Ametek IPS-4 Essential Health & Safety Requirements
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Ametek IPS-4 Essential Health & Safety Requirements

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

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

  • Page 2: Offices

    © 2008 AMETEK Process & Analytical Instruments Division This manual is a guide for the use of the IPS-4 IR Analyzer. 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;...

  • Page 3: Table Of Contents

    Table of Contents Offices ........................2 About This Document ..................5 Safety Notes ..................... 5 Important Safety Information ..............5 Warnings ....................6 Cautions .....................7 Special Warnings and Information ..............9 Equipment Used in Class I, Division 1 and Zone 1 Hazardous Loca- tions........................
  • Page 4 Recording Initial Sample Response Time ..........52 Analyzer Configuration ..................53 Maintenance and Troubleshooting ..............55 Before Performing Maintenance ..............55 Cleaning/Replacing Parts in the Sampling System ......... 56 Other Maintenance ..................57 Examining and Caring For the Flamepaths ..........58 4 | IPS-4 Zone1/Analyzer...

  • Page 5: About This Document

    About This Document This document primarily describes the essential health and safety requirements for the compo- nents that make up the Model IPS-4 Analyzer intended for use in explosive atmosphere loca- tions. These sections are described below. The procedures and information discussed in this document include only abbreviated steps to install, operate, and perform maintenance on the Model IPS-4 Analyzer.

  • Page 6: Warnings

    While handling a flash lamp, always wear protective devices (face mask, clothing) to prevent possible injury, especially to hand and face areas. Before working on the sample system, confirm that the system has been purged with Zero fluid and is isolated (blocked in) from the process. WARNING 6 | IPS-4 Zone1/Analyzer...

  • Page 7: Cautions

    Because ultraviolet radiation can harm your eyes, never look directly into the operating lamp. If the Xenon Flash Lamp must be viewed while energized, wear safety glasses that block ultra- WARNING violet radiation. If the Oven/Sample System Enclosure is heated, the components within it will be hot; take precautions to avoid burning yourself.
  • Page 8 The lamp assembly is fragile and should be handled with care. Take extreme care to avoid damaging the threads on the cable entry glands on the Disconnect Enclosure. Clean, defect-free threads are essential to ensure a flameproof connection. CAUTION | IPS-4 Zone1/Analyzer...

  • Page 9: Special Warnings And Information

    SPECIAL WARNINGS AND INFORMATION Equipment Used in Class I, Division 1 and Zone 1 Hazardous Locations Refer to Chapter 2 – Specifications for details about the suitability of this equipment in hazard- ous areas. Explosion Hazard – Substitution of Components May Impair Suitability for hazardous loca- tions.

  • Page 10: Warning Labels

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

  • Page 11: Classified, Hazardous Area Protection Components And Functions

    Start- Up” for instructions on how to initialize the purge system. If it is not required that the IPS-4 be powered on at this time, switching the power off at the power source will shut down the analyzer while maintaining the protective internal pressure. Switching the power on again will re-activate the IPS-4 if the purge controller is still in the normal pressurization mode.
  • Page 12 Pressurization system state diagram. Flanged Flameproof Enclosure: When the IPS-4 is supplied with the 4660 Sample System option, the flowmeters are installed in a flanged flameproof enclosure. Care must be taken to assure that all of the bolts are installed and the flange surfaces are kept in good condition.

  • Page 13: Specifications

    Specifications For a complete listing of all analyzer specifications, refer to the analyzer User Manual. Utility Requirements Power Consumption Without Oven Heater < 300 W maximum start-up (from a cold start) with continuous average, depending on ambient temperature. With Oven Heater <...

  • Page 14: Ambient Temperature Limits

    °C (302 °F). Approvals and Certifications The IPS-4 Analyzer is certified with regard to electrical safety for Pollution Degree 2 (normally nonconductive environmental pollution occurs with occasional condensation) and Installation Category II (local level transients, less than those found at power distribution level). Mains sup- ply voltage fluctuations are not to exceed 10 percent of the nominal supply voltage.

  • Page 15: Analyzer Markings

    Analyzer Markings The Model IPS-4 Analyzer will be marked with a corresponding label to indicate its Ex equip- ment certification and ratings. Figure 2a. IPS-4 ATEX Label for Zone 1 model WITHOUT 4660 sample system option. Figure 2b. IPS-4 ATEX 4660 Label for Zone 1 models WITH 4660 sample system option.
  • Page 16 Figure 2c. Figure 2d. IPS-4 Label for Div 1 models IPS-4 Label for Div 1 models WITHOUT 4660 sample system option. WITH 4660 sample system option. Figure 2e. IPS-4 Label for Zone 1 models With Dual Bench option. | IPS-4 Zone1/Analyzer...

  • Page 17: Installing The Analyzer

    Installing the Analyzer The Installation & Start-Up chapter contains information about the fol- lowing topics: • Where to find safety information in this guide before working with the analyzer. • How to store the analyzer before installation. • How to uncrate and inspect the analyzer for damage before installing •...

  • Page 18: Safety Considerations

    All regulatory agency and personnel safety procedures for your jurisdiction must be followed. The IPS-4 Analyzer is certified with regard to electrical safety for Pollution Degree 2 (normally nonconductive environmental pollution WARNING occurs with occasional condensation) and Installation Category II (lo- cal level transients, less than those found at power distribution level).

  • Page 19: Pre-Installation Requirements

    Pre-Installation Requirements Storage Prior to Installation If the analyzer is stored for any period of time prior to installation, it must be housed in a temperature-controlled environment where it is not sub- ject to dripping or splashing liquids, corrosive gases/liquids, high humid- ity, or excessive heat or cold.

  • Page 20: General Installation Information

    General Installation Information Figure 3 illustrates an example of the layout of components within the  IPS-4 Analyzer. The components in the Electronics Enclosure gener- ally do not change. However, many of the sample system components NOTE in the Oven/Sample System Enclosure in this example illustration are optional and are configured specifically for the application.
  • Page 21 • Supply tubing and pressure regulator(s) for the purge system. This line should be sized to assure that the pressure at the purge control- ler inlet will not drop below 60psi (4 bar) with a flow of up to 350 L/ min.
  • Page 22 Figure 3. Analyzer component layout details, example only. 22 | IPS-4 Zone1/Analyzer...

  • Page 23: Installing The Mechanical Components

    Information” tab of this manual and the Documentation Package shipped with the analyzer. Location and Environment The IPS-4 Analyzer is designed for operation in environments classified “Pollution Degree 2” per IEC 61010, so it must be shielded from conduc- tive pollution and subject to only temporary condensation.
  • Page 24 Refer to the customer- specific drawings in the “Supplemental Information” tab of this NOTE manual or the Documentation Package shipped with the analyzer. Figure 4a. Analyzer mounting details, example only. 24 | IPS-4 Zone1/Analyzer...
  • Page 25 Figure 4b. Analyzer mounting, door clearance. Essential Health & Safety Requirements | 25...
  • Page 26 The surrounding ambient temperature of the analyzer should be main- tained between -20 °C to +50 °C (-4 °F to +122 °F). If the analyzer system is mounted within an AMETEK-designed shelter, these conditions are taken into consideration in the design of shelter.

  • Page 27: Installing The Optical Bench Assembly

    Installing the Optical Bench Assembly After the analyzer has been installed, the Optical Bench Assembly can be mounted in the Electronics Enclosure. All electrical connections to the Optical Bench Assembly are made via pre-wired connector plugs (no hard wiring is required). Ensure there is no power being supplied to the analyzer while install- ing the Optical Bench Assembly.
  • Page 28 Figure 5a. Optical Bench NDIR Assembly. Figure 5B. Optical Bench UV Assembly. 28 | IPS-4 Zone1/Analyzer...

  • Page 29: Installing The Sample System

    “Supplemental Information” tab of this manual or the Documentation Package shipped with the analyzer for installation infor- mation. If the Sample Probe/Sample Tap is not supplied by AMETEK, refer to the information and drawings shipped with the probe.

