Zeiss Corona process User manual

User Manual
Carl Zeiss Spectroscopy GmbH
Corona process

Knowledge of this manual is required for the operation of the device. Therefore, please familiarize yourself with its
contents and pay special attention to information concerning the safe handling of the device.
We reserve the right to make changes in the interest of technical advancement. The user manual is not covered by
an update service.
© Unless expressly authorized, forwarding and duplication of this document, and the utilization and communication
of its contents are not permitted. Violations shall result in claims for damages.
All rights reserved in the event of granting of patents or registration of a utility model.
Carl Zeiss Spectroscopy GmbH
Carl-Zeiss-Promenade 10
07745 Jena, Germany
Service + 49 3641 64-1648
Office + 49 3641 64-2838
Fax + 49 3641 64-2485
E-Mail [email protected]
Internet www.zeiss.com/spectroscopy
Publication number: UM Corona process / E | 2017-05
3rd edition May 2017 Subject to technical changes

3Corona process | User Manual
Corona process Contents
Table of contents
1 About this User Manual 7
1.1 Introduction 7
1.2 Use of safety instructions 8
1.3 Formattings and text conventions 8
2 Safety 9
2.1 Intended use 9
2.2 Conformity 9
2.3 Safety instructions 10
2.4 Environmental management 11
2.5 Limitation of liability and warranty 12
3 Device description 13
3.1 Scope of supply 13
3.2 Technical design 14
3.2.1 Functional elements 14
3.2.2 Controls and indicators 15
3.2.3 Electrical connections 16
3.2.4 Mechanical interface 17
3.3 Functional description 18
3.4 Software 20
3.4.1 ZEISS InProcess 20
3.4.2 IP addresses 20
4 Installing the measuring system 21
4.1 Preparing the installation 21
4.2 Installing the Corona process 22
4.3 Connecting system components 24
4.4 Software installation 26
4.4.1 Installing the InProcess software 26
4.4.2 Activating licenses 27
5 System Operation 29
6 Help in case of faults 33

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Corona process Contents
7 Maintenance 35
7.1 Cleaning and care 35
7.2 Changing halogen lamps 36
7.3 Lamp calibration 45
7.4 Accessories and spare parts 55
7.5 Storage and transport 58
7.6 Disposal 58
8 Technical data 59
List of illustrations
Fig. 1 Scope of supply 13
Fig. 2 Functional elements 14
Fig. 3 Controls and indicators 15
Fig. 4 Electrical connections 16
Fig. 5 Mechanical interface 17
Fig. 6 Functional description 19
Fig. 7 Connection dimensions of the mounting device 22
Fig. 8 Fastening the mounting device and the Corona process 23
Fig. 9 Connecting system components 25
Fig. 10 Selecting the storage location and agreeing to the licensing terms 26
Fig. 11 Completing the installation 26
Fig. 12 Select service 29
Fig. 13 Select product configuration 30
Fig. 14 Select continuous measurement 31
Fig. 15 Save product 31
Fig. 16 Start measurement 32
Fig. 17 Removing the system cables 37
Fig. 18 Removing the Corona process from the mounting device 38
Fig. 19 Removing the base of the device from the device cover 39
Fig. 20 Finding the right lamp 40
Fig. 21 Disconnecting the lamp cable 41
Fig. 22 Unscrewing the lamp holder 41
Fig. 23 Removing the lamp holder 42
Fig. 24 Removing the old halogen lamp 43
Fig. 25 Aligning the halogen lamp 43

5Corona process | User Manual
Corona process
Fig. 26 Mounting the Corona process on the calibration device 45
Fig. 27 Selecting a measuring system 46
Fig. 28 Selecting a lamp 46
Fig. 29 Resetting the lamp counter 47
Fig. 30 Determining the white standard 48
Fig. 31 Selecting the *.csv file 48
Fig. 32 Mounting the white standard 49
Fig. 33 Confirming the alignment 49
Fig. 34 Positioning the white standard 50
Fig. 35 Continuing the white calibration 50
Fig. 36 Positioning the black standard 51
Fig. 37 Continuing the black calibration 51
Fig. 38 Continuing the distance correction 52
Fig. 39 Saving the distance correction 53
Fig. 40 Selecting a spare lamp 54
List of tables
Tab. 1 LED status displays 15
Tab. 2 Connection and environmental conditions 21
Tab. 3 General technical data 59
Tab. 4 Optical parameters 60
Tab. 5 Interface description 60
Contents

