Ametek Western Research IPS-4 User manual

IPS-4 Dual Bench (UV / IR) Analyzer
Zone 1 / Division 2
User Manual
PN 903-8804, Rev. L
Canada
A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS

© 2010–2019 AMETEK Canada LP, A Division of AMETEK Process & Analytical Instruments Printed in Canada
This manual is a guide for the use of the IPS-4 (Integrated Process Spectrophometer) Analyzer with Dual Bench Option. Data herein has been veried
and validated and is believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and above
the capabilities specied herein, conrmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and
assumes no obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.
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ii | IPS-4 Dual Bench (UV / IR) Analyzer

Contents
Offices .................................................................................................................................. ii
Safety Notes ....................................................................................................................... ix
Electrical Safety.................................................................................................................. ix
Grounding.......................................................................................................................... ix
Personnel and Equipment Safety Information.............................................................. x
Warnings ....................................................................................................................... x
Cautions ...................................................................................................................... xii
Warning Labels ................................................................................................................ xiii
Environmental Information (WEEE) ........................................................................... xiii
UV Source Lamps Disposal ........................................................................................... xiii
Electromagnetic Compatibility (EMC)......................................................................... xiv
Special Warnings and Information................................................................................ xv
Equipment Used in Class I, Division 1 and Zone 1 Hazardous Locations....... xv
EU Declaration of Conformity ...................................................................................... xvi
Warranty and Claims....................................................................................................xviii
CHAPTER 1 OVERVIEW....................................................................................................... 1-1
Optical Bench Configurations....................................................................................... 1-1
Basic Analytical Theory (Optical Bench) .............................................................. 1-1
Flow Diagram............................................................................................................ 1-1
Calculation Flow....................................................................................................... 1-2
Dispersive Ultraviolet/Visible (DUVV) Spectrometer ............................................... 1-4
Basic Analytical Theory ........................................................................................... 1-4
Optical Bench Design .............................................................................................. 1-4
UV Specifications...................................................................................................... 1-5
Wavelength Ranges............................................................................................. 1-5
Wavelength Accuracy.......................................................................................... 1-5
Wavelength Resolution........................................................................................ 1-5
3 nm..................................................................................................................... 1-5
Analyzer Range................................................................................................... 1-5
Photometric Range .............................................................................................. 1-5
Photometric Noise ............................................................................................... 1-5
Non-Dispersive Infrared (NDIR) Photometer............................................................ 1-6
Basic Analytical Theory ........................................................................................... 1-6
Optical Bench Design .............................................................................................. 1-6
NDIR Specifications ................................................................................................. 1-7
Wavelength Ranges............................................................................................. 1-7
Photometric Range .............................................................................................. 1-7
Photometric Noise ............................................................................................... 1-7
Sample System................................................................................................................. 1-7
Electronics ........................................................................................................................ 1-8
Classified, Hazardous Area Protection Components and Functions ..................... 1-9
Supplemental Information – Where Can I Find It?................................................. 1-12
Contents | iii

