Analytical Industries Inc (AII) PI2- UHP-50 Operating Manual
Analytical Industries, Inc.
PI2- UHP-50
PPB OXYGEN ANALYZER
OWNERS MANUAL
Revised Sep 20, 2016 Rev 2
Revised July 10, 2017 Rev 3
Revised Mar 05, 2018 Rev 4
Revised Sep 17, 2018 Rev 5
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Table of Contents
Introduction
1
Quality Control Certification
2
Safety
3
Features & Specifications
4
Operation
5
Maintenance
6
Spare Parts
7
Troubleshooting
8
Warranty
9
(UHPDS) Material Safety Data Sheet
1
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1. Introduction
Your new PI2-UHP 50/100 PPB oxygen analyzer is a precision device designed to give you years of use for
analyzing single digit PPB (parts per billion) level oxygen concentrations. This micro-processor based analyzer
features the new breakthrough “Pico-Ion” Sensor Technology developed exclusively by Advanced Instruments
Inc. and an extensive sample system digitally controlled to offer the user the utmost in performance and
simplicity. The sample system consists of 316L stainless steel pneumatic valves with orbital welded or VCR type
connections.
The sample system features separate sample and span inlets, a pressure regulator and flow control orifice,
sample bypass loop for isolating the sensor and an integral oxygen scrubber (PI2-UHP 50/100 only) for consistent
zero gas, all of which are controlled by the user friendly micro-processor based electronics.
The digital electronics also feature auto or manual ranging, auto-zero and auto-calibration at user specified
intervals, data acquisition, temperature compensated output, user selected signal averaging and temperature
coefficient for fine tuning the sensor performance in varying temperature environments.
This analyzer is designed to measure the oxygen concentration in inert gases, gaseous hydrocarbons, hydrogen
and a variety of gas mixtures.
In order to derive maximum performance from your new oxygen analyzer, please read and follow the guidelines
provided in this Owner’s Manual.
The serial number of this analyzer may be found on the inside and at the back of the analyzer. You should note
the serial number in the space provided below and retain this Owner’s Manual as a permanent record of your
purchase, for future reference and for warranty considerations.
Serial Number: _______________________
Every effort has been made to select the most reliable, state of the art materials and components designed for
superior performance and minimal cost of ownership. This analyzer was tested thoroughly by the manufacturer
for best performance.
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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2. Quality Control Certificate
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3. Safety
This section summarizes the essential generic precautions applicable to all analyzers. Additional precautions
specific to individual analyzers are contained in the following sections of this manual. To operate the analyzer
safely and obtain maximum performance, follow the basic guidelines outlined in this Owner’s Manual.
Caution: This symbol is used throughout the Owner’s Manual to CAUTION and alert the user to
recommended safety and/or operating guidelines.
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 analyzer 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 analyzer, 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 analyzer.
Inlet Sample Pressure: Recommended 30-50 PSIG, 100 PSIG maximum.
Outlet Pressure: The sample gas must be vented atmospheric pressure.
Instrument Air Pressure: Operation of the pneumatic valves which require a dedicated source of
compressed air with a minimum of 80-100 psig: Note: Do not attempt to use the sample gas to operate the
pneumatic valves.
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 analyzer is approved for indoor use only. It may be used outdoors with optional enclosures.
Mount the analyzer as recommended by the manufacturer.
Power: Supply power to the analyzer only as rated by the specification in Section 4 and/or markings on the
analyzer enclosure. The wiring/cords that connect the analyzer 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 analyzer. Never yank a power cord to remove it from an outlet or from
the analyzer.
ENSURE THAT POWER LINE INCULDES “SURGE PROTECTER” AND RFI/EMI FILTER TO PREVENT
INTERFERENCE FROM EXCESSIVE LINE VOLTAGE VARIATIONS
Operating Temperature: The maximum recommended operating temperature is 45 ºC. However, an
operating temperature of less than 35 oC is ideal to obtain maximum life of the oxygen sensor.
Heat: Situate and store the analyzer away from a direct source of heat.
Liquid and Object Entry: The analyzer should not be immersed in any liquid. Care should be taken so that
liquids are not spilled into and objects do not fall into the inside of the analyzer.
Handling: Do not use force when using the switches and knobs. Before moving your analyzer, be sure to
disconnect the wiring/power cord and any cables connected to the output terminals of the analyzer.
Serviceability: Except for replacing the oxygen sensor, there are no parts inside the analyzer for the operator
to service. Only trained personnel with authorization of their supervisor should conduct maintenance.
Troubleshooting: Consult the guidelines in Section 8 for advice on the common operating errors before
concluding that your analyzer is faulty. Do not attempt to service the analyzer beyond those means described
in this Owner’s Manual. Do not attempt to make repairs by yourself as this will void the warranty as per Section
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9 and may result in electrical shock, injury or damage. All other servicing should be referred to qualified service
personnel.
Cleaning: The analyzer should be cleaned only as recommended by the manufacturer. Wipe off
dust and dirt from the outside of the unit with a soft damp cloth then dry immediately. Do not use
solvents or chemicals.
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.
Nonuse Periods: Keep oxygen sensor from exposure to high oxygen levels as described in this manual (see
section Operation). Disconnect the power when the analyzer is left unused.
Warning: The analyzer must not be disconnected from power and gas line for more than a few hours to a
day. If it becomes necessary to disconnect power for extended period, remove sensor cable from
PCB A-1146 to disconnect sensor from electronic circuit. Failure to do so will keep sensor reacting with
oxygen that will continue to diffuse through sensor housing and may damage the sensor (with sample gas
flowing, oxygen diffusion through sensor housing becomes insignificant as it dilutes with sample gas).
It is recommended that the analyzer remain powered with gas flowing (if high purity sample gas is not
available, a gas with low PPM gas may be used with a flow rate as low as 0.1 SCFH). This will keep the sensor
ready for sampling a gas.
If it becomes necessary to transport the analyzer from one place to another, disconnect analyzer power only
when analyzer is to be transported and re-installed within a few hours to a day.
Caution: PI2-UHP-M analyzer is equipped with MANUAL VALVE, turn sample inlet and sample outlet valves to
OFF position before removing sample gas connection. Failure to adhere to this instruction may result in
permanent damage to the sensor.
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4. Specifications
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5. Operation
Principle of Operation
A breakthrough sensor technology of the second generation Pico-Ion oxygen sensor measures the partial
pressure of oxygen from less than 3 PPB to 100 PPM level in inert gases, gaseous hydrocarbons, helium,
hydrogen and mixed gas streaUHP.
Oxygen, the fuel for this electrochemical transducer, reacts chemically at the sensing electrode to produce an
electrical current output proportional to the oxygen concentration in the gas phase. The sensor’s signal output is
linear over all four ranges and remains virtually constant over its useful life. The sensor requires no maintenance
or electrolyte addition and is easily and safely replaced at the end of its useful life.
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Sample System Flow Schematic
The PI2-UHP 50/100 analyzer is equipped with a micro-processor controlled sample system that features precise
flow control and pneumatic valves for introducing sample or span gases, isolating the sensor with an integral
bypass loop during standby and upset conditions and an oxygen scrubber for delivering consistent zero gas
(during zero calibration) to the sensor.
Note: The pneumatic valves require a minimum of 80 psig pressure to open. The maximum pressure allowed is
100 psig.
Valve Operation: OPEN CLOSED
Mode: BYPASS 1, 5 2, 3,4,6,7
ZERO 1,4,6,7 2,3,5
SPAN 2,3,4 1,5,6,7
SAMPLE 1,3,4 2,5,6,7
STANDBY NONE 1,2,3,4,5,6,7
Flow schematic of PI2-UHP 50/100
The PI2-UHP 50/100-B analyzer is equipped with a micro-processor controlled sample system that except that
these models do not have integral oxygen scrubber and separate Span gas inlet.
Note: The menus displayed by the PI2-UHP-50/100 B have been modified to reflect the absence of the span
inlet port and zero scrubber system.
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Valve Operation: OPEN CLOSED
Mode: BYPASS 5 3,4
ZERO 3,4 5
SPAN 3,4 5
SAMPLE 3,4 5
STANDBY NONE 3,4,5
Flow Schematic of PI2-UHP 50/100-B
Caution: Do not change the valve positions until instructed to do so in this manual.
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Other Sample Handling Considerations
The sample system may include optional components positioned upstream of the analyzer such as additional
pressure regulator, particulate filter, isolation/directional flow control valves etc. Check the QC sheet to confirm
the Sample System of your analyzer.
To avoid damaging the sensor or sample system, observe the following guidelines:
1. Do not draw a vacuum or over-pressure the sensor. When sample gas flows into the analyzer, any
restriction on the vent line will cause a pressure build up within the analyzer sample system, a sudden
release of the sample pressure will draw a vacuum on the sensor.
2. The vacuum generated in 1 above may cause the sensor to leak electrolyte (voiding the sensor
warranty). The electrolyte leakage may damage the electrical contacts of the upper section of the sensor
housing assembly, the electrolyte might enter in the sample system and if it does, it will require a
complete overhaul of the sample system.
3. Do not supply sample gas with pressure above the recommended limit. High positive pressure can
damage the integral pressure regulator, the sensor and or other sample system components.
4. Do not introduce calibration span gas from a pressurized cylinder without first regulating the pressure to
within the recommended limits (30-50 PSIG).
