AMETEK Western Research

IPS-4 Analyzer
Full Spectrum Option
General Purpose/Division 2

User Manual

Process Instruments
455 Corporate Blvd.
PN 403469902, Rev B Newark, DE 19702
Offices

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[Link]

© 2011 AMETEK Process & Analytical Instruments Division

This manual is a guide for the use of the IPS-4 (Integrated Process Spectrophometer) Analyzer with Full Spectrum Option. Data herein has been
verified and validated and is believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and
above the capabilities specified herein, confirmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results
and assumes no obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.

ii | IPS-4 Full SpectrumGPDIV2

 Table of Contents
Offices ....................................................................................................................ii
SALES AND MANUFACTURING: .....................................................................ii
Safety Notes ........................................................................................................viii
Electrical Safety ...................................................................................................viii
Grounding ...........................................................................................................viii
Personnel and Equipment Safety Information................................................ ix
Warnings ...................................................................................................ix
Cautions .....................................................................................................x
Electromagnetic Compatibility (EMC) .............................................................xii
Special Warnings and Information..................................................................xiii
Equipment Used in Class I, Division 2 Hazardous Locations ................xiii
Warranty and Claims .........................................................................................xiv

Overview 1
OPTICAL BENCH CONFIGURATIONS........................................................... 1
Basic Analytical Theory (Optical Bench) .................................................... 1
Flow Diagram .................................................................................................. 1
Calculation Flow ............................................................................................. 2
Dispersive Ultraviolet/Visible (DUVV) Spectrometer ..................................... 4
Basic Analytical Theory ............................................................................... 4
Optical Bench Design ................................................................................... 4
UV Specifications ............................................................................................ 5
Wavelength Ranges ........................................................................................ 5
Wavelength Accuracy+/- 0.5 nm ..............................................................5
Wavelength Resolution3 nm ...................................................................... 5
Analyzer Rangeppm to 100 %, depending on the application. .......... 5
Photometric Range...................................................................................... 5
Photometric Noise ......................................................................................5
Non-Dispersive Infrared (NDIR) PhotometerBasic Analytical Theory . 6
Optical Bench Design .................................................................................... 6
NDIR Specifications ..........................................................................7
Wavelength Ranges ...................................................................................7
Photometric Noise .....................................................................................7
Sample System ................................................................................................ 7
Electronics ........................................................................................................ 7
Classified, Hazardous Area Protection Components and Functions ........... 9

Specifications 2
Analyzer Specifications ........................................................................................ 1
Analytes ............................................................................................................ 1
Response Linearity ......................................................................................... 1
Measurement Accuracy ................................................................................. 1

Contents | iii
 Repeatability .................................................................................................... 1
Linearity ........................................................................................................... 1
Stability ............................................................................................................. 1
24-Hour Zero Drift ......................................................................................... 1
Inputs................................................................................................................ 2
Outputs ............................................................................................................ 2
Sample System Limits .................................................................................... 2
Sample Pressure .........................................................................................2
Oven/Sample System Enclosure Temperature............................................2
Sample Transport ............................................................................................ 3
Instrument Air Requirements....................................................................... 3
Sample Fluid Flow Rate ................................................................................. 3
Electrical Requirements ................................................................................. 3
Power Consumption ...................................................................................3
Heated Sample Line ...................................................................................4
Supply Voltage ............................................................................................4
Cell Construction ............................................................................................ 4
Pressure Input Signals ................................................................................... 4
Environmental ................................................................................................ 4
Ambient Temperature .................................................................................4
Humidity ....................................................................................................4
Pollution Degree .........................................................................................4
Maximum Altitude.....................................................................................4
Installation Category ..................................................................................5
Enclosure Material .....................................................................................5
Ingress Protection .......................................................................................5
On-Board Temperature Sensor..................................................................... 5
Physical Dimensions ...................................................................................... 5
Approvals and Certifications ........................................................................ 6

Installation & Start-Up 3

Safety Considerations ........................................................................................... 2
Pre-Installation Requirements............................................................................. 3
Storage Prior to Installation .......................................................................... 3
Uncrating and Inspecting the Analyzer...................................................... 3
General Installation Information ................................................................. 4
Tools, Equipment, and Supplies Required for Installation ...................... 4
Installing the Mechanical Components ............................................................. 7
Mounting the Analyzer ................................................................................. 7
To mount the analyzer: .....................................................................................7
Installing the Optical Bench-UV Assembly ................................................ 7
Installing the Optical Bench IR Assembly ................................................ 10
Installing the Sample System...................................................................... 12
Installing the Sample Probe/Sample Tap ........................................................12
Installing and Connecting the Sample and Vent Lines ............................13

iv | IPS-4 Full SpectrumGPDIV2

 Installing and Connecting the Instrument Air/Zero Fluid Line..............14
Installing the Calibration (Span) Fluid Line (Optional) ..........................15
Connecting I/O Signals, Alarm Relay Contacts, and AC Power .................. 16
Electrical Connections.................................................................................. 16
Permanent Ethernet Cable Connections (Optional) ............................... 17
Start-Up and Verification ................................................................................... 18
Powering Up the Analyzer ................................................................................ 18
Start-Up Diagnostic Checklist .................................................................... 25
Sample System Leak Check ........................................................................ 26
Manually Zeroing the Analyzer Sample System ..................................... 27
Adjusting the Zero/Span Fluid Flow Rate ................................................ 28
Adjusting the Sample Flow Rate ................................................................ 28
Setting Sample Response Time .................................................................29
Normal Operation............................................................................................... 30
Recording Initial Readings .......................................................................... 30
Recording Initial Sample Response Time .................................................30
Analyzer Configuration ..................................................................................... 31

Controller / User Interface 4

Introduction to the User Interface Panel ........................................................... 2
User Interface Panel Components ............................................................... 2
Special Software Characters.......................................................................... 4
Working From the User Interface Panel – Conditions and Messages .... 5
Summary of Analyzer Operation ................................................................ 6
Working in the Main Menus ............................................................................... 6
HOME Menu Screen ...................................................................................... 6
System Status Messages (HOME Screen) .................................................9
Alarm and Warning Notification (HOME Screen) .................................10
ALARMS and WARNINGS Menu Screen................................................. 11
Viewing Current Alarms and Warnings..................................................11
Viewing Logged Alarms and Warnings ...................................................12
STATUS Menu Screen .................................................................................. 13
SETUP Menu Screen .................................................................................... 15
Calibration Control Screen .......................................................................16
Calibration Valves.....................................................................................19
Calibration Actions Screen .......................................................................19
Relay Setup Screens ..................................................................................... 22
Current Output Setup Screens ................................................................25
Setpoints ...................................................................................................27
Diagnostics Screen ...................................................................................28
System Settings Screen ...........................................................................30
Login/Set Passwords Screen .....................................................................30
Backup/Restore Settings Screen ...............................................................32
Ethernet Network Screen .........................................................................35
Customization Screen ...............................................................................38

Contents | v
 Modbus Screen .........................................................................................39

Maintenance & Troubleshooting 5

Safety Considerations ........................................................................................... 1
Maintenance........................................................................................................... 2
Preventive Maintenance................................................................................ 2
Analyzer Preventive Maintenance Schedule ..............................................3
Before Performing Maintenance .................................................................. 5
Locating a Plug in the Sample System .......................................................5
Detecting a Plug in the Sample System .....................................................5
Changing Out Replaceable Parts ................................................................. 7
Tools, Equipment, and Supplies Required for Maintenance ......................8
Measuring Cell Preventive Maintenance.................................................10
Infrared Source Assembly Replacement ................................................... 17
Xenon Flash Lamp Assembly Replacement ............................................. 21
Replacing the MCU Battery ........................................................................ 23
Troubleshooting and Diagnostics ..................................................................... 25
Alarm Conditions and Corrective Action........................................................ 27
Analyzer Reset .............................................................................................. 31

Service & Parts 6

Technical Support .................................................................................................. 1
Returning Equipment........................................................................................... 2
AMETEK Service & Aftermarket Sales Support ............................................... 3
Recommended Spare Parts .................................................................................. 4
Measuring Cell Assembly Spare Parts ......................................................... 4
Optical Bench Assembly Spare Parts ........................................................... 4
Spare Analyzer Fuses ..................................................................................... 5
Spare Battery, MCU Board ........................................................................... 5

User Web Interface 7

Introduction to the Web Interface ...................................................................... 2
Web Interface Components .......................................................................... 3
Working From the Web Interface – Conditions and Messages ............... 3
HOME Menu Screen ...................................................................................... 4
ALARMS Menu Screen .................................................................................. 5
Current Alarms and Warnings ..................................................................5
Logged Alarms and Warnings ...................................................................6
Alarm and Warning Notification ...............................................................6
TRENDS Menu Screen .................................................................................. 7
Parameters ..................................................................................................8
Intervals......................................................................................................8
SPECTRA Menu Screen ................................................................................. 9
Viewing Spectral Data ...............................................................................9
SETTINGS Menu Screen ............................................................................. 10
Calibration Settings Screen ......................................................................11

vi | IPS-4 Full SpectrumGPDIV2

 Actions Screen ..........................................................................................12
Current Output Screen ............................................................................13
Relay Setup Screens .................................................................................14
Network & Modbus Screen ......................................................................15
System & Customition Screen ................................................................16
Analytes Screen .......................................................................................17
Limits Screen ...........................................................................................18
Diagnostics Screen ...................................................................................19
Save/Restore Files Screen .........................................................................20

Modbus communication interface 8

Hardware: ........................................................................................................ 1
Configuration: ................................................................................................. 2
Analyzer Modbus Interface Parameters ............................................................ 3
Modbus Address ............................................................................................. 3
Modbus Functions .......................................................................................... 3
Holding Registers .................................................................................................. 4

APPENDIX – DRAWINGS a
Analyzer Light Path Schematic ........................................................................... 2
UV Schematic ......................................................................................................... 2
NDIR Schematic .................................................................................................... 2
Analyzer Mounting Details ................................................................................. 3
Analyzer Overall Component Layout ............................................................... 4
Detector Interface Board (403441901) ................................................................ 5
Detector Board (100-1955) .................................................................................... 6
Detector board (700030901).................................................................................. 6
Display Interface Board (100-1978)..................................................................... 7
Display Interface board (700043901) .................................................................. 7
Customer Connection Board (100-1971) ............................................................ 8
Relay Board (100-1942) ......................................................................................... 9
Analog Board (100-1922) .................................................................................... 10
MCU Board (100-2045) ....................................................................................... 11
Xenon Lamp Board (100-2061) .......................................................................... 12
Electronics Enclosure Wiring Diagram, Sheet 1 of 5 (403443001) ................ 13
Electronics Enclosure Wiring Diagram, Sheet 2 of 5 (403443001) ................ 14
Electronics Enclosure Wiring Diagram, Sheet 3 of 5 (403443001) ................ 15

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.
WARNING

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

! Important information that should not be overlooked.

NOTE

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

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

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

! Verify ground continuity of all equipment before applying power.

CAUTION

viii | IPS-4 Full SpectrumGPDIV2

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.
WARNING
If it is necessary to open the analyzer doors while the circuits are live, first monitor the area
for flammable gases and proceed only when the area is safe.

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

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

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

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

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

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

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.
CAUTION

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

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
CAUTION 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 fingers will absorb ultraviolet light. 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.

x | IPS-4 Full SpectrumGPDIV2

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

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

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-
fice 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-
CAUTION age to the internal circuits of this equipment when installed in harsh electrical 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. Below are
examples of the techniques and wiring practices to be followed.

In meeting the EMC requirements, the various analyzer configurations 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, flexible 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 sufficient 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.

xii | IPS-4 Full SpectrumGPDIV2

SPECIAL WARNINGS AND INFORMATION

Equipment Used in the General Purpose Class I, Division 2 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.
WARNING

! Risque d’explosion – La substitution de composants peut rendre ce materiel inacceptable pour

Avertisse- les emplacements est designé dangereux.
ment

! Explosion Hazard – Do Not Disconnect Equipment Unless Power Has Been Switched Off or
the Area is Known to be Non-Hazardous.
WARNING

Risque d’explosion – Avant de déconnecter l’équipement, coupez le courant où vous

! assurez que l’emplacement est designé non dangereux.
Avertisse-
ment

For installations using North American wiring practice, all input and output wiring must be in
accordance with Class I, Division 2 wiring methods (NEC Sec 501.10 and 505.15(b) or (CEC-18
106 and in accordance with the authority having jurisdiction.

Contents | xiii
 WARRANTY AND CLAIMS
We warrant that any equipment of our own manufacture or manufactured for us pursuant to our specifications 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 classification 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 firm who purchased the
goods, and the shipment date.

The warranty shall not apply to any equipment (or part thereof) which has been tampered with or altered after 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, fire 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 specifically 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.

xiv | IPS-4 Full SpectrumGPDIV2

 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 Electron-
ics, Full Spectrum options, sample system, and the various sub-systems that make up the
entire analyzer system.

OPTICAL BENCH CONFIGURATIONS

The Full Spectrum option of the IPS-4 incorporates both a dispersive ultraviolet/visible
(DUVV) spectrometer and a non-dispersive infrared (NDIR) photometer. This section
describes how the IPS-4 integrates the information obtained from both optical systems.
Specific information for the DUVV and NDIR optical systems, including theory, hard-
ware and software descriptions, and installation instructions are provided, under sec-
tions DUVV OPTICAL BENCH and NDIR OPTICAL BENCH.

Basic Analytical Theory (Optical Bench)

For this analyzer, the analytical measurement is transmittance, T (λ ) , over one or more
bands of wavelength,(λ ) . Transmittance is the ratio of the transmitted power (originating
from the source), l (λ ) to the incident power, l0 (λ ) or each wavelength (see equation
1.1).

$ ! # " !/"0 ! (EQUATION 1.1)

Flow Diagram
Both the DUVV and NDIR optical benches operate in parallel to measure transmittance.
Figure 1.1 illustrates the flow of information from the DUVV and NDIR optical benches
to the IPS-4 analyzer platform. A single PCB acts as the interface between the optical
benches and the MCU board where the signal processing occurs.

Overview | 1-1
 DUVV

Detector Array
Detector PCB
100-2046

Dual-Bench
Interface PCB MCU
NDIR 403441901 100-2045

Detector
Preamp
700043901

NDIR Interface PCB

700088901

Figure 1-1.
Signal Flow Diagram

Calculation Flow
The transmittance measurements contain chemical information that is used to determine
the analyzer output (e.g. concentration of HೣS). The following describes the flow of calcu-
lations relating transmittance to the desired analyzer output.

STEP 1: Calculate the transmittance at each wavelength

(see equation 1.1)

STEP 2: Calculate the absorbance at each wavelength

(EQUATION 1.2)
A(λ) = -log10(T(λ))

STEP 3: Map the transmittance OR absorbance to an analyte value .

In this step, the factory established calibration converts either transmittance or absor-
bance information into a value proportional to the analyte of interest. 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

1-2 | IPS-4 Full SpectrumGPDIV2

simultaneously to model the analyte(s) of interest.

STEP 4: Filter output of Step 3

A median filter is applied to the current analyte value reading V 1 incorporating the pre-
vious analyte value reading V0 . 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. The weight, wt, is calculated using
the following equation, where Vavg is the average of the last AVERAGE readings (EQUA-
TION 1.4). The values for MEDSZ, ALPHA, BETA, and AVERAGE dictate the response
lag due to filtering. There is a trade-off between response time and signal noise. Decreas-
ing the amount of filtering (e.g. decreasing MEDSZ) will speed up the response time of
the analyzer, but will also increase the noise on the analyte reading. Typically, the filter-
ing is adjusted at the factory to provide a T response of less than 30 seconds (from the
time the sample reaches the cell(s)). T90 is defined as the time required to see 90% of a
step change in the analyte value.

(EQUATION 1.3)

VIIR = V0 + (V1 − V0 ) • wt

(EQUATION 1.4)

wt =1 − ALPHA • e ( (
− BETA • abs Vavg −V0
))
STEP 5: Apply linearization

For some applications, linearization is then applied to the resulting filtered value. If
linearization is turned on, the value is checked against linearization breakpoints. The
response between any two consecutive breakpoints is assumed linear. The slope and
intercept are calculated for each segment and used to calculate the linearized value.

STEP 6: Convert to desired units of measure

STEP 7: Apply calibration span and offset corrections

Finally, calibration span and offset corrections are applied to the resulting filtered (and
potentially linearized) value, v (see equation 1.5).

(EQUATION 1.5)

Vsoc = v • SPAN + OFFSET

Overview | 1-3
 Dispersive Ultraviolet/Visible (DUVV) Spectrometer

Basic Analytical Theory

The DUVV optical bench measures transmittance, T (λ ) , over one or more bands of
wavelength, (λ ) . Transmittance is the ratio of the transmitted power (originating from
the source), I (λ ), to the incident power, I0 (λ ) for each wavelength (see equation 1.1)

The DUVV optical bench operates in the near ultraviolet (200 to 400 nm) and visible (400
to 800 nm) wavelength ranges of the electromagnetic spectrum.

Optical Bench Design

An optical bench is composed four main components: (1) a source EM radiation (or
“light”) in the wavelength region of interest; (2) a measuring cell with windows capable
of transmitting light in the region of interest and compatible with the sample composi-
tion; (3) a wavelength selection device to isolate wavelengths of interest for a specific
application; and (4) a detector (or sensor) that is sensitive to the wavelength region. The
combination of (3) and (4) is also referred to as a spectrograph. Figure 1-2 illustrates the
complete optical path from source to detector for the DUVV and optical bench.

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 sev-
eral styles of measuring cells for the IPS-4 (see Figure 5-2). When an application requires
sensitivity at shorter wavelengths, UV-grade fused silica windows are used.

Figure 1-2.
Analyzer light path
UV-schematic.

1-4 | IPS-4 Full SpectrumGPDIV2

For streams containing components that are incompatible with fused silica (e.g. hydro-
fluoric acid, HF) or that require higher maintain pressures, sapphire windows are also
available. Front-surface aluminum mirrors are used in the cell assembly. After the beam
passes through the cell, a diffraction grating disperses the light over a range of wave-
lengths. Next, a concave mirror focuses the beam onto a 512 or 1024 element photodiode
detector array.

UV Specifications

Wavelength Ranges
Wavelength Range Detector Grating

220-375 nm 512 pixels 1200/mm

300-500 nm 512 pixels 1200/mm
220-550 nm 1024 pixels 1200/mm
300-800 nm 1024 pixels 900/mm

Wavelength Accuracy
+/- 0.5 nm

Wavelength Resolution
3 nm

Analyzer Range
ppm to 100 %, depending on the application.

Photometric Range
The photometric absorbance range is dependent on wavelength.

Photometric Noise
The photometric noise is dependent on wavelength.
Typically +/- 0.001 AU

Overview | 1-5
 Non-Dispersive Infrared (NDIR) Photometer

Basic Analytical Theory

The NDIR optical bench measures transmittance, Tl (λ ) , over one or more bands of wave-
length, (λ ) . Transmittance is the ratio of the transmitted power (originating from the
source), l (λ ) , to the incident power, l0 ((λ ) for each wavelength (see equation 1.1).

The NDIR optical bench operates in the infrared (1-5 microns) wavelength range of the
electromagnetic spectrum.

Optical Bench Design

An optical bench is composed four main components: (1) a source EM radiation (or “light”)
in the wavelength region of interest; (2) a measuring cell with windows capable of transmit-
ting light in the region of interest and compatible with the sample composition; (3) a wave-
length selection device to isolate wavelengths of interest for a specific application; and (4)
a detector (or sensor) that is sensitive to the wavelength region. The combination of (3) and
(4) is also referred to as a spectrograph. Figure 1-3 illustrates the complete optical path from
source to detector for the NDIR optical bench.

A coiled filament, blackbody radiation steady-state emitter is utilized as the source for the
infrared spectral region. The near-collimated beam from the emitter assembly (containing a
parabolic reflector and CaFೣ lens) travels through the optical bandpass filter (up to six filters
located in the filter wheel assembly) and then through the measuring cell. There are several
styles of measuring cells for the IPS-4 (see Figure 5-2). Typically, sapphire windows and gold
mirrors are used in the cell assembly. Next, a condensing lens focuses the beam onto a two-
stage thermoelectrically cooled lead selenide (PbSe) detector.

CONDENSING

Figure 1- 3
Analyzer light path
NDIR-schematic.

1-6 | IPS-4 Full SpectrumGPDIV2

NDIR Specifications

Wavelength Ranges

1-5 microns

Photometric Range

The photometric absorbance range is dependent on wavelength.

Photometric Noise

The photometric noise is dependent on wavelength.

Typically +/- 0.001 AU

Sample System
The sample system is contained within an attached but separate, insulated enclosure
(Oven/Sample System Enclosure). If this enclosure is heated, components within this
enclosure are specified to operate at temperatures of up to 150 °C.

The system components are configurable for both gas and liquid applications. A typi-
cal configuration 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
fluid through the system, a Zero Fluid inlet, and a Span Fluid inlet. The system may also
contain pressure sensors/indicators, a filter, and other application-dependent compo-
nents. Information about specific (or optional) components that make up your sample
system – if applicable – are included in a separate Manual Supplement document, located
in the “Supplemental Information” section of this manual or the Documentation Package
shipped with the analyzer.

Electronics
The 512 or 1024 element channel detector is mounted on a board which performs some
signal conditioning. The signal passes to the MCU board which contains the main ana-
lyzer processor. The analyzer internal and external analog and digital inputs/outputs,
along with relays, etc., are handled by the Analog and Relay boards. The main user
interface consists of a keypad/display, also known as the User Interface 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.

Overview | 1-7
 The 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 and control temperatures in the sample line.

• Monitor and control temperatures in the probe.

• Monitor alarm relays and other system health.

• Control the sample system including valves, etc.

• Calculate the fluid absorbances and concentrations.

For external communication, RS232, RS485, and Ethernet ports are available. Analog
signals are also available to the customer through configurable 0–20 mA or 4–20 mA out-
puts.

1-8 | IPS-4 Full SpectrumGPDIV2

Classified, Hazardous Area Protection Components and Func-
tions
The General-purpose version of the IPS-4 is designed to be, and complies with require-
ments for, electrical equipment in Division 2 classified hazardous areas. The methods of
protection used to achieve Division 2 classification is type “n” (non-incendive) and type
“m” (encapsulation) and explosion proof protection.

Component selection, redundant heater control, and PCB design assure that under nor-
mal operating conditions within stated environmental specifications and some abnormal
conditions, the system will not produce any sparks or hot spots that could ignite sur-
rounding gases. For this reason, any repairs must not bypass these safety considerations
and must use only recommended components.

Overview | 1-9
 This page intentionally left blank.

1-10 | IPS-4 Full SpectrumGPDIV2

 SPECIFICATIONS

Analyzer Specifications

Analytes
Up to eight analytes, depending on the application.

Response Linearity
+/- 2% of full scale range

Measurement Accuracy
+/- 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.

Repeatability
< 1.0 % of full-scale range (application specific).

Linearity
< 2.0 % of full-scale range.

Stability
+/- 0.5% of full scale range

24-Hour Zero Drift

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

Specifications | 2-1
 Inputs
Two (2) non-isolated analog inputs, configurable as 0–20 mA, 4–20 mA, or 0–5 V.

Two (2) optically isolated discrete DC inputs (minimum voltage: 11.5 V; maximum volt-
age: 24.5 V).

22-key piezoelectric numeric keypad.

Outputs
256 x 64 pixel vacuum-fluorescent display with multilingual capability.

Two (2) isolated analog output pairs, configurable as 0–20 mA or 4–20 mA ,

standard UV/IR/DB
Four additional isolated analog output pairs, configurable as 0-20 mA or
4-20 mA optional (DB)”

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 max

RS485 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, depending on the ap-
plication See product markings or customer-specific drawings in the “Supplemental
Information” section of this manual.

Oven/Sample System Enclosure Temperature

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

2-2 | IPS-4 Full SpectrumGPDIV2

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

Liquid Applications:
Using sample stream pressure.
Minimum 5psi differential 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.

Nitrogen Requirements:

If using Nೣ :
Use only ultrahigh purity (UHP) Nitrogen.

For “application specific” NೣUHTXLUHPHQWVUHIHUWRಯ6XSSOHPHQWDO,QIRUPDWLRQDQG&XV

WRPHUVSHFLILFGUDZLQJSDFNDJH

Sample Fluid Flow Rate

Application specific.

Electrical Requirements
Power Consumption

Without Oven Heater

< 300 W maximum start-up (from a cold start) with continuous average, depending on
ambient temperature.

With Oven Heater

< 700 W maximum start-up (from a cold start) with continuous average, depending on
ambient temperature.

Specifications | 2-3
 Heated Sample Line

Depending on voltage and length - see customer wiring diagram. Max rating 240Vac
20A.

Supply Voltage

120 VAC (105–132 VAC), 47–63 Hz

OR
240 VAC (209–264 VAC), 47–63 Hz

Cell Construction
Gas and Liquid Cells available, in a variety of materials (body can be 316 stainless steel,
Hastelloy C-276, or Monel with Sapphire or UV-grade Quartz windows), 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)

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 then the
freezing point.

Humidity

0–90 % Relative Humidity.

Pollution Degree

Pollution Degree 2

Maximum Altitude

2000 metres

2-4 | IPS-4 Full SpectrumGPDIV2

Installation Category

Installation Category II

Enclosure Material

Stainless Steel main enclosures. Aluminum disconnect enclosure.

Ingress Protection

IP65 and NEMA Type 4x

On-Board Temperature Sensor

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

Physical Dimensions
Height: 660 mm (26”), analyzer only

Width: 947 mm (37.3”), analyzer only

Depth: 254 mm (10”), analyzer only

Weight: 86 kg (188 lb), without Backpan

(may vary, depending on system).

With Backpanel: Approximately 129 kg (285 lb))

Specifications | 2-5
 Approvals and Certifications
The IPS-4 Analyzer is certified with regard to electrical safety for Pollution Degree 2
(normally nonconductive environmental pollution occurs with occasional condensa-
tion) and Installation Category II (local level transients, less than those found at power
distribution level). Mains supply voltage fluctuations are not to exceed 10 percent of the
nominal supply voltage.

Other approvals and certifications:

For the General Purpose Division 2 Model include:

NEC/CEC: Class I Div 2 Groups A, B, C, D,

Class II Div 2 Groups F & G, and
Class III

2-6 | IPS-4 Full SpectrumGPDIV2

 INSTALLATION & START-UP

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

• Where to find safety information in this guide before working with the ana-
lyzer.

• 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 fittings and connections before powering up the ana-
lyzer.

• How to make all of the required electrical connections.

• How to apply power to the analyzer and configure 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
WARNING components inside the analyzer. Refer service requirements to qualified personnel.

Installation & Start-Up | 3-1

 Safety Considerations
Before beginning the installation of the analyzer and before powering 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
NOTE information describes procedures to follow to avoid personal injury and/or damage to
the equipment. All regulatory agency and personnel safety procedures for your
jurisdiction must be followed.

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

3-2 | IPS-4 Full SpectrumGPDIV2

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 subject to dripping or splashing
liquids, corrosive gases/liquids, high humidity, or excessive heat or cold.

Uncrating and Inspecting the Analyzer

The analyzer, along with its associated sample system, is shipped pre-mounted on a
backpanel either alone in a crate or in a crated weatherproof shelter. The Optical Bench
Assemblies are 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 Optical Bench Assembly from its
box and check it for any physical damage. Replace 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 components 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 physical damage.

After the inspection, close and secure all doors with at least one latch. This will keep
! the electronics equipment secure and will prevent damage to the doors and electronic
CAUTION 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 en-
! closure. DO NOT use any external instrument or tubing connectors as a handle for
CAUTION
lifting.

! The analyzer (on backpanel) weighs approximately 129 kg (285 lb)depending on the
WARNING system. Use caution when lifting it from its crate.

Installation & Start-Up | 3-3

 General Installation Information
Figure 3-1 illustrates an example of the layout of components within the IPS-4 Ana-
lyzer. 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.
NOTE
Customer-specific drawings for your analyzer are located in the “Supplemental Infor-
mation” section of this manual and in the Documentation 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 detection
agent is permissible).
• Ethernet cable (supplied by customer), for systems using a permanent Ether-
net connection. Length will vary, depending on application.
Minimum requirements: CAT 5e (maximum 100 m).
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.
• 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.
• 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. Sup-
plied by the customer.

3-4 | IPS-4 Full SpectrumGPDIV2

Installing the Mechanical Components

! Do not mount the Optical Bench Assembly in the Electronics Enclosure until after the
analyzer has been mounted in its designated location.
CAUTION

Mounting the Analyzer

The analyzer system comes mounted on a backpanel.

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

While installing the mechanical components, refer to customer-specific drawings for

your analyzer. These drawings are located in the “Supplemental Information” section 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 conductive pollution and subject to
only temporary condensation.

The entire analyzer system can be mounted directly on a wall, in a specially designed
cabinet, or in a custom-built shelter. With its IP65 / NEMA 4x 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 mini-
NOTE mize 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 3-2a:

Below: 610 mm (24”)

Front: 762 mm (30”) – door swing clearance
Oven/Sample System side: 762 mm (30”) – door swing clearance
Electronics Enclosure side: 762 mm (30”) – door swing clearance

The surrounding ambient temperature of the analyzer should be maintained 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.

