Keit IRmadillo User manual

DOC0535
10 July 2019, 16:56
www.keit.co.uk
[email protected]
User Manual
Rugged FTIR Spectrometer for Real-Time Process Analysis

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Table of Contents
Table of Contents.....................................................................................................2
Contact Keit..............................................................................................................6
1. Introduction........................................................................................................7
1.1 Introduction to the IRmadillo ...................................................................................7
1.2 Brief introduction to infrared spectroscopy..............................................................7
1.3 How FTIR spectrometers work................................................................................8
1.4 What makes the IRmadillo different? ......................................................................8
2. System overview................................................................................................9
2.1 System configuration ............................................................................................10
2.2 Controller..............................................................................................................10
2.3 Software ...............................................................................................................10
3. Safety................................................................................................................11
3.1 General safety ......................................................................................................11
3.2 Lifting instructions.................................................................................................11
3.3 Electrical safety.....................................................................................................12
3.4 Hazardous environment safety –Ex-certified models............................................12
3.5 Pressure safety notes...........................................................................................14
3.6 Ventilation and location.........................................................................................14
4. Installation........................................................................................................15
4.1 Installation location ...............................................................................................15
4.2 Spectrometer components....................................................................................16
4.2.1 Product label (A)............................................................................................16
4.2.2 Probe purge outlet (B)....................................................................................17
4.2.3 Probe (C).......................................................................................................17
4.2.4 ATR Element (D) ...........................................................................................17
4.2.5 Breather (E)...................................................................................................17
4.2.6 Earthing point (F)...........................................................................................17
4.2.7 Probe purge inlet (G) .....................................................................................17
4.2.8 Spectrometer body purge inlet (H).................................................................17
4.2.9 Communication port (I) ..................................................................................17
4.2.10 Power cable port (J).......................................................................................18

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4.2.11 Mounting holes (K).........................................................................................18
4.3 Connection to a vessel or pipeline for measuring..................................................19
4.3.1 Fluid tight seal to the instrument ....................................................................19
4.4 Electrical installation .............................................................................................20
4.4.1 Uninterruptible power supply (UPS)...............................................................20
4.4.2 Ensuring a power connection to the spectrometer .........................................20
Table 1 –IRmadillo power specifications .....................................................................20
4.4.3 Connecting the power cable to the instrument ...............................................21
4.5 Data communication connection...........................................................................23
4.5.1 Connecting the data communication cable to the spectrometer .....................23
4.5.2 Connecting the USB communication cable to the controller...........................23
4.5.3 Connecting the fibre data communication cable to the controller....................24
4.6 Purging the unit.....................................................................................................25
4.7 Stabilisation period................................................................................................26
5. Using the system and software......................................................................27
5.1 Software version: 4.0.7.........................................................................................27
5.2 Getting started......................................................................................................27
5.2.1 Manual sample acquisition.............................................................................27
5.2.2 Continuous collection.....................................................................................27
5.2.3 Collect a background scan.............................................................................27
5.2.4 Manual sample acquisition.............................................................................29
5.2.5 Monitoring a reaction or process....................................................................30
5.3 The Spectrometer tab...........................................................................................31
5.4 Manual sample acquisition....................................................................................36
5.5 Configure acquisition ............................................................................................41
5.6 Batch viewer.........................................................................................................44
5.7 Reaction monitor...................................................................................................49
5.8 Configure chemometrics.......................................................................................51
5.8.1 Supported model types..................................................................................53
5.8.2 Editing Camo model settings .........................................................................54
5.8.3 Common chemometrics errors.......................................................................55
5.9 Log viewer ............................................................................................................56
5.10 Offline viewer........................................................................................................59
6. Data communication integration and configuration.....................................60

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6.1 Modbus communications ......................................................................................60
6.1.1 Configure Keit controller ................................................................................60
6.1.2 Holding registers............................................................................................62
6.1.3 Representation of data in Modbus .................................................................62
6.1.4 Modbus RTU tutorial......................................................................................63
6.2 Modbus TCP server..............................................................................................66
6.2.1 Getting started with Modbus TCP ..................................................................67
6.3 OPC-UA................................................................................................................68
6.3.1 Licensing the OPC-UA server........................................................................69
6.3.2 UaExpert client ..............................................................................................70
6.3.3 OPC address space.......................................................................................70
6.4 Controller administrator guidance .........................................................................73
6.5 Connecting the spectrometer to Camo Analytics’ Process Pulse ..........................74
7. Maintenance.....................................................................................................76
7.1 Service and support contacts................................................................................76
7.2 Preventative maintenance and service intervals ...................................................76
7.3 Protecting and cleaning the dip probe ATR element .............................................76
7.3.1 Cleaning instructions: infrared glass probes...................................................77
7.3.2 Cleaning instructions: diamond probes ..........................................................78
7.4 Cleaning prior to Sterilise-in-Place (SIP)...............................................................79
7.5 ATR and O-ring.....................................................................................................79
7.6 Cleaning the fibre optic data cable connectors......................................................79
7.7 Troubleshooting....................................................................................................82
7.8 Remote Health Check...........................................................................................83
7.8.1 Remote access..............................................................................................83
7.8.2 Sending data manually ..................................................................................84
8. Accessories......................................................................................................85
8.1 Sample cell...........................................................................................................85
8.2 Flow cell................................................................................................................86
8.2.1 Introduction....................................................................................................86
8.2.2 Safety ............................................................................................................86
8.2.3 Specifications and safety limits (flow cell) ......................................................87
8.2.4 Installation .....................................................................................................88
8.2.5 Maintenance..................................................................................................91

