Adllaneed lnstrurnents 'ne.

IiPR·.SOO AIS

ppm Dxygen Trsnsmitter

with Optionsl SSlDple System

•

Dwner's an

2855 Metropolitan Place, Pomona, California 91767 USA • Tel: 909-392-6900, Fax: 909-392-3665, e-mail: info@aii1.com

Adllaneed Instrument5 Ine.

Table 01 Conlenls Introduction 1

Qua'lity Control Certification 2

Safety 3

Features &. Specifications 4

Oe.eration 5

Maintenance 6

Spare Parts 7

Troubleshooting 8

Warranty 9

Material Safety Data Sheets 10

A/R Explosion Proofing Electrical Connections Appendix A

Correlating readings - lCO display to 4-20mA signal output Appendix B

H2S SCrubber, Sample System, Media MSOS Appendix F

Maintenance H2S Scrubber &. Coalescing Filter Appendix G

1 InlroduClion Your new oxygen transmitter incorporated 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 variety of industrial oxygen applications.

TO obtain maximum performance from your new oxygen transmitter, 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 transmitter for superior performance and minimal cost of ownership. This transmitter 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 transmitter may be found on the inside the transmitter. 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.

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Adl/anced In!itrument!i Inc.

2 Qualitv Control Cenification

Date: 3/25/09 Customer: BP Exploration Co (Colombia) Ud Order No.: 4520050336 Pass

~ Model: GPR-1500AIS ppm Oxygen Transmitter S/ N 1" ~ O (;, S- b ~ sensor: ( ) GPR-12-333 ppm Oxygen sensor

(x) XLT-12-333 ppm Oxygen sensor ( ) XLT-12-333-F ppm Oxygen sensor S/N

Accessories: Owner's Manual

Configuration: A-1161-AIS-1 PCB Assembly Main/Dispaly SQftware Ver. ~ r J... -2 Power: ( ) A-1l66-AIS-AC PCB Assembly Alarms/AC Power 1l0V & Interconnection

( x) A-1l66-AIS-DC PCB Assembly Alarms/DC Power 12-24V & Interconnection

( ) A-1153-AIS-DC PeB Assembly Alarms/DC Power 12-24V & Interconnection

SPDT relays (B-3208, A-3267, Ex-proof window cover)

Ranges: 0-10 ppm, 0-100, 0-1000 ppm, 0-1%, 0-25%

Barometric pressure and temperature compensation

NEMA 4X rated wall mount enclosures

Test: Pass Pass Set default zero v'" Noise level < ± 1.0% FS ./ Set default span @ 600uA v"" Alarm delay

Zero calibration / Alarm bypass

Span calibration _V--;_ Alarm configurations; ALARM 1, ALARM 2

Analog signal output 4-20mA futl scale _t/'--..,.-- Alarm function; ALARM 1, ALARM 2

Calibrates with adequate span adjustment within 10-50% FS 7' Alarm relays; ALARM 1, ALARM 2

Baseline drift on zero gas < ± 2% FS over 24 hour period 1/ Alarm system tall, dry contact

Overall inspection for physical defects

Options: ( x) A-3393-5 sample System

ENCL-1079 NEMA 4X System Enclosure 23x19x9.8", fully plumbed and pre-drilled for power

Notes: 1 of 1 due by 4/15/09

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Advaneed 'nstrulDents 'ne.

3 Saletv General This section summarizes the essential precautions applicable to bhe GPR-1500AIS ppm Oxygen Transmitter. 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.

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.

Pressore and Flow Inlet Pressure: GPR-1500AIS ppm Oxygen Transmitters are designed for flowing samples, equipped with 1/8" bulkhead tube fitting connections on the side of the unit (unless otherwise indicated, either fitting can serve as inlet or vent) and are intended to operate at positive pressure regulated to between 5-30 psig.

Caution: If equipped with an optional H2S scrubber, inlet pressure must not exceed 30 psig.

Outlet Pressure: The sample gas vent pressure should be atmospherk.

InstaJlation 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.

Mounting: The transmitter is approved for indoor or outdoor use. Mount as recommended by the manufacturero

Power: Supply power to the transmitter only as rated by the specification or markings on the transmitter enclosure. The wiring that connects the transmitter to the power source should be installed in accordance with recognized electrical standards and so they are not pinched particularly near the power source and the point where they attach to the transmitter. Never yank wiring to remove it from a terminal connection. Power consumption is 30 watts, 40 watts with the optional De powered heater.

Operating Temperature: The maximum operating temperature is 45° e on an intermittent basis unless the user is willing to accept a dramatic reduction in expected sensor life - refer to analyzer specification where expected sensor Iife is specified at less than 1000 ppm oxygen at 25°e and 1 atmosphere of pressure.

Heat: Situate and store the transmitter away from sources of heat.

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Liquid and Object Entry: The transmitter 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 transmitter.

Handling: Do 1l0t use force when using the switches and knobs. Before moving your transmitter be sure to disconnect the wiringjpower cord and any cables connected to the output terminals ,Iocated on the transmitter.

Maintenance Serviceability: Except for replacing the oxygen sensor, there are no parts inside the transmitter for the operator to service. Only trained personnel with the authorization of their supervisor should conduct maintenance.

Oxygen sensor: DO NOT open the sensor. The sensor contains a corrosive Iiquid' 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 ofin accordance with local regulations.

Troubleshooting: Consult the guidelines in Section 8 for advice on the common operating errors before concluding that your transmitter is faulty. Do not attempt to service the transmitter 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. AII other servicing should be referred to qualified service personnel.

Cleaning: The transmitter should be c1eaned only as recommended by the manufacturero Wipe off dust and dirt from the outside of the unit with a 50ft damp c10th then dry immediately. Do not use solvents or chemicals.

Nonuse Periods: If the transmitter 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.

4 Features & Specifications Specifications and pricing are subject to change without notice. See last page for current specifications.

•

50peration Principie of Operation The GPR-1500AIS oxygen transmitter incorporates a variety of ppm range advanced galvanic fuel cell type sensors. The transmitter is

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Advanced InstrulDents IDe.

configured in two sections. The signal processing electronics and sensor are housed in a general purpose NEMA 4X rated enclosure. The terminals for incoming power, power supply, signal output, alarm relay contacts and intrinsic safety barriers are mounted on a PCB housed in an explosion proaf enclosure.

The two sets of electronics are interconnected using an explosion proof Y-fitting, explosion proof packing fiber and sealing cement - see Appendix A. Once connected, the intrinsic safety barriers Iimit the amount of voltage that f10ws to and from the signal processing electronics effectively preventing an explosive condition and meets the intrinsic safety standards required for use in Class 1, Division 1, Groups B, C, D hazardous areas.

Advanced Galvanic Sensor Technology The sensors function on the same principie and are specific for oxygen. They measure the partial pressure of oxygen from low ppm to 100% levels in inert gases, gaseous hydrocarbons, helium, hydrogen, mixed gases, acid gas streams and ambient airo

Oxygen, the fuel for this electrochemical transducer, diffusing into the sensor reacts chemically at the sensing electrode to produce an electricaI current output proportional to the oxygen concentratjon in the gas phase. The sensor's signar output is linear over all ranges and remains virtually constant over its useful life. The sensor requires no maintenance and is easily and safely replaced at the end of its useful life.

Proprietary advancements in design and chemistry add significant advantages to an extremely versatile oxygen sensing technology. Sensors for low ppm analysis recover from air to ppm levels in minutes, exhibit longer Iife and reliable quality. The expected life of our new generation of percentage range sensors now range to five and ten years with faster response times and greater stabílity. Another significant development involves expanding the operating temperature range for percentage range sensors from -30°C to 50°C.

Electronics The signar generated by the sensor is processed by state of the art low power mícro-processor based digital circuitry. The first stage amplifies the signa!. The second stage eliminates the low frequency noise. The third stage employs a high frequency filter and compensates for signal output variations caused by ambient temperature changes. The result is a very stable signa!. Sample oxygen is analyzed very accurately. Response time of 90% of fuI! scale is less than 10 seconds (actual experience may vary due to the integrity of sample line connections, dead volume and f10w rate selected) on all ranges under ambient monitoring conditions. 5ensitivity is typically 0.5% of full scale low range. Oxygen readings may be recorded by an external device vía the 0-lV signal output jack.

The circuit for the 4-20mA signal output and two adjustable alarms is powered by a DC/OC transformer that requires a 12-28 VDC power source and separate wiring for the outputs. A loop power source is not sufficient to power to the circuito The 4­20mA output is also represented on full scale oxygen readings to an externaI device.

Sample System: The GPR-1500AIS is supplied wíthout a sample conditioning system thereby giving users the option of adding their own or purchasing a factory designed sample conditioning system. Whatever the choice, the sample must be properly presented to the sensor to ensure an accurate measurement. Users interested in adding their own sample conditioning system should consult the factory. Advanced lnstruments lne. offers a fuI! line of sample handling, conditioning and expertise to meet your application requirements. Contact us at 909-392-6900 or e-mail usatinfo@aii1.com.

Accuracv & Callbration SinglePoint Calibration: As previously described the galvanic oxygen sensor generates an eledrical current proportional to the oxygen concentration in the sample gas. In the absence of oxygen the sensor exhibits an absolute zero, e.g. the sensor does not generate a current output in the absence of oxygen. Given these linearity and absolute zero properties, single point calibration fs possible.

Pressure: Because sensors are sensitive to the partial pressure of oxygen in the sample gas their output is a function of the number of molecules of

-fEMPeR"lURE ­

Adlliloced lostrument!!!i loc.

oxygen 'per unit volume'. Readouts in percent are permissible only when the total pressure of the sample gas being analyzed remains constant. The pressure of the sample gas and that of the calibration gasees) must be the same (reality < 1-2 psí).

Temperature: The rate oxygen molecules diffuse into the sensor is controlled by a Teflon membrane otherwise known as an 'oxygen diffusion limiting barrier' and all diffusion processes are temperature sensitive, the fact the sensor's electrical output will vary with temperature is normal. This variation is relatively constant 2.5% per oc. A temperature compensation circuit employing a thermistor offsets this effect with an accuracy of ±S% or better and generates an output function that is independent of temperature. There is no error if the calibration and sampling are performed at the same temperature or if the measurement is made immediately after calibration. Lastly, small temperature variations of 10-150 produce < 1% error.

Accuracy: In Iight of the aboye parameters, the overall accuracy of an analyzer is affected by two types of errors: 1) those producing 'percent of reading errors', illustrated by Graph A below, such as ±S% temperature compensation circuit, tolerances of range resistors and the 'play' in the potentiometer used to make span adjustments and 2) those producing 'percent of full scale errors', iIIustrated by Graph B, such as ±1-2% linearity errors in readout devices, which are realty minimal due to today's technology and the fact that other errors are 'spanned out' during calibration.

Graph C illustrates these 'worse case' specifications that are typically used to develop an transmitter's overall accuracy statement of < 1% of fuI! scale at constant temperature or < 5% over t-he operating temperature range. QC testing is typically < 0.5% prior to shipment.

,/ /

/ '" /

/ /

'","

/

/ '" " "

'" / , /

/ /

,,' ' ,

/ / /

//

/ '" / ,

/ '" "'"

///",'" /

'",,.. /

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A. PER.CENl or REAI>ING B. ?fRCElil or rUlL SCALE C. OVEIIAll ACCURACYERIIORS EP.1I01lS

Example 1: As íllustrated by Graph A any error, play in the multi-turn span pot or the temperature compensatíon circuit, during a span adjustment at 20.9% (air) of full scafe range woufd be multiplied by a factor of 4.78 (100/20.9) if used for measurements of 95-100% oxygen concentrations. Conversely, an error during a span adjustment at 100% of fuI! scale range is reduced proportionately for measurements of lower oxygen concentrations.

Zera Calibration: In theolY, the eleetrochemical galvanic fuel cell type oxygen has an absolute zero meaning it produces no signal output when exposed to an oxygen free sample gas. In realitv, expect the analyzer to generate an oxygen reading when sampling oxygen free sample gas due to contaminatíon or quality of the zera gas; minor leakage in the sample line connections; residual oxygen dissolved in the sensor's electrolyte; and, tolerances of the electronic components. The lero Offset capability of the analyzer is limited to 50% of lowest most sensitive range available with the analyzer.

Recommendation 1: lero calibrabon, see Determining True lero Offset below, is recommended only for online analyzers performing continuous analysis below 5% of the lowest most sensitive range available with a ppm analyzer, e.g. analysis below 0.5 ppm on the 10 ppm range, or below 0.1% (1000 ppm) with a percent analyzer.

Note 1: Once the zero offset adjustment is made, zero calibration is not required again until the sample system connections are modified, or, when installing a new oxygen sensor. As a result, zera calibration is not practical and therefore not recommended for higher ranges or portable analyzers.

Determining True lero Offset: Allow the transmítter approximately 24 hours to stabilize with flowing zero gas as evidenced by a stable reading or horizontal trend on an external recording device. Note 2: 24 hours is requíred to assure the sensor has consumed the oxygen that has dissolved into the electrolyte inside the sensor while exposed to air or percentage levels of oxygen. For optimum accuracy, utilize as much of the actual sample system as possible.

Span Calibration: lnvolves adjusting the transmitter electronics to the sensor's signal output at a given oxygen standard. Regardless of the oxygen concentration of the oxygen standard used, a typical span calibration takes appraximately 10 minutes.

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Adllanced InstrunJents Ine.

Note 3: The amount time required to get the analyzer back on line for normal use is influenced by a.) the level of oxygen analysis anticipated during normal operation (also determines the initial analyzer seleetion), and, b.) whether the sensor is new or has been in service tor at least two weeks. General guidelines for analyzers to come online following span calibration and exposure to a zero/purge!sample gas with an oxygen content below the stated thresholds:

,. measurements aboye 1000 ppm or 0.1% require less than 3 minutes ,. measurements above 100 ppm (parts-per-million analyzer) require less than 10 minutes ;¡. measurements below 10 ppm (part-per-million analyzer) require 20 minutes if the sensor has been in service at ppm levels

for at least two weeks, and, 60 minutes if the sensor is new assuming the zero/purge!sample gas has an oxygen concentration below 1 ppm

Recommendation 2: For 'optimum calibration accuracy' calibrate with a span gas approximating 80% of the full scale range one or two ranges higher than the full scale range of interest (normal use) to achieve the effect illustrated on Graph A and Example 1. Always calibrate at the sarne temperature and pressure of the sample gas stream.

