Dickey-John Instalab 700 NIR Operator'S Manual Download Page 9

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OPERATOR’S MANUAL

Instalab 700 NIR Product Analyzer

11001-1574-201107

INTRODUCTION 5

SPECIFICATIONS

•

Weight:

31 lbs/14.06 kg

•

Dimensions:

(Height) 13.93 in/35.4 cm, (Width) 15.52 in/39.42 cm,

(Depth) 14.25 in/36.19 cm

•

Language

: English with additional languages available in a future

release

•

Power Requirements

: 110/220 VAC, 50 to 60 Hz, <100 Watts

•

# of Optical Filters:

4 to10

•

Serial Computer Interface:

RS-232-C and USB

•

Printer

: Optional

•

Sample Integration Technique:

Rotating cup

•

Filter Bandpass:

approximately 10 nm

•

Light Source

: Tungsten Halogen

•

ETL Mark

: UL61010-1

•

Humidity:

5% RH to 95% RH to 27.7 degrees C, noncondensing

decreasing linearly to 60% RH at 35 degrees C, decreasing linearly to
50% at 40 degrees C

•

Temperature:

10- 40 degrees C (machine accuracy specification 10

degrees C - 35 degrees C)

•

Storage Temperature:

-20 degrees C to +60 degrees C

•

Calibration Storage:

Flash memory

•

Typical Analysis Time:

10 seconds

•

Detector:

Thermoelectrically cooled lead sulfide (Pbs)

•

Reference Measurement

: Through entire optical system, against

ceramic disk

•

Gain Setting

: Automatic for reference gain, calibration file controls

gain for sample

•

Diagnostics

: Diagnostic screens for troubleshooting

•

Indoor use only

Summary of Contents for Instalab 700 NIR

Page 1: ...ection 13 Product Characteristics 14 Sample Moisture Content 14 Sample Storage 15 Calibration Development 15 Log Data Collection 15 Lab Reference Values 18 Regression Analysis 18 Calibration File 18 C...

Page 2: ...Recommended Printer Setup 48 Results Settings 48 System File 50 Time and Date 51 Owner Data 52 Language 53 Audit Trail 55 LAN Settings 56 Startup 57 Power Down 58 Analyzing Product 59 Optics Temperatu...

Page 3: ...Noise Test 81 Troubleshooting 83 Maintenance 85 Checking the Air Filter 85 Cleaning Reference Disk And Sample Drawer 86 Cleaning Aperture Glass 89 Appendix A Worksheets 93 Appendix B Moisture Basis 9...

Page 4: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 IV...

Page 5: ...follows Be alert to the possibility of personal injury or death Use of the word WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury Use of...

Page 6: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 2 SAFETY NOTICES...

Page 7: ...gain for low reflectance samples Thermoelectrically cooled detector that maximizes sensitivity and dynamic range A completely sealed and thermally isolated optics chamber An integrated computerized s...

Page 8: ...riation Sample cup interchangeability Embedded processor along with Win CE operating system accomodates field updates Circuitry ensures excellent long and short term stability due to elimination of el...

Page 9: ...ximately 10 nm Light Source Tungsten Halogen ETL Mark UL61010 1 Humidity 5 RH to 95 RH to 27 7 degrees C noncondensing decreasing linearly to 60 RH at 35 degrees C decreasing linearly to 50 at 40 degr...

Page 10: ...ab 700 NIR Product Analyzer 11001 1574 201107 6 INTRODUCTION Figure 2 Dimensions Appropriate space must be left around the input power connector to allow easy disconnection at the unit 15 52 48 10 95...

Page 11: ...ample cup holder p n 46811 1211 4 inch open sample cup p n 46811 1410 A printer that is RS232 compatible or a USB printer that supports Printer Control Language PCL can connect to the IL700 to print t...

Page 12: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 8 INTRODUCTION...

Page 13: ...1 The Instalab should be placed on a level surface and in a location where it is protected from rapid changes in ambient temperature 2 Connect the power cord to a 3 wire grounded 120 VAC 60 Hz or a 2...

Page 14: ...drive only 3 USB devices are supported at any one time 1 USB Type B connection to connect the IL700 to a PC for downloading of software to the device installing calibrations or remotely accessing data...

Page 15: ...ons agree with the reference analysis For each constituent calibration other than moisture pay careful attention to the moisture basis Lab results must be adjusted to or compatible with this moisture...