CAUTION: Do not vent the sample to a line with pressure above atmospheric pressure. If the vent line pressure
is above atmospheric (below 10-20 inches of water and is varying, use a back-pressure regulator set at 20 inches
of water to stabilize the pressure at the sensor.
Installation
The PI2-UHP 50/100 series Oxygen Analyzers consist of an electronic
module, sensor housing and sample system housed in a 13.9”W x
9.9”H x 13.4”D enclosure suitable for bench-top or cart applications.
The enclosure can be panel or rack mounted with an optional bezel.
The analyzer includes a temperature controlled heating system to
maintain the temperature of the sensor at a pre-set temperature of
85 ◦F. The analyzer has been tested and calibrated by the
manufacturer prior to shipment.
Note: Analyzer is shipped from the factory with sensor placed in a
separate bag sealed under nitrogen. Install sensor as instructed later
in this section.
Caution: Do not change the factory settings of the analyzer until instructed to do so in this manual.
Sample/Span Gas Connections Considerations
Assemble the necessary hardware for mounting the analyzer and optional components (if provided or required by
the user). Perform the following steps
1. Use ¼” stainless steel compression type fittings for air input and sample vent line connections. Use ¼”
Face Seal type fittings for sample and span gas inlet connections. Caution: use clean/fresh gaskets for
making Face Seal type connections.
2. Use cleaned, preferably electro polished SS tubing for all sample/span gas connections. Plastic tubing
rated at 150 psig may be used to provide instrument air.
3. Review the application/sample analysis conditions to ensure the sample gas is suitable for analysis.
Sample and Span gas pressure 30-50 psig
Recommended sample and span gas pressure 30-50 PSIG (maximum pressure of 150 psig is acceptable). The 3050 psig pressure is recommended for ease of controlling of the gas flow rate by using the integral pressure
regulator.
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Caution: The integral pressure regulator is rated at a maximum of 150 psig input pressure. Excessive pressure
may permanently damage the pressure regulator and may also introduce undue pressure on the oxygen sensor.
Instrument air pressure - 80 psig
Analyzer sampling system consists of seven pneumatically controlled diaphragm valves. The valves are actuated
by solenoid valves that deliver air to the pneumatic valves. Minimum pressure required to activate the pneumatic
valve is 80 psig. Set the instrument air at 80 PSIG. A maximum air pressure of 100 psig may be used. However,
do not use air pressure above 100 psig. Excessive pressure may damage the solenoid valves controlling the
pneumatic valves.
Caution: The pneumatic valves require a dedicated source of instrument air at a minimum of 80 psig. Do not
attempt to split the sample gas feed to operate the pneumatic valves.
Power Requirement
The analyzer is rated at 100-240 VAC. Before establishing power to the analyzer, check the rating printed at the
back of the analyzer to ensure that the power available meets the required ratings.
Caution: Incorrect power may result in safety hazard and damage to the analyzer.
Establish power to the analyzer by the power cable provided with the analyzer. Ensure that EMI/RFI filter is
attached as close as possible to the analyzer power input terminal.
ENSURE THAT POWER LINE INCULDES “SURGE PROTECTER” AND RFI/EMI FILTER TO PREVENT INTERFERENCE
FROM EXCESSIVE LINE VOLTAGE VARIATIONS
Signal Output
The analyzer provides 0-1 VDC, 0-5 VDC and 4-20 mA isolated full scale output. Keep signal output lines separate
from AC power lines. For optimum results when connecting signal output to an external recording device, e.g., a
printer or a PLC, do not bundle signal output wires with power cable (bundling signal output and AC power line
may introduce excessive noise on the signal output line). Keep wire lengths taking signal output to a recording
device to less than three meters.
Mounting the Analyzer
The PI2- UHP 13.9”Wx9.9”Hx13.4”D configuration is designed for bench-top or cart use. The analyzer can be
panel 15”Wx12”H or rack 19”Wx12”H mounted with the optional bezels. When mounting the analyzer in a 19”
rack, allow sufficient room to access terminal connections at the rear of the enclosure.
When equipped with the optional bezels, the PI2- UHP bolts directly to any flat vertical surface, wall or bulkhead
plate with the appropriate cutout. To facilitate servicing the interior of the analyzer, position it approximately 5
feet off the floor.
Establishing Gas Connections
The PI2-UHP is designed for positive pressured samples and requires connections for incoming sample, span
calibration gas, instrument air (for the solenoid valves controlling the pneumatic valves) and the sample/span gas
vent.
NOTE: PI2-UHP-B does not have a separate Span inlet port. For these models, the user must connect the Span
gas to the Sample inlet port by using a TEE adaptor and a THREE-WAY valve for manually selecting the Sample
or Span gas.
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