cable gland connec- Removal of Contaminant Gases: In certain application, it tions are intact and free of corrosion. may be necessary to remove any contaminants that may interfere with measurements. Typically, a gas-specific scrubber is used to remove interfering gases such as oxides of sulfur and nitrogen or hydrogen sulfide. Should the flange surface be damaged, NEVER attempt to rework the surface of flange in the field. Consult the analyzer or enclosure manufacturer identified by one of the red metal labels The presence of such interfering gases can result affixed to the enclosure. in false oxygen readings and reduction in the expected life of the sensor. Consult factory for rec- See enclosure diagram on following page. ommendations concerning the proper selection and installation of scrubber or filter components. ProcessSensing.com 3. Installation Mounting - Enclosure Diagram GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Mounting - Enclosure Diagram ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Electrical Connections Power Consumption: The analyzer consumes a maximum 30 watts of power without the optional heater and 93 The analyzer electronics including the optional watts with the built-in optional heater system. integral heater system are powered by 110 or 220 VAC power which must be specified at order entry. The analyzer's power rating is located near the Power must be supplied through a separate conduit on the left side of the enclosure, see drawing previous page. power input terminal. Use a shielded power cord with minimum of 18 gauge Install cable glands, size 3/4"-14 NPT-M, or conduit using an approved electrical conducting type lubricant on the threads. The glands and conduit wires. If equipped with the optional integral heater system, the required internal wiring to the heater and controller has been installed at the factory. must be either a tapered type thread conforming to ANSI/ASME B1.20.1 standard or an ISO metric thread standard. The user simply connects an appropriate source of AC power to the power terminal as illustrated below. Bring the output and alarm connections through an approved Supply power to the analyzer only as rated by the specification and markings on the analyzer enclo- 3/4"-14 NPT-M conduit fitting on the right side of the enclosure, see drawing previous page. sure. The electronics are rated for 110 or 220 VAC. The accessories used for cable gland entry, size 3/4"-14 NPT-M, must be covered by a separate ATEX certificate and must be suitable to be used with the enclosure, see Appendix A. Supply appropriate AC power of the power. An improper voltage could permanently damage the heating system. Do not remove the protective Plexi-glass panel that covers the PCB. The cover prevents the user from touching any of the LIVE Ensure that the analyzer is properly grounded, see circuitry on the PCB. illustration below, and meets the requirements of recommended local electrical standards. If authorized by the factory to replacement failed components in the analyzer, disconnect the AC power source to avoid electric shock. There is no AC power present on the circuit board assemblies mounted on inside of analyzer door. See power and electrical feature connections, interconnection wiring and optional heater wiring diagrams along with installation procedures on the following pages. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Electrical Connections Procedure: 1. Insert the power cable through the user supplied ATEX approved conduit fitting on the left side of the analyzer. 2. Insert the signal output cable(s) through the user supplied ATEX approved conduit fittings on the right side of the analyzer. 3. Strip the ends of the wires approximately ¼ inch. 4. Loosen the terminal screws, insert the bare wire into the appropriate terminals and re-tighten with a small bladed screwdriver. 5. Note: If equipped with the optional temperature-controlled heater system, the necessary wiring to the heater and controller has been installed at the factory and no additional connections are required. The power connection services both the analyzer electronics and temperature-controlled heater system. 6. Connect the power ground directly to the ground terminal on the inside of the analyzer case, see previous page. 7. Pack and seal the seal fittings bringing power to and taking analog outputs and alarm interconnection wiring from the analyzer as recommended in Appendix A. 8. Establish power to the analyzer after making gas connections as below once installation is complete. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Electrical Connections - Analyzer Interconnection Diagram ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Electrical Connections - Optional Heater Wiring Diagram ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Gas Connections Establish Power to Electronics The analyzer's flow through configuration is designed for positive pressure samples and requires connection to 1/4'" diameter compression tube fittings. Addressing different sample conditions was discussed previously. Connect a power cable to analyzer's power terminal block. The electronics are rated for a power input of 100 or 230 VAC 50-60 Hz. With optional temperature-controlled heater system, however, supply only the voltage noted near the power terminal. Complementing the performance capabilities of the PPB (GPR-18 MS) and PPM (GPR-18) oxygen sensor is a sample system consisting of stainless steel and glass wetted parts, a unique proven leak-tight sensor housing design and a sample/bypass system. The LCD display will light up when power is applied to the analyzer. Assuming the analyzer has been installed as directed above, and the sensor has been installed at the factory, the reading displayed when the analyzer is turned on, reflects the oxygen value under static condition (i.e. The bypass system isolates the sensor from exposure to high oxygen concentration during transport, upset conditions and routine mainte- the axiom that all valves and fittings leak, the sensor is looking at equilibrium point of oxygen diffusing into the sample system and oxygen consumed by the sensor). nance and bring the analyzer on-line at PPB and PPM levels very quickly. The sample/bypass valve Installing the Oxygen Sensor is not required for the GPR-28. Analyzers are shipped with the oxygen sensor that the analyzer was calibrated, qualified and tested with at the factory as documented by the Quality Control & Calibration Certifica- tion and chart recordings in section 12. Circumstances vary but normally the oxygen sensor is installed prior to shipment and the analyzer is fully operational out of the box. If the oxygen sensor was shipped separately or if a new oxygen sensor must be installed in the field, it will be necessary to install a new sensor. The sensor is sealed in a special bag under application conditions. DO NOT open the bag until ready to install the sensor. DO NOT open the oxygen sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if touched or ingested, refer to section 10 Safety Data Sheet. 