Note 4: Calibrating with a span gas approximating 10% of the full scale range near the expected oxygen concentratíon of the sample gas is acceptable but less accurate than 'optimum calibration accuracy' method recommended - the rnethod usually depends on the gas available. calibrating at the same 10% of the full scale range for measurements at the higher end of the range results in magnification of errors as discussed in Graph A and Exaniple 1 and is not recommended. Of course the user can

( --always elect at his discretion to accept an accuracy error of ±2-3% of full scale range if no other span gas is available.

Air Calibration: Based on the inherent Iinearity of the electrochemical galvanic fuel cell type oxygen sensor enables the user to calibrate the analyzer with ambient air (20.9% oxygen) and operate the analyzer within the stated accuracy spec on the lowest most sensitive range available with the analyzer - there is no need to recalibrate the anafyzer with span gas containing a lower oxygen concentration. calibrating either a ppm or percent analyzer with ambient air (with the exception of Oxygen Purity Analyzers intended to measure elevated oxygen levels ranging from 50-100% oxygen) on the CAL or 0-25% range meets the 80% criteria discussed in Recommendation 2.

Recommendation 3: Air calibrate the analyzer (with the exception of Oxygen Purity Analyzers intended to measure elevated oxygen levels ranging from 50-100% oxygen) when operating a percent analyzer, installing and replacing a ppm oxygen sensor, to verify the oxygen content of a certified span gas or when a certified span gas is not available to calibrate a ppm analyzer (immediately following air calibration reintroduce a gas with a low oxygen concentration to expedite the return to ppm level measurements as per Note 3).

Install'ation Considerations Gas Sample Stream: Ensure the gas stream composition of the application ís consistent with the specifications and review the application conditions before initiating the installation. Consult the factory if necessary to ensure the sample is suitable for analysis.

Note: In natural gas applications such as extraction and transmission, a low voltage current ¡s applied to the pipeline itself to inhibit corrosion. As a result, electronic devices can be affected unless adequately grounded.

Contaminant Gases: A gas scrubber and f10w indícator with integral meteríng valve are required upstream of the transmitter to remove interfering gases such as oxides of sulfur and nitrogen or hydrogen sulfide that can produce false readings, reduce the expected tife of the sensor and void the sensor warranty if not identified at time of order placement. Installation of a suitable scrubber is required to remove the contaminant from the sample gas to prevent erroneous analysis readings aod damage to the sensor or optional components. Consult the factory for recommendations concerning the proper selection and installation of components.

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Adllanced Instruments Ine.

Expected Sensor Lite: With reference to the publish specification located as the last page of this manual, the expected life of all oxygen sensors is predicated on oxygen concentration « 1000 ppm or air), temperature (77°F/25°q and pressure (1 atmosphere) in "normal" applications. Deviations are outside the specifications and will affect the Iife of the sensor. As a rule of thumb sensor life is inversely proportional to changes in the parameters.

Optimum Accuracy: Determine if lero Calibration is recommended for your application. If it is lera Calibration should precede Span Calibration and both should be repeated after the analyzer has been allowed to stabilize, typically 24-36 hours after installation. For Span Calibration use a certified span gas with an oxygen content (balance nitragen) approximating BO% of the next higher full scale range aboye the intended measuring range is recommended for optimum accuracy, see Calibration and Accuracy.

Assuming the initial zera is performed according to the procedure described herein, the analyzer should not require lera Calibratíon again until the either the sensor is replaced or a change is made to the sample system or gas lines, and, it should not require 5pan Calibration again for up to 3 months under "normal" application conditions as described in the published specifications. One of the unique features of analyzers based on the electrochemical galvanic fuel cell type oxygen sensor is the fact that ít can be field calibrated at the users discretion to whatever standard of certified span gas the user elects to use.

Zero calibration: In theorv, the oxygen sensor produces no signal output when exposed to an oxygen free sample gas. In ~ expect the transmitter to generate an oxygen reading when sampling oxygen free sample gas due to contamination or quality of the zero gas; minor leakage in the sample line connections; residual oxygen díssolved in the sensor's electrolyte; and, tolerances of the electronic components.

lera calibration, see Determining True lera Offset below, is recommended only for online analyzers performing continuous analysis below 5% of the lowest most sensitive range available with a ppm analyzer, e.g. anatysis below 0.5 ppm on the 10 ppm range, or below 0.1% (1000 ppm) with a percent analyzer. Note: Once the zera offset adjustment is made, zera calibration is

-ñot required again until the sample system connections are modified, or, when installing a new oxygen sensor. As a result, zero calibration is not practical and therefore not recommended for hígher ranges or portable analyzers.

Determining True Zero Offset: Allow the transmitter approximately 24 hours to stabilize with f10wing zero gas as evidenced by a stable reading or horizontal trend on an external recording device. Note: 24 hours is required to assure the sensor has consumed the oxygen that has dissolved into the electrolyte inside the sensor while exposed to air or percentage levels of oxygen. For optímum accuracy, utilize as much of the actual sample system as possíble.

Span Calibration: Involves adjusting the transmitter electranics to the sensor's signal output at a given oxygen standard, e.g. a certified span gas with an oxygen content (balance nitragen) approximating 80% of the next higher full scale range aboye the ¡ntended measuring range is recommended for optimum accuracy, see Calibration and Accuracy.

Recommendation: Based on the inherent linearity of the gafvanic oxygen sensor enables the user to calibrate the analyzer with ambient air (20.9% oxygen) and operate the analyzer within the stated accuracy spec on the lowest most sensitive range available with the analyzer - there is no need to recalibrate the analyzer with span gas containing a lower oxygen concentratíon.

calibrating either a ppm or percent analyzer with ambient air (with the exception of Oxygen Purity Analyzers intended to measure elevated oxygen levels rangíng fram 50-100% oxygen) on the CAL or 0-25% range meets the 80% criteria discussed aboye. Air calibrate the analyzer (with the exception of Oxygen Purity Analyzers intended to measure elevated oxygen levels rangíng from 50-100% oxygen) when operatíng a percent analyzer, installing and replacing a ppm oxygen sensor, to verify the oxygen content of a certified span gas or when a certified span gas is not available to calibrate a ppm analyzer (immediately following air calibratíon reintroduce a gas with a low oxygen concentratían to expedite the return to ppm level measurements).

Materials: Assemble the necessary zera, purge 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 ppm and percentage range (above or below ambient air) analysis; hardware for mounting.

Temperature: The sample must be sufficiently cooled before it enters the transmitter and any optional components. A coiled 10 foot length of '14" stainless steel tubing is sufficient for coolíng sample gases as hígh as 1,BOooF to ambiento

Pressure &. Flow

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Advanced Instruments loc.

AII electrochemical oxygen sensors respond to partial pressure changes in oxygen. lhe sensors are equally capable of analyzing the oxygen content of a f10wing sample gas stream or monitoring the oxygen concentration in ambient air (such as a confined space such in a control room or an open area such as a landfill or bio-pond).

sample systems and/or flowing gas samples are generally required for applications involving oxygen measurements at levels other than ambient air and when the pressure exceeds ambiento In these situations, the use of stainless steel tubing and fittings is criticaI to maintaining the integrity of the gas stream to be sampled and the inlet pressure must always be higher than the pressure at the outlet vent which is normally at atmospheric pressure.

Flow Through Configuration: The sensor is exposed to sample gas that must f10w or be drawn through metal tubing insidethe transmitter. lhe internal sample system ineludes 1/8" compression inlet and vent flttings, a stáÍnless steel sensor housing with an o-ring seal to prevent the leakage of air and stainless steel tubing.

I Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, f10w rates aboye 5 SCFH generate backpressure and erroneous oxygen readings because the diameter of the integral tubing cannot evacuate the sample gas at the higher f10w rate. The direction the sample gas flows is not important,'thus either tube fitting can selVe as the inlet or vent ­just not simultaneously.

A flow indicator with an integral metering valve upstream of the sensor is recommended as a means of controlling the flow rate of the sample gas. A flow rate of 2 SCFH or 1 liter per minute is recommended for optimum performance.

Caution: Do not place your finger over the vent (it pressurizes the sensor) to test the f10w indicator when gas is f10wing to the sensor. Removing your finger (the restriction) generates a vacuum on the sensor and may damage the sensor (voiding the sensor warranty). To avoid generating a vacuum on the sensor (as described aboye) during operation, always select and install the vent fitting first and remove the vent fitting last.

Applícatíon Pressure - Positive: A f10w indicator with integral metering valve positioned upstream of the sensor is recommended for controlling the sample flow rate between 1-5 SCFH. To reduce the possibility of leakage for low ppm rneasurements, position a rnetering needle valve upstream of the sensor to control the flow rate and position a flow indicator downstream of the sensor. If necessary, a pressure regulator (with a metallic diaphragm is recommended for optimum accuracy, the use of diaphragms of more permeable materials may result in erroneous readings) upstream of the flow control valve should be used to regulate the ¡nlet pressure between 5-30 psig.

Caution: If equipped with a H2S scrubber, inlet pressure must not exceed 30 psig.

Application Pressure - Atmospheric or Slightly Negative: For accurate ppm range 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 f10w meter is generally not necessary te obtain the recommended flow rate with most sampling pumps.

Caution: If the transmitter is equipped with an optional flow indicator with integral metering valve or a metering flow control valve upstream of the sensor - open the metering valve completely 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 f10w rate is within the aboye parameters.

Recommendations to avoid erroneous oxygen readings and damaging the sensor: ;;.. Do not place your finger over the vent (it pressurizes the sensor) to test the f10w indicator when gas is f10wing to the

sensor. Removing your finger (the restriction) generates a vacuum on the sensor and may damage the sensor (voiding the sensor warranty).

)- Assure there are no restrictions in the sample or vent lines ;;.. Avoid drawing a vacuum that exceeds 14" of water column pressure - unless done gradually ,. Avoid excessive f10w rates aboye 5 SCFH which generate backpressure on the sensor. '" Avoid sudden releases of backpressure that can severely damage the sensor. ,. Avoid the collection of Iiquids or particulates on the sensor, they block the diffusion of oxvgen into the sensor.

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Advaneed Instruments Ine.

>- If the transmitter is equipped with an optional integral sampling pump (positioned downstream of the sensor) and a fiow control metering valve (positioned upstream of the sensor), completely open the flow control metering valve to avoid drawing a vacuum on the sensor and placing an undue burden on the pump.

Moisture &. Particulates: Installation of a suitable coalescing or particulate filter is required to remove condensation, moisture and/or particulates from the sample gas to prevent erroneous analysis readings and damage to the sensor or optional components. Moisture and/or particulates do not necessarily damage the sensor, however, coUection 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 when in fact the problem is easily remedied by blowing on the front of the sensor. Consult the factory for recommendations concerning the proper selection and installation of components.

Gas Connections: Inlet and outlet vent gas lines for ppm analysis require 1/8" or Y4" stainless steel compression flttings; hard plastic tubing with a low permeability factor can be used percentage range measurements.

Power Connection: Locate the appropriate power source to meet the analyzer or transmitter requirements, ensure that is properly grounded and meets the area classification.

IMounting tbe Transminer

The GPR-1S00AIS consists of two interconnected enclosures (without the optional sample conditioning system and panel) and measures 8"H x lS~3/4'W x 7''D. This configuration is designed ro be mounted directly to any flat vertical surface, wall or bulkhead plate with eight (8) of the appropriate screws. To facilitate servicing the interior af the transmitters, pasition it approximately S feet off ground leve!.

Remove the four (4) screws securing the top section of the enclosure, set them aside for reinstallation and raise the hínged top section 1800 until it locks in place. Locate the mounting holes cast into the enclosure.

Secure the enclosure to a vertical surface approximately S feet from the f100r or a level accessible to service personnel. This requires the user to supply four (4) additional proper síze screws and anchors.

Caution: Do not remove or discard the gaskets from either the enclosure or junction box. Failure to reinstall either gasket will void the NEMA 4 rating and RFI protection. The transmitters design provides protection from RFI that is maintained by leaving specific mating areas of the enclosure unpainted to maintain conduetivity the gasket, top and bottom sections of the enclosure. These unpainted areas are protected by gaskets and contribute to maintaining the NEMA 4 rating. Do not paint these areas. Paínting will negate the RFI proteetion. Note: If equipped with the optional H25 sample conditioning system, the transmitter and sample system are mounted to a back panel which has four (4) holes for mounting the 15-3/4"H x lS-3/4'W x 7"D panel to any vertical flat surface.

Gas Connhections The GPR~lS00AIS with its standard flow through configuratíon is designed for positíve pressure samples and requires connectíons for incoming sample and outgoing vent Iines. Zero and span inlet ports are offered as part of the optional sample systems. The user is responsible for calibratían gases and the required components, see belaw.

Flow rates of 1-5 SCFH cause no appreciable change in the oxygen reading. However, flow rates aboye 5 SCFH generate backpressure and erroneous oxygen readings because the diameter of the integral tubing cannot evacuate the sample gas at the higher flow rateo A fiow indicator with an integral metering valve upstream of the sensor is recommended as a means of controlling the flow rate of the sample gas. A f10w rate of 2 SCFH or 1 liter per minute is recommended for optimum performance.

Caution: Do not place your finger over the vent (it pressurizes the sensor) to test the flow indicator when gas is f10wing to the sensor. Removing your finger (the restrietion) generates a vacuum on the sensor and may damage the sensor (voiding the sensor warranty).

Procedure:

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Adllaoced lostruments Inc.

1. Caution: Do not change the factory setting until instructed to do in this manual. 2. Designate one of the bulkhead tube fittings as the VENT and the other 5AMPLE. 3. Regulate the pressure as described in Pressure and Flow aboye. 4. Connect a 1/8" vent line to the compression fitting to be used for venting the sample. 5. Connect a 1/8" ZERO, SPAN or SAMPLE line to the fitting designated SAMPLE. 6. If equipped with optional fittings and/or sampie system, connect the ZERO and SPAN gas lines. 7. Allow gas to flow through the transmitters and set the flow rate to 2 SCFH. 8. Note: If equipped with the optional H2S sample conditioning system: Regulate the pressure so that it does not exceed

30 psig use V4" tubing to make the appropriate connections as labeled on the sample panel.

Electrical Connections

Incoming power, power failure and set point alarm, and, output connections are ­made to a terminal block mounted on a PeS located in the lower explosion proof enclosure.

The PeS also includes a transformer to power the alarm relays and intrinsic safety barriers that limited the amount of voltage going to the upper electronics enclosure. With proper insulation of the incoming power (see Appendix A), this configuration the GPR-1500AIS meets the intrinsic safety standards for use in Class 1, Division 1, Groups A-D hazardous areas.

Caution: The integral 4-20mA converter ís internally powered and does not require external power. DO NOT supply any voltage to either of the two terminals of the 4-20mA output or the 4-20mA converter will be damaged.

To assure proper grounding, connect the 4-20mA signal output to the externaI device (PLC, DCS, etc.) before attempting any zero or span adjustments.

Procedure: Power requirements consist of a two wire shielded cable and a 12-28V DC with negative ground power supply. 1. Unscrew the cone shaped cover from the lower enclosure. 2. 5eparate the shielding from the wires of the cable. 3. Ensure the positive and negative terminals of the power supply are connected to the appropriate terminals of the barrier

strip as marked. 4. Connect the shielding of the cable to the ground screw inside the enclosure. Note: The terminals snap together, making it

possible to detach the section with the ground, install the shielded cable and reinstall. 5. Replace the cover. 6. The 4-20mA current output is obtained by conneeting the current measuring device between the positive and negative

terminalslabeled OUTPUT 4-20mA. 7. To check the signal output of the 4-20mA ElI integrated circuit connect an ammeter as the measuring device and confirm

the output is within ±O.lmA of 4mA. 8. Caution: To assure proper grounding, connect the 4-20mA signal output to the extemal device (PLC, DCS, etc.) before

attempting any zero or span adjustments.

Installino the Oxvgen Sensor

The GPR-1500AIS ppm Oxygen Transmitter is equipped with an integral oxygen sensor. They have been tested and calibrated by the manufacturer prior to shipment and are fully operational from the shipping container.

Caution: AII transmitters must be calibrated once the instaliation has been completed and periodically thereafter as described below. Following the initial installation and calibration, allow the transmitters to stabilize for 24 hours and calibrate with certified span gas.

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Caution: DO NOT open the oxygen sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if touched or ingested, refer to the Material Safety Data Sheet contained in the OWner's Manual 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 manner similar to that of a common battery in accordance with local regulations.

Procedure: 1. The sensor has not been installed at the factory (in standard configuration there are no valves

to isolate the sensor) and it will be necessary to install the sensor in the field. 2. Caution: Do not change the factory settings until instructed to do in this manual. 3. Connect the gas línes as previously described. 4. Purge the oxygen trapped in the newly connected gas lines for 3-5 minutes. 5. Flow zero gas or sample gas with a low ppm oxygen c:oncentration to the analyzer at the

predetermined flow rate of 2 SCFH. 6. Using the 5/16 wrench supplied loosen but do not remove the clamp bolt located under the

sensor housing, see photo. 7. Rotate the upper section of the sensor housing 900 to disengage from the clamp. 8. Remove the upper section by pulling it straight up and place it on a smooth surface. 9. Select the AUTO RANGING option from the SAMPLE menu with gas f10wing to the analyzer. 10. Remove the oxygen sensor from the bag and remove the red shorting device (including the gold ribbon) from the PCS

located at the rear of the sensor. Minimize the time the sensor is exposed to ambient airo 11. Immediately place the sensor in the bottom section of the sensor housing with the PCS facing up. 12. lmmediately place the upper section of the sensor housing over the sensor, gently push the upper section downward and

rotate 90° to engage the clamp. 13. Finger tighten the clamp bolt and then tighten it one full turo with the 5/16 wrench to securely lock the two sections of the

sensor housing. 14. The analyzer will OVER RANGE for a short period of time as indicated by the graphical LCD display. 15. Wait until the display shows a meaningful oxygen reading and begins to approach the expected oxygen content of the

sample gas.

Spao Gas Preparation

Caution: Do not contaminate the span gas cylinder when connecting the regulator. Bleed the air filled regulator (faster and more reliable than simply flowing the span gas) before attempting the initial calibration of the instrumento

Required components~

1. Certified span gas cylinder with an oxygen concentration, balance nitrogen, approximating 80% of the fuff scale range aboye the intended measuring range.

2. Regulator to reduce pressure to between 5 and 30 psig. 3. Flow meter to set the f10w between 1-5 SCFH, 4. Suitable fittings and a 4-6 ft. in length of 1/8" dia. metal tubing to connect the regulator to the f10w meter inlet 5. Suitable fitting and a 4-6 ft. in length of 1/8" dia. metal tubing to connect from the f10w meter vent to tube fitting

designated SAMPLE IN on the GPR-1200.

Procedure: 1. With the span gas cylinder valve c1osed, install the regulator on the cylinder. 2. Open the regulator's exit valve and partially open the pressure regulator's control knob. 3. Open slightly the cylinder va/ve. 4. Loosen the nut connecting the regulator to the cylinder and bleed the pressure regulator. 5. Retighten the nut connecting the regulator to the cylinder 6. Adjust the regulator exit valve and slowly bleed the pressure regulator. 7. Open the cylinder valve completely. 8. Set the pressure between 5-30 psig using the pressure regulator's control knob. 9. Caution: Do not exceed the recommended flow rateo Excessive f10w rate could cause the backpressure on the sensor and

may result in erroneous readings and permanent damage to the sensor.

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Establishinl Power to lbe ElecuoniCs

Once the two wires of the shielded cable are properly connected to the terminals insíde the junction box as described aboye, connect the other end of the two wires to a suitable 12-28V DC power supply with negative ground such as a PLC, DCS, etc.

The digital display responds instantaneously. When power is applied, the transmitter performs several diagnostic system status checks termed "START-UP TEST" as iIIustrated below:

START-UP TESI

ELECTRONICS - PASS TEMP SENSOR - PASS BAROMETR'IC SENSOR - PASS

REV.l.6l

Note: The transmitter display defaults to the sampling mode when 30 seconds elapses without user interface.

3.3 PPM

AUTO SAMPUNG 10 PPM, RANGE

24.5 e 100 KPA LOl 2PPM lOPPM HI2

Menu Navigation

The four (4) pushbuttons located on the front of the transmitter operate the micro-processor: 1. blue ENTER (select) 2. yellow UP ARROW 3. yellow DOWN ARROW 4. green MENU (escape)

MainMeno

Access the MAIN MENU by pressing the MENU key:

MAIN MENU

!ji. l,ti·':1Q!3 MANUAL SAMPlE CAUBRATION CONFIG ALARMS BYPASS ALARMS

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Banue Selection

The GPR-1500AIS transmitter is equipped with five (5) standard measuring ranges (see specification) and provides users with a choice of sampling modes. By accessing the MAIN MENU, users may select either the AUTO SAMPUNG (ranging) or MANUAL SAMPUNG (to lock on a single range) mode.

Note: For calibration purposes, use of the AUTO SAMPLE mode is recommended. However, the user can select the full scale MANUAL SAMPLE RANGE for calibration as dictated by the accuracy of the analysis required - for example, a span gas with an 80 ppm oxygen concentration with the balance nitrogen would dictate the use of the 0-100 ppm full scale range for calibratíon and a 0-10 ppm measuring range.

Auto Sampling: 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE. 3. Press the ENTER key to select the highlighted menu option. 4. The display returns to the sampling mode:

MAl" MENU

,¡,ui'li·': IQ i~ MANUAL SAMPLE CAUSRATION CONFIG ALAR.MS BY:PASS AJ.ARMS

3.3 PPM

AUTOSAMPIl.ING, 10 PPM RANGE

24.5,C 100 KPA LOl 2PPM 10PPM. HI2

The display will shift to the next higher range when the oxygen reading (actually the sensor's signal output) exceeds 99.9% of the upper limit of the current range. The display will shift to the next lower range when the oxygen reading drops to 85% of the upper limit of the next lower range. For example, if the transmitter is reading 1% on the 0-10% range and an upset occurs, the display will shíft to the 0-25% range when the oxygen reading exceeds 9.9%. Conversely, once the upset condition is corrected, the display will shift back to the 0­10% range when the oxygen reading drops to 8.5%.

Manual Sampling: 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade OJrsor using the ARROW keys to highlight MANUAL SAMPL'E. 3. Press the ENTER key to select the highlighted menu option. 4. The following display appears:

MAINl MENU

AUTO SAMPLE1: ',':11,.,./,,':1 Q! 3 CALIBRATION CONFIG ALARMS BVPASS ALARMS

»> MANUAL RANGE'

25% 1%,

1000 PPM 100 P,PM ![IIQª:¡

5. Advance the reverse shade cursor using the ARROW keys to highlight the desired MANUAL RANGE. 6. Press the ENTER key to select the highlighted menu option. 7. The following displays appears with the range selected and oxygen concentration of the sample gas:

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Advanced Instruments Ine.

MANUAL RANGE

~.s%

1%

1000 PPM 100 PPM

»> 3.3 PPM

MANUAL SAMPLING 10 PPM RANGE

24.5 e 100 KPA LO! 2PPM 10PPM HI2

The display will not shift automatically. Instead, when the oxygen readíng (actually the sensor's signal output) exceeds 110% of the upper Iimit of the current range an OVER RANGE warning will be displayed.

[Note: 3.3 PPM displayed on ranges of 1000 PPM and below, 0.0% displayed on ranges of 1% and aboye.

13.3 PPM

[ti14 ¡1¡f.Ütij; MANUAL SA}4PUNG 1000 PPM RANGE

24.5C 100KPA LOl 2P_~ft'I 1!DPPM HI2

Once the OVER RANGE warning appears the user must advance the transmitter to the next higher range via the menu and keypad Press MENU, select MANUAL 5AMPLING, press ENTER, select the appropriate MANUAL RANGE and press ENTER again.

Alarms

The CONFIG ALARM5 features a system that can be configured in the field. Two field adjustable alarm relays with dry contacts operate independently of one another which means the alarms can be set-up as:

,. HI and LO r LO and LO, LO, ,. HI and HI,HI ,. PERCENT (of full scale range which changes with auto-ranging) .,. % (oxygen value)

Additional feature ineludes delaying the activation of the local audible alarm and relay contacts for up 99 minutes to enable users to distinguish between transient occurrences and true upset conditions which is particularly useful on remote applications

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without affecting the 4-20mA signal output. The local audible alarm can be silenced or disabled as well without affeeting the 4­20mA signal output.

Note: A separate feature, BVPASS ALARMS described below, enables the user to disable the local audible alarm and relay contacts during calibration or servicing. The alarms are enabled when the alarm condition is correeted.

5et Alilrm Values: 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CONFIG ALARMS. 3. Press the ENTER key to select the highlighted menu option. 4. The following displays appears:

MAIN MENU

AUTO SA'MPLE MANUAL SAMPLE CALIBRA110N [gn:'; (#t-!'·';I:k BYPASS ALARMS

»> MAIN MENU

~;3'I.! •.';j:l'SET A!,ARM 2 SET ALARM DELAY ALARM 1 HIjLO ALARM 2 HIjlO ALARM5 AUDIBLE SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the SET ALARM 1 option. 6. Press the ENTER key to select the highlighted menu option. 7. The following displays appears with PERCENT as the default alarm value :

MAIN MENU

~;i:lI""",:11 SET ALARM 2 SET ALARM. DELAY ALARM 1 HI/LO ALARM 2 HI/LO ALARM5 AUDIBLE/SILENT

»> GAS CONCENTRAll0N

103;1;4:" PPM

8. Advance the reverse shade cursor using the ARROW keys to highlight the desired option. 9. Press the ENTER key to select the highlighted menu option.

Note: The PERCENT (of FS) alarm value is entered with one decimal, the PPM (oxygen) afarm value is entered as an integer.

01.0 GAS CONCENTRA110N

5Eili ALARM 1 VALUE»> PRESS UP OR DOWN' TO CHA'NGE VALUE ENTER TO SAVE MENU TO RETURN

GAS CONCENTRATION I 001, -----. 5ET ALARM i VALUE

1 __ .. _ ..1~-»>--------!"ERCENT ,

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Advsnced Instruments Ine.

m PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN

10. Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to reach to the desired digit of the alarm value.

11. Press the ARROW keys to enter the alarm value. 12. Repeat until the complete span value has been entered. 13. Note: If an alarm is set as a PERCENT value and subsequently changed te a PPM value, the PERCENT value is not retained

and is reset te 00.0. This holds if the alarm was first set as PPM value and then changed to a PERCENT value. 14. Save the alarm value by pressíng the ENTER key or abort by pressing the MENU key. 15. The system returns to the SAMPLlNG mode and displays:

3.3 PPM

AUTO SAMPUNG 10 PPM RANGE

~ Lg:~;PM -: lDl:pOM~P~I2 ,-------'-=-

Repeat the steps aboye to set the ALARM 2 value:

MAIN MENU MAIN MENU

»> SETALARM 1

MANUAL SAM PLE AUTO SAMPLE

~i31 VMel: fj CALIBRATlON SET ALARM DELAY

ALARM 1 HI/L.O¡;'Hii(OO'!j;J:f~ BYPASS ALARMS ALARM 2 HI/LO

ALARMS AUDIBLE/SILENT

Set Alarm Defay: Once the values for ALARM 1 and ALARM 2 have been entered, the user may elect to delay the activation of the local alarms and relay contacts for up te 99 minutes. This feature allows users to distinguish between transient occurrences and true upset conditions. This feature can be particularly useful on remote applications without affecting the 4-20mA signal output. 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CONAG ALARM5. 3. Press the ENTER key to select the highlighted menu option. 4. The following displays appear:

MAIN MENU MAIN MENU

»> SETALA~ 1

MANUAL SAMPLEi AUTO SAMIPlE

SET ALARM 2 CALIBRATlON '1"'" jo' ;1:'.]3 "'i

ALARM lIHI/lO BVPASS ALARMS SMijltcf·,'·!;I:b'"

AlARM 2 IIU/lO ALARMS_AUDIBLE/SILENIT

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Adllanced In!!!itruments Inc.

5. Advance the reverse shade cursor using the ARROW keys to highlight the SET ALARM DELAY. 6. Press the ENTER key to select the highlighted menu optian. 7. The following displays appear with last alarm delay value :

99 ,-----,I MAlNMENU DE.LAY IN MINUTES»>

SETALARM 1 PRESS UP OR DOWN TO CHANGE VALUE

S~TALARM 243 .. '.' '.';1:•.'# 'J\7

,ENTER 1'0 SAVE ALARM 2 Hl/lO ALARM 1 HI/lO

MENU TO REnlRN AlARMS AUDIBLE/SIlENT

8. Press the ENTER key to advance the underline cursor right or press the MENLJ key to advance the underline cursor left to reach to the desired digit of the alarm value.

9. Press the ARROW keys to enter the alarm value. 10. Repeat until the complete span value has been entered. 11. save the alarm value by pressing the ENTER key or abort by pressing the MENU key. 12. The system returns the SAMPUNG mode and displays:

3.3 PPM

AUTO SAMPUNG 10 PPM RANGE

24.5 e 100 KPA lO1! 2PPM lOPPM HI2

Set, HI/LO Alanns: 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CONFIG ALARMS. 3. Press the ENTER key to select the highlighted menu option. 4. The following dísplays appears:

MAIN MENU

AUTOSAMPlE MANUAL SAMPlE CAUBRATION [i·Hli(?t·"·'¡J:k BYPASS ALARMS

»> MAlN M~NU

SET ALARM 1 SET ALARM 2 SET AlARM DELAY

fJ"';J:'·UrmALARM 2 HI/lO ALARMS AUDIBLE SILENT

5. Advance the reverse shade cursor using the ARROW keys to highlight the ALARM 1 option, which appears as either ALARM 1 HI or ALARM 1 LO.