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8.2.6 Cleaning ........................................................................................................92
8.3 Flanged probe (Ex certified)..................................................................................93
8.3.1 Introduction....................................................................................................93
8.3.2 Safety ............................................................................................................93
8.3.3 Specifications and safety limits (welded flange probe)...................................94
8.3.4 Installation .....................................................................................................94
8.3.5 Maintenance..................................................................................................96
Appendix 1: Technical Specification Sheet (Model ASM0627, Ex-Certified
IRmadillo)................................................................................................................97
Appendix 2: Controller Specifications ................................................................98
Appendix 3: Technical Drawings IRmadillo...................................................... 101
Appendix 4: Declarations of Conformity............................................................104
Declaration of Conformity - IRmadillo (Ex-Certified Spectrometer) ................................104
Declaration of Conformity - Controller............................................................................105
Declaration of Conformity –Flow Cell............................................................................106
FCC Class A emissions statement ................................................................................107

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Contact Keit
Website: www.keit.co.uk
Postal address: Keit Ltd.
Unit 4, Zephyr Building
Eighth Street, Harwell Campus
Didcot
Oxfordshire
OX11 0RL
United Kingdom
Telephone number: [phone]
Support email: [email protected].uk
The triangle symbol on the product label means essential safety information
must be followed to prevent user injury or damage to the instrument. Before
installing or using the product the user must refer to and comply with the safety
notices in Section 3.

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1. Introduction
1.1Introduction to the IRmadillo
The IRmadillo is a vibration-tolerant, mid-infrared process spectrometer designed to enable
monitoring of either batch or continuous processes of liquids in a range of industries.
The IRmadillo has no moving parts and a rigid probe which is inserted directly into the reaction
vessel or process pipeline for continuous real-time analysis. The device is tolerant of extreme
vibration levels. The spectrometer can be combined with either multivariate analysis (i.e.,
chemometrics), or univariate analysis (i.e., peak height tracking) to act as a concentration
meter. This allows for accurate monitoring of a process/reaction state in real time at the point
of production.
1.2 Brief introduction to infrared spectroscopy
Spectroscopy is the study of how molecules interact with light. There are many different types
of spectroscopy spanning a wide range of light wavelengths (i.e., infrared, UV-visible,
microwave, NMR using radiowaves, and X-ray spectroscopy).
Infrared (IR) spectroscopy is a powerful technique that monitors chemicals by looking at the
vibration of chemical bonds. Different molecular bonds –and therefore chemical components
–can be identified at various parts of the infrared spectral range from near-infrared (NIR), to
mid-infrared (MIR) and far-infrared. Of these, the mid-infrared region is the most information-
rich area of the spectrum and therefore highly desirable for use in analysis.

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1.3 How FTIR spectrometers work
Fourier transform infrared spectrometers (FTIRs) use a computational process (Fourier
transform) that interprets the information of an interference pattern (interferogram) in the mid-
infrared region to generate a spectrum.
Conventional FTIR instruments use a Michelson interferometer which consists of a pair of
moving mirrors, designed to split and recombine light into an interference pattern. However,
the moving mirrors make the instrument highly sensitive to vibration, and therefore not suitable
for direct use in industrial environments.
To work aroundthis, some manufacturers have coupled conventional FTIRspectrometers with
long fibre optic probes connected to the instrument which has been removed to a stable safe
zone at some distance. Unfortunately, current fibre optic probe design is known to have a
fragile natureandis prone to performance failure when bent, handled, or twisted; again making
it difficult to achieve real-time process monitoring in a manufacturing environment.
1.4 What makes the IRmadillo different?
The IRmadillo is an FTIR instrument in that it creates an interferogram and requires a Fourier
transform to interpret the information for a spectrum. But rather than using a moving mirror to
create the interferogram it uses a proprietary arrangement of fixed mirrors to create an
interference pattern.
Unlike conventional FTIR spectrometers, the IRmadillo has no moving parts, making it
extremely resistant to vibration and therefore able to be used directly in the manufacturing
environment. It can be fixed directly onto the side of a reaction vessel or pipe at the point of
production rather than remotely located. This enables manufacturers to continuously monitor
their chemical reactions in real time with an in-line analytical instrument. The IRmadillo is an
innovation in process analytical technology that changes how manufacturers can monitor and
control their processes.

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2. System overview

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2.1 System configuration
The following communication protocols with the distributed control system (DCS) are currently
supported:
•OPC-UA over Ethernet
•Modbus RTU over RS-485 or RS-232
•Modbus TCP over Ethernet
•Others: contact Keit Ltd.
Historical records of spectra and detailed instrument diagnostics are stored locally on the
controller for preventative maintenance and fault finding.
The logfile is a record of registered events, configuration changes and errors.
The Data Link to the DCS allows only minor configuration changes. Significant changes can
only be made by logging into the controller locally using a keyboard, visual display unit (VDU),
and mouse.
2.2 Controller
The controller is delivered with the spectrometer software (Keit Spec) pre-installed. The
standard industrial controller allows direct connection of the system cables.
The controller is an industrial-grade computer which performs signal processing and provides
spectra and chemometrics data to the DCS.
2.3 Software
See Section 5 Using the system and software for full details. The controller uses the Microsoft
Windows 10 IOT operating system. It comes pre-configured with the following software:
Keit Spectrometer
(Keit Spec)
This auto-runs on startup and is the default application. It allows
viewing and saving of real-time data.
Project Viewer
For viewing of previously recorded spectra and diagnostics
information.
Log file viewer
For viewing the log of user interaction with the system
If you have any questions on the installation, please contact su[email protected].