Ametek Western Research IPS-4 User manual

AMETEK Western Research
IPS-4 Analyzer
Zone 1/Division 1
Essential Health & Safety
Requirements
PN 403268001, Rev D
Process Instruments
455 Corporate Blvd.
Newark, DE 19702

© 2008 AMETEK Process & Analytical Instruments Division
This manual is a guide for the use of the IPS-4 IR Analyzer. 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.
OfficesSALES AND MANUFACTURING:
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USA - Pennsylvania
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CHINA
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www.ametekpi.com
2 | IPS-4 Zone1/Analyzer

Table of Contents
Offices ..................................................................................................................... 2
About This Document .......................................................................................... 5
Safety Notes..................................................................................................... 5
Important Safety Information ...................................................................... 5
Warnings....................................................................................................6
Cautions .....................................................................................................7
Special Warnings and Information..................................................................... 9
Equipment Used in Class I, Division 1 and Zone 1 Hazardous Loca-
tions................................................................................................................... 9
Warning Labels ............................................................................................. 10
Classified, Hazardous Area Protection Components and Functions ......... 11
Specifications ....................................................................................................... 13
Utility Requirements.................................................................................... 13
Power Consumption .................................................................................13
Supply Voltage..........................................................................................13
Instrument Air .........................................................................................13
Outputs .......................................................................................................... 13
Ambient Temperature Limits...................................................................... 14
Sample System Limits.................................................................................. 14
Sample Pressure .......................................................................................14
Oven/Sample System Enclosure Temperature..........................................14
Approvals and Certifications...................................................................... 14
Analyzer Markings.............................................................................................. 15
Installing the Analyzer ....................................................................................... 17
Safety Considerations .................................................................................. 18
Pre-Installation Requirements.................................................................... 19
Storage Prior to Installation.....................................................................19
Uncrating and Inspecting the Analyzer...................................................19
General Installation Information.............................................................20
Tools, Equipment, and Supplies Required for Installation.......................20
Installing the Mechanical Components.................................................... 23
Mounting the Analyzer............................................................................23
Location and Environment ................................................................23
Installing the Optical Bench Assembly ....................................................27
Installing the Sample System...................................................................29
Installing the Sample Probe/Sample Tap ...........................................29
Installing and Connecting the Sample and Vent Lines .....................30
Installing and Connecting the Instrument Air/Zero Fluid Line.......31
Installing and Connecting the Purge Fluid Line ..............................33
Installing the Calibration (Span) Fluid Line (Optional) ...................34
Connecting I/O Signals, Alarm Relay Contacts, and AC Power ........... 36
Electrical Connections..............................................................................36
Essential Health & Safety Requirements | 3

Permanent Ethernet Cable Connections (Optional).................................37
Start-Up and Verification ................................................................................... 39
Powering Up the Analyzer.......................................................................... 39
Start-Up Diagnostic Checklist .................................................................... 46
Sample System Leak Check ........................................................................ 48
Manually Zeroing the Analyzer Sample System..................................... 49
Adjusting the Zero/Span Fluid Flow Rate ................................................ 50
Adjusting the Sample Flow Rate................................................................ 50
Setting Sample Response Time.................................................................51
Normal Operation............................................................................................... 52
Recording Initial Readings.......................................................................... 52
Recording Initial Sample Response Time .................................................52
Analyzer Configuration ..................................................................................... 53
Maintenance and Troubleshooting .................................................................. 55
Before Performing Maintenance................................................................ 55
Cleaning/Replacing Parts in the Sampling System ................................. 56
Other Maintenance ...................................................................................... 57
Examining and Caring For the Flamepaths ............................................. 58
4 | IPS-4 Zone1/Analyzer

About This Document
This document primarily describes the essential health and safety requirements for the compo-
nents that make up the Model IPS-4 Analyzer intended for use in explosive atmosphere loca-
tions. These sections are described below.
The procedures and information discussed in this document include only abbreviated steps to
install, operate, and perform maintenance on the Model IPS-4 Analyzer. They do, however, in-
clude all relevant safety warnings and cautions to ensure the safety of personnel and the analyz-
er in explosive atmosphere locations. [For complete and detailed descriptions of the procedures
discussed in this guide, refer to the analyzer User Manual.]
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.
Important Safety Information
Before working on the analyzer, read and understand the following Notes, Warnings, and
Cautions, which contain important safety and general information that applies to all aspects of
working on the analyzer.
Additional Notes, Warnings, and Cautions are included in individual procedures in this docu-
ment (and in the analyzer User Manual) to indicate special conditions to consider during instal-
lation, before opening its covers or doors, and while working on the analyzer.
!
CAUTION
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NOTE
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WARNING
Essential Health & Safety Requirements | 5