6. Press the ENTER key to toggle and change the displayed setting. After 3 seconds, the system returns to SAMPUNG mode.

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Advanced InstrulDents Inc.

3.3 PPM

AUTO SAMPUNG 10 PPM RANGI;

24.5 e 100 KPA L01 2PPM 10PPM HI2

7. Repeat steps 1 through 6 for the ALARM 2 HI/LO setting.

Set Local Alarms: 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CONFIG ALARMS. 3. Press the ENTER key to select the highlighted menu option. 4. The following displays appears:

MAIN MENU

AUTO SAMPLI; MANUAL SAMPLE CALIBRATlON t;·U'¡pcCf·"·j.;i:ka'YPASS ALARMS

»> MAIN MENU

SET ALARM 1 SETALARM 2 sET ALARM'DELAY ALARM 1 HI/LO AlARM 2 HI/LO

, .,

S. Advance the reverse shade cursor using the ARROW keys to highlight the ALARMS AUDIBLEjSILENT option, which appear as either ALARMS AUDIBLE or ALARMS SILENT.

6. Press the ENTER key to toggle and change the displayed setting. After 3 seconds, the system returns to SAMPUNG mode.

3.3 PPM

AUTO SAMPLING 10 IPPM RANGE

24.SC 100 KPA L01 2PPM 10PPM HU

Bypass Alarms: This feature, separate from CONFIG ALARMS aboye, enables the user to disable the local audible alarm and relay contacts during calibration or servicing. The alarms are enabled when the alarm condition is corrected. 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight BYPASS ALARMS. 3. The following displays appears:

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Adllanced Instruments loc.

IfAIN MENU

AUTO SAMPLE I'4ANUAL SAMPLE CAUBRATlON CONFlG ALARMS j~Sj g.$.$j., l·' ;1:&"

4. Press the ENTER key to bypass and disable both the local audible alarm and relay contacts. After 3 seconds, the system returns to SAMPUNG mode.

S. Note: The appropríate alarm settíng wíll alternately reverse shades índícatíng the alarm condítíon exísts but the BYPASS ALARM5 feature has disabled the local audible alarm and relay contacto The alarms are enabled when the alarm conditíon is corrected.

3.3 PPM

AUTO SAMPUNG 10 PPM IRANGE

24.5 e 100 KPA LOl 2PPM J" ••

Stan-up is complete ... Dmceed to Calibration

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Advanced Instruments IDC",

lero, Calibratioo

In theory, the oxygen sensor produces no signal output when exposed to an oxygen free sample gas. However, the transmitter will generate an oxygen reading when sampling oxygen free sample gas due to:

~ Contamination or quality of the zero gas ,. Minor leakage in the sample line connections ,. Residual oxygen dissolved in the sensor's electrolyte ~ Tolerances of the electronic components

Recommendation: lero calibration is recommended only for online analyzers ¡ntended for measurements below 1 ppm on the 10 ppm range and then only when the sample system connections are modified and when installing a new oxygen sensor. lt is not practical on higher ranges or portable analyzers for the following reasons:

1. Determining the true zero offset reguires the user allow the analyzer approximately 24 hours to stabilize with flowing zero gas as evidenced by a stable reading with no downward trend on an external recordíng device. Note: Approximately 24-36 hours is required to assure the sensor has consumed the oxygen that has dissolved into the electrolyte inside the sensor while exposed to air or percentage levels of oxygen. For optimum aCcuracy, utilize as much of the actual sample system as possible.

2. Thus it is not practical to find the true zero offset particularly in the case of applications requiring higher level oxygen measurements because of the low offset value, normally 50% of the most sensitive range, is not material to the accuracy of higher level measurements. Nor is it practical to zero a portable analyzer every time it is moved from one sample point to another.

3. caution: Prematurely zeroing the analyzer can cause a negative reading in both the ZERa and SAMPLE modes. 4. Satisfying users that the zera offset is reasonably acceptable for their application can be accomplished much quicker.

Unless the zero gas is contaminated or there is a significant leak in the sample connections, the analyzer should read less than 100 ppm oxygen within 10 minutes after being placed on zero gas thereby indicating it is operating normally.

Recommendation: Initiate the DEFAULT ZERa pracedure before performing either alERO or SPAN CAUBRATION.

Procedure: lero calibration should precede the span calibration and once performed should not have to be repeated with subsequent span calibrations. Normally, zero calibrations are performed when a new sensor is installed or changes are made in the sample system connectíons.

Refer to Span Calibration below for the detaíled procedure. Differences inelude the displays iIIustrated below, substituting a suitable zero gas for the span gas and the time required to determine the true zera offset of specific oxygen sensor, analyzer and sample system combination.

The maximum zero calibration adjustment permitted is 50% of the lowest full scale analysis range available. Accordingly, the analyzers lERa has not been adjusted prior to shipment because the factory conditions are different from the application condition at the users installation.

1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CAUBRATION. 3. Press the ENTER key to select the highlighted menu option. 4. The following displays appear:

MAIN MENO

AUTO SAMJ!liE MANUAL SAMPLE :',' Il~, ;1·,. (•.1 :-1 CONFIG ALARMS BYPASS ALARMS

»> CALIBRAnON

SPAN CALIBRATE

'43;11'"'' I':J ;'." ~. DEFAULT SPAN DEfAULT ZERO OUTPlit SPAN OUTPUTZERO

5. Advance the reverse shade cursor using the ARROW keys to highlíght lERO CAUBRATE.

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Adllanced Instrurnents IDe.

6. Press the ENTER key to select the highlighted menu option. 7. The following displays appear:

0.000 PPM

ZERO CALIBRTlON

~NTER TO CAUBRATE MENU TO ABº~T

8. Press the ENTER key to calibrate or MENU key to abort and return to SAMPUNG mode. 9. Allow approximately 60 seconds for the calibration process while the processor determines whether the signal output or

reading has stabilized within 60% of the full scale low range. 10. Both the lero Calibrate and Span calibrate functions result in the following displays:

OR PASSED fAILED

CAUBRATlON CAUBRATlON

The maximum zero calibration adjustment permitted is 50% of the lowest full scale range available. Accordingly, the transmitter's lERa has not been adjusted prior to shipment because the factory conditions are different from the application condition at the user's installation.

Default Zero The software will eliminate any previous zero calibration adjustment and display the actual the signal output of the sensor at a specified oxygen concentration. For example, assuming a zera gas is introduced, the display will reflect an oxygen reading representing basically the zero calibration adjustment as described aboye. This feature allows the user to test the sensor's signal output without removing it from the sensor housing.

Recommendation: Initiate the DEFAULT ZERO procedure before performing either a ZERO or SPAN CAUBRATION.

1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CAUBRATION. 3. Press the ENlCR key to select the highlighted menu option. 4. The following displays appear:

.MAIN MENU CALIBBATlON

»> AlWTO SAM PLE SPAN CALIBRATE' MANUAL SAMPLE ZERO CALIBRATE (ít.,'I:! .1·' ,r.pl DEFAULT SPAN CONFIG ALARMS ¡.,ª,.\IJlf34;t.: BYPASS ALARMS OUTPUTSPAN

OUTPUT ZERO

5. Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT lERa. 6. Press the ENTER key to select the highlighted menu optiofl.

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Advanced Instruments Ine.

7. The following display appears and after 3 seconds the system returns to the SAMPLlNG mooe:

FAetORY 3.3 PPM DEFAULTS

AUTO SAMPI,.,lNG SET 10 ppM RANGE

24.5 e 100 KPA LOl 2PPM 10PPMI H.IZ

OutputZero In rare instances the 4-20mA signal output may not agree to the reading displayed by the LeD. This feature enables the user to adjust the 4mA signal output when the LCD displays 00.00. Note: Adjust the 20mA signal output with the OUTPUT SPAN. 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CALlBRATION. 3. Press the ENTER key to select the highlighted menu option. 4. The following displays appear:

MAlN MENU CALIBRAnON

»> AUTO SAMPlE SPAN CAUBRATE MANUAL SAMPLE ZERO CALIBRATiE

DEFAUlT SPAN CONF1G ALARMS tít·'. r:\;IJ I len!

DEFAULT ZERO BYPASS AURMS OUTPUTSPAN

tui•• 4Ií*3§¡lt)

S. Advance the reverse shade cursor usíng the ARROW keys to highlight DEFAULT ZERD. 6. Press the ENTER key to select the highlighted menu option. 7. The followíng display appears:

OUTPUT ZERO OfFSET

PRESS UP OR DOWN TO CHANGE VAL,UE ENTER TO SAVE MENU TO RETURN

8. Compute the adjustment value as descríbed in Appendix B or consult the factory. The true adjustment value must be determined empirically by trial and error. Adjust the initial adjustment value for additional percent errors.

020.0

OUTPUT ZERO OFF5E-m-

PRESS UP OR DOWN TO CHA~GE VALUE IENTEcR TO SAVE MENU TO RETURN

9. Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to reach to the desired digit of the OUTPUT ZERO OFFSET value.

10. Press the ARROW keys to enter the OUTPUT ZERO OFFSET value. 11. Repeat until the complete OUTPUT ZERO OFFSET value has been entered. 12. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key. 13. The system returns to the SAMPUNG mode.

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Adllanced Instruments loe.

Spao Calibradoo

Maximum drift from calibration temperature is approximately 0.11% of reading per oc. The analyzer has been calibrated at the factory. However, in order to obtain reliable data, the analyzer must be calibrated at the initial start-up and periodically thereafter. The maximum calibration interval recommended is approximately 3 months, or as determined by the user's application.

Calibration involves adjusting the analyzer electronics to the sensor's signal output at a given oxygen standard, e.g. a certified span gas with an oxygen content (balance nitrogen) approximating 80% of the next higher full scale range aboye the intended measuring range is recommended for optimum accuracy, see Calibration and Accuracy.

Recommendation - based on the inherent linearity of the galvanic oxygen sensor air calibrate the analyzer as described below when installing and replacing the oxygen sensor (exception UHP and M5 versions of the PiCO Ion Sensor); or, to verify the oxygen content of a certified span gas; or, when a certified span gas is not available (immediately following air calibration reintroduce a gas with a low oxygen concentration to expedite the return to ppm level measurements).

Recommendation: lnitiate the DEFAULT SPAN procedure before performing either a ZERO or SPAN CAUBRATlON.

Caution: Prematurely initiating the SPAN CAUBRATlON key before the galvanic fuel cell sensor based analyzer reading has stabilized can result in erroneous readings. For example, to assure an accurate air calibration when installing a new ppm oxygen sensor from its packaged oxygen free atmosphere allow the oxygen sensor 2-3 minutes to reach equilibrium with the oxygen content of the ambient aír surrounding it before pressing the SPAN CAUBRATE key. A ppm Oxygen sensor that has not been allowed te reach equilibrium will generate a lower current output than a ppm oxygen sensor that has reached equilibrium. Pressing the SPAN CAUBRATE key before the ppm oxygen sensor has reached equilibrium forces the micro-processor to prematurely read the (erroneous low) current output of the ppm oxygen sensor and introduce larger (erroneous) than required electronic gain adjustment and display (also erroneous) CAUBRATlON SUCCESSFUL message to the user. The error wíll become evident when a zero gas with a low oxygen concentration is introduced into the ppm analyzer to purge it down below 10 ppm. The analyzer reading may stop and appear to stabilize as high as 1800 ppm - giving the user the (erroneous) impression there is a problem with the ppm oxygen sensor when in fact the problem lies with the user's failure to follow the recommended calibration procedure.

Required Components: Refer to lnstallíng Span Gas sectíon aboye. ,. Certified span gas cylinder with an oxygen concentration, balance nitrogen, approximating 80% of the full scale range

aboye the ¡ntended measuring range. ,. Regulator to reduce pressure te between 5 and 30 psig. ,. Flow meter to set the f10w between 1-5 SCFH, ,. Suitable fittings and a 4·6 ft. in length of 1/8" dia. metal tubing to connect the regulator to the f10w meter inlet ... Suitable fitting and a 4-6 ft. in length of 1/8" dia. metal tubing to connect to the f10w meter vent ... 1/8" male NPT to tube adapter fitting to connect the 1/8" dia. metal tubing from the flow meter vent to the mating male

quick disconnect fitting supplied with the GPR-1500AIS.

Proc:edure: The user must ascertain that the oxygen reading (actually the sensor's signal output) has reached a stable value within the limits entered below before entering the span adjustment. Failure to do so will result in an error. 1. This procedure assumes a span gas under positive pressure and is recommended for a transmitter without an optionaf

sampling pump, which if installed downstream of the sensor should be placed in the OFF position and disconnected so the vent is not restricted during calibration.

2. To assure an accurate calibration, the temperature and pressure of the span gas must c10sely approximate the sample conditions.

3. For calibration purposes, use of the AUTO SAMPLE mode is recommended. However, the user can select the full scale MANUAL SAMPLE RANGE for calibration as dictated by the accuracy of the analysis required - for example, a span gas with an 80 ppm oxygen concentration with the balance nitrogen would dictate the use of the 0-100 ppm full scale range for calibration and a 0-10 ppm measuring range. Select as described aboye.

4. Access the MAlN MENU by pressing the MENU key. S. Advance the reverse shade cursor using the ARROW keys to highlight AUTO SAMPLE. 6. Press the ENTER key to select the highlighted menu option. 7. The following displays appear:

25

Advance'd InstrumeDts Ine.

MAIN MENU 3.3 PPMf"iii.J,.,:IQ.ª MANUAL SAMPLE

AUTO SAMPUNGCAUBRATlON 10 PPM RANGE,CONFIG AlARMS

24.5 e 100 KPAIJVPASS ALARMS LOl lPPM l'OPPM HU.

8. Return to the MAIN MENU by pressing the MENU key. 9. Advance the reverse shade cursor using the ARROW keys to highfight CAUBRATION. 10. Press the ENTER key to select the highlighted menu option. 11. Repeat to select DEFAULT SPAN. 12. Repeat to select SPAN CALIBRATE. 13. The following displays appear:

MAIN MENU CALIBRATlON

»> AUTO SA'MPLE ~4 PI' ~I"·' I i~' ;',5 " MANUAL SAMPLE ZERO CAUBRATE

DEFAUlT SPAN CONFIG ALARMS rmr=hy.c.r:i

DEFAULT ZERO BVPASS ALA~MS OUTPlJT SPAN

OUTPUTZERO

14. Assure there are no restrictions in vent line. 15. Regulate the pressure and control the flow rate as described aboye at 5-30 psig and a 2 SCFH flow rateo 16. Allow the span gas to flow for 1-2 minutes to purge the air trapped in the span gas line. 17. Disconnect the sample gas line and install the purged span gas line. 18. Caution: Allow the span gas to f10w and wait until the reading is stable before proceeding wjth calibration.

