Ametek Western Research IPS-4 User Manual Download Page 2 | Manualshive

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© 2010–2019 AMETEK Canada LP, A Division of AMETEK Process & Analytical Instruments

Printed in Canada

This manual is a guide for the use of the IPS-4 (Integrated Process Spectrophometer) Analyzer with Dual Bench Option. Data herein has been 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.

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ii | IPS-4 Dual Bench (UV / IR) Analyzer

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Summary of Contents for Western Research IPS-4

Page 1: ...IPS 4 Dual Bench UV IR Analyzer Zone 1 Division 2 User Manual PN 903 8804 Rev L Canada A DIVISION OF AMETEK PROCESS ANALYTICAL INSTRUMENTS...

Page 2: ...Fax 713 849 1924 CANADA AMETEK Canada LP 2876 Sunridge Way N E Calgary AB T1Y 7H9 Canada Tel 403 235 8400 Toll Free 800 661 9198 Fax 403 248 3550 INDIA AMETEK Instruments India Pvt Ltd 1st Floor Pres...

Page 3: ...alytical Theory Optical Bench 1 1 Flow Diagram 1 1 Calculation Flow 1 2 Dispersive Ultraviolet Visible DUVV Spectrometer 1 4 Basic Analytical Theory 1 4 Optical Bench Design 1 4 UV Specifications 1 5...

Page 4: ...ensor 2 4 Environmental 2 5 Ambient Temperature 2 5 Humidity 2 5 Pollution Degree 2 5 Maximum Altitude 2 5 Installation Category 2 5 Enclosure Material 2 5 Ingress Protection 2 5 Physical Dimensions 2...

Page 5: ...System Leak Check 3 37 Manually Zeroing the Analyzer Sample System 3 39 Adjusting the Zero Span Fluid Flow Rate 3 40 Adjusting the Sample Flow Rate 3 41 Setting Sample Response Time 3 42 Normal Opera...

Page 6: ...yzer Configuration Settings 4 39 Restoring Analyzer Configuration Settings 4 39 Ethernet Network Screen 4 41 Customization Screen 4 44 Modbus Screen 4 46 CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING 5 1...

Page 7: ...RMS Menu Screen 7 5 Current Alarms and Warnings 7 5 Logged Alarms and Warnings 7 6 Alarm and Warning Notification 7 6 TRENDS Menu Screen 7 7 Parameters 7 8 Intervals 7 8 SPECTRA Menu Screen 7 9 Viewin...

Page 8: ...Disconnection Board 100 2076 A 10 Relay Board 100 2050 A 11 Analog Board 100 2047 A 12 MCU Board 100 2045 A 13 Xenon Lamp Power Supply Board 100 2061 UV Optical Bench A 14 Infrared Source Assembly In...

Page 9: ...ent 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...

Page 10: ...are live test the area for flammable gases and proceed only when the area is safe Purged Analyzer Hazardous Location Applications To work on the analyzer with it powered up and its Electronics Enclosu...

Page 11: ...it will be hot take precautions to avoid burning yourself The glass Xenon Flash Lamp is under high internal pressure which could result in flying glass fragments if ruptured Handle the tube with care...

Page 12: ...deal 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 s...

Page 13: ...METEK instruments Contact your dealer to see if this program is available in your area If you need further assistance in recycling your AMETEK product contact our office listed in the front of the ins...

Page 14: ...ique allowing high frequency shield bonding while avoiding the AC ground metal connection In the case of shielded cables the drain wire or braid connection must be kept short A minimal connection dist...

Page 15: ...ents est design 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 d connecter l quipement c...

Page 16: ...ting and measurement techniques Electrostatic discharge immunity test EN 61000 4 3 Testing and measurement techniques Radiated radio frequency electromagnetic field immunity test EN 61000 4 4 Testing...

Page 17: ...tection by flameproof enclosures d EN 60079 2 2014 Purged Pressurization p Equipment protection by pressurized enclosures p Certificate Number Presafe 15 ATEX 7029X Notified Body DEKRA Certification B...

Page 18: ...North American goods the name of the firm who purchased the goods and the shipment date The warranty shall not apply to any equipment or part thereof which has been tampered with or altered after leav...

Page 19: ...and NDIR optical systems including theory hardware and software descriptions and installation instructions are provided under sections DUVV OPTICAL BENCH and NDIR OPTICAL BENCH Basic Analytical Theory...

Page 20: ...Map the transmittance OR absorbance to an analyte value In this step the factory established calibration converts either transmit tance or absorbance information into a value proportional to the analy...

Page 21: ...analyte reading Typically the filtering is adjusted at the fac tory to provide a T90 response of less than 30 seconds from the time the sample reaches the Measuring Cell s T90 is defined as the time r...

Page 22: ...ctrum Optical Bench Design An Optical Bench is composed of four main components A source EM radiation or light in the wavelength region of interest Measuring Cell with windows capable of transmitting...

Page 23: ...surface aluminum mirrors are used in the Measuring Cell After the beam passes through the Measuring Cell a diffraction grating disperses the light over a range of wavelengths Next a concave mirror fo...

Page 24: ...our main components A source EM radiation or light in the wavelength region of interest A Measuring Cell with windows capable of transmitting light in the region of interest and compatible with the sa...

Page 25: ...s dependent on wavelength Typically 0 001 AU Sample System The sample system is contained within an attached but separate insulated enclosure Oven Sample System Enclosure If this enclosure is heated c...

Page 26: ...and a Xenon Lamp board Smaller processors on some of the ancillary boards all tied into the main MCU handle local tasks The main functions of the processors are to Control the lamp and detector setti...

Page 27: ...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 interfere with proper operation of the purge system...

Page 28: ...ee Sys tem 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 switch ing the power off at the power source will shut down t...

Page 29: ...RGE OPERATING OPERATING SET LEAK COMPENSATION TO THIS MIN PRESS TO RUN THIS TIMER VENT OPENS 0 2 wc 0 5mb min 0 8 wc 2 0mb 1 4 wc 3 5 mb min 4 wc 10mb Supply air lost or Door open Box pressure 0 5mb o...

Page 30: ...non standard derivative analyzer models or information that is intended to replace similar information in the Operator s Guide These documents can also include a non standard Spare Parts List or a se...

Page 31: ...of full scale range Measurement Accuracy 1 or 2 of full scale typical application specific Accuracy is determined by comparing analyzer response to a known standard sample after a calibration has bee...

Page 32: ...x 64 pixel vacuum fluorescent display with multilingual capability Four 4 isolated analog outputs configurable as 0 20 mA or 4 20 mA eight optional Up to eight 8 relays NO contact rating 100 VA 240 V...

Page 33: ...aspiration using Instrument Air or N2 as the drive gas Liquid Applications Using sample stream pressure Minimum 5 psi differential pressure inlet to outlet Instrument Air Requirements The aspirator me...

Page 34: ...iring diagram Max rating 240 Vac 20 A Supply Voltage 120 VAC 105 132 VAC 47 63 Hz OR 240 VAC 209 264 VAC 47 63 Hz Cell Construction Gas and Liquid Cells available in a variety of materials body can be...

Page 35: ...lution Degree 2 Maximum Altitude 2000 metres Installation Category Installation Category II Enclosure Material Stainless Steel main enclosures Aluminum disconnect enclosure Ingress Protection IP65 Zon...

Page 36: ...nal condensation Complies with all relevant European Directives Certifications and approvals include ATEX CE Certificate No Presafe 15 ATEX 702 X II 2 G Ex db pxb IIC T3 Gb IP 65 20 C Ta 50 C IECEx Ce...

Page 37: ...e inspection authority having jurisdiction Overpressure 0 5 mbar 0 2 wc min 2 mbar 0 8 wc nom 10 mbar 4 wc max Supply Pressure 4 15 bar 60 psi min 5 0 bar 72 5 psi max Max Leakage Rate 15 LPM 10 mbar...

Page 38: ...withthe Essential Health and Safety Requirementshasbeenassured by compliance with EN 60079 0 2012 A11 2013 EN 60079 1 2014 and EN 60079 2 2014 10 If the sign X is placed afterthe certificate number it...

Page 39: ...closure viaATEXcertifiedbushings The relaysforthe purgedportion of the enclosure are controlledbyanEx d pressure switchthatisoperatedbythe purge controller The pressure reliefvalve onthe pressurizeden...

Page 40: ...of EN 60079 1 18 Essential Health and Safety Requirements Essential HealthandSafetyRequirements EHSRs are covered bythe standardslistedatitem9 19 Drawings and documents Number Title Rev Date 403236001...

Page 41: ...SINSTRUMENTATION 2876 Sunridge Way NE Calgary Alberta Canada T1Y7H9 Phone 1 888 661 9198 Model No Serial No Tag No V Hz Watts 301 5320 F 3 x IPS 4 DB 403Axxx N A 120V 240V 50 60Hz 850Wmax 20 C Ta 50 C...

Page 42: ...D Du ua al l B Be en nc ch h P Pr ro oc ce es ss s S Sp pe ec ct tr ro op ph ho ot to om me et te er r Optional accessory Type of Protection E Ex xd d f fl la am me ep pr ro oo of f a an nd d E Ex x p...

Page 43: ...ocuments as amended S ST TA AN ND DA AR RD DS S The electrical apparatus and any acceptable variations to it specified in the schedule of this certificate and the identified documents was found to com...

Page 44: ...ertified bushings The relays for the purged portion of the enclosure are controlled by an Ex d pressure switch that is operated by the purge controller The pressure relief valve on the pressurized enc...

Page 45: ...240V 50 60Hz 850Wmax Purge Parameters Minimum Purging Flow Rate 225 l min Minimum Purge Time 5 Minutes Protective Gas Air or Nitrogen Minimum Supply Pressure 4 15 bar 60psi Maximum Supply Pressure 5...

Page 46: ...U O 1 2NPT NP Certificate No IECEx BAS 06 0015X Standards Versions IEC 60079 0 2011 IEC 60079 1 2014 X U Conditions From cert 1 Equipment ambient rating is within this range 2 not used for increased...

Page 47: ...rds Versions IEC 60079 0 2007 IEC 60079 1 2007 X U Conditions From cert Assembly is installed properly Rating Ex d IIC T Gb Ta 40 C to 70 C Note None 7 Adaptors Reducers and Stopping plugs Ex Innovati...

Page 48: ...2 18 IPS 4 Dual Bench UV IR Analyzer This page intentionally left blank...

Page 49: ...stallation 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 e...

Page 50: ...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...

Page 51: ...on 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 shelte...

Page 52: ...east 250 VAC 20 A and certified for the hazardous location to satisfy local electrical codes the switch must be certified by the local author ity for the appropriate hazardous location The power disco...

Page 53: ...NS PWB POWER SUPPLY DETECTOR INTERFACE PWB DISPLAY INTERFACE PWB MCU PWB RELAY PWB ANALOG PWB AC TERMINAL MAIN FUSES PRESSURE SWITCHES A1 INSTRUMENT AIR C4 HEATED SAMPLE LINE RTD C5 HEATED SAMPLE LINE...

Page 54: ...it must be shielded from conduc tive pollution and subject to only temporary condensation The entire analyzer system can be mounted directly on a wall in a spe cially designed cabinet or in a custom b...

Page 55: ...umentation Package Non Shelter Installations In a suitable accessible location mount the analyzer on a vibration free wall or instrument rack Shelter Installations In a suitable accessible location in...

Page 56: ...439 8mm 14 56 369 8mm 11 8 299 8mm 5 32 135 2mm 40 76 1035 2mm 38 965 2mm 28 45 722 7mm 21 7 551 3mm 19 7 500 5mm 50 12 7 6 PLS 22 558 8mm 22 558 8mm 48 1219 2mm 46 25 1174 8mm 48 1219 2mm C5 RTD 2 H...

Page 57: ...SYSTEMS SOCAR HAOR AZERBAIJAN MODEL IPS 4 ANALYZER FIELD UNIT INSTALLATION A REV WX 11062 3 3A 2019 05 01 FRONT VIEW BOTTOM VIEW 58 74 1491 9mm 27 81 706 3mm NOTES 1 XXX DIMENSION ARE IN INCHES xxx D...

Page 58: ...er OT over temperature Switch wiring harness connector from the Optical Bench to J401B on the Relay board 3 Connect the RTD cable connector from the Optical Bench to the in line connector labelled CON...

Page 59: ...ch Assembly boards cable connectors and other components discussed in this procedure WARNING Figure 3 3a UV Optical Bench Xenon Flash Lamp Assembly NOTE DO NOT ADJUSTTHE ANY COMPONENT ONTHE ASSEMBLY T...

Page 60: ...Optical Bench Assembly 3 Connect the ribbon cable from the Optical Bench to connector P2 on the Detector Interface board mounted to the MCU board 4 Clamp the ribbon cable using the clamp provided leav...

Page 61: ...d Manual Supplements that describe and illustrate installation operation if applicable and maintenance if applicable are included in the Supplemental Information section of this manual and the Documen...

Page 62: ...Sample Vent Line drawings if lines supplied by AMETEK for additional information see Final As Built drawings in the analyzer Documentation Package To avoid damaging the Sample or Vent Lines use two wr...

Page 63: ...trument Air Zero Fluid Line Instrument Air or Nitrogen can be used as the aspirator pneumatic valve drive fluid and to zero the analyzer This procedure assumes Instrument Air is being used for these f...

Page 64: ...supply to the analyzer 2 Before connecting it to the analyzer blow down purge the line to remove any liquids or particulate that may be present in it 3 Connect the line to the Instrument Air N2 supply...

Page 65: ...2 Before connecting the purge inlet purge the air line to clear any water or particulates 3 Connect the air supply to the 1 2 purge supply connection fitting on the top of the analyzer see Figure 3 4...

Page 66: ...3 18 IPS 4 Dual Bench UV IR Analyzer Figure 3 4 Purge System BYPASS PS2 PS1 DISCONNECT ENCLOSURE PURGE CONTROLLER IPS4 B A INLET PURGE SUPPLY NORMAL...

Page 67: ...wings package shipped with the analyzer To install the Span fluid line 1 Route the line from the calibration fluid supply to the analyzer 2 Before connecting it to the analyzer blow down purge the lin...

Page 68: ...heated sample line and HAG probe option connections but may be used for I O wiring if these options are not installed Five metric M25 straight thread conduit entries are provided on the Sample Line e...

Page 69: ...ing drawing Do not apply power to the system until after all of the wiring has been installed connected and verified and only if the purging system if used is ready for operation 4 Plug all unused cab...

Page 70: ...3 22 IPS 4 Dual Bench UV IR Analyzer Figure 3 5 Signal Disconnection Board 100 2076 and AC Disconnection Board 100 2077...

Page 71: ...ction The purge air supply is normally obtained from the Instrument Air supply connected directly to the Expo MiniPurge System The required purge air supply pressure for your analyzer is indicated on...

Page 72: ...any policy For normal analyzer operation the Purge Bypass Switch must be in the ACTIVE position and the key must be removed follow company policy B BY YP PA AS SS S A AC CT TIIV VE E Figure 3 6 Purge...

Page 73: ...e analyzer with it powered up and its Electronics Enclosure door open the Purge Bypass Switch must be in the BYPASS position When the Electronics Enclosure door is open take appropriate precau tions t...

Page 74: ...yzer test the area for flammable gases If a flammable gas atmosphere is present do not apply power to the analyzer or any alternate power sources that supply power to the analyzer components Proceed o...

Page 75: ...the left of the purge controller unit 2 With the Electronics Enclosure open Open the Bench Heater and Oven Heater fuses Refer to the Fuse Legend at the back of the Electronics Enclosure for the locat...

Page 76: ...e analyzer and open the Main AC Power and DC Power fuses After powering down the analyzer wait 5 minutes to allow the high voltage capacitors to discharge Review the Interconnect Wiring drawing part o...

Page 77: ...red into the Alarm Log until AFTER the system has left the Not Ready state for the first time after power up which occurs after the entire sample system has stabilized 2 3 hours and reached normal ope...

Page 78: ...ell 23 C Electronics 24 C Manifold Pressure 85 psia Aspirator Pressure 3 psia HOME ALARMS STATUS SETUP a Press the STATUS soft key to view the STATUS screen Figure 3 6 Check and record the current ope...

Page 79: ...to select Current Outputs and press ENTER to display the Current Output 1 screen Scroll down to select Current Outputs 1 screen Figure 3 7 Figure 3 7 Current Output Setup screen Current Out 1 Current...

Page 80: ...values to their corresponding settings values listed on the analyzer documentation If any of the settings need to be changed refer to Relay Setup Screens in Chapter 4 for details 10 If using an Ether...

Page 81: ...to correct and reset alarms refer to Alarm Conditions and Corrective Action in Chapter 5 If no alarms exist Figure 3 10 or after all alarm conditions have been cleared reset recheck the temperature of...

Page 82: ...operating at peak efficiency Response time may vary due to Sample Line length Record the initial sample response time in a log book as described under Recording Initial Readings later in this chapter...

Page 83: ...Notification HOME Screen and ALARMS Menu Screen in Chapter 4 For detailed information about these alarms refer to the alarm conditions and corrective action in the Maintenance and Troubleshooting cha...

Page 84: ...Reset Switch on the Optical Bench Refer to Figure 3 3 of this manual If the temperature zone values still do not increase check the fuses Bench Heater and Oven Heater if used for proper connections an...

Page 85: ...l to ensure proper analyzer operation If sample fluid migrates into the Optical Bench Assembly or Reflector Block due to a leak in the Measuring Cell Assembly the optics will become damaged and will l...

Page 86: ...ressure sensor first pressurize the system and then block it off and monitor for a drop over time If a pressure sensor and isolation valves are not available pressurize the system and bubble test all...

Page 87: ...SETUP menu Select the Calibration Control sub menu and press enter Scroll down to the Calibration sub menu and press enter to display the Calibration screen 3 Use the DOWN arrow key to select Start ze...

Page 88: ...sample system will cool the Measuring Cell and Oven Sample System Enclosure the optimum Zero fluid flow rate is the lowest consistent with a good zero A good zero can be defined as a state where the...

Page 89: ...sed to set the sample flow rate This is accomplished by first measur ing the sample stream pressure with no aspiration Drive Air Isolation Valve closed and then adjusting the Aspirator Pressure Regula...

Page 90: ...do this press ENTER to display the Calibration screen Use the DOWN arrow key to select Start zero calibration and press ENTER The message Please wait will appear while the analyzer initializes and pe...

Page 91: ...that maintenance is required Keep the log book in a safe location until you need to review it for pat terns of a longer sample response time Recording Initial Sample Response Time The analyzer sample...

Page 92: ...s shipped with each analyzer These configuration sheets list all of the settings applicable to the factory analyzer to meet customer requirements The files are provided on a CD and located in the Supp...

Page 93: ...m the analyzer User Interface Panel Analyzer operating temperatures alarm set points and default pa rameter settings Before working from the User Interface Panel read the section titled Introduction t...

Page 94: ...s which can be ac cessed by pressing the corresponding blank keypad square on the Soft Keys Keypad directly below it For information about the main menu items and the sub menu items refer to Working i...

Page 95: ...l also allow you to answer No to software prompts e g Restore settings Are you sure The ENTER key allows you to view sub menu items enter Edit mode select parameters and or their options initiate anal...

Page 96: ...beside a main menu item sub menu item or a parameter indicates this item is selected It also indicates the item is read only cannot be modified This character located in the lower left corner indicate...

Page 97: ...ert to Operator read only mode after 5 minutes of no keypad activity If security is enabled but you are not logged in the message Pass word required is displayed when you press ENTER to initiate ana l...

Page 98: ...in processor with read only variables such as Relay Solenoid Valve Status Current Outputs and other parameters A subset of these parameters may be changed from the User Interface Panel The sequence of...

Page 99: ...left side of this screen The right side of this screen displays the current operational status of the analyzer Descriptions of these states are described under System Status Messages HOME Screen in t...

Page 100: ...unit measured at the Manifold Block The manifold pressure is used for valve actuation and for zero flush if applicable Aspirator Pressure Displays the real time pressure psia or other unit being used...

Page 101: ...d valve is open The valve will close when the system state chang es to Measure mode Span This occurs following the Span Fluid Flush and indicates the analyzer is being spanned When complete the span f...

Page 102: ...ions that triggered the alarm s are reset For more information about active and historical alarms and warnings refer to Viewing Current Alarms and Warnings and Viewing Logged Alarms or Warnings in the...

Page 103: ...ings are displayed on the Current Alarms and Warnings screen Each line will occupy one alarm or warning description and up to six active alarms or warnings can be displayed on the screen at once If mo...

Page 104: ...the descriptions are displayed Figure 4 6 and 7 If there is no history Log empty is displayed Figure 4 8 and 9 To scroll through the list use the UP DOWN arrow keys Figure 4 8 No history of alarms Ala...

Page 105: ...Displays the real time temperature C of the Measuring Cell as mea sured by the Cell RTD mounted on the Cell inside the Oven Sample System Enclosure This parameter is available only for applications wi...

Page 106: ...r to the section Calibration Control in this chapter for descriptions about setting up all Auto Calibration parameters Next Cal 2 Displays the time remaining until the next Auto Calibration 2 func tio...

Page 107: ...ent Outputs Setpoints Diagnostics System Settings Modbus Figure 4 11 SETUP menu screen Calibration Control Relays Current Outputs Setpoints Diagnostics System Settings HOME ALARMS STATUS SETUP SETUP M...

Page 108: ...creen Calibration Settings Calibration Valves Calibration Actions Display Filter Verification HOME ALARMS STATUS SETUP Automatic Calibration 1 and 2 Screens Use these to set up the type of Auto Calibr...

Page 109: ...on screen Mode Use this to set up the type of Auto Calibration function that will be performed during normal analyzer operation Mode options include Zero Span For its regular sequence of operation the...

Page 110: ...ration functions 1 Select the parameter you wish to change and press ENTER 2 Use the UP DOWN arrow keys to view the options available for each parameter 3 Change the timer durations Auto cal timer int...

Page 111: ...flush time Defines the duration seconds the analyzer will flush the sample sys tem with Zero fluid during the analyzer s normal operating sequence Span flush time Defines the duration seconds the ana...

Page 112: ...the UP DOWN arrow key to increase decrease the value in in crements of one 1 00 When using this method the value counts up down from the current setting This works best for minor changes When no value...

Page 113: ...he options listed under this parameter To select a span fluid press ENTER to go into edit mode Use the UP DOWN arrow key to select the fluid you wish to span and then press ENTER to select the span fl...

Page 114: ...s During this operation the span solenoid is open and Span Hold is displayed in the Status area of the HOME screen Note that this mode does not actually Span the analyzer Start measure This function...

Page 115: ...s enter to display the Calibration Fluid Concentration screen Figure 4 16 Ensure that the concentration value for the Analyte being spanned corresponds with the concentration of the span fluid If not...

Page 116: ...er will display a Failed Cali bration message on the UIP to alert you that there is an issue with the wavelength positioning on the diode array Further diagnostics is then required to determine the ex...

Page 117: ...ay Filter Verification screen Display Filter Verification Result PASSED Date 11 25 2020 Filter Deviation 0 300 Wavelength 228 0 353 Wavelength 260 0 333 HOME ALARMS STATUS SETUP Neutral Density Filter...

Page 118: ...nalyzer can use up to eight relays to indicate the operational sta tus of the analyzer Each relay provides one SPST Form A dry poten tial free contact The relays are energized closed on start up Relay...

Page 119: ...cies of interest for the relay output You can assign a different relay for each channel To assign a relay to a channel select an analyte and press ENTER Note that the actual species name e g SO2 will...

Page 120: ...gs and press ENTER Repeat this step for each parameter and each relay When entering a value for the Relay Value and Delay parameters Use the UP DOWN arrow key to increase decrease the value in increme...

Page 121: ...that the species name will be displayed on the screen not Analyte e g SO2 Figure 4 20a Current Output Setup screen Current Outs Current Out 1 Current Out 2 Current Out 3 Current Out 4 HOME ALARMS STAT...

Page 122: ...to view the Current Output screen 3 Select the required parameter Source Full Zero Type or Over Range change the settings and press ENTER Repeat this step for each parameter and each output When ente...

Page 123: ...s Screen Setpoints Span Limits Pressure Limits Temperature Limits HOME ALARMS STATUS SETUP Span Limits If Span limits are exceeded calibration is required Pressure Limits If pressure limits are exceed...

Page 124: ...ell Pres Low Limit 142 15 2 PSI Pres X 2 High Limit 0 PSI Pres X 2 Low Limit 0 PSI Manifold Pres High Limit 70 100 PSI HOME ALARMS STATUS SETUP Figure 4 24 Temperature Limits Setpoints Screen Temperat...

Page 125: ...een Current Output 1 Diagnostics Diagnostics State Off Current Output 1 61 Type 4 20 mA Over Range Disabled HOME ALARMS STATUS SETUP Figure 4 26 Current Output Diagnostics Screen Current Output Diagno...

Page 126: ...4 30 Lamp Diagnostics Screen Lamp Diagnostics Wavelength 0 0 Measurement 16804 Dark Read 16718 Absorbance 0 1 Pixel 0 HOME ALARMS STATUS SETUP Lamp Diagnostics Monitor detector operation for a given w...

Page 127: ...he Password When a password has been entered the software will remain in Edit read write mode as log as the user is working from the User Interface Panel If no keys are pressed within 10 minutes the s...

Page 128: ...Password function before you can change parameter settings If you attempt to change the password without first entering the password the message System Locked appears Keys that can be used to enter a...

Page 129: ...ce for reference Locking the Password Use the Lock function to disable the password from the current session This reverts all analyzer functions to read only Changes to the analyzer settings cannot be...

Page 130: ...ings screen Backup settings Restore settings Restore factory settings HOME ALARMS STATUS SETUP NOTE Backup settings Saves the current analyzer configuration settings to a file that can later be used t...

Page 131: ...file called user xml The message Please wait appears while the analyzer backs up its settings Figure 4 34 Backup Settings screen Backup settings Are you sure Press for yes Press X for no HOME ALARMS...

Page 132: ...4 36 Press CANCEL X to answer no Press ENTER to answer yes The analyzer begins restoring con figuration settings from a file stored in the analyzer The message Please wait appears while the analyzer r...

Page 133: ...ress IP Subnet Mask A TCP IP number used to determine to which the TCP IP Subnet de vice belongs Devices in the same Subnet can be communicated with locally without going through a router This is a re...

Page 134: ...Control address unique byte num ber of the analyzer e g 00 0F 88 00 00 79 The MAC address is fac tory set This address is read only To set up Ethernet parameters For specific requirements for permanen...

Page 135: ...rious analyzer functions such as alarms To set the time use the RIGHT LEFT arrow key to select hours minutes and seconds and then either the UP DOWN arrow key or numeric keys to enter the time When us...

Page 136: ...meters on this screen include Date Format Defines the format for displaying the date which is displayed on the System screen Format options include MM DD YYYY DD MM YYYY DD MM YYYY MM DD YYYY Decimal...

Page 137: ...to change the time an inactive menu will display before it returns to the home screen User Time Out This displays and allows you to change the inactivity period a user is logged into to the system Scr...

Page 138: ...s setting used for Modbus communications The typical default is 0 It can also be set to 2 Modbus Address This displays and allows you to change the address assigned for Mod bus communications Valid ad...

Page 139: ...ENTER to go into Edit mode 2 For Baud Parity and Stop Bits use the UP DOWN arrow key to scroll through the available options To select an option when it is displayed press ENTER For Modbus Address and...

Page 140: ...4 48 IPS 4 Dual Bench UV IR Analyzer This page intentionally left blank...

Page 141: ...bleshoot the analyzer Before performing any maintenance service or troubleshooting on the analyzer review and follow all safety information in this chapter and under Personnel and Equipment Safety Inf...

Page 142: ...analyzer components or replacing any parts as part of regular preventive maintenance or when performing leak checks following the replacement of instrument air or other adjustments to any of the conne...

Page 143: ...or Gas Applications Plugs in the sample system generally can be avoided by ensuring all components of the sample system operate at least 10 C 18 F above the sample dew point temperature The risk of de...

Page 144: ...he list use the UP DOWN arrow key Monthly Zero the Analyzer Check Analyzer Response Time Manually Zero the analyzer from the Calibration screen select Start zero calibration and press ENTER After the...

Page 145: ...ediately Contact AMETEK for assistance Every Six Months Pressurization System Check Place any process control system that is using the analyzer measurements in manual and alert any personnel who would...

Page 146: ...if chipped cracked or scratched 3 5 Years Xenon Flash Lamp Assembly Replace the Xenon Flash Lamp Assembly The assembly may need to be replaced sooner if information from the analyzer diagnostics indi...

Page 147: ...ample system The next step is to locate and remove the plug The portion of the sample system with the high est risk of plugging is the sample inlet and the portion of the sample inlet most prone to pl...

Page 148: ...sample fluid migrates into the Optical Bench Assembly or Reflector Block due to a leak in the Measuring Cell Assembly the optics will become damaged and most likely require replacement Most leaks are...

Page 149: ...lean the front and back sides of the Windows If the Windows require a more thorough cleaning a high purity sol vent such as Isopropanol 99 can be used if suitable for use with removing contamination C...

Page 150: ...OWER SUPPLY DETECTOR INTERFACE PWB DISPLAY INTERFACE PWB MCU PWB RELAY PWB ANALOG PWB AC TERMINAL MAIN FUSES PRESSURE SWITCHES A1 INSTRUMENT AIR C4 HEATED SAMPLE LINE RTD C5 HEATED SAMPLE LINE RTD2 C3...

Page 151: ...ar as indicated in the Analyzer Preventive Maintenance Schedule Replace the o rings windows in the Measuring Cell If during an unscheduled cleaning see cleaning requirements above the Measuring Cell W...

Page 152: ...disconnect AC power from the analyzer and its temperature control zone circuitry by opening the Main AC Power DC Power Bench Heater and Oven Heater if used fuses Refer to the Fuse Legend at the back...

Page 153: ...pecific spare parts either in the Measuring Cell Manual Supplement or in a Custom Spare Parts List NOTE Figure 5 2 Measuring Cell Assembly 40 cm Measuring Cell MIRROR CAP 300 1261 2 PLS O RING 300 236...

Page 154: ...es from the Cell Loosen and remove the Cell RTD if used from the RTD Clamp not shown on the Cell Disconnect all other sample system parts tubing to allow removal of the Cell b Note the position of the...

Page 155: ...e to clean the front and back sides A high purity solvent such as Isopropanol 99 may also be used if suitable for use with the sample species Rinse with pharma ceutical grade distilled water Replace c...

Page 156: ...the Cell held vertically so that the Reflector Block end is down install a new o ring by using your thumbs to push it into the o ring groove until it is completely seated in the groove While holding t...

Page 157: ...plications If heated Sample and Vent Lines are used do not apply power to them until after the Leak Check has been performed Do not close the Oven Heater fuse if used until after the Leak Check has be...

Page 158: ...ics Enclosure doors and allow the ana lyzer to warm up to operating temperature and stabilize This could take up to 2 hours if the sample system has cooled completely 16 Zero and Span if applicable th...

Page 159: ...hing to prevent possible injury especially to hand and face areas When handling the flash lamp never touch the glass bulb of the lamp with bare hands Dust or fingerprints on the glass bulb may greatly...

Page 160: ...e explosion proof power disconnect switch to disconnect power from the analyzer and its temperature zone circuitry If heated Sample and Vent Lines are used disconnect power to them Open the Electronic...

Page 161: ...cal Bench Assembly as a guide gently push the Lamp Assembly straight into place Tighten by hand the blue knurled nut to secure the Lamp Assembly to the Optical Bench Assembly 8 Connect the DC Power Ca...

Page 162: ...hem 11 Open the Vent Line Shut Off valve in the Oven Sample System En closure Open the Sample Line Shut Off valve to allow sample fluid into the sample system 12 Close and secure the Electronics Enclo...

Page 163: ...ter 6 for reor dering part numbers NOTE Figure 5 3 2 Infrared IR Source Assembly 100 2847 To replace the Infrared Source Assembly Hazardous Locations Before proceeding test the area around the analyze...

Page 164: ...then close the Aspirator Air valve Purged Analyzers The Instrument Air supply must always remain on for the Purge By pass Switch to operate properly 5 Disconnect the DC Power Cable circular connector...

Page 165: ...ollow any Special Conditions for Safe Use listed in accompanying certifications Hazardous Location Applications Close the power disconnect switch breaker to apply main AC Power to the analyzer If heat...

Page 166: ...he alarms from the User Interface Panel and how to reset the analyzer if a system reset is required Generally most troubleshooting and diagnostics can be done by work ing from the User Interface Panel...

Page 167: ...tions open the Electronics Enclosure and the Oven Sample System Enclosure doors and Using an Ohm Meter measure the resistance of the Oven Heater Plate RTD and test it for an open circuit If the RTD is...

Page 168: ...controlled zone has exceeded its over temperature limit of 177 C 350 F the analyzer automatically switches to Zero Gas Flush mode Take appropriate safety precautions open the Electronics Enclosure do...

Page 169: ...Failed communications to the Analog board This alarm condition indicates that the MCU board cannot establish reliable communications with the Analog board Corrective Action Take appropriate safety pre...

Page 170: ...on occurs if the Detector data file also known as the DSP or digital signal processing file is missing or has become corrupt Corrective Action Contact AMETEK for assistance Calibration Required This w...

Page 171: ...disconnect switch breaker Reapply power Do not randomly reset the analyzer during normal operation Typical ly a reset is required only when analyzer configuration settings have been restored In this...

Page 172: ...5 32 IPS 4 Dual Bench UV IR Analyzer This page intentionally left blank...

Page 173: ...your local or nearest AMETEK Service Centre or the AMETEK factory AMETEK at 403 235 8400 or 1 800 661 9198 or contact your local AMETEK Western Research representative Before contacting AMETEK with qu...

Page 174: ...umber This will ensure your equipment is serviced and returned to you in a prompt and efficient man ner To obtain an RMA number contact your local or nearest AMETEK Service Center and have the followi...

Page 175: ...educted from the start up charge if you select that option START UPS Your decision to buy an AMETEK analyzer is greatly appreciated After the time and money spent on your analyzer wouldn t you expect...

Page 176: ...e Measuring Cell refer to the Supplemental Information section of this manual or the Documentation Package shipped with the analyzer for a Measuring Cell Manual Supplement or a Custom Spare Parts List...

Page 177: ...3 A DC Power F2 301 0861 2 0 A 301 0861 2 0 A Oven Heater F3 301 0862 4 0 A 301 0861 2 0 A Bench Heater F4 301 0860 1 0 A 301 0859 0 5 A These fuses are located on the AC Terminal in the Electronics...

Page 178: ...6 6 IPS 4 Dual Bench UV IR Analyzer This page intentionally left blank...

Page 179: ...o access moni tor and control your analyzer through a web interface What the various screens that make up the interface do and how to use them to work from the analyzer User Web Interface Before worki...

Page 180: ...Web Interface To access the IPS 4 analyzer using the Web Interface enter the analyzer s IP address in the web browser or internet explorer s web page address box The analyzer IP address is listed on t...

Page 181: ...tes can be displayed Alarm and warning notifications are displayed in the banner located below the header on every screen The most current notification is displayed with 1 of x if there are multiple a...

Page 182: ...nalyzer HOME Menu Screen The HOME screen Figure 7 2 displays the current operational status of the analyzer Descriptions of these states are described under System Status Messages HOME Screen in Chapt...

Page 183: ...to 15 active alarms or warnings can be displayed on the screen at once If more than 15 are active use the arrow keys to scroll through the list The alarm or warning at the top of the list is most rec...

Page 184: ...screen Each logged or historical alarm includes the time and date it was set The logged alarm at the top of the list is most recently reset alarm The log file could be up to 800 lines long After 800...

Page 185: ...eters in one second fifteen seconds or one hour intervals Use this screen to view the most recent data held in short term memory Data can not be saved Print to screen to capture data for troubleshooti...

Page 186: ...perature Analytes Concentration Intervals Trend intervals for selected parameters are available in one second fifteen seconds or one hour data points The analyzer stores 3600 parameter data points in...

Page 187: ...om the analyzer User Compare User Spectra to Live Spectra for trouble shooting Click Save User button to save user spectra to the hard drive The file is saved as a cookie in the browser Click Clear Us...

Page 188: ...eters The settings for your analyzer have been configured at the factory to meet specified customer requirements Changing the factory set con figuration could cause the analyzer to operate incorrectly...

Page 189: ...Settings Screen The CALIBRATION SETTINGS screen Figure 7 7 displays the available analyzer calibration controls and allows the user to set up and initialize the calibration functions Descriptions of...

Page 190: ...4 Dual Bench UV IR Analyzer Actions Screen The ACTIONS screen Figure 7 8 allows the user to enter calibration concentrations and initiate on demand calibration actions Figure 7 8 Settings Menu Action...

Page 191: ...en Figure 7 9 displays current output assignments and allows you to set up the parameters for each of the four current outputs Descriptions of these parameters are described under Current Output Setup...

Page 192: ...10 allow the user to view or set up the parameters for up to eight relays For example Concentration Alarms can be set up from this screen Relay Function option Descriptions of these parameters are des...

Page 193: ...tem to communicate over an Ethernet network for viewing analyzer and stream composition data viewing analyzer diagnostics or backing up restoring analyzer configuration settings Descriptions of these...

Page 194: ...ch UV IR Analyzer System and Customization Screen The SYSTEM and CUSTOMIZATION screen Figure 7 12 allows the user to view and or setup analyzer system parameters Figure 7 12 Settings Menu System and C...

Page 195: ...User Web Interface 7 17 Analytes Screen The ANALYTES screen Figure 7 13 allows you to view and modify ana lyte names and span factor min max Figure 7 13 Settings Menu Analyte Screen...

Page 196: ...zer Limits Screen The LIMITS screen Figure 7 14 allows you to view and modify pressure and temperature limits Descriptions of these parameters are described under Setpoints Screens in Chapter 4 Figure...

Page 197: ...or setting up external control systems Descriptions of these parameters are described under Diagnostics in Chapter 4 The analyzer should be in normal operations for lamp diagnostics The lamp does not...

Page 198: ...software Restore previously saved analyzer configuration settings and individ ual files from your PC Descriptions of these activities are described under Backup Restore Figure 7 16 Settings Menu Save...

Page 199: ...ting as a slave device The IPS 4 Analyzer supports RS 485 serial communication standards The physical communication connection between an IPS 4 analyzer and a cus tomer DCS SCADA PLC DAS or a general...

Page 200: ...e IPS 4 Analyzer the system designer should consider the follow ing The update rate is one time per minute or less Polling of these regis ters more frequently than once a second is not recommended The...

Page 201: ...the Modbus protocol is designed for communication among Program mable Logic Controllers PLCs not all Modbus function codes supported by a slave PLC are applicable to the IPS 4 analyzer Only the follow...

Page 202: ...boolean boolean LDUI 1 55 1 109 r uint16 uint16 FWVERHRB 256 56 1 110 r uint16 uint16 FWVERDIS 256 57 1 111 r uint16 uint16 CARDID 0 58 1 112 r uint16 uint16 HTRYID 0 59 1 113 rw int16 int16 MBPARITY...

Page 203: ...NAOUT1S 100 178 2 160 rw int16 int16 ANAOUT1T 0 180 1 161 rw uint16 uint16 ANAOUT1OR 0 181 1 162 rw uint16 uint16 ANAOUT1F 0 182 1 163 r float float ANAOUT2 0 183 2 164 rw float float ANAOUT2O 0 185 2...

Page 204: ...09 r uint16 uint16 RELAY5 0 278 1 210 rw uint16 uint16 RELAY5D 0 279 1 211 rw uint16 uint16 RELAY5F 0 280 1 212 rw char 20 char 20 RELAY5NM Relay 5 281 10 213 rw uint16 uint16 RELAY5S 0 291 1 214 rw f...

Page 205: ...float float ACONC8L 0 428 2 260 rw char 20 char 20 ALYTE1 T225nm 430 10 261 r float float ALYTE1CON 0 440 2 262 rw char 20 char 20 ALYTE2 T250nm 442 10 263 r float float ALYTE2CON 0 452 2 264 rw char...

Page 206: ...ELLHDC 0 00 585 2 309 rw float float CELLIT 5000 00 587 2 310 rw float float CELLPB 10 00 589 2 311 r float float CELLRTD 0 591 2 312 rw float float CELLSP 60 00 593 2 313 rw float float CELLST 20 00...

Page 207: ...70 2 359 rw float float DIIR 0 50 672 2 360 rw float float LAMIIR 1 674 2 361 rw float float CELLIIR 0 05 676 2 362 rw float float SAMLIIR 1 678 2 363 rw float float SCIIR 1 00 680 2 364 rw float floa...

Page 208: ...AM4 0 763 1 409 rw uint16 uint16 HOMEPARAM5 0 764 1 410 rw uint16 uint16 HOMEPARAM6 0 765 1 411 rw uint16 uint16 HOMEPARAM7 0 766 1 412 rw uint16 uint16 HOMEPARAM8 0 767 1 413 rw uint16 uint16 HOMEPAR...

Page 209: ...oat BETA3 100 941 2 459 rw float float BETA4 100 943 2 460 rw float float BETA5 100 945 2 461 rw float float BETA6 100 947 2 462 rw float float BETA7 100 949 2 463 rw float float BETA8 100 951 2 464 r...

Page 210: ...t ALYTE8MW 1 1028 2 510 rw uint16 uint16 SOFTCENTER1 39 1030 1 511 rw uint16 uint16 SOFTCENTER2 94 1031 1 512 rw uint16 uint16 SOFTCENTER3 152 1032 1 513 rw uint16 uint16 SOFTCENTER4 208 1033 1 514 r...

Page 211: ...1 559 rw char 20 char 20 CALSCHEDT2 00 00 00 1121 10 560 r char 20 char 20 NEXTCAL1 00 00 00 1131 10 561 r char 20 char 20 NEXTCAL2 00 00 00 1141 10 562 r int16 int16 DIAGS 0 1151 1 563 rw float floa...

Page 212: ...1 609 rw int16 int16 TRENDPAR23 0 1218 1 610 rw int16 int16 TRENDPAR24 0 1219 1 611 rw float float ZEROTOL 0 1220 2 612 rw float float REFSTARTW 0 1222 2 613 rw float float REFENDW 0 1224 2 614 rw fl...

Page 213: ...loat ANAOUT8 0 1307 2 679 rw float float ANAOUT8O 0 1309 2 680 rw uint16 uint16 ANAOUT8P 261 1311 1 681 rw float float ANAOUT8S 100 1312 2 682 rw int16 int16 ANAOUT8T 0 1314 1 683 rw int16 int16 ACROM...

Page 214: ...728 rw float float LINLEVEL7P1 0 1388 2 729 rw float float LINBREAK0P1 0 1390 2 730 rw float float LINBREAK1P1 0 1392 2 731 rw float float LINBREAK2P1 0 1394 2 732 rw float float LINBREAK3P1 0 1396 2...

Page 215: ...2 778 rw float float LINBREAK1P4 0 1488 2 779 rw float float LINBREAK2P4 0 1490 2 780 rw float float LINBREAK3P4 0 1492 2 781 rw float float LINBREAK4P4 0 1494 2 782 rw float float LINBREAK5P4 0 1496...

Page 216: ...r float float IRCHABS6 0 1592 2 810 rw uint16 uint16 ANAOUT5H 0 1594 1 811 rw uint16 uint16 ANAOUT6H 0 1595 1 812 rw uint16 uint16 ANAOUT7H 0 1596 1 813 rw uint16 uint16 ANAOUT8H 0 1597 1 814 rw uint...

Page 217: ...e main body of this manual as well as additional analyzer layout and wir ing diagram drawings Drawings such as Analyzer Mounting Details Unistruts and Analyzer Overall Component Layout are examples on...

Page 218: ...A 2 IPS 4 Dual Bench UV IR Analyzer Analyzer Light Path UV Optical Bench Schematic...

Page 219: ...Appendix A Drawings A 3 Analyzer Light Path NDIR Optical Bench Schematic CONDENSING...

Page 220: ...N FUSES PRESSURE SWITCHES A1 INSTRUMENT AIR C4 HEATED SAMPLE LINE RTD C5 HEATED SAMPLE LINE RTD2 C3B SAMPLE TRACE POWER TO HEAT TRACE JUNCTION BOX HTJB P2 SAMPLE LINE POWER FEED OVEN VENT UV OPTICAL C...

Page 221: ...PWB RELAY PWB ANALOG PWB AC TERMINAL MAIN FUSES C4 SAMPLE LINE RTD1 C5 SAMPLE LINE RTD2 C3B SAMPLE LINE HEAT TRACER POWER TO HEAT TRACE JUNCTION BOX P2 SAMPLE LINE POWER NDIR OPTICAL BENCH ASSEMBLY UV...

Page 222: ...A 6 IPS 4 Dual Bench UV IR Analyzer Detector Board 100 2046...

Page 223: ...Appendix A Drawings A 7 Display Interface Board 100 2049...

Page 224: ...2 J1B J1A J17 1C1 2C1 2C2 3C2 4C1 5C1 5C2 6C2 7C1 7C2 8C1 8C2 CT1 1 CT2 RET 3 I1 GND I2 GND PRET I3 I4 P PRET IN1 GND IN1 GND IN2 GND CM1 GNDEXC CM2 V VR RX TX 1 2 4 5 7 8 10 12 13 15 16 ETHERNET RS 2...

Page 225: ...Appendix A Drawings A 9 AC Disconnection Board 100 2077...

Page 226: ...lyzer Signal Disconnection Board 100 2076 RLY11 RLY12 RLY24 J3B J5B J6 D2 RLY1 RLY2 RLY4 RLY5 RLY6 RLY7 RLY10 RLY9 J3A RLY13 RLY14 RLY15 RLY17 RLY18 RLY19 RLY20 RLY22 RLY23 D1 R1 J4B RLY3 RLY16 RLY21...

Page 227: ...Appendix A Drawings A 11 Relay Board 100 2050...

Page 228: ...A 12 IPS 4 Dual Bench UV IR Analyzer Analog Board 100 2047...

Page 229: ...Appendix A Drawings A 13 MCU Board 100 2045...

Page 230: ...A 14 IPS 4 Dual Bench UV IR Analyzer Xenon Lamp Power Supply Board 100 2061 UV Optical Bench...

Page 231: ...Appendix A Drawings A 15 Infrared Source Assembly Interface Board 100 2838 IR Optical Bench...

Page 232: ...A 16 IPS 4 Dual Bench UV IR Analyzer Electronics Enclosure Wiring Diagram Sheet 1 of 5...

Page 233: ...Appendix A Drawings A 17 Electronics Enclosure Wiring Diagram Sheet 2 of 5...

Page 234: ...A 18 IPS 4 Dual Bench UV IR Analyzer Electronics Enclosure Wiring Diagram Sheet 3 of 5...

Page 235: ...Appendix A Drawings A 19 Disconnect Enclosure Wiring Diagram Sheet 4 of 5...

Page 236: ...A 20 IPS 4 Dual Bench UV IR Analyzer Disconnect Enclosure Wiring Diagram Sheet 5 of 5...

Page 237: ...t make up your analyzer and its sample system Supplemental Information Where Can I Find It in Chapter 1 describes the documents listed below This section can include Manual Supplements Analyzer Config...

Page 238: ...S 2 IPS 4 Dual Bench UV IR Analyzer This page intentionally left blank...

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