Buchi NIR-Online X-One User manual

NIR-Online®
Process Analyser X-One
Operation Manual
11593995 | C en

Imprint
Product Identification:
Operation Manual (Original) Process Analyser X-One
11593995
Publication date: 01.2022
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 Process Analyser X-One iii
Contents
1 About this document...........................................................................................................5
1.1 Warning notices in this document..........................................................................................5
1.2 Symbols.................................................................................................................................5
1.2.1 Warning symbols ........................................................................................................5
1.2.2 Mandatory directive symbols ......................................................................................5
1.3 Mark-ups and symbols ..........................................................................................................6
2 Safety....................................................................................................................................7
2.1 Proper use .............................................................................................................................7
2.2 Use other than that intended .................................................................................................7
2.3 Location of safety notices and warning signs on the product ................................................7
2.4 Residual risks ........................................................................................................................8
2.4.1 Risk of explosion from opening up the sensor............................................................8
2.4.2 Risk of explosion from unplugging the device power plug..........................................8
2.5 Staff qualification ...................................................................................................................8
2.6 Personal protective equipment (production)..........................................................................9
2.7 Personal protective equipment (laboratory)...........................................................................9
2.8 Modifications..........................................................................................................................9
3 Product description...........................................................................................................10
3.1 Description of function .........................................................................................................10
3.2 Configuration .......................................................................................................................11
3.2.1 Front view .................................................................................................................11
3.2.2 Rear view..................................................................................................................11
3.3 Type plate............................................................................................................................12
3.4 ATEX rating .........................................................................................................................13
3.5 Scope of delivery .................................................................................................................14
3.6 Technical data .....................................................................................................................14
3.6.1 Sensor ......................................................................................................................14
3.6.2 Installation box..........................................................................................................15
3.6.3 Ambient conditions ...................................................................................................15
3.6.4 Materials ...................................................................................................................15
3.6.5 Computer system requirements................................................................................15
3.6.6 Software....................................................................................................................16
4 Transport and storage ......................................................................................................18
4.1 Transport .............................................................................................................................18
4.2 Storage ................................................................................................................................18
5 Installation..........................................................................................................................19
5.1 Installation site (production).................................................................................................19
5.2 Installation site (laboratory) .................................................................................................19
5.3 Establishing installation point ..............................................................................................20
5.4 Installation point in piping system (example).......................................................................21
5.5 Installation (example) ..........................................................................................................22
5.6 Sensor installation ...............................................................................................................23
5.7 Connecting the sensor.........................................................................................................24
5.8 Connecting the video cable (optional accessory) ................................................................25
5.9 Establishing the electrical connection to the installation box...............................................26

Table of contents NIR-Online GmbH
iv Operation Manual Process Analyser X-One
6 Operation............................................................................................................................27
6.1 Journal button......................................................................................................................27
6.2 Entering reference data in the journal ................................................................................. 27
7 Cleaning and servicing .....................................................................................................28
7.1 Notes on servicing ...............................................................................................................28
7.2 Regular maintenance work..................................................................................................28
8 Taking out of service and disposal..................................................................................29
8.1 Disposal...............................................................................................................................29
8.2 Returning the instrument .....................................................................................................29
9 Appendix ............................................................................................................................30
9.1 Certificates...........................................................................................................................30
9.1.1 ATEX certificate ........................................................................................................30
9.1.2 CE certificate ............................................................................................................31
9.2 Spare parts and accessories ...............................................................................................32
9.2.1 Accessories ..............................................................................................................32
9.2.2 Spare parts specifications.........................................................................................32

NIR-Online GmbH About this document | 1
Operation Manual Process Analyser X-One 5/36
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 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.
1.2 Symbols
The following symbols are displayed in this operation manual or on the device:
1.2.1 Warning symbols
The following warning and directive symbols are displayed in this operation manual
or on the instrument.
Symbol Meaning
General warning
Dangerous electrical voltage
1.2.2 Mandatory directive symbols
Mandatory signs Meaning
Read manual

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6/36 Operation Manual Process Analyser X-One
1.3 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.

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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
Use of any other kind than that described in the section Chapter2.1 "Proper use",
page7 and any application that does not comply with the technical specifications
(see Chapter3.6 "Technical data", page14) constitutes use other than that in-
tended.
In particular, the following applications are not permissible:
Using the sensor in areas for which the sensors are not certified. For certification
details see Chapter3.4 "ATEX rating", page13
Use of the sensor in potentially explosive atmospheres without an overall assess-
ment by the responsibility holder.
Use of a sensor of which the screw sealing cap is damaged.
Damage or hazards attributable to use of the product other than as intended are en-
tirely at the risk of the operator alone.
2.3 Location of safety notices and warning signs on the product
The following safety signs and warning symbols are present on the sensor.

2 | Safety NIR-Online GmbH
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1
2
Fig.1: Location of safety notices and warning signs on the product
1
General warning
2
General warning
Clean Unit when dust exceeds 5
mm thickness
Do not separate when energized
Do not open in hazardous area.
2.4 Residual risks
The device has been developed and manufactured using the latest technological ad-
vances. Nevertheless, risks to persons, property or the environment can arise if the
device is used incorrectly.
Appropriate warnings in this manual serve to alert the user to these residual dan-
gers.
2.4.1 Risk of explosion from opening up the sensor
Opening up the sensor in potentially explosive atmospheres can cause an explosion.
uDo not open up the sensor housing.
2.4.2 Risk of explosion from unplugging the device power plug
Risk of explosion from unplugging the device power plug when the power is
switched on.
uDo not unplug the sensor when the power is switched on.
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:

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Operation Manual Process Analyser X-One 9/36
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.