Warnings
Review and follow these Warnings to avoid personal injury or environmental contamination.
High voltages are present in the analyzer housings. Always disconnect 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 components within the enclosures.
If it is necessary to open the analyzer’s covers or doors while the circuits are live, first monitor
the area for flammable gases (and proceed only when the area is safe). To work on the analyzer
with it powered up and its Electronics Enclosure door open, the Purge Control Unit must be in
BYPASS mode.
When the Electronics Enclosure and/or other enclosures are 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 qualified 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 hazardous
area, as specified by the Owner Company, local electrical-inspection authority, and National/
EU regulations.
Follow appropriate regulatory and/or company procedures to lock out the analyzer while work-
ing on the analyzer electronics.
Before working on the analyzer, test the area for flammable gases. If a flammable gas atmo-
sphere is present, do not open any doors without first disconnecting power and/or alternate
power sources to the analyzer.
The glass Xenon Flash Lamp is under high internal pressure which could result in flying glass
fragments if ruptured. Handle the tube with care to avoid dropping it, subjecting it to impacts,
applying excessive force to it, or scratching it.
While handling a flash lamp, always wear protective devices (face mask, clothing) to prevent
possible injury, especially to hand and face areas.
Before working on the sample system, confirm that the system has been purged with Zero fluid
and is isolated (blocked in) from the process.
!
WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
6 | IPS-4 Zone1/Analyzer

Because ultraviolet radiation can harm your eyes, never look directly into the operating lamp.
If the Xenon Flash Lamp must be viewed while energized, wear safety glasses that block ultra-
violet radiation.
If the Oven/Sample System Enclosure is heated, the components within it will be hot; take
precautions to avoid burning yourself.
Explosion Hazard – Do Not enter purge BYPASS mode in the presence of explosive atmo-
sphere.
Verify ground continuity of all equipment before applying power.
The sample gas may contain highly toxic and corrosive substances. Proper personal protective
equipment including fresh air breathing apparatus, eye protection, and skin protection MUST
BE worn when installing the sample tap and/or opening the main oven chamber for inspection
or maintenance.
If sampe gases contain highly toxic and corrosive compounds, analyzed sample must be re-
turned to the process or vented to a safe area.
Cautions
Review and follow these Cautions to avoid damaging the equipment.
The electronic circuit boards and other static-sensitive components should be stored and trans-
ported in static-shielding carriers or packages.
For electrical-shock protection, the analyzer must be operated from a grounded power source
that has a securely connected protective-ground contact.
If it becomes necessary to handle any of the electronic circuit boards, do not subject the boards
to static discharge. The ideal solution is a static-safe work area. Since such areas typically
are not available at analyzer installation sites, the use of a wrist strap connected directly to a
ground is recommended. If a wrist strap is not available, you should at the very least touch the
metal chassis (to ground yourself) before handling or touching the boards.
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
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CAUTION
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CAUTION
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CAUTION
Essential Health & Safety Requirements | 7

!
CAUTION
!
CAUTION
When handling the Xenon Flash Lamp, it is very important not to touch the lamp windows be-
cause residual oils from the fingers will absorb ultraviolet light. The window is the flat surface
at the end of the narrow glass tube. The lamp assembly is fragile and should be handled with
care.
Take extreme care to avoid damaging the threads on the cable entry glands on the Disconnect
Enclosure. Clean, defect-free threads are essential to ensure a flameproof connection.
8 | IPS-4 Zone1/Analyzer

