Buchi NIR-Online X-Sential User manual

NIR-Online®
X-Sential™
Operation Manual
11594282 | A en

Imprint
Product Identification:
Operation Manual (Original) X-Sential™
11594282
Publication date: 08.2021
NIR-Online GmbH
Altrottstrasse 31
D-69190 Walldorf
E-mail: [email protected]
NIR-Online reserves the right to make changes to this manual as required on the basis of future insights,
especially with respect to layout, illustrations and technical detail.
This manual is copyright. Information from it may not be reproduced, distributed, or used for competi-
tive purposes, nor made available to third parties. The manufacture of any component with the aid of
this manual without prior written agreement is also prohibited.

NIR-Online GmbH Table of contents
Operation Manual X-Sential™ iii
Table of contents
1 About this document...........................................................................................................5
1.1 Mark-ups and symbols ..........................................................................................................5
2 Safety....................................................................................................................................6
2.1 Proper use .............................................................................................................................6
2.2 Use other than that intended .................................................................................................6
2.3 Warning notices in this document..........................................................................................6
2.4 Warning and directive symbols..............................................................................................7
2.5 Staff qualification ...................................................................................................................7
2.6 Personal protective equipment (production)..........................................................................8
2.7 Personal protective equipment (laboratory)...........................................................................8
2.8 Modifications..........................................................................................................................8
3 Product description.............................................................................................................9
3.1 Description of function ...........................................................................................................9
3.2 Configuration .........................................................................................................................9
3.2.1 Front view ...................................................................................................................9
3.2.2 Rear view..................................................................................................................10
3.3 Scope of delivery .................................................................................................................10
3.4 Type plate............................................................................................................................11
3.5 Technical data .....................................................................................................................12
3.5.1 Sensor ......................................................................................................................12
3.5.2 Installation box..........................................................................................................13
3.5.3 Ambient conditions ...................................................................................................13
3.5.4 Materials ...................................................................................................................13
3.5.5 Software....................................................................................................................14
3.5.6 Computer system requirements................................................................................14
3.5.7 Installation site (laboratory).......................................................................................15
3.5.8 Installation site (production)......................................................................................15
4 Transport and storage ......................................................................................................16
4.1 Transport .............................................................................................................................16
4.2 Storage ................................................................................................................................16
5 Installation..........................................................................................................................17
5.1 Establishing installation point ..............................................................................................17
5.2 Installation point in piping system (example).......................................................................18
5.3 Installation (example) ..........................................................................................................19
5.4 Sensor installation ...............................................................................................................20
5.5 Connecting the sensor.........................................................................................................21
5.6 Establishing electrical connections......................................................................................22
6 Operation............................................................................................................................23
6.1 Journal button......................................................................................................................23
6.2 Entering reference data in the journal ................................................................................. 23
7 Cleaning and servicing .....................................................................................................24
7.1 Notes on servicing ...............................................................................................................24
7.2 Regular maintenance work..................................................................................................24

Table of contents NIR-Online GmbH
iv Operation Manual X-Sential™
8 Taking out of service and disposal..................................................................................25
8.1 Disposal...............................................................................................................................25
8.2 Returning the instrument .....................................................................................................25
9 Appendix ............................................................................................................................26
9.1 Certificates...........................................................................................................................26
9.1.1 CE certificate ............................................................................................................26
9.2 Spare parts and accessories ...............................................................................................27
9.2.1 Accessories ..............................................................................................................27
9.2.2 Mounting accessories ...............................................................................................27
9.2.3 Spare parts specifications.........................................................................................30

NIR-Online GmbH About this document | 1
Operation Manual X-Sential™ 5/34
1 About this document
This operation manual is applicable for all variants of the instrument.
Read this operation manual before operating the instrument and follow the instruc-
tions to ensure safe and trouble-free operation.
Keep this operation manual for later use and pass it on to any subsequent user or
owner.
NIR-Online GmbH accepts no liability for damage, faults and malfunctions resulting
from not following this operation manual.
If you have any questions after reading this operation manual:
uContact NIR-Online GmbH Customer Service.
[email protected]
1.1 Mark-ups and symbols
NOTE
This symbol draws attention to useful and important information.
RThis character draws attention to a requirement that must be met before the in-
structions below are carried out.
uThis character indicates an instruction that must be carried out by the user.
ðThis character indicates the result of a correctly carried out instruction.
Mark-up Explanation
Window Software Windows are marked-up like this.
Tab Tabs are marked-up like this.
Dialog Dialogs are marked-up like this.
[Button] Buttons are marked-up like this.
[Field names] Field names are marked-up like this.
[Menu / Menu item] Menus or menu items are marked-up like this.
Status Status is marked-up like this.
Signal Signals are marked-up like this.