Page 16: ...red to make a universal calibration agree with a reference lab A bias adjustment compensates for machine differences as well as reference lab differences Reference labs do not all agree and this bias...

Page 17: ...ether all constituents are of immediate interest or not This is necessary because in reflectance spectroscopy the reflectance at any given wavelength is influenced to some degree by each constituent p...

Page 18: ...hout the sample Also NIR is sensitive to particle size and particle size variations All samples in the training set and in future analysis should have a similar grinding process SAMPLE MOISTURE CONTEN...

Page 19: ...is necessary For moisture levels of 16 or greater double bag each sample CALIBRATION DEVELOPMENT LOG DATA COLLECTION Log data must be collected using all installed filters to collect reflectance data...

Page 20: ...ropriate Data Collect choice 4 Press the Enter button and type in the product name 5 Press the Enter button to accept 6 Open the drawer to start the reference scan Figure 7 Collecting Log Data Select...

Page 21: ...lts INSTALAB INSTALAB INSERT SAMPLE Enter ID INSTALAB 700 Enter ID INSTALAB 700 Sample ID Customer ID Sample ID Customer ID Product CORN File Log Data Analyzing INSTALAB 700 Analyzing INSTALAB 700 Ple...

Page 22: ...hile YYYYMMDD provides dating of the file The cal file is a 16 bit unicode text file that can be created on any text editor capable of formatting in 16 bit unicode The layout for this file is depicted...

Page 23: ...ation only NA Native calibration and Alternate MB A Alternate MB only blank Do not display this constituent Format 00 0 Display Format 00 0 00 00 00 000 Adj_Bias 0 Adjustable Bias Default Value 0 0 Ra...

Page 24: ...at test OK Indicate the cal le storage loca on using File Path highlighted in green Cal File Created File Path E Program automa cally determines what lters are needed File Name IL700 Soybeans3 2011081...

Page 25: ...over the direct drive version High oil products can require the use of a knife mill of the type used for home preparation of freshly ground coffee The Krups Mill or the Mitey Mill are examples Once a...

Page 26: ...motion Figure 12 Heaping Sample Using Scoopula 4 Dump the sample onto the center of the window Figure 13 Fill Sample Cup 5 Slide the sample off the tip of the scoopula to form a conical pile Do not d...

Page 27: ...la Figure 15 Tamping Sample Into Cup 7 Pack the sample until the surface is flat and flush with the rim of the cup Sample should be tightly packed to eliminate any air pockets 8 Carefully brush off al...

Page 28: ...oading tray Figure 18 Place Sample Cup Bottom Onto Filled Cup 11 Clean remaining sample residue from sample cup lip Figure 19 Remove Sample Residue NOTE Do not touch and or fingerprint the glass cover...

Page 29: ...p and a sample cup holder To prepare Sample 1 Place the sample cup holder onto a flat surface and put the sample cup into the holder Figure 20 Sample Cup and Holder 2 Using a spatula or appropriate ut...

Page 30: ...1107 26 SAMPLE PREPARATION Figure 22 Level Sample in Cup 4 Remove excess sample residue from sample cup lip and holder using a towel or cloth Figure 23 Remove Excess Residue 5 Remove cup from the hold...

Page 31: ...ing the Sample 1 Remove cover from base 2 Place a small amount of liquid onto the middle of the base glass such that it puddles in the center and covers an area approximately 20 mm in diameter NOTE Do...

Page 32: ...g is complete disassemble the sample cup and clean Do not immerse the base unit in cleaning solution Using minimal water on the glass and drying with a cloth is sufficient The top cover can be cleaned...

Page 33: ...Set aside the screws to re attach the large tray 2 Remove the sample tray from the plate Figure 27 Remove Standard Sample Tray 3 Remove the 2 2 Phillips screws from the sample motor mounting plate 4...

Page 34: ...duct Analyzer 11001 1574 201107 30 SAMPLE PREPARATION 7 Secure the plate with the 3 Allen heads screws Tighten to 6 in lbs Figure 29 Install Sample Tray 8 Place sample cup into tray Installation is co...

Page 35: ...re used to navigate through and interface with the unit 1 Text input boxes 2 Keypad icon enables keyboard 3 Navigation buttons 4 Virtual keyboard Figure 31 LCD Touch Screen Display USING EXTERNAL DEVI...

Page 36: ...nt requirements BACK Back button returns to the previous screen ENTER Enter button accepts action taken and proceeds to next screen Parameters changed on the screen typically requires the Enter button...

Page 37: ...y to a finger touch or stylus KEYPAD The Keypad icon appears on those screens that require text entry Pressing the Keypad icon opens the virtual keyboard for typing text on the screen The virtual keyb...

Page 38: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 34 NAVIGATION...

Page 39: ...assword must be created NOTE An external keyboard barcode scanner or mouse can be used to enter data into the unit To create an Admin User Name and Password or change an existing User Name and Passwor...

Page 40: ...and numbers Figure 34 Password Screens Contact DICKEY john Tech Support at 1 800 637 3302 or a local representative to reset instrument to open access mode Enter Password INSTALAB 700 Enter Password I...

Page 41: ...in Settings button Ethernet connectivity settings LAN Settings button To view System Setup options 1 At the Main Menu screen press the Setup button 2 Enter User Name and Password if required and press...

Page 42: ...ucts and their respective file names Do not highlight a product Press the Print button to print all parameters of a particular calibration Highlight the product 2 Press the Edit button to display the...

Page 43: ...ton and return to the Product List screen Pressing the Back button or Home button will not save changes Figure 37 Create a New Constituent NOTE For a constant to appear as a symbol in the Units column...

Page 44: ...has no Enter button to ensure a save has occurred Pressing the Back button or Home button will not save changes To Delete a Constituent 1 At the Edit Product screen highlight the constituent and pres...

Page 45: ...ile with the conflicting label Also if overwriting a file with the same name solves the conflicting label issue this is allowed after confirmation of the overwrite Products List INSTALAB 700 Products...

Page 46: ...o the IL700 using a USB memory device Follow the onscreen instructions to begin file import To Import a Product 1 Insert USB memory device into unit 2 At the Products List screen press the Import butt...

Page 47: ...STALAB 700 Directory Contents 1 Directories 0 Files Exist Push ENTER to view Import Products INSTALAB 700 Import Products INSTALAB 700 Label File Import HRWW_4 IL700 HRWW_4 20110908 Hard Disk Director...

Page 48: ...An existing file that has the same file name as an imported file can be overwritten with operator approval However overwriting a file of a different file name with the same product label name is prohi...

Page 49: ...printer prints only those parameters that show on the Results screen If no alternate moisture basis information displays it will not print If a parameter is hidden due to its calibration file configur...

Page 50: ...plies only to printing 8 Select the output format based on printer type PRN80 Standard 80 column printer output 80 characters per line SP200 RS232 only Star Printer compatible does not recognize the t...

Page 51: ...d Footer text can be added to print on a print ticket Owner Data text can be selected as the default or customized text can be entered To Enter a Header Footer 1 At the Printer Setup screen press the...

Page 52: ...bol is used before a numeric digit the auto sequence sample ID will auto sequence to the next lower number ABC 123 will auto advance to ABC 122 A dash symbol used within alpha characters will not affe...

Page 53: ...ally entered that can be manually changed if desired The Customer ID function performs in the same manner as Sample ID except Customer ID continues to used the last customer ID as opposed to Sample ID...

Page 54: ...screen indicates that files are exporting to the memory device displaying the file names transferred 4 At the File Write Complete screen press the Enter button to return to the System Setup menu 5 Mem...

Page 55: ...ect a date press the Date drop down arrow to display the calendar 3 Set the time by selecting the hour and minutes Select the PM check box if applicable 4 Press the Enter button when done Figure 48 Ti...

Page 56: ...ata button appears 2 Press the Owner Data button and enter name address phone number by pressing the keypad icon 3 Press the Enter button when finished Figure 49 Owner Data Screens System Setup 2 INST...

Page 57: ...ce into computer Select and download language file to USB memory device 3 Insert USB memory device into IL700 4 At the Admin Menu 1 screen press the System button 5 At the System Setup 1 screen press...

Page 58: ...lect button 14 Press the Enter button to confirm and start language reset 15 The instrument will start an automatic reboot and return to the Main Menu screen NOTE Do not power off instrument during re...

Page 59: ...it Trail screen If the printer output format is PRN80 or CSV01 the output format is CSV All other formats print in strip 4 Insert a USB memory device and press the USB button to transfer Audit Trail r...

Page 60: ...n Menu 1 screen press the More button to display the LAN Settings button Figure 53 LAN Settings Screen LAN Information INSTALAB 700 LAN Information INSTALAB 700 IP Address MAC Address Serial Number Ho...

Page 61: ...IMPORTANT The unit is designed to remain on and not be turned off If turned off the unit should be powered on for 3 hours before measurements are taken It is highly recommended that NO analysis is per...