Installation & Start-Up | 3-5

 3-6 |
XENON LAMP PWB UV OPTICAL NDIR OPTICAL

Figure 3-1.
BENCH ASSEMBLY BENCH ASSEMBLY
CELLS (APPLICATION SPECIFIC)
XENON FLASH
LAMP ASSEMBLY
OVEN ENCLOSURE

details, example only.

ELECTRONIC ENCLOSURE

Analyzer component layout

DISPLAY INTERFACE PWB
OVEN HEATER

IPS-4 Full SpectrumGPDIV2

DETECTOR INTERFACE PWB

RELAY PWB

MCU PWB
POWER SUPPLY
CAL (SPAN) FLUID IN
DC TERMINAL ASSEMBLY

ANALOG PWB

SAMPLE IN
AC TERMINAL/
MAIN FUSES
SAMPLE OUT

CUSTOMER OVEN VENT

CONNECTIONS PWB
SAMPLE LINE JUNCTION BOX

C4, SAMPLE LINE RTD1

P1, ANALYZER POWER
C6, ANALOG SIGNAL
C7, DISCRETE SIGNAL C5, SAMPLE LINE RTD2

P2, SAMPLE LINE POWER C3, SAMPLE LINE HEAT TRACER POWER

C2, HAG PROBE POWER

C1, HAG PROBE RTD

C1, HAG PROBE RTD

To mount the analyzer:

In a suitable, accessible location, mount the analyzer on a vibration-free wall or instru-

ment rack.

! Refer to customer-specific shelter drawings in the “Supplemental Information” section

of this manual or the Documentation Package shipped with the analyzer.
NOTE

Outdoor Installations:
In most cases, the analyzer must be shielded from harsh environmental elements 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.

Installing the Optical Bench-UV 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 installing the Optical
! Bench Assembly.
WARNING

Refer to Figure 3-3a for the locations of the Optical Bench Assembly, boards, cable con-
nectors, and other components discussed in this procedure.

To install the Optical Bench Assembly:

1. Using the locator pins on the UV Optical Bench Assembly, position the Bench
Assembly to the upper Window Housing Assembly (Figure 3-3a). Mount the
clamp on the interface and 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 con-
nector (labelled “CON2”) that leads to J402 on the Analog board.

4. Connect the DC cable connector from the Xenon Flash Lamp Assembly to J2
on the Xenon Lamp board, located near the top of the Electronics Enclosure.

Installation & Start-Up | 3-7

 3-8 |
Figure 3-2a.
48.00
[1219.2] .50
!

[ 12.7] 6 PLS
NOTE

46.25

Analyzer mounting
[1174.8]

details, example only.

19.70
[500.5] 28.45
22.00
21.70 [722.7]
[558.8]
[551.3]

IPS-4 Full SpectrumGPDIV2

48.00
[1219.2]
shipped with the analyzer.

22.00
HEATED SAMPLE LINE
[558.8] SLEEVE SHOWN
(OPTIONAL)

HEATED SAMPLE LINE DISCONNECT BOX SHOWN

(OPTION)
4 X 3/4" NPT (M25 OPTIONAL)

CUSTOMER WIRING CONNECTIONS

(TYPICAL)
1 X M20 (1/2" NPT OPTIONAL)
Figure 3-2a & 2b is an example of an analyzer layout. Mounting configuration and

4 X M25 (3/4" NPT OPTIONAL)

layout for your analyzer system may vary. Refer to the customer-specific drawings in

ACTUAL CONFIGURATION APPLICATION

the “Supplemental Information” section of this manual or the Documentation Package

SPECIFIC
 27.81 [706.3]

BOTTOM VIEW
58.74 [1491.9]

Figure 3-2b.
Analyzer mounting,
door clearance.

Installation & Start-Up | 3-9

 5. Connect the ribbon cable (Cable 5) from the Optical Bench to connector P4 on
the Detector Interface board, mounted to the MCU board.

6. If the lamp assembly is provided with a purge fitting, connect the tube from
the air inlet on the bottom of the enclosure to the fitting on the lamp.

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

Do not attempt to to adjust the optical bench. The optical bench has been factory
! aligned to the mounted cell. See additional information on the dual bench application
WARNING in the “Overview section of this manual.

Installing the Optical Bench IR 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 installing the Optical
! Bench Assembly.
WARNING
Refer to Figure 3-3b for the locations of the Optical Bench Assembly, boards, cable con-
nectors, and other components discussed in this procedure.

To install the Optical Bench Assembly:

1. Using the locator pins on the NDIR Optical Bench Assembly, position the
Bench Assembly to the lower Window Housing Assembly (Figure 3-3b).
Mount the clamp on the interface and secure the assembly in place.

2. Connect the three pin DC cable connector from DC supply to the mating con-
nector on the underside of the Optical Bench Assembly.

3. Connect the ribbon cable from the Optical Bench to connector P2 on the De-
tector Interface board, mounted to the MCU board.

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

5. Connect the purge supply tubing to the purge fitting on the Optical Bench
Assembly.

3-10 | IPS-4 Full SpectrumGPDIV2

 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
LAMB ASSEMBLY
CLAMP TO SECURE
OPTICAL BENCH
OPTICAL BENCH TO ANALYZER
ASSEMBLY

Figure 3-3a. NOTE:

Optical Bench-UV DO NOT ADJUST THE ANY COMPONENT ON THE ASSEMBLY,
THE OPTICAL BENCH COMES FACTORY ALIGNED TO THE IT'S
Assembly. WINDOW HOUSING AND CELL ASSEMBLIES.

Figure 3-3b.
Optical Bench-IR
Assembly.
CLAMP, TO SECURE
RIBBON CABLE OPTICAL BENCH
CONNECTS TO P2 TO ANALYZER
OF DETECTOR INTERFACE
BOARD
PURGE FITTING

3-PIN FEMALE POWER CONNECTOR,

CONNECTS TO POWER CABLE
FROM DC TERMINAL ASSEMBLY

Installation & Start-Up | 3-11

 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 com-
ponents can include, but are not limited to:
• Sample probe (or process tap)
• Sample/vent lines
• Filters
• Sample transport method
• Visual flow indicators (or meters)
• Span, Zero, Sample valves

If your application uses any of these or other special-requirement sample system com-
ponents, the customer-specific drawings and Manual Supplements – that describe and
illustrate installation, operation (if applicable), and maintenance (if applicable) – will be
included in the “Supplemental Information” section of this manual and the Documenta-
tion Package shipped with the analyzer.

All regulatory agency, personnel safety procedures, and installation/removal proce-

dures must be followed during the installation/removal of the sample system compo-
! nents. A breathing apparatus must be worn when installing/removing equipment from
WARNING 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 breathing apparatus.

Installing the Sample Probe/Sample Tap

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

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

3-12 | IPS-4 Full SpectrumGPDIV2

Installing and Connecting the Sample and Vent Lines

If an aspirator is used to drive the sample fluid (typical in gas applications), 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.
NOTE

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 ap-
propriate customer-specific Sample/Vent Line Installation drawings (if lines supplied by
AMETEK) for additional information. These drawings are located in the “Supplemental
Information” section 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 fit-
ting body does not turn on the line.
CAUTION

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 terminate 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-con-
! trol 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.
WARNING

Installation & Start-Up | 3-13

 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.
NOTE

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 func-
tions. The procedure is the same, regardless 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) specifications at all
times. If the Instrument Air cannot meet these requirements, an inlet filter
system must be installed.

• The air must be supplied to the analyzer pressure regulator at a pressure of

490–700 kPag (70–100 psig / 4.8–6.9 barg). Pressure requirements may vary,
depending on the application; refer to customer-specific drawings located in
the “Supplemental Information” section of this manual or the Documentation
Package shipped with the analyzer.

If using N2:

• Use only ultrahigh purity (UHP) Nitrogen.

3-14 | IPS-4 Full SpectrumGPDIV2

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

1. Route the line from the Instrument Air/Zero 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 Instrument Air/N2 supply and to the analyzer. The
plumbing for purge systems and the Instrument Air/N2 feed through the ana-
lyzer manifold is already made by AMETEK.

Installing the Calibration (Span) Fluid Line (Optional)

For applications that require spanning, the Span fluid line is supplied by the customer.
Refer to the customer-specific Flow Diagram in the “Supplemental Information” section
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 al-
ready made by AMETEK.

Installation & Start-Up | 3-15

 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.
WARNING

Refer to the “Electromagnetic Compatibility (EMC)” page in the contents section of

! this manual for information that discusses the EMC Directive regarding techniques
NOTE and wiring practices to be followed.

Electrical Connections
Termination points for power and all signals are located in the Electronics enclosures.
Four metric M25 straight thread conduit entries are provided on the bottom of the enclo-
sure for Analyzer power, analog signal, discete signal, and optional HAG probe power
and HAG probe RTD. NPT conduit adapters are available, or the installer may resize the
holes as needed.

All end-user input/output signal and alarm relay contact connections are made at the
Customer Connection board. AC power connections are made at the Terminal Block 1
and the Ground connection is made at the ground stud on the bottom of the Electronics
enclosure, near the power entry gland.

Four metric M25 straight thread conduit entries are provided on the Sample Line enclo-
sure. (Two on the right, two on the bottom and one on the left side of the enclosure. The
conduit entries are for sample line power, sample line trace power, and sample line RTD
#1, #2 wiring. Note that unused holes must be plugged with M25 or M32 hole plugs ap-
plicable to the enclosure. Do not use NPT hole plugs with thread adapters. Only prop-
erly certified conduit connectors must be used.

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 Information” section of this manual and in the Documentation Pack-
NOTE age shipped with the analyzer.

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

1. Open the Electronics Enclosure and open all of the main fuse (F1, F2, F3, F4)
at TB1 11, 12, 13, 14.

3-16 | IPS-4 Full SpectrumGPDIV2

 If a power-disconnect switch (breaker) was installed, open (turn off) the
breaker before making the AC power connections.

2. Route the analog input/output signal wiring and alarm relay contact con-
ductors through one of the Signal cable entry ports and into the Electronics
Enclosure.

Terminate the AC power wires wires at TB1 as detailed in the Customer Con-
nections drawing.

3. Route the AC power conductors through the Power cable entry port and into
the Electronics Enclosure.

Terminate the AC power wires as detailed in the Customer Connections

drawing.

! Do not apply power to the system until after all of the wiring has been installed, con-
nected, and verified, and only if the purging system (if used) is ready for operation.
NOTE

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 requirements for
the Ethernet cable is a CAT 5e (maximum 100 m) cable to connect the analyzer to the
network, up to a maximum of 100 m from the hub. For outdoor analyzer installations,
hazardous locations, and/or lengths greater than 100 m, special requirements may be
necessary. Contact your network administrator for information.

For systems using a permanent Ethernet connection, a ferrite core (Part Number
! 301-1044, supplied by AMETEK) must be installed on the Ethernet cable (supplied by
NOTE customer), inside the Electronics Enclosure.

For details about setting up Ethernet parameters, refer to “Ethernet Network Screen” in
Chapter 4.

To install the customer Ethernet cable and ferrite core:

1. Route the Ethernet cable through one of the Signal cable entry ports and into
the Electronics Enclosure. Pull through enough cable to loop around the fer-
rite.

2. Insert the Ethernet cable through the ferrite core and loop the cable once
around the ferrite, leaving enough cable length to reach the Ethernet port at
J18 on the Customer Connection board. Adjust the cable and ferrite so the
ferrite is as close as possible to the Customer Connection board.

Installation & Start-Up | 3-17

 Connect the cable to J18.

3. Route the cable to the network connection in the plant and connect it.

Start-Up and Verification

This section describes equipment and controls on the analyzer system that require
adjustments and settings before, during, and after power-up. Refer to Figure 3-1 for the
general locations of analyzer equipment or controls that require adjustments.

Powering Up the Analyzer

Before operating the analyzer for the first time, following a power-up or reset, or after
maintenance, manually backflush the analyzer sample system and adjust the sample
flow rate. Following initial power-up, a series of system checks should be performed
to ensure the analyzer is operating properly, prior to commissioning the analyzer into
service. If start-up problems occur refer to page 3-24 in this chapter, to power up the
analyzer and verify it is operating properly.

Hazardous Locations Applications:

! For verification and troubleshooting purposes during power up, it will be necessary to
WARNING
work with the analyzer doors open.

Before powering up the analyzer, test the area for flammable gases. If a flammable
! gas atmosphere is present, do not apply power to the analyzer or any alternate power
sources that supply power to the analyzer components. Proceed only when the area is
CAUTION
found to be safe. DO NOT LEAVE POWER CONNECTED TO THE ANALYZER
IF THE DOORS ARE OPEN UNLESS YOU ARE CONTINUOUSLY SAMPLING
THE AREA FOR FLAMMABLE GASES AND ATTENDING TO THE ANALYZ-
ER.

When the analyzer doors are open, take appropriate precautions to avoid electrical
shock. Hazardous voltages are present inside.

Do not apply main AC power to the analyzer if the Xenon Flash Lamp Assembly elec-
! trical connections have not been made.
NOTE

The analyzer is shipped from the factory without a password (security is disabled).
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 (Login/Set
NOTE
Password screen, SYSTEM SETTINGS menu).

Setting up security for the analyzer is necessary to ensure analyzer settings are not

3-18 | IPS-4 Full SpectrumGPDIV2

 inadvertently changed while working from the User Interface Panel. If changing the
password, be sure to record and store the password in a safe place for reference.

To power up the analyzer and verify it is operating properly:

1. Close the Main AC Power and DC Power fuses. Refer to the Fuse Legend
(at the back of the Electronics Enclosure) for the location of these fuses. If a
power-disconnect switch (breaker) was not installed, main AC power will be
applied to the analyzer.

2. With the Electronics Enclosure open:

Open the Bench Heater and Oven Heater fuses. Refer to the Fuse Legend
(at the back of the Electronics Enclosure) for the location of these fuses. If a
power-disconnect switch (breaker) was not installed, main AC power will be
applied to the analyzer.

Do not power up the temperature-control zone circuitry (Bench Heater fuse and
! Oven Heater fuse, if Oven/Sample System Enclosure is heated) until after the sample
NOTE system leak check has been performed and verified, as described later in this procedure.

If a power-disconnect switch was installed, close it to apply main AC power to

the analyzer.

3. After applying AC main power to the analyzer, the message “System Start-
ing” 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.

After the start-up screen, the system defaults to the HOME screen which
allows you to view the current status of up to nine factory-configured param-
eters. These parameters are displayed on the left side of this screen. The right
side of this screen displays the current operational status of the analyzer. De-
scriptions of these parameters and states are described under “HOME Menu
Screen” and “System Status Messages (HOME Screen),” in Chapter 4.

! If these screens do not appear, check the AC wiring to ensure it is properly connected.
WARNING

To check the AC wiring, take all necessary safety precautions to power down
the analyzer and open the Main AC Power and DC Power fuses.

Installation & Start-Up | 3-19

 Instructions for working from the “User Interface Panel”, refer to Chapter 4 page 4-5.
!
NOTE If changes need to be made to any of the parameters settings, a password must be
entered to allow the changes to be made. For details about entering a password, refer to
“Login/Set Passwords Screen” in Chapter 4 page 4-30.

> Heater 19 °C
Bench 24 °C
Cell 23 °C
Electronics 24 °C
Figure 3-6. Manifold Pressure 85 psia
STATUS menu Aspirator Pressure 3 psia
(example screen). HOME ALARMS STATUS SETUP

a. Press the STATUS soft key to view the STATUS screen (Figure 3-6).

Check and record the current operating temperature readings. This will
help you determine if the signal wiring is properly terminated and if all of
the circuitry is operating properly.

Pay close attention to the temperatures of the (Oven) Heater (if used), (Opti-
cal) Bench, and Cell (if used) readings. If these temperatures do not increase,
check the wiring for proper connections. If the wiring is properly connected,
it may indicate a shorted RTD for that temperature zone.

! The Oven Heater temperature parameter is available only for applications with a
heated Oven.
NOTE

b. Check the pressure of the pilot valves – Manifold block and Zero fluid (if
used) pressure. Adjust the Actuator/Zero pressure regulator to obtain a
minimum pressure of 490 kPag (70 psig / 4.8 barg).

c. Check the Aspirator Pressure (gas applications only) from the STATUS
screen; the pressure should be adjusted to the value stated on the system
drawings, or enough to see a flow on the Flow Indicator (or meter), if used,
or to achieve an acceptable response time. Typically, a good response time
is less than 30 seconds to T90 when the sample system is clean and operat-
ing at peak efficiency – response time may vary due to Sample Line length.
The response is application-specific and will vary, depending on the sample
system.

8. View the current output ranges. To do this:

a. Press the SETUP soft key to view the SETUP menu screen. Scroll down to
select Current Outputs and press ENTER to display the Current Outputs
1 thru 4 screen. Scroll down to select Current Outputs 1 screen (Figure
3-7).

3-20 | IPS-4 Full SpectrumGPDIV2

 Once the Analyzer has been powered dwon wait 2 minutes to allow the high-voltage
! capacitors to discharge.
WARNING

Review the Customer Connections drawing and check the wiring termina-
tions from the main AC power supply source to the analyzer.

Take all necessary safety precautions and reapply power to the analyzer by
closing the Main AC Power and DC Power fuses. Check the User Interface
Panel again to see if these screens appear. If so, continue with the next step.

4. Perform a leak (pressure) check to ensure there are no leaks in the system,
then return to this procedure and complete the remaining start-up and verifi-
cation tests.

To perform the leak check, follow the procedure under “Sample System Leak
Check,” later in this chapter.

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.

No alarms will be displayed on the HOME screen or entered into the Alarm Log
! until AFTER the system has left the Not Ready state for the first time after power-
NOTE up, which occurs after the entire sample system has stabilized (2–3 hours) and reached
normal operating temperature.

6. While performing the remaining start-up tests, close the analyzer doors to
allow the sample system to warm up to normal operating temperature (neces-
sary only if Oven/Sample System Enclosure is heated).

The Oven and the rest of the sample system will reach normal operating temperature
in approximately 2 hours, however (application-specific) analyzers may take up to
! another hour to stabilize.
NOTE

To minimize the time it takes for the entire sample system to warm up to normal op-
erating temperature, be sure to close the doors after performing the checks that require
them to be open.

7. While working from the User Interface Panel, perform the following checks
to ensure the analyzer temperature-control zone circuitry is operating prop-
erly and the system pressures are set appropriately. Record the temperature
value for each zone and the system pressures to use as a reference later while
comparing the values.

Installation & Start-Up | 3-21

 Check the Current Out 1 Source (species), Full (full-scale), and Zero (zero
point) settings/values and compare them to the settings/values listed on
the analyzer documentation shipped with the analyzer to ensure they cor-
respond.(Refer to drawing package for the “as shipped” configurations).

Current Out 1
Source Analyte 1
Full 1000.0
Zero 0.0
Figure 3-7. Type 4-20 mA
Current Output Setup Over Range Disabled
screen (Current Out 1). HOME ALARMS STATUS SETUP

b. Check the other outputs, comparing their settings/values to their

corresponding settings/values listed on the analyzer documentation.

If any of the settings need to be changed, refer to “Current Output Setup

Screens” in Chapter 4 for details.

9. View the relay settings. To do this:

a. Press the SETUP soft key to view the SETUP menu screen. Scroll down to
select Relays and press ENTER to display the Relay screen. Scroll down to
select Relay 1 and press ENTER to display the Relay 1 screen (Figure 3-8).
Relay 1
Function Disable
Source None
Value 0
Figure 3-8. Delay 0 Sec
Relay Setup screen
(Relay 1). HOME ALARMS STATUS SETUP

Check the Relay 1 Function (operational status setting for this relay), Source
(species), Value, and Delay (zero point) settings/values and compare them
to the settings/values listed on the analyzer documentation shipped with
the analyzer to ensure they correspond.

b. Check the other relays, comparing their settings/values to their correspond-

ing settings/values listed on the analyzer documentation.

If any of the settings need to be changed, refer to “Relay Setup Screens” in

Chapter 4 for details.

10. If using an Ethernet connection to communicate with the analyzer, set up the
Ethernet parameters as described in the section “Ethernet Network Screen” in
Chapter 4.

3-22 | IPS-4 Full SpectrumGPDIV2

 11. After approximately 2–3 hours, at which time the entire sample system has
now reached its normal operating temperature (application-specific) and has
stabilized, the system will leave the Not Ready state for the first time.

Temporarily open the Electronics Enclosure door and listen for an intermit-
tent clicking sound, which indicates the Xenon Flash Lamp is on (flashing).

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.

12. If the analyzer sample system cools down to below its normal operating tem-
perature 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 ALARMS soft key to view the ALARMS screen. From
here, use the UP/DOWN arrow key to select Current Alarms and press ENTER
again to view any active alarms (on the Current Alarms screen, Figure 3-9).

If any alarms exist, take appropriate action to correct the alarms before con-
tinuing. For more information about alarms and corrective action to take to
correct and reset alarms, refer to “Alarm Conditions and Corrective Action” in
Chapter 5.

If no alarms exist (Figure 3-10), or after all alarm conditions have been cleared
(reset), recheck the temperature of each zone from the
STATUS screen.

Compare the values to the values recorded earlier to ensure they have in-
creased, have reached their normal operating temperatures, and have stabi-
lized.

13. Open the Vent Line isolation valve (on the Sample Probe, process tap, or
inside the Oven/Sample System Enclosure). Open the Sample Line isolation
valve (on the Sample Probe, process tap, or inside the Oven/Sample System
Enclosure) to allow sample fluid into the sample system.

Cell Temperature
Heater Temperature

Figure 3-9.
Active alarms displayed
(example), Current
Alarms screen. HOME ALARMS STATUS SETUP

Installation & Start-Up | 3-23

 No alarms

Figure 3-10.
No active alarms,
Current Alarms screen. HOME ALARMS STATUS SETUP

14. Zero the analyzer as described under “Manually Zeroing the Analyzer Sam-
ple System,” later in this chapter. From the HOME screen (Figure 3-11), check
the response time of the analytes. Typically, a good response time is less than
30 seconds to T90 when the sample system is clean and operating at peak ef-
ficiency. Response time may vary due to Sample Line length.

Record the initial sample response time in a log book, as described under “Re-
cording Initial Readings,” later in this chapter.

Heater 21 °C Measure

Figure 3-11.
Bench 20 °C
HOME screen Cell 23 °C
(example). HOME ALARMS STATUS SETUP

15. For systems using an Aspirator:

Adjust the Aspirator Pressure Regulator to achieve normal operating flow
rates as described under “Adjusting the Sample Flow Rate,” later in this
chapter. 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.

3-24 | IPS-4 Full SpectrumGPDIV2

Start-Up Diagnostic Checklist
This checklist describes problems that can be encountered while powering up the ana-
lyzer 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.

Corrective Action
To view current alarms, press the ALARMS soft key to view the
ALARMs screen. For information about viewing current alarms, refer
to “Alarm Notification (HOME Screen)” and “ALARMS Menu Screen”
in Chapter 4. For detailed information about these alarms, refer to the
alarm conditions and corrective action in the “Maintenance & Trouble-
shooting” chapter of this manual.

Problem Encountered
The Xenon Flash Lamp is not operating (intermittent clicking sound is
not heard).

Corrective Action
Check the system state on the right side of the HOME screen. Note
that the Xenon Flash Lamp will not operate when the system is in the
Not Ready state.

If the system is in a state other than Not Ready, take appropriate

safety precautions and check for proper wiring connections.

Problem Encountered
The LEDs on the Relay, Customer Connection, or MCU boards are
not on.

Corrective Action
Take appropriate safety precautions and check for proper I/O wiring
connections.

Problem Encountered
Temperature zone values do not increase.

Corrective Action
The over-temperature circuits may have been tripped; press the Reset
Switch (S501) on the Relay board or the Reset Switch on the Optical
Bench. (Refer to Figure 3-3 of this manual.

Installation & Start-Up | 3-25

 If the temperature zone values still do not increase, check the fuses
(Bench Heater and Oven Heater, if used) for proper connections and
blown fuses (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.

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
N2), and Calibration (Span, if used) Fluid lines are installed on-site. Therefore, it is impor-
tant that a leak check is performed on the entire sample system prior to commissioning
the analyzer for operation for the first time, or following the replacement of any lines/fit-
tings or Measuring Cell parts.

If the analyzer is configured for a heated sample system, perform the sample system leak
check prior to applying power to the Oven/Sample System Enclosure circuitry (must not
be hot).

Preventing leaks in the sample handling system is critical to ensure proper analyzer
! operation. If sample fluid migrates into the Optical Bench Assembly or Reflector Block
due to a leak in the Measuring Cell Assembly, the optics will become damaged and will
CAUTION
likely require replacement. Most leaks are preventable with the regular replacement of
the Measuring Cell o-rings.

Do not use a leak detection fluid on hot fittings. If the analyzer system is at operating
temperature, the temperature-control zone circuitry fuses must be opened to allow the
temperature-control zones to cool before using a leak detection fluid on the fittings.

After all piping and electrical connections have been made:

Refer to the system Analyzer flow diagram in the Ametek supplied drawing package
(403900XXX-3).

Identify the portions of the system to be tested.

Identify the location of the pressure sources that can be applied for leak testing.

! When pressurizing the system, do not exceed the rated pressure for that branch of the
sample system.
NOTE

3-26 | IPS-4 Full SpectrumGPDIV2

If a portion of the system includes a pressure sensor, first, pressurize the system and then
block it off and monitor for a drop over time.

If a pressure sensor and isolation valves are not available, pressurize the system and bub-
ble-test all joints with a soap solution. (eg. Snoop or the fluid specific to the Analyzer.)

Manually Zeroing the Analyzer Sample System

The Zero function forces the analyzer to purge the sample system with a Zero fluid to
remove any residual contaminants in the sample system.

For heated systems, all temperature zones must be at their operating set points before
performing a Zero. If necessary, view the temperature zones to verify this.

Pressing CANCEL at any time during this procedure will abort the procedure and
! return the software to the HOME screen.
CAUTION

To manually zero the analyzer:

1. Ensure that the Zero fluid cylinder source is connected and turned on.

2. Press the SETUP soft key to display the SETUP menu. Select the Calibration
Control sub-menu and press enter. Scroll down to the Calibration sub-menu
and press enter to display the Calibration screen.

3. Use the DOWN arrow key to select Start zero calibration and press ENTER to
purge the sample system with Zero fluid. The message “Please wait ...” will
appear while the analyzer performs the calibration function.

Run the zero for 10 minutes.

Typically, the IPS-4 Analyzer controls the zero 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).

4. From the Calibration screen, select Start measure and press ENTER to return
the analyzer to Measure mode.

5. Press the HOME soft key to return to the HOME screen.

6. Turn off the Zero fluid.

The zero is complete and the analyzer is now on-line.

Installation & Start-Up | 3-27

 Adjusting the Zero/Span Fluid Flow Rate
When the zero or span (if used) flow solenoid is in an energized state, Instrument Air
(or Nitrogen or distilled water) flows into the sample path via a solenoid manifold block
and a flow meter. The flow rate of Zero/Span (if used) fluid must be high enough to ad-
equately 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 ad-
! justments 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). Since excess air flow into the analyzer sample system will
cool the Measuring Cell and Oven/Sample System Enclosure, the optimum Zero fluid
flow rate is the lowest consistent with a good zero.

A good zero can be defined as a state where the concentration outputs are stable and fur-
ther increases in Zero fluid flow rate do not reduce the concentrations observed on the
analyzer User Interface Panel. A mid-scale flow indicator (or meter) should be sufficient
for this purpose.

While the sample system is warming up, or when the analyzer is in standby mode (Not
Ready state), zero flow may be desired. During these conditions, it is important that the
sample system is kept free of contamination by the sample fluid.

For additional information, refer to the Sample System Manual Supplement in the “Sup-
plemental Information” section of this manual or in the Documentation Package shipped
with the analyzer.

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. View the flow indicator (or
meter), if used.

To avoid damaging the pressure transducer, do not set the pressure higher than 105
! kPag (15 psig).
CAUTION

The analyzer pressure – measured by the pressure transducer – can also be used to set
the sample flow rate. This is accomplished by first measuring the sample stream pressure
with no aspiration (Drive Air Isolation Valve closed) and then adjusting the Aspirator
Pressure Regulator with the Drive Air Isolation Valve open to obtain a pressure of 5–10

3-28 | IPS-4 Full SpectrumGPDIV2

mmHg 0.20–0.39 inHg or 0.10–0.20 psi) less than the value obtained with the valve closed.
View the Measuring Cell pressure (Cell Pressure) from the STATUS screen.

Applications Without an Aspirator:

If an Aspirator is not used, a Metering Valve or Ball Valve may be used to adjust and
control the sample flow through the system. Refer to customer-specific drawings for
appropriate settings for your application. View the flow indicator, when used in specific
applications.

Setting Sample Response Time

Sample response time can also be used as a parameter for setting the Aspirator Pressure.
Response time is determined by switching the analyzer from Zero Gas Flush mode to
Measure mode and recording the time it takes the analyzer to display the first reading
after the switch.

To check the sample response time:

1. Observe the output concentration from the HOME screen.

2. Press the SETUP soft key to display the SETUP menu and then press the
DOWN arrow key until the Calibration sub-menu item is displayed and se-
lected.