2 | Safety NIR-Online GmbH
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2 Safety
2.1 Proper use
The sensor is used to analyze substances and samples in production and in the labo-
ratory. The sensor is intended exclusively for that purpose.
The sensor can be used in laboratories and production facilities for the following op-
erations:
Quality control
Process optimization
Reference measurements
2.2 Use other than that intended
The use of the instrument other than described in proper use and specified in tech-
nical data is use other than that intended.
The operator is responsible for damages or hazards that are caused by use other
than that intended.
Specially the following uses are not permitted:
Use of the sensor in areas which require explosion-safe devices.
2.3 Warning notices in this document
Warning notices warn you of dangers that can occur when handling the device.
There are four danger levels, each identifiable by the signal word used.
Signal word Meaning
DANGER Indicates a danger with a high level of risk which could result in
death or serious injury if not prevented.
WARNING Indicates a danger with a medium level of risk which could result in
death or serious injury if not prevented.
CAUTION Indicates a danger with a low level of risk which could result in mi-
nor or medium-severity injury if not prevented.
NOTICE Indicates a danger that could result in damage to property.

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Operation Manual X-Sential™ 7/34
2.4 Warning and directive symbols
The following warning and directive symbols are displayed in this operation manual
or on the instrument.
Symbol Meaning
General warning
Dangerous electrical voltage
Material damage
Read manual
1
Fig.1: Location of safety notices and warning signs on the instrument
1
General warning
Clean Unit when dust exceeds 5
mm thickness
2.5 Staff qualification
Unqualified persons are unable to identify risks and are therefore exposed to greater
dangers.
The device may only be operated by suitably qualified persons.
These operating instructions are aimed at the following target groups:

2 | Safety NIR-Online GmbH
8/34 Operation Manual X-Sential™
Users
Users are persons that meet the following criteria:
They have been instructed in the use of the device.
They are familiar with the contents of these operating instructions and the appli-
cable safety regulations and apply them.
They are able on the basis of their training or professional experience to assess
the risks associated with the use of the device.
Operator
The operator is responsible for the following aspects:
The instrument must be correctly installed, commissioned, operated and serviced.
Only suitably qualified staff may be assigned the task of performing the opera-
tions described in these operating instructions.
The staff must comply with the locally applicable requirements and regulations for
safe and hazard-conscious working practices.
Safety-related incidents that occur while operating the instrument are to be re-
ported to the manufacturer.
[email protected]
NIR-Online service technicians
Service technicians authorized by NIR-Online have attended special training courses
and are authorized by NIR-Online GmbH to carry out special servicing and repair
measures.
2.6 Personal protective equipment (production)
Follow the rules regarding personal protective equipment that are applicable at the
installation site.
The operation of the sensor does not require additional protective equipment.
2.7 Personal protective equipment (laboratory)
Depending on the application, hazards due to heat and/or corrosive chemicals may
arise.
uAlways wear appropriate personal protective equipment such as safety goggles,
protective clothing and gloves.
uMake sure that the personal protective equipment meets the requirements of
the safety data sheets for all chemicals used.
2.8 Modifications
Unauthorized modifications may impair safety and lead to accidents.
uUse only genuine NIR-Online accessories, spare parts and consumables.
uTechnical modifications to the instrument or accessories should only be carried
out with the prior written approval of NIR-Online GmbH and only by authorized
NIR-Online service technicians.
NIR-Online GmbH accepts no liability whatsoever for damage arising as a result of
unauthorized modifications.

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Operation Manual X-Sential™ 9/34
3 Product description
3.1 Description of function
The sensor is an optical instrument for nondestructive determination of substances
and concentrations in a sample.
A sample absorbs and reflects light across the entire wavelength spectrum according
to its color and chemical composition. The signal reflected by the sample is recorded
and analyzed by a spectrometer.
The sensor uses a lamp to produce near-infrared radiation that interacts with the
molecules of the sample. The interaction between sample and light produces a
characteristic spectrum.
The light reflected from the sample is collected through two sets of fiber optics
that direct the light to the NIR and visible spectrophotometers, respectively. The
visible spectrophotometer consists of a diffraction grating to spatially disperse the
light according to wavelength and a silicon photodiode array containing multiple
elements which measure the light intensity for specific wavelength intervals. The
NIR spectrophtometer consists of a diffraction grating to spatially disperse the
light according to wavelength and an indium-gallium-arsenide photodiode array
containing multiple elements.
The produced measurement results are converted to data sequences.
The data sequences are transferred to a computer via an interface.
A computer program compares the data sequence curve with a calibration model
and in that way determines the chemical composition of the sample.
3.2 Configuration
3.2.1 Front view
12
3
Fig.2: Front View
1 Measurement window 2 Flange
3 Heat sink