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. Spent sensor or a leaking sensor should be disposed of in accordance with local regulations. After sensor installation, the analyzer must be calibrated to ensure correct sample analysis. Review section 4 Calibration to determine whether the next step is Zero or Span Calibration. Depending on the circumstances and type of oxygen sensor, there are several procedures with different requirements as described on next page. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 3. Installation Procedure Applicable to GPR-18 MS and GPR-18 if Zero Calibration is to follow (section 4 Calibration): 1. Select the analyzer's highest range available range, adjust as the reading trends downward. 2. Initiate the flow of a high purity N2 zero gas, regulate the pressure to the lowest value expected in the sam- ple gas and then set the flow rate, see section 11 Specification. 3. Place the Sample/Bypass valve in the Sample position before installing the oxygen sensor. 4. Use the 5/16 wrench supplied to loosen the clamp bolt under the sensor housing. 5. With the bolt loose, rotate the upper sensor housing 90° to disengage it from the clamp. 6. Remove the oxygen sensor from the bag (if replacing an existing sensor see section 6). 7. Place the oxygen sensor in the bottom section of the sensor housing, PCB facing up. 8. Remove the two red shorting strips (including the gold ribbon) from the sensor's PCB. 9. Place the upper section of the sensor housing over the oxygen sensor, gently push downward and rotate 90° Procedure Applicable to GPR-18 and GPR-28 if Air to engage the clamp. Calibration is to follow: 10. Use the 5/16 wrench to re-tighten the clamp bolt. 1. Select the range of the analyzer to the 0-25% range. 11. The analyzer will display the O2 content of the gas. 2. Initiate the flow of sample gas, regulate the pressure 12. Confirm the downward trend of the O2 concentration to lowest value expected in the sample with an external recording device. 3. Gas and then set the flow rate, see section 11 Specifi- 13. Proceed to section 4 Calibration to complete Zero Cali- cation. bration 4. Place the Sample/Bypass valve in the Sample position before installing the oxygen sensor. Procedure Applicable to GPR-18 MS, GPR-18 and 5. Use the 5/16 wrench supplied to loosen the clamp bolt GPR-28 if Span Calibration is to follow: 1. Select the range that accommodates the O2 content of 6. under the sensor housing. After loosening the bolt, rotate the upper sensor hous- 2. the span gas, see section 11 Specification. Initiate the flow of span gas, regulate the pressure to 7. the lowest value expected in the sample gas and then ing 90° to disengage it from the clamp. Remove the oxygen sensor from the bag (if replacing an existing sensor, see section 6). 3. set the flow rate, see section 11 Specification. 8. Place the Sample/Bypass valve in the Sample position Remove the two red shorting strips (including the gold ribbon) from the sensor PCB. 4. 5. before installing the oxygen sensor. Use the 5/16 wrench supplied to loosen the clamp bolt under the sensor housing. With the bolt loose, rotate the upper sensor housing 90° to disengage it from the clamp. 9. 10. Proceed to section 4 Calibration and follow the Air Calibration procedure. Upon completion of the Air Calibration procedure, immediately place the new sensor in the bottom section, PCB facing up. 6. Remove the oxygen sensor from the bag (if an existing sensor, see section 6). replacing 11. Place the upper section of the sensor housing over the sensor, gently push downward and rotate 90° to en- 7. 8. Immediately place the oxygen sensor in the bottom section of the sensor housing, PCB facing up. Remove the two red shorting strips (including the gold 12. 13. gage the clamp. Use the 5/16 wrench to re-tighten the clamp bolt. The analyzer will immediately display the O2 content 9. ribbon) from the sensor's PCB. Place the upper section of the sensor housing over the 14. of the gas. Confirm the downward trend of the O2 concentration oxygen sensor, gently push downward with an external recording device. 10. and rotate 90° to engage the clamp. 11. Use the 5/16 wrench to re-tighten the clamp bolt. 12. The analyzer will immediately display oxygen content of the gas. 13. Confirm the downward trend of the O2 concentration with an external recording device. 14. Proceed to section 4 Calibration. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 4. Calibration In order to accurately measure the oxygen concentration in a sample gas stream, it is necessary to calibrate (adjust the accuracy) the analyzer electronics to the oxygen sensor's signal output when exposed to certified gas standard. Calibration can involve one or both Zero and Span Calibrations. The user is responsible for making provision for calibration gases and regulating the sample and span gas pressure and flow as described below. Flow devices can minimize the influence of increasing pressure but drops in pressure actually change the partial pressure at the oxygen sensor. To prevent erratic oxygen readings, set the flow rate only after the pressure is regulated, see section 11 Specifications, at the lowest pressure anticipated under sampling conditions. Recommendation: Consider installing 3-way valves be- Temperature: The rate at which oxygen molecules dif- fore the sample inlet to provide a permanent connection for fuse into the sensor is controlled by a Teflon membrane Zero gas (if required) and/or Span gas and a means of otherwise known as an 'oxygen diffusion limiting barrier. switching from SAMPLE to ZERO or SPAN gas and vice ver- All diffusion processes are temperature sensitive, the sen- sa without breaking gas line connections. This arrangement sor's electrical signal output also varies with temperature. eliminates the possibility of exposing the sensor to high oxygen when changing gas lines to switch gas sources. Changes in temperature result in a 2.54%/ºC variation in the sensor's signal output which in- Accuracy versely affects expected sensor life. Single Point Calibration: The galvanic oxygen sensor generates an electrical current that is both linear and pro- With reference to Dalton's Law of partial pressure, the oxygen diffusion limiting barrier allows and requires