The wait time will vary depending on the amount oxygen introduced to the sensor when the gas lines were switched. 19. Press the ENTER key to select the SPAN CAUBRATE option. 20. Note: A span gas concentration aboye 1000 ppm dietates the selection of the PERCENT option. 21. Advance the reverse shade cursor using the ARROW keys to highlight the desired GAS CONCENTRATION. 22. Press the ENTER key to select the highlighted menu option.

GAS CONCENTRATlON

PERCENT m

23. The following displays appear: ,.---------- ...,

PRESS UP OR DOWN TO CHANGE VALUE EN~ER TO SAVE MIENU TO RETURN

»>

"..---------- ..I

SPAN CALIBRATlON ENTER TO CALIBRATE MENU TO ABORT

24. Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to reach to the desired digit of the alarm value.

25. Press the ARROW keys to enter the alarm value. 26. Repeat until the complete span value has been entered.

26

Adllaoced IOf'trumeots Ine.

27. Save the adjusbnent value by pressing the ENTER key or abort by pressing the MENU key. 28. Allow approximately 60 seconds for the calibration process while the processor determines whether the signal output or

reading has stabilized within 60% of the fuJl scale low range. Both the Zero Calibrate and Span Calibrate functions result in the following displays:

OR J>ASSED FAIlED

CALIBRAmo.N CAUBRA1Ii10N

29. If the calibratíon is successful, the transmitter returns to the SAMPUNG mode after 30 seconds. 30. If the calibration is unsuccessful, return to the SAMPUNG mode with span gas flowing through the transmitter, make sure

the reading stabilizes and repeat the calibration before concluding the equipment is defective. 31. Before disconnecting the span gas line and connecting the sample gas line, restart if necessary the f10w of sample gas and

allow it to flow for 1-2 minutes to purge the air inside the line. , 32. Disconnect the span gas line and replace it with the purged sample gas line. 33. Wait 10-15 minutes to ensure the reading is stable and proceed to sampling.

Default Span The software will set the SPAN adjustment based on the average oxygen reading (actually the sensor's signal output) at any specific oxygen concentration. For example, when a span gas is introduced, the micro-processor will display an oxygen reading within ±SO% of the span gas value. This feature allows the user to test the sensor's signal output without removing it from the sensor housing.

Recommendation: Initiate the DEFAULT SPAN procedure before performing either a ZERO or SPAN CAUBRATION.

1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CAUBRATION. 3. Press the ENTER key to select the highlighted menu option. 4. The following displays appears:

MAIN MENU CALIBRATlON

»> AU;r¡O SAMPlE SPAN CALIBRATE MAtoIUAl SAMPLE ZERO CAUBRATE l!!1'~hf.S'('HI l.]ª,jii il;:Z·'~1 Co.NfIGo ALARM5 DEFAULT ZERO BYPASS ALARMS OUTPUTSPAN

OUTPUTZERO

S. Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT SPAN. 6. Press the ENTER key to select the highlighted menu oplion. 7. The following displays appear and after 3 seconds the system returns to the SAMPLING mode:

FACTORY DEFAUl,TS

SE'!"

3.1 PPM

AUTO SAMPUNG 10 PPM RANGE

24.5 C 100lKPA LOl 2PPM 10PPM Hll.2

27

Adllaneed InstrulDents ,oc.

Output Span: In rare instances the 4-20mA signal output may not agree to the reading displayed by the LCD. This feature enables the user to adjust the 20mA signal output should the LCD display not agree. Note: Adjust the 4mA signal output with the OUTPUT ZERO option described aboye. 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlight CAUBRATION. 3. Press the ENTER key to select the highlighted menu option. 4. lhe following displays appear:

M'AIN MENU CAUBRATION

»> AUTO SAMPLE SPAN CALlBRAn: MANUAL SAMPLE 2ERO CALIBRATE :...,i' :1>'." tl):1 DEFAULT SPAN CONFlG ALARMS DEFAULT ZERO BYPASS ALARMS [.111 I a'", i.,:¡

OUTPUTZERO

S. Advance the reverse shade cursor using the ARROW keys to highlight DEFAULT SPAN. 6. Press the ENTER key to select the highlighted menu option. 7. lhe following display appears

OUTPUT SPAN OFFSET

PRESS UP OR DOWN TO CH'ANGE VAlUE ENTER TO SAVE MENU TO RETURN

8. Compute the adjustment value as described in Appendix B or consult the factory. lhe true adjustment value must be determined empirically by trial and error. Adjust the initial adjustment value for additional percent errors.

09~.O

OVTPVT SPAN OFFSET

PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO RETURN

9. Press the ENTER key to advance the underline cursor right or press the MENU key to advance the underline cursor left to reach to the desired digit of the OUTPUT SPAN OFFSET value.

10. Press the ARROW keys to enter the OUTPUT SPAN OFFSET value. 11. Repeat steps 9 and la until the complete OUTPUT SPAN OffSET value has been entered. 12. Save the adjustment value by pressing the ENTER key or abort by pressing the MENU key. 13. lhe system returns to the SAMPUNG mode.

28

Adllanced Instruments Inc~

S8mpling

GPR-1500AIS ppm Oxygen Transmitter requires positive pressure to f10w the sample gas by the sensor to measure the oxygen cancentration in a sample gas. If not available see Pressure & Flow section.

Note: Prematurely initiating the ZERO CAUBRATION procedure can cause the analyzer to display a negative reading in both the ZERO and SAMPLE modes. Prematurely initiating the SPAN CAUBRATION procedure can cause erroneously high offsets and inaccurate readings.

Procedure: 1. Following calibration the transmitter returns to the SAMPLE mode after 30 seconds. 2. Select the desired sampling mode - auto or if manual, the range that provides maximum resolution - as described aboye. 3. Use metal tubing to transport the sample gas to the transmitter. 4. lhe main consideration is to eliminate air leaks which can affect oxygen measurements aboye or below the 20.9% oxygen

concentration in ambíent air - ensure the sample gas tubing connections fit tightly into the 1/8" male NPT to tube adapter, and, the NPT end is taped and securely tightened into the mating male quick disconnect fittings which mate with the female fittings on the transmitter

5. Assure there are no restrictions in the sample line. 6. For sample gases under positive pressure the user must provide a means of controlling the inlet pressure between 5-30

psig and the f10w of the sample gas between 1-5 SCFH, a f10w rate of 2 SCHF is recommended 7. Far sample gases under atmospheric ar slightly negative pressure an optional sampling pump is recommended to draw the

sample into the transmitter. Generally, no pressure regulation or f10w control device is ¡nvolved. 8. Caution: If the transmitter is equipped with an optional sampling pump and is intended for use in both positive and

atmospheric/slightly negative pressure applications where a f10w meter valve is involved - ensure the valve is completely apen when operating the sampling pump. Refer to the Pressure & Flow section aboye.

9. Assure the sample is adequately vented for optimum response and recovery - and safety. 10. Allow the oxygen reading to stabilize for approximately 10 minutes at each sample point.

To avoid erroneous oxygen readings and damaging the sensor: ? Do not place your finger over the vent (it pressurizes the sensor) to test the f10w indicator when gas is f10wing to the

sensor. Removing your finger (the restrietion) generates a vacuum on the sensor and may damage the sensor (voiding the sensor warranty).

? Assure there are no restrictions in the sample or vent lines » Avoid drawing a vacuum that exceeds 14" of water column pressure - unless done gradually ,. Avoid excessive f10w rates aboye 5 SCFH which generate backpressure on the sensor. ,. Avoid sudden releases of backpressure that can severely damage the sensor. ,. Avoid the collection of particulates, Iiquids or condensabon callect on the sensor that could block the diffusion of oxygen

into the sensor. :;. If the transmitter is equipped with an optional integral sampling pump (positioned downstream of the sensor) and a flow

control metering valve (positioned upstream of the sensor), completely open the flow control metering valve to avoid drawing a vacuum on the sensor and placing an undue burden on the pump.

Standbv The transmitter has no special storage requirements. lhe sensor should remain conneeted during storage periods. Store the transmitter with the power OFF. If storing for an extended period of time protect the analyzer from dust, heat and moisture.

29

Advanced Instrument§ Ine.

16 Maintenance Generally, c1eaning the electrical contacts or replacing filter elements is the extent of the maintenance requirements of this transmitter.

Sensor Beplacement Periodically, the oxygen sensor will require replacement. The operating lite is determined by a number of factors that are influenced by the user and therefore difficult to predict. The Features & Specifications define the normal operating conditions and expected life of the standard sensor utilized by the GPR-1500AIS transmitter. Expected sensor life is inversely proportional to changes in oxygen concentration, pressure and temperature.

Serviceability: Except for replacing the oxygen sensor, there are no parts inside the transmitter for the operator to service. Only trained personnet with the authorization of their supervisor should conduct maintenance.

Cautlon: DO NOT apen the oxygen sensor. The sensor contains a corrosive liquid electrolyte that could be harmful if touched or ingested, refer to the Material Safety Data Sheet contained in the Owner's Manual. 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. Procedure: 1. Remove the four (4) screws securing the transmitter's front panel. 2. Caution: Do not discard the gaskets from the enclosure. 3. Using the 5/16 wrench supplied loosen but do not remove the clamp bolt located in the

center of the housing with the elbows attached. 4. Rotate the upper section of the sensor housing 90° to disengage from the clamp. 5. Remove the upper section by pulling it straight up and place it on a smooth surface. 6. Remove the old axygen sensor and dispose of it as you would a battery. 7. Remove the new oxygen sensor from the shipping bago 8. Remove the red {abel and the gold ribbon (shorting device) from the PeB at the rear of the

sensor. 9. Caution: Minimize the time the sensor is exposed to ambient airo 10. Place the new sensor in the bottom section of the sensor housing with the PeB facing up. 11. Place the upper section of the sensor housing over the sensor. 12. Span calibrate the transmitter in 20.9% ambient airt once the reading stabilízes - see

aboye. 13. Gently push the upper section downward and rotate 90° to engage the clamp. 14. Finger tighten the clamp bolt and one full turn with the 5/16 wrench to compressed the o-ring sea!. 15. Connect zero gas or low oxygen content sample gas line to purge the sensor of oxygen.

30

Adllaneed In§truments Ine.

1SparePans Recommended spare parts for the GPR-1500AIS ppm Oxygen Transmitter:

Remll. GPR-12-333 XLT-12-333

Other spare parts:

ltem No. HTR-10D4 A-1004-2-14 A-1016-A S-2762-A-2-14 MTR-1011 MTR-1D14 ORNG-1DD7 A-1l51-AIS-1 A-1l66-AIS-Ae A-1l66-AIS-DC

Descriltien ppm Oxygen Sensor ppm Oxygen Sensor

Oescription Heater Low Power Sensor Housing Housing Sensor Stainless Steel Housing Sensor Bottom Assembly Stainless Steel Housing Sensor Upper Assembly Staínless Steel Meter Digital Panel LCD Sacklight Meter Digital Panel LCO Low Temperature O-ring 3/32 x 1-3/8 x 1-9/16 Viton PCS Assembly Majn / Display pes Assembly Interconnection / Ae Power Supply PeS Assembly Interconnection / DC Power Supp[y

8 Troubl'eshOOlinu Symptom Possible Cause Recommended Action

Slow recovery or At installation, defective sensor

Air leak in sample system connection(s)

Abnormality in zero gas Damaged in service - prolonged exposure to aír, 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 f10w rate, if the O2 reading changes inversely with the change in f10w rate indicates an air leak - correct source of leak Qualify zero gas (using portabfe transmitter) Replace sensor

Replace sensor

Hígh O2 reading Transmitter calibrated before sensor stabílized Allow O2 reading to stabílize before making the after installing caused by: span/calíbration adjustment or replacing sensor 1) Prolonged exposure to ambient air, worse Continue purge with zero gas

if sensor was unshorted 2) Air leak in sample system connection(s) Leak test the entire sample system (above) 3) Abnormality in zero gas Qualify zero gas (using portable transmitter)

High O2 reading Flow rate exceeds limits Correct pressure and flow rate Sampling Pressurized sensor Remove restríction on vent line

Improper sensor selection Replace GPRjPSR sensor with XLT sensor when CO 2 or acid gases are present

31

Ad'llanced 'n!!iitrument!!ii IDe.

Symptom Possible Cause Recommended Action

Response time slow Air leak, dead legs, distance of sample line, low f10w rate, volume of optional filters and scrubbers

Leak test (above), reduce dead volume or ¡ncrease f10w rate

O2 reading doesn't Pressure and temperature of the sample is Calibrate the transmitter (calibrate at pressure and agree to expected O2 different than span gas temperature of sample) values Abnormality in gas Qualify the gas (use a portable transmitter)

Erratic O2 reading or

No O2 reading

Change in sample pressure

Dirty electrical contacts in upper section of sensor housing .

Corroded solder joints on sensor PeS 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

Improper sensor selection

Presence of interference gases Unauthorized maintenance Sensor nearing end of Iife

Sensors without PCB use mV setting. Calibrate the transmitter (calibrate at pressure and temperature 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, f10w sample or zero gas for 2-3 hours to f1ush sample system and sensor housing Sensor: Replace if leaking and retum it to the factory for warranty determination

Wipe with alcohol and Iint free towel or f10w sample or zero gas for 2-3 hours to f1ush Replace GPR/PSR sensor with XLT sensor when CO2

or acid gases are presento Consult factory.

Replace sensor and install scrubber Consult factory. Replace sensor

Erratic O2 reading or

Negative O2 reading or

No O2 reading accompanied by electrolyte leakage

Pressurizing the sensor by flowing gas to the sensor with the vent restricted or SHUT OFF valve c10sed and suddenly removing the restriction draws a vacuum on the sensor

or partially opening the valves upstream of the transmitter when using a pump downstream of the transmitter to draw sample from a process at atmospheric pressure or a slight vacuum. Placing a vacuum on the sensor in excess 4" cf water column is strongly discouraged.

A premature adjustment of the ZERO OFFSET potentiometer is a common problem

Zero the transmitter. If not successful replace the sensor

Avoid drawing a vacuum on the sensor, a pressurized sensor may not leak but still produce negative readings.

From MAIN MENU select DEFAULT ZERO

32

Advaneed Instruments Ine.