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3.2.2 Rear view
12
3
4
5
6
Fig.3: Rear view
1 Journal Button 2 Power and scanning indicator light
3 Type plate (part) 4 Ground connection
(Equipotential bonding)
5 Power and signal connector 6 Type plate (part)
3.3 Scope of delivery
NOTE
The scope of delivery depends of the configuration of the purchase order.
Accessories are delivered as per the purchase order, order confirmation, and deliv-
ery note.

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Operation Manual X-Sential™ 11/34
3.4 Type plate
The type plate identifies the instrument. See Chapter3.2.2 "Rear view", page10
5
6
7
8
15
14
1
2
3
4
9
13
12 10
11
Fig.4: Type plate
1 Company name and address 2 Product option
3 Revision number 4 Product name
5 Serial number 6 Production date
7 IP class 8 ATEX information
9 Power consumption
(nominal)
10 Power consumption
(maximum)
11 Ambient temperature 12 Current draw
(maximum)
13 Certificates 14 Operating voltage
15 Product type
The following product options are possible:
Letter Option
A NIR
D VIS
E Gold reflector
(X-One)
G Lamp position rev. 1.3.2
N System temperature 0 - 80 °C
O Humidity sensor 0-100% RH
S X-Quvette
(Fiber lens (approx. 0 - 2 cm))

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Letter Option
V External button
X2 X-Beam 002
(approx. 15 cm measurement distance)
3.5 Technical data
3.5.1 Sensor
Specifications X-Sential
Dimensions (W x D x H) 200 x 200 x 100 mm
Weight 5 kg
Max. operating pressure 30 bar at flange
Product temperature
(temperature at flange
with water cooling)
-10 °C to +130 °C
Product temperature
(temperature at flange
without water cooling)
-10 °C to + 70 °C
Vibrations 0.2 G at 0.1 - 150 Hz
Wavelength spectrum
NIR range
900 - 1700 nm; 11100 - 5880 cm-1
Wavelength spectrum
Visible range
350 - 900 nm; 28500 - 11100 cm-1
Detector Diode array
Average measurement
time
20 spectra/s
IP Code IP69 / IPX9K
Type of lamp Tungsten-halogen dual lamp
Lifetime lamp 18000 h (2 x 9000 h)
Minimum clearance on
all sides
100 mm
Connection Voltage 85 to 264 VAC
Frequency 50/60 Hz
Power consumption 30 W
Temperature stabiliza-
tion
ASDC (Advanced Spectral Drift Control): active tempera-
ture control to ±1°C from set system operating tempera-
ture. Deviations will lead to automatic white reference
measurement to account for spectral drifts.

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3.5.2 Installation box
Specifications Installation box
Dimensions (W x D x H) 300 x 300 x 167mm
Weight
(excluding cables)
6 kg
Weight
(inc. cables, 2 x 10 m)
7.4kg
Frequency 50/60 Hz
Power consumption 30 W
Power supply 85 - 264 VAC
3.5.3 Ambient conditions
Max. altitude above sea
level
2500 m
Ambient temperature -10 °C ≤ Tamb ≤ +40 °C
Max. relative air humid-
ity
< 90 % non-condensing
Storage temperature max. 45 °C
3.5.4 Materials
Component Materials of construction
Casing Aluminium (nickel coated), SS 316L 1.4404 flange
Seals NBR (standard sealing material)
FFKM (optional)

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3.5.5 Software
The sensor is controlled via the SX-Suite software package. It consists of the follow-
ing components:
Name Description Typical usage User Occurence
SX-Server Instrument
driver / usage
of special func-
tions
Read out instru-
ment status
Operator As required
Setup of instru-
ment hardware
NIR admin For installation
and mainte-
nance
Name Special function Description User Occurence
SX-Server Conveyor belt Optimized for
measurement
of moving ob-
jects on a con-
veyor belt
NIR admin As required
Mix Control end-
point of mixing
processes
NIR admin As required
Sample move-
ment detection
Verify sample
flow
NIR admin As required
Name Description Typical usage User Occurence
SX-Center User interface
(online/lab
mode)
Recipe/product
and calibration
mangement
Operator Daily workflow
(if not fully au-
tomated)
View results (ta-
ble, trend,
charts, reports)
Reference data
management
SX-Backup Data backup
scheduler
Automated
backup of mea-
surement data,
results and cali-
brations
NIR admin During installa-
tion
3.5.6 Computer system requirements
The system requirements for the computer are as follows:
Operating system Windows 10 Pro
Cental processing unit Intel Core i5 generation 6600 or later
RAM At least 4 GB