6Corona process | User Manual
Corona process

7Corona process | User Manual
About this User Manual
Corona process
1 About this User Manual
1.1 Introduction
Welcome to the Corona process User Manual.
The Corona process spectrometer system has been developed especially for use
in the food industry.
The optical concept enables the determination of the ingredients and color of
solid and pasty organic materials at a distance of 90 – 600 mm to the sample.
Depending on the chemometric model used, the wavelength range of
380 – 1650 nm enables the determination of moisture, protein, fat and other
ingredients and of the color, e.g. for process optimization and control in the
manufacture of footstuffs.
The accessories adapted to the application areas of the Corona process enable
simple and fast integration in its facilities and systems.
The information contained in this User Manual will enable you to install the
Corona process spectrometer system properly and operate it safely and
effectively. Furthermore, it will provide you with information on maintenance and
troubleshooting.
Please familiarize youself with the contents of the User Manual and observe all of
the general and safety-related instructions it contains.
The Corona process spectrometer system may be installed, operated and
maintained only by qualified and properly instructed personnel.
This User Manual is therefore aimed at the qualified personnel authorized to
perform the installation on-site as well as at other authorized persons in order to
enable them to perform their duties.
Experience in handling metrology equipment and technical or scientific training
are required.
Store the User Manual and all other applicable documents you received on
purchasing and accepting delivery of the device together in a safe place.
Make sure that the User Manual and all other valid documents are freely available
to every user at all times.
• ZEISS InProcess software description: "InProcess Manual"
• Description of the license activation: "ZEISS License Activation Manual"
• Delivery notes
Welcome
Purpose of this manual
Audience
Storage
Other applicable documents

8Corona process | User Manual
About this User Manual Corona process
1.2 Use of safety instructions
The safety instructions in this User Manual stipulate various hazard levels,
depending on the risk classification concerned.
Warning
Dangerous situation – Failure to observe this safety note could result in
serious injuries or even death.
Caution
Dangerous situation – Failure to observe this safety note could result in
slight injuries or property damage.
Note
General reference to important or useful information concerning the
device and its operation.
Note
Important note on environmental protection.
1.3 Formattings and text conventions
"Bold" character format
• for texts which are used in the software, e.g. names of buttons, tools, menus,
...
• for keyboard commands, e.g.: Ctrl + C
• for product designations
Instruction manuals
• Stands for a requirement that must be fulfilled in order to successfully perform
the upcoming action.
1 Stands for an action step to be executed.
Requirements
Procedure

9Corona process | User Manual
Safety
Corona process
2 Safety
2.1 Intended use
The Corona process is a spectrometer which was developed especially for use in
the food industry. It is used to determine the ingredients and color of solid and
pasty organic materials in diffuse reflection at a distance of 90 –600 mm to the
sample.
The Corona process can be installed in ATEX Zone 22 and is protected against
dust and temporary immersion (IP67).
The spectrometer may only be used for its intended purpose as described.
Any other use is contrary to its intended purpose. The operator alone shall be
held liable for any damage resulting from improper use. In this case, any warranty
claim is null and void.
2.2 Conformity
The Corona process was designed and tested according to the currently
applicable directives and standards and left our factory in perfect condition. To
maintain this state and ensure safe operation, all instructions and warning notes
listed must be observed.
The following directives, standards and classifications were applied and observed
within the scope of the CE Declaration of Conformity.
Safety requirements for electrical equipment for measurement, control and
laboratory use
Safety regulations for potentially explosive atmospheres
Safety requirements for electrical equipment for measurement, control, and
laboratory use
Enclosure protection degree as per DIN EN 60529
Protection class (protection by low voltage) according to DIN EN 61140
Potentially explosive atmospheres
Explosion Protection Marking:
Ex marking according to 94/9EC
II Equipment group
3D Category 3D Zone 21/22
EX tc Protection by enclosure
IIIC Conductive dust
T70 °C Max. surface temperature
The devices bear the  marking
DIN EN 61010-1
DIN EN 60079-0
DIN EN 61326-1
IP67
III
Zone 22
II 3D Ex tc lllC T70 °C


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Safety Corona process
2.3 Safety instructions
Warning
ELECTRICAL ENERGY HAZARD
The device may be operated only at the operating voltage specified in
Section 8 “Technical data”.
Before performing maintenance and repair work or replacing
components, the respective device must be disconnected from all
power sources. Please also ensure that it cannot be accidentally
switched on again.
The Corona process must not be operated in damaged or damp
condition.
RISK OF EXPLOSION
The device must not be opened in a potentially explosive atmosphere.
It is prohibited to mount the plugs with a higher torque than 15 Nm in
order to guarantee the tightness and the explosion protection of the
spectrometer.
Please also note that the power supply unit must not be used in a
potentially explosive atmosphere. Unplug the power connector of the
device only when the device is deenergized.
Caution
GENERAL RISK
The Corona process, including its original accessories, must be used for
the purposes described in the present User Manual. The manufacturer
cannot be held liable for any other use.
Warning signs and safety instructions must not be removed and must
always be clearly legible.
The devices may be operated only by properly trained personnel. This
personnel must be instructed concerning the possible risks when the
device is in operation and in the appropriate applications.
The device is sealed very tightly; therefore, do not open it.
Modifications or repairs of the device and any other devices operated
together with the Corona process may be performed only by Service
employees or authorized personnel. The manufacturer shall not be
liable for damage caused by inadmissible actions performed on the
device. In addition, such inadmissible interventions shall render all
warranty claims null and void.

11Corona process | User Manual
Safety
Corona process
Caution
RADIATION ENERGY HAZARD
Never look directly into the measuring beam. The bundled light of the
halogen lamp can cause eye damage.
THERMAL ENERGY HAZARD
Caution: Hot surfaces.
GENERAL RISK
The personnel designated to perform the maintenance and repair work
must be appropriately qualified for this work.
Apart from the work described in Section 7 “Maintenance”, it is
prohibited to perform any other interventions on the device. Otherwise
the device may be irreparably damaged.
The device may be opened only by ZEISS service engineers or by other
persons authorized by ZEISS.
Note
Defective equipment must not be disposed of with household waste,
but should be disposed of in compliance with the applicable legal
requirements.
2.4 Environmental management
Our company has implemented a certified environmental management system
that complies with ISO 14001. This product was developed, inspected and
produced in accordance with the applicable environmental regulations and
directives of the European Union.
The product and its accessories comply with EU Directives 2002/95/EC (RoHS) and
2002/96/EC (WEEE) to the extent applicable to this product.
We have installed a take-back and recycling process that ensures proper recycling
in accordance with the above-mentioned EU Directives.
For details concerning disposal and recycling, please contact your local dealer or
service organization. The system must not be disposed of as domestic waste or
be disposed of via municipal waste disposal facilities.
If the product is resold, the seller is obligated to inform the purchaser regarding
its proper disposal.

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Safety Corona process
2.5 Limitation of liability and warranty
Carl Zeiss Spectroscopy GmbH will not accept any warranty claims and shall
be exempted from statutory liability for any damage to equipment caused by
nonobservance of the applicable safety instructions, even during the warranty
period.
The warranty granted by Carl Zeiss Spectroscopy GmbH ensures the safety,
reliability and performance of the device only if the pertaining safety instructions
are observed.
The manufacturer guarantees that the device is free of material or manufacturing
defects when delivered. Possible defects must be notified to us immediately and
steps be taken to minimize damage. If notified of such a defect, the manufacturer
is obligated to rectify it at his discretion, either by repairing the instrument or
delivering an intact replacement.
No guarantee is provided for defects caused by natural wear (wearing parts in
particular) and improper use.
The manufacturer shall not be liable for damage caused by faulty operation,
negligence or any other tampering with the device, particularly the removal
or replacement of device components, or the use of accessories from other
manufacturers. Any such action shall lead to a forfeit of all warranty claims.
Apart from the work described in Section 7 “Maintenance”, no inadmissible
maintenance or repair work may be performed on the device. Repairs may be
performed only by employees of ZEISS Service or by persons authorized by ZEISS.
Contact the Customer Service Dept. of Carl Zeiss Spectroscopy GmbH
([email protected]) if any defects or faults occur on the device or
individual components.
The Corona process should be inspected by the Customer Service Dept. of
CarlZeiss Spectroscopy GmbH at least once a year to ensure optimal and safe
operation of the system.
Note
For details concerning the warranty, please refer to the General Terms
and Conditions of Carl Zeiss Spectroscopy GmbH. which can be found
on the internet at "http://www.zeiss.com/corporate/en_de/legal-
information/company-information.html".

13Corona process | User Manual
Device description
Corona process
3 Device description
3.1 Scope of supply
The basic equipment of the standard version of the Corona process contains the
following components:
Fig. 1
Abnahme-
Protokoll
Lieferschein
Corona extreme
Gebrauchsanweisung
2
1
34
5
7
8
6
Scope of supply
Corona process spectrometer
Acceptance report
Delivery note and other documents accompanying the device
Set of documents (User Manual and other applicable documents)
Mounting device (see Section 7.4 “Accessories and spare parts” on page 55)
Power supply cable
Ethernet cable
Digital IN / OUT cable
1
2
3
4
5
Optional accessories:
(always compare with delivery note) 6
7
8

