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Ametek IPS-4 User Manual

Dual bench (uv / ir) analyzer zone 1 / division 2
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IPS-4 Dual Bench (UV / IR) Analyzer
Zone 1 / Division 2
User Manual
Canada
A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS
PN 903-8804, Rev. L

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  • Page 1 IPS-4 Dual Bench (UV / IR) Analyzer Zone 1 / Division 2 User Manual Canada A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS PN 903-8804, Rev. L...

  • Page 2: Offices

    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;...

  • Page 3: Table Of Contents

    Contents Offices ..........................ii Safety Notes ........................ix Electrical Safety ........................ix Grounding .......................... ix Personnel and Equipment Safety Information .............. x Warnings ........................x Cautions ........................xii Warning Labels ........................ xiii Environmental Information (WEEE) ................xiii UV Source Lamps Disposal ................... xiii Electromagnetic Compatibility (EMC) .................
  • Page 4 Safety Considerations ..................... 3-2 Pre-Installation Requirements..................3-2 Storage Prior to Installation ..................3-2 Uncrating and Inspecting the Analyzer ..............3-3 General Installation Information ................3-3 Tools, Equipment, and Supplies Required ............3-4 iv | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 5 Installing the Mechanical Components ............... 3-6 Mounting the Analyzer ................... 3-6 Location and Environment .................. 3-6 Installing the Optical Bench-UV Assembly ............3-10 Installing the Optical Bench IR Assembly ............3-11 Installing the Sample System................3-13 Installing the Sample Probe/Sample Tap ............3-14 Installing and Connecting the Sample and Vent Lines ........
  • Page 6 Replacing the Xenon (UV) Flash Lamp Assembly ..........5-19 Replacing the Infrared (IR) Source Assembly ............ 5-23 Troubleshooting and Diagnostics ................5-26 Alarm Conditions and Corrective Action ............5-27 Analyzer Reset ......................5-31 vi | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 7 CHAPTER 6 SERVICE AND PARTS ..................6-1 Technical Support ......................6-1 Returning Equipment ..................... 6-2 AMETEK Service and Aftermarket Sales Support ............. 6-3 Recommended Spare Parts .................... 6-4 Measuring Cell Assembly Spare Parts ..............6-4 Optical Bench Assembly Spare Parts ..............6-4 Spare Analyzer Fuses ....................
  • Page 8 Electronics Enclosure Wiring Diagram, Sheet 3 of 5 ..........A-18 Disconnect Enclosure Wiring Diagram, Sheet 4 of 5 ..........A-19 Disconnect Enclosure Wiring Diagram, Sheet 5 of 5 ..........A-20 SUPPLEMENTAL INFORMATION ..................S-1 viii | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 9: Safety Notes

    Safety Notes WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as follows: An operating procedure which, if not strictly observed, may result in personal injury or envi- ronmental contamination. WARNING An operating procedure which, if not strictly observed, may result in damage to the equipment.

  • Page 10: Personnel And Equipment Safety Information

    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.
  • Page 11 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 WARNING block ultraviolet radiation. If the Oven/Sample System Enclosure is heated, the components within it will be hot; take precautions to avoid burning yourself.

  • Page 12: Cautions

    The window is the flat sur- CAUTION face at the end of the narrow glass tube. The lamp assembly is fragile and should be handled with care. xii | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 13: Warning Labels

    UV Source Lamps Disposal AMETEK recommends that all UV lamps – whether they are new, used, or damaged in any way – need to be disposed of in an environmentally safe manner. Most UV lamps do not contain restricted substances listed under the European RoHS 2 directive.

  • Page 14: Electromagnetic Compatibility (Emc)

    CAUTION environments. The various configurations of the IPS-4 Analyzer should not produce, or fall victim to, electromagnetic disturbances as specified in the European Union’s EMC Directive (if applicable to your application). Strict compliance to the EMC Directive requires that certain installation techniques and wiring practices are used to prevent or minimize erratic behavior of the Analyzer or its electronic neighbors.

  • Page 15: 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 16: Eu Declaration Of Conformity

    Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use – Part 1. General requirements. Canada A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS Page 1 of 2 PN 903-8805 Rev C xvi | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 17 Notified Body: DEKRA Certification B.V. 0344 Meander 1051, 6825 MJ Arnhem The Netherlands ____________________________ Randy Meads Quality Assurance Manager Calgary, Alberta, Canada July 12, 2019 Canada A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS Page 2 of 2 Contents | xvii...

  • Page 18: Warranty And Claims

    Process photometric analyzers, process moisture analyzers, and sample systems are warranted to perform the intended measurement, only in the event that the customer has supplied, and AMETEK has accepted, valid sample stream com- position data, process conditions, and electrical area classification prior to order acknowledgment. The photometric light sources are warranted for ninety (90) days from date of shipment.

  • Page 19: Chapter 1 Overview

    OVERVIEW This chapter discusses the features of the IPS-4 Analyzer and a summary of how the entire system operates. This chapter also provides an overview of the AMETEK electronics, Dual Bench options, sample systems, and the various sub-systems that make up the entire analyzer system.

  • Page 20: Calculation Flow

    This calibration will be unique for each application. Because two Optical Benches are operating in parallel, transmittance information from one or both of the covered spectral ranges can be used simultane- ously to model the analyte(s) of interest. 1-2 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 21 STEP 4: Filter output of Step 3. A median filter is applied to the current analyte value reading incorpo- rating the previous analyte value reading The size of the median filter is set in parameter MEDSZ. The median filter is follow by an IIR filter (Equation 1.3) weighted by a non-linear function defined by ALPHA and BETA parameters.

  • Page 22: Dispersive Ultraviolet/Visible (Duvv) Spectrometer

    Figure 1-2 illustrates the complete NOTE optical path from source to detector for the DUVV and Optical Bench. Figure 1-2. Analyzer light path, UV schematic. 1-4 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 23: Uv Specifications

    A Xenon flash lamp is utilized as the source for the ultraviolet and visible regions. The collimated beam from the Xenon lamp travels through the Measuring Cell. There are several types of Measuring Cells for the IPS-4 (see Figure 5-2). When an application requires sensitivity at shorter wave- lengths, UV-grade fused silica windows are used.

  • Page 24: Non-Dispersive Infrared (Ndir) Photometer

    Figure 1-2 illustrates the complete NOTE optical path from source to detector for the NDIR Optical Bench. CONDENSING Figure 1-3. Analyzer light path, NDIR schematic. 1-6 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 25: Ndir Specifications

    (up to six filters located in the filter wheel assembly) and then through the Measuring Cell. There are several types of Measuring Cells for the IPS-4 (see Figure 5-2). Typically, Sapphire windows and gold mirrors are used in the Measuring Cell. Next, a con- densing lens focuses the beam onto a two-stage thermoelectrically cooled lead selenide (PbSe) detector.

  • Page 26: Electronics

    • Calculate the fluid absorbances and concentrations. For external communication, RS-232, RS-485, and Ethernet ports are avail- able. Analog signals are also available to the customer through configu- rable 0–20 mA or 4–20 mA outputs. 1-8 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 27: Classified, Hazardous Area Protection Components And Functions

    Classified, Hazardous Area Protection Components and Functions The Division 1 and Zone 1 versions of the IPS-4 are designed to be, and comply with requirements for, electrical equipment in Division 1 and Zone 1 classified hazardous areas respectively. The methods of protection used include type “p”...
  • Page 28 IPS-4. See “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 the analyzer while maintaining the protective internal pressure.
  • Page 29 IPS-4 PURGE SYSTEM STATE DIAGRAM START Apply AC No air >60psi air + Key in Bypass POWER OFF BYPASS MODE ALARM (RED) ANALYZER ON Loss of air Key Active Loss of air + Air in ≥ 60psi Key to Key to...

