Ametek Western Research IPS-4 User manual

AMETEK Western Research
IPS-4 Analyzer
Fiber Optic UV/VIS Option
General Purpose
User Manual
PN 403370901, Rev B
Process Instruments
455 Corporate Blvd.
Newark, DE 19702

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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: 918-
459-0165
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: +1-
403-248-3550
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
© 20010 AMETEK Process & Analytical Instruments Division
This manual is a guide for the use of the IPS-4 (Integrated Process Spectrophometer) Analyzer with Fiber Optic UV/VIS 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 suitabil-
ity 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.

Contents | iii
Contents
OfficesSALES AND MANUFACTURING:......................................................................ii
Safety Notes....................................................................................................................viii
Electrical Safety..............................................................................................................viii
Grounding.......................................................................................................................viii
Personnel and Equipment Safety Information ...................................................................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 (SOFTWARE VERSION 3.0)....................................................................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 RangeThe photometric absorbance range is dependent on
wavelength. ........................................................................................................... 5
Photometric NoiseThe photometric noise is dependent on wavelength.Typi-
cally +/- 0.001 AU ................................................................................................. 5
Electronics .................................................................................................................................6
Classified, Hazardous Area Protection Components and Functions.......................7
Specifications ..............................................................................................................................1
Analyzer Specifications....................................................................................................1
Analytes.....................................................................................................................................1
Response Linearity...................................................................................................................1
Measurement Accuracy...........................................................................................................1
Repeatability .............................................................................................................................1
Linearity ....................................................................................................................................1
Stability......................................................................................................................................1
Inputs .........................................................................................................................................2
Outputs......................................................................................................................................2
Air / N2Quality Requirements........................................................................................3

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Air Quality: ...............................................................................................................................3
Nitrogen Quality ......................................................................................................................3
Sample Fluid Flow Rate ..........................................................................................................3
Electrical Requirements...........................................................................................................3
Power Consumption< 500 W maximum start-up (from a cold start) with
continuous average, depending on ambient temperature. ........................... 3
Supply Voltage....................................................................................................... 3
Cell Construction ................................................................................................... 3
Environmental........................................................................................................3
Ambient Temperature ............................................................................................3
Humidity.................................................................................................................4
Pollution Degree .................................................................................................... 4
Maximum Altitude .................................................................................................. 4
Installation Category..............................................................................................4
Enclosure Material.................................................................................................4
Physical Dimensions................................................................................................................4
Approvals and Certifications .................................................................................................5
Installation & Start-Up ................................................................................................................1
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 ........................................................................6
Mounting the Analyzer ...........................................................................................................6
Location and Environment.....................................................................................6
Installing the Sample System ...............................................................................................10
Installing the Sample Probe/Sample Tap............................................................. 10
Connecting I/O Signals, Alarm Relay Contacts, and AC Power ............................11
Electrical Connections ...........................................................................................................11
Permanent Ethernet Cable Connections (Optional)..........................................................12
Start-Up and Verification ...............................................................................................14
Powering Up the Analyzer ...................................................................................................14
Start-Up Diagnostic Checklist ..............................................................................................20
Manually Zeroing the Analyzer Sample System...............................................................21
Adjusting the Zero/Span Fluid Flow Rate.........................................................................21
Recording Initial Readings ...................................................................................................22
Analyzer Configuration..................................................................................................24
Controller / User Interface..........................................................................................................1
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