  • Page 30: Installing And Connecting The Sample And Vent Lines

    Installing and Connecting the Sample and Vent Lines The Sample and Vent Lines can be supplied by AMETEK or the customer. Heated lines, which are not supplied by AMETEK, can only be monitored by the analyzer; they cannot be controlled.

  • Page 31: Installing And Connecting The Instrument Air/Zero Fluid Line

    To install the Sample and Vent Lines: 1. Lay out the Sample and Vent Lines. Route the Sample Line from the analyzer to the sample probe (or process tap) and the Vent Line from the analyzer to the return/vent location. Ensure there are no loops, sags, or other traps in the Sample and Vent Lines.
  • Page 32 3. Connect the line to the Instrument Air/N supply and to the analyzer. The plumbing for purge systems and the Instrument Air/N feed through the analyzer manifold is already made by AMETEK. 32 | IPS-4 Zone1/Analyzer...

  • Page 33: Installing And Connecting The Purge Fluid Line

    Installing and Connecting the Purge Fluid Line Instrument Air or Nitrogen can be used to operate the purge system. This procedure assumes that Instrument Air is being used and is the same for Nitrogen. If using instrument air, the air must meet the ANSI/ISA-7.0.01 (1996) specification.

  • Page 34: Installing The Calibration (Span) Fluid Line (Optional)

    3. Connect the line to the calibration fluid supply and to the analyzer. The plumbing for the calibration fluid feed through the analyzer manifold is already made by AMETEK. 34 | IPS-4 Zone1/Analyzer...
  • Page 35 P U R G E S U P P LY P U R G E C O N T R O LLE R A C T IV E B Y P A S S IN LE T IP S -4 P S 2 D IS C O N N E C T E N C LO S U R E...

  • Page 36: Connecting I/O Signals, Alarm Relay Contacts, And Ac Power

    We recommend that three be used, but all six may be used if needed. 3/4” NPT conduit adaptors are available from AMETEK. Note that unused holes must be plugged with M32 hole plugs. Do not use 3/4” NPT hole plugs with thread adapters. Only properly certified conduit connectors must be used.

  • Page 37: Permanent Ethernet Cable Connections (Optional)

    Terminate the signal and alarm relay contact wires as detailed in the Customer Connections drawing. 3. Route the AC power conductors through the Power cable entry port and into the Disconnect Enclosure. Terminate the AC power wires as detailed in the Customer Connec- tions drawing.
  • Page 38 Figure 7. Signal Disconnection Board 100-2076 and AC Disconnection Board 100-2077 38 | IPS-4 Zone1/Analyzer...

  • Page 39: Start-Up And Verification

    Start-Up and Verification This section describes equipment and controls on the analyzer system that require adjustments and settings before, during, and after power-up. Re- fer to Figure 4 for the general locations of analyzer equipment or controls that require adjustments. The customer-specific Component Layout draw- ing illustrates the actual layout for your system.
  • Page 40 3. After applying AC main power to the analyzer, the message “System Starting” is displayed momentarily on the top line of the User Inter- face Panel. Following this, the AMETEK Process Instruments start-up screen will appear. This screen also displays the software version.
  • Page 41 If these screens do not appear, check the AC wiring to ensure it is properly connected. WARNING To check the AC wiring, take all necessary safety precautions to power down the analyzer and open the Main AC Power and DC Power fuses.
  • Page 42 If the wiring is properly connected, it may indicate a shorted RTD for that temperature zone.  The Oven Heater temperature parameter is available only for applica- tions with a heated Oven. NOTE 42 | IPS-4 Zone1/Analyzer...
  • Page 43 b. Check the pressure of the pilot valves – Manifold block and Zero fluid (if used) pressure. Adjust the Actuator/Zero pressure regula- tor to obtain a minimum pressure of 490 kPag (70 psig / 4.8 barg). c. Check the Aspirator Pressure (gas applications only) from the STATUS screen;...
  • Page 44 ALARMS ALARMS screen. From here, use the arrow key to select Current DOWN Alarms and press again to view any active alarms (on the Cur- ENTER rent Alarms screen, Figure 11). 44 | IPS-4 Zone1/Analyzer...
  • Page 45 If any alarms exist, take appropriate action to correct the alarms before continuing. For more information about alarms and corrective action to take to correct and reset alarms, refer to “Alarm Conditions and Cor- rective Action” in Chapter 5. If no alarms exist (Figure 12), or after all alarm conditions have been cleared (reset), recheck the temperature of each zone from the STATUS screen.