a portional to the oxygen concentration in the sample gas. small amount of the actual sample to permeate into the sensor to make the oxygen measurement. This provides In the absence of oxygen, the sensor exhibits an absolute zero, e.g. the oxygen sensor does not generate a current several performance advantages: 1. Unaffected by changes in flow rate, 0.1 to 10 SCFH. signal output in the absence of oxygen. Given the specifici- 2. Unaffected by changes in background gases (except ty, linearity and absolute zero properties, calibration of the analyzer is possible. a single point 3. GPR-12-2000 MS2 Pico Ion PPB oxygen sensor). Unaffected by moisture and particulates. Pressure: Galvanic oxygen sensors are accurate at any pressure provided the pressure is constant. Oxygen sensors are sensitive to the partial pressure of oxygen in the sample gas and their output is a function of the number of oxygen molecules 'per unit volume' of the sample gas. The number of oxygen molecules per unit volume will increase proportionally with pressure. Expected sensor life is inversely proportional to pressure. Because pressure varies in real world applications, a flow control device is positioned between the pressure regulator and the oxygen sensor to reduce and stabilize the pressure at the oxygen sensor. The type of flow control valve or fixed restrictor varies with the flow sensitivity of the oxygen A temperature compensation circuit offsets the 2.54%/ºC sensor. variation in the sensor's signal output once the electronics and sensor's diffusion barrier and electrolyte reach equilib- The GPR-18 MS oxygen sensor is more flow sensitive and rium. Accuracy is +5% full scale range over the operating requires the precision of a flow restrictor, whereas, the temperature range, see section 11 Specifications. membrane clad oxygen sensors found in the GPR-18 and GPR-28 are not flow sensitive and use a metering valve to maintain the pressure. A variation of ~10º F produces < 2% FS error in the O2 reading until equilibrium is reached. To prevent erratic oxygen readings, calibrate the analyzer at the temperature nearest the temperature anticipated under sampling conditions ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 4. Calibration Calibration Gas Preparation In theory, the galvanic fuel cell type oxygen sensor has It is essential that when using a certified standard zero or span gas to adjust the analyzer sensitivity that the integrity an absolute zero meaning it does generate a signal output when exposed to an oxygen free zero gas. of the gas is maintained during installation of a pressure regulator (on the gas cylinder) to regulate the gas pressure In reality, the sensor generates a signal output or posi- when making tive oxygen reading when sampling a zero gas due to: gas connection to the analyzer. 1. Minor leakage in the sample line connections. Required Components: 2. 1. Certified zero or span (as recommended in section 11 3. Specifications) gas cylinder. 4. 2. Regulator to set gas pressure to 5-30 psig. 3. Suitable fittings and 1/8" or 1/4" dia. metal tubing to Impurities in the zero gas, e.g. accuracy % tag. Tolerances of the electronic components. Lack of quality control during manufacturing of the sensor that results in residual oxygen dissolved inside the sensor. connect the regulator to the flow meter/analyzer SAM- PLE IN inlet The term ZERO OFFSET is applied to the fully stabilized 4. Suitable fitting nect from the and 1/8" or 1/4" metal tubing to conflow meter vent to the analyzer tube oxygen reading evidenced by a flat horizontal trend on an external recording device after 12-30 hours of continuous fitting designated as SAMPLE OUT. exposure to flowing high purity zero gas. Use additional flow meter only if the equipped with an integral flow meter. analyzer is not This horizontal trend indicates: 1. The sensor has consumed all the oxygen that dis- Procedure: solved into the sensor's electrolyte during installation 1. With the span gas cylinder valve closed, install the reg- or exposure to high levels of oxygen, ulator on the cylinder. 2. The remaining oxygen value represents the sum total 2. Open the regulator's exit valve and partially open the of elements 1-4 listed above, pressure regulator's control knob. 3. The ZERO OFFSET value the analyzer electronics will 3. Open slightly the cylinder valve. deduct from all subsequent readings including Span 4. Loosen the nut connecting the regulator to the cylinder Calibration for optimum accuracy. and bleed the pressure regulator. 5. Retighten the nut connecting the regulator to the cylin- The manufacturer's Quality Control testing prior der. to shipment confirms the zero offset, above, is 6. Adjust the regulator exit valve and slowly bleed the within acceptable limits. However, owing to the pressure regulator. differences in the user's sample system leakage 7. Open the cylinder valve completely and then close the and zero gas accuracy, no Zero Calibration adjust- regulator exit valve. ment is made by the factory. 8. Set the pressure as specified in section 11 using the pressure regulator's control knob. The following Zero Calibration procedure assumes 9. Caution: Do not exceed the recommended flow rate. the user is installing the analyzer for the first Excessive flow rate could cause backpressure on sensor time. and may result in erroneous readings and permanent damage to sensor. Procedure for Zero Calibration: 1. Connect the zero gas to either the sample inlet or Zero Calibration Zero/Span valve if present. 2. Connect an external recording device to monitor the Zero Calibration (preceding Span Calibration) is trend of the reading to the 0-1V or 4-20 mA analog required for optimum accuracy only when analyz- signal outputs. ing a sample with an expected value of less than 3. Refer to section 11 Specifications and set the pressure 5% to 10% of the most sensitive range available. and flow rate as specified. Perform a Zero Calibration when initially installing 4. Initiate the flow of ultra-high purity nitrogen zero gas the analyzer, the customer's sample system is to the analyzer. interrupted, and a new sensor is installed. 5. Allow 12-30 hours for the O2 trend to stabilize parallel to the X axis on the external recording device. Zero Calibration produces an adjustment that is too small to affect the accuracy and thus is not The time required for stabilization, clean-up, recommended for the following measurements : recovery, purge down depends on: 1. Above 10% of the most sensitive ranges on i)If the gas lines were adequately purged. the GPR-18 MS and GPR-18. ii)Quality of the zero gas, 2. 