Ametek Western Research IPS-4 User manual

AMETEK Western Research
IPS-4 Analyzer
Infrared
Zone 1/Division 1
User Manual
PN 700076902, Rev A
Process Instruments
455 Corporate Blvd.
Newark, DE 19702

Ofces
© 2008 AMETEK Process & Analytical Instruments Division

believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities speci-

or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.
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: 281 463 2820, 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
ii | IPS-4 Analyzer, Infrared Z1/Div1

Table of Contents
Offices .....................................................................................................................ii
Safety Notes ........................................................................................................viii
Electrical Safety...................................................................................................viii
Grounding...........................................................................................................viii
Personnel and Equipment Safety Information................................................ix
Warnings...................................................................................................ix
Cautions .....................................................................................................x
Warning Labels ..................................................................................................... xi
Environmental Information (WEEE) ................................................................xi
Electromagnetic Compatibility (EMC).............................................................xii
Special Warnings and Information..................................................................xiii
Warranty and Claims.........................................................................................xiv
EC Declaration of Conformity ..........................................................................xv
CHAPTER 1 OVERVIEW
Principles of Operation .....................................................................................1-1
Basic Analytical Theory ..............................................................................1-1
The Implementation ...................................................................................1-2
Optical System and Measurement ..........................................................1-2
Sample System.........................................................................................1-3
Electronics ...............................................................................................1-4
Classified, Hazardous Area Protection Components and Functions ........1-5
Analyzer Electronics and Sample System Features ......................................1-7
CHAPTER 2 SPECIFICATIONS
Methodology.......................................................................................................2-1
Wavelength Ranges.....................................................................................2-1
Analyzer Range.......................................................................................2-1
Photometric Range ..................................................................................2-1
Analyzer Specifications .....................................................................................2-2
Analytes.........................................................................................................2-2
Response Time .............................................................................................2-2
Measurement Accuracy ..............................................................................2-2
Repeatability.................................................................................................2-2
Linearity........................................................................................................2-2
Stability..........................................................................................................2-2
Temperature Drift........................................................................................2-2
24-Hour Zero Drift ......................................................................................2-2
Inputs.............................................................................................................2-3
Outputs .........................................................................................................2-3
Sample System Limits.................................................................................2-3
Sample Pressure ......................................................................................2-3
Oven/Sample System Enclosure Temperature.........................................2-3
Contents | iii

Sample Transport.........................................................................................2-4
Instrument Air Requirements....................................................................2-4
Zero Fluid .....................................................................................................2-4
Sample Fluid Flow Rate..............................................................................2-4
Electrical Requirements..............................................................................2-5
Power Consumption ................................................................................2-5
Supply Voltage.........................................................................................2-5
Measuring Cell Construction ....................................................................2-5
Pressure Input Signals ................................................................................2-5
Xenon Flash Lamp.......................................................................................2-5
Environmental .............................................................................................2-6
Ambient Temperature ..............................................................................2-6
Humidity.................................................................................................2-6
Pollution Degree......................................................................................2-6
Maximum Altitude..................................................................................2-6
Installation Category...............................................................................2-6
Enclosure Material ..................................................................................2-6
Ingress Protection....................................................................................2-6
On-Board Temperature Sensor..................................................................2-6
Physical Dimensions ...................................................................................2-7
Approvals and Certifications.....................................................................2-7
CHAPTER 3 INSTALLATION & START-UP
Safety Considerations........................................................................................3-2
Pre-Installation Requirements..........................................................................3-3
Storage Prior to Installation .......................................................................3-3
Uncrating and Inspecting the Analyzer...................................................3-3
General Installation Information..............................................................3-4
Tools, Equipment, and Supplies Required for Installation ...................3-4
Installing the Mechanical Components..........................................................3-6
Mounting the Analyzer ..............................................................................3-6
Location and Environment......................................................................3-6
Installing the Optical Bench Assembly ..................................................3-11
Installing the Sample System...................................................................3-13
Installing the Sample Probe/Sample Tap...............................................3-13
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).......................3-18
Connecting I/O Signals, Alarm Relay Contacts, and AC Power...............3-20
Electrical Connections...............................................................................3-20
Permanent Ethernet Cable Connections (Optional)............................3-23
Start-Up and Verification ................................................................................3-23
Powering Up the Analyzer.......................................................................3-23
Start-Up Diagnostic Checklist .................................................................3-30
Sample System Leak Check .....................................................................3-32
iv | IPS-4 Analyzer, Infrared Z1/Div1