3. Manually zero the analyzer. To do this, press ENTER to display the Calibration
screen. Use the DOWN arrow key to select Start zero calibration and press
ENTER. The message “Please wait ...” will appear while the analyzer initializes
and performs the calibration function.

Run the manual zero for 10 minutes. For more information about setting the
Zero fluid flow rate, refer to “Adjusting the Zero/Span Fluid Flow Rate” in this
chapter.

4. From the Calibration screen, select Start measure and press ENTER to return
the analyzer to Measure mode.

5. Press the HOME soft key to return to the HOME screen and observe the ana-
lyte output concentration(s) again.

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

Installation & Start-Up | 3-29

 Normal Operation
After the analyzer is set up and started, the analyzer User Interface Panel defaults to the
HOME screen. During normal operation, the top three lines of the User Interface Panel
display the output names with their corresponding values displayed to the right. The
User Interface Panel is updated once per second.

Recording Initial Readings

Before operating the analyzer, it is important to observe the analyzer to understand what
normal operating conditions are, and how to use this information later to help you deter-
mine problems with the analyzer.

AMETEK recommends that you observe and record this information every month to ob-
tain a history. From these recordings, you will be able to determine if there are problems
with the analyzer, such as increasing sample response. These problems typically indicate
that maintenance is required.

Keep the log book in a safe location until you need to review it for patterns of a longer
sample response time.

Recording Initial Sample Response Time

The analyzer sample response time can be used for two functions. One function is to
help you set the sample fluid flow rate, as discussed earlier in this chapter, under “Set-
ting Sample Response Time.” The other function is to help you determine if the typical
response time is increasing, which can indicate a plug in the sample system which, in
turn, can indicate maintenance is required.

To check and record the initial sample response time:

1. Manually zero the analyzer.

2. After the zero is complete, view the HOME screen and observe the analyte
output concentration changes. Observe and record the time it takes the
analyzer to display the first reading after the analyzer System State switches
from “Zero” to “Measure”.

! It is important to record the response time only after performing a manual Zero func-
tion to simulate the same conditions during the original recordings.
NOTE

3. If the sample response time is adequate (first reading after a Zero function
and after the analyzer System State switches from “Zero” to “Measure” is less

3-30 | IPS-4 Full SpectrumGPDIV2

 than 30 seconds to T90), no further adjustment is necessary.

! The sample response time may vary, depending on Sample Line length.
NOTE

4. Record these signals in a log book every month.

Analyzer Configuration
The Parameter List (Factory Settings) file is shipped with each analyzer. These configu-
ration sheets list all of the settings applicable to the factory analyzer (to meet customer
requirements). The files are provided on a CD and located in the “Supplemental In-
formation” section of this manual and in the Documentation Package shipped with the
analyzer.

If any changes are made to the original configuration, be sure to record the changes for
later reference. 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.

Installation & Start-Up | 3-31

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3-32 | IPS-4 Full SpectrumGPDIV2

 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 commands

to view various screens. Information about passwords and how to change
them is also discussed in this chapter.

• What the various keys that makes up the keypad do, and how to use them
to work from the analyzer User Interface Panel.

• Analyzer operating temperatures, alarm set points, and default parameter

settings.

Before working from the User Interface Panel, read the section titled “Introduction to
! the User Interface Panel,” in the following pages. This section discusses the functions
NOTE that can be performed by pressing the keypad keys.

This section also discusses how to enter Edit mode, and how to quickly return to the
HOME screen from anywhere in the software.

! Pressing ENTER after making any changes will save the configuration data in non-
volatile memory – the old values will be overwritten.
NOTE

Controller / User Interface | 4-1

 Introduction to the User Interface Panel
Figure 4-1 illustrates the layout of the analyzer User Interface Panel.

Vacuum Fluorescent Display

(256 by 64 dot graphic)

Soft Keys Keypad

Main Keypad

Figure 4-1.
User Interface Panel
layout.

User Interface Panel Components

The User Interface Panel is made up of two main areas:

• The Vacuum Fluorescent Display consists of a 256 by 64 dot graphic display. The
information displayed depends on the mode of operation you are working in.

- The bottom line displays the main menu items which can be accessed by
pressing the corresponding blank keypad square (on the Soft Keys Keypad)
directly below it.

For information about the main menu items, and the sub-menu items, refer
to “Working in the Main Menus” in this chapter.

- 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.).

• The Main Keypad allows you to change information from any of the editable
parameters. The keypad consists of:

4-2 | IPS-4 Full SpectrumGPDIV2

Key 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.

• The decimal (‘•’) key can be used to enter a decimal character

or as part of a password.

X The CANCEL key allows you to discard any changes you make
to operating parameters while in Edit mode, or to back out
of previous menu levels one level at a time until the HOME
screen is displayed. This key will also allow you to answer “No”
to software prompts (e.g., “Restore settings. Are you sure?”).

8 The ENTER key allows you to view sub-menu items, enter Edit
mode, select parameters and/or their options, initiate analyzer
functions (e.g., calibration), and to exit Edit mode and save any
changes that have been made. This key will also allow you to
answer “Yes” to software prompts (e.g., “Restore settings.
Are you sure?”).
ñ ò The UP and DOWN arrow keys are used to scroll up or down to
view sub-menu items or parameters that are not currently on
the screen, as indicated by a DOWN arrow icon on the lower-
left side of the screen. These keys are also used to change
a selected character – to the next or previous alphanumeric
character – while working in Edit mode.

ï ð While working in Edit mode, the LEFT arrow key works as a

backspace for the cursor.

Controller / User Interface | 4-3

 Special Software Characters
While working from the User Interface Panel, the following special characters are seen:

Character Description
u This character (cursor) beside a menu or sub-menu item indi-
cates the item is selected, and that it has additional sub-menus
or parameters to view. This character beside a parameter
indicates the parameter can be modified.

To view the sub-menus, or to enter Edit mode, press the ENTER

key when this cursor is next to the required item.

> This character (cursor) beside a main menu item, sub-menu

item, or a parameter indicates this item is selected. It also
indicates the item is read-only (cannot be modified).

˜ This character, located in the lower-left corner, indicates there

are other options to be viewed below the items currently being
displayed. To scroll down, press the DOWN arrow key.

— This character, located in the lower-left corner, indicates there

are other options to be viewed above the items currently being
displayed. To scroll up, press the UP arrow key.

—
˜ 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 UP or DOWN arrow key.

4-4 | IPS-4 Full SpectrumGPDIV2

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 configurable parameters can be
changed until a password is entered in the Change Password function (Login/Set
NOTE
Password screen, SYSTEM SETTINGS menu).

Setting up security for the analyzer is necessary to ensure analyzer settings are not
inadvertently changed while working from the User Interface Panel. If changing the
password, be sure to record and store the password in a safe place for reference.

• If security is enabled (if a password has been entered in the Change Password
function – Login/Set Password screen, SYSTEM SETTINGS menu), the software will
revert to Operator (read-only) mode after 5 minutes of no keypad activity.

• If security is enabled but you are not logged in, the message “Password required”
is displayed when you press ENTER to initiate analyzer functions (such as calibration
functions) or go into Edit mode to change the configuration settings.

• A maximum of nine characters can be used to enter a password.

• On all screens, a cursor (‘>’ or ‘u’ ) is displayed beside the current item; to view
other related items that are not currently displayed (if available), press the UP or DOWN
arrow keys.

The cursor ‘>’ indicates the item is read-only. The ‘u’ cursor indicates the item is
editable.

• When the ‘u’ cursor is next to a sub-menu item press ENTER to view parameters
under that item.

• When in Edit mode (for numeric entries only) the cursor ( ‘_’ ) is displayed on or
to the right of the selected character.

• You can view all menus and sub-menus – and the current settings or values of all
parameters or functions on each screen – without a password.

• The display will revert to the HOME screen if no keys are pressed within 60 sec-
onds.

• Active alarm names will flash on the HOME screen only. To stop the flashing,
press any key once. The alarm will begin flashing again after 20 seconds of no keypad
activity, unless the alarm is reset.

• To return to the HOME screen from any other screen (except when in Edit mode),
press the HOME soft key.

Controller / User Interface | 4-5

 Summary of Analyzer Operation
The analyzer’s EEPROM contains a number of files that define its configuration for the
intended application. The configuration variables are contained in a file named “params.
xml.” This file consists of approximately 500 parameters and their default settings. A CD
with the Parameter List (Factory Settings) file is shipped with each analyzer.

This list includes variables to set up Communications, Units of Measures, Language, Tim-
ers for analyzer operations, Inputs, Outputs, Relays and Solenoids, Alarm Limits, Lamp
Control, Heater Setpoints and Control, Filtering, and various other parameters. It is also
continuously updated by the main processor with (read-only) variables such as Relay/
Solenoid/Valve Status, Current Outputs, and other parameters.

A subset of these parameters may be changed from the User Interface Panel. The se-
quence of analyzer operations is defined by a file called “[Link].” The proces-
sor continuously communicates with the “[Link]” and “[Link]” files to
define what function the analyzer should be performing at any given time. These files
also control the setting of valves and other devices.

Examples of “states” include Zero, Span, and Measure. These and other states are de-
scribed in detail under “System Status Messages (HOME Screen),” later in this chapter.

Generally, the analyzer will sequence through a series of factory-set, predefined states.
However, through settings that can be changed from the User Interface Panel, you can
vary the interval between analyzer states, manually change the analyzer to another state,
or enable or disable certain states.

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 se-
quence once the offending condition has been cleared (reset).

Working in the Main Menus

During normal operation, the concentrations of the analytes can be displayed on the
HOME screen. Other parameters that display real-time system temperatures or pres-
sures 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 UP or DOWN arrow key.

The bottom line displays the main menu items which can be accessed by pressing the
corresponding keypad square (soft key) directly below each item.

HOME Menu Screen

The HOME screen (Figure 4-2) allows the user to configure up to nine analytes or param-
eters, whose real-time results will be displayed. These parameters are displayed on the

4-6 | IPS-4 Full SpectrumGPDIV2

 left side of this screen.

The right side of this screen displays the current operational status of the analyzer. De-
scriptions of these states are described under “System Status Messages (HOME Screen),”
in the following pages. Also, new alarms and warnings that have been set are displayed
on this screen. Refer to “Alarm and Warning Notification (HOME Screen),” later in this
section, for more information.

When you press ENTER, the software goes into Edit mode, allowing you to set up the
parameters that are displayed. Items that can be displayed here include:

Heater (optional)
Displays the real-time temperature (°C) of the Oven Heater, as measured by the Oven
Heater RTD (sealed inside the Oven Heater). This parameter is available only for applica-
tions with a heated Oven.

Bench
Displays the real-time temperature (°C) of the Optical Bench, as measured by the Optical
Bench RTD.

Measure
u Heater 21 °C
Figure 4-2.
Bench 20 °C
HOME screen Cell 23 °C
(example). HOME ALARMS STATUS SETUP

Cell (heated Cell is optional)

Displays the real-time temperature (°C) of the Measuring Cell, as measured by the Cell
RTD (mounted on the Cell, inside the Oven/Sample System Enclosure). This parameter is
available only for applications with a heated Oven.

Manifold Pressure
Displays the real-time pressure (psia, or other unit) measured at the Manifold Block. The
manifold pressure is used for valve actuation and for zero flush (if applicable).

Aspirator Pressure
Displays the real-time pressure (psia, or other unit) being used to drive the Aspirator
system (gas applications only).

Cell Pressure
Displays the real-time pressure (psia, or other unit) being measured in the Measuring
Cell.

Controller / User Interface | 4-7

 Tec Temperature
Displays the temperature of the NDIR sensor.

Probe Temperature
Displays temperature @ sample probe.

Sample/Vent line Temperature

Displays temperature of sample/vent bundle.

4-8 | IPS-4 Full SpectrumGPDIV2

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. Messages that can be displayed here include:

Not Ready
During this state, the analyzer is not measuring sample fluid due to alarm conditions
that must be resolved before it will resume normal sampling operation.

Sample Flush
Indicates the analyzer is allowing sample fluid into the sample system. There will be a
short delay before it reaches the Measuring Cell, where the analyzer begins measuring
the sample.

Measure
Indicates the analyzer is measuring analyte values.

Span Fluid Flush

Indicates the sample system is being flushed with Span fluid (span fluid valve is open).
The valve will close when the system state changes to Measure mode.

Span
This occurs following the Span Fluid Flush and indicates the analyzer is being spanned.
When complete, the span fluid valve is closed.

Zero Fluid Flush

Indicates the sample system is being flushed with Zero fluid (zero fluid valve is open).
The valve has to be closed by changing the system state to Measure or Span mode.

Zero
Indicates the analyzer is being zeroed. During this function, the zero fluid valve remains
open until the Zero is complete. The Zero consists of an average reading of a factory-set
number of readings (usually 10 to 90; default = 60). The valve has to be closed by chang-
ing the system state to Measure or Span mode.

Span Hold
Indicates the analyzer is measuring concentration with the span fluid valve open. To
leave this state, the analyzer must be manually changed to another state from the Cali-
bration screen.

Zero Hold
Indicates the analyzer is measuring concentration with the zero fluid valve open. To
leave this state, the analyzer must be manually changed to another state from the Cali-
bration screen.

Controller / User Interface | 4-9

 Alarm and Warning Notification (HOME Screen)

When an alarm or warning is set by the analyzer, the message will flash on the HOME
screen only. The information on the HOME screen will be replaced by a reverse (white)
screen with the alarm name in black text. It will then switch to a black screen with white
text and will continue to flash until the alarm conditions that triggered the alarm(s) are
reset.

For more information about active and historical alarms and warnings, refer to “Viewing
Current Alarms and Warnings” and “Viewing Logged Alarms or Warnings” in the fol-
lowing pages.

Alarms and warnings that have been reset (no longer active) are stored in the Alarm Log
and Warning Log, accessed from the ALARMS AND WARNINGS screen. Logged (or
historical) alarms and warnings – which occupy two lines – 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 Full SpectrumGPDIV2

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

u Current Alarms and Warnings

Alarm Log
Warnings Log

Figure 4-3.
ALARMS and
WARNINGS screen. HOME ALARMS STATUS SETUP

Viewing Current Alarms and Warnings

All active alarms and warnings are displayed on the Current Alarms and Warnings
screen. Each line will occupy one alarm or warning description and up to six active
alarms or warnings can be displayed on the screen at once. If more than six are active,
use the DOWN arrow key to scroll down the list. The alarm or warning at the top of the
list is most recent; the alarm or warning at the bottom is the oldest.

To view active conditions, select Current Alarms and Warnings and press ENTER. If there
are alarms active, the alarm description is displayed (Figure 4-4). If no alarms are active,
“No alarms” is displayed (Figure 4-5).

For a complete list of alarms and warnings generated by the analyzer, refer to the
! “Maintenance & Troubleshooting” chapter.
NOTE

Cell Temperature
Heater Temperature

Figure 4-4.
Active alarms displayed,
Current Alarms (example
screen). HOME ALARMS STATUS SETUP

No alarms

Figure 4-5.
No active alarms,
Current Alarms screen. HOME ALARMS STATUS SETUP

Controller / User Interface | 4-11

 Viewing Logged Alarms and Warnings

Alarms that have been reset (no longer active) are stored in the Alarm Log, accessed
from the ALARMS screen. Each logged (or historical) alarm – which occupies two lines
– includes the time and date it was set and reset. The logged alarm at the top of the list is
most recently reset alarm; the alarm at the bottom is the oldest. The Alarm Log will be
cleared when the analyzer is powered off.

To view the history of alarms or warnings that have been reset, select Alarm Log or
Warnings Log and press ENTER. If there is history of alarms or warnings that have been
reset, the descriptions are displayed (Figure 4-6 and 7). If there is no history, “Log empty”
is displayed (Figure 4-8 and 9).

To scroll through the list, use the UP/DOWN arrow keys.

Alarm Log
05/13/2005 [Link] 05/13/2005 [Link]
Cell Temperature
Figure 4-6. 05/13/2005 [Link] 05/13/2005 [Link]
History of alarms Heater Temperature
displayed, Alarm Log
(example screen). HOME ALARMS STATUS SETUP

Warnings Log
05/13/2005 [Link] 05/13/2005 [Link]
Intensity to low during zero calibration
Figure 4-7. 05/13/2005 [Link] 05/13/2005 [Link]
History of warnings Zero calibration failed
displayed, Warning Log
(example screen). HOME ALARMS STATUS SETUP

Alarm Log
Log empty

Figure 4-8.
No history of alarms,
Alarm Log screen. HOME ALARMS STATUS SETUP

Warnings Log
Log empty

Figure 4-9.
No history of
warnings, Warnings
Log screen. HOME ALARMS STATUS SETUP

4-12 | IPS-4 Full SpectrumGPDIV2

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 customer specifications. This screen is
particularly useful when performing analyzer diagnostics. These outputs are read-only.

The list of available options for each item include:

> Heater 19 °C
Bench 24 °C
Cell 23 °C
Electronics 24 °C
Figure 4-10. Manifold Pressure 85 psia
STATUS menu screen Aspirator Pressure 3 psia
(example). HOME ALARMS STATUS SETUP

Heater (optional)
Displays the real-time temperature (°C) of the Oven Heater, as measured by the Oven
Heater RTD (sealed inside the Oven Heater). This parameter is available only for applica-
tions with a heated Oven.

Bench
Displays the real-time temperature (°C) of the Optical Bench, as measured by the Optical
Bench RTD.

Cell (heated Cell is optional)

Displays the real-time temperature (°C) of the Measuring Cell, as measured by the Cell
RTD (mounted on the Cell, inside the Oven/Sample System Enclosure). This parameter is
available only for applications with a heated Oven.

Electronics
Displays the real-time temperature (°C) inside the Electronics Enclosure. This tempera-
ture is measured by a sensor on the MCU board.

Manifold Pressure
Displays the real-time pressure (psia, or other unit) being measured in the Manifold
Block, for the Manifold and Zero fluid (if used).

Aspirator Pressure
Displays the real-time pressure (psia, or other unit) being measured in the Aspirator sys-
tem (gas applications only).

Cell Pressure
Displays the real-time pressure (psia, or other unit) being measured in the Measuring
Cell.

Controller / User Interface | 4-13

 Next Cal 1
Displays the time remaining until the next Auto-Calibration 1 function. The duration
and units between Auto-Calibrations is determined by the duration entered in the timer
interval and the unit entered in the unit on the Automatic Calibration 1 screen. The
Calibration Trigger (TIMER 1) 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.

Next Cal 2
Displays the time remaining until the next Auto-Calibration 2 function. The duration
and units between Auto-Calibrations is determined by the duration entered in the timer
interval and the unit entered in the unit on the 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 Full SpectrumGPDIV2

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. Changing the factory-set configuration could cause the ana-
CAUTION lyzer to operate incorrectly.

To view other sub-menu items under this screen, use the UP/DOWN arrow keys to scroll
through the list of analyzer functions to select the appropriate sub-menu item.

u Calibration Control
Relays
Current Outputs
Setpoints
Diagnostics
Figure 4-11. System Settings
SETUP menu screen. HOME ALARMS STATUS SETUP

Detailed descriptions of each sub-menu item – and the parameters under each – are
listed in the following pages (each listed as a heading in this manual). The list of available
sub-menu items includes:

• Calibration Control

• Relays

• Current Outputs

• Setpoints

• Diagnostics

• System Settings

• Modbus

Controller / User Interface | 4-15

 Calibration Control Screen

The Calibration Control screen displays the available analyzer calibration controls and
allows the user to initialize the calibration functions.

u Calibration Settings
Calibration Valves
Calibration Actions

Figure 4-12.
Calibration Control
screen. HOME ALARMS STATUS SETUP

Calibration Settings Screen

The Calibration Settings screen (Figure 4-13) displays all of the available analyzer cali-
bration functions and allows the user to set up the calibration functions.

Automatic Calibration 1 and 2 Screens

u Automatic Calibration 1
Automatic Calibration 2
Flush Times

Figure 4-13.
Calibration Settings
screen. HOME ALARMS STATUS SETUP

Use these to set up the type of Auto-Calibration function that will be performed during
normal analyzer operation. The two setup screens allow multiple timers to be set.

Calibration Trigger
Use this to select how auto-calibration is triggered.

Automatic Calibration 1
uCalibration Trigger Timer
Mode Zero + Span
Timer Interval 0 day
Figure 4-14. Unit day
Calibration Settings Start Time [Link]
screen. HOME ALARMS STATUS SETUP

4-16 | IPS-4 Full SpectrumGPDIV2

Calibration Trigger options include:
• Timer
Enables the Auto-Calibration timer. The system will automatically Zero and/
or Span the analyzer.

• Input1 and Input 2

Auto-Calibration will be initiated by a user-supplied contact closure.

• Off
Disables Auto-Calibration. The system will not automatically Zero or Span
the analyzer regardless of what the automatic calibration mode function
is set to. The analyzer can still be manually calibrated using the Start zero
calibration, Start span calibration or Start zero+span calibration functions
on the Calibration screen.

Mode
Use this to set up the type of Auto-Calibration function that will be performed during
normal analyzer operation.

Mode options include:

Zero + Span
For its regular sequence of operation, the analyzer will perform a Zero, followed by a
Span, and then return to Measure mode

Span only
For its regular sequence of operation, the analyzer will perform a Span and then return
to Measure mode.

Zero only
For its regular sequence of operation, the analyzer will perform a Zero and then return to
Measure mode.

This function is not available for applications with multi-species span capability (i.e.,
when “Select span fluid” function is available on the Calibration screen). In this
! case, Auto cal – if enabled (ON) – will perform a zero calibration only. Span calibra-
NOTE tion must be done manually as described under “Manually Starting a Span Function”
on page 4-21.

Timer interval
Defines the time between each Auto-Calibration cycle. The unit is determined by the
Unit setting.

Controller / User Interface | 4-17

 Unit
Use this to set the time units that will be used to determine the frequency of each Auto-
Calibration function. The unit can be set to hours or days. This function works in con-
junction with the Timer interval.

Start Time
Use this to set the start Auto-Calibration in military time.

To set up calibration functions:

1. Select the parameter you wish to change and press ENTER.

2. Use the UP/DOWN arrow keys to view the options available for each parameter.

3. Change the timer durations (Auto cal timer interval, Zero flush time, Span flush
time):

• Use the UP/DOWN arrow key to increase/decrease the duration in increments

of one (1.00). When using this method, the value counts up/down from the
current setting. This works best for minor changes.

• If a value exists, use the LEFT arrow key as a backspace to remove (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.

Flush Times

The Flush Times screen (Figure 4-15) displays all of the available flush times.

Zero flush time

Defines the duration (seconds) the analyzer will flush the sample system with Zero fluid
during the analyzer’s normal operating sequence.

Span flush time

Defines the duration (seconds) the analyzer will flush the sample system with Span fluid
during the analyzer’s normal operating sequence.

Flush Times
uZero 10 sec
Span 30 sec
Sample 20 sec
Figure 4-15.
Flush Times Settings
screen. HOME ALARMS STATUS SETUP

Sample flush time

Defines the duration (seconds) the analyzer will flush the sample system with sample
fluid before it will begin measuring.

4-18 | IPS-4 Full SpectrumGPDIV2

Calibration Valves

The Calibration Valves screen (Figure 4-16) allows the user to enter the calibration fluid
concentration value used for each analyte (Analyte cal conc). Note that the actual species
name will be displayed on the screen, not “Analyte” (e.g., SO2).

To enter calibration fluid concentration:

1. Select the analyte you wish to enter a calibration fluid concentration for and press
ENTER to go into Edit mode.

2. Changing the concentration value:

• Use the UP/DOWN arrow key to increase/decrease the value in increments

of one (1.00). When using this method, the value counts up/down from the
current setting. This works best for minor changes.

• When no value exists, use the numeric and decimal keys to enter a value.

• When a value exists, use the LEFT arrow key as a backspace to erase the
characters to the left of the cursor ( ‘_’ ), then use the numeric and decimal
keys to enter the new value. This works best for drastic changes.

3. For multi-species spanning, repeat Steps 1 and 2 for each species that will be
spanned.

Calibration Actions Screen

The Calibration action screen displays all of the available analyzer calibration functions
and allows the user to initialize the calibration functions. Figures 4-17a and 4-17b illus-
trate the differences between analyzers that use single-species spanning and those that
use multi-species spanning.

Start zero calibration

This function forces the analyzer into the Zero calibration portion of the normal operat-
ing sequence, starting with the “Zero Flush” mode, then “Zero.” The analyzer zero is
automatically adjusted based on the average reading during the zero calibration.

u Analyte 1 cal conc 0.0

Analyte 2 cal conc 0.0
Analyte 3 cal conc 0.0

Figure 4-16.
Calibration Valves
screen. HOME ALARMS STATUS SETUP

Controller / User Interface | 4-19

 Select Span Fluid (for applications that require multiple span fluids)
This function is used in applications where multiple span fluids are required. The span
fluid connected to the Cal (Span) Fluid Inlet port must correspond to the fluid selected
from the options listed under this parameter.

To select a span fluid, press ENTER to go into edit mode. Use the UP/DOWN arrow
key to select the fluid you wish to span and then press ENTER to select the span fluid.

u Start Zero Calibration

Start Span Calibration
Figure 4-17a. Start ZeroCalibration+Span Calibration
Calibration screen, Inject Zero Fluid
applications with Inject Span fluid
single span fluid. Start measure
HOME ALARMS STATUS SETUP

u Start zero calibration

Select Span Fluid
Figure 4-17b. Start span Calibration
Calibration screen, Start Zero+Span Calibration
applications with Inject Zero fluid
multi-span fluids. Inject Span fluid
HOME ALARMS STATUS SETUP

Next, select Start span calibration and press ENTER to start the span.

Start span calibration

This function forces the analyzer into the Span mode of the normal operating sequence,
starting with the “Span Fluid Flush” mode. The analyzer span (calibration) is automati-
cally adjusted based on an integrated reading during the span calibration. After the span
is complete, the analyzer will return to normal operation (Measure mode).

Inject Zero fluid

This function injects Zero fluid into the sample system to flush the Measuring Cell of
light-absorbing compounds. During this operation, the zero solenoid is open and “Zero
Hold” is displayed in the Status area of the HOME screen. Note that this mode does not
actually Zero the analyzer.

Inject Span fluid

This function injects Span fluid into the sample system, which can be used to observe
the analyzer’s response to species of known concentration(s). During this operation,
the span solenoid is open and “Span Hold” is displayed in the Status area of the HOME
screen. Note that this mode does not actually Span the analyzer.

Start measure
This function returns the analyzer to normal Measure mode from any of the Inject Zero
fluid, Inject Span fluid, Zero Gas Flush, or Span Gas Flush functions. To return the

4-20 | IPS-4 Full SpectrumGPDIV2

analyzer to Measure mode, select this function and press ENTER. The message “Please
wait ...” appears while the analyzer performs a 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.

Manually Starting a Span Calibration

This section applies only to systems with multi-species spanning capability.

! 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. Zero the analyzer, as described in Chapter 3 of this manual.

2. Ensure the Span fluid cylinder is connected to the Span Fluid Inlet on the right
side of the analyzer and is turned on.

For applications using multiple span fluids:

It is important to connect the appropriate Span fluid cylinder for the corresponding fluid
being spanned.

3. From the SETUP menu, select the Calibration Control sub-menu and press enter.
Scroll down to the Calibration Fluid Concentration sub-menu and press enter to display
the Calibration Fluid Concentration screen (Figure 4-16).

Ensure that the concentration value for the Analyte being spanned corresponds
with the concentration of the span fluid. If not, edit the value as described under “Cali-
bration Fluids Screen,” later in this section.

4. For applications using multiple span fluids:

From the Calibration screen (Figure 4-17b), choose Select Span Fluid and press ENTER to
go into Edit mode. Use the UP/DOWN arrow key to select the fluid you wish to span and
then press ENTER to select the span fluid.

5. From the Calibration screen, select Start span calibration and press ENTER to start
the span. The analyzer will span the selected fluid and then return to normal operation
(Measure mode).

Controller / User Interface | 4-21

 6. Turn off the Span fluid.

The span process is complete and the analyzer is now on-line.

7. For applications using multiple span fluids:

Repeat Steps 2 through 6 for each span fluid.

8. Press the HOME soft key to return to the HOME screen.

Relay Setup Screens

The Relay Setup screens (Figure 4-18a and 4-18b) allow the user to view or set up the
parameters for up to eight relays. For example, Concentration Alarms can be set up from
this screen (Relay Function option).

Relay 1
u Function Disable
Source None
Value 0
Figure 4-18b. Delay 0 Sec N
Relay Setup screen Normal Oper Normally Open
(Relay 1). HOME ALARMS STATUS SETUP

u Relays
Relay 1
Relay 2
Relay 3
Figure 4-18a. Relay 4
Relay Setup screen. Relay 5
˜ HOME ALARMS STATUS SETUP

4-22 | IPS-4 Full SpectrumGPDIV2

Relay 1–8 Function
The analyzer can use up to eight relays to indicate the operational status of the analyzer.
Each relay provides one SPST (Form A) dry (potential free) contact. The relays are ener-
gized (closed) on start-up.

Relay Function options include:

Disable
Select Disable to turn off the functionality of a relay.

Calibrating
The relay will be de-energized if the analyzer is in a calibration state (Span Flush, Span,
Zero Flush, or Zero).

Data Valid
The relay will be de-energized when the analyzer is in any state other than the Measure
state.