  • Page 46: Start-Up Diagnostic Checklist

    “Alarm 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 & Trouble- shooting” chapter of this manual. 46 | IPS-4 Zone1/Analyzer...
  • Page 47 Problem Encountered Xenon Flash Lamp is not operating (intermittent clicking sound is not heard). Corrective Action Check the system state on the right side of the HOME screen. Note that the Xenon Flash Lamp will not operate when the system is in the Not Ready state.

  • Page 48: Sample System Leak Check

    After all piping and electrical connections have been made: Refer to the system Analyzer flow diagram in the Ametek supplied draw- ing package (403900XXX-3). Identify the portions of the system to be tested.

  • Page 49: Manually Zeroing The Analyzer Sample System

    Zero fluid. The message “Please wait ...” will appear while the analyzer performs the calibration func- tion. Run the zero for 10 minutes. Typically, the IPS-4 Analyzer controls the zero flow rate; no adjust- ments are required.  NOTE If the customer provides the sample system zero, run the manual zero at a flow rate of 2.5 L/minute (0.08 scfm).

  • Page 50: Adjusting The Zero/Span Fluid Flow Rate

    Span (if used) fluid must be high enough to adequately flush the Measur- ing Cell of sample fluid to obtain a “good zero.” Typically, the IPS-4 Analyzer controls the zero (and span, if used) flow rate; no adjustments are required.

  • Page 51: Setting Sample Response Time

    Valve closed) and then adjusting the Aspirator Pressure Regulator with the Drive Air Isolation Valve open to obtain a pressure of 5–10 mmHg (0.20–0.39 inHg or 0.10–0.20 psi) less than the value obtained with the valve closed. View the Measuring Cell pressure (Cell Pressure) from the STATUS screen.

  • Page 52: Normal Operation

    AMETEK recommends that you observe and record this information every month to obtain a history. From these recordings, you will be able to determine if there are problems with the analyzer, such as increasing sample response.

  • Page 53: Analyzer Configuration

    takes the analyzer to display the first reading after the analyzer Sys- tem State switches from “Zero” to “Measure”.  It is important to record the response time only after performing a manual Zero function to simulate the same conditions during the NOTE original recordings.
  • Page 54 This page intentionally left blank. 54 | IPS-4 Zone1/Analyzer...

  • Page 55: Maintenance And Troubleshooting

    Maintenance and Troubleshooting Generally, there is limited maintenance required to ensure the analyzer remains operating at peak efficiency, other than that described in the “Analyzer Preventive Maintenance Schedule” [located in the Maintenance and Troubleshooting chapter of the analyzer User Manual]. This section discusses preventive maintenance that must be followed to ensure con- tinued and proper operation of the analyzer.

  • Page 56: Cleaning/Replacing Parts In The Sampling System

    The components within the enclosure will be hot; take precautions to avoid burning yourself. WARNING 3. Continue with the procedures to disassemble, clean, replace parts in, and reassemble the appropriate sampling system component and all associated sample system tubing. 56 | IPS-4 Z1/Div1 Analyzer...

  • Page 57: Other Maintenance

    Electronics Enclosure open If a procedure for a certain maintenance task is not described in the ana- lyzer User Manual, contact AMETEK Service Personnel for details about performing the required maintenance. For complete details about operating and maintaining the purge system, refer to the “Pressurized Enclosure System User’s Manual”...

  • Page 58: Examining And Caring For The Flamepaths

    (example, a suitable agent is Isopropanol). CAUTION When performing equipment maintenance in hazardous areas, all safety standards and procedures must be followed, as specified by the Owner Company, local electrical-inspection authority, and National/ WARNING EU regulations. 58 | IPS-4 Z1/Div1 Analyzer...

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