SPECIAL WARNINGS AND INFORMATION
Equipment Used in Class I, Division 1 and Zone 1
Hazardous Locations
Refer to Chapter 2 – Specifications for details about the suitability of this equipment in hazard-
ous areas.
Explosion Hazard – Substitution of Components May Impair Suitability for hazardous loca-
tions.
Risque d’explosion – La substitution de composants peut rendre ce materiel inacceptable pour
les emplacements est designé dangereux.
Explosion Hazard – Do Not Disconnect Equipment Unless Power Has Been Switched Off or
the Area is Known to be Non-Hazardous.
Risque d’explosion –Avant de déconnecter l’équipement, coupez le courant où vous
assurez que l’emplacement est designé non dangereux.
For installations using North American wiring practice, all input and output wiring must be
in accordance with Class I, Division 1 and Zone 1 wiring methods (NEC Sec 501.10(a) and
505.15(b)) or IEC 60079-14) and in accordance with the authority having jurisdiction.
!
WARNING
!
WARNING
Essential Health & Safety Requirements | 9

PROTECTIVE CONDUCTOR TERMINAL
CAUTION - Risk of electric shock
CAUTION - Refer to accompanying documents
CAUTION - Hot Surface
Warning Labels
These symbols may appear on the instrument in order to alert you of existing conditions.
10 | IPS-4 Zone1/Analyzer

Classified, Hazardous Area Protection Components and Functions
The Division 1/Zone 1 versions of the IPS-4 are designed to be, and comply with requirements
for, electrical equipment in Division 1 and Zone 1 classified hazardous areas. The methods of
protection used include type “p” (pressurized), and type “d” (Flameproof enclosure).
The purge system, redundant heater control, disconnect assembly and enclosure designs assure
that the system will not ignite surrounding gases. For this reason, any repairs must not bypass
these safety considerations and must use only recommended components.
The purge system consists of the electronics enclosure, a purge controller, an overpressure vent,
a bypass switch and power/signal disconnect assembly. It maintains a positive pressure in the
electronics enclosure that prevents flammable and corrosive gases from contacting electrical
components. The oven enclosure and the seals between the enclosures are designed to assure
that the required 5x factor of safety to assure that the sample containment system will not inter-
fere with proper operation of the purge system.
The disconnect assembly receives a pneumatic signal from the purge controller when the enclo-
sure has been adequately purged and the overpressure is maintained. Until these conditions are
met, the relays in the disconnect assembly break all power and signal connections between the
field and the analyzer. When the electronics enclosure is opened or the pressurization gas sup-
ply is lost, the system will shut the analyzer down and transfer a set of contacts that may be used
to provide an alarm.
The bypass switch enables operation of the analyzer by applying air pressure to the disconnect
assembly - bypassing the purge controller. This feature must only be used when the area is
known to be safe and is being continuously monitored (See Combustible Gas Detection protec-
tion techniques in NFPA70 article 500 and 505). Figure 1 is a state diagram showing the opera-
tion of the pressurization system and the pressure settings.
The analyzer must be installed and operated in accordance with this instruction manual. Instru-
ment air or nitrogen may be used as the purge gas.
Once the analyzer has been located in an area contaminated with flammable gases or vapors
the IPS-4 purge system must be activated to keep these gasses out of the enclosure. For this
reason, AC power and an instrument air supply must be connected to the IPS-4. See “System
Start- Up” for instructions on how to initialize the purge system. If it is not required that the
IPS-4 be powered on at this time, switching the power off at the power source will shut down
the analyzer while maintaining the protective internal pressure. Switching the power on again
will re-activate the IPS-4 if the purge controller is still in the normal pressurization mode.
For the protection system to operate properly, the cover on the disconnect enclosure must be
properly installed and the electronics and oven enclosure doors must be securely shut. All door
latches must be properly tightened with the key.
!
CAUTION
!
CAUTION
Essential Health & Safety Requirements | 11

Flanged Flameproof Enclosure:
When the IPS-4 is supplied with the 4660 Sample System option, the flowmeters are installed in
a flanged flameproof enclosure. Care must be taken to assure that all of the bolts are installed
and the flange surfaces are kept in good condition. The minimum flamepath length must be at
least 1 inch (25.4mm) and smooth (250 microinches or better). The gap between the flange sur-
faces with the bolts tightened must not exceed 0.0015 inches (0.0381MM).
Figure 1.
Pressurization system state diagram.
12 | IPS-4 Zone1/Analyzer

