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PI2114 H Analyzer Service Manual Picarro, Inc 3105 Patrick Henry Drive Santa Clara, CA 95054, USA Tel: 408.962.3944 www.picarro.com Document Number 40-0049 Rev C...
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PI2000 Series Gas Analyzers. Picarro, Inc. reserves the right to change or update the contents of this manual and to change the specifications of its products at any time without prior notification. Every effort has been made to keep the information in this document current and accurate as of the date of publication or revision.
1. User Safety Warning Symbols Used in This Manual The following icons are used throughout this manual to emphasize important information in the text. These icons indicate dangers to either the operator or to the analyzer, and other important information. Consult the user’s manual for important information (When you see this symbol placed at hazard points on equipment, consult the user manual).
WARNING appropriate laser safety glasses. General Safety Using this analyzer in a manner not specified by Picarro may result in damage to the analyzer, and render it unsafe to operate. WARNING Only authorized persons may open the analyzer cover or perform internal maintenance.
CDRH issued by the FDA and CE by the European Union. CDRH Certification The PI2114 Hydrogen Peroxide Analyzer complies with 21 CFR Chapter 1, sub-chapter J. The PI2114 Hydrogen Peroxide Analyzer classified as a Class 1 laser system when all panels and covers are on.
CE Certification The PI2114 Hydrogen Peroxide Analyzer complies with the European standards thus the instrument is affixed with a CE label. This CE label is located on the rear of the instrument. Label Locations The warning labels are located in the following positions.
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Figure 3: Warning labels Front inside the analyzer (top) The inside of the analyzer should not be accessed under normal operation. Only remove the top cover when replacing the filter (see page 58). User Safety...
2. Hazards Overview The hazards identified and explained in this section might be encountered during maintenance or service tasks. Hazardous Voltage ELECTRICAL HAZARD: There are two locations that the voltage potentials operate above 30 Volts RMS. The first location is in the rear of the instrument on power entry adapter in which the power WARNING cord plug plugs into.
Title 21 Code of Federal Regulations, Chapter 1, WARNING sub-chapter J. LASER BEAM: The Hot and Warm Box with the PI2114 H Analyzer contains the output fiber end of the fiber laser used. The fiber laser is Class 3B with an operating wavelength between 1200–...
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location of the Hot and Warm Box and the location of the laser warning labels. Take precautions during service tasks to prevent accidental exposure to both direct and reflected beams. Diffuse as well as specular beam reflections can cause severe eye or skin damage. Figure 5: Laser Hazard Labels inside...
Figure 7: Class 1 Laser Product Label The PI2114 H Analyzer is classified as a Class 1 laser product when all panels and covers are on. A Class 1 laser product label is attached to the top panel of the instrument.
Heavy replaceable components bear the Lifting Hazard alert labels. Pictorial hazard alerts call attention to the hazard in procedures requiring removal of heavy components. This will be the case should PI2114 Hydrogen Peroxide Analyzer needs to be removed for relocation or return to the factory for repair.
Avoid lifting heavy objects with one hand. Try to always balance the loads in both hands or get a cart. The PI2114 Hydrogen Peroxide Analyzer’s weight is 48 lbs. There is a heavy object label affixed to the top cover/enclosure of the Analyzer.
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The WEEE directive sets minimum standards for recycling of electrical and electronic waste. Those standards must be met. Local practice may exceed the minimum standards. The crossed-out wheeled bin symbol represents that hazardous content is included in the equipment. The equipment and parts with hazardous content shall not be disposed of with unsorted municipal waste.
3. Safety Interlock Overview The PI2114 Hydrogen Peroxide Analyzer is equipped with the Safety Interlock Switch. There is only one safety interlock switch on the Analyzer. This safety interlock switch when triggered will remove power from the power supply feeding to all the electronics within. Even with the safety interlock...
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Safety Interlock Wiring The PI2114 system power supply DC output is enabled with a PS_ON# active-low signal from the motherboard to the power supply. When PS-ON is pulled to TTL low, the DC output are enabled; when PS-ON is pulled to TTL high or open-circuited (interlock switch open) the DC outputs are disabled.