99% of percent range applications involving iii)Length of time the sensor was exposed to am- the GPR-28, which has no Zero Calibration bient air during installation, e.g. red shorting capability. devices removed (unshorted) before being connected (shorted) to the upper section of the sensor housing. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 4. Calibration 6. If after 2 hours, the oxygen value displayed is not be- Span Calibration low 5 PPM, perform a complete check of all external sample system connections and allow the zero gas to Involves periodically adjusting the analyzer electronics to the sensor's signal output when it is exposed to a gas with flow overnight before concluding the tive and notifying the factory. sensor is defec- a known oxygen content, see below or section 11. 7. Once the analyzer reading stabilizes, the reading should be well below 50% of the most sensitive range, the limit of the ZERO OFFSET adjustment. Recommended Calibration Gases: GPR-18 MS: certified span gas of 7.5-9 PPM oxygen balance nitrogen. Prematurely adjusting the ZERO control knob will GPR-18: certified span gas of 75-90 PPM oxy- result in erroneous low or even negative oxygen readings when sampling gases with very low O2 concentrations. gen balance nitrogen or clean source ambient air 20.9% oxygen. GPR-28: clean source of ambient air 20.9% 6. Turn the ZERO knob on the analyzer's front panel ½ turn at a time until the analyzer display reads 0.00 to complete the Zero Calibration and activate the ZERO oxygen or a certified span gas oxygen balance with the oxygen content approximating 7590% of FS. 7. 8. OFFSET. Place the Sample/Bypass valve in the Bypass position before disconnecting the zero gas line. Connect the span gas line as described previously and The frequency of calibration varies with the application conditions, the degree of accuracy required and the Quality Assurance requirements of the user. allow the span gas to flow for 30 seconds to purge the ambient air through the gas lines. 9. Proceed to SPAN CALIBRATION Ensure accuracy, allow the oxygen reading to stabilize on the certified span gas standard before making the Span Calibration adjustment. Subsequent Zero Calibration requires eliminating the previous ZERO OFFSET Changes such as: Replacing the oxygen sensor Servicing the user's sample system Replacing an electronic PCB or other component Correcting for zero drift as determined by repeating the Zero Calibration procedure above. require eliminating the prior ZERO OFFSET and performing a new Zero Calibration to establish a new ZERO OFFSET. Procedure for Eliminating the Zero Offset: 1. Loosen the top section of the sensor housing, twist it 90 degrees and pull it up until it disengages from the sensor. 2. The resulting reading represents the ZERO OFFSET stored in the analyzer electronics. 3. Allow the reading to stabilize. 4. Adjust the ZERO knob on the analyzer's front panel until the analyzer reads 0.00. 5. After eliminating the ZERO OFFSET, the reading on all ranges should be zero with +/- one digit of the range. Install the oxygen sensor and perform a new Zero Calibration as described above. The Span Calibration process itself only takes 1530 minutes. However, the time required to bring the analyzer back on-line can vary depending on the span gas used, exposure time and purging the sensor after Span Calibration with the lowest oxygen concentration gas available. Recommendations to minimize downtime (see Recovery section 11 Specifications): GPR-18 MS PPB Oxygen Analyzer: 1. Minimize exposure of the sensor to air when installing new sensor, 2. DO NOT calibrate with span gas containing more than 900 PPM oxygen balance nitrogen. 3. Change the gas line immediately upon com- pletion of Span Calibration to lowest oxygen concentration gas available and purge: i) place the Sample/Bypass valve in the Bypass position, ii) change the gas lines from Span to lowest oxygen concentration gas available, iii) initiate the flow of low oxygen con- centration gas and purge the gas lines for 30 seconds, iv) place the Sample/Bypass valve in the Sample position, allow the ana- lyzer reading to stabilize, 1. If the lowest oxygen concentration gas was not the sample gas, repeat (3) above with the sample gas. GPR-18: As above, except #2 is not applicable. GPR-28: No special requirements. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 4. Calibration Procedure Span Gas Calibration: 1. Place the Sample/Bypass valve in the Bypass position. 2. Connect the span gas line to either the SAMPLE INLET or Zero/Span valve if present. 3. Connect a metal vent line to the fitting designated SAMPLE OUT or VENT. 4. Optional: Connect an external recording device to monitor the trend of the reading to the 0-1V or 4-20 mA analog signal outputs. 5. Assure there are no restrictions in the vent line. 6. Initiate the flow of the span gas to the analyzer. 7. Set the pressure and flow rate as described in the pre- ceding sub-section titled Accuracy. 8. Purge the gas lines with span gas for 30 seconds. 9. Place the Sample/Bypass valve in the Sample position. 10. The sensor will detect the oxygen content in the span gas and the analyzer's reading will move toward it. 11. Ensure accuracy, allow the oxygen reading to stabilize (15-30 minutes) on the certified span gas standard before making the Span Calibration adjustment. 12. Turn the SPAN knob on the analyzer's front panel ½ turn at a time until the analyzer displays the oxygen content of the certified span gas standard. 13. Place the Sample/Bypass valve in the Bypass position 10. After air calibration, reinstall the sensor as previously before disconnecting the span gas line. described. 14. Connect the sample gas line as described previously 11. With sample gas flowing, the oxygen reading will start and allow the sample gas to flow for 30 seconds to trending down. purge the ambient air through the gas lines. 12. Manually turn the RANGE selector switch to lower 15. Proceed to SAMPLING. ranges and follow the progress of the sensor's recov- ery, see section 11 Specifications. 13. Proceed to SAMPLING. Procedure Ambient Air Calibration: DO NOT calibrate the GPR-18 MS with a span gas Sampling containing more than 900 PPM oxygen balance nitrogen. After ZERO and SPAN calibration, the analyzer is ready to analyze the sample gas stream. Select the appropriate 1. Place the analyzer in the OXYGEN mode and select the CAL (0-25%) range. range of interest by turning the RANGE selector switch to the desired range. 2. Access the interior of the analyzer by removing the bolts securing the front door. 3. Using the 5/16 wrench supplied, loosen but do not remove the clamp bolt holding the two sections of the sensor housing. 