Fault
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 [Link] Limit
Select this to enable an analyte concentration Low Limit [Link] Limit
Select this to enable an analyte concentration High Limit Alarm.

Heartbeat
Relay periodicaly will turn on and off to indicate that the
Analyzer is “ON”.

Check Request
Relay will be “ON” if any warnings are active.

User
Relay action controlled by analyzer internal task.

Relay 1–8 Source

Defines the assignment for each of the eight relay outputs, which are displayed on the
right side of the screen. This parameter only applies if Relay Function is set to Low Limit
or High Limit. Options include:

NONE
Select NONE if you do not wish to assign a relay to an output channel.

Analyte 1–8
Defines the analyte (species) of interest for the relay output.
You can assign a different relay for each channel. To assign a relay to a channel, select an
analyte and press ENTER. Note that the actual species name (e.g., SO2) will be displayed
on the screen, not “Analyte.”

Controller / User Interface | 4-23

 Relay 1–8 Value
Defines the Low or High Alarm Limit threshold for each relay (user input required).
This parameter only applies if Relay Function is set to Low Limit or High Limit.

Relay 1–8 Delay

Defines the delay time to de-energize the relay after the analyte concentration goes out-
side the limit set with Relay Value.

For example, if Relay Delay is set to 5 seconds, the analyte concentration can exceed the
High Limit for up to 5 seconds at a time without de-energizing the relay. If the concen-
tration stays high for more than 5 seconds, the relay will be de-energized. The range
is 0–3600 seconds. This parameter only applies if Relay Function is set to Low Limit or
High Limit.

To change the settings for a relay:

1. Enter a password to allow changes to be made to the relay settings.

2. Select one of the Relay (1–8) sub-menus. Press ENTER to view the parameters
for that relay.

3. Select the required parameter (Relay Function, Source, Value, or Delay), change
the settings, and press ENTER.

Repeat this step for each parameter and each relay.

When entering a value for the Relay Value and Delay parameters:

• Use the UP/DOWN arrow key to increase/decrease the value in increments of

one (1.00). This works best for minor changes. The relay value is displayed
on the right side of the screen.

• If a value exists, use the LEFT arrow key as a backspace to 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.

4-24 | IPS-4 Full SpectrumGPDIV2

Current Output Setup Screens

The Current Output screens (Figure 4-19a and 4-19b) display current output 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 [Link] 1–8
This defines the analyte (species) of interest for the current output.
You can assign a different species for each channel. To assign an analyte to a channel,
select an analyte (species) and press ENTER. Note that the species name will be displayed
on the screen, not “Analyte” (e.g., SO2).

Full
This is the output full-scale value, where the user enters the current full-scale set point
corresponding to 20 mA DC for the output. For example, if Current Out 1 Full = 100
ppm, Output 1 would read 20 mA at 100 ppm.

Current Outs
u Current Out 1
Current Out 2
Current Out 3
Figure 4-19a. Current Out 4
Current Output Setup
screen. HOME ALARMS STATUS SETUP

Current Out 1
uSource Analyte 1
Full 1000.0
Zero 0.0
Figure 4-19b. Type 4-20 mA
Current Output Setup Over Range Disabled
screen (Current Out 1). HOME ALARMS STATUS SETUP

Zero
This is the output low-scale value, where the user enters the current low-scale set point
corresponding to 4 mA DC for the output. For example, if Current Out 1 Zero = 0 ppm,
Output 1 would read 4 mA at 0 ppm.

Type
This allows you to select the output value range, either 4–20 mA DC or 0–20 mA DC for
the output. Select ‘0’ for 4–20 mA DC or ‘1’ for 0–20 mA DC.

Over Range
When enabled, output readings of 3.8 and 20.5 mA will occur if the analyzer exceeds 4-20
mA.

Controller / User Interface | 4-25

 To change the settings for a current output:

1. Enter a password to allow changes to be made to the current output

settings.

2. Select one of the Current Output (1–8) sub-menus. Press ENTER to view the
Current Output screen.

3. Select the required parameter ( Source, Full, Zero, Type, or Over Range), change
the settings, and press ENTER.

Repeat this step for each parameter and each output.

When entering a value for the Full and Zero parameters:

• Use the UP/DOWN arrow key to increase/decrease the value in increments

of one (1.00). This works best for minor changes. The range is 0–100. The
current zero-scale set point is displayed on the right side of the screen.

• If a value exists, use the LEFT arrow key as a backspace to 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.

4-26 | IPS-4 Full SpectrumGPDIV2

Setpoints

The Setpoints screens (Figure 4-20 thru 4-23) allow you to view configured normal oper-
ating (factory set) parameters for span, pressure, and temperature low/high limits.

Setpoints
> Span Limits
Pressure Limits
Temperature Limits

Figure 4-20.
Setpoints Screen. HOME ALARMS STATUS SETUP

Span Limits
If Span limits are exceeded, calibration is required.

Pressure Limits
If pressure limits are exceeded, the system alarm will activate and the analyzer will go
into “Not Ready” state. Limits are disabled if set to 0.

Temperature Limits
If temperature limits are exceeded, and in some heated applications, the system alarm
will activate and the analyzer will go into “Not Ready” state.

Heater set point should not exceed 190º.

! Cell set point should not exceed 150º.
CAUTION

Span Limits
uSpan Limit Low 1 0.90
Span Limit High 1 1.10

Figure 4-21.
Span Limits
Setpoints Screen. HOME ALARMS STATUS SETUP

Pressure Limits
uCell Pres High Limit 142-15.2 PSI
Cell Pres Low Limit 142-15.2 PSI
Pres X 2 High Limit 0 PSI
Figure 4-22. Pres X 2 Low Limit 0 PSI
Pressure Limits Manifold Pres High Limit 70-100 PSI
Setpoints Screen. ˜ HOME ALARMS STATUS SETUP

Temperature Limits
uBench Deviation Limit 2º C
Bench Set Point 50º C
Heater Deviation Limit 0º C
Figure 4-23. Heater Set Point 190º C
Temperature Limits
Setpoints Screen. ˜ HOME ALARMS STATUS SETUP

Controller / User Interface | 4-27

 Diagnostics Screen

The diagnostics screen (Figure 4-24) 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 4-24.
Diagnostics Screen.
HOME ALARMS STATUS SETUP

Current Output Diagnostics

Test analog outputs.

Current Output Diagnostics

> Current Output 1 Diagnostics
Current Output 2 Diagnostics
Figure 4-25. Current Output 3 Diagnostics
Current Output Current Output 4 Diagnostics
Diagnostics
Diagnostics Screen. HOME ALARMS STATUS SETUP
Current Output 1 Diagnostics
uDiagnostics State Off
Current Output 1 61%
Figure 4-26. Type 4-20 mA
Current Output Over Range Disabled
Diagnostics
Diagnostics Screen. HOME ALARMS STATUS SETUP

Relay Diagnostics
Force relay contacts on or off to test the hardware.

Relay Diagnostics
uDiagnostics State Off
Relay 1 On
Relay 2 On
Figure 4-27. Relay 3 On
Relay Diagnostics Relay 4 On
Diagnostics Screen. HOME ALARMS STATUS SETUP

4-28 | IPS-4 Full SpectrumGPDIV2

Valve Diagnostics
Force valve contacts on or off to test the solenoid valves.

Valve Diagnostics
uDiagnostics State Off
Valve 1 On
Valve 2 Off
Figure 4-28. Valve 3 Off
Valve Diagnostics Valve 4 Off
Diagnostics Screen. HOME ALARMS STATUS SETUP

Lamp Diagnostics
Monitor detector operation for a given wavelength.

Lamp Diagnostics
uWavelength 0.0
Measurement 16804
Dark Read 16718
Figure 4-29. Absorbance 0.1
Lamp Diagnostics Pixel 0
Diagnostics Screen. HOME ALARMS STATUS SETUP

Controller / User Interface | 4-29

 System Settings Screen

The System Settings screen (Figure 4-30) allows the user to view and/or setup analyzer
system parameters.

> Log in/Set Passwords

Backup/Restore
Ethernet Network
System
Customization
Figure 4-30.
System Settings HOME ALARMS STATUS SETUP
Screen.

Login/Set Passwords Screen

The Login/Set Password screen (Figure 4-31) allows you to set up password protec-
tion for users who need access to modify analyzer configuration parameter settings, or
restrict users to read-only function. The analyzer 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.

When you first power up the analyzer, or following a system reset, the software secu-

u Enter Password
Change Password
Lock

Figure 4-31.
Login/Set Password
screen. HOME ALARMS STATUS SETUP

rity level defaults to read-only mode – you will have to re-enter the password to allow
changes. Password protection can also be removed, as described under “Removing the
Password.”

When a password has been entered, the software will remain in Edit (read-write) mode
as log as the user is working from the User Interface Panel. If no keys are pressed within
10 minutes, the software will revert to read-only mode. The password will have to be re-
entered before further changes can be made.

Enter Password
Use this function to enter a password that will allow you to make changes to many of the
analyzer configuration settings, or to perform calibration and other functions. Because
the analyzer is shipped from the factory without a password, you must first enter a pass-
word in the Change Password function. Record and store the password in a safe place
for reference.

4-30 | IPS-4 Full SpectrumGPDIV2

If you attempt to enter a password but one hasn’t been entered in the Change
Password function yet, the message “Use Change Password to enable” is displayed.

If you enter a password incorrectly, the message “Password incorrect” is displayed. If a

password has been entered here, and you press ENTER, the message “System Unlocked”
is displayed.

Change Password
Use this function to enter a password for the first time after installing the analyzer or
whenever you are changing the password. The password entered here is the password
that must be entered in the Enter Password function that will allow you to change the
analyzer configuration settings.

Because the analyzer is shipped from the factory without a password, you must enter a
password in the Change Password function before you can change parameter settings.
If you attempt to change the password without first entering the password, the message
“System Locked” appears.

Keys that can be used to enter a password include any of the numeric keys (0–9), deci-
mal key ( . ), and the minus ( – ) key. A maximum of nine characters can be used for the
password.

Lock
Use this functions to clear the password from memory and “lock” all parameters, set-
tings, and functions as read-only. When you select Lock and press ENTER, the param-
eters are locked out and the message “System locked” is displayed. When the system is
locked, a padlock icon ( ) appears in the top-right corner of the HOME screen.

Changing the Password

Occasionally, you should change the password that allows you to make changes to the
analyzer configuration settings. If password protection already exists, you must enter the
existing password before you can change it.

To change the password:

1. Select Enter Password and press ENTER. Key in the password and press EN-
TER again. The software will now allow you to change the password.

2. Select Change Password and press ENTER. Key in the new password and
press ENTER. Record and store the password in a safe place for reference.

Controller / User Interface | 4-31

 Locking the Password

Use the Lock function to disable the password from the current session. This reverts all
analyzer functions to read-only. Changes to the analyzer settings cannot be made until
the password is entered again.

To lock out all users:

Select Lock and press ENTER. The message “System Locked” appears. A padlock icon ap-
pears on the top-right side of the HOME screen to indicate the system is currently locked
from making any changes.

Removing the Password

To remove password protection:

1. Select Enter Password and press ENTER. Key in the password and press EN-
TER. The software will now allow you to remove the password.

2. Select Change Password and press ENTER. Leave the password blank and
press ENTER again. The password is removed.

Backup/Restore Settings Screen

The Backup/Restore screen (Figure 4-32) allows you to back up the current analyzer con-
figuration settings, restore previously saved analyzer configuration settings, or restore
analyzer configuration parameters to their original factory-shipped settings.

If major changes are made to the analyzer configuration settings, it is important to

! make a backup copy of these settings. This file can then be used to restore all param-
NOTE eters to their most recently used settings or the factory-default settings in the event of
a serious internal system error.

u Backup settings
Restore settings
Restore factory settings

Figure 4-32.
Backup/Restore
Settings screen. HOME ALARMS STATUS SETUP

4-32 | IPS-4 Full SpectrumGPDIV2

Backup settings
Saves the current analyzer configuration settings to a file that can later be used to restore
these settings. The settings are stored in a file called “[Link].” See “Backing Up Analyz-
er Configuration Settings” for details about how to save configuration settings to a file.

Restore settings
Retrieves and restores the most recently saved analyzer configuration settings from the
“[Link]” file. See “Restoring Analyzer Configuration Settings” for details about how to
restore configuration settings.

Restore factory settings

Retrieves and restores the original factory-set analyzer configuration settings from the
“[Link]” file. See “Restoring Analyzer Configuration Settings” for details about how
to restore configuration settings.

Backing Up Analyzer Configuration Settings

To back up configuration settings:

1. Press the SETUP soft key and then use the DOWN arrow to scroll down until
the Backup/Restore sub-menu is selected. Press ENTER to view the Backup/
Restore screen.

2. Select Backup settings and press ENTER. The software will prompt: “Backup
settings. Are you sure?” (Figure 4-33).

•Press CANCEL (X) to answer no.

•Press ENTER (8 ) to answer yes. The analyzer begins backing up its

current configuration settings to a file called “[Link].” The message
“Please wait ...” appears while the analyzer backs up its settings.

Backup settings. Are you sure?

Press 8 for yes.
Press X for no.
Figure 4-33.
Backup Settings
screen. HOME ALARMS STATUS SETUP

Restoring Analyzer Configuration Settings

To restore configuration settings:

1. Press the SETUP soft key and then use the DOWN arrow to scroll down until the
Backup/Restore sub-menu is selected. Press ENTER to view the Backup/Restore screen.

Controller / User Interface | 4-33

 2. Select the appropriate type of file restoration:

• Select Restore settings if you wish to restore settings you last saved using
the Backup settings command.

• Select Restore factory settings if you wish to restore settings to the factory
default settings.

3. Press ENTER to initiate the command to restore the settings. The software will
prompt: “Restore settings. Are you sure?” (Figure 4-34) or “Restore factory
settings. Are you sure?” (Figure 4-35).

•Press CANCEL (X) to answer no.

• Press ENTER (8 ) to answer yes. The analyzer begins restoring configuration

settings from a file stored in the analyzer. The message “Please wait ...” ap-
pears while the analyzer restores its settings.

- If you selected Restore settings, the analyzer begins restoring its most
recently saved configuration settings (when the Backup settings com-
mand was last used) from a file called “[Link].”

- If you selected Restore factory settings, the analyzer begins restoring

the original factory default configuration settings from a file called
“[Link].”

After the settings have been restored, the analyzer enables the settings.

Recycle power to the Analyzer..

Restore settings. Are you sure?

Press 8 for yes.
Press X for no.
Figure 4-34.
Restore Settings
screen. HOME ALARMS STATUS SETUP

Restore factory settings. Are you sure?

Press 8 for yes.
Press X for no.
Figure 4-35.
Restore Factory
Settings screen. HOME ALARMS STATUS SETUP

4-34 | IPS-4 Full SpectrumGPDIV2

Ethernet Network Screen

The Ethernet Network screen (Figure 4-36) allows the user to enter Ethernet 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 configuration settings. For addresses, contact your net-
work administrator.

When changing the IP Address, IP Subnet Mask, and Gateway IP address, use the
numeric keys to enter a new value. When a period ( . ) character is necessary, after every
third digit of an address, the system will only accept input from the decimal key ( ‘.’ ).
Use the LEFT arrow key as a back space and to delete numerical characters to the left of
the cursor, or the RIGHT arrow key to advance to the right of the cursor.

u Ethernet Enable Enabled

DHCP Enable Disabled
IP Address ##.##.###.#
IP Subnet Mask ###.###.#.#
Figure 4-36. Gateway ##.##.#.#
Ethernet Network MAC address ##-##-##-##-##-##
screen. HOME ALARMS STATUS SETUP

Ethernet enable
Allows the user to enable or disable the Ethernet interface, to allow communication be-
tween the analyzer and network. This should be set disabled when the Ethernet is not in
use to prevent unauthorized network access.

To change this, press ENTER to enter Edit mode and then use the UP/DOWN arrow
keys to toggle between Enabled or Disabled.

DHCP enable
Allows the user to enable or disable the DHCP (Dynamic Host Configuration Protocol)
client. This function should be disabled to ensure the network uses a static address. The
DHCP server must be on the same Subnet as the analyzer.

IP Address
Defines the network of the analyzer. This is a required parameter. To change this, press
ENTER to enter Edit mode and change this address.

IP Subnet Mask
A TCP/IP number used to determine to which the TCP/IP Subnet device belongs. Devices
in the same Subnet can be communicated with locally without going through a router.
This is a required parameter.

Controller / User Interface | 4-35

 To change this, press ENTER to enter Edit mode and change this address. This address
must be set to at least [Link].

Gateway (optional)
A Gateway (or “Router”) is a device which is used to forward IP packets to a remote des-
tination. The definition of “remote,” in this case, is a device that is not directly attached to
the same network segment as the sending device (e.g., the same Ethernet segment). This
function defines the Gateway IP address for the network, which allows local network
traffic to be sent to another network.

Setup of this parameter is required only if communicating from outside the internal net-
work. To change this, press ENTER to enter Edit mode and change this address.

MAC address
Defines the MAC (Media Access Control) address (unique byte number) of the analyzer
(e.g., 00-0F-88-00-00-79). The MAC address is factory-set. This address is read-only.

To set up Ethernet parameters:

For specific requirements for permanent Ethernet connections, refer to “Permanent

! Ethernet Cable Connections (Optional)” in Chapter 3.
NOTE

1. Ensure the Ethernet cable is connected.

2. Enter a password to allow changes to be made to the analyzer configuration

settings.

3. Press the SETUP soft key and then scroll down and select Ethernet Network.
Press ENTER to view the Ethernet Network screen.

4. Enter the IP Address, IP Subnet Mask address, and Gateway IP address (if
required), pressing ENTER after entering each address.

5. Ensure the DHCP server is on the same server as the analyzer.

6. Press CANCEL to back out of this sub-menu.

7. Reset the analyzer to allow the changes to take effect.

4-36 | IPS-4 Full SpectrumGPDIV2

System Screen

The System screen (Figure 4-37) allows the user to view and/or set up analyzer system
parameters.

Model Name, Serial Number, and Software Version are not editable, as indicated by the
‘>’ cursor.

System Time and System Date are editable, as indicated by the ‘u’ cursor. To enter Edit
mode for either of these parameters, press ENTER and then press the appropriate nu-
meric character. You can also use the 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
System Time [Link]
System Date 07/11/2005
Figure 4-37.
System screen. HOME ALARMS STATUS SETUP

Model Name
This displays the Analyzer Model name.

Serial Number
This displays the analyzer serial number.

Software Version
This displays the analyzer software version.

System Time
The System Time clock is used for time-stamping various analyzer functions
(such as alarms).

To set the time, use the RIGHT/LEFT arrow key to select hours, minutes, and sec
onds and then either the UP/DOWN arrow key or numeric keys to enter the time.
When using the numeric keys to enter a value (while setting the time), the
cursor (the active, editable character) will move one character to the right
and skip over the colon ( : ) character.

System Date
The System Date is used for date-stamping various analyzer functions (such as
alarms). The format is defined by the Date format setting on the Customization
screen.

To set the date, use the RIGHT/LEFT arrow keys to toggle between day (DD), month
(MM), and year (YY) and the UP/DOWN arrow key to set the day, month, and year. When
using the numeric keys to enter a value, the cursor (the active, editable character) will
move one character to the right after each input.

Controller / User Interface | 4-37

 Customization Screen

The Customization screen (Figure 4-38) allows the user to view how information is dis-
played.

To customize how the analyzer displays information, use the UP /DOWN arrow key to
select an item and then press ENTER to go into Edit mode. Then, press the UP or DOWN
arrow key to scroll through the list of options and press ENTER to select the option.

Parameters on this screen include:

Date Format
Defines the format for displaying the date, which is displayed on the System screen.
Format options include:
- MM/DD/YYYY - DD/MM/YYYY
- DD-MM-YYYY - MM-DD-YYYY

u Date Format: MM/DD/YYYY

Decimal Point Period
Language English
Menu Home Time 60 min
User Time-out 300 min
Figure 4-38. Screen Brightness 75%
Customization screen. HOME ALARMS STATUS SETUP

Decimal point
Defines the format for displaying the decimal point in a value:
- Period (example, 3.14)
- Comma (example, 3,14)

Language
Defines the language in which the software descriptions will be displayed. To view the
software in a language other than the default English, select Language, press ENTER,
then use the UP/DOWN arrow keys to scroll through the list until you locate the language
of choice. Press ENTER again to select the language.

Available languages for viewing the software include:*

- English - German
- Russian - French
- Spanish

*For Customer software applications, all languages may not be available.

Menu Home Time

This displays and allows you to change the time an inactive menu will display before it
returns to the home screen.

4-38 | IPS-4 Full SpectrumGPDIV2

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.

Modbus Screen

The Modbus screen (Figure 4-39) allows the user to view and/or set up Modbus param-
eters to enable the analyzer to communicate with the Modbus master.

Baud
This displays and allows you to change the current Baud Rate at which data will be
transferred using Modbus communications. The typical default is 9600. Other options
include 115200, 57600, 38400, 19200.

Parity
This displays and allows you to change the current Parity setting used for Modbus com-
munications. The typical default is even. Other options include odd or none.

u Baud: 9600
Parity even
Stop Bits 0
Modbus Address 1
Modbus Timeout 3000 msec
Figure 4-39. Modbus Port Off
Modbus screen. HOME ALARMS STATUS SETUP

Stop Bits
This displays and allows you to change the current Stop Bits setting used for Modbus
communications. The typical default is 0. It can also be set to 2.

Modbus Address
This displays and allows you to change the address assigned for Modbus communica-
tions. Valid addresses are 1–247. Setting the address to zero (‘0’) disables Modbus.

Modbus Timeout
This displays and allows you to change the time out value (duration) that the software
will use to attempt to establish communications with the analyzer when using Modbus
communications. AMETEK recommends a value of 1000 ms.

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.

Controller / User Interface | 4-39

 To change these parameters:

1. Select the parameter you wish to change and press ENTER to go into Edit
mode.

2. For Baud, Parity, and Stop Bits, use the UP/DOWN arrow key to scroll through
the available options. To select an option when it is displayed, press EN-
TER.

For Modbus Address and Modbus Timeout, enter a value using the numeric
keys.

3. Reset the analyzer to allow the changes to take effect.

4-40 | IPS-4 Full SpectrumGPDIV2

 MAINTENANCE & TROUBLESHOOTING

The Maintenance & Troubleshooting chapter discusses preventive main-

tenance 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 messages to
diagnose and troubleshoot problems with the analyzer.

Safety Considerations
Before performing any maintenance, service, or troubleshooting on
the analyzer, review and follow all personnel and equipment safety in-
! formation under “Personnel and Equipment Safety Information” fol-
NOTE lowing the Table of Contents near the beginning of this manual. This
information describes procedures to follow to avoid personal injury
and/or damage to the equipment. All regulatory agency and person-
nel safety procedures for your jurisdiction must be followed.

Personnel should be thoroughly familiar with the operation of the

analyzer before performing the maintenance procedures described in
this section.

Maintenance & Troubleshooting | 5-1

 Maintenance
Generally, there is limited maintenance required to ensure the analyzer
remains operating at peak efficiency, other than that described in the “An-
alyzer Preventive Maintenance Schedule.” This section discusses preven-
tive maintenance that must be followed to ensure continued and proper
operation of the analyzer. This section also describes parts that require
replacing and the frequency in which they should be replaced, according
to this schedule.

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.

For Gas Applications:

Plugs in the sample system generally can be avoided by ensuring all
components of the sample system operate at least 10 °C (18 °F) above the
sample dew point temperature. The risk of developing a collection of
liquids in low spots or plugging in the sample system is further reduced
by sloping the Sample Line to the analyzer and the Vent Line back to the
sample stream or other dispersal method.

Preventing leaks in the sample handling system is critical to proper

! analyzer operation. The analyzer sample system must be leak checked
CAUTION whenever it has been dismantled for maintenance or repair. Refer to
“Sample System Leak Check” in Chapter 3 for details.

The “Analyzer Preventive Maintenance Schedule” suggests actions and

their frequency when caring for the analyzer. Procedures and exploded-
view drawings that are intended to assist you when changing out parts
can be found in appropriate sections later in this chapter or in a Manual
Supplement which is included in the “Supplemental Information”section of
this manual and the Documentation Package shipped with the analyzer.

5-2 | IPS-4 Full Spectrum GPDIV 2

Analyzer Preventive Maintenance Schedule

Frequency Task
As required Clean the Analyzer
Cleaning the exterior of the analyzer is required occasionally to re-
move dust and other debris. Use a damp cloth to clean the analyz-
er’s exterior, including the User Interface Panel screen.
Daily Check for Alarms
To view alarms, press the ALARMS soft key to view the Alarms
screen.

To view active alarms, select Current Alarms and press ENTER. For
detailed information about these alarms, refer to the alarm condi-
tions and corrective action in the “Troubleshooting and Diagnostics”
section of this chapter.

Check the history buffers to see if alarms are recurring. The history
buffers contain alarms that have been reset. To view a history of
alarms that were set by the analyzer but have since been reset,
select Alarm Log and press ENTER. If there is a history of alarms
that have been reset, the alarm descriptions are displayed. If there
is no history of alarms, “Log empty” is displayed. To scroll through
the list, use the UP/DOWN arrow key.
Monthly Zero the Analyzer / Check Analyzer Response Time
Manually Zero the analyzer (from the Calibration screen, select
Start zero calibration and press ENTER).

After the Zero is complete, determine the sample response time by

switching the analyzer back to Measure mode (from the Calibra-
tion screen, select Start measure and press ENTER). Press the
HOME soft key to return to the HOME screen.

Observe the readings and record the time it takes the analyzer to
display the first reading after the switch. Typically, a good response
time is less than 30 seconds to T90. Check your log book to verify
response times. A response time that is slower than normal may
suggest plugging problems in the analyzer sample system.

Refer to “Manually Zeroing the Analyzer Sample System” and “Ad-

justing the Sample Flow Rate” in Chapter 3. Also, refer to “Locating
a Plug in the Sample System” in this chapter for more information.
Monthly Temperature-Control Zones
Check the operating temperatures of all temperature-control zones
to ensure they are all within 5 °C (typical; set point may vary) of
their set points. Temperature deviations can be set to alarm. Re-
cord and compare the current temperatures to the actual settings.

Maintenance & Troubleshooting | 5-3

 Frequency Task
Monthly Pressure Readings
Check the Aspirator, Pneumatic Valve/Zero, and Manifold pressure
readings from the STATUS screen.

Aspirator pressure should be set higher than 70 kPa (10 psi) above
the sample stream pressure.

Pneumatic Valve/Zero supply pressure should be set in the range

of 420–560 kPa (60–80 psig), typically 560 kPa (80 psig) for high
pressure applications. For the Zero supply, the pressure should be
set to approximately 140 kPa (20 psig) above the sample stream
pressure.

Manifold pressure should be set approximately 560–700 kPa

(80–100 psig). Refer to “Adjusting the Sample Flow Rate” in Chap-
ter 3 for more details.

CAUTION:
To avoid damaging the pressure transducer, do not set the pressure
higher than the Cell pressure transducer rating. See drawing pack-
age for maxium pressure ratings.

Every Three Months Outdoor Systems

If your analyzer system is installed outdoors, check the condition
of the seals on the doors. These seals are essential in the analyzer
maintaining its IP65 and NEMA 4 rating.

The secondary gaskets (with the wire mesh) on the door are used
for electrical contact between each door and its enclosure. Ensure
these gaskets are intact.

If the seals are damaged, cracked, or show signs of wear, replace

them immediately. Contact AMETEK for assistance.

Frequency Task

Every Six Months Sheltered Systems

If your analyzer system is installed in a custom shelter, check the
air filters for the shelter purge and air conditioning systems and
replace them if necessary. Depending on the location of the site
and its environmental conditions, it may be necessary to check and
replace these filters more frequently.
Every Six Months Sample/Vent Lines
Inspect the Sample Line and Vent Line for sags, sharp bends, or
damage to the outer skin. If necessary, take appropriate safety pre-
cautions and replace the lines. Perform a leak check on all associ-
ated fittings after replacing any line(s).
Every Year Measuring Cell
Clean the Measuring Cell and the rest of the analyzer sample sys-
tem. This schedule is a minimum requirement. If other conditions
are found to be present, as outlined in this chapter under “Measur-
ing Cell Preventive Maintenance,” cleaning may be required more
frequently.

At the same time, replace the o-rings (always) and windows and/or
window/mirror combinations (if chipped, cracked, or scratched).

5-4 | IPS-4 Full Spectrum GPDIV 2

18–24 Months Xenon Flash Lamp
Replace the lamp. The lamp may need to be replaced sooner if
information from the analyzer diagnostics indicates related alarms.
Refer to “Replacing the Xenon Flash Lamp Assembly” in this chap-
ter.
36 Months Infrared Source
Replace the source. The source may need to be replaced sooner if
information from the analyzer diagnostics indicates related alarms.
Refer to “Replacing the Infrared Source Assembly” in this chapter.

Before Performing Maintenance

Under normal operating conditions, lethal concentrations of H2S
! or other toxic gases/liquids from the sample stream may be present
WARNING within the analyzer sample system.

Before working on the sample system, manually Zero the analyzer

(from the Calibration screen, select Start zero calibration and press
ENTER), isolate it (block it in) from the sample stream, and disconnect
the main AC power. This procedure is necessary prior to changing out
any analyzer components or replacing any replaceable parts (as part
of regular preventive maintenance), or performing leak checks follow-
ing the replacement of instrument air or other adjustments to any of
the connections points in the analyzer sample system. If this is not
possible, a breathing apparatus must be worn while servicing
the sample system.