4. Theory of Operation Overview The PI2114Hydrogen Peroxide Analyzer is a laser based, cavity based gas analyzer. The Analyzer uses the Beer-Lambert law for optical absorption of a specific gas molecules, and applies the principle of operation based on the measurement of a decay rate (ring down time).
Proper use of the PI2114 Hydrogen Peroxide Analyzer does not include personnel protection or monitoring of the occupied space. The PI2114 Analyzer is not a safety device. CAUTION Dependencies The Gas Analyzer Cavity module resides in the “Hot Box,” which provides thermal stability.
Laser Path During operation, the path of the light leaving the laser travels through the coupled fiber, enters the Warm Box, through the PMFDM, then to the PMTC. From the PMTC, the path splits to the Wavelength Monitor and ends. The remaining light travels out of the Warm Box, through another laser fiber entering the Hot Box, and finally into the optical cavity.
5. Analyzer Overview Intended Use The Picarro PI2114 Hydrogen Peroxide Analyzer is designed for the accurate measurement of residual vaporized hydrogen peroxide, H , in units of parts per billion (ppb). The unit uses cavity ring-down spectroscopy and wavelength monitoring to facilitate precise and continuous monitoring of vaporized hydrogen peroxide.
Analyzer Back Panel Figure 16: Back Panel INLET VACUUM 4 – 20mA Output Analog Outputs Power Switch Soft Power Button Display Ports Power Connector USB Ports Serial Ports Feature Description INLET 1/4" PFA Swagelok Compression Fitting Connect to gases to be sampled. VACUUM 3/8"...
Analog Outputs Hirose HR25-7TP-8P(72) Connectors Connect for analog signal streaming. See page 40 for configuration instructions. The analyzer’s universal power supply automatically adjusts to power sources ranging from 100-240 VAC, 50/60 Hz, 250 W max. NOTE Only use the USB ports to connect to flash drives, mice, or keyboards.
This analyzer is designed to be used in an indoor environment. Do not operate or store the unit outside or exposed to the elements. WARNING If the equipment is used in a manner not specified by Picarro, the protection provided by the equipment may be impaired. WARNING...
6. Hardware Setup Overview Items/Tools Required: • 5/8" open end wrench • 11/16" open end wrench • Pump • Power Cord If you rack-mount the analyzer, be sure to support it with a shelf or additional rails, the analyzer cannot support itself on the front rackmounts alone.
8. Connect the external vacuum pump to a power source using the remaining AC power cable. Use only the AC power cables supplied with the analyzer or a similarly rated cable. Check with Picarro technical support if you have questions about power cable replacement. CAUTION...
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Figure 19: 4–20mA output with terminal connector in place By default, the settings for the four channels are as follows: Iout0 Iout1 Iout2 Iout3 Cavity Cavity Monitoring Temperature Temperature Pressure Units Degrees C Degrees C Torr 1000.0 100.0 100.0 1000.0 To connect to the output: 1.
Figure 21: Retaining screws at the bottom of the terminal connector 3. Insert the stripped end of the wire into the terminal. 4. Tighten the retaining screw. 5. Repeat for each desired terminal. 6. Slide the terminal connector back onto the analyzer with the retaining screws facing down;...
Figure 22: Orientation of ferrules and nut 2. Loosely connect the nut to the INLET on the back panel of the analyzer about a full turn, being careful not to let the ferrules fall out. 3. Insert the tubing into the back of the nut, feeding it in as far as possible without deforming the tubing.
7. Operate the Analyzer Power Up the System This section describes the steps to power on the system. These steps are sufficient for operating the instrument at the default values. 1. Switch on the external vacuum pump. Always turn on the external pump before turning on the analyzer. This ensures a rapid start-up sequence.
Figure 23: Home Screen Use the buttons on the Home Screen to select a task: Button Function Begin normal operation (see Operation Manual). Files Copy validation reports or user history to a USB drive (see Operation Manual). Config Perform configuration tasks. Service Perform service tasks (for trained personnel only).
