Ametek Western Research IPS-4 User manual

AMETEK Western Research
IPS-4 Analyzer
Full Spectrum Option
General Purpose/Division 2
User Manual
PN 403469902, Rev B
Process Instruments
455 Corporate Blvd.
Newark, DE 19702

© 2011 AMETEK Process & Analytical Instruments Division
This manual is a guide for the use of the IPS-4 (Integrated Process Spectrophometer) Analyzer with Full Spectrum Option. Data herein has been
verified 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 specified herein, confirmation 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.
Offices
SALES AND MANUFACTURING:
USA - Delaware
455 Corporate Blvd., Newark DE 19702 • Tel: [phone], Fax: [phone]
USA - Oklahoma
2001 N. Indianwood Ave., Broken Arrow OK 74012 • Tel: [phone], Fax: [phone]
USA - Pennsylvania
150 Freeport Road, Pittsburgh PA 15238 • Tel: [phone], Fax: [phone]
CANADA - Alberta
2876 Sunridge Way N.E., Calgary, AB T1Y 7H9 • Tel: [phone], Fax: [phone]
WORLDWIDE SALES AND SERVICE LOCATIONS:
USA - TexasTel: 713-466-4900, Fax: [phone]
CHINA
Beijing / Tel: [phone], Fax: [phone]
Chengdu / Tel: [phone], Fax: [phone]
Shanghai / Tel: [phone], Fax: [phone]
FRANCE
Tel: [phone], Fax: [phone]
GERMANY
Tel: [phone], Fax: [phone]
MIDDLE EAST - Dubai
Tel: [phone], Fax: [phone]
SINGAPORE
Tel: [phone], Fax: [phone]
www.ametekpi.com
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Table of Contents
Offices ....................................................................................................................ii
SALES AND MANUFACTURING:.....................................................................ii
Safety Notes ........................................................................................................viii
Electrical Safety...................................................................................................viii
Grounding...........................................................................................................viii
Personnel and Equipment Safety Information................................................ix
Warnings...................................................................................................ix
Cautions .....................................................................................................x
Electromagnetic Compatibility (EMC).............................................................xii
Special Warnings and Information..................................................................xiii
Equipment Used in Class I, Division 2 Hazardous Locations ................xiii
Warranty and Claims.........................................................................................xiv
Overview 1
OPTICAL BENCH CONFIGURATIONS........................................................... 1
Basic Analytical Theory (Optical Bench) .................................................... 1
Flow Diagram.................................................................................................. 1
Calculation Flow............................................................................................. 2
Dispersive Ultraviolet/Visible (DUVV) Spectrometer ..................................... 4
Basic Analytical Theory ............................................................................... 4
Optical Bench Design ................................................................................... 4
UV Specifications............................................................................................ 5
Wavelength Ranges........................................................................................ 5
Wavelength Accuracy+/- 0.5 nm ..............................................................5
Wavelength Resolution3 nm...................................................................... 5
Analyzer Rangeppm to 100 %, depending on the application........... 5
Photometric Range...................................................................................... 5
Photometric Noise ......................................................................................5
Non-Dispersive Infrared (NDIR) PhotometerBasic Analytical Theory . 6
Optical Bench Design .................................................................................... 6
NDIR Specifications ..........................................................................7
Wavelength Ranges ...................................................................................7
Photometric Noise .....................................................................................7
Sample System ................................................................................................ 7
Electronics........................................................................................................ 7
Classified, Hazardous Area Protection Components and Functions ........... 9
Specifications 2
Analyzer Specifications ........................................................................................ 1
Analytes............................................................................................................ 1
Response Linearity......................................................................................... 1
Measurement Accuracy ................................................................................. 1
Contents | iii