Purpose: SPAN CALlBRAll0N of digital (reference to analog) ppm O2 analyzer already in-servíce. TROU BLESHOOT ppm O2 analyzer te cenfirm response and stability under controlled conditions.

PreUminary Test 1.) COllfírm metal sarnple system components - no pl(lStl:. L 2.) leak. Test Varo¡ analyzer fIow rate upJdown and observe reading.I I

1,) TQ,rerl anj 's,-,~,~p' c:>nne..'tlon;; 2,) STO? ,i rcad,...;) IS mt ,tatle and

~nta<;t fól.'lQry,No<$?Ves

Set-up 1.) Piare analyzer SAt"l'lEIBYPASS vdlve(s) in eYPASS mode, see (a) below. 2.) Seloct AUT0-RANGING mode or MANUAlly selecl rc.l\le for Spéll gas 3.) Perform DEFAUlT ZERO or MANUAlly eliminate previous zelO adjustmellts 4.) Perform DEFAULT SPAN Note: Zeroing lhe analyzer is OIlly recornmended for continuous analysis < 1 ppm

whidl normally e:<cludes portable éIldlyzers - cOIlstanUy changíng gas Unes.

I ,

1.) Comed the span gas lioe or If equipped with a 3-way SAMPlE/SPAN valve place it in Ihe SPAN lnode,

2.) AJlow Ihespan gas te liow fOl' 5-10 mirutes to purge Ihe air (20.9% O~)

fi'om ínside Ihe span gas Une - during connection or leClks during standby.

11 analyzer is not equlpped \\Iilh eVPASS SAMPlE SYSTErv1, see (d) below: 1.) Purge lhe Spéll gas line before connecti19 te !he analyzer. 2.) Conn et the gas lineo; eJ5 quickly as Dossible - sorre air \ViII be introduc.ed 3.) AlIow edra time fer !he reading to stobilize - !he sensor 11Im e:<posed te alr. 4.) When off-line, Illdintain gas Aow thru analyzer or cap connections (inlet filsl)

Ito avoid damaging the sensor by eJ<posíng it to ait' (209°,ó 0;».

I 1,) Place anCllyzer SAMPLEIBYPASS valve(s) in SAMPLE mode, see (a) 001011I. 2,) Allow Ihe reading to stabilize, normally 2-10 minutes unle~ e:<posed lo air. 3,) Once stable - initiate ü\llBRATlON routíne (or unlock and adjust SPAN knob)

fmm MAIN t-1Er-oAJ, select SPAN CALIBRAlE, enter SPAN 'tALUE, press ENTIR.

1.)ConT sr-3~ 99S .....,' por~1e analyzer o::alnráteo wlm alTblent ar,

~ ?) Rep",..t at \;!,3$t t"":"'. 3.) R'"P13C~ :¡en.O<" ",d rep; 3t o:-.:e.

No 4,) 1f LJIlsu=fu! wlt'l n~ senS()',

Ves STa:> znd o)ntact fa::tor.¡

Note: SPAN CALIBRATION ls complete and for TROUBLESHOOTING purposes demollstrates!he sensorjanaly2el' responds norrnally - !.ill.Qer contr..QJ.l.!:.d. . m!ltions.

For TROUBLESHOOT1NG purposes only: Connect one of Ule dnalyzer;s sigrldl oulputs lo llIl external rec.ordilg devlc:e and conlnue Ihe fIow of span gas for 1-2 holl's.

1.) ~iéce ~nsor ",">d rep",« once.

~ L.) Jfum~;ful """m rr:w sensor, No STCP 31">d rontact foctory

Ves

1.) Place analyzer SAMPLE/BVPASS valve(s) In BVP¡\SS mode, see (a) 001011I, 2.) Conoect Gas lile - as aboye for sanlP1e gas. 3,) Place analyzer SAMPLE!BVPASS valve(s) in SAMPlE mode, see (a) below.

T

SHJT OFf Vf,LVE - o;;en fi'st, cbse la,!

Conned GdS Lile

CaUbratiOl1 Procedure

Troubleshooting

Saflllling

: Rev 7f06 Pa'.;¡e 10' L

Adllanced In,strum,ents Inc.

Purpose: AlR CAUBRATlON of digital (reference to analog) ppm 0 1 analyzer (only use for 0-25% range): ao) when ínstalling a ne...... sensor, b.) when span gas (ínstTument air piped to sensor - address as SPAN CALlBRAnO ') is not available or c.) when it is advanrageous from a troubleshooting standpoint to employ a portabie analyzer tIlat has been calibrated with

ambient air as a "referee" te conflrm other analyzers or span gas ... alues.

Note 1: The drawback te alr calibrabon is tne time required lor a ppm sensor exposed te air (1-2 minutes for calibration purposes) to recover te me O-la ppm range and the added requirement for low ppm 0 1 concentration gas (sample. zero, purge or span) to purge me sensor 01 me oxygen that dissolves ínto the sensor's eleetro!yte when exposed te air (20.9% or 209,000 ppm o, )

Note 2: Expected recovery time ro 10 ppm on 1-2 ppm purge gas is < 1 hr at installatiOl1 aOO < 20 minutes for an analyzer that has been in-se!Vice > 2 weeks. For higher pl?m analvsis, expected recovery time to SO-lOO ppm on 1-2 ppm purge gas is < 10 minutes.

Prdminary 1,) Conf.rm ~I ""mple .ystem eomponents - no plastic_

Set-up 1.) 5elect AUTO-RANGING mode 01 MAlIUAlLY y.lect 0-25% range for alr ~lIb atíco 2.) Perform DEFAULT lERO or MANUAlLY e~minate prevlous lero adjustments flote: leroin; the anal\,%er Is only re:ommended fOI continuous analySls < 1 ppm whleh normally excludes portlltlie

analyzers - due to !he constant changing 01 gas lines. 3.) Perfolm DEFAULT SPAN 4,) InstaU only: Place analyzer SAM?LE/BYPASS valve(s) In SAMPLE mode, see <al 139, 1 S.) In!itllll only: Connect the c¡¡as líne 01 11 ec¡uippe:l with a 3·way SAMPlE/S?AJI v.,1ve pl.ce it In the SAMPLE mode. 1;,) Start the IOVII ppm O, gas (sample, 'ero,. purge Of spanl fiowing at 2'SCf"H to purge the

line 01 a¡r and atbl'r alr ealibration to purge the senSQ1 a.nd expedite reeovery t<:l ppm levels.

To aeeess tI>e senso! fOI repla:ement 01 air calibrallon:Accessing Sensor 1.) Locate !he SS sensor houslng ¡n.ide the analyzer. 2..) Using a 5/16" wrench, lcosen the bolt in the eentel 01 !he ¡,,,ttom secuon. 3,) Rotate the upper s""tion 01 the sensor housing 90° 4.) PUI1-up genlly to ~parate the sensor houslng (00 NOT lose or dry off the o""ng).

1.) Short sensor acros. pes fOil. t,e,,,porarily CalibratlOn Procedure 2.} CJ.an :ontact plns (damp la;)

3.) Perfonn eontinuíty test - cente< pln to ves black wire, outer pin to red wir.

1.1) Repl.cement: a,) Ren'lO'\'e 'o!d sensor' and dispose of - local regs fOI batteries. b,) Remove 'new ~n~r' from N, purged shlpplng package c.) Remove led shortíng tabs from the pcs lolls

1.2) ln-service .Ir :ali¡'C3tion - if necessary, remove shOfting devke alter e.ontl.nuity test.

Ves 3.) A1low the reading to stablllle, normally 2·10 minutes unless expo~d to air pre'\liously, 4,) Once stable "' initiate U.UBRATION routíne (or unlock and adjust SPAN knob) from

MAlN MENU, setect SPAN CAUBRATE, enter SPAN VALUE, plesS ENTER.

2,) lnsert PeS end 01 sensor lnto upper sectlon maklng contad wlth pins and hold it steady.

1,) Repeat w,th current sensor, 2.) Replaee sensor and repeal. 3.) 1I unsuccessful with new

sensor, STOP and eontaet fadory,

1.) Place the sensor in th. bottom sectlon and reassemble the sensor housing, 2.) lñe low ppm O, gas <above) should alrea"r be flowing at 2 SCFH to purge the to purge

the sensor and expedíte 'ecovery to 10 ppm rlnge - oontinue for 60·90 minutes.

1.) Pelform LEAl( TEST, see pq. 1 l,) If sueeessful, continue plirgc 1 hr. 3.) 11 unsu((essful afuo!r additional

.=:>----.....·1 purge, replaee ~e:lSOr and r.peat. No 4.) 11 unsuccessflJl with new

senSOr, !>íOP and con:act lactory.

1.) Place analyzer 5ANPLE!BYPASS va!ve(s) In 6YPA5S mode, see (a) 139.1 2,) Connect Gas Une· see 139. 1 - for sample gas as neees••ry 3.) Place anal\,%er SAMPlEjBYPAS5 .... l\Ie($) In SAMPLE mode, see (al pg. 1

Rev 7}06 Page l 01 2

34

Advanced Instr.uflJents Inc.

9 WarralQ The design and manufacture of GPR Series oxygen analyzers, monitors 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 maintaíned in accordance with the Owner's Manual, the units will províde many years of reliable service.

Coverage Under normal operating conditions, the monitor, analyzers and sensor are warranted to be free of defects in materials and workmanship far the periad specified in accordance with the most recent published specifications, said period begins with the date of shipment by the manufacturero The manufacturer ¡nformation and serial number of this analyzer are located on the rear of the analyzer. Advanced Instruments Ine. reserves the right in its sole discretion to invalídate this warranty if the serial number does not appear on the analyzer.

If your Advanced Instruments lne. monitor, 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 replaee your Advaneed lnstruments lnc. analyzer, we may replace it with a new or reeonditioned one of the same or upgraded designo This warranty applies to all monítors, 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 c1aim for a given serial number and/or the aboye warranty periodo Under no circumstances will the warranty extend to more than one customer or beyond the warranty periodo

Limitations Advanced lnstruments Ine. will not pay for: loss of time; inconvenienee; loss of use of your Advanced Instruments lne. analyzer or property damage eaused by your Advaneed Instruments lne. analyzer or its failure to work; any speeial, incidental or consequential damages; or any damage resulting from alterations, misuse or abuse; lack of proper maintenance; unauthorized repair or modifieation of the analyzer; affixing of any attachment not provided with the analyzer or other failure to follow the Owner's Manual. Some states and provinees do not allow Iimitations 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 attaehment not provided with the analyzer; fire, flood, or acts of God; or other failure to follow the Owner's Manual.

Service Call Advanced lnstruments lne. at 909-392-6900 (or e-mail info@aii1.eom) between 7:30 AM and 5:00 PM Paeific Time Monday thru Thursday or 8:00 AM to 12:00 pm on Friday. Trained technieians 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:

Advanced Instruments lne. 2855 Metropolitan Plaee Pomona, Ca 91767 USA

Be sure to pack the analyzer seeurely. lnclude your name, address, telephone number, and a description of the operating problem. After repairing or, at our option, replacing your Advaneed lnstruments lne. analyzer, we will ship it to you at no cost for parts and labor.

35

Adllanced Instruments Ine.

liD MSOS - Material SalelV Data Sheet Product Identificatíon Product Name

Synonyms

Manufacturer

Emergency Phone Number

Preparation / Revision Date

Notes

Specific Generíc Ingredients Cardnogens at levels > 0.1%

Others at levels > 1.0%

CAS Number

Chemical (Synonym) and Family

General,Requirements Use

Handling

Storage

Physical Properties Boíling Point Range

Melting Point Range

Freezing Point

Molecular Weight

Spedfic Gravity

Vapor Pressure

Vapor Density

pH

Solubility in H20

% Volatiles by Volume

Evaporation Rate

Appearance and Odor

Fir;e and Explosion Data Flash and Fire Poínts

Flammable Umíts

Extinguishing Method

Spedal Fire Fighting Procedures

Unusual Fire and Explosion Hazards

IReactivity IOilta

Stabilíty

Conditions Contributing to Instability

Incompatibility

Hazardous Decomposition Products

Conditions to Avoid

Oxygen sensor Series - PSR, GPR, AH, XLT

Electrochemical sensor, Galvaníc Fuel (el!

Advanced Instruments Inc., 2855 Metropolitan Place, Pomona, o.. 91757 USA

909-392-6900

January 1, 1995

Oxygen sensors are sealed, contaln protective coverings and in normal conditions do not present a health hazard. Information applíes to electrolyte unless otherwíse noted.

None

Potassium Hydroxide or Acetic Acid, lead

Potassium Hydroxíde = KOH 1310-58-3 or Acetic Acid =64-19-7, lead = Pb 7439-92-1

Potassium Hydroxide (KOH) - Base or Acetic Aád (CHJC02H) - Acid, lead (Pb) - Metal

Potassium Hydroxide or Acetic Acid - electrolyte, lead - anode

Rubber or latex gloves, safety glasses

Indefinitely

KOH = 100 to 11S0 e or Acetic Acid = 100 to 1170 C

KOH -10 to 00 e or Acetic Add - NA, lead 3270 e KOH = -40 to -100 C or Acetic Acid = -40 to -100 C

KOH = 56 or Acetic Acid - NA, lead =207

KOH = 1.09 @ 20' C, Acetic Add =1.05 @ 20' (

KOH = NA or Acetic Acid = 11.4 @ 20" C

KOH - NA or Acetic Add =2.07

KOH > 14 or Acetic Acid = 2-3

Complete

None

Similar to water

Aqueous solutions: KOH = Colorless, odorless or Acetic Acid = Colorless, vinegar-like odor

Not applicable

Not flammable

Not applicable

Not applicable

Not applicable

Stable

None

KOH = Avoid contact with strong adds or Acetic Acid = Avoíd contact with strong bases

KOH = None or Acetic Acid = Emits toxic fumes when heated

KOH = None or Acetic Add = Heat

36

Advanced 'nstruments Ine.

Spill or Leak Steps jf material is released

Disposal

Health Hazafid Information Primary Route(s) of Entry

Exposure Umits

Ingestion

Eye

Skin

Inhalation

Symptoms

Medical Conditions Aggravated

cardnogenic Reference Data

Other

Special Proteetion Information Ventilation Requirements

Eye

Hand

Respirator Type

Other Special Protection

Special Precautions Precautions

Transportation

Sensor is packaged in a sealed plastic bag, check the sensor inside for eledrolyte leakage. If the sensor leales inside the plastic bag or inside an analyzer sensor housing do not remove it without rubber or latex gloves and safety glasses and a source of water. Flush or wipe all surfaces repeatedly with water or wet paper towel (ftesh each time).