When the power returns after an unplanned outage, the analyzer will restart automatically. If short power outages will be a routine operating environment, Picarro recommends using power conditioning or an uninterrupted power supply to help prevent damage to the operating system or other software corruption that may occur with repeated crashes.
8. System Configuration Configuration Menu The Configuration Menu can be accessed from the Home Screen upon starting up the analyzer. If the analyzer is operating it must first be shut down to access the Home Screen. After clicking the Config button, you will be prompted to log in –...
Clock The Clock Menu will display the current local time and time zone if the analyzer is connected to a network. The time and time zone can also be set manually by checking off the Set Time Manually option. Any modifications of the date, time, and time zone are logged in the User History with the credentials of the logged in user.
Figure 29: Serial Port Configuration User Management User management is available from the Configuration Menu or, if you are already signed in as an administrator, from the Tools menu on the Data Viewer. User management includes: • Managing user accounts, such as adding users and changing passwords.
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• • • Shut Down (software shutdown) • • Validation • Configure Data Viewer (full access) • User Management To view the User Management Window from the Home Screen: 1. From the Config.menu, click Users. 2. Log in as an admin (default user name is admin; default password is admin.) Figure 30: User...
4–20 mA Output Configuration A current output proportional to a signal can be more immune to electrical noise in an industrial setting. The data must be scaled appropriately so that the available span is filled without saturating the output. For each Channel (#0-3) you can select from the following signal options: •...
0-1000ppb H on Channel 1). Analog Signal Output The PI2114 Analyzer is configured with an optional Electrical Interface Card (EIC) that provides 4 analog signals for monitoring various measurement results and analyzer parameters. Two circular connectors, on the back panel of the analyzer are available for analog output.
Modbus Settings From the Config Menu window, select Modbus. If Modbus is not an available option then please contact Picarro to have it enabled. This will open the Modbus Settings window shown in Figure 34. Figure 34: Modbus Settings Window From this window, you can configure: •...
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MODBUS Register Types Name Size Access Input Register 16 bits Read-only Holding Register 16 bits Read-write Discrete Input 1 bit Read-only Coils 1 bit Read-write Setup Notes for MODBUS TCP • MODBUS is configured for TCP/IP on port 50500. • When MODBUS is configured on port 50500, communication is also possible via port 502.
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• System time is in "milliseconds Since 0001-01-01 AD" Input Register Map Most of the readings in Picarro analyzer are the float type and need 32-bit data. Each parameter utilizes 2 registers, out of which the first one will be storing MSB and the second one will be storing the LSB of the float number.
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Address Description Units Type Comments 24-25 O, 30sec float trailing average 26-27 O, 2min float trailing average 28-29 O, 5min float trailing average 30-31 O, max (full float Value is 50,000 (5%) scale range) 32-33 O, min float Value is set to 0 34-35 Concentration float...
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Address Description Units Type Comments 212-213 Instrument cal float slope, H 214-215 Instrument cal float offset, H 216-217 User cal slope, float 218-219 User cal offset, float 220-221 Instrument cal float slope, H 222-223 Instrument cal float offset, H 224-225 User cal slope, float 226-227...
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Address Description Units Type Comments 260-261 Reserved 262-263 Reserved 264-265 Reserved 266-267 Reserved 268-269 Reserved 270-271 Reserved 272-273 Reserved 274-275 Reserved Address Description Type Comments Error code Error for each control command of COIL • NO_ERROR = 0 • ERROR_HANDLER_ERROR = 1 •...
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Holding Register Map Holding Register Address Description Units Type Comments Integer representing System time milliseconds from 1AD January 1 to now User Name String 8-11 Password String 200-201 User data 1 Float 202-203 User data 2 Float 204-205 User data 3 Float 206-207 User data 4...
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Coil Register Map Coil Registers Address Description Units Comments Quit host application Shutdown It will take approximately 2 min to Instrument shutdown Get system time After this please read Sync Time holding register User login (Coming Before executing this command, in near future) user need to set user name and user password holding register...