Repeatability.................................................................................................... 1
Linearity ........................................................................................................... 1
Stability............................................................................................................. 1
24-Hour Zero Drift .........................................................................................1
Inputs................................................................................................................ 2
Outputs ............................................................................................................ 2
Sample System Limits.................................................................................... 2
Sample Pressure .........................................................................................2
Oven/Sample System Enclosure Temperature............................................2
Sample Transport............................................................................................ 3
Instrument Air Requirements....................................................................... 3
Sample Fluid Flow Rate................................................................................. 3
Electrical Requirements................................................................................. 3
Power Consumption ...................................................................................3
Heated Sample Line ...................................................................................4
Supply Voltage............................................................................................4
Cell Construction............................................................................................ 4
Pressure Input Signals ................................................................................... 4
Environmental ................................................................................................ 4
Ambient Temperature .................................................................................4
Humidity....................................................................................................4
Pollution Degree.........................................................................................4
Maximum Altitude.....................................................................................4
Installation Category..................................................................................5
Enclosure Material .....................................................................................5
Ingress Protection.......................................................................................5
On-Board Temperature Sensor..................................................................... 5
Physical Dimensions ...................................................................................... 5
Approvals and Certifications........................................................................6
Installation & Start-Up 3
Safety Considerations........................................................................................... 2
Pre-Installation Requirements............................................................................. 3
Storage Prior to Installation .......................................................................... 3
Uncrating and Inspecting the Analyzer...................................................... 3
General Installation Information................................................................. 4
Tools, Equipment, and Supplies Required for Installation ...................... 4
Installing the Mechanical Components............................................................. 7
Mounting the Analyzer ................................................................................. 7
To mount the analyzer: .....................................................................................7
Installing the Optical Bench-UV Assembly................................................ 7
Installing the Optical Bench IR Assembly ................................................ 10
Installing the Sample System...................................................................... 12
Installing the Sample Probe/Sample Tap ........................................................12
Installing and Connecting the Sample and Vent Lines ............................13
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Installing and Connecting the Instrument Air/Zero Fluid Line..............14
Installing the Calibration (Span) Fluid Line (Optional)..........................15
Connecting I/O Signals, Alarm Relay Contacts, and AC Power.................. 16
Electrical Connections.................................................................................. 16
Permanent Ethernet Cable Connections (Optional)............................... 17
Start-Up and Verification ................................................................................... 18
Powering Up the Analyzer ................................................................................ 18
Start-Up Diagnostic Checklist .................................................................... 25
Sample System Leak Check ........................................................................ 26
Manually Zeroing the Analyzer Sample System..................................... 27
Adjusting the Zero/Span Fluid Flow Rate ................................................ 28
Adjusting the Sample Flow Rate................................................................ 28
Setting Sample Response Time.................................................................29
Normal Operation............................................................................................... 30
Recording Initial Readings.......................................................................... 30
Recording Initial Sample Response Time .................................................30
Analyzer Configuration ..................................................................................... 31
Controller / User Interface 4
Introduction to the User Interface Panel........................................................... 2
User Interface Panel Components ............................................................... 2
Special Software Characters.......................................................................... 4
Working From the User Interface Panel – Conditions and Messages.... 5
Summary of Analyzer Operation ................................................................ 6
Working in the Main Menus ...............................................................................6
HOME Menu Screen...................................................................................... 6
System Status Messages (HOME Screen).................................................9
Alarm and Warning Notification (HOME Screen) .................................10
ALARMS and WARNINGS Menu Screen................................................. 11
Viewing Current Alarms and Warnings..................................................11
Viewing Logged Alarms and Warnings ...................................................12
STATUS Menu Screen .................................................................................. 13
SETUP Menu Screen.................................................................................... 15
Calibration Control Screen.......................................................................16
Calibration Valves.....................................................................................19
Calibration Actions Screen.......................................................................19
Relay Setup Screens ..................................................................................... 22
Current Output Setup Screens ................................................................25
Setpoints...................................................................................................27
Diagnostics Screen ...................................................................................28
System Settings Screen ...........................................................................30
Login/Set Passwords Screen .....................................................................30
Backup/Restore Settings Screen ...............................................................32
Ethernet Network Screen .........................................................................35
Customization Screen...............................................................................38
Contents | v