4. Rotate the upper section of the sensor housing 90º to disengage from the clamp. If the oxygen concentration is higher than the selected range, the display will show 1-- indicating over-range condition. If this occurs, select a higher range until the display show oxygen reading. 5. Remove the upper section by pulling it straight up and let it rest on your 1st and 2nd fingers. Adjust the flow rate if necessary as specified in section 11. 6. With your other hand, remove the oxygen sensor from the bottom section of the housing. 7. Place the sensor in the upper section of the sensor housing ensuring the PCB contacts the two gold pins. 7. Use your thumb (see photo right) to hold the sensor and upper section of the sensor housing together. 8. With the sensor exposed to ambient air allow the reading to stabilize for 1-2 minutes. 9. After the reading stabilizes, turn the SPAN knob until the LED display reads the 20.9%. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 5. Operation As detailed in section 1 Introduction, the Explosion Proof To prevent chattering of the relays, the alarm will Series of Oxygen Analyzers are designed with an explosion remain active until the oxygen reading has fallen proof enclosure, flame arrestors, breather device, actuators and ATEX certified for use in hazardous areas. 2% below the alarm set point (high alarm) or risen 2% above the alarm set point (low alarm) The preceding sections 2, 3, 4 detail the basic do's and after the alarm was activated. don'ts, setup and calibration information, review them. Procedure (see photo below): * The analyzer shall not have an internal source of release 1. of oxygen or any other oxidizers in concentrations greater than 21%. 2. Open the front door to access the DISPLAY SELECT slide switch (highlighted in red) located on the A-1107 PCB Assembly Main/Display. Slide the switch to the ALM1 (high) or ALM2 (low). 3. The LED display indicates the current alarm set point. Analyzer Features 4. The set point is displayed as a value on a given range. 5. Use a small bladed screwdriver to adjust the potenti- Oxygen Display The analyzers are equipped with a 3-1/2 digit LED display that shows oxygen concentration from PPB to % level depending on the range of analysis selected. 6. ometer slowly, a ½ a turn at a time to allow the electronic processing to catch up . . . until the display reads the desired alarm set point value. Once the alarm values are set, slide the DISPLAY SELECT switch back to OXYGEN position. Display Mode Selection The DISPLAY SELECT slide switch (circled in red in photo at right) is located on the main signal processing PCB mounted on the inside of analyzer front door. The slide switch has been set to the O2 position at the factory. Advance this slide switch to select one of the three available DISPLAY modes: OXYGEN to display the oxygen reading ALARM 1 to set Alarm 1 Set point ALARM 2 to set Alarm 2 Set point Oxygen Alarms The analyzers are equipped with two user adjustable alarms that when activated trigger SPDT Form C, normally closed, non-latching relays rated @ 5A, 30VDC or 240VAC resistive. The alarm set point represents a value. When the oxygen reading exceeds ALARM 2 (high alarm) or falls below ALARM 1 (low alarm) set point, the corresponding relay is activated. The alarms are fully adjustable by the two potenti- Power Fail Alarm ometers accessible from the auxiliary panel (circled A dry contact rated at 1A @ 30 VDC is provided as a power in yellow in the photo at right) on the inside of the failure alarm. The contact is normally open but closes door with a small bladed screwdriver. Optionally, when the power to the analyzer is switched off or inter- the alarm controls might have been installed exter- rupted. nal to the analyzer by using actuators. Sensor Fail Alarm To configure alarms as "Fail safe" (inactive when A relay contact rated at 1A @ 30 VDC is provided for sen- energized) - connect positive lead to NO and nega- sor fail alarm. The contact is normally open but closes tive to the C, common or neutral. when oxygen signal goes to zero or falls below zero. To connect to an active relay, connect the live cable to the common terminal C and the secondary cable to the normally open NO terminal. To break the connection upon relay activation, connect the secondary cable to the normally closed NC terminal. Adjusting the ZERO OFFSET to 00.00 activates the Sensor Failure Alarm possibly causing a spike in the trend analysis. To avoid the momentary spike, set the ZERO OFFSET to 0.01 PPM. The sensor failure alarm becomes active when the display indicates `000' on any range of the analyzer. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 5. Operation Signal Outputs Range Selection The analyzer provides an isolated 4-20mA signal output and See section 11 Specifications: the analyzers are equipped a 0-1V full scale signal output for external recording devic- with four (4) standard measuring ranges. The GPR-18 is es. The integral IC on the main PCB converts the 0-1V sig- equipped with a 5th range of 0-25% for air calibration nal with negative ground to a 4-20mA fully isolated signal. only. The ranges available are indicated around the RANGE A finer adjustment of the zero offset of the 4-20mA con- selector knob located in the center of the control panel of verter can be provided by a potentiometer, R99, mounted the analyzer. Simply turn the pointer on the RANGE knob on the main PCB Assembly. Consult factory for instructions. to the desired range. DO NOT supply any voltage to either of the two * The analyzer shall not have an internal source of release terminals of the 4-20mA converter. Supplying of oxygen or any other oxidizers in concentrations greater power to 4-20 mA IC will permanently damage the than 21%. IC. The integral 4-20mA converter is internally powered and does not require external power. If the oxygen concentration is higher than the Range ID selected range, the display will show 1---- indicat- A voltage output corresponding to each range is provided. ing over-range condition. Select a higher range The output of the highest range (normally CAL) is 5V. The until the oxygen reading is displayed. range ID voltage will change by 1V with each remaining range. Before concluding the sensor is not "coming down to expected ppb or PPM levels" or "is not re- Temperature Controlled Heater System sponding to sample gas": If the optional temperature controlled heater system is in- 1. Confirm that the display selector switch stalled, the temp controller is accessible only by opening (highlighted in red in photo on previous the front door of the enclosure. The controller is PID and is page) inside of the enclosure door is posi- set at the factory to maintain the analyzer