Page 62: ...n the Home screen that will power down the unit in the same manner as the on off switch A Power Down screen must be acknowledged before the unit will shut down The On Off button must be pressed again...

Page 63: ...chamber The bar is red until the temperature reading is within 50 degrees C of the optimum set point of 50 00 degrees C The bar turns green when the temperature is within 10 degrees C of the setpoint...

Page 64: ...ntry of a Sample ID can be avoided by enabling the Automatic ID at the Results Settings screen SELECTING PRODUCT To select a product for testing 1 At the Main Menu screen press the Analyze button A pr...

Page 65: ...Last Enabled Customer ID will continue loading a Customer ID until the next power cycle occurs If neither are required this screen is skipped 5 During analysis a testing status bar indicates progress...

Page 66: ...ns Figure 59 Analysis Results Screen ANALYSIS READINGS DEFINED READING As Is Actual sample moisture is moisture basis Out of Limits A reading that is above or below calibration limits Example 12 5 As...

Page 67: ...e ID is required The Results screen displays log values instead of predictions Perform a Log Data Collection 1 At the Main Menu screen press the Analyze button 2 To view the Data Collect options press...

Page 68: ...e Enter button to proceed A testing status bar indicates progress Press the Enter button to perform another Log Data Collection Press the Home button to return to the Main Menu screen Figure 61 Log Da...

Page 69: ...label and its value 12 Press the Enter button to perform another log data collection or press the Home button to return to the Main menu screen Figure 62 Log Data Results Show Log Data INSTALAB 700 Sh...

Page 70: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 66 ANALYZING PRODUCT...

Page 71: ...duct s specific results details Press the Back button to return to the Results view screen Figure 63 Results Screen Results View INSTALAB 700 Results View INSTALAB 700 06 Mar 09 02 04 PM 06 Mar 09 02...

Page 72: ...A query of records can be performed by selecting a check box to enable last number of records last number of days by product name by customer id 5 Press the Enter button to display query results At th...

Page 73: ...of records to display or print starting with the last sample taken such as printing the last 5 samples LAST NUMBER OF DAYS Allows entry of a specified number of days to display or print starting with...

Page 74: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 70 RESULTS...

Page 75: ...d take several minutes if a large quantity of records are being backed up Do not interrupt the transfer until a File Write Complete message appears NOTE Files are exported as an xls file To Delete Tes...

Page 76: ...the Delete All button 2 Press the Delete All button to initiate deletion of records 3 Press Enter to confirm and begin record deletion A confirmation screen displays indicating files are removed and d...

Page 77: ...ice into unit 2 At the Database View screen press the Save and Delete All button 3 A File Write Complete screen indicates files have been exported and deleted Figure 67 Save and Delete All Records INS...

Page 78: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 74 DATABASE STORAGE RECORD...

Page 79: ...value and the respective Raw Log value Raw Log measurements can be conducted on a sample or on the reference disk To perform a Raw Log Measurement 1 At the Diagnostic Menu 01 screen press the Raw Logs...

Page 80: ...vice Press the Back button to return to the main Diagnostics menu Figure 69 Raw Logs Screen In Standard Gain mode all raw logs displayed are normalized to a gain of 1 for both sample and reference In...

Page 81: ...on is pressed Values will populate on the Reference Drift screen in approximately 5 to 10 seconds Press the Refresh button to perform additional tests Press the Print button to print screen results Pr...

Page 82: ...relative drift flag potential problems with drift The Store function should only be performed if an ERROR 6 message persists during normal operation and limited to an average of no more than once eve...

Page 83: ...etector typically used for troubleshooting 1 At the Diagnostics Menu 01 screen press the More button to display the Diagnostics Menu 02 screen 2 Press the Temperature button to display system temperat...

Page 84: ...ollow onscreen instructions 3 Carefully press and hold finger on the center of the target 4 Repeat as the target moves around the screen 5 With a keyboard attached press the Enter button to accept new...

Page 85: ...iagnostics Menu 02 screen Press the Diagnostic File button Figure 75 Diagnostics File Screen NOISE TEST A Noise Test is used by a repair technician for troubleshooting purposes 1 At the Diagnostics Me...

Page 86: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 82 DIAGNOSTICS...

Page 87: ...turns off or unplug instrument power Wait a few seconds and then power on The IL700 performs a number of self checks to verify proper unit operation If a fault is detected due to an operator procedura...