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Address Description Units Comments Set User data 8 Get User data 9 Set User data 9 Get User data 10 Set User data 10 Get User data 11 Set User data 11 Get User data 12 Set User data 12 Get User data 13 Set User data 13 Get User data 14...
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• Memory map is continuous memory, so if user try to read address for which functionality is not available it will return 0 (for example reading address 0 for coil register) • If user tries to read address outside of maximum register memory map, request will be exception (for example reading address 156 for coil register) Gas ID Map...
9. Maintenance Consumables and Replacement Parts The following parts can be ordered directly from Picarro as needed over the lifetime of the analyzer. For contact information please see page 97. Part Expected Servicing Description Number Frequency S1020 Particulate filter kit for input sample line...
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Figure 34: Case Fan Power Connection Fan Power Connection 3. Flip the analyzer so that it rests upside Down & the bottom layer is accessible open the bottom cover using 2 mm hex drive. 4. Locate the PCBA. Safely remove the power connectors out from the PCBA.
Hard Drive Replacement Items/Tools Required: • 2.5 mm Hex drive • 2 mm Hex driver • Phillips Screwdriver • Static wrist-strap • Static wrist-strap The analyzer must be powered off. Line power must be unplugged and Static wrist-strap needs to be worn for grounding yourself to protect the instrument electronics.
5. Using 2.5 mm hex key unscrew all four corner screws and lift the Hard drive assembly out. Using Phillips Screwdriver unscrew all the four side screws holding the hard drive assembly and replace with the new hard drive. CPU Fan Replacement Items/Tools Required: •...
The inner filter is inside the analyzer’s internal hot box and is NOT user replaceable. Do NOT open the hot box. If you suspect the inner filter is clogged, contact Picarro for replacement by a Picarro- CAUTION certified technician. USER REPLACEMENT OF THE INNER FILTER OR BREAKING THE ANTI-TAMPER TAPE ON THE INNER FILTER VOIDS THE WARRANTY.
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• 2 mm hex wrench Safety Requirements Follow the safety precautions as described in Section 1, “User Safety.” Remove the Old Particulate Filter 1. Shut down the analyzer (see page 32). 2. Wait for the indicator on the front panel to turn off. 3.
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Figure 39: Filter Cover and Filter Cover Bulkhead Foam Bulkhead Foam 10. Carefully slide the bulkhead foam to the side of the analyzer, and then lift it up and out. This will reveal the Jam Nut. Figure 40: Removing the Bulkhead Foam Be careful not to tear the foam when sliding it to the side and lifting it out of the analyzer.
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11. Use the " wrench to loosen the jam nut enough that the filter cover can slide free (about 1 full turn should be enough). Figure 41: Jam Nut Loosening the Jam Nut 12. With the jam nut loose, slide the filter cover towards the side of the analyzer and then lift up to remove it.
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13. Use the needle nose pliers to hold the filter while using the " wrench to unscrew the Output Filter Nut. (Once loosened with the wrench, it may be easier to unscrew the nut by hand.) Figure 44: Loosen the Output Filter Nut 14.
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Figure 46: Filter orientation Input Output Flange 3. Shift the Bulkhead fitting towards the filter and thread the Input Filter Nut onto the input end of the filter until finger tight. Be careful to avoid cross-threading. 4. Use the needle nose pliers to hold the filter while using the "...
CAUTION Required Tools A Pump Rebuild Kit (part number S2009) can be ordered directly from Picarro and includes 4 diaphragms, 8 valves, a 46 mm diaphragm key, and a silicone rubber tube for the pump’s silencer. In addition to the above, you will also need the following tools: •...
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Safety Requirements Follow the safety precautions as described in Section 1, “User Safety.” Checking Diaphragms and Valves Before starting the procedure, familiarize yourself with the different parts involved as outlined below: Figure 48: Diagram of the diaphragms and valves in A2000 Position Component Housing cover...