CHAPTER 2 SPECIFICATIONS ........................................................................................... 2-1
Analyzer Specifications .................................................................................................. 2-1
Analytes...................................................................................................................... 2-1
Response Linearity................................................................................................... 2-1
Measurement Accuracy ........................................................................................... 2-1
Repeatability.............................................................................................................. 2-1
Linearity..................................................................................................................... 2-1
Stability....................................................................................................................... 2-1
24-Hour Zero Drift ................................................................................................... 2-2
Inputs.......................................................................................................................... 2-2
Outputs ...................................................................................................................... 2-2
Sample System Limits.............................................................................................. 2-3
Sample Pressure .................................................................................................. 2-3
Oven/Sample System Enclosure Temperature..................................................... 2-3
Sample Transport...................................................................................................... 2-3
Instrument Air Requirements................................................................................. 2-3
Sample Fluid Flow Rate........................................................................................... 2-3
Electrical Requirements........................................................................................... 2-4
Power Consumption ............................................................................................ 2-4
Heated Sample Line ............................................................................................ 2-4
Supply Voltage..................................................................................................... 2-4
Cell Construction...................................................................................................... 2-4
Pressure Input Signals ............................................................................................. 2-4
On-Board Temperature Sensor............................................................................... 2-4
Environmental .......................................................................................................... 2-5
Ambient Temperature .......................................................................................... 2-5
Humidity............................................................................................................. 2-5
Pollution Degree.................................................................................................. 2-5
Maximum Altitude.............................................................................................. 2-5
Installation Category........................................................................................... 2-5
Enclosure Material .............................................................................................. 2-5
Ingress Protection................................................................................................ 2-5
Physical Dimensions ................................................................................................ 2-5
Approvals and Certifications......................................................................................... 2-6
Special Condition of Use ......................................................................................... 2-7
ATEX and IECEx Certificates and Analyzer Markings ....................................... 2-8
IPS-4 Dual Bench Analyzer ATEX Certificate ................................................... 2-8
IPS-4 Dual Bench Analyzer Marking............................................................... 2-11
IPS-4 Dual Bench Analyzer IECEx Certificate................................................. 2-12
CHAPTER 3 INSTALLATION AND START-UP................................................................... 3-1
Safety Considerations..................................................................................................... 3-2
Pre-Installation Requirements....................................................................................... 3-2
Storage Prior to Installation .................................................................................... 3-2
Uncrating and Inspecting the Analyzer................................................................ 3-3
General Installation Information........................................................................... 3-3
Tools, Equipment, and Supplies Required ........................................................... 3-4
iv | IPS-4 Dual Bench (UV / IR) Analyzer

Installing the Mechanical Components....................................................................... 3-6
Mounting the Analyzer ........................................................................................... 3-6
Location and Environment.................................................................................. 3-6
Installing the Optical Bench-UV Assembly........................................................ 3-10
Installing the Optical Bench IR Assembly .......................................................... 3-11
Installing the Sample System................................................................................ 3-13
Installing the Sample Probe/Sample Tap........................................................... 3-14
Installing and Connecting the Sample and Vent Lines ..................................... 3-14
Installing and Connecting the Instrument Air/Zero Fluid Line....................... 3-15
Installing and Connecting the Purge Fluid Line ............................................. 3-17
Installing the Calibration (Span) Fluid Line (Optional)................................... 3-19
Connecting I/O Signals, Alarm Relay Contacts, and AC Power............................ 3-20
Electrical Connections............................................................................................ 3-20
Permanent Ethernet Cable Connections (Optional)......................................... 3-21
Start-Up and Verification ............................................................................................. 3-23
Purged Analyzers ................................................................................................... 3-23
Powering Up the Analyzer.................................................................................... 3-26
Start-Up Diagnostic Checklist .............................................................................. 3-35
Sample System Leak Check .................................................................................. 3-37
Manually Zeroing the Analyzer Sample System............................................... 3-39
Adjusting the Zero/Span Fluid Flow Rate .......................................................... 3-40
Adjusting the Sample Flow Rate.......................................................................... 3-41
Setting Sample Response Time ............................................................................ 3-42
Normal Operation......................................................................................................... 3-43
Recording Initial Readings.................................................................................... 3-43
Recording Initial Sample Response Time........................................................... 3-43
Analyzer Configuration ............................................................................................... 3-44
CHAPTER 4 CONTROLLER / USER INTERFACE............................................................. 4-1
Introduction to the User Interface Panel..................................................................... 4-2
User Interface Panel Components ......................................................................... 4-2
Special Software Characters.................................................................................... 4-4
Working From the User Interface Panel – Conditions and Messages.............. 4-5
Summary of Analyzer Operation .......................................................................... 4-6
Working in the Main Menus ......................................................................................... 4-7
HOME Menu Screen................................................................................................ 4-7
System Status Messages (HOME Screen).......................................................... 4-9
Alarm and Warning Notification (HOME Screen) .......................................... 4-10
ALARMS and WARNINGS Menu Screen........................................................... 4-11
Viewing Current Alarms and Warnings........................................................... 4-11
Viewing Logged Alarms and Warnings ............................................................ 4-12
STATUS Menu Screen ............................................................................................ 4-13
SETUP Menu Screen.............................................................................................. 4-15
Calibration Control Screen................................................................................ 4-16
Calibration Settings Screen .........................................................................4-16
Flush Times..................................................................................................4-19
Contents | v