interior tempera- tioned to the far right in the OXYGEN DIS- ture at 85°F (30°C) PLAY. 2. Perform a flow test as described in section 8 DO NOT change this setting. A higher temperature Troubleshooting to check for leaks in the setting may drastically reduce sensor life and pos- sample system connections. sibly cause damage to the electronic circuitry of 3. Perform a Span Calibration, as this condition both the controller and the analyzer. When power could result from not allowing the oxygen is applied to the temperature controller, the con- reading to stabilize before making the adjust- troller initially tunes itself and then maintains the ment. temperature at the set point. Standby It is recommended that at initial start-up, or when replacing oxygen sensor or when trouble shooting, set the set point around 60°F (15°C) to turn heater off (to prevent overheat- The analyzer has no special storage requirements. The sensor should remain installed in the sensor hous- ing of heater element). ing during storage periods place the 4-way SAMPLE/ BYPASS crossover valve in the BYPASS position. Keep the analyzer front door closed and securely fastened when the temperature controller is ON. Store the analyzer with power OFF. Heater Runaway Protection As part of the optional temperature controlled heater system, the analyzer is protected in the event the temperature controller should fail and thereby allowing the heater to runaway damaging the interior of the analysis unit. The protection is provided by a J2 type device positioned between the temperature controller and the heater. This device cuts off power to the heater if temperature inside the enclosure exceeds 158oF (70°C). Should the F2 device fail, correct the problem and replace J2. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 6. Maintenance The extent of the maintenance requirements of this analyz- Analyzer Enclosure er involves periodically replacing the oxygen sensor, clean- ing and lubricating the o-ring in the sensor housing and the Inspect and clean the machined surfaces of both the bot- machined surfaces of the analyzer cover and bottom sec- tom base and the hinged cover of the enclosure. tion. The sealing surfaces must be inspected and free of nicks, While none of the components are serviceable in dirt or any foreign particle build-up that would prevent a themselves, the section 7 Spare Parts is provided proper seal. in the unlikely event a component fails and has to be replaced. Cleaning & Closing the enclosure: 1. Wipe the sealing surfaces with a clean lint-free cloth. DO NOT attempt to service the analyzer or replace 2. Apply a light coating of Killark "LUBG" lubricant to the component parts on your own, consult the factory sealing surfaces. or a factory trained service technician. Please re- 3. Close the hinged cover and mate to enclosure base. view section 9 Warranty. 4. Install the bolts thru the cover into enclosure base. 5. Finger tighten bolts. Sensor Replacement 6. Torque all bolts to 30 ft/lbs. Periodically, the oxygen sensor will require replacement. After installation, the unit must be inspected reg- Section 11 Specifications defines the normal operating con- ularly to verify the enclosure mounting bolts are ditions and expected life of the various sensors employed tight and in good condition, the cover bolts are by the various analyzers. torqued to 30ft/lbs., conduit/cable gland connec- tions are intact and free of corrosion. Section 4 Calibration, Accuracy defines the factors that can influence the expected life of an oxygen. In reality, ex- pected sensor life is determined by a number of factors that DO NOT attempt to repair the flange sealing sur- are influenced by the user and therefore virtually impossible faces should they appear to be damaged, they to predict. are not intended to be repaired. Contact the ana- lyzer or enclosure manufacturer identified by one DO NOT open the oxygen sensor. The sensor con- of the red metal labels affixed to the enclosure. tains a corrosive liquid electrolyte that could be harmful if touched or ingested, refer to section 10 Troubleshooting: Consult the guidelines in section 8 for Safety Data Sheet for information. advice on the common operating errors before concluding that your analyzer is faulty. Do not attempt to service the Install the replacement oxygen sensor as outlined analyzer beyond those means described in the Instructions in section 3 Installation, Installing the Oxygen Sen- for Use. sor. Remove the existing sensor and dispose of in accordance with local regulations. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 7. Spare Parts Description Oxygen Sensor(s) GPR-18 MS GPR-18 GPR-28 GPR-12-2000 MS2 GPR-12-333 XLT-12-333 (CO2 Background) GPR-11-32 XLT-12-333 (CO2 Background) PCB Assy Power / Interconnection Sample Panel Assy Sensor Housing Assy SS Sensor Housing SS Upper Assy w/Cable Valve 4-way Sample/Bypass A-1107-MS2 A-1107-M A-1107-C A-4753 A-1004-4-3-14 B-2762-B-2-32 VALV-1031 A-4565 A-1004-4-3-5 B-2762-A-2-32 Not Applicable Amplifier E/I converter Breather Device 1/2" NPT Controller Temperature Flame Arrestor 1/2" NPT Flowmeter Assy Flowmeter SS, Max Inlet 200 psig, 1/8" FNPT, Scale 5 Fuse Holder for TR5 Fuse Fuse 3A TR5 Series 250VAC Heater Rod 75W 240VAC LCD 3.5 DGT 2VFS (29 / 19) O-Ring Viton Black Size -126 PCB Assy Main / Display Sensor Housing SS Bottom Assy Sensor Temperature Pepi J2 Runaway Protector Temperature Sensor RTD IC-1007 ENCL-1146 CTRL-1004 FITN-1262 A-4565 FMTR-1002 FUSE-1003 FUSE-1010 HTR-1006 MTR-1002 ORNG-1007 A-1106-C A-4541-4 SNSR-1002 SNSR-1006 ProcessSensing.com 8. Troubleshooting GPR-x8 Explosion Proof Oxygen Analyzers Symptom Possible Cause Recommended Action Slow recovery or response time At installation, defective sensor Failure to purge gas lines with Bypass, air leak in connections, dead legs, distance of sample line, low flow rate, volume of optional filters and scrubbers Abnormality in zero gas Damaged in service - prolonged exposure to air, electrolyte leak Sensor nearing end of life Replace sensor if recovery unacceptable or O2 reading fails to reach 10% of lowest range Leak test the entire sample system: Vary the flow rate, if the O2 reading changes inversely with the change in flow rate indicates an air leak - correct source of leak Qualify zero gas (using portable analyzer) Replace sensor Replace sensor High O2 reading after installing or replacing sensor Analyzer calibrated before sensor stabilized caused by: 1) Prolonged exposure to ambient air, worse if sensor was unshorted 2) Air leak in sample system connection(s) 3) Abnormality in zero gas Allow O2 reading to stabilize before making the span/calibration adjustment