Modbus Screen .........................................................................................39
Maintenance & Troubleshooting 5
Safety Considerations........................................................................................... 1
Maintenance........................................................................................................... 2
Preventive Maintenance................................................................................ 2
Analyzer Preventive Maintenance Schedule..............................................3
Before Performing Maintenance.................................................................. 5
Locating a Plug in the Sample System.......................................................5
Detecting a Plug in the Sample System .....................................................5
Changing Out Replaceable Parts ................................................................. 7
Tools, Equipment, and Supplies Required for Maintenance ......................8
Measuring Cell Preventive Maintenance.................................................10
Infrared Source Assembly Replacement................................................... 17
Xenon Flash Lamp Assembly Replacement ............................................. 21
Replacing the MCU Battery........................................................................ 23
Troubleshooting and Diagnostics ..................................................................... 25
Alarm Conditions and Corrective Action........................................................ 27
Analyzer Reset .............................................................................................. 31
Service & Parts 6
Technical Support.................................................................................................. 1
Returning Equipment........................................................................................... 2
AMETEK Service & Aftermarket Sales Support............................................... 3
Recommended Spare Parts.................................................................................. 4
Measuring Cell Assembly Spare Parts......................................................... 4
Optical Bench Assembly Spare Parts........................................................... 4
Spare Analyzer Fuses ..................................................................................... 5
Spare Battery, MCU Board ........................................................................... 5
User Web Interface 7
Introduction to the Web Interface ...................................................................... 2
Web Interface Components .......................................................................... 3
Working From the Web Interface – Conditions and Messages ............... 3
HOME Menu Screen...................................................................................... 4
ALARMS Menu Screen.................................................................................. 5
Current Alarms and Warnings..................................................................5
Logged Alarms and Warnings ...................................................................6
Alarm and Warning Notification...............................................................6
TRENDS Menu Screen ..................................................................................7
Parameters ..................................................................................................8
Intervals......................................................................................................8
SPECTRA Menu Screen................................................................................. 9
Viewing Spectral Data ...............................................................................9
SETTINGS Menu Screen ............................................................................. 10
Calibration Settings Screen......................................................................11
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Actions Screen ..........................................................................................12
Current Output Screen ............................................................................13
Relay Setup Screens .................................................................................14
Network & Modbus Screen ......................................................................15
System & Customition Screen ................................................................16
Analytes Screen .......................................................................................17
Limits Screen ...........................................................................................18
Diagnostics Screen ...................................................................................19
Save/Restore Files Screen .........................................................................20
Modbus communication interface 8
Hardware:........................................................................................................ 1
Configuration:................................................................................................. 2
Analyzer Modbus Interface Parameters ............................................................ 3
Modbus Address............................................................................................. 3
Modbus Functions.......................................................................................... 3
Holding Registers.................................................................................................. 4
APPENDIX – DRAWINGS a
Analyzer Light Path Schematic ........................................................................... 2
UV Schematic......................................................................................................... 2
NDIR Schematic .................................................................................................... 2
Analyzer Mounting Details ................................................................................. 3
Analyzer Overall Component Layout ............................................................... 4
Detector Interface Board (403441901) ................................................................ 5
Detector Board (100-1955).................................................................................... 6
Detector board (700030901).................................................................................. 6
Display Interface Board (100-1978)..................................................................... 7
Display Interface board (700043901) .................................................................. 7
Customer Connection Board (100-1971)............................................................ 8
Relay Board (100-1942) ......................................................................................... 9
Analog Board (100-1922) .................................................................................... 10
MCU Board (100-2045) ....................................................................................... 11
Xenon Lamp Board (100-2061) .......................................................................... 12
Electronics Enclosure Wiring Diagram, Sheet 1 of 5 (403443001)................ 13
Electronics Enclosure Wiring Diagram, Sheet 2 of 5 (403443001)................ 14
Electronics Enclosure Wiring Diagram, Sheet 3 of 5 (403443001)................ 15
Supplemental Information S
Contents | vii

Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as fol-
lows:
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 equip-
ment.
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 qualified electrician should make electrical connections and
ground checks.
Any use of the equipment in a manner not specified by the manufacturer may impair the safety protection
originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specifications 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
viii | IPS-4 Full SpectrumGPDIV2

!
WARNING
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 doors on the analyzer to check or perform maintenance on any components
within the enclosures.
If it is necessary to open the analyzer doors while the circuits are live, first monitor the area
for flammable gases and proceed only when the area is safe.
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 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 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
!
WARNING
!
WARNING
!
WARNING
!
WARNING
Contents | ix

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
ultraviolet radiation.
If the Oven/Sample System Enclosure is heated, the components within it will be hot; take
precautions to avoid burning yourself.
Cautions
Review and follow these Cautions to avoid damaging the equipment.
The electronic circuit boards and other static-sensitive components should be stored and
transported 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 typi-
cally 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.
When handling the Xenon Flash Lamp, it is very important not to touch the lamp windows
because residual oils from the fingers will absorb ultraviolet light. The window is the flat sur-
face at the end of the narrow glass tube. The lamp assembly is fragile and should be handled
with care.
!
WARNING
!
WARNING
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
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