Page 88: ...red for a calibration file is not available on the unit The file can be loaded but no analysis is permitted until suitable wavelengths are installed 22 Duplicate product labels Product labels must be...

Page 89: ...ental conditions To Check the Air Filter 1 Remove the filter cover located on the back of the unit to gain access to the filter Filter cover can be removed by grabbing two sides and pulling NOTE Unit...

Page 90: ...place mesh screen onto filter 5 Snap cover back onto the unit CLEANING REFERENCE DISK AND SAMPLE DRAWER The reference disk and the sample drawer must be cleaned periodically based on surrounding envi...

Page 91: ...87 Figure 81 Remove Sample Cup 3 Push the drawer stop levers inward on both sides and pull the drawer to the full open position Figure 82 Push In On Levers 4 Pull the drawer out to gain access to the...

Page 92: ...free cloth or soft brush IMPORTANT In conditions where the reference disk has an oily residue alcohol on a cotton swab should be used to remove the residue After the alcohol is completely dry use a c...

Page 93: ...Turn the unit power OFF 2 Unplug power cord and all cables from the unit 3 Place the unit on its back side Figure 86 Place Unit on Back Side 4 The sample drawer must be removed to gain access to the a...

Page 94: ...l is completely dry use a cloth to clean the sample glass to ensure any trace of alcohol is removed IMPORTANT Inspect the drawer on the back right side for a bent tab A bent tab should be straightened...

Page 95: ...ide of the drawer and insert into the track grooves Figure 90 Insert Drawer 8 Carefully close drawer and ensure that the drawer tab slides between the upper and lower portion of the sensor and that th...

Page 96: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 92 MAINTENANCE...

Page 97: ...duct ___________________________ Grinder Serial ______________________ CONSTITUENT CONSTITUENT CONSTITUENT CONSTITUENT Sample N Standard Analysis Standard Analysis Standard Analysis Standard Analysis...

Page 98: ...___________________________ Grinder Serial ______________________ CONSTITUENT CONSTITUENT CONSTITUENT CONSTITUENT Sample N Standard Analysis Standard Analysis Standard Analysis Standard Analysis Insta...

Page 99: ...Date ______________________________ MOISTURE PROTEIN CONSTITUENT CONSTITUENT CONSTITUENT MB U LL KA K0 K1 K2 K3 K4 K5 K6 K7 K8 K9 MB U LL KA K0 K1 K2 K3 K4 K5 K6 K7 K8 K9 MB U LL KA K0 K1 K2 K3 K4 K5...

Page 100: ...Date ______________________________ MOISTURE PROTEIN CONSTITUENT CONSTITUENT CONSTITUENT MB U LL KA K0 K1 K2 K3 K4 K5 K6 K7 K8 K9 MB U LL KA K0 K1 K2 K3 K4 K5 K6 K7 K8 K9 MB U LL KA K0 K1 K2 K3 K4 K5...

Page 101: ...the following moisture basis selections As Is Fixed Moisture typically a recognized standard moisture value Dry basis a subset of fixed moisture Example Wheat protein can be measured on an NIR instru...

Page 102: ...tion Post processing can allow another moisture basis to be used For As Is native moisture basis the moisture must explicitly be determined to allow such conversions to another moisture basis When obt...

Page 103: ...llows for an alternate moisture basis to be used in addition to the native moisture basis To calculate an AMB the following requirements must be met MC_Basis N AND MB XX X or MB A or AMB A AND MC_Basi...

Page 104: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 100 APPENDIX B...

Page 105: ...nts With the reference gains established per above the gains used for sample measurements will be addressed Every calibration file is based on either a Standard gain selection or an Enhanced gain sele...

Page 106: ...typically does not happen on standard wavelength optical filters however a special filter can be used that has lower transmittance and a X4 gain can be selected as the reference measurement In the En...

Page 107: ...a computer such as performing an analysis transferring constituents to a computer and checking reference drift A list of the remote commands to perform these and similar functions can be obtained by c...

Page 108: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 104 APPENDIX D...

Page 109: ...to enable data streaming A placeholder exists for all ten possible constituents and constituent parameters For each possible constituent a placeholder exists for Native constituent value MB Alternate...

Page 110: ...OPERATOR S MANUAL Instalab 700 NIR Product Analyzer 11001 1574 201107 106 APPENDIX E...

Page 111: ...ut DICKEY john s written consent damage to any associated equipment or lost profits or special damages Said part will not be considered defective if it substantially fulfills the performance expectati...

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