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Summary of Analyzer Operation ..........................................................................................6
Working in the Main Menus ...........................................................................................7
HOME Menu Screen................................................................................................................7
Bench..........................................................................................................................................7
System Status Messages (HOME Screen) ...........................................................8
Alarm and Warning Notification (HOME Screen)................................................... 9
ALARMS and WARNINGS Menu Screen............................................................................9
Viewing Current Alarms and Warnings ..................................................................9
Viewing Logged Alarms and Warnings................................................................ 11
STATUS Menu Screen............................................................................................................12
SETUP Menu Screen ..............................................................................................................13
Calibration Control Screen ..................................................................................14
Calibration Settings Screen............................................................................................14
Flush Times ....................................................................................................................16
Calibration Values................................................................................................17
Manually Starting a Zero Calibration ..............................................................................19
Manually Starting a Span Calibration .............................................................................19
Relay Setup Screens...........................................................................................20
Current Output Setup Screens ............................................................................23
Setpoints..............................................................................................................24
Diagnostics Screen..............................................................................................26
System Settings Screen ..................................................................................... 27
Login/Set Passwords Screen ..............................................................................28
Removing the Password.................................................................................................30
Backup/Restore Settings Screen.........................................................................30
Backing Up Analyzer Configuration Settings..................................................................31
Restoring Analyzer Configuration Settings.....................................................................31
Ethernet Network Screen ....................................................................................32
System Screen .................................................................................................... 35
Customization Screen ......................................................................................... 36
Modbus Screen ................................................................................................... 37
Maintenance & Troubleshooting ..........................................................................................1
Safety Considerations.......................................................................................................1
Maintenance .......................................................................................................................2
Preventive Maintenance..........................................................................................................2
Analyzer Preventive Maintenance Schedule .........................................................3
Before Performing Maintenance ............................................................................................5
Changing Out Replaceable Parts ...........................................................................................5
Tools, Equipment, and Supplies Required for Maintenance.................................. 6
Measuring Cell Preventive Maintenance ...............................................................8
Xenon Flash Lamp Assembly Replacement..........................................................9
Replacing the Xenon Flash Lamp Assembly..................................................................10
Replacing the MCU Battery............................................................................................12
Troubleshooting and Diagnostics.................................................................................14

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Alarm Notification – Viewing Alarms on the User Interface Panel................................14
Viewing Current Alarm Messages........................................................................14
Viewing Historical Alarm Messages..................................................................... 15
Alarm Conditions and Corrective Action...........................................................................16
Analyzer Reset........................................................................................................................18
Service & Parts ............................................................................................................................1
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
Controller / User Web Interface..................................................................................................1
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 Spectra Data ...........................................................................................9
SETTINGS Menu Screen .......................................................................................................10
Calibration Settings Screen ................................................................................. 11
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 .............................................................................................1
Hardware:..................................................................................................................................1
Configuration:...........................................................................................................................2

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Analyzer Modbus Interface Parameters ........................................................................3
Modbus Address ......................................................................................................................3
Modbus Functions ...................................................................................................................3
Holding Registers..............................................................................................................4
APPENDIX – DRAWINGS ............................................................................................................1
Analyzer Light Path Schematic.......................................................................................2
Analyzer Mounting Details, Unistruts..........................................................................3
Analyzer Overall Component Layout ...........................................................................4
Detector Interface Board (100-1937) ...............................................................................5
Detector Board (403378901)..............................................................................................6
Display Interface Board (100-1978).................................................................................7
Customer Connection Board (100-1971) ........................................................................8
Relay Board (100-1942)......................................................................................................9
Analog Board (100-1922).................................................................................................10
MCU Board (100-1914) ....................................................................................................11
Xenon Lamp Board (100-2061).......................................................................................12
Electronics Enclosure Wiring Diagram, Sheet 1 of 3 (WX-102877).........................13
Electronics Enclosure Wiring Diagram, Sheet 2 of 3 (WX-102877).........................14
Electronics Enclosure Wiring Diagram, Sheet 3 of 3 (WX-102877).........................15
Supplemental Information ..........................................................................................................1

viii | IPS-4 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 environmental 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 housing. 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 pro-
tection 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

Contents | ix
!
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 ana-
lyzer before opening the door on the analyzer to check or perform maintenance
on any components within the enclosure.
If it is necessary to open the analyzer door 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 Com-
pany.
Follow appropriate regulatory and/or company procedures to lock out the ana-
lyzer while working on the analyzer electronics.
Before working on the analyzer, test the area for flammable gases. If an explo-
sive gas atmosphere is present, do not open any doors without first discon-
necting power and/or alternate power sources to the analyzer.
The glass Xenon Flash Lamp is under high internal pressure which could re-
sult 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 scratch-
ing it.
While handling a flash lamp, always wear protective devices (face mask, cloth-
ing) 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

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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.
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 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 chas-
sis (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 surface at the end of the narrow glass tube. The
lamp assembly is fragile and should be handled with care.
!
WARNING
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION