AMETEK Western Research IPS-4 UV Analyzer Zone 1/Division 1 · This manual is a guide for the use...

AMETEK Western ResearchIPS-4 UV Analyzer

Zone 1/Division 1

User Manual

PN 403235901, Rev G

Process Instruments 455 Corporate Blvd.Newark, DE 19702

© 2008 AMETEK Process & Analytical Instruments Division

This manual is a guide for the use of the IPS-4 (Integrated Process Spectrophometer) 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; 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.

OfficesSALES AND MANUFACTURING:

USA - Delaware

455 Corporate Blvd., Newark DE 19702 • Tel: 302-456-4400, Fax: 302-456-4444

USA - Oklahoma

2001 N. Indianwood Ave., Broken Arrow OK 74012 • Tel: 918-250-7200, Fax: 918-459-0165

USA - Pennsylvania

150 Freeport Road, Pittsburgh PA 15238 • Tel: 412-828-9040, Fax: 412-826-0399

CANADA - Alberta

2876 Sunridge Way N.E., Calgary, AB T1Y 7H9 • Tel: +1-403-235-8400, Fax: +1-403-248-3550

WORLDWIDE SALES AND SERVICE LOCATIONS:

USA - TexasTel: 713-466-4900, Fax: 713-849-1924

CHINA

Beijing / Tel: 86 10 8526 2111, Fax: 86 10 8526 2141

Chengdu / Tel: 86 28 8675 8111, Fax: 86 28 8675 8141

Shanghai / Tel: 86 21 6426 8111, Fax: 86 21 6426 7818

FRANCE

Tel: 33 1 30 68 89 20, Fax: 33 1 30 68 89 29

GERMANY

Tel: 49 21 59 91 36 0, Fax: 49 21 59 91 3639

MIDDLE EAST - Dubai

Tel: 971 4 881 2052, Fax: 971 4 881 2053

SINGAPORE

Tel: 65 6484 2388, Fax: 65 6481 6588

www.ametekpi.com

ii | IPS-4 Z1/Div1 Analyzer

Table of ContentsOfficesSALES AND MANUFACTURING: .........................................................iiSafety Notes ........................................................................................................viiiElectrical Safety ...................................................................................................viiiGrounding ...........................................................................................................viiiPersonnel and Equipment Safety Information ................................................ ix

Warnings ...................................................................................................ixCautions .....................................................................................................x

Electromagnetic Compatibility (EMC) .............................................................xiiSpecial Warnings and Information ..................................................................xiii

Equipment Used in Class I, Division 1 and Zone 1 Hazardous Loca-tions................................................................................................................xiii

Warranty and Claims .........................................................................................xiv

OVERVIEW 1Principles of Operation ........................................................................................ 1

Basic Analytical Theory ................................................................................. 1The Implementation ...................................................................................... 2

Optical System and Measurement .............................................................2Sample System............................................................................................3Electronics ..................................................................................................4

Classified, Hazardous Area Protection Components and Functions ........... 5Flanged Flameproof Enclosure: ..................................................................6

Analyzer Electronics and Sample System Features ......................................... 7

SPECIFICATIONS 2Methodology .......................................................................................................... 1

Wavelength Ranges ........................................................................................ 1Analyzer Range ............................................................................................... 1Photometric Range ......................................................................................... 1

Analyzer Specifications ........................................................................................ 2Analytes ............................................................................................................ 2Response Time ................................................................................................ 2Measurement Accuracy ................................................................................. 2Repeatability .................................................................................................... 2Linearity ........................................................................................................... 2Stability ............................................................................................................. 2Temperature Drift ........................................................................................... 224-Hour Zero Drift ......................................................................................... 2Inputs ................................................................................................................ 3Outputs ............................................................................................................ 3Sample System Limits .................................................................................... 3

Sample Pressure .........................................................................................3

Contents | iii

Oven/Sample System Enclosure Temperature ............................................4Sample Transport ............................................................................................ 4Instrument Air Requirements ....................................................................... 4Zero Fluid ........................................................................................................ 4Sample Fluid Flow Rate ................................................................................. 4Electrical Requirements ................................................................................. 5

Power Consumption ...................................................................................5Supply Voltage ............................................................................................5

Measuring Cell Construction ....................................................................... 5Pressure Input Signals ................................................................................... 5Xenon Flash Lamp .......................................................................................... 5Environmental ................................................................................................ 6

Ambient Temperature .................................................................................6Humidity ....................................................................................................6Pollution Degree .........................................................................................6Maximum Altitude.....................................................................................6Installation Category ..................................................................................6Enclosure Material .....................................................................................6Ingress Protection .......................................................................................6

On-Board Temperature Sensor ..................................................................... 6Physical Dimensions ...................................................................................... 7Approvals and Certifications ........................................................................ 7

INSTALLATION & START-UP 3Safety Considerations ........................................................................................... 2Pre-Installation Requirements............................................................................. 3

Storage Prior to Installation .......................................................................... 3Uncrating and Inspecting the Analyzer ...................................................... 3General Installation Information ................................................................. 4Tools, Equipment, and Supplies Required for Installation ...................... 4

Installing the Mechanical Components ............................................................. 7Mounting the Analyzer ................................................................................. 7

Location and Environment .........................................................................7Installing the Optical Bench Assembly ..................................................... 11Installing the Sample System...................................................................... 13

Installing the Sample Probe/Sample Tap ..................................................13Installing and Connecting the Sample and Vent Lines ............................14Installing and Connecting the Instrument Air/Zero Fluid Line ..............15Installing and Connecting the Purge Fluid Line ....................................17Installing the Calibration (Span) Fluid Line (Optional) ..........................18

Connecting I/O Signals, Alarm Relay Contacts, and AC Power .................. 20Electrical Connections .................................................................................. 20Permanent Ethernet Cable Connections (Optional) ............................... 21

Start-Up and Verification ................................................................................... 23Powering Up the Analyzer .......................................................................... 23

iv | IPS-4 Z1/Div1 Analyzer

Start-Up Diagnostic Checklist .................................................................... 30Sample System Leak Check ........................................................................ 32Manually Zeroing the Analyzer Sample System ..................................... 33Adjusting the Zero/Span Fluid Flow Rate ................................................ 34Adjusting the Sample Flow Rate ................................................................ 34

Setting Sample Response Time .................................................................35Normal Operation ............................................................................................... 36

Recording Initial Readings .......................................................................... 36Recording Initial Sample Response Time .................................................36

Analyzer Configuration ..................................................................................... 37

CONTROLLER / USER INTERFACE 4Introduction to the User Interface Panel ........................................................... 2

User Interface Panel Components ............................................................... 2Special Software Characters .......................................................................... 4Working From the User Interface Panel – Conditions and Messages .... 5Summary of Analyzer Operation ................................................................ 6

Working in the Main Menus ............................................................................... 7HOME Menu Screen ...................................................................................... 7

System Status Messages (HOME Screen) .................................................9Alarm and Warning Notification (HOME Screen) .................................10

ALARMS and WARNINGS Menu Screen ................................................. 11Viewing Current Alarms and Warnings ..................................................11Viewing Logged Alarms and Warnings ...................................................12

STATUS Menu Screen .................................................................................. 13SETUP Menu Screen .................................................................................... 15

Calibration Control Screen .......................................................................16Calibration Valves .....................................................................................19Calibration Actions Screen .......................................................................20Relay Function option. ............................................................................ 22Current Output Setup Screens ................................................................25Setpoints ...................................................................................................27Diagnostics Screen ...................................................................................28System Settings Screen ...........................................................................30Login/Set Passwords Screen .....................................................................30Backup/Restore Settings Screen ...............................................................32Ethernet Network Screen .........................................................................35System Screen ...........................................................................................37Customization Screen ...............................................................................38Modbus Screen .........................................................................................39

MAINTENANCE & TROUBLESHOOTING 5Safety Considerations ........................................................................................... 1Maintenance ........................................................................................................... 2

Preventive Maintenance ................................................................................ 2

Contents | v

Analyzer Preventive Maintenance Schedule ..............................................3Before Performing Maintenance .................................................................. 5

Locating a Plug in the Sample System .......................................................6Detecting a Plug in the Sample System .....................................................6Preventing a Plug in the Sample System (Gas Applications) ....................7

Changing Out Replaceable Parts ................................................................. 8Tools, Equipment, and Supplies Required for Maintenance ......................9Measuring Cell Preventive Maintenance .................................................11Xenon Flash Lamp Assembly Replacement ..............................................18

Troubleshooting and Diagnostics ..................................................................... 24Alarm Notification – Viewing Alarms on the User Interface Panel ...... 24

Viewing Current Alarm Messages ...........................................................24Viewing Historical Alarm Messages ........................................................25

Alarm Conditions and Corrective Action ................................................. 26Analyzer Reset .............................................................................................. 30

SERVICE & PARTS 6Technical Support .................................................................................................. 1Returning Equipment ........................................................................................... 2AMETEK Service & Aftermarket Sales Support ............................................... 3Recommended Spare Parts .................................................................................. 4

Measuring Cell Assembly Spare Parts ......................................................... 4Optical Bench Assembly Spare Parts ........................................................... 4Spare Analyzer Fuses ..................................................................................... 5Spare Battery, MCU Board ........................................................................... 5

CONTROLLER / USER WEB INTERFACE 7Introduction to the Web Interface ...................................................................... 2

Web Interface Components .......................................................................... 3Working From the Web Interface – Conditions and Messages ............... 3HOME Menu Screen ...................................................................................... 4ALARMS Menu Screen .................................................................................. 5

Current Alarms and Warnings ..................................................................5Logged Alarms and Warnings ...................................................................6Alarm and Warning Notification ...............................................................6

TRENDS Menu Screen .................................................................................. 7Parameters ..................................................................................................8Intervals......................................................................................................8

SPECTRA Menu Screen ................................................................................. 9Viewing Spectra Data ................................................................................9

SETTINGS Menu Screen ............................................................................. 10Calibration Settings Screen ......................................................................11Actions Screen ..........................................................................................12Current Output Screen ............................................................................13Relay Setup Screens .................................................................................14Network & Modbus Screen ......................................................................15

vi | IPS-4 Z1/Div1 Analyzer

System & Customition Screen ................................................................16Analytes Screen .......................................................................................17Limits Screen ...........................................................................................18Diagnostics Screen ...................................................................................19Save/Restore Files Screen .........................................................................20

MODBUS COMMUNICATION INTERFACE 8Hardware: ........................................................................................................ 1Configuration: ................................................................................................. 2

Analyzer Modbus Interface Parameters ............................................................ 3Modbus Address ............................................................................................. 3Modbus Functions .......................................................................................... 3

Holding Registers .................................................................................................. 4

APPENDIX – DRAWINGS AAnalyzer Light Path Schematic ........................................................................... 2Analyzer Mounting Details ................................................................................. 3Analyzer Overall Component Layout ............................................................... 4Detector Interface Board (100-1937) ................................................................... 5Detector Board (100-1955) .................................................................................... 6Display Interface Board (100-1978) ..................................................................... 7Customer Connection Board (100-1971) ............................................................ 8Signal Disconnection Board (100-2076) ............................................................. 9Relay Board (100-1942) ....................................................................................... 11Analog Board (100-1922) .................................................................................... 12MCU Board (100-1914) ....................................................................................... 13Xenon Lamp Board (100-2061) .......................................................................... 14Electronics Enclosure Wiring Diagram, Sheet 1 of 4 (WX-102878) .............. 15Electronics Enclosure Wiring Diagram, Sheet 2 of 4 (WX-102878) .............. 16Electronics Enclosure Wiring Diagram, Sheet 3 of 4 (WX-102878) .............. 17Disconnect Enclosure Wiring Diagram, Sheet 4 of 4 (WX-102878) ............. 18

SUPPLEMENTAL INFORMATION S

Contents | vii

Safety Notes

WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as fol-lows:

An operating procedure which, if not strictly observed, may result in personal injury or envi-ronmental contamination.

An operating procedure which, if not strictly observed, may result in damage to the equip-ment.

Important information that should not be overlooked.

Electrical Safety

High voltages are present in the analyzer housings. Always shut down power source(s) before perform-ing maintenance or troubleshooting. Only a qualifi ed electrician should make electrical connections and ground checks.

Any use of the equipment in a manner not specifi ed by the manufacturer may impair the safety protection originally provided by the equipment.

Grounding

Instrument grounding is mandatory. Performance specifi cations and safety protection are void if instru-ment is operated from an improperly grounded power source.

Verify ground continuity of all equipment before applying power.

!CAU-

NOTE

!CAUTION

!WARNING

viii | IPS-4 Z1/Div1 Analyzer

!WARNING

Personnel and Equipment Safety Information

This section describes important safety information to avoid personal injury and damage to the equipment while installing, operating, maintaining, or servicing the equipment. All safety regulations, standards, and procedures at the analyzer location must be followed.

All personnel involved with the installation, start-up, operation, maintenance, service, or troubleshooting of the IPS-4 Analyzer must review and follow these Warnings and Cautions.

Warnings

Review and follow these Warnings to avoid personal injury or environmental contamination.

Always disconnect main AC power and/or external power sources to the analyzer before opening any doors on the analyzer to check or perform maintenance on any components within the enclosures.

If it is necessary to open the analyzer doors while the circuits are live, fi rst monitor the area for fl ammable gases and proceed only when the area is safe.

All electrical connections, adjustments, or servicing of the analyzer should be performed only by properly trained and qualifi ed personnel.

All electrical connections, materials, and methods (plus all safety policies and procedures) must be made in compliance with local wiring regulations and electrical code for the hazard-ous area, and be approved by the Owner Company.

Follow appropriate regulatory and/or company procedures to lock out the analyzer while working on the analyzer electronics.

Before working on the analyzer, test the area for fl ammable gases. If a fl ammable gas atmo-sphere is present, do not open any doors without fi rst disconnecting power and/or alternate power sources to the analyzer.

The glass Xenon Flash Lamp is under high internal pressure which could result in fl ying glass fragments if ruptured. Handle the tube with care to avoid dropping it, subjecting it to impacts, applying excessive force to it, or scratching it.

While handling a fl ash lamp, always wear protective devices (face mask, clothing) to prevent possible injury, especially to hand and face areas.

Before working on the sample system, confi rm that the system has been purged with Zero fl uid and is isolated (blocked in) from the process.

!WARNING

!WARNING

!WARNING

!WARNING

!WARNING

Contents | ix

Because ultraviolet radiation can harm your eyes, never look directly into the operating lamp. If the Xenon Flash Lamp must be viewed while energized, wear safety glasses that block ultraviolet radiation.

If the Oven/Sample System Enclosure is heated, the components within it will be hot; take precautions to avoid burning yourself.

Cautions

Review and follow these Cautions to avoid damaging the equipment.

The electronic circuit boards and other static-sensitive components should be stored and transported in static-shielding carriers or packages.

For electrical-shock protection, the analyzer must be operated from a grounded power source that has a securely connected protective-ground contact.

If it becomes necessary to handle any of the electronic circuit boards, do not subject the boards to static discharge. The ideal solution is a static-safe work area. Since such areas typi-cally are not available at analyzer installation sites, the use of a wrist strap connected directly to a ground is recommended. If a wrist strap is not available, you should at the very least touch the metal chassis (to ground yourself) before handling or touching the boards.

When handling the Xenon Flash Lamp, it is very important not to touch the lamp windows because residual oils from the fi ngers will absorb ultraviolet light. The window is the fl at sur-face at the end of the narrow glass tube. The lamp assembly is fragile and should be handled with care.

!WARNING

!WARNING

!CAUTION

!CAUTION

!CAUTION

!CAUTION

x | IPS-4 Z1/Div1 Analyzer

PROTECTIVE CONDUCTOR TERMINAL(BORNIER DE L’ECRAN DE PROTECTION)Schutzerde

CAUTION - Risk of electric shock(ATTENTION-RISQUE DE DÉCHARGE ÉLECTRIQUE)Achtung - Hochspannung Lebensgefahr

CAUTION - Refer to accompanying documents(ATTENTION-SE RÉFERER AUX DOCUMENTS JOINTS)Achtung (Beachten Sie beiliegende Dokumente)

CAUTION - Hot Surface(ATTENTION-SURFACE CHAUDE)Achtung - Heiße Oberfläche

Warning LabelsThese symbols may appear on the instrument in order to alert you of existing conditions.

Environmental Information (WEEE)This AMETEK product contains materials that can be reclaimed and recycled. In some cases the product may contain materials known to be hazardous to the environment or human health. In order to prevent the release of harmful substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reaches its “end of life.”

Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a municipal waste system (residential trash). The Wheelie Bin marking on this product is a reminder to dispose of the product properly after it has completed its useful life and been removed from service. Metals, plastics and other components are recyclable and you can do your part by one of the following these steps:

• When the equipment is ready to be disposed of, take it to your local or regional waste collection administration for recycling.

• In some cases, your “end-of-life” product may be traded in for credit towards the purchase of new AMETEK 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 of-fi ce listed in the front of the instruction manual.

Contents | xi

Electromagnetic Compatibility (EMC)

Read and follow the recommendations in this section to avoid performance variations or dam-age to the internal circuits of this equipment when installed in harsh electrical environments.

The various confi gurations of the IPS-4 Analyzer should not produce, or fall victim to, electromagnetic disturbances as specifi ed 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. Below are examples of the techniques and wiring practices to be followed.

In meeting the EMC requirements, the various analyzer confi gurations described in this manual rely heavily on the use of metallic shielded cables used to connect to the customer’s equipment and power. Foil and braid shielded I/O and DC power cables are recommended for use in otherwise unprotected situ-ations. In addition, hard conduit, fl exible conduit, and armor around non-shielded wiring also provides excellent control of radio frequency disturbances. However, use of these shielding techniques is effective only when the shielding element is connected to the equipment chassis/earth ground at both ends of the cable run. This may cause ground loop problems in some cases. These should be treated on a case-by-case basis. Disconnecting one shield ground may not provide suffi cient protection depending on the electronic environment. Connecting one shield ground via a 0.1 microfarad ceramic capacitor is a technique allow-ing high frequency shield bonding while avoiding the AC-ground metal connection. In the case of shield-ed cables the drain wire or braid connection must be kept short. A minimal connection distance between the shield’s end and the nearest grounded chassis point, ground bar or terminal is highly recommended. An even greater degree of shield performance can be achieved by using metallic glands for shielded cable entry into metal enclosures. Expose enough of the braid/foil/drain where it passes through the gland so that the shield materials can be wrapped backwards onto the cable jacket and captured inside the gland, and tightened up against the metal interior.

Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. However, if this becomes a necessity, adhere to proper techniques and wiring practices. Install an appropriate transient voltage suppression device (low voltage MOV, “Transzorb,” or R/C) as close as possible to the inductive device to reduce the generation of transients. Do not run this type of signal wiring along with other I/O or DC in the same shielded cable. Inductive load wiring must be separated from other circuits in conduit by using an additional cable shield on the offending cable.

In general, for optimum protection against high frequency transients and other disturbances, do not allow installation of this Analyzer where its unshielded I/O and DC circuits are physically mixed with AC mains or any other circuit that could induce transients into the Analyzer or the overall system. Examples of elec-trical events and devices known for the generation of harmful electromagnetic disturbances include mo-tors, capacitor bank switching, storm related transients, RF welding equipment, static, and walkie-talkies.

!CAUTION

xii | IPS-4 Z1/Div1 Analyzer

SPECIAL WARNINGS AND INFORMATION

Equipment Used in Class I, Division 1 and Zone 1 Hazardous Locations

Refer to Chapter 2 – Specifi cations for details about the suitability of this equipment in hazardous areas.

Explosion Hazard – Substitution of Components May Impair Suitability for hazardous loca-tions.

Risque d’explosion – La substitution de composants peut rendre ce materiel inacceptable pour les emplacements est designé 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 déconnecter l’équipement, coupez le courant où vous assurez que l’emplacement est designé non dangereux.

For installations using North American wiring practice, all input and output wiring must be in accordance with Class I, Division 1 and Zone 1 wiring methods (NEC Sec 501.10(a) and 505.15(b) or (CEC-18 106 or IEC 60079-14) and in accordance with the authority having jurisdiction.

!WARNING

!