Calibration Valves.............................................................................................. 4-20
Calibration Actions Screen................................................................................ 4-21
Manually Starting a Zero Calibration.........................................................4-22
Manually Starting a Span Calibration........................................................4-23
Manually Starting a Neutral Density Filter Verification............................4-24
Neutral Density Filter Verification Diagnostic Chart.................................4-25
Relay Setup Screens ............................................................................................... 4-26
Current Output Setup Screens ......................................................................... 4-29
Setpoints............................................................................................................ 4-31
Diagnostics Screen ............................................................................................ 4-33
System Settings Screen ..................................................................................... 4-34
The System Settings screen (Figure 4-31) allows the user to view
and/or setup analyzer system parameters. ....................................................... 4-34
Login/Set Passwords Screen .............................................................................. 4-35
Changing the Password................................................................................4-37
Locking the Password...................................................................................4-37
Removing the Password...............................................................................4-37
Backup/Restore Settings Screen ........................................................................ 4-38
Backing Up Analyzer Configuration Settings.............................................4-39
Restoring Analyzer Configuration Settings................................................4-39
Ethernet Network Screen .................................................................................. 4-41
Customization Screen........................................................................................ 4-44
Modbus Screen .................................................................................................. 4-46
CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING............................................... 5-1
Safety Considerations..................................................................................................... 5-1
Maintenance..................................................................................................................... 5-3
Preventive Maintenance.......................................................................................... 5-3
Analyzer Preventive Maintenance Schedule....................................................... 5-4
Expo Technologies MiniPurge®System With eTimer (Optional) Preventive
Maintenance Schedule......................................................................................... 5-6
Locating a Plug in the Sample System................................................................ 5-7
Detecting a Plug in the Sample System .............................................................. 5-7
Changing Out Replaceable Parts ........................................................................... 5-8
Tools, Equipment, and Supplies Required for Maintenance ............................... 5-9
Measuring Cell Preventive Maintenance.......................................................... 5-11
Replacing the Xenon (UV) Flash Lamp Assembly ............................................ 5-19
Replacing the Infrared (IR) Source Assembly.................................................... 5-23
Troubleshooting and Diagnostics ............................................................................... 5-26
Alarm Conditions and Corrective Action........................................................... 5-27
Analyzer Reset ........................................................................................................ 5-31
vi | IPS-4 Dual Bench (UV / IR) Analyzer

CHAPTER 6 SERVICE AND PARTS.................................................................................... 6-1
Technical Support............................................................................................................ 6-1
Returning Equipment..................................................................................................... 6-2
AMETEK Service and Aftermarket Sales Support ..................................................... 6-3
Recommended Spare Parts............................................................................................ 6-4
Measuring Cell Assembly Spare Parts................................................................... 6-4
Optical Bench Assembly Spare Parts..................................................................... 6-4
Spare Analyzer Fuses ............................................................................................... 6-5
Expo Technologies MiniPurge®System With eTimer Spare Parts.................... 6-5
CHAPTER 7 USER WEB INTERFACE ................................................................................ 7-1
Introduction to the Web Interface ................................................................................ 7-2
Web Interface Components .................................................................................... 7-3
Working From the Web Interface – Conditions and Messages ......................... 7-3
HOME Menu Screen................................................................................................ 7-4
ALARMS Menu Screen............................................................................................ 7-5
Current Alarms and Warnings........................................................................... 7-5
Logged Alarms and Warnings ............................................................................ 7-6
Alarm and Warning Notification........................................................................ 7-6
TRENDS Menu Screen ............................................................................................ 7-7
Parameters ........................................................................................................... 7-8
Intervals............................................................................................................... 7-8
SPECTRA Menu Screen........................................................................................... 7-9
Viewing Spectral Data......................................................................................... 7-9
SETTINGS Menu Screen ....................................................................................... 7-10
Calibration Settings Screen............................................................................... 7-11
Actions Screen ................................................................................................... 7-12
Current Output Screen ..................................................................................... 7-13
Relay Setup Screens .......................................................................................... 7-14
Network and Modbus Screen ............................................................................ 7-15
System and Customization Screen.................................................................... 7-16
Analytes Screen ................................................................................................. 7-17
Limits Screen .......................................................................................................... 7-18
Diagnostics Screen ............................................................................................ 7-19
Save/Restore Files Screen .................................................................................. 7-20
CHAPTER 8 MODBUS COMMUNICATION INTERFACE .................................................. 8-1
Hardware:.................................................................................................................. 8-1
Configuration:........................................................................................................... 8-2
Analyzer Modbus Interface Parameters ...................................................................... 8-3
Modbus Address....................................................................................................... 8-3
Modbus Functions.................................................................................................... 8-3
Holding Registers............................................................................................................ 8-4
Contents | vii