The sample system is defined as all components in the analyzer sys-

tem through which sample fluid passes.

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. Leaks are potentially dangerous and will even-
tually lead to corrosion problems.

Detecting a Plug in the Sample System

This is best done by observing the analyzer measurement response time

immediately following a Zero function. A typical response is less than 30
seconds to T90. Observe your analyzer and learn what a normal response
time is. Use the recorded response time as a reference for detecting the
formation of plugs in the sample system.

Maintenance & Troubleshooting | 5-5

 If the sample response time is longer than normal, it is most likely due
to plugging somewhere in the sample system. The next step is to locate
and remove the plug. The portion of the sample system with the high-
est risk of plugging is the sample inlet and the portion of the sample inlet
most prone to plugging is the valve on the sample probe or process tap.
One way to confirm that a plug is in the sample inlet is to close the Vent
Line Shut Off valve (in the Oven/Sample System Enclosure) and Zero the
analyzer.

Observe the Cell Pressure reading from the STATUS screen, and if the
reading approaches the Zero fluid supply pressure, a plug is present
somewhere in the sample inlet.

To avoid damaging the pressure transducer, do not set the pressure

! higher than the sample system rating.
CAUTION

After confirming that the plug is somewhere in the sample inlet, take
! all appropriate safety precautions and dismantle the sample system,
NOTE starting at the Sample Probe or process tap.

Plugs in the vent side of the sample system are rare. Plugs in the vent sys-
tem cause the aspirator drive air to flow back into the Measuring Cell and,
essentially, simulate a Zero condition.

Preventing a Plug in the Sample System (Gas Applications)

This is done by supplying and maintaining the necessary heat and insula-
tion to the sample system.

Check current operating temperatures and compare them to the set point
temperatures for each temperature zone.

To check the analyzer sample system for possible plugging:

1. While working from the User Interface Panel, manually force the
analyzer to continuously backflush the sample system with Zero fluid
(Zero Gas Flush mode).

2. The flow indicator should be in the centre of the meter for an optimal
flow rate.

3. Close the Sample Valve on the Sample Probe. Observe the flow indica-
tor. If the flow reduces to a stop, a large plug has occurred somewhere
in the sample system.

Open the Sample Valve on the Sample Probe.

5-6 | IPS-4 Full Spectrum GPDIV 2

4. Close the Vent Line Shut Off valve (in the Oven/Sample System Enclo-
sure). Observe the flow indicator. If the flow reduces to a stop, a large
plug has occurred somewhere in the sample system.

5. After locating the cause of the restriction or plug (and after cleaning
or replacing the part or line), leak test the fittings or connections that
were loosened or replaced. To do this, follow the procedures under
“Sample System Leak Check” in Chapter 3.

6. Return the Vent Line Shut Off valve to the open position. Both isola-
tion valves should be open.

7. After the Zero is complete, determine the sample response time by

switching the analyzer back to Measure mode (from the Calibration
screen, select Start measure and press ENTER). Observe the readings
and record the time it takes the analyzer to display the first reading
after the switch. The recorded values can be used later as a reference
while testing response time.

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. Drawings of the assembly are also included under each section.

Preventing leaks in the sample system is critical to ensure proper

analyzer operation. If sample fluid migrates into the Optical Bench
! Assembly or Reflector Block due to a leak in the Measuring Cell
CAUTION Assembly, the optics will become damaged and most likely require
replacement. Most leaks are preventable with regular cleaning and
replacement of the Measuring Cell o-rings.

If the User Interface Panel displays alarm messages that indicate a

faulty component requires replacement [as described under “Alarm
! Conditions and Corrective Action” later in this chapter], review this
manual for replacement procedures.
CAUTION
For complex maintenance procedures not discussed in this manual,
such as replacing heaters, RTDs, or electronics boards, consult with
your AMETEK distributor or representative.

Maintenance & Troubleshooting | 5-7

 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” section of this manual and the Documen-
tation Package shipped with the analyzer.

• Set of open-end wrenches for fittings and set of metric ball drivers.

• O-ring removal tool.

• Flat blade instrument screwdriver.

• Soft, non-abrasive cloth to place Cell interior parts on.

• Kimwipes® EX-L or an equivalent extra low-lint tissue to clean the

front and back sides of the Windows.

If the Windows require a more thorough cleaning, a high purity sol-

vent such as Isopropanol (99 %) can be used (if suitable for use with
removing contamination).

• Cotton swabs, to clean the interior of the Cell Body and other metal
parts.

If the Cell requires a more thorough cleaning, use only non-abrasive

cleaning materials that are suitable for use with the sample species
and the Cell.

For example:
If suitable for the species, an acceptable material is Chem-Thane – or a
nonabrasive detergent and water solution. Reagent-grade acetone (if
suitable), can then be used to rinse the Cell Body, followed by a rinse
with pharmaceutical-grade distilled water.

• Pharmaceutical-grade distilled water, to rinse all Cell parts.

• Reagent-grade acetone as a secondary cleaner for the interior of the

Cell Body and other metal parts (must be suitable for use with the
sample species).

5-8 | IPS-4 Full Spectrum GPDIV 2

 Actual layout and components may vary. Refer to customer-specific
! drawings in the “Supplemental Information” section of this manual
NOTE
or the Documentation Package shipped with the analyzer.
Figure 5-1.
Analyzer component
layout details.

Maintenance & Troubleshooting | 5-9

 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. While the Measuring Cell is disassem-
bled, clean its chambers and parts.

More frequent cleaning may be required if the sample fluid contains

! excessive contaminants.
NOTE

Clean the Measuring Cell and its windows:

• If the analyzer responds slowly to zero when the sample system is free
of restrictions, or

• If evidence of contamination is present in the Sample Line and/or Vent

Line, or

• Every year as indicated in the “Analyzer Preventive Maintenance

Schedule.”

Replace the o-rings/windows in the Measuring Cell:

• If, during an unscheduled cleaning (see cleaning requirements above),

the Measuring Cell Windows are found to be damaged (scratched,
cracked, or chipped).

Replace the o-rings in the Measuring Cell every time this assembly is
apart.

• Every year as indicated in the “Analyzer Preventive Maintenance

Schedule.”

This procedure is based on a 40 cm Measuring Cell. For other Cells,

! refer to the Measuring Cell Manual Supplement in the “Supplemen-
tal Information” section of this manual and the Documentation Pack-
NOTE
age shipped with the analyzer.

O-ring part numbers can vary, depending on the application. Verify

all part numbers before ordering/replacing.

When cleaning the Cell and/or other sample system components,

! use only cleaning materials that are suitable for use with the
WARNING sample species.

5-10 | IPS-4 Full Spectrum GPDIV 2

To clean the Measuring Cell and replace its o-rings:

1. Manually zero the analyzer for 10 minutes.

2. After the zero is complete, close the Sample Line and then the Vent
Line Shut Off valves (in the Oven/Sample System Enclosure) to isolate
the analyzer from the sample stream.

3. Power down the analyzer:

Hazardous Location applications:

If an external, flame-proof disconnect switch (breaker) has been
installed, open the breaker. If no external breaker has been installed,
follow the power down procedure for “General Purpose (GP) Applica-
tions,” below.

Before proceeding, test the area around the analyzer for flammable
gases. If a flammable gas atmosphere is present, do not power down
! the analyzer or any alternate power sources that supply power to the
WARNING analyzer components. Proceed only when the area is found to be safe.

General Purpose (GP) applications:

Open the Electronics Enclosure door and disconnect AC power from
the analyzer and its temperature-control zone circuitry by opening the
Main AC Power, DC Power, Bench Heater, and Oven Heater (if used)
fuses. Refer to the Fuse Legend at the back of the Electronics Enclo-
sure for the locations of these fuses.

For all applications:

! Wait 2 minutes to allow the high-voltage capacitors to discharge.
WARNING

For all applications:

! If heated Sample and Vent Lines are used, disconnect power to them.
NOTE

4. If the Oven/Sample System Enclosure is heated:

Wear insulated gloves and open the door to allow the Oven to cool
down enough to ensure safe handling.

! The components within the enclosure will be hot; take precautions to

avoid burning yourself.
WARNING

Maintenance & Troubleshooting | 5-11

 CELL BODY CELL PLATE
SCREW 20 CM SHOWN 100-2015
300-1671
(2 PLS)
CELL WINDOW
APLLICATION SPECIFIC
(2 PLS)

REFLECTOR BLOCK

SCREW
300-8430
(3 PLS)

O-RING
MIRROR (2 PLS) FITING APLLICATION SPECIFIC
272285001 (IR) 203336018 (4 PLS)
403007001 (UV) (2 PLS)

O-RING
300-2361 (2 PLS)

MIRROR CAP
300-1261 (2 PLS)

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 of this
! manual for a Measuring Cell Manual Supplement and for application-
specific spare parts, either in the Measuring Cell Manual Supplement
NOTE or in a Custom Spare Parts List.

5-12 | IPS-4 Full Spectrum GPDIV 2

5. Removing/cleaning parts in the Measuring Cell:

The analyzer sample system will be under positive pressure.

!
WARNING
Various lengths of screws are encountered while disassembling the
Measuring Cell Assembly. Take note of where each length is used and
be sure to replace the screws in their original locations when reassem-
! bling these parts later.
NOTE

a. Disconnect the Sample Line and Vent Line tubes from the Cell.

Loosen and remove the Cell RTD (if used) from the RTD Clamp
(not shown) on the Cell.

Disconnect all other sample system parts/tubing to allow removal

of the Cell.

b. Note the position of the Cell and its Sample/Vent fittings and Re-
flector Block.

Remove the three screws that secure the Cell to the Window
Housing Assembly (not shown). Carefully pull the Cell straight out
from the Window Housing and place it on a work bench or other
suitable location to work on the removed cell.

If the Oven/Sample System Enclosure is heated, close its door to

help maintain the temperature inside the enclosure while working
on the Cell.

! In the next steps use a soft, non-abrasive cloth to place the Cell parts
on.
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.

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. Set the Window aside on a soft, non-abrasive cloth.

d. While holding the Cell vertically so that the Reflector Block end is
up, remove the three M4 x 20 mm screws that secure the Reflector
Block to the Cell. Remove the Reflector Block carefully to ensure
the Cell Window behind it does not drop out.

e. With the Reflector Block end up, carefully remove the o-rings and
Cell Window from the Cell.

Maintenance & Troubleshooting | 5-13

 Inspect the Windows for any chips, cracks, or scratches. If they are
not damaged, they can be cleaned and reused; set them aside on a
soft, nonabrasive cloth.

If the Windows are suitable for reuse, use Kimwipes® EX-L or an

equivalent extra low-lint tissue to clean the front and back sides. A
high purity solvent, such as Isopropanol (99 %), may also be used
(if suitable for use with the sample species). Rinse with pharma-
ceutical-grade distilled water.

! Replace chipped, cracked, or scratched Windows when reassembling

the Cell.
CAUTION

f. Systems with a Cell RTD:

Note the position of the Cell RTD Clamp (see Cell RTD in Figure
5-1) and remove it from the Cell.

g. Inspect the interior of the Cell Body for foreign material. If neces-
sary, use a cotton swab to clean the Cell Body.

If a more thorough cleaning is required, use only cleaning materi-

als that are suitable for use with the sample species and the Cell.

Clean the fittings using the same method as the Cell Body.

For example:
If suitable for the species, an acceptable material is Chem-Thane –
or a nonabrasive detergent and water solution. The Cell Body can
then be rinsed with reagent-grade acetone (if suitable), followed
by a rinse with pharmaceutical-grade distilled water.

h. Allow all components to dry thoroughly before reassembling. Dry,

oil-free instrument air can be used to remove any remaining mois-
ture from the passages in the Cell Body and fittings.

6. Replacing parts/reassembling the Measuring Cell:

a. Insert a new o-ring in the o-ring groove on the flat surface of the
Reflector Block.

With the Cell held vertically so that the Reflector Block end of the
Cell is up, install a new o-ring by using your thumbs to push it
into the o-ring groove until it is completely seated in the groove.

While holding the edge of the Window, carefully place it in the

Cell.

Orient the Reflector Block correctly, and place it on the Cell.

Ensure the Cell Window does not slide out of position when the
Reflector Block is placed against the Cell.

5-14 | IPS-4 Full Spectrum GPDIV 2

 It is critical to reassemble the Reflector Block in the exact orientation
! as it was assembled at the factory.
CAUTION

Secure the Reflector Block to the Cell using three M4 x 20 mm

screws. Tighten the screws evenly.

b. With the Cell held vertically so that the Reflector Block end is
down, install a new o-ring by using your thumbs to push it into
the o-ring groove until it is completely seated in the groove.

While holding the edge of the Window, carefully place it in the

Cell, on top of the o-ring. Install a second, new o-ring on top of the
Window.

If an Optical Bench/Cell Insulator is used, properly align it and

secure it to the Cell using the three M4 x 12 mm screws.

c. Systems with a Cell RTD:

Replace the RTD Clamp on the Cell but do not tighten it until the
Cell is in place in the Oven/Sample System Enclosure.

7. Properly orient the Cell in the Oven/Sample System Enclosure and

secure it to the Window Housing Assembly using the three M4 x 40
mm screws. Tighten the screws evenly.

8. Reconnect the Sample Line and Vent Line tubes to the Cell.

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.

9. Take all necessary precautions to safely power up the analyzer and

prepare it for operation:

When the analyzer doors are open, take appropriate precautions to

! avoid electrical shock. Hazardous voltages are present inside.
WARNING

Hazardous Location Applications:

If an external, flame-proof disconnect switch (breaker) has been
installed, close the breaker. If no external breaker has been installed,
follow the power up procedure for “General Purpose (GP) Applica-
tions,” below.
For verification and troubleshooting purposes during power up, it
! will be necessary to work with the analyzer doors open.
NOTE

Maintenance & Troubleshooting | 5-15

 ! Before proceeding, test the area around the analyzer for flammable
WARNING gases. If a flammable gas atmosphere is present, do not apply power to
the analyzer or any alternate power sources that supply power to the
analyzer components. Proceed only when the area is found to be safe.

General Purpose (GP) Applications:

Apply power to the analyzer and its temperature-control zone circuit-
ry by closing the Main AC Power, DC Power, and Bench Heater fuses.

For all applications:

! If heated Sample and Vent Lines are used, do not apply power to them
NOTE until after the Leak Check has been performed.

Do not close the Oven Heater fuse (if used) until after the Leak Check
has been performed.

10. Perform a leak check on all of the fittings that were reconnected. If
necessary, follow the procedure under “Sample System Leak Check,”
in Chapter 3.

After the leak check has been performed and has passed, return to this
procedure and continue with the remaining steps.

11. For applications with heated Sample Systems:

Apply power to the Sample and Vent Line circuitry.

Close the Oven Heater fuse to apply power to the Oven Heater
temperature-control zone circuitry.

Close the analyzer enclosure doors and secure them with their latches
to allow the analyzer to warm up to operating temperature and stabi-
lize. This could take up to 2 hours if this sample system is allowed to
cool completely.

12. Zero and Span (if applicable) the analyzer.

Open the Vent Line Shut Off valve (in the Oven/Sample System En-
closure). Open the Sample Line Shut Off valve to allow sample fluid
into the sample system.

13. Switch the analyzer back to Measure mode (from the Calibration
screen, select Start measure and press ENTER). Press the HOME soft key
to return to the HOME screen.

14. Adjust the Aspirator Pressure Regulator to achieve normal operating

flow rates, as indicated on system drawings. The Flow Indicator (if
used) should be in the centre of the meter for an optimal flow rate.

15. Close and secure the analyzer enclosure doors with their latches.

5-16 | IPS-4 Full Spectrum GPDIV 2

 Infrared Source Assembly Replacement
The typical life span of the Infrared Source is approximately 36 months
of continuous operation. However, the Infrared Source can exhibit signs
of degradation after 12–15 months. When the Infrared Source requires
replacement, the entire assembly (Figure 5-3) is replaced. See Figure 5-1
for the location of this assembly in the Electronics Enclosure.

! Refer to “Optical Bench Assembly Spare Parts” in Chapter 6 for reor-

dering part numbers.
NOTE

Figure 5-3.
Infrared Source
Assembly (700046901)

Maintenance & Troubleshooting | 5-17

 To replace the Infrared Source Assembly:
1. Manually zero the analyzer for 10 minutes.

2. After the zero is complete, close the Sample Line and then the Vent
Line Shut Off valves (in the Oven/Sample System Enclosure) to isolate
the analyzer from the sample stream.

3. Power down the analyzer:

Hazardous Location applications:

If an external, flame-proof disconnect switch (breaker) has been
installed, open the breaker. If no external breaker has been installed,
follow the power down procedure for “General Purpose (GP) Applica-
tions,” below.

Before proceeding, test the area around the analyzer for flammable
! gases. If an explosive gas atmosphere is present, do not power down
the analyzer or any alternate power sources that supply power to the
WARNING
analyzer components. Proceed only when the area is found to be safe.

General Purpose (GP) applications:

Open the Electronics Enclosure door and disconnect AC power from
the analyzer and its temperature-control zone circuitry by opening the
Main AC Power, DC Power, Bench Heater, and Oven Heater (if used)
fuses. Refer to the Fuse Legend at the back of the Electronics Enclo-
sure for the locations of these fuses.

! The Infrared Source runs at elevated temperature. Allow sufficient

time for the source to cool before handling.
WARNING

! For all applications:

If heated Sample and Vent Lines are used, disconnect power to them.
NOTE

4. Disconnect the DC Power Cable circular connector (from the Lamp

Housing) and the 15 pin ribbon cable from the underside of the optical
bench located on the underside of the optical bench assembly. (see
Figure 5-1 for location).

5. Loosen the locking clamp on the circular mount and carefully remove
the optical bench. Remove the bench cover.

6. Disconnect the wires at TB1 located on the Interface PCB (700030901)

assembly.

5-18 | IPS-4 Full Spectrum GPDIV 2

 Remove the two screws holding the Infrared Source Assembly in
place, and slide the assembly from the bench.

7. Insert the new assembly into the optical bench. Coat the three contact
faces with a thin coat of heat-sink compound.

Insert the two screws removed earlier and attach the wires to TB1 pins
three (red) and 4 (black).

8. Replace the cover and slide the bench back onto its mounting stud.
Retighten the locking clamp.

9. Take all necessary precautions to safely power up the analyzer and

prepare it for operation:

Hazardous Location Applications:

If an external, flame-proof disconnect switch (breaker) has been
installed, close the breaker. If no external breaker has been installed,
follow the power up procedure for “General Purpose (GP) Applica-
tions,” below.

Before proceeding, test the area around the analyzer for flammable
! gases. If an explosive gas atmosphere is present, do not apply power to
CAUTION the analyzer or any alternate power sources that supply power to the
analyzer components. Proceed only when the area is found to be safe.

When the analyzer doors are open, take appropriate precautions to

avoid electrical shock. Hazardous voltages are present inside.

General Purpose (GP) Applications:

Apply power to the analyzer and its temperature-control zone cir-
cuitry by closing the Main AC Power, DC Power, Bench Heater, and
Oven Heater (if used) fuses.

For all applications:

! If heated Sample and Vent Lines are used, apply power to them.
CAUTION

Close the analyzer enclosure doors and secure them with their latches
to allow the analyzer to warm up to operating temperature and stabi-
lize. This could take up to 2 hours if this sample system is allowed to
cool completely.

10. Zero and Span (if applicable) the analyzer.

Maintenance & Troubleshooting | 5-19

 Open the Vent Line Shut Off valve (in the Oven/Sample System En-
closure). Open the Sample Line Shut Off valve to allow sample fluid
into the sample system.

11. Switch the analyzer back to Measure mode (from the Calibration
screen, select Start measure and press ENTER). Press the HOME soft key
to return to the HOME screen.

12. Adjust the Aspirator Pressure Regulator to achieve normal operating

flow rates, as indicated on system drawings. The Flow Indicator (if
used) should be in the centre of the meter for an optimal flow rate.

13. Close and secure the analyzer enclosure doors with their latches.

5-20 | IPS-4 Full Spectrum GPDIV 2

Xenon Flash Lamp Assembly Replacement
The typical life span of the Xenon Flash Lamp is approximately 18–24
months of continuous operation. However, the Xenon Flash Lamp can
exhibit signs of degradation after 12–15 months. When the Xenon Flash
Lamp requires replacement, the entire assembly (Figure 5-3) is replaced.
See Figure 5-1 for the location of this assembly in the Electronics Enclo-
sure.

Refer to “Optical Bench Assembly Spare Parts” in Chapter 6 for reor-

! dering part numbers.
NOTE

The glass Xenon Flash Lamp is under high internal pressure which
could result in flying glass fragments if ruptured. Do not subject the
lamp to drop impact, vibration, or shock.
! While handling a flash lamp, always wear protective devices (face
WARNING
mask, clothing) to prevent possible injury, especially to hand and face
areas.

When handling the flash lamp, never touch the glass bulb of the lamp
with bare hands. Dust or fingerprints on the glass bulb may greatly
! reduce transmittance in the ultraviolet range.
CAUTION
If the glass bulb must be cleaned, wipe it using a soft, lint-free cloth
moistened with high-quality alcohol.

Replacing the Xenon Flash Lamp Assembly

To replace the Xenon Flash Lamp Assembly:

1. Manually zero the analyzer for 10 minutes.

2. After the zero is complete, close the Sample Line and then the Vent
Line Shut Off valves (in the Oven/Sample System Enclosure) to isolate
the analyzer from the sample stream.

3. Power down the analyzer:

Hazardous Location Applications:

If an external, flame-proof disconnect switch (breaker) has been
installed, close the breaker. If no external breaker has been installed,
follow the power up procedure for “General Purpose (GP) Applica-
tions,” below.

Maintenance & Troubleshooting | 5-21

 DC CABLE CONNECTOR
(CONNECTS TO J2 ON
XENON LAMP BOARD)

Figure 5-3.
Xenon Flash Lamp
Assembly 403225901

Before proceeding, test the area around the analyzer for flammable
gases. If a flammable gas atmosphere is present, do not power down
! the analyzer or any alternate power sources that supply power to the
WARNING analyzer components. Proceed only when the area is found to be safe.

4. 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).

5. 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. Dispose of the Lamp Assembly fol-
lowing company policy, or local regulations.

! Do not use any tool to loosen the blue nut on the Optical Bench when
removing or replacing the Lamp Assembly.
WARNING

6. Take the new Xenon Flash Lamp Assembly 403225901 and, using the
alignment pin on the Optical Bench Assembly as a guide, gently push
the Lamp Assembly straight into place.

Tighten, by hand, the blue knurled nut to secure the Lamp Assembly
to the Optical Bench Assembly.

7. Connect the DC Power Cable from the Lamp Housing to J2 on the

Xenon Lamp board.

5-22 | IPS-4 Full Spectrum GPDIV 2

8. Take all necessary precautions to safely power up the analyzer and
prepare it for operation:

! Do not apply main AC power to the analyzer if the Xenon Flash Lamp
Assembly electrical connections have not been made.
NOTE

For all applications:

If heated Sample and Vent Lines are used, apply power to them.
Close the analyzer enclosure doors and secure them with their latches
to allow the analyzer to warm up to operating temperature and stabi-
lize. This could take up to 2 hours if this sample system is allowed to
cool completely.

9. Zero and Span (if applicable) the analyzer.

Replacing the MCU Battery

The battery on the MCU board powers the analyzer clock when the main
analyzer AC power is not connected. The clock’s primary function is to
timestamp the Alarm Log entries.
The battery’s expected life-span is greater than five years; therefore, it is
important to order and stock a battery when your analyzer is approaching
five years from the original manufacture date. It is also possible that the
battery can become damaged by a power spike. Ordering information is
located in Chapter 6.

When the battery is beginning to show signs of weakening, a “Battery

Fail” alarm will be displayed on the Alarm Log screen.

To replace the MCU battery:

1. Manually zero the analyzer for 10 minutes.

2. After the zero is complete, close the Sample Line and then the Vent
Line Shut Off valves (in the Oven/Sample System Enclosure) to isolate
the analyzer from the sample stream.

3. Power down the analyzer:

Hazardous Location Applications:

If an external, flame-proof disconnect switch (breaker) has been
installed, open the breaker. If no external breaker has been installed,
follow the power down procedure for “General Purpose (GP) Applica-
tions,” below.

Before proceeding, test the area around the analyzer for flammable
! gases. If a flammable gas atmosphere is present, do not power down
WARNING the analyzer or any alternate power sources that supply power to the
analyzer components. Proceed only when the area is found to be safe.

Maintenance & Troubleshooting | 5-23

 General Purpose (GP) applications:
Open the Electronics Enclosure door and disconnect AC power from
the analyzer and its temperature-control zone circuitry by opening the
Main AC Power, DC Power, Bench Heater, and Oven Heater (if used)
fuses. Refer to the Fuse Legend at the back of the Electronics Enclo-
sure for the locations of these fuses.

For all applications:

! Wait 2 minutes to allow the high-voltage capacitors to discharge.
WARNING

For all applications:

! If heated Sample and Vent Lines are used, disconnect power to them.
NOTE

4. While wearing a grounding wrist strap, use an appropriate tool to

remove the battery from the MCU board (J3). Insert the new battery.

5. Take all necessary precautions to safely power up the analyzer and

prepare it for operation:

Hazardous Location Applications:

If an external, flame-proof disconnect switch (breaker) has been
installed, close the breaker. If no external breaker has been installed,
follow the power up procedure for “General Purpose (GP) Applica-
tions,” below.
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. Proceed only when the area is found to be safe.

When the analyzer doors are open, take appropriate precautions to

avoid electrical shock. Hazardous voltages are present inside.

General Purpose (GP) Applications:

Apply power to the analyzer and its temperature-control zone cir-
cuitry by closing the Main AC Power, DC Power, Bench Heater, and
Oven Heater (if used) fuses.

! For all applications:

If heated Sample and Vent Lines are used, apply power to them.
NOTE
Close the analyzer enclosure doors and secure them with their latches
to allow the analyzer to warm up to operating temperature and stabi-
lize. This could take up to 2 hours if this sample system is allowed to
cool completely.

6. Check the System Time and System Date (System screen, SETUP
menu) and set them to the current time and date.

5-24 | IPS-4 Full Spectrum GPDIV 2

 7. Zero and Span (if applicable) the analyzer.

Open the Vent Line Shut Off valve (in the Oven/Sample System En-
closure). Open the Sample Line Shut Off valve to allow sample fluid
into the sample system.

8. Switch the analyzer back to Measure mode (from the Calibration

screen, select Start measure and press ENTER). Press the HOME soft key
to return to the HOME screen.

9. Adjust the Aspirator Pressure Regulator to achieve normal operating

flow rates, as indicated on system drawings. The Flow Indicator (if
used) should be in the centre of the meter for an optimal flow rate.

10. Close and secure the analyzer enclosure doors with their latches.

Troubleshooting and Diagnostics

This section describes how the analyzer detects and displays errors as-
sociated with its operation, what the errors mean, and action to take to
correct the errors. This section also discusses how to view the alarms from
the User Interface Panel and how to reset the analyzer if a system reset is
required.

Generally, most troubleshooting and diagnostics can be done by work-

ing from the User Interface Panel on the front of the analyzer Electronics
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

Alarm Notification –

Viewing Alarms on the User Interface Panel

The analyzer incorporates a built-in diagnostics function that continuous-

ly monitors the operation of the analyzer and all of its operating param-
eters. Alarms generated by operating parameters that exceed factory-set
parameter set points are displayed on the User Interface Panel.

When an alarm is set by the analyzer, the alarm message flashes on the
HOME screen to alert the user. The information on the HOME screen will
be replaced by a reverse (white) screen with the alarm name in black text.
It will then switch to a black screen with white text and will continue to
flash until the alarm conditions that triggered the alarm are reset.

Maintenance & Troubleshooting | 5-25

 Viewing Current Alarm Messages

All active alarms are displayed on the Current Alarms screen. Each line
will occupy one alarm description. Up to six active alarms can be dis-
played on the screen at once. If more than six alarms are active, use the
UP/DOWN arrow keys to scroll through the list. The alarm at the top of the
list is most recent alarm; the alarm at the bottom is the oldest.

To view active alarms:

1. Press the ALARMS soft key to view the ALARMS screen.

2. Select Current Alarms and press ENTER.

If there are active alarms, the alarm descriptions is displayed. No time

or date is displayed with active alarms.

If there are no active alarms, “No alarms” is displayed.

To back out of this menu, press CANCEL.

Viewing Historical Alarm Messages

Alarms that have been reset (no longer active) are stored in the Alarm
Log, accessed from the ALARMS screen. Logged (or historical) alarms
– which occupy two lines – include the time and date each alarm was
set and reset. The logged alarm at the top of the list is most recently re-
set alarm; the alarm at the bottom is the oldest. The Alarm Log will be
cleared when the analyzer is powered down.

To view a history of alarms that have been reset:

1. Press the ALARMS soft key to view the ALARMS screen.

2. Select Alarm Log and press ENTER.

If there is a history of reset alarms, the alarm descriptions are dis-

played.

If there is no history of alarms, “Log empty” is displayed.