  • Page 30: Supplemental Information - Where Can I Find It

    • Optical Bench Calibration Summary Report (Pixel to Wavelength) Sheet, which is a summary report. • Signed Final QC (Quality Control) Document, which includes AMETEK Testing Quality Control information for the analyzer. • Final "As-Built" drawings which are customer-specific drawings for the analyzer system.

  • Page 31: Chapter 2 Specifications

    SPECIFICATIONS Analyzer Specifications Analytes Up to eight analytes, depending on the application. Response Linearity +/- 1% 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 been performed.

  • Page 32: 24-Hour Zero Drift

    Two form C loss of purge alarm contacts rated 240 Vac 5 A max. RS-485 serial port, isolated. RS-232 serial port, non-isolated. Fast Ethernet (IEE802.3). Modbus TCP (Supports single Modbus Client ). 2-2 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 33: Sample System Limits

    Sample System Limits Sample Pressure Up to 10,000 kPag (1,450 psig / 100 barg) can be accommodated, depend- ing on the application. See product markings or the Final “As-Built” draw- ings in the analyzer Documentation Package. Oven/Sample System Enclosure Temperature For applications with a heated sample system, the Oven will operate at temperatures up to 150 °C (302 °F).

  • Page 34: Electrical Requirements

    Manifold Block: 0–100 psig Measuring Cell: (0–30 psia, 0–100 psia, or 0–500 psia) On-Board Temperature Sensor The electronics temperature is measured by a solid-state temperature sen- sor located on the MCU board. 2-4 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 35: Environmental

    Environmental Ambient Temperature -20 °C to +50 °C (-4 °F to +122 °F), without external heating or cooling. * When liquids are used, ambient temperature is greater than the freezing point. Humidity 0–90 % Relative Humidity Pollution Degree Pollution Degree 2 Maximum Altitude 2000 metres Installation Category...

  • Page 36: Approvals And Certifications

    Approvals and Certifications The IPS-4 Analyzer is certified for indoor use only, Installation Category II (local level transients, less than those found at power distribution level), and Pollution Degree 2 (normally nonconductive environmental pollu- tion occurs with occasional condensation). Complies with all relevant European Directives.

  • Page 37: Special Condition Of Use

    1 or 2 of IEC/EN 60079-1. • The installer must install appropriate protection from light to ensure that the resistance to light of the IPS-4, or parts of the IPS-4 is satisfac- tory. • The installer must ensure that the installation minimizes the risk from electrostatic discharge.

  • Page 38: Atex And Iecex Certificates And Analyzer Markings

    ATEX and IECEx Certificates and Analyzer Markings For installation sites with potentially explosive atmospheres that require ATEX and IECEx certification, AMETEK’s ATEX and IECEx certificates for the IPS-4 Dual Bench Analyzer (and their markings) are included in the following pages. IPS-4 Dual Bench Analyzer ATEX Certificate...
  • Page 39 Issue 1 [15] Description of Product The IPS-4-DB is a dual-bench process spectrophotometer that is housed in a two part IP 65 rated stainless steel enclosure, and has a certified purge control system, an Expo MiniPurge Model 07 1XLC/ss/PO or Model 07 1XLC/SS/ET/PO, SIRA 01 ATEX 1295X on the part of the enclosure that houses the electronics.
  • Page 40 Original issue 2016-08-19 2016-9207 Updated to new 60079-2 and added second model purge 2018-09-27 2016-9207 r1 controller. END OF CERTIFICATE DNV GL Presafe AS, Veritasveien 3, 1363 Høvik, Norway 3 of 3 2-10 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 41: Ips-4 Dual Bench Analyzer Marking

    IPS-4 Dual Bench Analyzer Marking ATEX-certified IPS-4 Purged Analyzers are marked with this label. AMETEK ENERGY AND PROCESS INSTRUMENTATION 2876 Sunridge Way NE Calgary, Alberta Canada T1Y7H9 Phone: 1-888-661-9198 Model No. IPS-4 DB Serial No. 403Axxx Tag No. V/Hz/Watts 120V/240V 50-60Hz 850Wmax 20xx Year of Manuf.

  • Page 42: Ips-4 Dual Bench Analyzer Iecex Certificate

    U U n n i i t t e e d d S S t t a a t t e e s s o o f f A A m m e e r r i i c c a a 2-12 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 43 I I E E C C E E x x C C e e r r t t i i f f i i c c a a t t e e o o f f C C o o n n f f o o r r m m i i t t y y Certificate No: IECEx ETL 16.0044X Issue No: 0...
  • Page 44 Equipment and systems covered by this certificate are as follows: The IPS-4-DB is a dual-bench process spectrophotometer that is houses in a two part IP 65 rated stainless steel enclosure. In incorporates a certified purge system on the side of the enclosure that houses the electronics to provide the Ex px protection. The other side is not purged but the only electrical component within it is an certified Ex d heater.
  • Page 45 Title: Drawing No.: Rev. Level: Date: Certification drawing IPS-4, Dual Bench, IECEx 403475903 11/9/2016 IPS-4 Analyzer Full Spectrum Option 1 Zone 1 User Manual 403469901 Conditions of Manufacture (routine tests) IEC 60079-2 Section 17.1 Functional Test • • IEC 60079-2 Section 17.2 Leakage Test...
  • Page 46 -retested Rating Ex db IIC Note Retested with enclosure item 5 Certificate issued by: Intertek 3933 US Route 11 South Cortland NY 13045-2995 United States of America Page 2 of 2 2-16 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 47 Certificate No: IEC Ex ETL 16.0044X Issue No. 0 Annex No. 1 No.: Item: Manufacturer: Part No.: Details: Ametek Part # Certificate No. IECEx INE 11.0018X 403476001 IEC 60079-0: 2011 Standards/Versions: M.A.M. part # GUB IEC 60079-1: 2007 5S (disconnect...
  • Page 48 This page intentionally left blank. 2-18 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 49: Chapter 3 Installation And Start-Up

    INSTALLATION and START-UP The Installation and 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 50: Safety Considerations

    All regulatory agency and personnel safety proce- dures 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 51: Uncrating And Inspecting The Analyzer

    General Installation Information Figure 3-1 illustrates an example of the layout of components within the IPS-4 Analyzer. The components in the Electronics Enclosure generally do not change. However, many of the sample system components in the Oven/Sample System Enclosure in this example illustration are optional and are configured specifically for the application.

  • Page 52: Tools, Equipment, And Supplies Required

    Special requirements may be necessary for outdoor analyzer installations, hazardous locations, and/or lengths greater than 100 m. Systems using Ethernet also require a ferrite core (supplied by AMETEK). For systems using a temporary Ethernet connection, a crossover cable must be used.
  • Page 53 Figure 3-1. IPS-4 (Zone 1) component layout details, example only.  Actual layout may vary. Refer to customer-specific Final “As-Built” drawings shipped with the analyzer. NOTE Installation and Start-Up | 3-5...

  • Page 54: Installing The Mechanical Components

    Documentation Package. 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 55 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 56 Figure 3-2a. IPS-4 (Zone 1) mounting details, example only.  Actual layout may vary. Refer to customer-specific Final “As-Built” drawings shipped with the analyzer. NOTE 3-8 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 57 DISCONNECT BOX ARE EPOXY PAINTED CAST ALUMINUM. Figure 3-2b. IPS-4 (Zone 1) mounting, MODCON SYSTEMS/SOCAR HAOR - AZERBAIJAN door clearance. MODEL IPS-4 ANALYZER / FIELD UNIT INSTALLATION REV. 2019/05/01 WX-11062-3-3A  Actual layout may vary. Refer to customer-specific Final “As-Built”...

  • Page 58: Installing The Optical Bench-Uv Assembly

    Do not attempt to adjust the Optical Bench. The Optical Bench has been factory aligned to the mounted Measuring Cell. See additional WARNING information on the dual Optical Bench application in the Overview section of this manual. 3-10 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 59: Installing The Optical Bench Ir Assembly

    HEATER/OT SWITCH RIBBON CABLE, CONNECTS WIRING HARNESSS, TO P4 ON DETECTOR INTERFACE CONNECTS TO BOARD ON ELECTRONIC J401B ("BENCH HTR") ENCLOSURE DOOR. ON RELAY BOARD RTD CABLE, CONNECTS TO DC CABLE CONNECTOR, IN-LINE CONNECTORS CONNECTS TO J2 ON ("CON2") LEADING TO XENON LAMP BOARD J402 ON ANALOG BOARD XENON FLASH...
  • Page 60 TO ANALYZER CONNECTS TO P2 OF DETECTOR INTERFACE BOARD PURGE FITTING 3-PIN FEMALE POWER CONNECTOR, CONNECTS TO POWER CABLE FROM DC TERMINAL ASSEMBLY Figure 3-3b. IR Optical Bench, Infrared Source Assembly. 3-12 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 61: Installing The Sample System

    Installing the Sample System Sample systems will vary for each application, depending on the hazard- ous location, whether the application is gas or liquid, heated or non-heat- ed, etc. Sample system components can include, but are not limited to: • Sample probe (or process tap) •...

  • Page 62: Installing The Sample Probe/Sample Tap

    Installing the Sample Probe/Sample Tap If the Sample Probe is supplied by AMETEK, refer to the Final “As-Built” drawings in the analyzer Documentation Package for installation informa- tion. If the Sample Probe/Sample Tap is not supplied by AMETEK, refer to the information and drawings shipped with the probe.

  • Page 63: 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 64 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. 3-16 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 65: 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 66 PURGE SUPPLY PURGE CONTROLLER NORMAL BYPASS INLET IPS4 DISCONNECT ENCLOSURE Figure 3-4. Purge System. 3-18 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 67: 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. Installation and Start-Up | 3-19...

  • Page 68: Connecting I/O Signals, Alarm Relay Contacts, And Ac Power

    Interconnect Wiring drawing (part of the analyzer NOTE Final “As-Built” drawings package) specifically details the signal, relay contact, and AC power connection points. The Final “As-Built” drawings are located in the analyzer Documentation Package. 3-20 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 69: Permanent Ethernet Cable Connections (Optional)

    To make the signal, relay contact, and AC power connections: 1. Open the Disconnect Enclosure or Sample Line Disconnect Box. If a power-disconnect switch (breaker) was installed, open (turn off) the breaker before making the AC power connections. AC Power and relay connections are made at the AC Disconnect board.
  • Page 70 Figure 3-5. Signal Disconnection Board 100-2076 and AC Disconnection Board 100-2077. 3-22 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 71: Start-Up And Verification

    This function effectively prevents an internal explosion when the ana- lyzer is powered up and operating under normal sampling conditions. AMETEK analyzers that require purged enclosures in hazardous locations use an Expo Technologies MiniPurge System With eTimer to perform this ®...
  • Page 72 These checks are discussed in the following power-up procedure. If problems are encountered during power-up, refer to “Start-Up Diagnostic Checklist” in this chapter, for help in diagnosing and correcting problems. 3-24 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 73 Replace parts immediately if damage or wear is apparent. Contact AMETEK if there is any doubt about the integrity of any flamepath. Installation and Start-Up | 3-25...

  • Page 74: Powering Up The Analyzer

    (bypass key on the “ACTIVE” position and the purge controller indicators GREEN (left) and BLACK (right). Do not apply main AC power to the analyzer if the Xenon Flash Lamp Assembly electrical connections have not been made. CAUTION 3-26 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 75 3. After applying AC main power to the analyzer, the message “System Starting” is displayed momentarily on the top line of the User Interface Panel. Following this, the AMETEK Process Instruments start-up screen will appear. This screen also displays the software version.
  • Page 76 To perform the leak check, follow the procedure under “Sample System Leak Check,” later in this chapter. 3-28 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 77 5. After the leak check has been performed and has passed, close the Bench Heater fuse and Oven Heater fuse (if Oven/Sample System Enclosure is heated) to apply power to the Measuring Cell and Oven Heater temperature-control zone circuitry. Ensure that the sample system door has been closed and latched.
  • Page 78 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). 3-30 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 79 c. Check the Aspirator Pressure (gas applications only) from the STATUS screen; the pressure should be adjusted to the value stated on the system Final “As-Built” drawings, or enough to see a flow on the Flow Indicator (or meter), if used, or to achieve an ac- ceptable response time.
  • Page 80 If there is no clicking sound, and the analyzer is in a state other than the Not Ready state, this can indicate problems with the wiring. If necessary, power down the analyzer and check all associated wiring. 3-32 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 81 12. If the analyzer sample system cools down to below its normal oper- ating temperature and returns to the Not Ready state, wait until it warms up enough and the analyzer leaves the Not Ready state. Check the User Interface Panel for current alarms. To view alarms that have been detected, press the soft key to view the ALARMS ALARMS...
  • Page 82 The optional Flow Indicator (or meter), if used, will provide a visual indication of sample flow. 16. Close and secure the analyzer doors. The start-up and verification checks are complete and the analyzer is ready for normal operation. 3-34 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 83: Start-Up Diagnostic Checklist

    Start-Up Diagnostic Checklist This checklist describes problems that can be encountered while powering up the analyzer and/or preparing it for normal operation. If the analyzer experiences problems during power-up, review this checklist and perform the corresponding corrective action to fix any problems. Problem Encountered Status/error code conditions for current alarms are displayed on the User Interface Panel.
  • Page 84 (located at TB1 in Electronics Enclosure). If the temperature zone values still do not increase, take appropriate safety precautions and check the proper connections for the appropri- ate temperature zone wiring. 3-36 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 85: Sample System Leak Check

    Sample System Leak Check The analyzer sample system has been pressure-checked for leaks at the factory as part of AMETEK’s quality assurance procedures. However, fittings can loosen during transport. Also, the Sample, Vent, Instrument Air (or N ), and Calibration (Span, if used) Fluid lines are in- stalled on-site.
  • Page 86 If a pressure sensor and isolation valves are not available, pressurize the system and bubble-test all joints with a soap solution. (e.g., Snoop or the fluid specific to the Analyzer.) 3-38 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 87: Manually Zeroing The Analyzer Sample System

    “Please wait ...” will appear while the analyzer performs the calibra- tion function. 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 88: Adjusting The Zero/Span Fluid Flow Rate

    Zero/Span (if used) fluid must be high enough to adequately flush the Measuring 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. 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 89: Adjusting The Sample Flow Rate

    Adjusting the Sample Flow Rate Applications With an Aspirator: The Aspirator Pressure Regulator is used to control the sample flow through the system. A typical sample flow rate is in the range of 3.0–5.0 L/minute (0.1–0.2 scfm) and can be achieved by adjusting the Aspirator Pressure higher than 70 kPa (10 psi) above the sample stream pressure.