APPENDIX A – DRAWINGS...................................................................................................A-1
Analyzer Light Path, UV Optical Bench Schematic.................................................. A-2
Analyzer Light Path, NDIR Optical Bench Schematic ............................................. A-3
Analyzer Overall Component Layout, Zone 1, Example ........................................ A-4
Analyzer Overall Component Layout, Division 2, Example................................... A-5
Detector Board (100-2046)............................................................................................. A-6
Display Interface Board (100-2049).............................................................................. A-7
Customer Connection Board (100-1971)..................................................................... A-8
AC Disconnection Board (100-2077)............................................................................ A-9
Signal Disconnection Board (100-2076) .................................................................... A-10
Relay Board (100-2050) ................................................................................................ A-11
Analog Board (100-2047) ............................................................................................. A-12
MCU Board (100-2045) ................................................................................................ A-13
Xenon Lamp Power Supply Board (100-2061), UV Optical Bench....................... A-14
Infrared Source Assembly Interface Board (100-2838), IR Optical Bench........... A-15
Electronics Enclosure Wiring Diagram, Sheet 1 of 5 .............................................. A-16
Electronics Enclosure Wiring Diagram, Sheet 2 of 5 .............................................. A-17
Electronics Enclosure Wiring Diagram, Sheet 3 of 5 .............................................. A-18
Disconnect Enclosure Wiring Diagram, Sheet 4 of 5.............................................. A-19
Disconnect Enclosure Wiring Diagram, Sheet 5 of 5.............................................. A-20
SUPPLEMENTAL INFORMATION ........................................................................................ S-1
viii | IPS-4 Dual Bench (UV / IR) Analyzer

Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as
follows:
An operating procedure which, if not strictly observed, may result in personal injury or envi-
ronmental contamination.
An operating procedure which, if not strictly observed, may result in damage to the
equipment.
Important information that should not be overlooked.
Electrical Safety
High voltages are present in the analyzer housings. Always shut down power source(s) before perform-
ing maintenance or troubleshooting. Only a qualied electrician should make electrical connections and
ground checks.
Any use of the equipment in a manner not specied by the manufacturer may impair the safety protection
originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specications and safety protection are void if instru-
ment is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.
!
CAUTION

NOTE
!
CAUTION
!
WARNING
Contents | ix

Personnel and Equipment Safety Information
This section describes important safety information to avoid personal injury and damage to the equipment
while installing, operating, maintaining, or servicing the equipment. All safety regulations, standards, and
procedures at the analyzer location must be followed.
All personnel involved with the installation, start-up, operation, maintenance, service, or troubleshooting
of the IPS-4 Analyzer must review and follow these Warnings and Cautions.
Warnings
Review and follow these Warnings to avoid personal injury or environmental contamination.
Always disconnect main AC power and/or external power sources to the analyzer before
opening any covers or doors on the analyzer to check or perform maintenance on any compo-
nents within the enclosures.
If it is necessary to open the analyzer’s covers or doors while the circuits are live, test the
area for ammable gases (and proceed only when the area is safe).
Purged Analyzer (Hazardous Location) Applications
To work on the analyzer with it powered up and its Electronics Enclosure door open, the
Purge Bypass Switch must be in the “BYPASS” position.
When the Electronics Enclosure door is open, take appropriate precautions to avoid electrical
shock. Hazardous voltages are present inside.
All electrical connections, adjustments, or servicing of the analyzer should be performed only
by properly trained and qualied personnel.
All electrical connections, materials, and methods (plus all safety policies and procedures)
must be made in compliance with local wiring regulations and electrical code for the hazard-
ous area.
Follow appropriate regulatory and/or company procedures to lock out the analyzer while
working on the analyzer electronics.
Before working on the sample system, conrm that the system has been purged with Zero uid
and is isolated (blocked in) from the process.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
x | IPS-4 Dual Bench (UV / IR) Analyzer