!WARNING

!Avertisse-

ment

Avertissement

Contents | xiii

WARRANTY AND CLAIMSWe warrant that any equipment of our own manufacture or manufactured for us pursuant to our specifi cations which shall not be, at the time of shipment thereof by or for us, free from defects in material or workmanship under normal use and service will be repaired or replaced (at our option) by us free of charge, provided that written notice of such defect is received by us within twelve (12) months from date of shipment of portable analyzers or within eighteen (18) months from date of shipment or twelve (12) months from date of installation of permanent equipment, whichever period is shorter. All equipment requiring repair or replacement under the warranty shall be returned to us at our factory, or at such other location as we may designate, transportation prepaid. Such returned equipment shall be examined by us and if it is found to be defective as a result of defective materials or workmanship, it shall be repaired or replaced as aforesaid. Our obligation does not include the cost of furnishing any labor in connection with the installation of such repaired or replaced equipment or parts thereof, nor does it include the responsibility or cost of transportation. In addition, instead of repairing or replacing the equipment returned to us as aforesaid, we may, at our option, take back the defective equipment, and refund in full settlement the purchase price thereof paid by Buyer.

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 classifi cation prior to order acknowledgment. The photometric light sources are warranted for ninety (90) days from date of shipment. Resale items warranty is limited to the transferable portion of the original equipment manufacturer’s warranty to AMETEK. If you are returning equipment from outside the North America, a statement should appear on the documentation accompanying the equipment being returned declaring that the goods being returned for repair are North American goods, the name of the fi rm 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 leaving our control or which has been replaced by anyone except us, or which has been subject to misuse, neglect, abuse or im-proper use. Misuse or abuse of the equipment, or any part thereof, shall be construed to include, but shall not be limited to, damage by negligence, accident, fi re or force of the elements. Improper use or misapplications shall be construed to include improper or inadequate protection against shock, vibration, high or low temperature, overpressure, excess voltage and the like, or operating the equipment with or in a corrosive, explosive or combustible medium, unless the equipment is specifi cally designed for such service, or exposure to any other service or environment of greater severity than that for which the equipment was designed.

The warranty does not apply to used or secondhand equipment nor extend to anyone other than the original purchaser from us. Should the Buyer’s technical staff require the on-site assistance of AMETEK’s agents or employees for service calls covered by this warranty clause, the Buyer shall pay travel time plus actual travel and living expenses.

THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION AND WARRANTIES OF FITNESS OR OF MERCHANT-ABILITY OTHER THAN AS EXPRESSLY SET FORTH HEREIN, AND OF ALL OTHER OBLIGATIONS OR LI-ABILITIES ON OUR PART. IN NO EVENT SHALL WE BE LIABLE UNDER THIS WARRANTY OR ANY OTHER PROVISION OF THIS AGREEMENT FOR ANY ANTICIPATED OR LOST PROFITS, INCIDENTAL DAMAGES, CONSEQUENTIAL DAMAGES, TIME CHANGES OR ANY OTHER LOSSES INCURRED BY THE ORIGINAL PURCHASER OR ANY THIRD PARTY IN CONNECTION WITH THE PURCHASE, INSTALLATION, REPAIR OR OPERATION OF EQUIPMENT, OR ANY PART THEREOF COVERED BY THIS WARRANTY OR OTHERWISE. WE MAKE NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN-TIES OF FITNESS OR OF MERCHANTABILITY, AS TO ANY OTHER MANUFACTURER’S EQUIPMENT, WHETHER SOLD SEPARATELY OR IN CONJUNCTION WITH EQUIPMENT OF OUR MANUFACTURE. WE DO NOT AUTHORIZE ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH EQUIPMENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY.

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xvi | IPS-4 Z1/Div1 Analyzer

Overview | 1-1

OVERVIEW

Th is chapter discusses the features of the IPS-4 Analyzer and a summary of how the entire system operates. Th is chapter also provides an overview of the AM-ETEK electronics and sample system, and the various sub-systems that make up the entire analyzer system.

Principles of Operation

Basic Analytical Theory

Th e analyzer measures, over one or more bands of wavelength, the absorbances of ultraviolet radiation (light) by a gas or liquid sample. Th e concentrations of the components absorbing the light (absorbers) are then determined from relation-ships developed through application of the ideal gas law and the laws of Bouguer, Beer, and Lambert.

Th us, the absorbance, A, due to a single absorber is,

where l is the path length of the light in the fl uid sample, [x] is the concentra-tion (mole percent) of absorber x, k is the molar absorptivity of absorber x at the measuring wavelength, T and P are the temperature and pressure of the fl uid sample, respectively, and R is the universal fl uid constant.

If more than one component is present, the total absorbance at a given wavelength is the sum of the absorbances of the individual components. In this case, absor-bance measurements at additional wavelengths are required to develop a system of linear equations. If the number of measured wavelengths is equal to or greater than the number of components being measured, absorbances of each component may be determined using standard methods of linear algebra.

In practice, several wavelengths are used to calculate concentration [x]. Methods are implemented to correct for non-linearity.

1-2 | IPS-4 Z1/Div1 Analyzer

The Implementation

Th e analyzer is comprised of a Xenon Flash Lamp light source, a lens and aper-ture, a Measuring Cell, a diff raction grating, front surfaced focusing mirror, and a detector array, as indicated in Figure 1-1.

Th e Measuring Cell is contained within the Oven/Sample System Enclosure, which can also contain optional sample system components such as a heater, an aspirator, a Span fl uid inlet, fi lter (liquid trap), and fl ow indicator (or meter). An optional pressure transducer can be used to monitor the pressure at the outlet of the Measuring Cell.

Optical System and Measurement

Th e Xenon Flash Lamp emits light through ultraviolet, visible, and near infrared wavelengths. Th e lamp fl ashes at frequencies of 50 fl ashes per second, adjusted to optimize the light intensity. Th e number of fl ashes per measurement is factory-set, typically between 10 and 40.

Th e light passes through a lens and aperture to provide a collimated (not diverg-ing nor converging) beam. Th e collimated beam enters a Measuring Cell through which the fl uid of interest is passed. Th e beam is refl ected off mirrors at the end of the Measuring Cell, and returns through the Cell to a polychromator. Alternate Measuring Cells allow the light to pass either once or multiple times through the sample before exiting to the polychromator.

Th e polychromator consists of a diff raction grating to disperse the light over a range of wavelengths, and a concave mirror which focuses the beam onto a 512 or 1024 element detector array. Th e signals are read from the array at least once per second. Prior to each array reading, a “dark current” (or background measure-ment) is taken. Aft er a measurement is read off the array, the lamp is turned off for up to one second. Compensation for this background reading is required to calculate the concentrations of the gases or liquids in the sample. Depending on the grating type, and which of the two detectors are chosen, diff erent subsets of the wavelength range between 220 nm and 800 nm are available. Th e polychroma-tor is maintained at a constant temperature for stability.

Overview | 1-3

Figure 1-1. Analyzer light path schematic.

Sample System

Th e sample system is contained within an attached but separate, insulated enclo-sure (Oven/Sample System Enclosure). If this enclosure is heated, components within this enclosure are specifi ed to operate at temperatures of up to 150 °C.

Th e system components are confi gurable for both gas and liquid applications. A typical confi guration for the sample system contains the connections for the inlet and outlet sample lines, the Measuring Cell, an aspirator (gas applications only) to drive the sample fl uid through the system, a Zero Fluid inlet, and a Span Fluid inlet. Th e system may also contain pressure sensors/indicators, a fi lter, and other application-dependent components. Information about specifi c (or optional) components that make up your sample system – if applicable – are included in a separate Manual Supplement document, located in the “Supplemental Informa-tion” tab of this manual or the Documentation Package shipped with the analyzer.


Electronics

Th e 512 or 1024 element channel detector is mounted on a board which performs some signal conditioning. Th e signal passes to the MCU board which contains the main analyzer processor. Th e analyzer internal and external analog and digital in-puts/outputs, along with relays, etc., are handled by the Analog and Relay boards. Th e main user interface consists of a keypad/display, also known as the User In-terface Panel. Other boards include the Customer Connection board, a Display Interface board to run the display, and a Xenon Lamp board. Smaller processors on some of the ancillary boards – all tied into the main MCU – handle local tasks.

Th e main functions of the processors are to:

• Control the lamp and detector settings.

• Monitor and control temperatures in the Oven/Sample System Enclosure (if required) and Optical Bench.

• Monitor sample system pressure.

• Monitor alarm relays and other system health.

• Control the sample system including valves, etc.

• Calculate the fl uid absorbances and concentrations.

For external communication, RS232, RS485, and Ethernet ports are available. Analog signals are also available to the customer through confi gurable 0–20 mA or 4–20 mA outputs.

Overview | 1-5

Classified, Hazardous Area Protection Components and Functions

Th e Division 1/Zone 1 version of the IPS-4 is designed to be, and complies with requirements for, electrical equipment in Division 1 and Zone 1 classifi ed hazard-ous areas. Th e methods of protection used include type “p” (pressurized), and type “d” (Flameproof enclosure).

Th e purge system, redundant heater control, disconnect assembly and enclosure designs assure that the system will not ignite surrounding gases. For this reason, any repairs must not bypass these safety considerations and must use only recom-mended components.

Th e purge system consists of the electronics enclosure, a purge controller, an over-pressure vent, a bypass switch and power/signal disconnect assembly. It main-tains a positive pressure in the electronics enclosure that prevents fl ammable and corrosive gases from contacting electrical components. Th e oven enclosure and the seals between the enclosures are designed to assure that the required 5x fac-tor of safety to assure that the sample containment system will not interfere with proper operation of the purge system.

Th e disconnect assembly receives a pneumatic signal from the purge controller when the enclosure has been adequately purged and the overpressure is main-tained. Until these conditions are met, the relays in the disconnect assembly break all power and signal connections between the fi eld and the analyzer. When the electronics enclosure is opened or the pressurization gas supply is lost, the system will shut the analyzer down and transfer a set of contacts that may be used to provide an alarm.

Th e bypass switch enables operation of the analyzer by applying air pressure to the disconnect assembly - bypassing the purge controller. Th is feature must only be used when the area is known to be safe and is being continuously monitored (See Combustible Gas Detection protection techniques in NFPA70 article 500 and 505). Figure 1-2 is a state diagram showing the operation of the pressurization system and the pressure settings.

Th e analyzer must be installed and operated in accordance with this instruction manual. Instrument air or nitrogen may be used as the purge gas.

Once the analyzer has been located in an area contaminated with fl ammable gases or vapors the IPS-4 purge system must be activated to keep these gasses out of the enclosure. For this reason, AC power and an instrument air supply must be connected to the IPS-4. See “System 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 main-taining 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.

!CAUTION


For the protection system to operate properly, the cover on the discon-nect enclosure must be properly installed and the electronics and oven enclosure doors must be securely shut. All door latches must be properly tightened with the key.

Flanged Flameproof Enclosure:

When the IPS-4 is supplied with the 4660 Sample System option, the fl owmeters are installed in a fl anged fl ameproof enclosure. Care must be taken to assure that all of the bolts are installed and the fl ange surfaces are kept in good condition. Th e minimum fl amepath length must be at least 1 inch (25.4mm) and smooth (250 microinches or better). Th e gap between the fl ange surfaces with the bolts tightened must not exceed 0.0015 inches (0.0381MM)

!CAUTION

Figure 1-2. Pressurization system state diagram.

Overview | 1-7

Analyzer Electronics and Sample System Features

Th e analyzer has been designed to comply with electrical classifi cation require-ments for general purpose and hazardous areas specifi c to this analyzer’s intended application. Depending on the application, some of these features may not be available for your analyzer.

For specifi c information about the Sample System and Measuring Cell, refer to the separate Sample System and/or Measuring Cell Manual Supplements included in the “Supplemental Information” tab of this manual and in the Documentation Package shipped with the analyzer.

Key features include:

Safe transport of the sample fl uidwhich may contain toxic concentration levels, from the extraction point through the sample system, and then returned via the Vent Line to the sample stream or other return/vent location.

Multi-Component AnalysisUp to fi ve components can be measured.

Auto-CalibrationAutomatically performs a Zero, Span, or Zero + Span (user confi gurable) to update the analyzer zero, span the analyzer, or perform both functions on a regular basis.

Th e Auto-Zero and Auto-Span functions can be initiated on command by the user, at user-specifi ed intervals, or by a remote dry (potential free) contact closure.

Xenon Flash LampLow power consumption (1–4 Watts) and long life expectancy (18 to 24 months). Th e Xenon Flash Lamp is a smaller lamp that uses a simpler power supply than other comparable analyzers, resulting in fewer problems with heat dissipation and more usable wavelengths in a single lamp.

Simplifi ed maintenancePreventive maintenance made easy with simplifi ed replacement and setup of the lamp assembly, and cleaning and replacing parts in the Measuring Cell.

Two analog input signal channelsEach non-isolated analog input is jumper selectable to read a 0–20 mA or 4–20 mA signal or a 0–5 V signal. Two (2) optically isolated discrete DC inputs are also available.

Four independent analog output signal channelsTh e full-scale concentration for each output are confi gurable as either 0–20 mA or 4–20 mA.


Sample control system that can control and monitor the state of up to fi ve tempera-ture-control zones within the sample systemTemperature-control zones include the Oven/Sample System Enclosure and Optical Bench. Th ree other zones are currently spare. Sample and Vent Lines can be monitored only.

Th e temperature-control zones are protected by independent over-tempera-ture circuits. If any of these zones are found to be out of range, the analyzer automatically forces its sample system into Not Ready mode to avoid con-tamination of the system.

User Interface PanelProvides access to a readout of system parameters, alarm set points, local diagnostics, and user input. Th e calibration and confi guration functions can be protected by a password.

Up to eight status relaysIndicate faults, non-critical conditions, and operational status of the analyzer.

Reliable electronics control systemControls the overall operation of the analyzer.

Ethernet CommunicationAllows for remote communication with the analyzer for early-detection diag-nostics (troubleshooting) to determine imminent failure of parts (e.g., lamp failure, due to diminishing voltage levels).

Gas and Liquid applicationsSample systems designed to accommodate gas and liquid applications.

Specifi cations | 2-1

SPECIFICATIONS

Methodology

Diode array ultraviolet based spectrophotometer.

Wavelength Ranges

220–375 nm 512 element array




Analyzer Range

ppm to 100 %, depending on the application.

Photometric Range

0–3.0 AU (wavelength dependent); minimum full-scale is 0.1 AU at specifi ed precision.

2-2 | IPS-4 UV Z1/Div1 Analyzer

Analyzer Specifi cations

Analytes

Up to fi ve analytes, depending on the application.

Response Time

< 2 seconds for the photometric measurement.< 30 seconds to T90.

Excludes external sample system lag time.

Measurement Accuracy

< 1.0 % of full-scale range (application specifi c).

Repeatability

< 1.0 % of full-scale range (application specifi c).

Linearity

< 1.0 % of full-scale range.

Stability

0.5 % of full-scale range.

Temperature Drift

0.0003 AU / °C (typical)

24-Hour Zero Drift

< 1.0 % of full-scale range over 24 hours.


Inputs

Two (2) non-isolated analog inputs, confi gurable as 0–20 mA, 4–20 mA, or 0–5 V.

Two (2) optically isolated discrete DC inputs (minimum voltage: 11.5 V; maxi-mum voltage: 24.5 V).

22-key piezoelectric numeric keypad.

Outputs

256 x 64 pixel vacuum-fl uorescent display with multilingual capability.

Four (4) isolated analog outputs, confi gurable as 0–20 mA or 4–20 mA (two are standard; two are optional).

Up to eight (8) relays (NO, contact rating 100 VA, 240 V maximum), which indicate the operational status of the analyzer. Each relay provides one SPST (Form A) dry (potential free) contact.

Two form C loss of purge alarm contacts rated 240Vac 5A maxRS485 serial port, isolated.

RS232 serial port, non-isolated.

Fast Ethernet (IEE802.3).

Modbus TCP (Supports single Modbus Client).

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 customer-specifi c drawings in the “Supplemental Information” tab of this manual.


Oven/Sample System Enclosure Temperature

For applications with a heated sample system, the Oven will operate at tem-peratures up to 150 °C (302 °F).

Sample Transport

Gas Applications:By aspiration, using Instrument Air or N2 as the drive gas.

Liquid Applications:Using sample stream pressure. Minimum 5psi diff erential pressure inlet to outlet.

Instrument Air Requirements

The aspirator medium must be transported in 316 stainless steel.

Minimum pressure:490–700 kPag (70–100 psig / 4.8–6.9 barg)

Air Quality:As per ANSI/ISA-S7.0.01 (1996) Quality Standard for Instrument Air.

Zero Fluid

Other fl uids may be used, depending on application.

Gas Applications:UHP Nitrogen or Instrument Air for non-fl ammable streams.

Liquid Applications:Distilled water, of at least pharmaceutical grade.

Sample Fluid Flow Rate

Application specifi c.


Electrical Requirements

Power Consumption

Without Oven Heater< 300 W maximum start-up (from a cold start) with continuous average, de-pending on ambient temperature.

With Oven Heater< 700 W maximum start-up (from a cold start) with continuous average, de-pending on ambient temperature.

Supply Voltage

120 VAC (105–132 VAC), 47–63 HzOR240 VAC (209–264 VAC), 47–63 Hz

Measuring Cell Construction

Gas and Liquid Cells available, in a variety of materials (body can be 316 stain-less steel, Hastelloy C-276, or Monel with Sapphire or UV-grade Quartz win-dows), to suit a variety of applications.

Pressure Input Signals

Two pressure input signals.

Manifold Block: 0–100 psig

Measuring Cell: (0–30 psia, 0–100 psia, or 0–500 psia)

Xenon Flash Lamp

1–4 W continuous average.

Life expectancy: 18 to 24 months


Environmental

Ambient Temperature

-20 °C to +50 °C (-4 °F to +122 °F), without external heating or cooling.

Humidity

0–90 % Relative Humidity.

Pollution Degree

Pollution Degree 2

Maximum Altitude

2000 metres

Installation Category

Installation Category II

Enclosure Material

Stainless Steel main enclosures. Aluminum disconnect enclosure.

Ingress Protection

IP65 (Zone 1) and NEMA Type 4 (Div 1)

On-Board Temperature Sensor

The electronics temperature is measured by a solid-state temperature sensor located on the MCU board.


Physical Dimensions

Height: 530 mm (20.9”), analyzer only

Width: 780 mm (30.7”), analyzer only

Depth: 300 mm (11.8”), analyzer only

Weight: 66 kg (145 lb), without Backpan(may vary, depending on system).

With Backpan: Approximately 90 kg (200 lb))

Approvals and Certifi cations

The IPS-4 Analyzer is certifi ed with regard to electrical safety for Pollution Degree 2 (normally nonconductive environmental pollution occurs with oc-casional condensation) and Installation Category II (local level transients, less than those found at power distribution level). Mains supply voltage fl uctua-tions are not to exceed 10 percent of the nominal supply voltage.

Other approvals and certifi cations:

For the Zone1/Division1 Model include:

NEC/CEC: Class I Div 1 Groups A, B, C, D, Class II Div 1 Groups F &G, and Class III

Class I Zone 1 AEx d px IIC T3, Class I Zone 1 Ex d p IIC T3

CENELEC: II 2 G ATEX Ex d px IIC T3 IP65

For all NEC, CEC and ATEX Certifi cations: when the 4660 sample system option is installed, the gas group rating changes from IIC to IIB+H2.

NOTE


This page intentionally left blank.

Installation & Start-Up | 3-1

INSTALLATION & START-UP

The Installation & Start-Up chapter contains information about the following topics:

• Where to fi nd 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 it.

• Tools, equipment, and supplies required for installation.

• How to install the mechanical components and sample lines, and perform a leak check on all of the fi ttings and connections before powering up the analyzer.

• How to make all of the required electrical connections.

• How to apply power to the analyzer and confi gure it for operation.

• What to expect during normal operation.

The installation of the analyzer must be in accordance with all of the customer (end user) and local regulatory standards and procedures. There are no operator-serviceable components inside the analyzer. Refer service requirements to qualifi ed personnel.

!WARNING


Safety Considerations

Before beginning the installation of the analyzer and before power-ing it up, review and follow all safety requirements under “Important Safety Notes, Warnings, and Cautions” following the Table of Contents near the beginning of this manual. This information describes proce-dures to follow to avoid personal injury and/or damage to the equip-ment. All regulatory agency and personnel safety procedures for your jurisdiction must be followed.