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Hard disk space At least 80 GB free disk space
Use a hard disk suitable for continuous operation.
Data backup
Network or external
hard disk
At least 0.5 GB free disk space
Additional 20 MB per day and sensor
Screen resolution At least 1280x1024
LAN At least 1 x 100 Mbit/s LAN
USB 2.0/3.0 At least 1 USB connection per sensor and 1x USB per Data-
Lab I/O box
PCI/PCIe 1 slot for Profibus card
(for Profibus connection)
Software Word and Microsoft Excel 2003 or later
3.5.7 Installation site (laboratory)
The installation site has a firm, level surface.
The installation site meets the safety requirements. See Chapter2 "Safety",
page6
The installation site has enough space that cables can be routed safely.
The installation site has no obstacles (e.g. water taps, drains, etc.).
The installation site has an own mains outlet socket for the instrument.
The installation site is not exposed to external thermal loads, such as direct solar
radiation.
The installation site allows that the power supply can be disconnected at any time
in an emergency.
The installation site meets the specifications according to the technical data (e.g.
weight, dimension, etc.). See Chapter3.5 "Technical data", page12
3.5.8 Installation site (production)
The installation site has a firm, level surface.
The installation site meets the safety requirements. See Chapter2 "Safety",
page6
The installation site has enough space that cables can be routed safely.
The installation site is not exposed to external thermal loads, such as direct solar
radiation.
The installation site meets the specifications according to the technical data (e.g.
weight, dimension, etc.). See Chapter3.5 "Technical data", page12
The installation site meets the specifications according to the installation point.
See Chapter5.1 "Establishing installation point", page17
The installation site has a own mains outlet socket for the instrument.
The installation site has a sample removal point at a distance of < 1 m.
The installation site allows a direct product measurement.
The installation site has constant product flow.
The layer thickness of the product to be measured is at least 30 mm.

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16/34 Operation Manual X-Sential™
4 Transport and storage
4.1 Transport
NOTICE
Risk of breakage due to incorrect transportation
uMake sure that all parts of the device are safely packed in such a way as to pre-
vent breakage, ideally in the original box.
uAvoid sharp movements during transit.
uAfter transportation, check the device for damage.
uDamage that has occurred in transit should be reported to the carrier.
uKeep packing for future transportation.
4.2 Storage
uMake sure that the ambient conditions are complied with (see Chapter3.5 "Tech-
nical data", page12).
uWherever possible, store the device in its original packaging.
uAfter storage, check the device for damage and replace if necessary.

NIR-Online GmbH Installation | 5
Operation Manual X-Sential™ 17/34
5 Installation
5.1 Establishing installation point
The fixing points or bolts conform to M6 A2-70/7.3 Nm.
Establish the installation point according to the specified data of the flange.
40
60
R60
15°
15°
140
Fig.5: Dimensions of flange

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5.2 Installation point in piping system (example)
< 1 m
1
2
3
4
5
Fig.6: Configuration
1 Flow restrictor 2 Bypass
3 Analyser 4 Sample removal point
5 Flow restrictor

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5.3 Installation (example)
Production Server/Control room
Remote computer
Installation box
with mains adapter
Sensor cables
(power supply,
RS 422)
USB converter
1 sensor per measurement
point
Up to 4 sensors per computer
Process control
system
SX-Client
Display:
- Results
- Charts
Chemometric
software
manual calibration
SX-Plus
Remote access via Ethernet
Frame
grabber card USB
Optional
interfaces:
-Profibus
-4-20 mA/1-9 V
-TCP/IP
-OPC/XML/SQL
-Modbus
Control center
Product flow
Data cable
(RS422)

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5.4 Sensor installation
The following installation positions are possible:
Fig.7: Fixing sensor with screws
Tools required:
Torque wrench, size Torx T30
Tightening torque: 8.4 Nm +-1
Precondition:
RInstallation point has been established. See Chapter5.1 "Establishing installation
point", page17.
RThe fixing points or bolts conform to M6 A2-70 15 mm
uFix the sensor to the installation point using the bolts.