  • Page 90: Setting Sample Response Time

    If the sample response time is adequate (first response after a Zero is less than 30 seconds to T90), no further adjustment is necessary.  The sample response time may vary, depending on Sample Line length. NOTE 3-42 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 91: 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 92: Analyzer Configuration

    If the MCU board is ever replaced, this data must be re-entered in order to override the factory defaults. If necessary, refer to the Parameter List (Factory Settings) to revert the analyzer back to its original settings. 3-44 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 93: Chapter 4 Controller / User Interface

    CONTROLLER / USER INTERFACE The Controller / User Interface chapter contains information about the following topics: • An introduction to the User Interface Panel, and how to enter com- mands to view various screens. Information about passwords and how to change them is also discussed in this chapter. •...

  • Page 94: Introduction To The User Interface Panel

    The other lines can display the output results (concentrations, temperatures, pressures), alarms (current and historical), system status, system information, and various configurable parameters that allow you to set up the analyzer to perform various functions (calibration, communication, etc.). 4-2 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 95 • The Main Keypad allows you to change information from any of the editable parameters. The keypad consists of: Description 0–9 Numeric keys 0–9 are used to enter numerical data or as part of a password. – The minus (‘–’) key can be used as part of a negative number or as part of a password.

  • Page 96: Special Software Characters

    When both of these characters (located in the lower-left corner) are displayed, there are other options to be viewed above and below the items currently being displayed. To scroll through other options, press the arrow key. DOWN 4-4 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 97: Working From The User Interface Panel - Conditions And Messages

    Working From the User Interface Panel – Conditions and Messages While working from the User Interface Panel, the following conditions apply:  The analyzer is shipped from the factory without a password (security is disabled). Upon powering up the analyzer for the first time, all con- NOTE figurable parameters can be changed until a password is entered in the Change Password function (Login/Set Password screen, SYSTEM...

  • Page 98: Summary Of Analyzer Operation

    The analyzer will leave its normal sequence of states if there is an alarm condition, such as a temperature or pressure out of range, and will return to the first state in the sequence once the offending condition has been cleared (reset). 4-6 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 99: Working In The Main Menus

    Working in the Main Menus During normal operation, the concentrations of the analytes can be dis- played on the HOME screen. Other parameters that display real-time sys- tem temperatures or pressures can also be displayed. Up to three analytes or parameters can be displayed on the screen at one time. To view more concentrations or other data, scroll up or down using the DOWN row key.
  • Page 100 Displays the real-time pressure (psia, or other unit) being measured in the Measuring Cell. Tec Temperature Displays the temperature of the NDIR sensor. Probe Temperature Displays temperature at the sample probe. Sample/Vent line Temperature Displays temperature of sample/vent bundle. 4-8 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 101: System Status Messages (Home Screen)

    System Status Messages (HOME Screen) While working from the HOME screen, messages that are displayed on the right side of this screen indicate the current operating status (mode) of the analyzer, also known as System Status or System State. Please refer to supplemental material/documentation for any modes not described below.

  • Page 102: Alarm And Warning Notification (Home Screen)

    – include the time and date each alarm was set and reset. The alarm or warning at the top of the list is most recent; the alarm or warning at the bottom is the oldest. 4-10 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 103: Alarms And Warnings Menu Screen

    ALARMS and WARNINGS Menu Screen The ALARMS and WARNINGS screen (Figure 4-3) displays active ana- lyzer alarm conditions (Current Alarms and Warnings screen) that have been set by the built-in diagnostics function and a history of alarms and warnings that have been reset (Alarm Log or Warnings Log screen). The alarms are read-only.

  • Page 104: Viewing Logged Alarms And Warnings

    Alarm Log empty Figure 4-8. No history of alarms, HOME ALARMS STATUS SETUP Alarm Log screen. Warnings Log empty Figure 4-9. No history of warnings, Warnings HOME ALARMS STATUS SETUP Log screen. 4-12 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 105: Status Menu Screen

    STATUS Menu Screen The STATUS screen (Figure 4-10) displays the real-time data results of various analyzer functions. These items are factory-set, according to cus- tomer specifications. This screen is particularly useful when performing analyzer diagnostics. These outputs are read-only. > Heater 19 °C Bench 24 °C...
  • Page 106 Automatic Calibration 2 screen. The Calibration Trigger (TIMER 2) must be selected for the countdown time to be displayed. Refer to the section “Calibration Control” in this chapter for descriptions about setting up all Auto-Calibration parameters. 4-14 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 107: Setup Menu Screen

    SETUP Menu Screen The SETUP screen (Figure 4-11) provides access to the sub-menu screens containing the functional parameters that control the operation of the analyzer. This screen allows the user to set up certain parameters. The settings for your analyzer have been configured at the factory to meet specified customer requirements.

  • Page 108: Calibration Control Screen

    Automatic Calibration 1 Calibration Trigger Timer ► Mode Zero + Span Timer Interval 0 day Unit Figure 4-14. Start Time 00:00:00 Calibration Settings HOME ALARMS STATUS SETUP screen. 4-16 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 109 Calibration Trigger Use this to select how auto-calibration is triggered. Calibration Trigger options include: • Timer Enables the Auto-Calibration timer. The system will automatically Zero and/or Span the analyzer. • Input1 and Input2 Auto-Calibration will be initiated by a user-supplied contact clo- sure.
  • Page 110 LEFT (erase) the characters to the left of the cursor ( ‘_’ ) if applicable, then use the numeric keys to enter the new value. This works best for drastic changes. 4-18 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 111: Flush Times

    Flush Times The Flush Times screen (Figure 4-15) displays all of the available flush times. Flush Times Zero 10 sec ► Span 30 sec Sample 20 sec Figure 4-15. Flush Times Settings HOME ALARMS STATUS SETUP screen. Zero flush time Defines the duration (seconds) the analyzer will flush the sample sys- tem with Zero fluid during the analyzer’s normal operating sequence.

  • Page 112: Calibration Valves

    3. For multi-species spanning, repeat Steps 1 and 2 for each species that will be spanned. Analyte cal conc ► Analyte cal conc Analyte cal conc Figure 4-16. Calibration Valves HOME ALARMS STATUS SETUP screen. 4-20 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 113: Calibration Actions Screen

    Calibration Actions Screen The Calibration action screen displays all of the available analyzer calibra- tion functions and allows the user to initialize the calibration functions. Figures 4-17a and 4-17b illustrate the differences between analyzers that use single-species spanning and those that use multi-species spanning. Start Zero Calibration ►...