Continue purge with zero gas Leak test the entire sample system (above) Qualify zero gas (using portable analyzer) High O2 reading Sampling Reading doesn't agree to expected O2 values Flow rate exceeds limits Pressurized sensor Improper sensor - CO2 affects GPR sensor Abnormality in gas Pressure and temperature of the sample is different than span gas Abnormality in gas Failure to allow reading to stabilize before zero and/or span calibration adjustments Calibration error caused by turning the zero and/or span potentiometer more than ½ turn at a time (electronics need time to keep up Correct pressure and flow rate Remove restriction on vent line, replace sensor Use XLT sensor when CO2 or acid gases are present Qualify the gas (use a portable analyzer) Calibrate the analyzer (calibrate at pressure and temperature of sample) Qualify the gas (use a portable analyzer) Repeat calibration procedure and allow reading (sensor) to stabilize Repeat calibration, allow reading to stabilize and make adjustments ½ turn at a time ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 8. Troubleshooting Symptom Possible Cause Recommended Action Erratic O2 reading Change in sample pressure Dirty electrical contacts in upper section of sensor housing Corroded solder joints on sensor PCB from corrosive sample or electrolyte leakage from sensor Corroded spring loaded contact in upper section of sensor housing from liquid in sample or electrolyte leakage from sensor Liquid covering sensing area Presence of interference gases Presence of sulfur gases and/or CO2 Unauthorized maintenance Repeat calibration at the temperature and pressure of sample Clean contacts with alcohol (minimize exposure time of MS sensor to ambient air to extent possible) Replace sensor and return sensor to the factory for warranty determination Upper section of sensor housing: Clean contacts with alcohol, flow sample or zero gas for 2-3 hours to flush sample system and sensor housing Sensor: Replace if leaking and return it to the factory for warranty determination Wipe with alcohol and lint free towel or flow sample or zero gas for 2-3 hours to flush Consult factory Replace sensor and install scrubber, contact factory Replace sensor, obtain authorized service No O2 reading Negative O2 reading Failure of an electronic component or power surge that sends a charge to the sensor Pressurizing the sensor by: a) Flowing gas to the sensor with the vent restricted or SHUT OFF valve closed and suddenly removing the restriction draws a vacuum and can damage the sensor and/or cause electrolyte leakage b) Drawing a vacuum on the sensor by partially opening the FLOW valve upstream of the sensor when using a pump downstream to draw sample from a process at atmospheric pressure or a slight vacuum can damage the sensor and cause it to leak electrolyte Service the analyzer, check the power source and THEN replace the sensor Introduce span gas to determine if the sensor responds. If successful calibrate the analyzer and resume sampling If not successful, inspect for electrolyte leakage, check and clean the contacts in the upper section of the sensor housing, flow a little warm water followed by air or clean sample through the analyzer for 2-3 hours to push the electrolyte through the sample system and THEN replace the sensor ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 9. Warranty The design and manufacture of Analytical Industries 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. Prior to shipment every analyzer is thoroughly tested by the manufacturer and documented in the form of a Quality Control Certification that is included in the Owner's Manual accompanying every analyzer. When operated and maintained in accordance with the Owner's Manual, the units will provide many years of reliable service. Coverage Under normal operating conditions, the analyzers and sensors are warranted to be free of defects in materials and workmanship for the period specified in accordance with the most recent published specifications, said period begins with the date of shipment by the manufacturer. The manufacturer information and serial number of this analyzer are located on the rear of the analyzer. Analytical Industries Inc. reserves the right in its sole discretion to invalidate this warranty if the serial number does not appear on the analyzer. If your Analytical Industries Inc. analyzer and/or oxygen sensor is determined to be defective with respect to material and/or workmanship, we will repair it or, at our option, replace it at no charge to you. If we choose to repair your purchase, we may use new or reconditioned replacement parts. If we choose to replace your Analytical Industries Inc. analyzer, we may replace it with a new or reconditioned one of the same or upgraded design. This warranty applies to all monitors, analyzers and sensors purchased worldwide. It is the only one we will give, and it sets forth all our responsibilities. There are no other express warranties. This warranty is limited to the first customer who submits a claim for a given serial number and/or the above warranty period. Under no circumstances will the warranty extend to more than one customer or beyond the warranty period. Limitations Analytical Industries Inc. will not pay for: loss of time; inconvenience; loss of use of your Analytical Industries Inc. analyzer or property damage caused by your Analytical Industries Inc. analyzer or its failure to work; any special, incidental or consequential damages; or any 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 or other failure to follow the Owner's Manual. Some states and provinces do not allow limitations on how an implied warranty lasts or the exclusion of incidental or consequential damages, these exclusions may not apply. Exclusions 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 label or attachment not provided with the analyzer; fire, flood, or acts of God; or other failure to follow the Owner's Manual. Service Call Analytical Industries Inc. at 909-392-6900 (or e-mail info@aii1.com) between: 7:30 AM and 5:00 PM PST . . . Monday thru Thursday 8:00 AM and 12:00 PM PST . . . Friday. Trained technicians will assist you in diagnosing the problem and arrange to supply you with the required parts. You may obtain warranty service by returning you analyzer, postage prepaid to: Analytical Industries Inc. 2855 Metropolitan Place Pomona, Ca 91767 USA Be sure to pack the analyzer securely. Include your name, address, telephone number, and a description of the operating problem. After repairing or, at our option, replacing your Analytical Industries Inc. analyzer, we will ship it to you at no cost for parts and labor. ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet GPR Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet GPR Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet GPR Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet GPR Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet GPR Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet GPR Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet GPR Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet XLT Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet XLT Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet XLT Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet XLT Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet XLT Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet XLT Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet XLT Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet XLT Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet XLT Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 10. Safety Data Sheet XLT Series Oxygen Sensors ProcessSensing.com 10. Safety Data Sheet XLT Series Oxygen Sensors GPR-x8 Explosion Proof Oxygen Analyzers ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers 11. Specifications GPR-18 MS GPR-18 GPR-28 Analysis Ranges: Application: Accuracy: Sensitivity: Linearity: Display: Alarms: Signal Output: 0-1 , 0-10, 0-100, 0-1000 PPM FS 0-10, 0-100, 0-1000 PPM, 0-1% FS 0-25% (Cal Only) 0-1, 0-5, 0-10, 0-25% FS 10 PPB to 1000 PPM oxygen 50 PPB to 1% oxygen 0.05% to 21% oxygen in inert gases streams in hydrocarbon, He, H2, mixed in hydrocarbon, He, H2, mixed and acid (CO2) gas streams (a) and acid (CO2) gas streams (a) + 1% of FS range under constant conditions < 0.5% of FS range < 1% over all ranges 3-1/2 digit bright red LCD; resolution 0.001 PPM 2 adjustable form C relay contacts non-latching; sensor and power failure 0-1V and 4-20mA Sample Pressure: 5-30 psig Flow Rate: Sensor Model: Response Time: Recovery Time: 1.5-2 SCFH (700-950ml/min) GPR-12-2000-MSE GPR-12-333 (a) GPR-11-60 (b) < 20 seconds < 10 seconds 90% of final FS reading 90% of final FS reading O2 Level Duration O2 Target Recovery on N2 O2 Level Duration O2 Target Recovery on N2 O2 Level Duration O2 Target Recovery on N2 Air 30 sec 1 PPM 45 min Air 2 min 10 PPM 60 min * Air 2 min 0.1% < 30 sec 9 PPB 2 min 10 PPB 10 min Air 2 min 1 PPM 20 min Calibration: Sensor Life: Compensation: 1 PPM 5 min 10 PPB 15 min 1 month interval using certified gas of 7.5 - 9 PPM O2 balance N2 12-18 months in < 100 PPM O2 at 25ºC and 1 atm * Installation ** In service for 2 weeks at 1 PPM 1 month interval using certified gas of 75 - 90 PPM O2 balance N2 or 20.9% air 24 months in < 1000 PPM O2 at 25ºC and 1 atm Temperature 1 month interval using 20.9% air 60 months in Air at 25ºC and 1 atm Sample System: Flow control and bypass valves; flow indicator Flowmeter with integral valve Connections: Controls: Wetted Parts: Operating Temp. Range: Enclosure: Power: 1/4" compression tube fittings Explosion proof actuators for range selection, zero and span calibration adjustments 300 series stainless steel Sensor 0...45ºC (32...90°F) Sensor GPR 0...45ºC (32...90°F), XLT -10...+45ºC (14...90°F) Enclosure 20...+60ºC (-4...+140°F) 16 x 18 x 11" (406 x 457 x 280mm) Wall mount, 70lbs (31.8 Kg) Unpainted aluminum Specify 100/120 or 220/240 VAC ATEX & UKEX/IECEx Classification: II 2 G Ex db IIB or IIB+H2 T6 Gb // Ex db IIB or IIB+H2 T6 Gb Build Options: Sample conditioning systems Temperature controlled heater system (a) use XLT-12-333 for gases with > 0.5% CO2 present (b) use XLT-11-24 for gases with > 0.5% CO2 present ProcessSensing.com GPR-x8 Explosion Proof Oxygen Analyzers Appendix A Regulations regarding equipment certified for use in haz- Explosion Proof Sealing Cement ardous areas require electrical connections be protected by conduit and/or cable gland entry. Analytical Industries Inc. Directions: recognizes the need of safe operation of this analyzer and strongly recommends the user to adhere to all local 1.After tamping packing fiber between and around conductors, prepare the sealing resin. safety related directives during installation and operation. 2.Use only ATEX approved sealant. The accessories 3/4"-14 NPT-M, used for must be cable gland entry, size covered by a separate 3.Prepare the sealant by mixing the resin catalyzing agent as recommended by the manufacturer. 4.Apply the resin as recommended by the manufacturer. certificate in accordance with the standards: EN 60079-14:2014; IEC 60079-14:2013 EN 60079-17:2014; IEC 60079-17:2013 The following sealant for sealing fittings is ATEX approved. And they must be suitable to be used with the enclosure and the type of hazardous location: ELFIT RESIN (Part A) CRV420 ELFIT CATHALIZING AGENT (Part B) CRV420H72 5.Mixture ratio: 100 grams Part A to 25 grams Part B II 2 G 6.Blend mixture to obtain a homogeneous compound. Ex db IIB or IIB+H2 T6 Gb 7.Immediately fill the sealing connection. Electrical connections require approved explosion proof 8.Cure 72 hours for the mixture to setup. sealing fittings and packing around wires and cables coming into or going out of the enclosure. Conduit seals and fittings must be certified "Ex d" components per EN60079-1 whose design and installation comply with ATEX standards for hazardous locations Consult manufacturer instructions for complete details related to mixing two components and pouring the resulting resin in the sealing fittings. Sealing fittings must be installed within 18" of this enclosure for IIB + H2 locations. Engage at least five threads on all fill plugs. All unused openings must be closed with a Killark CUP, CUPX, PLUG, GO-8177 series close=up plug or an Ex d certified close-up plug or sealing plug. Explosion Proof Packing Fiber (nonasbestos) For use as packing at the hub of sealing fittings. Use only ATEX approved packing fiber. These instructions are supplied in good faith from information which we believe to be reliable. However, since users and not Analytical Industries Inc. control the application, installation and operation of our products, users therefore assume all associated risk and liability. Contact and/or exposure may cause skin, lung or eye irritation. Use gloves and long sleeve coveralls to protect skin. Use a mask or respirator to prevent inhalation or eye contact during application. Directions: 1. To prevent leakage of the liquid cement, tamp packing fiber between and around conductors where they enter fitting 2. Ensure conductors DO NOT contact each other or the fitting wall. 3. Leave enough space inside the fitting - space/ length equivalent to the inside diameter of the conduit but not less than 5/8". ProcessSensing.com