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1. Use the 15 mm open end wrench to loosen the nut holding on the housing cover. Figure 49: Loosen the nut securing the housing cover 2. With the Phillips screwdriver, remove the two screws at the base of the pump handle and then carefully dislodge and remove the handle.
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Figure 51: Remove the housing screws and then the housing cover 5. Remove the head cover and valves you would like to inspect. It is recommended to only service one side at a time. Figure 52: Visually inspect the valves Maintenance...
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Figure 53: Removing the valves from the head cover 6. Carefully remove the valves and clean if necessary. Do not use sharp instruments to remove the valves. If the valves appear worn or show damage, replace with new valves provided in the S2009 Pump Rebuild Kit.
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Replacing the Diaphragm 1. Carefully fold in the edges of the diaphragm to reveal the diaphragm support disc below. Do not use any sharp tools as this can damage the diaphragm. Figure 55: Lift the edges of the diaphragm 2. Align the 46 mm diaphragm key with the edges of the diaphragm support disc.
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3. Apply pressure on the diaphragm key and turn counter clockwise to release the diaphragm clamping disc. As you remove the components be sure to note the order they are removed in and the number of washers. Figure 57: Order of components beneath the diaphragm...
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Figure 59: Confirm the number of washers 8. Apply pressure and turn the diaphragm key clockwise to secure the components. Replacing the Valves and Assembling Pump Heads Figure 60: Visually inspect diaphragms 1. Visually inspect both diaphragms, they should be properly seated and locked in prior to replacing the head covers.
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Figure 61: Replace head covers above diaphragms 2. Replace the head covers and valves over the diaphragm clamping discs. Figure 62: Replace housing cover 3. Replace the housing cover. 4. Align the housing cover with the screw holes in the housing. 5.
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Figure 63: Replace handle and align screws 7. Reseat the handle on top of the housing cover and align the screw holes. 8. Use the size 2 Phillips screwdriver to screw and tighten both screws at the base of the handle. 9.
10. Surrogate Gas Validation Procedure 10.1 Validation Overview The Surrogate Gas Validation Procedure is a method to validate the existing calibration of the instrument without having to use the actual gas the instrument is tuned to measure. The surrogate gas operates close to the same spectral line of the targeted gas the gas analyzer is tuned to measure.
• Four cylinders of input gases: • One cylinder of zero air (dry synthetic hydrocarbon-free air). • Three methane standard cylinders. Three cylinders of methane, each with a different concentration, certified within +/- 2% composition uncertainty. We recommend concentrations of 2, 10, and 100ppm.
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Figure 64: Beginning System Validation 5. Click Next. The first time validation is run, this will display the Edit Cylinders page. Use this page to specify the concentrations and uncertainties of the cylinders being used in this procedure. On subsequent uses, the system will remember the saved values and skip directly to the Zero-Air Measurement step.
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Button Function Add a new cylinder to the list. Delete Remove the highlighted cylinder from the list. (Click to highlight.) Update Click on a cylinder, make changes to the values shown at the bottom of the table, and click Update to save the updated values.
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Figure 67: Zero-Air Measurement6 When the measurement is complete, the system will prompt you: Figure 68: Measurement Done dialog 13. Click OK to proceed to the next step, Calibrant 1 Preparation. Figure 69: Calibrant 1 Preparation 14. Disconnect the zero-air cylinder from the analyzer INLET. 15.
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16. Open the valve on the first methane cylinder (the regulator should already be set to 2–3 psi). 17. Connect the cylinder to the analyzer INLET. 18. Select the cylinder from the Select Cylinder list. 19. Click Next to begin measuring the first cylinder. Figure 70: Calibrant 1 Measurement...
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Download Report. Downloading the report will prompt you to sign in to the File Manager, which you can use to copy the report to a USB drive. See PI2114 Operation Manual for more information on the File Manager. 24. To return to the Data Viewer, click Exit Program.
10.5 Example of Results from Validation In the example below, we collected data using four cylinders with nominal methane concentrations of 0, 2.058, 10.0, and 100.2 ppm. Approximately five minutes of data were acquired for each concentration. Scaling for the relative sensitivity difference between methane and H (methane produces spectra 70-fold weaker) these standards are comparable to 0, 30, 145.7, and 1427 ppb of H in terms of their utility in evaluating the...