  • Page 114: Manually Starting A Zero Calibration

    Sample Flush before switching back to Measure mode. Manually Starting a Zero Calibration Refer to “Manually Zeroing the Analyzer Sample System” in Chapter 3 for information about how to perform a manual zero on the analyzer. 4-22 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 115: Manually Starting A Span Calibration

    Manually Starting a Span Calibration This section applies only to systems with multi-species spanning capabil- ity.  Pressing CANCEL at any time during this procedure will abort the procedure and return the software to the HOME screen. NOTE To introduce Span fluid: 1.

  • Page 116: Manually Starting A Neutral Density Filter Verification

    Manually Starting a Neutral Density Filter Verification The neutral density filter (NDF) is an optical diagnostics tool that can be used to check the response and alignment of the IPS-4’s UV Optical Bench pathway. This user-initiated feature provides additional diagnostics and preventive diagnostics on the UV Optical Bench, which can help avoid timely and costly repairs.

  • Page 117: Neutral Density Filter Verification Diagnostic Chart

    “Neutral Density Filter Verification Diagnostic Chart“ first, and perform the Corrective Action to try to correct the problem. If the error message still doesn’t clear, contact AMETEK Service for assistance. 5. To view the results of the filter verification, select Calibration Control from the SETUP menu and press Enter.

  • Page 118: Relay Setup Screens

    The relay will be de-energized if any system fault alarm condition is triggered within the analyzer diagnostic system. The analyzer requires service. The relay will reset automatically upon correction of the fault alarm. 4-26 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 119 Low Limit Select this to enable an analyte concentration Low Limit Alarm. High Limit Select this to enable an analyte concentration High Limit Alarm. Heartbeat Relay periodically will turn on and off to indicate that the Ana- lyzer is “ON”. Check Request Relay will be “ON”...
  • Page 120 LEFT characters to the left of the cursor ( ‘_’ ) if applicable, then use the numeric keys to enter the new value. This works best for drastic changes. 4-28 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 121: Current Output Setup Screens

    Current Output Setup Screens The Current Output screens (Figure 4-20a and 4-20b) display current out- put assignments and allows you to set up the parameters for each of the four current outputs. Source Defines the analyte assigned to each analog output. Current Out Source options include: NONE Select NONE if you do not wish to assign an output to a channel.
  • Page 122 LEFT characters to the left of the cursor ( ‘_’ ) if applicable, then use the numeric keys to enter the new value. This works best for drastic changes. 4-30 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 123: Setpoints

    Setpoints The Setpoints screens (Figures 4-21, 4-22, 4-23, and 4-24) allow you to view configured normal operating (factory set) parameters for span, pres- sure, and temperature low/high limits. Setpoints > Span Limits Pressure Limits Temperature Limits Figure 4-21. HOME ALARMS STATUS SETUP Setpoints Screen.
  • Page 124 Setpoints Screen. Temperature Limits º Bench Deviation Limit º Bench Set Point º Heater Deviation Limit º Heater Set Point Figure 4-24. Temperature Limits  HOME ALARMS STATUS SETUP Setpoints Screen. 4-32 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 125: Diagnostics Screen

    Diagnostics Screen The Diagnostics screen (Figure 4-25) allows the user to disable normal operations while troubleshooting or setting up external control systems. Diagnostics ►Current Output Diagnostics Relay Diagnostics Valve Diagnostics Lamp Diagnostics UV Diagnostic IR Diagnostic Figure 4-25. HOME ALARMS STATUS SETUP Diagnostics Screen.

  • Page 126: System Settings Screen

    The System Settings screen (Figure 4-31) allows the user to view and/or setup analyzer system parameters. ► Log in/Set Passwords Backup/ Restore Ethernet Network System Figure 4-31. Customization System Settings HOME ALARMS STATUS SETUP Screen. 4-34 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 127: Login/Set Passwords Screen

    Login/Set Passwords Screen The Login/Set Password screen (Figure 4-32) allows you to set up pass- word protection for users who need access to modify analyzer configura- tion parameter settings, or restrict users to read-only function. The ana- lyzer is shipped from the factory without a password. Upon powering up the analyzer for the first time, all configurable parameters can be changed until a password is entered in the Change Password function.
  • Page 128 , the parameters are locked out and the message ENTER “System locked” is displayed. When the system is locked, a padlock icon ( ) appears in the top-right corner of the HOME screen. 4-36 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 129: Changing The Password

    Changing the Password Occasionally, you should change the password that allows you to make changes to the analyzer configuration settings. If password protection al- ready exists, you must enter the existing password before you can change To change the password: 1.

  • Page 130: Backup/Restore Settings Screen

    Settings” for details about how to restore configuration settings. Restore factory settings Retrieves and restores the original factory-set analyzer configuration settings from the “factory.xml” file. See “Restoring Analyzer Configu- ration Settings” for details about how to restore configuration settings. 4-38 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 131: Backing Up Analyzer Configuration Settings

    Backing Up Analyzer Configuration Settings To back up configuration settings: 1. Press the soft key and then use the arrow to scroll down SETUP DOWN until the Backup/Restore sub-menu is selected. Press to view ENTER the Backup/Restore screen. 2. Select Backup settings and press .
  • Page 132 Restore Settings HOME ALARMS STATUS SETUP screen. Restore factory settings. Are you sure? Press for yes.  Press X for no. Figure 4-36. Restore Factory HOME ALARMS STATUS SETUP Settings screen. 4-40 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 133: Ethernet Network Screen

    Ethernet Network Screen The Ethernet Network screen (Figure 4-37) allows the user to enter Ether- net settings. This is used to enable your analyzer system to communicate over an Ethernet network for viewing analyzer and stream composition data, viewing analyzer diagnostics, or backing up/restoring analyzer con- figuration settings.
  • Page 134 5. Ensure the DHCP server is on the same server as the analyzer. 6. Press to back out of this sub-menu. CANCEL 7. Reset the analyzer to allow the changes to take effect. 4-42 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 135 RIGHT LEFT arrow key to jump over a character. The cursor will jump over the colon ( : ) and slash ( / ) characters when entering the time and date. ►Model Name IPS-4 Serial Number 12345678 Software Version 1.10...

  • Page 136: Customization Screen

    ENTER Available languages for viewing the software include:* - English - German - Russian - French - Spanish *For Customer software applications, all languages may not be available. 4-44 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 137 Menu Home Time This displays and allows you 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. Screen Brightness This displays and allows you to change the screen brightness.

  • Page 138: Modbus Screen

    Modbus Port This displays and allows you to change the Modbus communications with the analyzer when using Modbus communications Port format. The default options include Modbus RTU and Modbus TCP . 4-46 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 139 To change these parameters: 1. Select the parameter you wish to change and press to go into ENTER Edit mode. 2. For Baud, Parity, and Stop Bits, use the arrow key to scroll DOWN through the available options. To select an option when it is displayed, press ENTER For Modbus Address and Modbus Timeout, enter a value using the...
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  • Page 141: Chapter 5 Maintenance And Troubleshooting

    MAINTENANCE and TROUBLESHOOTING The Maintenance and Troubleshooting chapter discusses preventive maintenance to keep the analyzer system operating at peak efficiency, how to check for plugging in the analyzer sample system, and how to replace internal parts. This chapter also discusses how to view alarm mes- sages to diagnose and troubleshoot problems with the analyzer.
  • Page 142 If a wrist strap is not available, you should at the very least touch the metal chassis to ground yourself before handling the boards. 5-2 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 143: Maintenance

    Preventive Maintenance To reduce the occurrence of problems with the analyzer, AMETEK recom- mends that you follow the “Analyzer Preventive Maintenance Schedule,” as outlined in the following pages. Since most analyzer problems originate within the sample handling system, the primary objective of the preven- tive maintenance schedule is proper care of the sample system.