In accordance with federal, state and local regulations.

Ingestion, eye and skin contact

Potassium Hydroxide - ACGIH TLV 2 mg/cubic meter or Acetic Acid - ACGIH TLV / OSHA PEL 10 ppm (TWA), lead - OSHA PEL .OS mg/cubic meter

Electrolyte could be harmful or fatal if swallowed. KOH = Oral LOSO (RAT) = 2433 mg/kg or Acetic Acid = Oral LOSO (RAT) = 6620 mg/kg

Electrolyte is corrosive and eye contact could result in permanent 1055 of visiono

Electrolyte is corrosive and skin contact could result in a chemical bum.

Liquid inhalaríon is unlikely.

Eye contact - burning sensation. Skin. contact - soapy s1ick feeling.

None

KOH and Acetic Acid = NTP Annual Report on cardnogens - not listed; LARC Monographs - not listed; OSHA - not listed

Lead is listed as a chemical known to the State of california to cause birth defects or other reproductive harm.

None

Safety glasses

Rubber or latex gloves

Not applicable

None

Do not remove the sensor's protective Teflon and PeS coverings. Do not probe the sensor with sharp objects. Wash hands thoroughly after handling. Avoid contact with eyes, skin and clothing. Empty sensor body may contain hazardous residue.

Not applicable

37

Ad'llanced Instrum'ent!!i 'ne.

Ap,peodix A Electrical connections require an approved explosion proof sealing fitting and packing around wires and cables (for incoming power for the analyzer electronics, power failure alarm relays, set point alarm relays and 4-20mA signal output) coming into and out of the explosion proaf enciosure that houses the interconnection PeS. Further full compJiance with hazardous area electrical code requires the wires and cables to be protected by conduit. Advanced Instruments recognizes that safety is an important factor and offers for the convenience of our customers an approved sealing fitting and packing material as options.

ExPlosion Pr••1Packina Filler (non-asbestos) For use as packing at the hub of sealing fittings. Note: These instructions are supplied from information and data which we believe is reliable and is given in good faith. 5ince OUr methods of application and conditions under which our products are put to use are beyond our control, we are not able to guarantee the application and/or use of same. The user assumes all risks and liability in connection with the application and use of our products.

Oirections: Tamp packing fiber between and around conductors where they enter fitting to prevent leakage of the liquid cement. Leave enough space in the fitting for length equivalent to the inside diameter of the conduit but, not less then 5/8".

Caution: ., Avoid getting in eyes or breathing dust. ., Use barrier cream, gloves and long sleeve shirts if dust or fiber is irritating . ., Prolonged contact may cause lung, eye or skin irritation.

ExPlosion Prool Sealina Cemem Directions: Tamp packing fiber between and around conductors where they enter the sealing fitting to prevent leakage of liquid cemento Make sure conductors are not in contact with each other or with fitting wall. Leave space in the fitting for a sealing length equivalent to the trade size of the conduct seal but not less than 5/8". FiIl marked shipping container with c1ean cold water to the "water line" (35 mi to be precise). Caution: Do not exceed the required amount of water. Gradually pour cement from the plastic bag into the water and stir thoroughly for proper mixture. FiII fitting completely within five (5) minutes after mixing, then tamp with blunt stick to expel any air bubbles. C10se up any opening in the fitting to insure integrity of the seal. Fittings requiring more than 10 oZ. of cement must be filled from a single mixture of cement and water. DO NOT POUR IN STAGES. Allow cement at least 72 hours to cure.

Warning: At least flVe threads must engage on all filll plugs.

Caution: Water-mix sealing compound should not be poured or installed at temperattlre below 40F (4e). Maintain temperature at or aboye 40F for at least 72 hours after pouring. esA certífied when used with any eSA certified sealing fitting. Adaco No. 1 sealing cement must be used as a part of any Adalet UL listed fitting.

Notice: This instruction is supplied from information and data which we believe is reliable and is given in good faith. 5ince the methods of application and conditions under which our products are put to use are beyond our control, we are not able to guarantee the application and/or use of same. The user assumes all risks and Iiability in connection with the application and use of our products.

Caution: Prolonged breathing or ingestion may cause internal obstruction, seek medical careo

., Do not get into eyes or on skin - flush for 15 minutes. ~ Large amounts on skin when hardening may burn . ., Use adequate ventilation. To reorder: 5pecify P/N ENCL-1071-KIT

38

Adllaneed Instrumenm loe.

AppendixB, ¡Correlatino Readings -leO Displav and 4-20mA or 0-1V Signal OutPUIS,

In rare instances the signal output may not agree to the reading displayed by the Leo. The OUTPUT ZERO and OUTPUT SPAN features enable the user to adjust the signal output to correlate with the LCD reading.

For optimum accuracy make two separate adjustments as follows: 1. OUTPUT ZERO feature: To adjust the 4mA or OV signal output and reqUires zero gas. 2. OUTPUT SPAN feature: To adjust the 20mA or 1V signal output and requires span gas near full range.

Note: In the field or in the absence of the preferred gases, use the OUTPUT SPAN feature and adjust the 20mA or 1V signal output using the span gas available.

Guideline: If the actual signal output value < the theoretical LCD value, the adjustment value will be < 100%. 1f the actual signal output value > the theoretical LCO value, the adjustment value will be > 100%.

Procedure = regardless of type of adjustment ­ with examples: Signal Output

4-20mA O~lY

1) The OlJTPlJT lERO and OlJTPlJT SPAN default values ... 100.0% 100.0%

2) Adjust the ~actual sign,,1 output" ..• 24mA 1.2V

to the ntheoretiCillI signal output H basedl on the "span gas value" of .•. 84 ppm span gas 84% span gas

3) "nd the "actu;lllCO reading" ... 60 ppm 80%

a) "actual LCD reading" divided by the "span gas value" 60/84 =.71 80/84 = .95

b) 16mA (20mA less 4mA) multiplied by \he result in 3a) .71 x 16 = 11.36 NA

e) 4mA plus the result of 3b) = "theoretieal signal outputH 4 + 11.36;; 15.36mA ,95V (from a)

4) "Adjustment Va'lue" '" ("theoretical H divided by "actual signal output ") x 100 (15.36/24) x 100 ;; 64 (.95/ 1.2) x 100 ;; 79

5) Proof = ("actual signal output" multiplied by "adjustment value") divided by 100 (24 x 64) / 100;; 15.36mA (1.2 x 79) / 100 = .95V

6) ENTER "adjustment valueH via OlJTPUT lERO or OlJTPlJT SPAN routines below. 64 79

7) Fine tuning ... after ehecking the new"actual signal outputH at the PLC 19.5mA .98V

8) Repeat Step #4 and substitute the latest "actual signal outputH (15.36/19.5) x 100 =78.8 (.95/ .98) x 100;; 96.9

9) Proof;; ("actual signal outputH multiplied by "adjustment valueH ) divided by 100 (19.5 x 78.8) 1100 = 15.36 (.98 x 96.9) 1100 =95

10) ENTER "adjustment valueH via OUTPlJT lERO or OlJTPUT SPAN routines below. 75 95

39

Adllanced Instrument§ Inc.

OutputZero Procedure: 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARROW keys to highlíght CAllBRAnON. 3. Press the ENTER key to select the highlíghted menu option. 4. The following displays appear:

MAIN MENU

AUTO SAMPLI; MANUAL SAMPLE (íf.~'i:hti.h)tl »> CONFlG ALARMS BYPASS ALA.RMs

CALIBRADON

SPAN CALIBRATE ZERO CALIBRATE DEFAULli SPAN DEFAUlT ZERO OUTPUTSPAN [.11 •• Al) f~ª;J,',

5. Advance the reverse shade cursor using the ARRDW keys to highlight DUTPUT ZERD. 6. Press the ENTER key to select the highlighted menu option. . 7. The following display appears:

~----- .. I '

: 100.0 t I - 1

""------, OUTPU'f ZERO OFFSET

PRI;SS 'UP- OR DOWN TO CHANGE VALUE ENTER TO SAV:E MENU TO RE1\JRN

8. Enter the OUTPUT ZERD adjustment value as follows ... 9. Selecting digits of the adjustment value to change - Press the ENTER key to advance the underline cursor right or press

the MENU key to advance the underline cursor left to reach to the desired digit. 10. Changing the digits of the adjustment value ... Press the UP/DDWN ARRDW keys to change a digít of the adjustment

value. 11. Repeat steps 9 and 10 until the complete zero value has been entered and the following display appears.

OUTPUl" ZERO OFFSET

PRE$ UP OR DOWN TO CHANGE VALUE I;NTER TO SAVE MENU TO RE1\JRN

12. Save the adjusbnent value by pressing the ENTER &<ey or abort by pressing the MENU key. 13. The system returns to the SAMPllNG mode. 14. Note: After the initial adjustment is made, check the actual signal output at the PLC and if necessary calculate a further

fine tuning adjustment value as illustrated above. 15. Enter subsequent fine tuning adjustments as described above,

Output Span Procedure: 1. Access the MAIN MENU by pressing the MENU key. 2. Advance the reverse shade cursor using the ARRDW keys to highlight CAllBRATlON. 3. Press the ENTER key to select the highlíghted menu option. 4. The following displays appear:

40

Adllanced Instruments Inc.

MAIN MENU

AUTO SAMPLE MANUAL SAMPLEt!J 11 :!;,., ,t.):1 CONFIG ALARMS· BYPASS ALARMS

»>

CAUBRATlON

SPA'N CAUBRATE ZERO CALIBRATE DEFAULT SPAN DEFAULTZEROr:m ,Ji) ..14·':1 OUTPUTZERO

5. Advance the reverse shade cursor using the ARROW keys to highlight OUTPUT 5PAN. 6. Press the ENTER key to select the highlighted menu option. 7, The following display appears:

, 100.0: ,-----­OUTPUT SPAN OFfSET

PRESS UP OR DOWN TO CHANGE VALUE ENTER TO SAVE MENU TO REnJRN

8. Enter the adjustment value as follows ... 9. Selecting digits of the adjustment value to change - Press the ENTER key to advance the underline cursor right or press

the MENU key to advance the underline cursor left to reach to the desired dígito 10. Changing the digits of the adjustment value ... Press the UP/DOWN ARROW keys to change a digit of the adjustment

value. 11. Repeat steps 9 and 10 until the complete span value has been entered and the following display appears.

06~.O

OUliPUli SPAN OF,FSET

PRESS UP OR DOWN TO CHANGE VALUE EN:rER TO SAVE MENU TO RE1lJRN

12. saye the adjustment value by pressing the E:NTER key or abort by pressing the MENUI key. 13. The system returns to the SAMPUNG mode. 14. Note: After the initial adjustment is made, check the actual sígnal output at the PLC and if necessary calculate a further

fine tuning adjustment value as iIIustrated above. 15. Enter subsequent fine tuning adjustments as described above.

07~.O

'OUTPUT SPÁN OFFSET

PRESS UP OR DOWN TO CHANGE VALUE ENTER To SAVE MENU TD RETURN

16. saye the adjustment value by pressing the ENTER key or abort by pre$Sing the MEi'iU Ikev. 17. The system returns to the SAMPUNG mode.

41

Adllanced InstrunJents Ine.

AppendiK F H2S.Scrubbers &Sample Systems

Advaneed lnstruments lne. offers a complete line of efficient hydrogen sulfide (HzS) scrubbers !md sample coooltioning systems for:

»Prepllring a gas strellm conUlining HzS fer oxygen analysis »Zero gas generation for HzS tr"zlnsmitters

The scrubber medill selectively removes HzS and other oxidizing gases from the gas stream that can interiere with the oxygen measurement. As an iOOication the scrubber is nearing the end of its useful l¡fe the media changes color from purple te orange te bro",,'O to white as it tS consumed.

The information included herein is based on data sheets published by the manufacturer of the scrubbng media as follow: the media not only adsorbs gases but 1IIso chemically transforms them into harmless end products that remain trapped in the media. Unlike adsorption, chemisorption is an jnstanteous anó irreversible process that perrnanently removes unwanted gases from the environment. The polZlssium permanganllte (KMn04), the purple eolored media inside the scrubber, tums into mangllnese oxide aOO elemental sulfur salt which are stllble non-Ieachable solids.

Scrubbers ane available in refillable: )- 1.0" x 6" (P/N B-2734-6) plexi-glass container with SS connections )- 1.5" x 12" (P/N B-2734) plexi-glass conUliner with SS connections )- 2.0" x 24" (P/N A-2839) stllinless steel container with SS connections )- 2.5" x 6" (P/N 8-3247) plexi-glass container with SS connections )- 2.5" x 24" (P/N B-3247-24) plexi-glass container with SS eonnections

They can be installed in-line or as plIrt of a complete serubber sal11'le coOOitioning system. More elaborate custom designed scrubber sllmple conditioning systems can inelude dual scrubbers aOO vlIlve system that can eliminlltc downtime. Opel"lltors símply switch the gas flow to the fresh scrubber whíle servicing Ihe other one.