“Edit Cylinder” step. If the analyzer did not pass and there is no discrepancy between the nominal values of the calibrants in the report and the values of the cylinders used during validation, contact Picarro. Surrogate Gas Validation Procedure...
11. User Management 11.1 Overview User management includes: • Managing user accounts, such as adding users and changing passwords. • Setting user policies, such as password requirements and session duration. • Viewing and saving user histories. There are three user roles defined in the system: operator, technician, and administrator.
3. From the Tools menu, select User Administration to view the User Management window. Figure 76: User Management Window The User Management window has three tabbed states: User Accounts, User Policies, and User History. 4. Make any desired changes and click LogOff and Quit to return to the Data Viewer.
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Figure 77: User Accounts To change a password: 1. In the User Management window, click the User Accounts tab. 2. From the list of users, click the user you want to change. 3. Click Change Pwd to prompt for a new password. Figure 78: Change Password...
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To Change a User’s Role: 1. In the User Management window, click the User Accounts tab. 2. From the list of users, click the user you want to change. 3. Click Change Role to see a menu of available roles. Figure 79: Change Roles 4.
3. Fill in the fields in the Add User window. 4. Click Next to open the New User Account dialog. 5. Review the user information and click OK to accept or Cancel to go back and edit the information. 11.3 Set User Policies 1.
Policy Description Previous passwords When set, prevents a user from reusing a recent password. The system can remember up to 10 old passwords. Limit login attempts Tell the system to disable a user account after a set number of failed password attempts.
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4. To copy the user history onto a USB drive, click Download. This will direct you to the File Manager, which will prompt you to log in again. See PI2114 Operation Manual for details on copying files from the analyzer.
12. Transportation & Storage 12.1 Packing the Analyzer Shut down the instrument using the Quit button in the Data Viewer. Clean dry gas should be attached to the instrument prior to shutting down. This prevents condensation inside the system during storage or shipment.
This section lists problems that may occur during installation and operation of the analyzer, and step-by-step procedures that will provide resolution in most cases. If these instructions do not solve the problem, contact Picarro Technical Support. Analyzer Won’t Turn On 13.2...
13.3 Cavity Pressure Unlocked The cavity pressure should automatically adjust to the correct value during normal operation. The “Pressure Locked” message in the Measurement Status panel of the Data Viewer indicates that the cavity pressure is within operating parameters. If the cavity pressure is out of operating specification, the Measurement Status in the Data Viewer will display a “Pressure Unlocked”...
13.4 GUI Does Not Update Graphs During Operation In the event the GUI becomes unresponsive during operation, it may be necessary to restart the instrument. The device may still be sending data even if the GUI is unresponsive. You may wish to finish your measurements before restarting. NOTE If the computer responds to the mouse: 1.
13.6 Unusual Measurements or Slow Response Time Filters can become clogged with continual use. Some symptoms of a clogged filter are: • The analyzer pressure is low. • Low flow into the analyzer, causing unusual measurements. • Response time is slower than usual. If you suspect liquid may have been sucked into the inlet line, do NOT turn off the analyzer.
13.8 Measurement Status Messages Message Description Aborting… Disabling Data Manager Exiting measuring state. Leaving Measuring Measuring This is the normal mode of operation. The analyzer will scan and report concentration measurements until it is shutdown. Parking Entering parking state Parking Sample Entering parking state Preparing Sample Manager Spectral scanning has started.
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Message Description Starting Temp and Pressure Entering warming state. Stabilizing The temperature of the “hot box” (HB – the Temperature Locked: HB chamber containing the analyzer’s optical cavity and gas handling system) is stable. Achieving stability is typically the longest step in the startup sequence.
To track incidents and enable our customers to follow progress using the online Picarro Support Community, Picarro has adopted a case number structure for service requests. If you need help from Picarro, please contact us in accordance with these instructions.
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