The IPS-4 Analyzer is certifi ed with regard to electrical safety for Pol-lution Degree 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 voltage fl uctuations are not to exceed 10 percent of the nominal supply voltage.

NOTE

!WARNING


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.

Uncrating and Inspecting the Analyzer

The analyzer, along with its associated sample system, is shipped pre-mounted on unistruts (or on a backpan) either alone in a crate or in a crated weatherproof shelter. The Optical Bench Assembly is shipped in a separate box within the Analyzer crate.

Upon receiving the analyzer system, remove the shipping crate and check the exterior of the shelter and/or analyzer for damage. Remove the Opti-cal Bench Assembly from its box and check it for any physical damage. Re-place the Optical Bench Assembly in its box until it is ready to be installed.

Open the shelter and/or analyzer and check to ensure that all of the com-ponents within are secure and that there is no physical damage. Check that all of the components and wiring within the Electronics Enclosure and Oven/Sample System Enclosure are secure and that there is no physi-cal damage.

After the inspection, 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-shelter systems, avoid damaging the analyzer piping or instrumentation by lifting it out of its shipping crate using only its unistruts or backpan, or metal enclosure. DO NOT use any external instrument or tubing connectors as a handle for lifting.

The analyzer (on unistruts) weighs approximately 74 kg (163 lb) to 100 kg (220 lb), depending on the system. Use caution when lifting it from its crate.

!CAUTION

!CAUTION

!WARNING


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 compo-nents in the Oven/Sample System Enclosure in this example illustra-tion are optional and are configured specifically for the application.

Customer-specific drawings for your analyzer are located in the “Supplemental Information” tab of this manual and in the Documen-tation Package shipped with the analyzer.

Tools, Equipment, and Supplies Required for Installation

While installing the analyzer, the following tools, equipment, and supplies are required:

• Door latchkeys (two keys are supplied with the analyzer), attached to the exterior of the analyzer.

• Set of open-end wrenches for fittings and set of metric ball drivers.• Wire Cutters, strippers, and crimpers.• Flat blade instrument screwdriver.• Soft, non-abrasive cloth.• Wrist Strap (for grounding).• Detergent-based leak detector (Snoop® or another suitable leak detec-

tion agent is permissible).• Ethernet cable (supplied by customer), for systems using a permanent

Ethernet connection. Length will vary, depending on application.Minimum requirements: CAT 5e (maximum 100 m).Special requirements may be necessary for outdoor analyzer installa-tions, hazardous locations, and/or lengths greater than 100 m.Systems using Ethernet also require a ferrite core (supplied by AM-ETEK).

For systems using a temporary Ethernet connection, a crossover cable must be used.

• One power-disconnect switch (breaker), rated for at least 250 VAC, 20 A. For safety reasons during maintenance, this switch allows the main AC power to be disconnected from the analyzer. Supplied by customer.

• A supply of 1/4” O.D. 316 stainless steel tubing for the Instrument Air (or N2) and Span fluid lines. Length will vary, depending on the distance between the analyzer and the supply source. Supplied by the customer.

• Supply tubing and pressure regulator(s) for the purge system. This line should be sized to assure that the pressure at the purge control-

NOTE


ler inlet will not drop below 60psi (4 bar) with a flow of up to 350 L/min. Installation of one or two regulators is required to assure that the inlet pressure does not exceed the rated inlet pressure (60-115psi) and should allow for possible failure of one regulator to avoid hazards of excessive air pressure on the enclosure.


Figure 3-1. Analyzer component layout details, example only.

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Installing the Mechanical Components

Do not mount the Optical Bench Assembly in the Electronics En-closure until after the analyzer has been mounted in its designated location.

Mounting the Analyzer

The analyzer system comes mounted on a backpan.

Figure 3-2 illustrates the mounting hole locations and dimensions, plus necessary clearances on all sides.

While installing the mechanical components, refer to customer-specific drawings for your analyzer. These drawings are located in the “Supple-mental 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.

The entire analyzer system can be mounted directly on a wall, in a spe-cially designed cabinet, or in a custom-built shelter. With its IP65 / NEMA 4 rating, the analyzer system is also suitable for installation in outdoor locations.

Regardless of which installation method is used, be sure to install the analyzer in a vibration-free location, and as close as possible to the sample extraction point to minimize the amount of sample lag time.

The minimum allowable clearances are (if possible, provide extra room to allow sufficient access for servicing the analyzer). See Figure 3-2:

Below: 610 mm (24”)Front: 762 mm (30”) – door swing clearanceOven/Sample System side: 762 mm (30”) – door swing clearanceElectronics Enclosure side: 457 mm (18”) – door swing clearance

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.

NOTE

NOTE


NOTE

Figure 3-2 is an example of an analyzer layout. Mounting confi gu-ration and layout for your analyzer system may vary. Refer to the customer-specifi c drawings in the “Supplemental Information” tab of this manual or the Documentation Package shipped with the analyzer.

Figure 3-2a. Analyzer mounting details, example only.

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To mount the analyzer:

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, install the analyzer in a vibration-free loca-tion.

Refer to customer-specifi c shelter drawings in the “Supplemental In-formation” tab of this manual or the Documentation Package shipped with the analyzer.

Outdoor Installations:In most cases, the analyzer must be shielded from harsh environmental ele-ments such as wind, rain, and sun. In these cases a rain shelter or sun shade is required.

Also, proper water drainage must be considered in the mounting location to allow for suitable and safe working conditions for service personnel.

NOTE


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.

Refer to Figures 3-1 and 3-2 for the locations of the Optical Bench As-sembly, boards, cable connectors, and other components discussed in this procedure.

To install the Optical Bench Assembly:

1. Slide the Optical Bench onto the Window Housing inside the Elec-tronics Enclosure (Figure 3-1). Install the clamp to secure the assembly in place.

2. Connect the Heater/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 “CON2”) that leads to J402 on the Analog board.

4. Connect the DC cable connector from the Xenon Flash Lamp Assem-bly to J2 on the Xenon Lamp board, located near the top of the Elec-tronics Enclosure.

5. Connect the ribbon cable (Cable 5) from the Optical Bench to connec-tor P2 on the Detector Interface board, mounted to the MCU board.

!WARNING


Figure 3-3. Optical Bench Assembly.


Clamp the ribbon cable using the clamp provided, leaving enough length on each end to avoid pulling or binding.

Installing the Sample System

Sample systems will vary for each application, depending on the hazardous location, whether the application is gas or liquid, heated or non-heated, etc. Sample system components can include, but are not limited to:

• Sample probe (or process tap)

• Sample/vent lines

• Filters

• Sample transport method

• Visual fl ow indicators (or meters)

• Span, Zero, Sample valves

If your application uses any of these or other special-requirement sample system components, the customer-specifi c drawings and Manual Supplements – that describe and illustrate installation, operation (if applicable), and mainte-nance (if applicable) – will be included in the “Supplemental Information” tab of this manual and the Documentation Package shipped with the analyzer.