Manually Zeroing the Analyzer Sample System..................................3-34
Adjusting the Zero/Span Fluid Flow Rate .............................................3-35
Adjusting the Sample Flow Rate.............................................................3-35
Setting Sample Response Time..............................................................3-36
Normal Operation............................................................................................3-37
Recording Initial Readings.......................................................................3-37
Recording Initial Sample Response Time ..............................................3-37
Analyzer Configuration ..................................................................................3-38
CHAPTER 4 CONTROLLER / USER INTERFACE
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.....................................................................................4-18
Calibration Fluid Concentration ...........................................................4-19
Calibration Screen .................................................................................4-20
Manually Starting a Zero Calibration............................................4-21
Manually Starting a Span Calibration...........................................4-21
Relay Setup Screens ..............................................................................4-23
Current Output Setup Screens .............................................................4-25
Setpoints................................................................................................4-27
Diagnostics Screen ................................................................................4-28
System Settings Screen ........................................................................4-30
Login/Set Passwords Screen ..................................................................4-30
Changing the Password...................................................................4-31
Locking the Password......................................................................4-32
Removing the Password..................................................................4-32
Backup/Restore Settings Screen ............................................................4-32
Backing Up Analyzer Configuration Settings................................4-33
Restoring Analyzer Configuration Settings...................................4-33
Ethernet Network Screen ......................................................................4-35
System Screen........................................................................................4-37
Customization Screen............................................................................4-38
Modbus Screen ......................................................................................4-39
Contents | v

CHAPTER 5 MAINTENANCE & TROUBLESHOOTING
Safety Considerations........................................................................................5-1
Maintenance........................................................................................................5-2
Preventive Maintenance.............................................................................5-2
Analyzer Preventive Maintenance Schedule...........................................5-3
Before Performing Maintenance ...............................................................5-5
Locating a Plug in the Sample System....................................................5-5
Detecting a Plug in the Sample System ..................................................5-5
Preventing a Plug in the Sample System (Gas Applications).................5-6
Changing Out Replaceable Parts ..............................................................5-8
Tools, Equipment, and Supplies Required for Maintenance ...................5-9
Measuring Cell Preventive Maintenance..............................................5-11
Xenon Flash Lamp Assembly Replacement...........................................5-19
Replacing the Xenon Flash Lamp Assembly...................................5-20
Replacing the MCU Battery...........................................................5-23
Troubleshooting and Diagnostics ..................................................................5-26
Alarm Notification – Viewing Alarms on the User Interface Panel...5-26
Viewing Current Alarm Messages ........................................................5-27
Viewing Historical Alarm Messages .....................................................5-27
Alarm Conditions and Corrective Action..............................................5-28
Analyzer Reset ...........................................................................................5-31
CHAPTER 6 SERVICE & PARTS
Technical Support...............................................................................................6-1
Returning Equipment........................................................................................6-2
AMETEK Service & 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
Spare Battery, MCU Board ........................................................................6-5
CHAPTER 7 MODBUS COMMUNICATION INTERFACE
Hardware:.....................................................................................................7-1
Configuration:..............................................................................................7-2
Analyzer Modbus Interface Parameters .........................................................7-3
Modbus Address..........................................................................................7-3
Modbus Functions.......................................................................................7-3
Holding Registers...............................................................................................7-4
APPENDIX DRAWINGS
Analyzer Light Path Schematic .......................................................................A-2
Analyzer Mounting Details, ...........................................................................A-3
Analyzer Overall Component Layout ........................................................... A-4
vi | IPS-4 Analyzer, Infrared Z1/Div1

Micro Controller Board (700029902)...............................................................A-5
Preamp Assembly (700043901) ........................................................................A-6
Display Interface Board (100-1978)................................................................. A-7
Customer Connection Board (100-1971)........................................................ A-8
Relay Board (100-2050) ..................................................................................... A-9
Analog Board (100-2047) ................................................................................A-10
MCU Board (100-2045S) ................................................................................. A-11
Interface Board (700030901)...........................................................................A-12
Electronics Enclosure Wiring Diagram, Sheet 1 of 3 .................................A-13
Electronics Enclosure Wiring Diagram, Sheet 2 of 3 ................................A-14
Electronics Enclosure Wiring Diagram, Sheet 3 of 3 ................................A-15
Disconnect Enclosure Wiring Diagram .......................................................A-16
SUPPLEMENTAL INFORMATION
Essential Health and Safety Information
EXPO MiniPurge System manual
Contents | vii

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
performing 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
instrument is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.
!
CAUTION

NOTE
!
CAUTION
!
WARNING
viii | IPS-4 Analyzer, Infrared Z1/Div1

!
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 regu-
lations, standards, and procedures at the analyzer location must be followed.
All personnel involved with the installation, start-up, operation, maintenance, service, or trou-
bleshooting 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 open-
ing 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 hazardous area,
and be approved by the Owner Company.
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.
Before working on the sample system, confirm that the system has been purged with Zero fluid
and is isolated (blocked in) from the process.
If the Oven/Sample System Enclosure is heated, the components within it will be hot; take
precautions to avoid burning yourself.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
Contents | ix

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.
The optical bench contains an infrared source. Use care when handling the source and adjacent
metal surfaces.
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
x | IPS-4 Analyzer, Infrared Z1/Div1