Speclflca tions: lnlet connections: 1/4" SS tube fitting (refill port) Outlet connections: 1/4" SS tube fitting Pressure rating: 30 psig maximum Temperlltu re: ·200c te 450C (-40F te llJOF) Application conditions: Free of moisture (ITllIY require cOlllescing filter) Materials of construction: clear acrylic lInd/or stainless steel Scrubber life: V!lries with flow rate, media volume, H2S concentration

iDlmenslons H2S Flow Service partNo. Concentratlon Bate Ufe·Oays

1.5- x 12'" 1.0% (10,000 ppm) 1{3 SCFH (150 sccm) 3.6 (P/N 8-2734) 0.1% ( 1,000 ppm) same 36.8

0.01% ( 100 ppm) same 368.2

2.S·x 6· 1.0% (10,CXXl ppm) 1/3 SCFH (150 sccm) 6.0 (P/N B-3247) 0.1% ( 1,000 ppm) same 59.6

0.01% ( 100 ppm) same 596.4

42

8-2734-6 8-2734 8-3247

1x6" 1.5x12" 2.Sx6"

8-3251 H2S Scrubber Sy5tem

GPR-1500 AlS wIth 8-3247 H2S Scrubber

A-3393 H2S Scrubber System

Advanced InstrulDentli Inc~

@@0@

SPAN GAS IN

o '7

H2S Sample SJstem

A-3393 STANDARD CONFlGURATION

• B-33S9 S4M'I.f P,<;ld IN:n 9-OM'>I) 1 A..TR·1OO2·_ F1LTB<CO\I3aI<G 2. Al~'IOO . AlIJE SS:;W AYSA"FUf.1l>~

3 FMlJ'•. ] 7'1 FlO'''I'I~ ¡r-.'TEl3W. VALIJE 4 !lo~"7·1 SOl.UlélS\ M2S C1.EAA 'O.YeIlll8 2 5" O S. 6--3330-A·18 SEN~ -uJ5IN3 ~SSEMll SS • FI1N-IOlt> BlL~LN1CN 1I0'TO lj,!"

s.o.M'U:, Sf"'~, VB' CCN-éCTlO'IS

A-3393-2 COHTIlIIUOUS ORAlN OPTlON:

.00 {) VA:..Y·100'1 V VE SS 2·WAY l-EI'Bl. .13 R5'l.Al:f 7 RoT1H024 Fll'l15t CQ'\LfSCJ!'fj, I D'W /O) VAl. ·1633 VAlVE "'""me 2....1~1C~" I

A-3393-4 PR.fSSURE REGlAATOR .. GAUGE OPTlON:

R.5'lXE IH3S8 SA"Ili "Ala (R6'l.ACES 1>-3:3':<9) N:J) 9 RE(;. J 1.3 ;'-'-fS:U'.f Rro..LATO'l. SS N:J) 1O.11EG-10CJ? ~

A-3J93~ PRESSURE RfGlAATOR .. GAUGE WITH CONTINUOUS ORAlN OPTlON:

CONTINUOUS ORAlN SET-tJP:

A. OPENYAl~

B. QOSE YALYE

C. $El REGU.ATOR., 20· 30 PS IG D. el'L"N 'iAlVE 10 3 SCfH ON FlOW Io'ETER

E. CPEN VAl\1ó TO 1.5 SCfH ON FlOW 1-ETm. F. SETVAlYEONFlOWt-t:lffi TOlSCFH

FOR Sl'AN GoIS, AF1ER Sl'AN, OPEN YAl\ € FOR SAM'l

®

FlOW 1.5 SCFH

A-3393-1 NO H2S SCRUBSER OPTION:

A,-3393-3 NO H2S SCRUBSER WlTH CONTlNUOUS ORAlN OPTION:

CO"eIN" C\?TIO ,- 1 2

A-3393-5 NO H2S SCRU98ER WITH PRfSSURf UGlLATOR • GAUGE OPTION:

A,-3393-7 NO H2S SCRUB8fR WITH PRESSURE REGUlATOR .. GIWGE WITH CONTINUOUS DRAlN OPlION:

Advllnced Instruments Inc. ~:JI..I.""'fI4lSN"Il'<JI."V""QiTAC'~P6'''''~:i:'~oCi'CCO''''44~,,11"O(H" T}Ot'tJ7 1$ 10K~00t<ED0I:~J/II"'·~"'4",€f ~JooOYJ' W~~.t'O"~

r~-Ata:SLt&.~O'tlo<n'Wl5I.~ ,ID "K:.11:;" ~Vó.oll·,r.«.l~~ ·.AI.;,oAAA;..m

C;.A,:,¡¡~SCAlJ:~our'!T'..e.L.Cs"~l€.~.~~t:.lYLA:'IoQ.----I '~'9..1AtrTO'If*Oo __~O<Y.I-lpTlON.......m'-JL...If-"'"'-- ~

GPR-1500 AIS/IS SAMPLE SYSTEM A-3393

J: u.. U Vl lI) ....

VENT

43

Adllaoeed lostrumeots loe.

Material Safety Dala Sheet U.S. Department of Labor May be used lo comply with Occupallonal Salely ana Heallh AdmmlslrallOn OS¡-Ws Hazard Communicalion Standard. (Non-Mandatory Form)

. CFR 1910.1200. Sl'andard mus! be orm Approved Isufted lar sPEf<:lf,e r uirements OBM No. 1218-0D72

ENTln' (As ¡¡sed on Laoel and List) Note B!anl<. spa""s am no! pe,mirtod // any Wltm /S not appkcatJle. or neUNISORB t1ARK 2 ¡nform.oon is .~bIiI. ,.". ce musi blI t1JlIrkfKJO ro indicare In.'

Section I ManufacltJrer'.. Nome Eme<gency Telephonc Number

7 3) 943-3753UNISORB CORPORATIQ

1elephone Number for InJOTrrnJ'IOnAddreu (N:Jmbe;. S'ma: CíIy. SI.'e. Bnd Z/P Codto) (7 3) 9~3-3753

13 O GENOA STRE5:':' J."-:'1UARY 7, 2002

Sigoalure or Prepare< (OpI/onal)SOUTH HOUSTON, T>: 77'.J87

Section 11 - Hazardous Ingredients/ldentity Information HazQfdou~ Com¡:>:X":en1s (Spe:¡f,c Chemi<:a lden!;t.,.: Common Name{s)) ACGIH TLV

lSmg/m 10mq/m'Alumi um OHide: Activatcd Alumina NO:'le(Th'll.) (T\'IJ\.)

~m9/m· ~mg/m' Pota~$ium permanganate: Potass·w. Salt Non€:('1%'\ or Mn) (T\'IA r

uminum Oxide: CAS - 1344-2B-l

Potassium Permanganate: ~ - 7722-64-7

Section 11I - Physical/Chemical Characteristics Boillng Point

NI.:" Spc.·dfic Gmvftv

3.2

Va¡xJl' Pressure (mm Hg ) ¡,lA

MeltIn9Poln1 2050·

Vapor Density (Air o ')

NI.'" EVJporallon Rala

NIA

Solubilily III Water

ln501uble Appeamnce and OdOl

Purple Spheres, No Oaor

section IV - Fire and Explosion Hazard Data Flash PoiI\! (M"lhoO U~ flarnma.bll! LJ UEl

No.eNot FlaJTOllable N/A Exmg . hill9 Media

Foam, Carbon Dioxide, O' 1',. hemical eclal File Flghllng ProcedUl!!S

Use RespildtOPj Protection Unus.ua! Fll'e en:! ExpIosIon Haza;ds

None

44

VenULallOn Local Exl>aust RecollUllE'nded if ~usling is exc~ssive Kcne

OlhPr

None

Adllanced Instrumen'ts loe.

J !SORB MARI< 2

reduc~n9 aqents and easi1y oy~di~ed materials,

Haxardou!! Polymcriza\lOn

MayOceur Cond!llons lo AIIOld None

W,Il Nol Oeeu'

X Section VI • Heatth Hazard Data ROUie(s) 01 Enlty ? Skln? Ingestion?

'es 'fes Yes Hea':h Hazard$ (ACtll and Cnrome)

CHRO!\. : Carcinog<mtclty: NTP? AlU1lÚ.num Ox e: t o 1 Potassiurn Pe~n9anate:

Sqts and S~om5 01 Expowre Brown disco oration oE th

tissue.

hazards. OStiA Regulated

OSHA.

MedalCond s ~"eraIIyAgg:;ov¡1tedbyE"I'CJSUle !~rit:ation o: open wounds or b rns.

EmergencyandF.-stAldProcedureo; ;:;YE: F:ush ith larga amounts oi water ior al: mi;]. Seek medical hel? immediate_y. j,GEST ON: Give larga quantities of water. Seek medical "~lp imm<:diately. 1 :!.l'.LATIO.": Remove to fresh airo Seek medical help iJm1edi tely.

~I : Wash ~it;J ? enty o: water. Seek m dieal tention t irritation pers¡sts.

Section VII - Precautions for Safe Handling and Use Steps \0 Be Taken 11 case MlJteriallS Released or sp¡1Je<l Sweep or shovel material and discard in protected refuse con ainer. '1'0 clean floors, flush with water 'nto sewcr if oCrnUtted by Feder , State, and loe requlations. Wasle O,sposaI Method

ew ma~~ ial may b~ di posed of in tandflll. Jsed mdteri~l that has been exposed to Loxía chemicals should be examinec and disposed or i aeco_dance with all cegulat·ons. p~ lo Be Teken 11 Handling and SIO(,ng Ha~dle J ae_orcance ~ith control measures be1ow. 5tore in sealed contain es i~ a co01, dcy locaLio.. Oll>er PceocaUlions

Non_

Section VIII - Control Measures R~tOI"t Prclection (specdy rype) Use NIOSH aporoved rcsoirato~y orotectioa if ex~osure l~~s are exceedec.

PIOlldi,,,, GJove!, IEy* Prol*<:tlC>n Rubber gloves _~cowmende -aee shj~ld or 90991es

O:l\er Prote<:tlve Clothmg or Equ¡pmert Normal wo:k clothinq ccvec.nq ~nms and legs shculd b wc:n.

Wotk Hyglene Practlces Remove conta, nated e oth_ng a.c wash before re se. Wash with soap nd wal oC befare

3t1n9, drinking, or using to~ t iae it~es. afe y shower, eye ath and ~ashlng

acilities shou d be avall~ e.

45

Advanced Instruments Ine.

Appendix G Ilimenance - H2S Scrullller 5ervicing any of the H25 scrubbers will depend on severaI factors as iIIustrated in Appendix F and inelude: the (average) H25 coneentration (average), volume of scrubber media and flow rate through the scrubber (often times maximizing the service Iife means longer system response time) see Appendix F.

Required equipment: 1. 2x 7/16" open end wrenches 2. lx 9/16" open end wrench 3. 1x 1" open end or adjustable wrench

Procedure: 1. Separate the top connection to the serubber using a 7/16" and the 9/16" open end wrenches on the two top nuts. 2. Hold the second nut with the 9/16" open end wrench. • 3. With one of the 7/16" open end wrenches tum the top nut counter c10ckwise until the fitting disengages. 4. 5eparate the bottom connection to the scrubber using both 7/16" open end wrenches. 5. Hold the nut at the bottom of the scrubber with a 7/16" open end wrench. 6. With the other 7/16" open end wrench turn the nut below counter c10ckwise until the fitting disengages. 7. Carefully, do not loose the ferrules inside the fitting, remove the stainless tubing from the top and bottom of the scrubber. 8. Carefully pull the scrubber from its mounting clip which is attaehed to the back panel. 9. Once the scrubber is free, hold the scrubber with one hand and using the 1" open end or adjustable wrench with the other

hand, turn the 1" nut counter c10ckwise and remove the 1" nut at the top of the scrubber. 10. There is no need to remove the 7/16" fitting at the bottom of the scrubber. 11. With the 1" nut removed, empty the spent media through the opening. 12. FiII the scrubber with fresh media (should be rich purple in color). 13. Reverse the aboye steps to re-assemble and install the scrubber.

MainteRance - Coalesc.ng Filter Servicing the coalescing filter (P/N FLTR-1002-2) depends on the c1eanliness and moisture content of the sample and maintenance intervals.

Required equipment: 1. Channel locks 2. Damp rag 3. Lubricant (a thin coat applied to the o-ring after eleaning helps ensure a tight seal and extend o-ring Iife)

Procedure: 1. Unscrew the c1ear polycarbonate bowl by turning it counter c1oekwise. 2. Note: It is probably stuck tight - use the damp rag to grip if removing by hand or to prevent damage to the bowl jf using

the channellocks. 3. The bowl seals to the head section with an o-ring, do not lose the o-ringo 4. The filter element screws into the head section, carefully turn it counter clockwise and remove. 5. Using the damp c1oth, c1ean the inside of the bowl and the o-ring before reassembling - apply a very thin coat of lubricant

to the o-ringo 6. Reverse the aboye steps to re-assemble the filter.

46

Technical Specifications

Accuracy:

Analysis:

Application:

Approvals:

Area ClaSSification:

Alarms:

calibration:

Compensation:

Connections:

Controls:

Display:

Endosures:

Flow Sensitivity:

Linearity:

Pressure:

Power:

Recovery Time:

Response Time:

Sample System:

Sensitivity:

Sensor Model:

Sensor Life:

Signal Output:

Temp. Range:

Warranty:

Wetted Parts:

< 1% of F5 range under constant conditions

0-10 ppm, 0-100, 0-1000 ppm, 0-1%, 0-25% FS ranges; auto­ranging or manually lock on single range

Oxygen analysis from 100 ppb to 1% in inert, hydrocarbon, helium, hydrogen, mixed and acid (COz) gas streams

CE, ATEX ¡ntrinsic Safety certification (pending) Zone 1

Meets recognized intrínsic safety standards fer use in Zone 1; Class 1, Division 1, Group A to D hazardous areas

Two user configurable alarms: magnetic coil relays rated 3A at lOOVAC, field programmable time delays, 2 ppm deadband, bypass for calíbration; sensor and system fail.

Certified gas of O2 balance Nz approximating SO% of range aboye analysis range recommended for optimum results.

Barometric pressure and temperature

1/4" compression tube fittings

Water resistant keypad; menu driven and field selectable range selection, calibration value and alarm functions

Graphical LCD 2.75x1.375"; resolutíon .01 ppm; displays real time ambient temperature and pressure

A1uminum ex-proof, fiberglass NEMA 4X, 16x9x6", 20 lbs

None between 0.5-5 SCFH, 2 SCFH recommended

> .995 over all ranges

Inlet - regulate to 5-30 psig; vent - atmospheric

12-2SVDC (suitable for solar powered systems); 100-240VAC

50 seconds in air to < 10 ppm in < 1 hour on N2 purge

90% of final F5 reading in 15 seconds

Flow meter; shown with optional A-3393 H25 Sample SY$lem 15x16" panel with coalescing filter, 3-way sample/span valve, H2S scrubber 240g of media, bypass valve aplional

< 0.5% af FS range

GPR-12-333 for inert gases, HC, He, H2 and mixed gases XlT-12-333 with > 0.5% COz present - no maintenance

24 months at 25°C and 1 atm; average Oz < 1,000 ppm

4-20mA or 1-SV

S° to 450 ( (GPR sensor), -20· to 4S·C (XLT sensor)

12 manths analyzer; 12 manths sensor

Staínless $leel

6PR-'500 AIS pplIJ Oxygen TranslIJltter

Intrinsically Sate Design ATEX Certification (pending) Zone 1 Class 1, Division 1, Groups A to O

Tailored tor Natural Gas Applications & Outdoor Battery Powered Installations

Advanced Sensor Technology Accuracy < 1% fS Range fast Recovery to < 10 ppm No Maintenance, 24 Month Lite Compatible in 0-100% COz

De or AC Power, Integral Barriers Field Selectable Alarms with Time Delay

4-20mA or 1-5V Signal Outputs l' 5 Standard Ranges Auto or Manual Ranging ISO 9001:2000 Approved QA System

Optional Equipment

Intrinsically safe integral heater for extended temperature range - 40·C/F

Expand Sample System to indude bypass valve, pressure regulator w/gauge and/or continuous liquid drain with regulating valves - consult factory.

2855 Metropalitan Place, Pomana, CA 91767 USA • Tel: 909-392-6900, Fax: 909-392-3665, www,aii1.com, e-mail: info@aii1.com Rev 6/07