All regulatory agency, personnel safety procedures, and installation/removal procedures must be followed during the installation/removal of the sample system components. A breathing apparatus must be worn when installing/removing equipment from the extraction point. The sample stream may be under positive pressure, and injury or death from inhaling toxic gases/liquids in the stream could result from attempting to install/remove equipment without the use of a breath-ing apparatus.

Installing the Sample Probe/Sample Tap

If the Sample Probe is supplied by AMETEK, refer to customer-specific drawings in the “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.

!WARNING


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.

If an aspirator is used to drive the sample fluid (typical in gas ap-plications), the Sample and Vent Lines must be minimum 3/8” O.D. to avoid back pressure. This is of particular importance for the Vent Lines.

For Vent Lines longer than 15 metres (50 feet), 1/2” O.D. tubing is recommended.

This procedure applies to both unheated and heated Sample and Vent Lines. Refer to appropriate customer-specific Sample/Vent Line Installa-tion drawings (if lines supplied by AMETEK) for additional information. These drawings are located in the “Supplemental Information” tab of this manual and the Documentation Package shipped with the analyzer.

To avoid damaging the Sample or Vent Lines, use two wrenches to ensure that the fitting body does not turn on the Teflon line.

Heated Lines only:• Refer to customer-specific Sample/Vent Line drawings.

• When laying out the lines, ensure the ends with the electrical leads are at the location of the external power supply.

• Install heat shrink around the Sample and Vent Line wiring and termi-nate the Sample and Vent Line wiring to the external power source.

Refer to power termination instructions supplied with the Sample and Vent Lines for details.

Ensure there is no power being supplied to the Sample and Vent Line temperature-control zone circuits or external power source. Do not apply power until the entire system has been installed, leak checked, and the analyzer is ready for power-up.

NOTE

!WARNING


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. Provide support where needed.

2. Make the connections at the analyzer. Refer to Figure 3-2.

3. Connect the Sample Line to the sample probe or process tap.

4. Connect the Vent Line from the analyzer to the return/vent location.

Pressure at the analyzer inlet connector must not exceed the ratings marked on the inlet and on the system drawings.

Installing and Connecting the Instrument 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 functions. The procedure is the same, regard-less of which medium is being used.

The customer supplies the Instrument Air/Zero fluid line. The tubing must be 1/4” O.D. 316 stainless steel tubing with appropriate 1/4” tube connectors.

If using Instrument Air:

• The Instrument Air must meet the ANSI/ISA-7.0.01 (1996) specifica-tions at all times. If the Instrument Air cannot meet these require-ments, an inlet filter system must be installed.

• The air must be supplied to the analyzer pressure regulator at a pres-sure of 490–700 kPag (70–100 psig / 4.8–6.9 barg). Pressure require-ments may vary, depending on the application; refer to customer-spe-cific drawings located in the “Supplemental Information” tab of this manual or the Documentation Package shipped with the analyzer.

If using N2:

• Use only ultrahigh purity (UHP) Nitrogen.

NOTE


To install the Instrument Air (or Zero fluid) line:

1. Route the line from the Instrument Air/Zero fluid supply to the ana-lyzer.

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 and to the analyzer. The plumbing for purge systems and the Instrument Air/N2 feed through the analyzer manifold is already made by AMETEK.


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. If using nitrogen, use only ultrahigh purity (UHP) nitrogen.

The purge gas must be supplied via a pressure regulator and maintained at 60 to 115psi (4 to 8 bar) and must be able to provide a flow of at least 300L/min (after the initial purge, the flow is very low - just enough to compensate for leaks from the enclosure).

1. Provide a source of either Instrument Air or UHP grade Nitrogen.

2. Before connecting the purge inlet, purge the air line to clear any water or particulates

3. Connect the air supply to the ¼” purge supply connection fitting on the top of the analyzer (see figure 3-4).

4. Ensure that the Bypass Switch is in the ACTIVE position and that all enclosure doors are closed and latched

5. Open the purge inlet valve and set the regulator to 60 to 65 PSI (4 bar). The left indicator should change from Red to Green and the right from Black to Yellow.

6. After approximately 5 minutes, the right indicator should change from Yellow to Black indicating a successful purge.

7. Open the electronics enclosure. The indicators on the purge controller should go back to red and yellow.

8. Close the inlet valve and open the door and proceed with the analyzer installation.

The purge system should only be placed into BYPASS if the area is known to be clear of flammable gases.

!WARNING


Installing the Calibration (Span) Fluid Line (Optional)

For applications that require spanning, the Span fluid line is supplied by the customer. The line must be 1/4” 316 stainless steel tubing. Refer to the customer-specific Flow Diagram in the “Supplemental Information” tab of this manual or the Documentation 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 line to remove any liquids or particulate that may be present in it.

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.


Figure 3-4. Purge System.

BYPASS

PS2

PS1

DISCONNECTENCLOSURE

PURGECONTROLLER

IPS-4

B

A

INLET

PURGESUPPLY

ACTIVE


Connecting I/O Signals, Alarm Relay Contacts, and AC Power

The analog input/output signals, alarm relay contacts, and AC power requirements are specific to each analyzer installation.

For AC electrical supply cable and conduit requirements, refer to – and comply with – local wiring regulations and electrical codes for the area.

Refer to the “Electromagnetic Compatibility (EMC)” page in the con-tents section of this manual for information that discusses the EMC Directive regarding techniques and wiring practices to be followed.

Electrical Connections

Termination points for power and all signals are located in the Disconnect assembly enclosure. Six metric M32 straight thread conduit entries are provided (three on the bottom of the enclosure and three on the side) for power, relay, and signal wiring. We recommend that three be used, but all six may be used if needed. 3/4-inch NPT conduit adaptors are available from AMETEK. Note that unused holes must be plugged with M32 hole plugs. Do not use 3/4-inch NPT hole plugs with thread adapters. Only properly certified conduit connectors must be used. WIRING SEALS MUST BE LOCATED AT THE WALL OF THE DISCONNECT ASSEMBLY ENCLOSURE. NO ADDITIONAL ENTRIES CAN BE ADDED TO THE DISCONNECT ENCLOSURE WITHOUT VOIDING THE CERTIFICA-TION.

Figure 3-5 illustrates the general locations of all customer termination points, while the Customer Connections drawing specifically details the signal, relay contact, and AC power connection points. This customer-specific drawing is located in the “Supplemental Informa-tion” tab of this manual and in the Documentation Package shipped with the analyzer.

To make the signal, relay contact, and AC power connections:

1. Open the Disconnect Enclosure.

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.

2. Route the analog input/output signal wiring and alarm relay contact conductors through one of the Signal cable entry ports and into the

NOTE

NOTE

!WARNING


Disconnect Enclosure.

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.

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 cable entry ports with certified plugs.

Permanent Ethernet Cable Connections (Optional)

When using the Ethernet interface on the analyzer, the minimum re-quirements for the Ethernet cable is a CAT 5e (maximum 100 m) cable to connect the analyzer to the network, up to

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