  • Page 144: Analyzer Preventive Maintenance Schedule

    5 °C (typical; set point may vary) of their set points. Temperature deviations can be set to alarm. Record and compare the current temperatures to the actual settings. 5-4 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 145 Ensure these gaskets are intact. If the seals are damaged, cracked, or show signs of wear, replace them immediately. 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 be affected by alarms from the pressurization system.

  • Page 146: Expo Technologies Minipurge ® System With Etimer (Optional) Preventive Maintenance Schedule

    Expo MiniPurge Type X / ET Size 1 Manual (ML 422). ® See “Expo Technologies MiniPurge System With eTimer Spare ® Parts” in Chapter 6 for spare parts ordering information. 5-6 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 147: Locating A Plug In The Sample System

    Locating a Plug in the Sample System If analyzer problems occur, they are most likely related to improper sample system operation, such as plugs or leaks. Plugs in the sample sys- tem cause problems in analyzer response time, either to changing process conditions or to Zero fluid.

  • Page 148: Changing Out Replaceable Parts

    This section discusses the parts that should be changed out and/or cleaned, according to the “Analyzer Preventive Maintenance Schedule.” These descriptions focus on the AMETEK sample system. When replacing parts in the analyzer refer to Figure 5-1 for the location of the main assem- bly.

  • Page 149: Tools, Equipment, And Supplies Required For Maintenance

    Tools, Equipment, and Supplies Required for Maintenance While working on the Cell the following tools, equipment, and supplies are required (supplied by AMETEK only where indicated): • Measuring Cell spare parts. Refer to either the Measuring Cell Manual Supplement or the Custom Spare Parts List (if applicable), located in the “Supplemental Information”...
  • Page 150 Figure 5-1. Analyzer component layout details. Actual layout may vary. Refer to customer-specific Final “As-Built”  drawings shipped with the analyzer. NOTE 5-10 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 151: Measuring Cell Preventive Maintenance

    Measuring Cell Preventive Maintenance The o-rings in the Measuring Cell should be replaced every year to avoid a leak in the sample system. If the sample system operates above atmo- spheric pressure, sample fluid can leak from the Measuring Cell into the Oven/Sample System Enclosure.
  • Page 152 Wear insulated gloves and open the door to allow the Oven to cool down enough to ensure safe handling. The Oven enclosure and components within the Oven are hot; take precautions to avoid burning yourself. WARNING 5-12 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 153 Figure 5-2. Measuring Cell Assembly (40 cm Measuring Cell).  Figure 5-2 illustrates a 40 cm Measuring Cell. If your application uses a different Cell, refer to the “Supplemental Information” tab NOTE of this manual for a Measuring Cell Manual Supplement and for application-specific spare parts, either in the Measuring Cell Manual Supplement or in a Custom Spare Parts List.
  • Page 154 In the next steps use a soft, non-abrasive cloth to place the Cell parts NOTE c. If the Measuring Cell has an Optical Bench/Cell Insulator, remove the three screws that secure it to the Cell and remove the Insulator. 5-14 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 155 Use an o-ring removal tool to remove the outer o-ring from the Cell. Take care not to scratch or damage the o-ring groove. Carefully remove the Cell Window from the Cell by grasping it by its outer edge and lifting it out of the Cell. Avoid touching the win- dow surfaces.
  • Page 156 Reconnect all other sample system parts/tubing (use Teflon tape on fit- tings that originally were taped). Systems with a Cell RTD: Replace the RTD in its clamp and hand-tighten it. Do not overtighten. 5-16 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 157 10. GP Analyzers Only: Turn on the Instrument Air supply to the analyzer and open the Aspi- rator Air valve. 11. Take all necessary precautions to safely power up the analyzer and prepare it for operation: Before proceeding, test the area around the analyzer for flammable gases.
  • Page 158 Final “As-Built” drawings. The Flow Indicator (if used) should be in the centre of the meter for an optimal flow rate. The procedure is complete. 5-18 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 159: Replacing The Xenon (Uv) Flash Lamp Assembly

    Replacing the Xenon (UV) Flash Lamp Assembly The typical life expectancy of the Xenon Flash Lamp is 3–5 years of contin- uous operation. However, if the Xenon Flash Lamp begins to exhibit signs of degradation prior to the 3-year mark, replace the Xenon Flash Lamp Assembly (Figure 5-3.1).
  • Page 160 Turn off the Instrument Air supply to the analyzer and 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. 5-20 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 161 5. Disconnect the DC Power Cable connector (from the Lamp Housing) at J2 on the Xenon Lamp board located near the top of the Electronics Enclosure (see Figure 5-1 for location). 6. While holding the Lamp Assembly with one hand, loosen (by hand) the blue knurled nut that secures it to the Optical Bench Assembly and remove the Lamp Assembly.
  • Page 162 Final “As-Built” drawings. The Flow Indicator (if used) should be in the centre of the meter for an optimal flow rate. The procedure is complete. 5-22 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 163: Replacing The Infrared (Ir) Source Assembly

    Replacing the Infrared (IR) Source Assembly The typical life expectancy of the Infrared Source is 3–5 years of continu- ous operation. However, if the Infrared Source begins to exhibit signs of degradation prior to the 3-year mark, replace the Infrared Source Assem- bly (Figure 5-3.2).
  • Page 164 9. Replace the Optical Bench cover. Slide the Optical Bench back onto its mounting stud and tighten the locking clamp. 10. GP Analyzers Only: Turn on the Instrument Air supply to the analyzer and open the Aspi- rator Air valve. 5-24 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 165 11. Take all necessary precautions to safely power up the analyzer and prepare it for operation: Before proceeding, test the area around the analyzer for flammable gases. If an explosive gas atmosphere is present, do not apply power to WARNING the analyzer or any alternate power sources that supply power to the analyzer components.

  • Page 166: Troubleshooting And Diagnostics

    Enclosure. Typical diagnostic errors to watch for include pressure and temperature related alarms.  For more information about viewing diagnostics information from the User Interface Panel, refer to the descriptions in Chapter 4. NOTE 5-26 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 167: Alarm Conditions And Corrective Action

    Alarm Conditions and Corrective Action This section lists all of the IPS-4 Analyzer system alarm messages (Condi- tion/Alarm Name), describes what triggers the alarms, and provides action that is required to reset the alarms (Description and Suggested Corrective Action). The system alarm relay contact opens on alarm. A system alarm can ...
  • Page 168 User Interface Panel, check that the full-scale range is correct for the current sample. If Pressure Transducer alarms persist during normal operation, contact the factory. A range change and recalibration may be required. 5-28 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 169 Enclosure door – for proper connections and inspect it for damage (cuts, nicks, burn marks, etc.). For cable connection locations, refer to the Electronics Enclosure Wiring Diagram in the Appendix. One or both boards may need to be replaced. Contact AMETEK for • assistance.
  • Page 170 Perform a successful zero calibration: Contact AMETEK for assistance. • Span Cal Failure This warning is generated after a span calibration failure. Corrective Action: Perform a successful span calibration: Contact AMETEK for assistance. • 5-30 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 171: Analyzer Reset

    Analyzer Reset If a situation arises where the analyzer must be reset, take appropriate safety precautions power down the analyzer using the power-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 CAUTION been restored.
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  • Page 173: Chapter 6 Service And Parts

    SERVICE and PARTS The Service and Parts chapter discusses what to do if you need techni- cal support from AMETEK, or if you are returning parts for service. This chapter also lists the recommended spare parts to have on hand to en- sure all consumable and replaceable parts are replaced according to the “Analyzer Preventive Maintenance Schedule”...