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Device description Corona process
3.2 Technical design
3.2.1 Functional elements
Fig. 2
6
15
2
4
3
7
Functional elements
Connection panel (Ethernet, Digital IN / OUT, power supply) and status display
Cooling element
Carrying handle and mounting interface
Device base (carrier for the measuring optics, the electronics and the connection
panel)
Device cover
Distance sensor
Measuring window
1
2
3
4
5
6
7

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Device description
Corona process
3.2.2 Controls and indicators
Fig. 3
POWER 12–24V
1
Controls and indicators
Status LED
LED signal color Description
flashing blue after connection to the power supply
not lit during initialization (max. 30 s)
(no light beam visible in measuring window)
flashing blue after complete initialization
(no light beam visible in measuring window)
Tab. 1 LED status displays
Note
The light beam is visible only following initialization by the InProcess
or Aspect software.
1

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Device description Corona process
3.2.3 Electrical connections
Fig. 4
POWER 12–24VIN OUTETHERNET
1
2
3
Electrical connections
"ETHERNET" connection –
14-pin socket
"Digital IN OUT" connection –
10-pin socket
PIN Color Assignment
1 bk/wh OUT 3
2 violet IN 0
3 brown OUT 2
4 white IN 1
5 green OUT 1
6 yellow IN 2
7 gray OUT 0
8 pink IN 3
9 blue GND
10 red GND
"12 – 24 V DC POWER" connection (power supply) –
3-pin socket
PIN Wire number Assignment
1 1 12 – 24 V DC
2 2 GND
3 – n. k.
1
2
3
Ethernet cable FVG-2 W
Lemo connector FVG-2 W
1
2
3
4 5
6
7
89
10
Lemo connector FVG-2 W
1
2 3

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Device description
Corona process
3.2.4 Mechanical interface
Fig. 5
1
22
253
28
110
28
92 68 220
57
35
360
279
1
Mechanical interface
Mounting interface – Arbor with D = 22 mm and length = 110 mm
Variant 1: Fastening of the Corona process with optional mounting device (in
mounting package 000000-2107-066) from Carl Zeiss Spectroscopy
GmbH (see also Section 4).
Variant 2: Fastening of the Corona process via a customer-installed mounting
device. The connection dimensions are specified in the above Fig. 5
"Mechanical interface".
Note
For detailed information on mounting the Corona process on a
customer interface, refer to Section 4 “Installing the measuring
system” on page 21.
1

18 Corona process | User Manual
Device description Corona process
3.3 Functional description
The Corona process is a measuring system which is used to determine the
ingredients and color of solid and pasty organic materials. It features two
spectrometers which enable the wavelength range of 380– 1650 nm. Internal
referencing ensures consistently reproducible and reliable results.
The optical design enables installation of the Corona process directly above a
conveyor belt or other open conveyor systems. At the same time, the sample can
pass by the Corona process at a measuring distance of 90 to 600 mm.
The Corona process is equipped with two redundant halogen lamps and
automatically switches over to the second lamp if the first one fails.
The stainless steel housing and the hygiene standard adhered to the design allow
the use of the device in the food industry.
The Corona process features a mounting option for installing it on open
transport systems, e.g. above conveyor belts.
The Corona process is operated at 12– 24 V SELV/PELV and may be connected
only to the intended power supply (safety extra-low voltage).
It has a voltage input which is connected to a 12-24 V DC power supply (40 W
power supply unit / inrush current < 4 A).
The Corona process can be connected to a computer via an Ethernet interface to
perform measurements, calculations and displays of ingredients.
Furthermore, the Corona process offers the possibility of utilizing 4 digital inputs
and 4 digital outputs.

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Device description
Corona process
Fig. 6
Corona process
12
3
4
5
6
90 – 600 mm
Functional description
Mounting device (in mounting package 000000-2107-066)
or customer-installed mechanical interface
Mounting interface (handle)
Corona process measuring system
Lighting and measuring beam
Sample material
Conveyor belt (example)
1
2
3
4
5
6

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Device description Corona process
3.4 Software
3.4.1 ZEISS InProcess
The ZEISS InProcess software included in the scope of supply is required to
control the Corona process measuring system and process the generated
measurement data.
Note
For details on installation, setup and use of the software, see Section
4.4 or refer to the "InProcess Manual" included in the scope of supply.
The software manual is available on the attached CD.
The Corona process measuring system is approved for use with the following
software packages:
• InProcess
• Aspect Plus
The OSISSDK Software Development Kit (000000-2101-333) is available for
developing your own software.
3.4.2 IP addresses
Corona process measuring systems are delivered with predefined IP addresses.
The following standard IP addresses are to be used:
• Corona process: 192.168.0.177
If several Corona process measuring systems are operated in a device group with
a single PC, each system must have its own IP address. In this case, the IP address
must be changed.