3 | Product description NIR-Online GmbH
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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.

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3.2 Configuration
3.2.1 Front view
12
3
Fig.2: Front View
1 Measurement window 2 Flange
3 Heat sink
3.2.2 Rear view
12
3
4
5
6
Fig.3: Rear view
1 Power and signal connector 2 Video cable connection
3 Journal Button 4 Type plate
5 Power and scanning indicator light 6 Ground connection
(Equipotential bonding)

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3.3 Type plate
The type plate identifies the instrument. The type plate is attached to the rear panel.
See Chapter3.2.2 "Rear view", page11
NOTE
Labeling
Instruments without mark.
uInstruments without ATEX mark are not suitable for ATEX operation. See Chap-
ter3.4 "ATEX rating", page13
4
5
6
7
17
16
15
1
2
3
8
12
14
11 9
10
13
Fig.4: Type plate
1 Company name and address 2 Revision number
3 Product name 4 Serial number
5 Production date 6 IP class
7 ATEX rating 8 Power consumption
(nominal)
9 Power consumption
(maximum)
10 Ambient temperature
11 Current draw
(maximum)
12 ATEX certification number
13 Certification center number 14 Certificates
15 Operating voltage 16 Product type
17 Product option
The following product options are possible:
Letter Option
A NIR

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Letter Option
B FEEDER/X-ROT
(without ATEX certification)
C CAMERA
D VIS
E Gold reflector
(X-One)
F Silver reflector
(X-Two/X-Four (diffusion lamps), X-Three)
G Lamp position rev. 1.3.2
H Lamp position rev. 1.3.6
(X-Two/X-Four/X-View (diffusion lamps))
I Camera setting flange
(0 mm)
K Camera setting X-ROT
(15 mm)
L Camera setting
(20 mm (X-Cell+X-Cool))
N System temperature 0 - 80 °C
O Humidity sensor 0-100% RH
S X-Quvette
(Fiber lens (approx. 0 - 2 cm))
T Bluetooth®
(without ATEX certification)
U Camera setting special flange ZB-0103
V External button
X = X-Beam
(without ATEX certification)
(approx. 40 cm measurement distance)
X2 X-Beam 002
(approx. 15 cm measurement distance)
3.4 ATEX rating
The sensor is certified according to the following European Union ATEX Directive rat-
ings:
II 2 D Ex tb [op is Da] IIIC T80°C Db
Meaning of the rating marks:
Rating Meaning according to Directive 2014/34/EU
II Device group approved for all Ex zones except mining
2 D Device category approved for dust zone 21

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Rating Meaning according to Directive 2014/34/EU
Ex Explosion-safe
tb Protection class protected by enclosure
[op is Da] Intrinsically safe optical radiation approved for dust zone 20
IIIC Dust group conductive dusts
T80 °C Temperature classification max. surface temperature = 80° C
Db Device safety level zone 21, adequate safety in event of fore-
seeable faults
3.5 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.
3.6 Technical data
3.6.1 Sensor
Specifications X-One
Dimensions (W x D x H) 220 x 220 x 135mm
Weight 7.5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 - 5900 cm-1
Detector Diode array
Average measurement
time
V3: 50 spectra/s
V3S: 200 spectra/s
IP code IP66 (IEC 60529)
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

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Specifications X-One
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.
ATEX Dust: II 2 D Ex tb [op is Da] IIIC T80°C Db
Gas: II 2 G Ex pxb [op ist Ga] IIC T4 Gb
3.6.2 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
3.6.3 Ambient conditions
Max. altitude above sea level 2500 m
Ambient temperature -10 °C ≤ Tamb ≤ +40 °C
Max. relative air humidity < 90 % non-condensing
Storage temperature max. 45 °C
3.6.4 Materials
Component Materials of construction
Casing Stainless steel (1.4301 high-gloss polished)
Heat sink Nickel and zinc-coated aluminum
Seals FFKM (standard)
3.6.5 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
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

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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
3.6.6 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

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Name Description Typical usage User Occurence
SX-Backup Data backup
scheduler
Automated
backup of mea-
surement data,
results and cali-
brations
NIR admin During installa-
tion

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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3.6 "Tech-
nical data", page14).
uWherever possible, store the device in its original packaging.
uAfter storage, check the device for damage and replace if necessary.

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5 Installation
5.1 Installation site (production)
Make sure that the installation site meets the following requirements:
Minimum space requirements: 230 mm x 280 mm x 140 mm (W x D x H).
At least 100 mm clearance on all sides. The clearance ensures air circulation and
prevents the instrument from overheating.
The installation point meets the specifications. See Chapter5.3 "Establishing in-
stallation point", page20.
Do not expose the sensor to any external sources of heat such as direct sunlight.
The layer thickness of the product to be measured is at least 30 mm.
A constant product flow is ensured.
The product flow can be directly measured.
There is a sample removal point at a distance of < 1 m.
5.2 Installation site (laboratory)
Make sure that the installation site meets the following requirements:
Firm, level surface
Minimum space requirement: 230 mm x 280 mm x 140 mm (W x D x H).
Take into account the maximum product dimensions and weight.
At least 100 mm clearance on all sides. The clearance ensures air circulation and
prevents the sensor from overheating.
The sensor is not exposed to any external sources of heat such as direct sunlight
NOTE
Make sure that the power supply can be disconnected at any time in an emergency.

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5.3 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