Use the UP/DOWN arrow keys to scroll through the list (if there are
more than three logged alarms).

To back out of this menu, press CANCEL.

5-26 | IPS-4 Full Spectrum GPDIV 2

 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 & Suggested Corrective Ac-
tion).

Note: The system alarm relay contact opens on alarm. A system alarm
! can result from any of the alarm conditions listed below. Some alarms
NOTE may not apply based on the system hardware configuration. For ex-
ample, systems without a heated sample system will not have a heater
RTD alarm.

Condition/Alarm Name Description & Suggested Corrective Action

Heater Temperature This alarm applies only to systems with a heated Oven/Sample System
Enclosure.
This alarm condition indicates the Oven Heater Plate temperature is
approaching its over-temperature limit; a soft shutdown of the heater
will occur. A soft shutdown means the system will shut down the heater
to ensure the temperature of the heater plate does not continue to
increase to ensure it will not exceed its temperature rating.

Corrective Action:
Take appropriate safety precautions, open the Electronics Enclosure
and the Oven/Sample System Enclosure doors, and:
• Using an Ohm Meter, measure the resistance of the Oven Heater
Plate RTD and test it for an open circuit. If the RTD is faulty, contact
AMETEK for assistance.
Cell Temperature
Bench Temperature
Oven Temperature Note:
The Cell and Over Temperature alarms apply only to systems with a
heated Oven/Sample System Enclosure.

These alarm conditions indicate that the specific temperature-controlled

zone (Cell, Bench, Oven) is operating below or above its set point value
by more than 5 °C (typical; set point may vary).
If one of these alarms is caused by low temperatures in any of the
temperature-controlled zones, the analyzer will automatically switch to
Not Ready mode to ensure the system does not become plugged due
to a low temperature in one of its zones.
This error can also be caused by a blown fuse, power interruption, or a
power spike, a failed heater, or wiring problems.

Corrective Action:
For alarms caused by Low / High Temperatures:
• From the User Interface Panel:
- Check current operating temperatures for each temperature zone
and compare them to their set point temperatures.
- Check each of the associated configuration parameters for
temperature control. These parameters may have been lost as a
result of a power interruption or a power spike.

Maintenance & Troubleshooting | 5-27

 Condition/Alarm Name Description & Suggested Corrective Action
Corrective Action (continued):
• Take appropriate safety precautions, open the Electronics Enclosure
door, and:
- Check the fuse(s) for the zone(s) which caused the alarm (i.e.,
Bench Heater or Oven Heater, if used). Refer to the Fuse Legend
at the back of the Electronics Enclosure for the locations of these
fuses.
• Other checks/corrective action:
- Using an Ohm Meter, measure the resistance of the associated
RTD (Cell, Bench, or Oven) and test it for an open circuit. If the
RTD is faulty, contact AMETEK for assistance.
- Check the electrical connections between the heater and the Relay
board. Check for proper connections and damage to the wiring.
- Replace the Relay board. Contact AMETEK for assistance.
- Replace the Customer Connection board. Contact AMETEK for
assistance.

For alarms caused by High temperatures only:

• If the Oven Heater temperature-controlled zone has exceeded its
over-temperature limit of 177 °C/350 °F, the analyzer automatically
switches to Zero Gas Flush mode.
Take appropriate safety precautions, open the Electronics Enclosure
door, and:
- Manually reset the alarm by pressing the OT (Over-Temperature)
Reset Switch, S501, on the Relay board (see Figure 5-4) to re-
energize the tripped Oven Heater circuit.
- Check the LEDs for the Oven Heater Over-Temp circuit (D502 on
the Relay board) to check if it is experiencing problems.
- Check the fuse for the Over-Temperature circuit (F3, located at TB1
13). Refer to the Fuse Legend for the locations of these fuses.
Pressure transducer 1
Pressure transducer 2 These alarm conditions indicate that the concentration of the output
exceeds its full-scale range by more than 10 psia (typical; set point and
pressure unit may vary).

Corrective Action:
• The parameters have exceeded the normal operating range. From the
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.
Condition/Alarm Name Description & Suggested Corrective Action
Manifold pressure
Aspirator pressure These alarm conditions indicate that the pressure within these
components exceeds its full-scale range by more than 10 psia (typical;
set point and pressure unit may vary).

Corrective Action:
• The parameters have exceeded the normal operating range. From
the User Interface Panel, check that the full-scale range is correct for
the current sample. If Manifold or Aspirator pressure alarms persist
during normal operation, contact the factory. A range change and

5-28 | IPS-4 Full Spectrum GPDIV 2

 recalibration may be required.
Internal error This alarm condition indicates that the analyzer has detected a serious
malfunction.

Corrective Action:
Take appropriate safety precautions, open the Electronics Enclosure
door and:
• Check all of the ribbon cables between boards for proper connections
and inspect them for damage (cuts, nicks, burn marks, etc.). For
cable connection locations, refer to the Electronics Enclosure Wiring
Diagram in the Appendix.
• Contact AMETEK for assistance.
Failed communications to the Analog board
This alarm condition indicates that the MCU board cannot establish
reliable communications with the Analog board.

Corrective Action:
Take appropriate safety precautions, open the Electronics Enclosure
door and:
• Check the ribbon cable (Cable 3) between the MCU board (P3) and
Analog board (J101) – both boards mounted on the Electronics
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.
Failed communications to the Relay board
This alarm condition indicates that the MCU board cannot establish
reliable communications with the Relay board.

Corrective Action:
Take appropriate safety precautions, open the Electronics Enclosure
door and:
• Check the flat cable (Cable 3) between the MCU board (P3, on
the Electronics Enclosure door) and Relay board (J101, on the
Electronics Enclosure backpan) 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.
Condition/Alarm Name Description & Suggested Corrective Action
Relay board firmware not compatible
This alarm condition occurs if the Relay board cannot communicate with
the MCU board due to incompatible firmware versions.

Corrective Action:
The Relay board and/or MCU board firmware will have to be replaced:
• Contact AMETEK for assistance.

Maintenance & Troubleshooting | 5-29

 Display board firmware not compatible
This alarm condition occurs if the Display board cannot communicate
with the MCU board due to incompatible firmware versions.

Corrective Action:
The Display board and/or MCU board firmware will have to be replaced:
• Contact AMETEK for assistance.
File system error This alarm condition occurs if the Detector data file (also known as the
DSP, or digital signal processing, file) is missing or has become corrupt.

Corrective Action:
• Contact AMETEK for assistance.

Condition/Warning Name Description & Suggested Corrective Action

Calibration Required
This warning is generated after a span calibration failure or a zero
calibration failure.

Corrective Action:
Perform a successful span calibration:
• Contact AMETEK for assistance.
Zero Cal Required
This warning is generated after a zero calibration failure or if a zero has
not been performed.

Corrective Action:
Perform a successful zero calibration:
• Contact AMETEK for assistance.
Zero Cal Failure
This warning is generated after a zero calibration failure.

Corrective Action:
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 Full Spectrum GPDIV 2

Figure 5-4.
Over-Temperature alarm Reset Switch
(S501), Relay board (100-1942).

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. In this case the analyzer will reset itself automatically
upon power-up, and will enable the restored settings.

Maintenance & Troubleshooting | 5-31

 This page intentionally left blank.

5-32 | IPS-4 Full Spectrum GPDIV 2

 SERVICE & PARTS

The Service & Parts chapter discusses what to do if you need technical support from
AMETEK, or if you are returning parts for service. This chapter also lists the recom-
mended spare parts to have on hand to ensure all consumable and replaceable parts
are replaced according to the “Analyzer Preventive Maintenance Schedule” included in
Chapter 5.

Technical Support
AMETEK Western Research is committed to providing you the best technical support in
the industry. If you need service or application assistance, contact your local or nearest
AMETEK Service Centre or the AMETEK factory AMETEK at (403) 235-8400 or 1-800-661-
9198), or contact your local AMETEK Western Research representative.

Before contacting AMETEK with questions regarding the installation, operation, or main-
tenance/troubleshooting of your analyzer system, carefully review the contents of this
manual. If you are unable to find an explanation for your problem in this manual, please
gather the following information prior to contacting AMETEK:

• Model number of the analyzer.

• Serial number of the analyzer experiencing problems.

• Purchase order number.

• AMETEK part number for the specific component you are enquiring about, if
known.

• Information describing the problem.

• Billing address, shipping address, and telephone number.

Service & Parts | 6-1

 Returning Equipment
If you need to return parts or equipment for repair, you will need a Return Material
Authorization (RMA) number. This will ensure your equipment is serviced and returned
to you in a prompt and efficient manner. To obtain an RMA number, contact your local or
nearest AMETEK Service Center and have the following information available:

• Model number of the analyzer.

• Serial number of the analyzer.

• Purchase order number.

• Billing address, shipping address, and telephone number.

6-2 | IPS-4 Full SpectrumGPDIV2

 ?? ANSWERS TO YOUR QUESTIONS ??
The choice is yours...
Whether by phone or in person, we can meet the needs required to keep
your analyzer running at peak performance. Our factories are located in
Calgary, Alberta and Newark, Delaware with a Sales & Service Centre in
Houston, Texas. Depending on the programs you select, we will have a
factory-trained representative talking to you within minutes – 24 hours
a day, 365 days a year or on-site within 24 hours. We stock parts at all
MINUTES OR HOURS, three locations.
WE’RE THERE FOR YOU
ANYTIME / ANYWHERE

AMETEK SERVICE & AFTERMARKET SALES SUPPORT

• PRE-lNSTALLATlON INSPECTIONS • ASAP

To ensure you order the correct analyzer with the AMETEK SERVICE ASSISTANCE PROGRAM.
options your operation requires, schedule a factory- AMETEK’s exclusive ASAP program lets you select
trained Service Engineer to inspect the proposed a service package from a menu of service options.
analyzer location. The on-site charge for this visit ASAP options include 24 hour phone support, 24
can be deducted from the start-up charge if you hour on-site guarantee, rapid parts shipment, and
select that option. many more service benefits. ASAP plans may be
• START UPS written to provide coverage for a single analyzer,
Your decision to buy an AMETEK analyzer is greatly or all of the AMETEK process analyzers at your
appreciated. After the time and money spent on facility.
your analyzer, wouldn’t you expect a fast and suc- • AFTERMARKET SALES
cessful start up? We can ensure that will happen! Our Aftermarket Sales group will keep you sup-
Schedule us to be there before you power up the plied with the parts to maintain your analyzer to
system. We will guarantee a satisfactory commis- factory specifications. This is also the group that
sioning of your analyzer. will keep your analyzer current with upgrades
• WARRANTY VALIDATION and retrofits.
Upon start-up, we will validate your 1 year war-
ranty. AMETEK’s warranty policy covers all parts • TECHNICAL SUPPORT
and on-site time. Incurred costs will be the respon- Just call AMETEK and a factory trained Service En-
sibility of the customer. gineer will be there to answer your questions. With
• WARRANTY EXTENSIONS over 200 years of combined field service experience,
AMETEK offers a 2 or 3 year warranty extension our engineers are available to provide operational
for your analyzers. The warranty is identical to the support or troubleshooting expertise.
original policy supplied with the analyzer. Contact • TRAINING
AMETEK Service for more details. We will train your service technicians at our
• SPARE PARTS KITS Technology Transfer Centres located in Calgary,
These parts allow each customer to properly main- Newark, or at your facility. Our TTCs have equip-
tain their analyzers according to the recommended ment similar to yours for hands-on training. A
Preventive Maintenance Schedule (listed in the
manual), to ensure optimal operations.
PROCESS INSTRUMENTS
Canada: 1-800-661-9198 U.S.A.: 1-800-537-

Service & Parts | 6-3

 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 Main-
tenance Schedule” in Chapter 5).

! Content is subject to change without notice.

NOTE

Measuring Cell Assembly Spare Parts

Measuring Cell spare parts that are required as part of the “Analyzer Preventive Mainte-
nance Schedule” for your analyzer vary, depending on the application. AMETEK recom-
mends having this part available, to ensure your analyzer will operate at peak efficiency.

Before ordering spare parts for the Measuring Cell, refer to the “Supplemental Informa-
tion” section of this manual or the Documentation Package shipped with the analyzer for
a Measuring Cell Manual Supplement or a Custom Spare Parts List. If the Cell maintenance
procedure is described in a separate Manual Supplement, check that document first for a
Spare Parts list. If included, use those part numbers; if not, use the part numbers listed in
the Custom Spare Parts List.

Optical Bench Assembly Spare Parts

* Xenon Flash Lamp life expectancy is 18–24 months; therefore, only a 2-year quan-
! tity is included in this list.
NOTE

Optical Bench Assembly, Preventive Maintenance Spare Parts

Part No. Description 2 Year Qty
403225901 Xenon Flash Lamp Assembly 1*
(Optical Bench) (see Note, above)
700087901 Infraed Source Assembly 1*
(Optical Bench) (see Note, above)

6-4 | IPS-4 Full SpectrumGPDIV2

Spare Analyzer Fuses
Choose the appropriate fuses (120 or 240 VAC) for the application.

Choose the appropriate fuses (120 or 240 VAC) for the application.
! These main analyzer fuses do not need to be changed out at regular intervals, but
NOTE 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

120 V Analyzers 240 V Analyzers
Description (Location) Part No. Fuse Type Part No. Fuse Type
Main AC Power (F1) 301-0863 6.3 A 301-0863 6.3 A
DC Power (F2) 301-0861 2.0 A 301-0861 2.0 A
Oven Heater (F3) 301-0862 4.0 A 301-0861 2.0 A
Bench Heater (F4) 301-0860 1.0 A 301-0859 0.5 A
These fuses are located on the AC Terminal in the Electronics Enclosure.

Spare Battery, MCU Board

* MCU battery life expectancy is approximately five years; therefore, only a 5-year
quantity is included in this list.
!
NOTE It is important to order a replacement battery when your analyzer is approaching five
years from the original manufacture date. However, it is possible that the battery can
become damaged by a power spike, resulting in the need for a replacement.

Battery, IPS-4 Analyzer – Recommended Part to Have On-Site

Part No. Description 5-Year Qty
301-0382 Cell Lithium Coin Ext. Temp 1*
(MCU Board) (see Note, above)

Service & Parts | 6-5

 This page intentionally left blank.

6-6 | IPS-4 Full SpectrumGPDIV2

 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, monitor, and
control your analyzer through a web interface

• What the various screens that make up the interface do and how to use them
to work from the analyzer User Web Interface.

Before working from the Web Interface, read the section titled “Introduction to the
! Web Interface,” in the following pages. This section discusses the functions that can be
NOTE performed.

Web Interface | 7-1

 Introduction to the Web Interface
Figure 7-1 illustrates the layout of the analyzer Web Interface. To access the IPS-4 analyz-
er using the Web Interface enter the analyzer’s IP address in the web browser or internet
explorer’s web page address box.

The analyzer IP address is listed on the Ethernet Network Screen on the user interface
panel. To use the web interface the analyzer ethernet must be enabled. Refer to Chapter
4 for ethernet network information.

Analyzer IP Address

Figure 7-1.
Web Interface with
Analyzer IP Address.

7-2 | IPS-4 Full SpectrumGPDIV2

Web Interface Components
The Web Interface is divided into six sections. Navigation buttons located on the left-
hand side of the screen are used to view analyzer status, 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 sec-
tion.

• The web interface header displays the “state” of the analyzer and the concen-
tration of the analytes being measured. This section is read only.

- Examples of “states” include Zero, Span, and Measure. These and other states
are described in detail under “System Status Messages (HOME Screen),” in
Chapter 4.

- Analytes are factory set. Up to six analytes can be displayed.

• Alarm and warning notifications are displayed in the banner located below
the header on every screen. The most current notification is displayed with 1
of x if there are multiple active notifications.

Working From the Web Interface – Conditions and Messages

While working from the Web Interface, the following condition applies:

The Web Interface is shipped from the factory without password protection. All con-
figurable parameters can be changed through the web interface.
!
NOTE
Trend and Spectral data are stored in temporary memory. For security reasons, tempo-
rary data can not be stored directly onto the computer hard drives. Any intentional or
unintentional recycling of power will cause a loss of saved data.

Data cannot be saved directly to your computer. To make a record of diplayed informa-
tion use your PC screen capture function and paste the image into another program.

Web Interface | 7-3

 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.

Analyzer State Analyte Concentration

Navigation
Buttons

Displays Real Time System

Temperatures and Pressures
Figure 7-2.
Home Screen.

7-4 | IPS-4 Full SpectrumGPDIV2

 ALARMS Menu Screen
The ALARMS screen (Figure 7-3) displays any active analyzer alarm condition 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.

Current Alarms and Warnings

All active alarms and warnings are displayed on the Active Alarms screen. Each line will
occupy one alarm or warning description and up to 15 active alarms or warnings can be
displayed on the screen at once. If more than 15 are active, use the arrow keys to scroll
through the list. The alarm or warning at the top of the list is most recent.

To view active conditions, click the Show Active button. If there are alarms active, the
alarm description is displayed (Figure 7-3). If no alarms are active, the display will be
empty.

! For a complete list of alarms and warnings generated by the analyzer, refer to the
NOTE “Maintenance & Troubleshooting” chapter.

Alarms / Warnings
Notification Banner

Indicates Number
of Active Alarms

Figure 7-3.
Active Alarms Screen.

Web Interface | 7-5

 Logged Alarms and Warnings

Alarms that have been reset (no longer active) are stored in the Alarm Log, accessed
from the ALARMS screen. Each logged (or historical) alarm includes the time and date
it was set. The logged alarm at the top of the list is most recently reset alarm. The log file
could be up to 800 lines long. After 800 lines it will overwrite the oldest messages.

Alarm and Warning Notification

When an alarm or warning is set by the analyzer, the alarm is displayed in the banner
accross the top of the screen.

Most Current Active Alarm

Use Check
Boxes to Filter
Alarms/Warnings
Displayed

Click to Show only Log of All Alarms

Active Alarms
Figure 7-4.
Alarm Log Screen.

7-6 | IPS-4 Full SpectrumGPDIV2

 TRENDS Menu Screen
The TRENDS screen (Figure 7-5) displays the trends of selected parameters in one sec-
ond, fifteen seconds or one hour intervals. Use this screen to view the most recent data
held in short term memory. Data can not be saved. Print to screen to capture data for
troubleshooting.

To refresh the display with the most recent data click the “Get Trends” button.

Move cursor over data points

for information

Select Parameter
to Display

Select Trending
Interval

Click to
Refresh Display

Figure 7-5.
Trends Menu Screen.

Web Interface | 7-7

 Parameters

Trends for the following system parameters are available for display:

• Bench Temperature
• Heater Temperature
• Lamp Temperature
• Cell Temperature
• Cell Pressure
• Manifold Pressure
• Aspirator Pressure
• Electronics Temperature
• Analytes Concentration

Intervals

Trend intervals for selected parameters are available in one second, fifteen seconds or
one hour data points. The analyzer stores 3600 parameter data points in temporary
memory prior to overwriting data.

• 1 second interval will contain 60 minutes before overwriting

• 15 second interval will contain 900 minutes or 15 hours before overwriting

• 1 hour interval will contain 3,600 hours or 150 days before overwriting.

7-8 | IPS-4 Full SpectrumGPDIV2

 SPECTRA Menu Screen
The SPECTRA screen (Figure 7-6) allows the user to temporarily store spectra and com-
pare it to future live spectra readings.

Select data
source to display

Click to
Update Chart

Click to View
Spectra

Click to Clear
User Data
Click to Save
User Data

Figure 7-6.
Spectra Menu Screen.

Viewing Spectral Data

Live
View Live Spectra by selecting the data source to display.

• Click “Update Chart” to refresh the screen using stored data.

• Click “Get Spectra” to retrieve live data from the analyzer.

User
Compare User Spectra to Live Spectra for trouble shooting.

• Click “Save User” button to save user spectra to the hard drive. The file is
saved as a cookie in the browser.

• Click “Clear User” to delete the last saved spectra.

Web Interface | 7-9

 SETTINGS Menu Screen
The SETTINGS screen provides access to the sub-menu screens containing the function-
al 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. Changing the factory-set configuration could cause the ana-
NOTE lyzer to operate incorrectly.

Detailed descriptions of each menu item and parameters are described in Chapter 4. The
list of available sub-menu items includes:

• Calibration Control

• Actions

• Current Outputs

• Relays

• Network & Modbus

• System & Custom

• Analytes

• Limits

• Diagnostics

7-10 | IPS-4 Full SpectrumGPDIV2

 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.

Use to
Set up Calibration

View and Modify

Settings

Click to Save Settings

Figure 7-7.
Settings Menu
Calibration Screen.

Web Interface | 7-11

 Actions Screen

The ACTIONS screen (figure 7-8) allows the user to enter calibration concentrations and
initiate on demand calibration actions.

Enter Cal Fluid Concentration

Initiate
Action

View and Modify

Settings

Click to Save Settings

Figure 7-8.
Settings Menu
Actions Screen.

7-12 | IPS-4 Full SpectrumGPDIV2

 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.

View and Modify

Settings

Click to Save Settings

Figure 7-9.
Settings Menu
Current Output Screen.

Web Interface | 7-13

 Relay Setup Screens

The Relay Setup screens (Figure 7-10) allow the user to view or set up the parameters for
up to eight relays. For example, Concentration Alarms can be set up from this screen (Re-
lay Function option). Descriptions of these parameters are described under “Relay Setup
Screens” in Chapter 4.

View and Modify

Settings

Relay Function Options Click to Save Settings

Figure 7-10.
Settings Menu
Relay Setup Screen.

7-14 | IPS-4 Full SpectrumGPDIV2

 Network & Modbus Screen

The NETWORK & MODBUS screen (Figure 7-11) allows the user to enter ethernet set-
tings and set up modbus parameters.

Ethernet settings
Enable the analyzer system to communicate over an Ethernet network for viewing ana-
lyzer and stream composition data, viewing analyzer diagnostics, or backing up/restoring
analyzer configuration settings. Descriptions of these parameters are described under the
“Ethernet Network Screen” in Chapter 4.

Modbus screen
Set up Modbus parameters to enable the analyzer to communicate with the Modbus
master. Descriptions of these parameters are described under the “Modbus Screen” in
Chapter 4.

Use to Use to
Enter Ethernet Settings Set Up Modbus Parameters

View and Modify

Settings

Click to Save Settings

Figure 7-11.
Settings Menu
Network & Modbus Screen.

Web Interface | 7-15

 System & Customition Screen

The SYSTEM & CUSTOMIZATION screen (Figure 7-12) allows the user to view and/or
setup analyzer system parameters.

Use to
View System Parameters Customize Display

View and Modify

Settings

Click to Save Settings

Figure 7-12.
Settings Menu
Sytem & Cumstomization
Screen.

7-16 | IPS-4 Full SpectrumGPDIV2

 Analytes Screen

The ANALYTES screen (figure 7-13) allows you to view and modify analyte names and
span factor min/max.

Use to Change Use to

Name Enter Min/Max Values

View and Modify

Settings

Click to Save Settings

Figure 7-13.
Settings Menu
Analyte Screen.

Web Interface | 7-17

 Limits Screen

The LIMITS screen (figure 7-14) allows you to view and modify pressure and tempera-
ture limits. Descriptions of these parameters are described under “Setpoints Screens” in
Chapter 4.

Use to Change Use to Change

Pressure Limits Temperature Limits

View and Modify

Settings

Click to Save Settings

Figure 7-14.
Settings Menu
Limits Screen.

7-18 | IPS-4 Full SpectrumGPDIV2

 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 pa-
rameters 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. For the diagnostics to operate, click the ‘Turn Diagnostics
NOTE On button’.

Click to put
Analyzer in Diagnostics
Mode Use to Check
Current outputs

Use to Check
Solenoid
Valves

Use to Test
Hardware

Enter Wavelength
to Test During Normal Operation

Figure 7-15.
Settings Menu
Diagnostics Screen.

Web Interface | 7-19

 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.

• Restore previously saved analyzer configuration settings and individual files

from your PC.

Descriptions of these activities are described under “Backup/Restore

Click to Save or
Transfer Data

Figure 7-16.
Settings Menu
Save/Restore Files Screen.

If major changes are made to the analyzer configuration settings, it is important to

make a backup copy of these settings. This file can then be used to restore all param-
! eters to their most recently used settings or the factory-default settings in the event of
NOTE
a serious internal system error.

7-20 | IPS-4 Full SpectrumGPDIV2

 MODBUS COMMUNICATION INTERFACE

This chapter describes the customer serial communication interface on Model IPS-4
Analyzer. The communication protocol implemented is Modicon Modbus as defined in
“Modicon Modbus Protocol Reference Guide” (PI-MBUS-300 RevJ). The Modbus proto-
col transmission mode implemented is Remote Terminal Unit (RTU) with the analyzer
operating as a slave device.

The IPS-4 Analyzer supports RS485 serial communication standards. The physical com-
munication connection between a Model IPS-4 analyzer and a customer DCS\SCADA\
PLC\DAS or a general-purpose computer is RS485. The analyzer RS485 connection sup-
ports 2-wire multi-drop systems.

Hardware:
The jumpers on the CPU board J9 connector should be installed between 1&2 and 3&4
pins.

The converter terminal marked TD(B) which is same as Tx+ should be connected to the
CCB_J14 connector marked Tx+ (pin3) on the Customer Connection Board, and TD(A)
should be connected to Tx- (pin 4).

Modbus Communication Interface | 8-1

 Configuration:
IPS4
IU2BAUD (105) is set by default to 9600
MBPARITY(113) default 1
MBSTOPBIT(114) default 1
MBUSADD (115) default 1
MBUSPORT(116) default 0
MBUSTO(117) default 3000

MBUSPORT should be set to 1 to enable MODBUS RTU operations.

MBUSPORT should be set to 4 to enable MODBUS TCP operations.

! Make sure that you rebooted the analyzer after changing the MBUSPORT parameter
value to 1.
NOTE

When designing a Modbus RS485 multi-drop communication system with the Model
IPS-4 analyzer, the system designer should consider the following:

• The update rate is one time per minute or less. Polling of these registers more
frequently than once a second is not recommended.

• The maximum polling rate of a Modbus multi-drop system is determined by a

number of factors including the number of devices on the system, the number
of registers being polled from each device, the baud rate in half-duplex opera-
tion. Calculations, and possibly experimentation, are needed to attain optimal
system operation.

• When operating in MODBUS TCP mode. Use TCP Port 502 for modbus com-
munications.

• Modbus TCP is only available on software version:

2.05 or later (UV)

3.03 or later (Full Spectrum)

8-2 | IPS-4 Full SpectrumGPDIV2

Analyzer Modbus Interface Parameters
A number of analyzer Modbus interface parameters need to be set up in order to estab-
lish communication with the Modbus master. These parameters are accessed via the
service port on the analyzer using a service program running on a PC.

Modbus Address
The analyzer needs to be assigned a Modbus slave address, which can be a number from
1 to 247 .

Modbus Functions
As the Modbus protocol is designed for communication among Programmable Logic
Controllers (PLCs), not all Modbus function codes supported by a slave PLC are appli-
cable to the IPS-4 analyzer. Only the following relevant function codes are implemented:

CODE DESCRIPTION
03 read multiple holding register (4x references)
06 write one holding register (4 references)
16 write multiple holding registers (4x references)
Figure 8-1(B7-1).
Modbus Functions Screen

In accordance with MODBUS protocol specifications, all address references in Modbus

messages are numbered relative to zero. For example, the first holding register in a Mod-
bus slave being referenced as 40001 would be addressed as 0.