  • Page 174: Returning Equipment

    Return Material Authorization (RMA) number. 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 following information available: •...

  • Page 175: Ametek Service And Aftermarket Sales Support

    ASAP plans may be written to provide • START UPS coverage for a single analyzer, or all of the AMETEK Your decision to buy an AMETEK analyzer is greatly process analyzers at your facility.

  • Page 176: Recommended Spare Parts

    Recommended Spare Parts This section lists the spare parts to have on-site for the IPS-4 Analyzer, some that are required as part of as analyzer preventive maintenance (see “Analyzer Preventive Maintenance Schedule” in Chapter 5).  Content is subject to change without notice.

  • Page 177: Spare Analyzer Fuses

    NOTE These main analyzer fuses do not need to be changed out at regular intervals, but AMETEK recommends these fuses are available in the event that a replacement fuse is required. Fuses, IPS-4 Analyzer – Recommended Parts to Have On-Site...
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  • Page 179: Chapter 7 User Web Interface

    USER WEB INTERFACE The User Web Interface chapter contains information about the following topics: • An introduction to the User Web Interface, and how to 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.

  • Page 180: Introduction To The Web Interface

    Introduction to the Web Interface Figure 7-1 illustrates the layout of the analyzer 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.

  • Page 181: Web Interface Components

    Web Interface Components The Web Interface is divided into six sections. Navigation buttons lo- cated on the left-hand side of the screen are used to view analyzer sta- tus, alarms, trends, and spectra; view and change analyzer settings; and transfer data. The information displayed on the right-hand side varies depending on the selected section.

  • Page 182: 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 Chapter 4. Figure 7-2. Home Screen. 7-4 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 183: Alarms Menu Screen

    ALARMS Menu Screen The ALARMS screen (Figure 7-3) displays any active analyzer alarm con- dition that has been set by the built-in diagnostics function and a history of alarms and warnings that have been reset (Figure 7-4). The alarms are read-only.

  • Page 184: Logged Alarms And Warnings

    Alarm and Warning Notification When an alarm or warning is set by the analyzer, the alarm is displayed in the banner across the top of the screen. Figure 7-4. Alarm Log Screen. 7-6 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 185: Trends Menu Screen

    TRENDS Menu Screen The TRENDS screen (Figure 7-5) displays the trends of selected param- 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.

  • Page 186: Parameters

    • 1 second interval will contain 60 minutes before overwriting • 15 second interval will contain 900 minutes or 15 hours before over- writing • 1 hour interval will contain 3,600 hours or 150 days before overwrit- ing. 7-8 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 187: Spectra Menu Screen

    SPECTRA Menu Screen The SPECTRA screen (Figure 7-6) allows the user to temporarily store spectra and compare it to future live spectra readings. Figure 7-6. Spectra Menu Screen. Viewing Spectral Data Live View Live Spectra by selecting the data source to display. •...

  • Page 188: Settings Menu Screen

    Chapter 4. The list of available sub-menu items includes: • Calibration Control • Actions • Current Outputs • Relays • Network and Modbus • System and Custom • Analytes • Limits • Diagnostics 7-10 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 189: Calibration Settings Screen

    Calibration 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 these parameters are described under “Calibration Settings Screens” in Chapter 4. Figure 7-7.

  • Page 190: Actions Screen

    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, Actions Screen. 7-12 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 191: Current Output Screen

    Current Output Screen The CURRENT OUTPUT screen (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 Screens” in Chapter 4. Figure 7-9.

  • Page 192: Relay Setup Screens

    For example, Concentration Alarms can be set up from this screen (Relay Function option). Descriptions of these parameters are described under “Relay Setup Screens” in Chapter 4. Figure 7-10. Settings Menu, Relay Setup Screen. 7-14 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 193: Network And Modbus Screen

    Network and Modbus Screen The NETWORK and MODBUS screen (Figure 7-11) allows the user to enter Ethernet settings and set up modbus parameters. Figure 7-11. Settings Menu, Network and Modbus Screen. Ethernet settings Enable the analyzer system to communicate over an Ethernet network for viewing analyzer and stream composition data, viewing analyzer diagnostics, or backing up/restoring analyzer configuration settings.

  • Page 194: System And Customization Screen

    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 Customization Screen. 7-16 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 195: Analytes Screen

    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. User Web Interface 7-17...

  • Page 196: 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 7-14. Settings Menu, Limits Screen. 7-18 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 197: Diagnostics Screen

    Diagnostics Screen The DIAGNOSTICS screen (Figure 7-15) allows the user to disable normal operations while troubleshooting 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 flash in diagnostics mode.

  • Page 198: Save/Restore Files Screen

    Save/Restore Files Screen The SAVE/RESTORE FILES screen (Figure 7-16) allows you to: • Save IPS-4 software, user configuration settings, and individual files (matrix.xml for example) to your PC. • Restore analyzer configuration parameters to their original factory- shipped settings and upgrade software.

  • Page 199: Chapter 8 Modbus Communication Interface

    Remote Terminal Unit (RTU) with the analyzer operating 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-purpose computer is RS-485. The analyzer RS-485 connection supports 2-wire multi-drop systems.

  • Page 200: Configuration

    PORT parameter value to 1. NOTE When designing a Modbus RS-485 multi-drop communication system with the 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.

  • Page 201: Analyzer Modbus Interface Parameters

    Modbus Functions As 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 following relevant function codes are implemented: Code...