Specifications
For a complete listing of all analyzer specifications, refer to the analyzer User Manual.
Utility Requirements
Power Consumption
Without Oven Heater
< 300 W maximum start-up (from a cold start) with continuous average, depending on ambient
temperature.
With Oven Heater
< 700 W maximum start-up (from a cold start) with continuous average, depending on ambient
temperature.
Supply Voltage
120 VAC (105–132 VAC), 47–63 Hz OR
240 VAC (209–264 VAC), 47–63 Hz
Instrument Air
The aspirator medium must be transported in 316 stainless steel.
Minimum pressure:
490–700 kPag (70–100 psig / 4.8–6.9 barg)
Air Quality:
As per ANSI/ISA-S7.0.01 (1996) Quality Standard for Instrument Air.
Outputs
256 x 64 pixel vacuum-fluorescent display with multilingual capability.
Four (4) isolated analog outputs, configurable as 0–20 mA or 4–20 mA(two are standard; two are
optional).
Up to eight (8) relays (NO, contact rating 100 VA, 240 V maximum), which indicate the opera-
tional status of the analyzer. Each relay provides one SPST (Form A) dry (potential free) contact.
Two Form C loss of purge alarm contacts rated 240Vac 5A max
RS485 serial port, isolated.
RS232 serial port, non-isolated.
Essential Health & Safety Requirements | 13

Fast Ethernet (IEE802.3).
Modbus TCP (Supports single Modbus Client).
Ambient Temperature Limits
-20 °C ≤ Ta ≤ 50 °C , without external heating or cooling.
Sample System Limits
Sample Pressure
Up to 10,000 kPag (1,450 psig / 100 barg) can be accommodated, depending on the application.
See product markings or customer-specific drawings in the “Supplemental Information” tab of
this manual.
Oven/Sample System Enclosure Temperature
For applications with a heated sample system, the Oven will operate at temperatures up to 150
°C (302 °F).
Approvals and Certifications
The IPS-4 Analyzer is certified with regard to electrical safety for Pollution Degree 2 (normally
nonconductive environmental pollution occurs with occasional condensation) and Installation
Category II (local level transients, less than those found at power distribution level). Mains sup-
ply voltage fluctuations are not to exceed 10 percent of the nominal supply voltage.
Approvals and certifications for the Zone1/Division1 Model include:
NEC/CEC: Class I Div 1 Groups A, B, C, D, Class II Div 1
Groups F & G, and Class III
Class I Zone 1 AEx d px IIC T3, Class I Zone 1
Ex d px IIC T3
ATEX: II 2 G ATEX Ex db pxb IIC T3 Gb IP65
NOTE - models with the 4660 sample system flowmeter installed are reduced to gas groups
BCD and IIB+H2.

NOTE
14 | IPS-4 Zone1/Analyzer

Analyzer Markings
The Model IPS-4 Analyzer will be marked with a corresponding label to indicate its Ex equip-
ment certification and ratings.
Figure 2a.
IPS-4 ATEX Label for Zone 1 model
WITHOUT 4660 sample system option.
Figure 2b.
IPS-4 ATEX 4660 Label for Zone 1
models WITH 4660 sample system option.
Essential Health & Safety Requirements | 15

Figure 2c.
IPS-4 Label for Div 1 models
WITHOUT 4660 sample system option.
Figure 2d.
IPS-4 Label for Div 1 models
WITH 4660 sample system option.
Figure 2e.
IPS-4 Label for Zone 1 models
With Dual Bench option.
16 | IPS-4 Zone1/Analyzer

Essential Health & Safety Requirements | 17
Installing the Analyzer
The Installation & Start-Up chapter contains information about the fol-
lowing topics:
• Where to find safety information in this guide before working with
the analyzer.
• How to store the analyzer before installation.
• How to uncrate and inspect the analyzer for damage before installing
it.
• Tools, equipment, and supplies required for installation.
• How to install the mechanical components and sample lines, and per-
form a leak check on all of the fittings and connections before power-
ing up the analyzer.
• How to make all of the required electrical connections.
• How to apply power to the analyzer and configure it for operation.
• What to expect during normal operation.
The installation of the analyzer must be in accordance with all of the
customer (end user) and local regulatory standards and procedures.
There are no operator-serviceable components inside the analyzer.
Refer service requirements to qualified personnel.
!
WARNING

18 | IPS-4 Zone1/Analyzer
Safety Considerations
Before beginning the installation of the analyzer and before powering
it up, review and follow all safety requirements under “Important
Safety Notes, Warnings, and Cautions” following the Table of Con-
tents near the beginning of this manual. This information describes
procedures to follow to avoid personal injury and/or damage to the
equipment. All regulatory agency and personnel safety procedures
for your jurisdiction must be followed.
The IPS-4 Analyzer is certified with regard to electrical safety for
Pollution Degree 2 (normally nonconductive environmental pollution
occurs with occasional condensation) and Installation Category II (lo-
cal level transients, less than those found at power distribution level).
Mains supply voltage fluctuations are not to exceed 10 percent of the
nominal supply voltage.