Modbus Communication Interface | 8-3

 Holding Registers
ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
1 sh uint uint USR_CHKSUM 0
2 sh uint uint SYS_CHKSUM 0
3 sh char[36] char[36] PASS 0
4 sh char[36] char[36] LPASS 0
5 sh uint uint PARAM_CNT 0
6 rs char[20] char[20] SERIAL 403XXXX 0 10
7 rs char[6] char[6] MAC 0 10 3
8 rws uint uint IP [Link] 13 2
9 rws uint uint SUBNET [Link] 15 2
10 rws uint uint GW [Link] 17 2
11 rws uint uint DNS 0 19 2
12 rws uint16 uint16 DHCPE 1 21 1
13 rws uint16 uint16 TCPE 1 22 1
14 rws uint uint SVRIP 0 23 2

100 rw int16 int16 CFGFILEVER 20 25 1

101 r int16 int16 MODELID 1 26 1
102 r char[20] char[20] VERSION v2.0 27 10
103 r char[20] char[20] NAME IPS-4 37 10
104 rw uint uint IU1BAUD 115200 47 2
105 rw uint uint IU2BAUD 9600 49 2
106 rw uint uint EU1BAUD 115200 51 2
107 rw uint uint EU2BAUD 115200 53 2
108 rw boolean boolean LDUI 1 55 1
109 r uint16 uint16 FWVERHRB 256 56 1
110 r uint16 uint16 FWVERDIS 256 57 1
111 r uint16 uint16 CARDID 0 58 1
112 r uint16 uint16 HTRYID 0 59 1
113 rw int16 int16 MBPARITY 1 60 1
114 rw int16 int16 MBSTOPBIT 1 61 1
115 rw uint16 uint16 MBUSADD 1 62 1
116 rw uint16 uint16 MBUSPORT 0 63 1
117 rw uint uint MBUSTO 3000 64 2
118 rw int16 int16 PIXELS 1024 66 1
119 r char[20] char[20] SYSTIME 0 67 10
120 r char[20] char[20] SYSDATE 0 77 10
121 rw uint16 uint16 ACUNIT 1 87 1
122 rw char[20] char[20] CONCUNIT %T 88 10
123 rw int16 int16 FLOATFRMT 0 98 1
124 rw uint16 uint16 IDATEFRMT 0 99 1
125 rw int16 int16 LANGUAGE 0 100 1
126 rw char[10] char[10] PRESUNIT psi 101 5
127 rw char[10] char[10] TEMPUNIT degreeC 106 5
128 r uint uint DATAVALID 0 111 2
129 rw uint16 uint16 AUTOCAL 0 113 1
130 rw int16 int16 CALMODE 0 114 1
131 r int16 int16 DMODE 0 115 1
132 r int16 int16 MANCMD 0 116 1
133 rw int16 int16 COMPPT 0 117 1
134 r uint uint SYSALARM1 0 118 2
135 r uint uint SYSALARM2 0 120 2
136 r uint uint SYSALARM3 0 122 2
137 r uint uint CONCALARM 0 124 2

8-4 | IPS-4 Full SpectrumGPDIV2

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
138 r int16 int16 SYSSTATUS 0 126 1
139 r int16 int16 SYSSTATE 0 127 1
140 r uint uint TOTUPTIME 0 128 2
141 r uint uint UPTIME 0 130 2
142 r int int TIMER1 0 132 2
143 r int int TIMER2 0 134 2
144 r int int TIMER3 0 136 2
145 rw uint uint MFTIME 15 138 2
146 rw uint uint CALTIME 0 140 2
147 rw uint uint ZFTIME 15 142 2
148 rw uint uint SFTIME 15 144 2
149 rw int16 int16 ANAHOLD 0 146 1
150 r float float ANAIN1 0.00 147 2
151 rw int16 int16 ANAIN1T 1 149 1
152 rw char[20] char[20] ANAIN1U Percent 150 10
153 r float float ANAIN2 0.00 160 2
154 rw int16 int16 ANAIN2T 1 162 1
155 rw char[20] char[20] ANAIN2U Percent 163 10
156 r float float ANAOUT1 0 173 2
157 rw float float ANAOUT1O 0 175 2
158 rw uint16 uint16 ANAOUT1P 261 177 1
159 rw float float ANAOUT1S 100 178 2
160 rw int16 int16 ANAOUT1T 0 180 1
161 rw uint16 uint16 ANAOUT1OR 0 181 1
162 rw uint16 uint16 ANAOUT1F 0 182 1
163 r float float ANAOUT2 0 183 2
164 rw float float ANAOUT2O 0 185 2
165 rw uint16 uint16 ANAOUT2P 263 187 1
166 rw float float ANAOUT2S 100 188 2
167 rw int16 int16 ANAOUT2T 0 190 1
168 rw uint16 uint16 ANAOUT2OR 0 191 1
169 rw uint16 uint16 ANAOUT2F 0 192 1
170 r float float ANAOUT3 0 193 2
171 rw float float ANAOUT3O 0 195 2
172 rw uint16 uint16 ANAOUT3P 0 197 1
173 rw float float ANAOUT3S 100.00 198 2
174 rw int16 int16 ANAOUT3T 0 200 1
175 rw uint16 uint16 ANAOUT3OR 0 201 1
176 rw uint16 uint16 ANAOUT3F 0 202 1
177 r float float ANAOUT4 0 203 2
178 rw float float ANAOUT4O 0 205 2
179 rw uint16 uint16 ANAOUT4P 0 207 1
180 rw float float ANAOUT4S 100 208 2
181 rw int16 int16 ANAOUT4T 0 210 1
182 rw uint16 uint16 ANAOUT4OR 0 211 1
183 rw uint16 uint16 ANAOUT4F 0 212 1
184 rw boolean boolean ANAOUTENA 1 213 1
185 r uint16 uint16 RELAY1 1 214 1
186 rw uint16 uint16 RELAY1D 0 215 1
187 rw uint16 uint16 RELAY1F 3 216 1

Modbus Communication Interface | 8-5

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
188 rw char[20] char[20] RELAY1NM Relay 1 217 10
189 rw uint16 uint16 RELAY1S 0 227 1
190 rw float float RELAY1V 0 228 2
191 r uint16 uint16 RELAY2 0 230 1
192 rw uint16 uint16 RELAY2D 0 231 1
193 rw uint16 uint16 RELAY2F 5 232 1
194 rw char[20] char[20] RELAY2NM Relay 2 233 10
195 rw uint16 uint16 RELAY2S 0 243 1
196 rw float float RELAY2V 0 244 2
197 r uint16 uint16 RELAY3 0 246 1
198 rw uint16 uint16 RELAY3D 0 247 1
199 rw uint16 uint16 RELAY3F 4 248 1
200 rw char[20] char[20] RELAY3NM Relay 3 249 10
201 rw uint16 uint16 RELAY3S 0 259 1
202 rw float float RELAY3V 0 260 2
203 r uint16 uint16 RELAY4 0 262 1
204 rw uint16 uint16 RELAY4D 0 263 1
205 rw uint16 uint16 RELAY4F 0 264 1
206 rw char[20] char[20] RELAY4NM Relay 4 265 10
207 rw uint16 uint16 RELAY4S 0 275 1
208 rw float float RELAY4V 0 276 2
209 r uint16 uint16 RELAY5 0 278 1
210 rw uint16 uint16 RELAY5D 0 279 1
211 rw uint16 uint16 RELAY5F 0 280 1
212 rw char[20] char[20] RELAY5NM Relay 5 281 10
213 rw uint16 uint16 RELAY5S 0 291 1
214 rw float float RELAY5V 0 292 2
215 r uint16 uint16 RELAY6 0 294 1
216 rw uint16 uint16 RELAY6D 0 295 1
217 rw uint16 uint16 RELAY6F 0 296 1
218 rw char[20] char[20] RELAY6NM Relay 6 297 10
219 rw uint16 uint16 RELAY6S 0 307 1
220 rw float float RELAY6V 0 308 2
221 r uint16 uint16 RELAY7 0 310 1
222 rw uint16 uint16 RELAY7D 0 311 1
223 rw uint16 uint16 RELAY7F 0 312 1
224 rw char[20] char[20] RELAY7NM Relay 7 313 10
225 rw uint16 uint16 RELAY7S 0 323 1
226 rw float float RELAY7V 0 324 2
227 r uint16 uint16 RELAY8 0 326 1
228 rw uint16 uint16 RELAY8D 0 327 1
229 rw uint16 uint16 RELAY8F 0 328 1
230 rw char[20] char[20] RELAY8NM Relay 8 329 10
231 rw uint16 uint16 RELAY8S 0 339 1
232 rw float float RELAY8V 0 340 2
233 rw boolean boolean RELAYENA 1 342 1
234 r uint16 uint16 VALVE1 1 343 1
235 rw char[20] char[20] VALVE1NM Valve 1 344 10
236 r uint16 uint16 VALVE2 0 354 1
237 rw char[20] char[20] VALVE2NM Valve 2 355 10

8-6 | IPS-4 Full SpectrumGPDIV2

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
238 r uint16 uint16 VALVE3 0 365 1
239 rw char[20] char[20] VALVE3NM Valve 3 366 10
240 r uint16 uint16 VALVE4 0 376 1
241 rw char[20] char[20] VALVE4NM Valve 4 377 10
242 r uint16 uint16 VALVE5 1 387 1
243 rw char[20] char[20] VALVE5NM Valve 5 388 10
244 rw float float ACONC1H 0 398 2
245 rw float float ACONC1L 0 400 2
246 rw float float ACONC2H 0 402 2
247 rw float float ACONC2L 0 404 2
248 rw float float ACONC3H 0 406 2
249 rw float float ACONC3L 0 408 2
250 rw float float ACONC4H 0 410 2
251 rw float float ACONC4L 0 412 2
252 rw float float ACONC5H 0 414 2
253 rw float float ACONC5L 0 416 2
254 rw float float ACONC6H 0 418 2
255 rw float float ACONC6L 0 420 2
256 rw float float ACONC7H 0 422 2
257 rw float float ACONC7L 0 424 2
258 rw float float ACONC8H 0 426 2
259 rw float float ACONC8L 0 428 2
260 rw char[20] char[20] ALYTE1 T225nm 430 10
261 r float float ALYTE1CON 0 440 2
262 rw char[20] char[20] ALYTE2 T250nm 442 10
263 r float float ALYTE2CON 0 452 2
264 rw char[20] char[20] ALYTE3 T275nm 454 10
265 r float float ALYTE3CON 0 464 2
266 rw char[20] char[20] ALYTE4 T300nm 466 10
267 r float float ALYTE4CON 0 476 2
268 rw char[20] char[20] ALYTE5 T325nm 478 10
269 r float float ALYTE5CON 0 488 2
270 rw char[20] char[20] ALYTE6 T350nm 490 10
271 r float float ALYTE6CON 0 500 2
272 rw char[20] char[20] ALYTE7 T375nm 502 10
273 r float float ALYTE7CON 0 512 2
274 rw char[20] char[20] ALYTE8 T400nm 514 10
275 r float float ALYTE8CON 0 524 2
276 rw int16 int16 ANALYTES 8 526 1
277 rw int16 int16 BENAT 1 527 1
278 rw float float BENDEVT 5.00 528 2
279 rw float float BENDT 0 530 2
280 r float float BENHDC -0.70 532 2
281 rw float float BENIT 240 534 2
282 rw float float BENPB 5 536 2
283 r float float BENRTD 0 538 2
284 rw float float BENSP 50 540 2
285 rw float float BENST 5 542 2
286 rw int16 int16 HEATERAT 1 544 1
287 rw float float HEATERDEVT 0 545 2

Modbus Communication Interface | 8-7

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
288 rw float float HEATERDT 0 547 2
289 r float float HEATERHDC -0.87 549 2
290 rw float float HEATERIT 0 551 2
291 rw float float HEATERPB 50.00 553 2
292 r float float HEATERRTD 0 555 2
293 rw float float HEATERSP 100 557 2
294 rw float float HEATERST 4.00 559 2
295 r float float ELECTEMP 0 561 2
296 rw int16 int16 LAMAT 1 563 1
297 rw float float LAMDEVT 0 564 2
298 rw float float LAMDT 0 566 2
299 r float float LAMHDC -1.00 568 2
300 rw float float LAMIT 240 570 2
301 rw float float LAMPB 5 572 2
302 r float float LAMRTD 0 574 2
303 rw float float LAMSP 60 576 2
304 rw float float LAMST 5 578 2
305 rw int16 int16 CELLAT 1 580 1
306 rw float float CELLDEVT 0 581 2
307 rw float float CELLDT 0 583 2
308 r float float CELLHDC 0.00 585 2
309 rw float float CELLIT 5000.00 587 2
310 rw float float CELLPB 10.00 589 2
311 r float float CELLRTD 0 591 2
312 rw float float CELLSP 60.00 593 2
313 rw float float CELLST 20.00 595 2
314 rw float float SAMDEVT 0 597 2
315 rw int16 int16 SAMLAT 1 599 1
316 rw float float SAMLDT 0 600 2
317 r float float SAMLHDC 0 602 2
318 rw float float SAMLIT 720 604 2
319 rw float float SAMLPB 10 606 2
320 r float float SAMLRTD 0 608 2
321 rw float float SAMLSP 110.00 610 2
322 rw float float SAMLST 15 612 2
323 rw float float VENDEVT 0 614 2
324 rw int16 int16 VENLAT 1 616 1
325 rw float float VENLDT 0 617 2
326 r float float VENLHDC 1.00 619 2
327 rw float float VENLIT 720 621 2
328 rw float float VENLPB 10 623 2
329 r float float VENLRTD 0 625 2
330 rw float float VENLSP 100 627 2
331 rw float float VENLST 15 629 2
332 r int16 int16 REMIN1 0 631 1
333 r int16 int16 REMIN2 0 632 1
334 rw int16 int16 LAMPM 15 633 1
335 rw int16 int16 LAMPF 0 634 1
336 rw int16 int16 FREQ 2000 635 1
337 r int16 int16 LAMDF 0 636 1

8-8 | IPS-4 Full SpectrumGPDIV2

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
338 r float float PRESX1 0 637 2
339 rw float float PRESXS1 30.00 639 2
340 rw float float PRESXOS1 0.03 641 2
341 r float float PRESX2 0 643 2
342 rw float float PRESXS2 100 645 2
343 rw float float PRESXOS2 0 647 2
344 r float float MPRES 0 649 2
345 r float float APRES 0 651 2
346 r int16 int16 VALFAULT 0 653 1
347 r int16 int16 HTRFAULT 0 654 1
348 r int16 int16 FSI 0 655 1
349 r float float OT1 0 656 2
350 r float float OT2 0 658 2
351 r float float OT3 0 660 2
352 rw int int ZEROCNT 15 662 2
353 rw int16 int16 AGAIN 0 664 1
354 rw int16 int16 MPER 20 665 1
355 rw int16 int16 PMPER 20 666 1
356 rw int16 int16 WUPER 100 667 1
357 rw float float BENIIR 0.10 668 2
358 rw float float HEATERIIR 0.05 670 2
359 rw float float DIIR 0.50 672 2
360 rw float float LAMIIR 1 674 2
361 rw float float CELLIIR 0.05 676 2
362 rw float float SAMLIIR 1 678 2
363 rw float float SCIIR 1.00 680 2
364 rw float float VENLIIR 1 682 2
365 rw float float PIIR 0.50 684 2
366 rw float float APRESX1H 0 686 2
367 rw float float APRESX1L 0 688 2
368 rw float float APRESX2H 0 690 2
369 rw float float APRESX2L 0 692 2
370 rw float float AMPRESH 0 694 2
371 rw float float AMPRESL 0 696 2
372 rw float float AAPRESH 0 698 2
373 rw float float AAPRESL 0 700 2
374 rw float float AOT1H 0 702 2
375 rw float float AOT1L 0 704 2
376 rw float float AOT2H 0 706 2
377 rw float float AOT2L 0 708 2
378 rw float float AOT3H 0 710 2
379 rw float float AOT3L 0 712 2
380 r uint uint PULSECNT 0 714 2
381 rw int16 int16 MEDSZ 3 716 1
382 rw int16 int16 AVGSZ 20 717 1
383 rw float float ALPHA 0.99 718 2
384 rw float float BETA 100 720 2
385 rw float float NORMTEMP 20 722 2
386 rw float float NORMPRES 14.70 724 2
387 rw int16 int16 NEGCONCON 0 726 1

Modbus Communication Interface | 8-9

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
388 rw int16 int16 ADJUSTSPAN 1 727 1
389 rw float float CALGAS1 0 728 2
390 rw float float CALGAS2 0 730 2
391 rw float float CALGAS3 0 732 2
392 rw float float CALGAS4 0 734 2
393 rw float float CALGAS5 0 736 2
394 rw float float CALGAS6 0 738 2
395 rw float float CALGAS7 0 740 2
396 rw float float CALGAS8 0 742 2
397 rw float float SPANAN1 1.00 744 2
398 rw float float SPANAN2 1.00 746 2
399 rw float float SPANAN3 1.00 748 2
400 rw float float SPANAN4 1.00 750 2
401 rw float float SPANAN5 1.00 752 2
402 rw float float SPANAN6 1.00 754 2
403 rw float float SPANAN7 1.00 756 2
404 rw float float SPANAN8 1.00 758 2
405 rw uint16 uint16 HOMEPARAM1 0 760 1
406 rw uint16 uint16 HOMEPARAM2 0 761 1
407 rw uint16 uint16 HOMEPARAM3 0 762 1
408 rw uint16 uint16 HOMEPARAM4 0 763 1
409 rw uint16 uint16 HOMEPARAM5 0 764 1
410 rw uint16 uint16 HOMEPARAM6 0 765 1
411 rw uint16 uint16 HOMEPARAM7 0 766 1
412 rw uint16 uint16 HOMEPARAM8 0 767 1
413 rw uint16 uint16 HOMEPARAM9 0 768 1
414 r int16 int16 LASTCMD 0 769 1
415 r int int SMVAR1 0 770 2
416 r int int SMVAR2 0 772 2
417 r int int SMVAR3 0 774 2
418 r int int SMVAR4 0 776 2
419 r int int SMVAR5 0 778 2
420 rw int int SMNVVAR1 0 780 2
421 rw int int SMNVVAR2 0 782 2
422 rw int int SMNVVAR3 0 784 2
423 rw int int SMNVVAR4 0 786 2
424 rw int int SMNVVAR5 0 788 2
425 rw uint uint LOGSAVEINT 60 790 2
426 r uint uint SELSPAN 0 792 2
427 rw char[20] char[20] SPANNM1 Span 1 794 10
428 rw char[20] char[20] SPANNM2 Span 2 804 10
429 rw char[20] char[20] SPANNM3 Span 3 814 10
430 rw char[20] char[20] SPANNM4 Span 4 824 10
431 rw char[20] char[20] SPANNM5 Span 5 834 10
432 rw char[20] char[20] SPANNM6 Span 6 844 10
433 rw char[20] char[20] SPANNM7 Span 7 854 10
434 rw char[20] char[20] SPANNM8 Span 8 864 10
435 rw uint uint SPANMAP1 1 874 2
436 rw uint uint SPANMAP2 2 876 2
437 rw uint uint SPANMAP3 4 878 2

8-10 | IPS-4 Full SpectrumGPDIV2

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
438 rw uint uint SPANMAP4 8 880 2
439 rw uint uint SPANMAP5 16 882 2
440 rw uint uint SPANMAP6 32 884 2
441 rw uint uint SPANMAP7 64 886 2
442 rw uint uint SPANMAP8 128 888 2
443 rw char[10] char[10] CONCUNIT2 %T 890 5
444 rw char[10] char[10] CONCUNIT3 %T 895 5
445 rw char[10] char[10] CONCUNIT4 %T 900 5
446 rw char[10] char[10] CONCUNIT5 %T 905 5
447 rw char[10] char[10] CONCUNIT6 %T 910 5
448 rw char[10] char[10] CONCUNIT7 %T 915 5
449 rw char[10] char[10] CONCUNIT8 %T 920 5
450 rw float float ALPHA2 0.99 925 2
451 rw float float ALPHA3 0.99 927 2
452 rw float float ALPHA4 0.99 929 2
453 rw float float ALPHA5 0.99 931 2
454 rw float float ALPHA6 0.99 933 2
455 rw float float ALPHA7 0.99 935 2
456 rw float float ALPHA8 0.99 937 2
457 rw float float BETA2 100 939 2
458 rw float float BETA3 100 941 2
459 rw float float BETA4 100 943 2
460 rw float float BETA5 100 945 2
461 rw float float BETA6 100 947 2
462 rw float float BETA7 100 949 2
463 rw float float BETA8 100 951 2
464 rw uint uint ALYTE1RES 1 953 2
465 rw uint uint ALYTE2RES 1 955 2
466 rw uint uint ALYTE3RES 1 957 2
467 rw uint uint ALYTE4RES 1 959 2
468 rw uint uint ALYTE5RES 1 961 2
469 rw uint uint ALYTE6RES 1 963 2
470 rw uint uint ALYTE7RES 1 965 2
471 rw uint uint ALYTE8RES 1 967 2
472 rw boolean boolean MANSPAN 0 969 1
473 rw int16 int16 SPANCNT 1 970 1
474 rw int int CALSCHED -1 971 2
475 rw uint16 uint16 CALDAY 0 973 1
476 rw float float APRESSPAN 100 974 2
477 rw float float APRESOS 0 976 2
478 rw float float APRESIIR 0.5 978 2
479 rw float float MPRESSPAN 100 980 2
480 rw float float MPRESOS 0 982 2
481 rw float float MPRESIIR 0.5 984 2
482 rw boolean boolean RELAY1NC 1 986 1
483 rw boolean boolean RELAY2NC 1 987 1
484 rw boolean boolean RELAY3NC 1 988 1
485 rw boolean boolean RELAY4NC 1 989 1
486 rw boolean boolean RELAY5NC 1 990 1
487 rw boolean boolean RELAY6NC 1 991 1

Modbus Communication Interface | 8-11

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
488 rw boolean boolean RELAY7NC 1 992 1
489 rw boolean boolean RELAY8NC 1 993 1
490 rw uint16 uint16 MENUTO 60 994 1
491 rw uint16 uint16 PWDTO 300 995 1
492 rw uint16 uint16 SCRSVTO 0 996 1
493 rw uint16 uint16 SCRBRIGHT 3 997 1
494 rw float float ALYTE1DEN 1 998 2
495 rw float float ALYTE2DEN 1 1000 2
496 rw float float ALYTE3DEN 1 1002 2
497 rw float float ALYTE4DEN 1 1004 2
498 rw float float ALYTE5DEN 1 1006 2
499 rw float float ALYTE6DEN 1 1008 2
500 rw float float ALYTE7DEN 1 1010 2
501 rw float float ALYTE8DEN 1 1012 2
502 rw float float ALYTE1MW 1 1014 2
503 rw float float ALYTE2MW 1 1016 2
504 rw float float ALYTE3MW 1 1018 2
505 rw float float ALYTE4MW 1 1020 2
506 rw float float ALYTE5MW 1 1022 2
507 rw float float ALYTE6MW 1 1024 2
508 rw float float ALYTE7MW 1 1026 2
509 rw float float ALYTE8MW 1 1028 2
510 rw uint16 uint16 SOFTCENTER1 39 1030 1
511 rw uint16 uint16 SOFTCENTER2 94 1031 1
512 rw uint16 uint16 SOFTCENTER3 152 1032 1
513 rw uint16 uint16 SOFTCENTER4 208 1033 1
514 r uint uint SYSWARN1 0 1034 2
515 r uint uint SYSWARN2 0 1036 2
516 r uint uint SYSWARN3 0 1038 2
517 rw uint16 uint16 PTSEED 1 1040 1
518 rw float float PRESXVMAX1 4.096 1041 2
519 rw float float PRESXVMIN1 0 1043 2
520 rw float float PRESXSF1 100 1045 2
521 rw float float PRESXVMAX2 4.096 1047 2
522 rw float float PRESXVMIN2 0 1049 2
523 rw float float PRESXSF2 100 1051 2
524 rw int16 int16 STATICPT 0 1053 1
525 rw float float STCELLT 0 1054 2
526 rw float float STCELLP 0 1056 2
527 rw uint16 uint16 ANAOUT1H 0 1058 1
528 rw uint16 uint16 ANAOUT2H 0 1059 1
529 rw uint16 uint16 ANAOUT3H 0 1060 1
530 rw uint16 uint16 ANAOUT4H 0 1061 1
531 rw uint uint MINDARK 10000 1062 2
532 rw uint uint MAXDARK 20000 1064 2
533 rw uint uint ZEROMININT 2000 1066 2
534 rw float float ZERODRIFTMULT 10 1068 2
535 rw float float ALYTE1SPLO 0.5 1070 2
536 rw float float ALYTE1SPHI 3 1072 2
537 rw float float ALYTE2SPLO 0.5 1074 2

8-12 | IPS-4 Full SpectrumGPDIV2

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
538 rw float float ALYTE2SPHI 3 1076 2
539 rw float float ALYTE3SPLO 0.5 1078 2
540 rw float float ALYTE3SPHI 3 1080 2
541 rw float float ALYTE4SPLO 0.5 1082 2
542 rw float float ALYTE4SPHI 3 1084 2
543 rw float float ALYTE5SPLO 0.5 1086 2
544 rw float float ALYTE5SPHI 3 1088 2
545 rw float float ALYTE6SPLO 0.5 1090 2
546 rw float float ALYTE6SPHI 3 1092 2
547 rw float float ALYTE7SPLO 0.5 1094 2
548 rw float float ALYTE7SPHI 3 1096 2
549 rw float float ALYTE8SPLO 0.5 1098 2
550 rw float float ALYTE8SPHI 3 1100 2
551 rw float float CELLLENGTH 1.00 1102 2
552 rw char[20] char[20] CALSCHEDT1 [Link] 1104 10
553 rw uint16 uint16 AUTOCAL2 0 1114 1
554 rw uint uint CALTIME2 0 1115 2
555 rw uint16 uint16 ACUNIT2 0 1117 1
556 rw uint16 uint16 CALDAY2 0 1118 1
557 rw int16 int16 CALMODE1 0 1119 1
558 rw int16 int16 CALMODE2 0 1120 1
559 rw char[20] char[20] CALSCHEDT2 [Link] 1121 10
560 r char[20] char[20] NEXTCAL1 [Link] 1131 10
561 r char[20] char[20] NEXTCAL2 [Link] 1141 10
562 r int16 int16 DIAGS 0 1151 1
563 rw float float ALYTE1FSR 100 1152 2
564 rw float float ALYTE2FSR 100 1154 2
565 rw float float ALYTE3FSR 100 1156 2
566 rw float float ALYTE4FSR 100 1158 2
567 rw float float ALYTE5FSR 100 1160 2
568 rw float float ALYTE6FSR 100 1162 2
569 rw float float ALYTE7FSR 100 1164 2
570 rw float float ALYTE8FSR 100 1166 2
571 rw float float QUADTERM 0 1168 2
572 rw float float LINEARTERM 1 1170 2
573 rw float float INTERCEPT 1 1172 2
574 rw float float DIAGWAVEL 250 1174 2
575 r int int DIAGPIXEL 0 1176 2
576 r float float DIAGMEAS 0 1178 2
577 r float float DIAGDARK 0 1180 2
578 r float float DIAGABSORB 0 1182 2
579 rw int16 int16 CALDIGINPUT 0 1184 1
580 rw float float THRESWL 0 1185 2
581 r uint uint HEARTBEAT 0 1187 2
582 rw float float ABVER 0 1189 2
583 rw uint uint HW_DISABLE 0 1191 2
584 rw int16 int16 TRENDINTVL1 1 1193 1
585 rw int16 int16 TRENDINTVL2 15 1194 1
586 rw int16 int16 TRENDINTVL3 3600 1195 1
587 rw int16 int16 TRENDPAR1 0 1196 1

Modbus Communication Interface | 8-13

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
588 rw int16 int16 TRENDPAR2 0 1197 1
589 rw int16 int16 TRENDPAR3 0 1198 1
590 rw int16 int16 TRENDPAR4 0 1199 1
591 rw int16 int16 TRENDPAR5 0 1200 1
592 rw int16 int16 TRENDPAR6 0 1201 1
593 rw int16 int16 TRENDPAR7 0 1202 1
594 rw int16 int16 TRENDPAR8 0 1203 1
595 rw int16 int16 TRENDPAR9 0 1204 1
596 rw int16 int16 TRENDPAR10 0 1205 1
597 rw int16 int16 TRENDPAR11 0 1206 1
598 rw int16 int16 TRENDPAR12 0 1207 1
599 rw int16 int16 TRENDPAR13 0 1208 1
600 rw int16 int16 TRENDPAR14 0 1209 1
601 rw int16 int16 TRENDPAR15 0 1210 1
602 rw int16 int16 TRENDPAR16 0 1211 1
603 rw int16 int16 TRENDPAR17 0 1212 1
604 rw int16 int16 TRENDPAR18 0 1213 1
605 rw int16 int16 TRENDPAR19 0 1214 1
606 rw int16 int16 TRENDPAR20 0 1215 1
607 rw int16 int16 TRENDPAR21 0 1216 1
608 rw int16 int16 TRENDPAR22 0 1217 1
609 rw int16 int16 TRENDPAR23 0 1218 1
610 rw int16 int16 TRENDPAR24 0 1219 1
611 rw float float ZEROTOL 0 1220 2
612 rw float float REFSTARTW 0 1222 2
613 rw float float REFENDW 0 1224 2
614 rw float float ZERODRIFT1 0 1226 2
615 rw float float ZERODRIFT2 0 1228 2
616 rw float float ZERODRIFT3 0 1230 2
617 rw float float ZERODRIFT4 0 1232 2
618 rw float float ZERODRIFT5 0 1234 2
619 rw float float ZERODRIFT6 0 1236 2
620 rw float float ZERODRIFT7 0 1238 2
621 rw float float ZERODRIFT8 0 1240 2
622 rw float float SPANDRIFT1 0 1242 2
623 rw float float SPANDRIFT2 0 1244 2
624 rw float float SPANDRIFT3 0 1246 2
625 rw float float SPANDRIFT4 0 1248 2
626 rw float float SPANDRIFT5 0 1250 2
627 rw float float SPANDRIFT6 0 1252 2
628 rw float float SPANDRIFT7 0 1254 2
629 rw float float SPANDRIFT8 0 1256 2
630 rw int16 int16 LINEARIZE 0 1258 1
631 rw float float LINLEVEL0 0 1259 2
632 rw float float LINLEVEL1 0 1261 2
633 rw float float LINLEVEL2 0 1263 2
634 rw float float LINLEVEL3 0 1265 2
635 rw float float LINLEVEL4 0 1267 2
636 rw float float LINLEVEL5 0 1269 2
637 rw float float LINBREAK0 0 1271 2