  • Page 202: Holding Registers

    DATAVALID uint16 uint16 AUTOCAL int16 int16 CALMODE int16 int16 DMODE int16 int16 MANCMD int16 int16 COMPPT uint uint SYSALARM1 uint uint SYSALARM2 uint uint SYSALARM3 uint uint CONCALARM 8-4 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 203 Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size int16 int16 SYSSTATUS int16 int16 SYSSTATE uint uint TOTUPTIME uint uint UPTIME TIMER1 TIMER2 TIMER3 uint uint MFTIME uint uint CALTIME uint uint ZFTIME uint uint SFTIME int16 int16 ANAHOLD...
  • Page 204 RELAY8F char[20] char[20] RELAY8NM Relay 8 uint16 uint16 RELAY8S float float RELAY8V boolean boolean RELAYENA uint16 uint16 VALVE1 char[20] char[20] VALVE1NM Valve 1 uint16 uint16 VALVE2 char[20] char[20] VALVE2NM Valve 2 8-6 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 205 Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size uint16 uint16 VALVE3 char[20] char[20] VALVE3NM Valve 3 uint16 uint16 VALVE4 char[20] char[20] VALVE4NM Valve 4 uint16 uint16 VALVE5 char[20] char[20] VALVE5NM Valve 5 float float ACONC1H float float ACONC1L...
  • Page 206 VENLPB float float VENLRTD float float VENLSP float float VENLST int16 int16 REMIN1 int16 int16 REMIN2 int16 int16 LAMPM int16 int16 LAMPF int16 int16 FREQ 2000 int16 int16 LAMDF 8-8 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 207 Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size float float PRESX1 float float PRESXS1 30.00 float float PRESXOS1 0.03 float float PRESX2 float float PRESXS2 float float PRESXOS2 float float MPRES float float APRES int16 int16 VALFAULT int16...
  • Page 208 Span 4 char[20] char[20] SPANNM5 Span 5 char[20] char[20] SPANNM6 Span 6 char[20] char[20] SPANNM7 Span 7 char[20] char[20] SPANNM8 Span 8 uint uint SPANMAP1 uint uint SPANMAP2 uint uint SPANMAP3 8-10 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 209 Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size uint uint SPANMAP4 uint uint SPANMAP5 uint uint SPANMAP6 uint uint SPANMAP7 uint uint SPANMAP8 char[10] char[10] CONCUNIT2 char[10] char[10] CONCUNIT3 char[10] char[10] CONCUNIT4 char[10] char[10] CONCUNIT5 char[10] char[10] CONCUNIT6...
  • Page 210 MINDARK 10000 1062 uint uint MAXDARK 20000 1064 uint uint ZEROMININT 2000 1066 float float ZERODRIFTMULT 1068 float float ALYTE1SPLO 1070 float float ALYTE1SPHI 1072 float float ALYTE2SPLO 1074 8-12 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 211 Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size float float ALYTE2SPHI 1076 float float ALYTE3SPLO 1078 float float ALYTE3SPHI 1080 float float ALYTE4SPLO 1082 float float ALYTE4SPHI 1084 float float ALYTE5SPLO 1086 float float ALYTE5SPHI 1088 float float...
  • Page 212 LINEARIZE 1258 float float LINLEVEL0 1259 float float LINLEVEL1 1261 float float LINLEVEL2 1263 float float LINLEVEL3 1265 float float LINLEVEL4 1267 float float LINLEVEL5 1269 float float LINBREAK0 1271 8-14 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 213 Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size float float LINBREAK1 1273 float float LINBREAK2 1275 float float LINBREAK3 1277 float float LINBREAK4 1279 float float LINBREAK5 1281 float float ANAOUT5 1283 float float ANAOUT5O 1285 uint16 uint16...
  • Page 214 LINBREAK4P2 1430 float float LINBREAK5P2 1432 float float LINBREAK6P2 1434 float float LINBREAK7P2 1436 float float LINLEVEL0P3 1438 float float LINLEVEL1P3 1440 float float LINLEVEL2P3 1442 float float LINLEVEL3P3 1444 8-16 | IPS-4 Dual Bench (UV / IR) Analyzer...
  • Page 215 Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size float float LINLEVEL4P3 1446 float float LINLEVEL5P3 1448 float float LINLEVEL6P3 1450 float float LINLEVEL7P3 1452 float float LINBREAK0P3 1454 float float LINBREAK1P3 1456 float float LINBREAK2P3 1458 float float...
  • Page 216 ANAOUT7H 1596 uint16 uint16 ANAOUT8H 1597 uint uint ZEROMAXINT 70000 1598 float float IRDIAGWAVEL 1000 1600 IRDIAGPIXEL 1602 float float IRDIAGMEAS 1604 float float IRDIAGDARK 1606 float float IRDIAGABS 1608 8-18 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 217: Appendix A - Drawings

    APPENDIX A – DRAWINGS This Appendix includes many of the drawings that are included in the 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”...

  • Page 218: Analyzer Light Path, Uv Optical Bench Schematic

    Analyzer Light Path, UV Optical Bench Schematic A-2 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 219: Analyzer Light Path, Ndir Optical Bench Schematic

    Analyzer Light Path, NDIR Optical Bench Schematic Appendix A – Drawings...

  • Page 220: Analyzer Overall Component Layout, Zone 1, Example

    Analyzer Overall Component Layout, Zone 1, Example  Actual layout may vary. Refer to customer-specific Final “As-Built” drawings shipped with the analyzer. NOTE A-4 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 221: Analyzer Overall Component Layout, Division 2, Example

    Analyzer Overall Component Layout, Division 2, Example  Actual layout may vary. Refer to customer-specific Final “As-Built” drawings shipped with the analyzer. NOTE Appendix A – Drawings...

  • Page 222: Detector Board (100-2046

    Detector Board (100-2046) A-6 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 223: Display Interface Board (100-2049

    Display Interface Board (100-2049) Appendix A – Drawings...

  • Page 224: Customer Connection Board (100-1971

    AUX. POWER RELAY CONTACTS CONTACT INPUT ETHERNET CURRENT OUT 1-2 PRET CURRENT OUT 3-4 RS-232 PRET IN1+ IN1- ANALOG IN 1 ANALOG IN 2 RTD1 RTD2 RS-485 IN2+ IN2- GNDEXC V+ VR A-8 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 225: Ac Disconnection Board (100-2077

    AC Disconnection Board (100-2077) Appendix A – Drawings...

  • Page 226: Signal Disconnection Board (100-2076

    Signal Disconnection Board (100-2076) RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8 RLY9 RLY10 RLY11 RLY12 RLY13 RLY14 RLY15 RLY16 RLY17 RLY18 RLY19 RLY20 RLY21 RLY22 RLY23 RLY24 A-10 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 227: Relay Board (100-2050

    Relay Board (100-2050) Appendix A – Drawings A-11...

  • Page 228: Analog Board (100-2047

    Analog Board (100-2047) A-12 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 229: Mcu Board (100-2045

    MCU Board (100-2045) Appendix A – Drawings A-13...

  • Page 230: Xenon Lamp Power Supply Board (100-2061), Uv Optical Bench

    Xenon Lamp Power Supply Board (100-2061), UV Optical Bench A-14 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 231: Infrared Source Assembly Interface Board (100-2838), Ir Optical Bench

    Infrared Source Assembly Interface Board (100-2838), IR Optical Bench Appendix A – Drawings A-15...

  • Page 232: Electronics Enclosure Wiring Diagram, Sheet 1

    Electronics Enclosure Wiring Diagram, Sheet 1 of 5 A-16 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 233: Electronics Enclosure Wiring Diagram, Sheet 2

    Electronics Enclosure Wiring Diagram, Sheet 2 of 5 Appendix A – Drawings A-17...

  • Page 234: Electronics Enclosure Wiring Diagram, Sheet 3

    Electronics Enclosure Wiring Diagram, Sheet 3 of 5 A-18 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 235: Disconnect Enclosure Wiring Diagram, Sheet 4

    Disconnect Enclosure Wiring Diagram, Sheet 4 of 5 Appendix A – Drawings A-19...

  • Page 236: Disconnect Enclosure Wiring Diagram, Sheet 5

    Disconnect Enclosure Wiring Diagram, Sheet 5 of 5 A-20 | IPS-4 Dual Bench (UV / IR) Analyzer...

  • Page 237: Supplemental Information

    SUPPLEMENTAL INFORMATION This section consists of information and documents that are not part of the main manual, but which describe and illustrate installation, operation, layout, and maintenance procedures for non-standard or optional equipment – and derivative analyzer models – that make up your analyzer and its sample system.
  • Page 238 This page intentionally left blank. S-2 | IPS-4 Dual Bench (UV / IR) Analyzer...

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