NOTE
!
WARNING

Essential Health & Safety Requirements | 19
Pre-Installation Requirements
Storage Prior to Installation
If the analyzer is stored for any period of time prior to installation, it must
be housed in a temperature-controlled environment where it is not sub-
ject to dripping or splashing liquids, corrosive gases/liquids, high humid-
ity, or excessive heat or cold.
Uncrating and Inspecting the Analyzer
The analyzer, along with its associated sample system, is shipped pre-
mounted on unistruts (or on a backpan) either alone in a crate or in a
crated weatherproof shelter. The Optical Bench Assembly is shipped in a
separate box within the Analyzer crate.
Upon receiving the analyzer system, remove the shipping crate and check
the exterior of the shelter and/or analyzer for damage. Remove the Opti-
cal Bench Assembly from its box and check it for any physical damage. Re-
place the Optical Bench Assembly in its box until it is ready to be installed.
Open the shelter and/or analyzer and check to ensure that all of the com-
ponents within are secure and that there is no physical damage. Check
that all of the components and wiring within the Electronics Enclosure
and Oven/Sample System Enclosure are secure and that there is no physi-
cal damage.
After the inspection, close and secure all doors with at least one latch.
This will keep the electronics equipment secure and will prevent dam-
age to the doors and electronic components during installation.
For non-shelter systems, avoid damaging the analyzer piping or
instrumentation by lifting it out of its shipping crate using only its
unistruts or backpan, or metal enclosure. DO NOT use any external
instrument or tubing connectors as a handle for lifting.
The analyzer (on unistruts) weighs approximately 74 kg (163 lb) to
100 kg (220 lb), depending on the system. Use caution when lifting it
from its crate.
!
CAUTION
!
CAUTION
!
WARNING

20 | IPS-4 Zone1/Analyzer
General Installation Information
Figure 3 illustrates an example of the layout of components within the
IPS-4 Analyzer. The components in the Electronics Enclosure gener-
ally do not change. However, many of the sample system components
in the Oven/Sample System Enclosure in this example illustration are
optional and are configured specifically for the application.
Customer-specific drawings for your analyzer are located in the
“Supplemental Information” tab of this manual and in the Documen-
tation Package shipped with the analyzer.
Tools, Equipment, and Supplies Required for Installation
While installing the analyzer, the following tools, equipment, and supplies
are required:
• Door latchkeys (two keys are supplied with the analyzer), attached to
the exterior of the analyzer.
• Set of open-end wrenches for fittings and set of metric ball drivers.
• Wire Cutters, strippers, and crimpers.
• Flat blade instrument screwdriver.
• Soft, non-abrasive cloth.
• Wrist Strap (for grounding).
• Detergent-based leak detector (Snoop®or another suitable leak detec-
tion agent is permissible).
• Ethernet cable (supplied by customer), for systems using a permanent
Ethernet connection. Length will vary, depending on application.
Minimum requirements: CAT 5e (maximum 100 m).
Special requirements may be necessary for outdoor analyzer installa-
tions, hazardous locations, and/or lengths greater than 100 m.
Systems using Ethernet also require a ferrite core (supplied by AM-
ETEK).
For systems using a temporary Ethernet connection, a crossover cable
must be used.
• One power-disconnect switch (breaker), rated for at least 250 VAC,
20 A. For safety reasons during maintenance, this switch allows the
main AC power to be disconnected from the analyzer. Supplied by
customer.
• A supply of 1/4” O.D. 316 stainless steel tubing for the Instrument
Air (or N2) and Span fluid lines. Length will vary, depending on the
distance between the analyzer and the supply source. Supplied by the
customer.
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NOTE