8-14 | IPS-4 Full SpectrumGPDIV2

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
638 rw float float LINBREAK1 0 1273 2
639 rw float float LINBREAK2 0 1275 2
640 rw float float LINBREAK3 0 1277 2
641 rw float float LINBREAK4 0 1279 2
642 rw float float LINBREAK5 0 1281 2
643 r float float ANAOUT5 0 1283 2
644 rw float float ANAOUT5O 0 1285 2
645 rw uint16 uint16 ANAOUT5P 261 1287 1
646 rw float float ANAOUT5S 100 1288 2
647 rw int16 int16 ANAOUT5T 0 1290 1
648 r float float ANAOUT6 0 1291 2
649 rw float float ANAOUT6O 0 1293 2
670 rw uint16 uint16 ANAOUT6P 261 1295 1
671 rw float float ANAOUT6S 100 1296 2
672 rw int16 int16 ANAOUT6T 0 1298 1
673 r float float ANAOUT7 0 1299 2
674 rw float float ANAOUT7O 0 1301 2
675 rw uint16 uint16 ANAOUT7P 261 1303 1
676 rw float float ANAOUT7S 100 1304 2
677 rw int16 int16 ANAOUT7T 0 1306 1
678 r float float ANAOUT8 0 1307 2
679 rw float float ANAOUT8O 0 1309 2
680 rw uint16 uint16 ANAOUT8P 261 1311 1
681 rw float float ANAOUT8S 100 1312 2
682 rw int16 int16 ANAOUT8T 0 1314 1
683 rw int16 int16 ACROMAG 0 1315 1
684 rw float float SPANLIM1 10 1316 2
685 rw float float SPANLIM2 10 1318 2
686 rw float float SPANLIM3 10 1320 2
687 rw float float SPANLIM4 10 1322 2
688 rw float float SPANLIM5 10 1324 2
689 rw float float SPANLIM6 10 1326 2
690 rw float float SPANCHLIM1 1 1328 2
691 rw float float SPANCHLIM2 1 1330 2
692 rw float float SPANCHLIM3 1 1332 2
693 rw float float SPANCHLIM4 1 1334 2
694 rw float float SPANCHLIM5 1 1336 2
695 rw float float SPANCHLIM6 1 1338 2
696 r uint16 uint16 IRSTAT 0 1340 1
697 rw uint16 uint16 IRMODE 0 1341 1
698 rw uint16 uint16 IRIIR 0 1342 1
699 r uint16 uint16 IRVER 0 1343 1
700 r float float TECTMP 0 1344 2
701 rw uint16 uint16 TECSP 20 1346 1
702 rw uint16 uint16 OFNUM 6 1347 1
703 rw uint16 uint16 MFREQ 1200 1348 1
704 r uint16 uint16 MFLAG 0 1349 1
705 rw float float ALYTE1OFFSET 0 1350 2
706 rw float float ALYTE2OFFSET 0 1352 2

Modbus Communication Interface | 8-15

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
707 rw float float ALYTE3OFFSET 0 1354 2
708 rw float float ALYTE4OFFSET 0 1356 2
709 rw float float ALYTE5OFFSET 0 1358 2
710 rw float float ALYTE6OFFSET 0 1360 2
711 rw float float ALYTE7OFFSET 0 1362 2
712 rw float float ALYTE8OFFSET 0 1364 2
713 rw uint16 uint16 SCINOTFLAG 0 1366 1
714 rw uint16 uint16 DELAYIIR 0 1367 1
715 rw uint16 uint16 ZEROADJUST 0 1368 1
716 rw uint16 uint16 FORCEZERO 0 1369 1
717 rw uint16 uint16 LIN1SOURCE 0 1370 1
718 rw uint16 uint16 LIN2SOURCE 0 1371 1
719 rw uint16 uint16 LIN3SOURCE 0 1372 1
720 rw uint16 uint16 LIN4SOURCE 0 1373 1
721 rw float float LINLEVEL0P1 0 1374 2
722 rw float float LINLEVEL1P1 0 1376 2
723 rw float float LINLEVEL2P1 0 1378 2
724 rw float float LINLEVEL3P1 0 1380 2
725 rw float float LINLEVEL4P1 0 1382 2
726 rw float float LINLEVEL5P1 0 1384 2
727 rw float float LINLEVEL6P1 0 1386 2
728 rw float float LINLEVEL7P1 0 1388 2
729 rw float float LINBREAK0P1 0 1390 2
730 rw float float LINBREAK1P1 0 1392 2
731 rw float float LINBREAK2P1 0 1394 2
732 rw float float LINBREAK3P1 0 1396 2
733 rw float float LINBREAK4P1 0 1398 2
734 rw float float LINBREAK5P1 0 1400 2
735 rw float float LINBREAK6P1 0 1402 2
736 rw float float LINBREAK7P1 0 1404 2
737 rw float float LINLEVEL0P2 0 1406 2
738 rw float float LINLEVEL1P2 0 1408 2
739 rw float float LINLEVEL2P2 0 1410 2
740 rw float float LINLEVEL3P2 0 1412 2
741 rw float float LINLEVEL4P2 0 1414 2
742 rw float float LINLEVEL5P2 0 1416 2
743 rw float float LINLEVEL6P2 0 1418 2
744 rw float float LINLEVEL7P2 0 1420 2
745 rw float float LINBREAK0P2 0 1422 2
746 rw float float LINBREAK1P2 0 1424 2
747 rw float float LINBREAK2P2 0 1426 2
748 rw float float LINBREAK3P2 0 1428 2
749 rw float float LINBREAK4P2 0 1430 2
750 rw float float LINBREAK5P2 0 1432 2
751 rw float float LINBREAK6P2 0 1434 2
752 rw float float LINBREAK7P2 0 1436 2
753 rw float float LINLEVEL0P3 0 1438 2
754 rw float float LINLEVEL1P3 0 1440 2
755 rw float float LINLEVEL2P3 0 1442 2
756 rw float float LINLEVEL3P3 0 1444 2

8-16 | IPS-4 Full SpectrumGPDIV2

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
757 rw float float LINLEVEL4P3 0 1446 2
758 rw float float LINLEVEL5P3 0 1448 2
759 rw float float LINLEVEL6P3 0 1450 2
760 rw float float LINLEVEL7P3 0 1452 2
761 rw float float LINBREAK0P3 0 1454 2
762 rw float float LINBREAK1P3 0 1456 2
763 rw float float LINBREAK2P3 0 1458 2
764 rw float float LINBREAK3P3 0 1460 2
765 rw float float LINBREAK4P3 0 1462 2
766 rw float float LINBREAK5P3 0 1464 2
767 rw float float LINBREAK6P3 0 1466 2
768 rw float float LINBREAK7P3 0 1468 2
769 rw float float LINLEVEL0P4 0 1470 2
770 rw float float LINLEVEL1P4 0 1472 2
771 rw float float LINLEVEL2P4 0 1474 2
772 rw float float LINLEVEL3P4 0 1476 2
773 rw float float LINLEVEL4P4 0 1478 2
774 rw float float LINLEVEL5P4 0 1480 2
775 rw float float LINLEVEL6P4 0 1482 2
776 rw float float LINLEVEL7P4 0 1484 2
777 rw float float LINBREAK0P4 0 1486 2
778 rw float float LINBREAK1P4 0 1488 2
779 rw float float LINBREAK2P4 0 1490 2
780 rw float float LINBREAK3P4 0 1492 2
781 rw float float LINBREAK4P4 0 1494 2
782 rw float float LINBREAK5P4 0 1496 2
783 rw float float LINBREAK6P4 0 1498 2
784 rw float float LINBREAK7P4 0 1500 2
785 rw float float TECDEV 1 1502 2
786 rw float float TECDEVDELAY 4 1504 2
787 rw float float MAXTECSP 25 1506 2
788 rw float float MINTECSP -10 1508 2
789 rw float float TECSPSTEP 5 1510 2
790 rw float float TECSTEPTIME 60 1512 2
791 rw uint16 uint16 TECSTEPAUTO 0 1514 1
792 rw uint16 uint16 MINIRDARKSG 0 1515 1
793 rw uint16 uint16 MAXIRDARKSG 65535 1516 1
794 rw uint16 uint16 MINIRMEASSG 0 1517 1
795 rw uint16 uint16 MAXIRMEASSG 65535 1518 1
796 rw uint16 uint16 STEPAUTOZRO 0 1519 1
797 rw float float CELLLENGTH2 20 1520 2
798 rw char[20] char[20] IRCHNM1 chn1 1522 10
799 rw char[20] char[20] IRCHNM2 chn2 1532 10
800 rw char[20] char[20] IRCHNM3 chn3 1542 10
801 rw char[20] char[20] IRCHNM4 chn4 1552 10
802 rw char[20] char[20] IRCHNM5 chn5 1562 10
803 rw char[20] char[20] IRCHNM6 chn6 1572 10
804 r float float IRCHABS1 0 1582 2
805 r float float IRCHABS2 0 1584 2

Modbus Communication Interface | 8-17

 ID Access Data Type Data Type mnemonic value MB Starting Regs MB Reg Size
806 r float float IRCHABS3 0 1586 2
807 r float float IRCHABS4 0 1588 2
808 r float float IRCHABS5 0 1590 2
809 r float float IRCHABS6 0 1592 2
810 rw uint16 uint16 ANAOUT5H 0 1594 1
811 rw uint16 uint16 ANAOUT6H 0 1595 1
812 rw uint16 uint16 ANAOUT7H 0 1596 1
813 rw uint16 uint16 ANAOUT8H 0 1597 1
814 rw uint uint ZEROMAXINT 70000 1598 2
815 rw float float IRDIAGWAVEL 1000 1600 2
816 rw int int IRDIAGPIXEL 0 1602 2
817 r float float IRDIAGMEAS 0 1604 2
818 r float float IRDIAGDARK 0 1606 2
819 r float float IRDIAGABS 0 1608 2

8-18 | IPS-4 Full SpectrumGPDIV2

 APPENDIX – 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 wiring diagram drawings.

Drawings such as “Analyzer Mounting Details, Unistruts” and “Analyzer Overall Compo-
nent Layout” are examples only; customer-specific drawings for your system are located
in the “Supplemental Information” section of this manual and in the Documentation
Package shipped with the analyzer.

Appendix – Drawings | A-1

 Analyzer Light Path Schematic

UV Schematic NDIR Schematic

A-2 | IPS-4 Full SpectrumGPDIV2

 48.00
[1219.2] .50

!
NOTE
[ 12.7] 6 PLS
46.25
[1174.8]

analyzer.
19.70
[500.5] 28.45
22.00
21.70 [722.7]
[558.8]
[551.3]

48.00
[1219.2]
Analyzer Mounting Details

22.00
HEATED SAMPLE LINE
[558.8] SLEEVE SHOWN
(OPTIONAL)

HEATED SAMPLE LINE DISCONNECT BOX SHOWN

(OPTION)
4 X 3/4" NPT (M25 OPTIONAL)

CUSTOMER WIRING CONNECTIONS

(TYPICAL)
1 X M20 (1/2" NPT OPTIONAL)
4 X M25 (3/4" NPT OPTIONAL)
ACTUAL CONFIGURATION APPLICATION
SPECIFIC

Actual layout may vary. Refer to customer-specific drawings in the “Supplemental

Information” section of this manual or the Documentation Package shipped with the

Appendix – Drawings | A-3

 XENON LAMP PWB UV OPTICAL NDIR OPTICAL
BENCH ASSEMBLY BENCH ASSEMBLY
CELLS (APPLICATION SPECIFIC)

!
NOTE
XENON FLASH
LAMP ASSEMBLY
OVEN ENCLOSURE

ELECTRONIC ENCLOSURE

analyzer.
DISPLAY INTERFACE PWB
OVEN HEATER

A-4 | IPS-4 Full SpectrumGPDIV2

DETECTOR INTERFACE PWB

RELAY PWB

MCU PWB
POWER SUPPLY
CAL (SPAN) FLUID IN
DC TERMINAL ASSEMBLY

ANALOG PWB
Analyzer Overall Component Layout

SAMPLE IN
AC TERMINAL/
MAIN FUSES
SAMPLE OUT

CUSTOMER OVEN VENT

CONNECTIONS PWB
SAMPLE LINE JUNCTION BOX

C4, SAMPLE LINE RTD1

P1, ANALYZER POWER
C6, ANALOG SIGNAL
C7, DISCRETE SIGNAL C5, SAMPLE LINE RTD2

P2, SAMPLE LINE POWER C3, SAMPLE LINE HEAT TRACER POWER

C2, HAG PROBE POWER

C1, HAG PROBE RTD

Actual layout may vary. Refer to customer-specific drawings in the “Supplemental

C1, HAG PROBE RTD

Information” section of this manual or the Documentation Package shipped with the
Detector Interface Board (403441901)
C20 C13

+
C7 R6 U6
P2 R9
+
C5 P4
C3
R7
C19 JP1 C14

C9 X1 C18 J3 R8 R13 1
U5
C8
U10 J4
U8 D2
R10 1 3 5
U2 C15
R11

U1
R4 C11
U11 U9 C12 U12 2 4 6
C17
R12
C10

403441901
REV
C2
TP1
U13 J1
U7
C6

GND C21

Appendix – Drawings | A-5

 Detector Board (100-1955)

Detector board (700030901)

TP1 TB1 U7 TP2 U4 R12
TP9 TP7
P1 C40
R10
PS1
1 C21
C1
2 3 4 R20
1

+
C19 C23 C36
C14
J4 R9 L5
C13 C18 R18
C38 R21
C2 U13

R6 L3 P3
J3 R25
R5 C37 R19 R28
U3 C12 R22
R7
C20 R17 R37
L1
C5 C8 C42 R36 R38
+
D1 U6 R35
R8
C10 C9
U2 R32 J2
C6 J1 700030901 U10 C11
C3 L4 C28 C16
U5 TP4
C4 C31 C32 TP6 R24
C45
C30 D2
U11 R26
C7 R2 R3
R23 R13 RV1
R1 TP8 C44
R33
C39 U9 R15
C27 REV P2
R30 D4 R31
R27
C34
C35

R29
C41

C33 C43
R4 R11 TP3
D5

A-6 | IPS-4 Full SpectrumGPDIV2

Display Interface Board (100-1978)

Display Interface board (700043901)

P100 VOTP102 TP100 TP101

COM
VI
700043901

C101
R101
C104

R102
R100

R103
C100

U100
C102
REV

C103 C105

Appendix – Drawings | A-7

 Customer Connection Board (100-1971)

A-8 | IPS-4 Full SpectrumGPDIV2

Relay Board (100-1942)

Appendix – Drawings | A-9

 Analog Board (100-1922)

A-10 | IPS-4 Full SpectrumGPDIV2

MCU Board (100-2045)

Appendix – Drawings | A-11

 Xenon Lamp Board (100-2061)

A-12 | IPS-4 Full SpectrumGPDIV2

 SOLENOID VALVES DETECTOR BOARD
S1 S2 S3 S4 S5 (PROGRAMMED) FUSE RATINGS
TB2-8
SHEET3 TB2-1 XLB_J2 100-2046 AC LINE VOLTAGE
TERM
(SHEET3) DB_J1 120 V 240 V
BENCH 1AT 0.5 A T
14

WHT
BLK
BLK
BLK
BLK

RED
RED
RED
RED
RTD 301-0860 301-0859
CABLE17

18BLK300
18RED300
XENON FLASH LAMP DIB_P2 4AT 2AT

SSR1-4/A2
SSR1-3/A1
1 18BLK600

1 18BLK600
1 18BLK600
1

2
3 18GRN/YEL600
4

2 18BLK600
3
2 18WHT600
3 18GRN/YEL600
4
2
3
4
7
8
9
13

1
2
1
2
3
4
5
6
10
ASSY. 100-1994 OPTICAL BENCH ASSY. 301-0862 301-0861
CON3A
100-1987 or 100-1999 4B 4A 2AT
CABLE16 BLK 3B 3A WHT 12 301-0861

RB_J402
RB_J401B

RB_J401A
RB_J401C
16GRN/YEL600
AB_J404 CELL RTD
RB_J109 RB_J203 RED 2B 2A WHT

18RED300
18BLK300
G-IN
GOUT
GOUT

N/C
N/C

L-IN
LOUT
L-IN
N-IN
N/C
LOUT
NOUT
LOUT
NOUT
WHT 1B RED 6.3 A T
1A 11
OVEN HTR BENCH & LAMP BENCH HTR LAMP HTR 12 VDC SOLENOID VALVES 301-0863
CABLE3
4 HTR MCU_P3 CON3B
3
2 4B 4A

CT
1
CABLE15 BLK 3B 3A RED

RB_J404
S/V LINE
AB_J402
RED 2B 2A RED
SSR2-4/A2 22BLK300 4 WHT 1B 1A WHT
BENCH RTD
SSR2-3/A1 22RED300 3 TB2-1
2 SHEET3 TB2-8 CUSTOMER CON2B CON2A
1
RELAY BOARD

SR
SHIELD SHIELD

S/V LINE
RB_J403
(PROGRAMMED) 100-2050 CONNECTION PRESSURE
22BLU300 4 BOARD 100-1971 TRANSDUCER
SV-OT-1 BLK 4B 4A BLK
22YEL300

18BLK300
18RED300
SV-OT-0 3 CABLE13 WHT 3B 3A WHT
2 RB_J101 AB_J302

+
CCB_J19 GRN 2B 2A GRN

SHEET2
1

RB_J504
RED 1B 1A RED

OT RELAYS
1C1 AUX. POWER 1 22BLU600 CON4B CON4A
VL SL OVEN HEATER 1C2 2 22RED600
OT RTD OT RTD OT RTD RELAY CONTACTS CONTACT IN FLOW SW IN 2C1 CCB_J1B 3 22GRN600

SHEET4
2C2 4 22YEL600
RB_J503 RB_J502 RB_J501 RB_J301 RB_J201 RB_J202
3C1 5 22VLT600 RED 6
3C2 6 22OR600 5
4C1 7 22GRY600

1
1
1
1
1
4

2
2
2
2
2

4
4
4
4
4

3
3
3
3
3

9
8
7
5
4
3
2
1

11

16
15
14
13
12
10
TB3-13 22RED300 8 22BLK600 CABLE9 SENSOR 2
C4

4C2 3

SHEET2
0.1u

TB3-12 22RED300 AB_J304 301-0759

5C1 RELAY CONTACTS 9 22WHT600 2
22WHT300

RED
RED
WHT
TB3-11 5C2 10 22BRN600 BLK 1
6C1 11 22BLU600 WHT NOTE: PIN 1
END
6C2 12 22RED600 HAS A NOTCH
RED 6 NC

22YEL600
22GRN600
22RED600
22BLU600
22GRY300

22VLT600

22BLK600
22WHT300
22BLK300

22BRN300

22GRY600
18BLK600 13

22OR600
22GRN600

22WHT600
22BRN600

22RED600
22BLU600

22OR600
22VLT600
22GRN600
22YEL600
SSR1-2/T1 5 NC

18
14 22YEL600
4 NC
18WHT600 15 22VLT600 CABLE8 SENSOR 1
C3

3 VS

17
0.1u

16 22OR600 AB_J304 301-0759

2 COM
18WHT600 CCB_J1A BLK 1 VOUT
PS1 ACN

16
WHT
WHT CCB_J2B
18WHT600 1 22GRY300

15
2 22BLK300
18BLK600 CONTACT INPUT 3 22WHT300

14
4 22BRN300
18BLK600 CCB_J2A

13
ETHERNET
CCB_J17

18BLK600
18BLK600

12
PS1 ACL CABLE12

SHEET3
MCU_J5 NDIR OPTICAL BENCH ASSY.
18BLK600

11
18BLK 600 CCB_J18 22VIO-250 BRAID
SSR1-1/L1 CCB_J8
CON-A PS1-GND
18BLK600 700046901

10
22BRN-300 18RED 600
WHT/RED
CON-B IRB_P10 IRB_P20
SHEET3

18BLK600 22GRY PS1-(+)

9
CON-D DIB_P2 CABLE5 CABLE18
PS1 CURRENT OUT 1-2 18BLK600
SHEET3

18GRN/YEL600 PS1-(-)

8
5 4 3 2 1
CCB_J9 CCB_J16

7
CCB_J10
18WHT600 RS-232 8

VAR1

6
CURRENT OUT 3-4
CIRCUIT BOARDS
CCB_J12

5
CABLE6 SYMBOL BOARD NAME PART No. SHEET

VAR2
MCU_P6 AB ANALOG BOARD 100-2047 2

4
CCB_J15 CCB CUSTOMER CONNECTION BOARD 100-1971 1
18BLK600 CCB_J11 CABLE7 DB DETECTOR BOARD 100-2046 1

3
CCB_J3 MCU_P7 DIB DETECTOR INTERFACE BOARD 100-2048 2
CCB_J6 DIO DISPLAY INTERFACE BOARD 100-2049 2

2
SHEET2

MCU MCU BOARD 100-2045 2

CABLE2

VAR3
AB_J103 RB RELAY BOARD 100-2050 1
ANALOG IN 1

1
XLB XENON LAMP BOARD 100-2061 3
4B 4A
END CABLE14 WIRE CODE
BLK 3B 3A RED
AB_J401 RED 2B 2A RED ANALOG XX YYY/YYY ZZZ
TB1 WHT 1B 1A WHT RS-485

14GRN/YEL 600
BRAID
IN2 RTD1 RTD2
CCB_J13

LF1 CON1B CON1A CCB_J7 CCB_J4 CCB_J5 CCB_J14 AWG COLOR VOLTAGE RATING

LOAD
BACK PANEL GROUND
V+
VR
TX+
TX-

RX+
RX-

GROUND POINT E STUD A LINE

CM1
CM2
GND

EXC

CM1
CM2
GND

EXC

OVEN RTD
18GRN/YEL 600 OVEN HEATER OT RTD
18GRN/YEL600 WHT/RED
L
WHT OVEN
N
GROUND STUD H 14GRN/YEL600 GRN/YEL G HEATER TB3-7 22 WHT 300
TB3-8 22 RED 300
(SHEET2) GROUND GROUND 22 RED 300
BRAID OVEN HEATER CONDUIT TB3-9
STUD B STUD C
BACK PANEL
GROUND POINT D
Electronics Enclosure Wiring Diagram, Sheet 1 of 4 (403444001)

Appendix – Drawings | A-13

 CONNECTOR AND COVER
DIO_P1 271228001,28078801
DISPLAY-CN2 DISPLAY INTERFACE

DIO_P3
BOARD 100-2049
DIO_P2
DIO_P4
1 16 CABLE NUMBER

4
3
2
CABLE1 100-2029
18RED300
TB2-3 CABLE2 273119003
CABLE3 273119002

CABLE11
18BLK300

SHEET3
TB2-6 CABLE4 301-0733
CABLE5 100-2029

KEY
PAD
CABLE5
IRB_P10 CABLE6 301-0897
CABLE7 301-0897
CABLE3
RB_J101

SHEET1
CABLE8 301-0930
CABLE9 301-0930
MCU_P3
CABLE10 301-0896

A-14 | IPS-4 Full SpectrumGPDIV2

CABLE11 301-0738
CABLE7
CCB_J15 CABLE12 301-0849

CABLE3

MCU_P7
CABLE13 301-0936
DIB_P2 DIB_P4
CABLE14 301-0930

DIB_P1
MCU_P2
DETECTOR INTERFACE

SHEET1
CABLE15 301-0930
CABLE6 (PROGRAMMED) 403441901
CCB_J12 CABLE16 301-0930

AB_J101
CONNECTOR AND COVER

MCU_P6
271229001,280517001
CABLE17 273119001
MCU BOARD 100-2045 1 18RED300 CABLE18 700065901
2
TB2-4
(PROGRAMMED)
3
CABLE10 4
MCU_P1 MCU_J5 5

MCU_P4
SHEET3

MCU_P5
6 18BLK300
TB2-5

CABLE17
DB_J1 (SHEET1)
CABLE12
CCB_J17 (SHEET1)
CABLE4
XLB_J1 (SHEET3)
CABLE16
CON3B
CABLE15
CON2B BRAID GROUND STUD F
SHEET1

MCU_P3
CABLE14 (KEYPAD PLATE)
CON1B
GROUND STUD G
(BEZEL MOUNTING SCREW)
SHIELD

SHIELD
SHIELD

WHT
WHT
WHT

BLK
BLK
BLK

RED
RED
RED

CABLE3
1
4

2
3
1
1

4
1
2
3
4

2
3
2
3
4

14GRN/YEL600 GROUND
SHIELD
STUD B (SHEET 1)
BLK 4
CABLE13 GROUND
WHT 3 AB_J404 AB_J403 AB_J402 AB_J401
CON4B GRN 2
STUD H
AB_J101 CELL RTD LAMP RTD BENCH RTD OVEN HEATER
RED 1 RTD

AB_J302
SENSOR 1
PRESSURE
4
3
2
ANALOG BOARD

AB_J303
SHIELD 1
SENSOR2
PRESSURE
CABLE9 (PROGRAMMED) 100-2047
SENS2 1 18RED300
TB2-2

SHEET1
BLK 6 2 18BLK300
WHT 5 TB2-7
12 VDC
AB_J104
SHEET3

RED 4
AB_J103
SHIELD 3
BLK 2
AB_J304
SENSOR3

WHT 1
CABLE8
Electronics Enclosure Wiring Diagram, Sheet 2 of 4 (403444001)

SENS1 RED

CABLE2 CCB_J3
(SHEET1)
 TB1-11
18BLK600 XENON LAMP BOARD 100-2061

18BLK600
TB1-18
XLB_J2 XLB_J1 XLB_J3

1/L1 2/T1 * SWITCH SETTING

SSR 1 XENON FLASH
2
CABLE4
CABLE1

3 LAMP ASSY. CABLE

4 (SHEET1)
4/A2 3/A1 5
- + 6
CUSTOMER 7
18RED300 J403-1 8
CONNECTION
MCU_P1

18BLK300 J403-2
(SHEET2)

BOARD OFF ON
CON* 22BRN300 CCB_J16_3
22BLK300
CUSTOMER
18BLK300 - CCB_J16_5 CONNECTION
C B A BOARD
22GRY300 CCB_J16_2
+
(SHEET1)

18RED300
F E D
AUX 18BLK300
M L K
TB1 TB4 J H G
IRB_P20

11 I0+ RTN 46
12 RTN OUT3 45 18RED300
13 RTN OUT2 44 18BLK300 22GRY300
14 I1+ RTN 43 22GRY300
15 RTN OUT1 42 END

DIGITAL OUTPUT

ANALOG OUTPUTS
16 RTN OUT0 41 SHIELD
CABLE 18

CCB_J19-1
(SHEET1) 18RED300 18RED300 RB_J109-1 (SHEET1)
1

TB2 TB3 18RED300 AB_J104-1

21 I2+ COM 36 PS1 18RED300
22 RTN RED DIO_P4-1
COM 35 +V
23
+12V 18RED300 18RED300 MCU_P4-1

RS485
RTN D 34 +V
24 I3+ D 33 12V RET 18BLK300 RED
25 RTN +B 18RED300 -V
32 BLK BLK
SHEET2

18BLK300

PWR

ANALOG OUTPUTS
26 RTN A 31 -V
18BLK300 MCU_P4-6
18BLK300 DIO_P4-3
ACN
8 7 6 5 4 3 2

ACL 18BLK300 AB_J104-2

18BLK300 RB_J109-2 (SHEET1)
10 9

R1

18BLK600 RS-75-12
1M

TB1-12
18WHT600 CCB_J19-2 18BLK300
TB1-16 END
18GRN/YEL600 (SHEET1)
SHEET 1
TB1-8
TB2
Electronics Enclosure Wiring Diagram, Sheet 3 of 4 (403444001)

Appendix – Drawings | A-15

 22 RED 300
J503-3
22 RED 300
J503-2
J503-1 22 WHT 300
22 RED 300
CCB-J5-CM2
22 RED 300
CCB-J5-CM1
CCB-J5-EXC 22 WHT 300

SHEET 1
J504-4 22 BLU 300

J504-3 22 YEL 300

J403-4 22 BLK 300

J403-3 22 RED 300

SV-OT
0

4
12BLK600

A-16 | IPS-4 Full SpectrumGPDIV2

4/A2 1/L1
6

SSR2
+3/A1 2/T1
12BLK600
1

JUNCTION BOX 12BLK600

12 GRN/YEL600

TB3

GROUND
STUD 1 2 3 4 5 6 7 8 9 10 11 12 13 14

G L N N L G
POWER HEAT TRACER RTD1 RTD2
Disconnect Enclosure Wiring Diagram, Sheet 4 of 5 (403444001)
 SUPPLEMENTAL INFORMATION

This chapter consists of information that supports the operation of this analyzer. All
information in this chapter comprises the Documentation Package. A duplicate of the
Documentation Package is also shipped with the analyzer.

Information typically included in this chapter includes:

• Essential Health and Safety information

• Quality Control/factory information.

• Customer-specific system drawings that include customer installation respon-

sibilities and requirements, a flow diagram, mounting information, customer-
specific component layout diagram, and a customer connection diagram.
Other drawings may also be included as required.

• Manual Supplements – that describe and illustrate installation, operation (if ap-
plicable), and maintenance (if applicable) procedures for specific components
or optional equipment that make up your sample system.

Supplements are typically used for Measuring Cells, Sample Systems, or in-
formation that is intended to replace similar information in the User Manual.

• Other customer-specific information may also be included (application-specif-

ic).

• Any OEM products incorporated with this analyzer system, if applicable (ex-
ample, EXPO MiniPurge System manual, if used).

Supplemental Information | S-1

 This page intentionally left blank.

S-2 | IPS-4 Full SpectrumGP/DIV2