TABLE OF CONTENTS - DICKEY-john€¦ · Instalab 600 Series Analyzers 11001-1360-200512 INTRODUCTION 5 • Digital microprocessor circuitry provides fast, easy field changes to incorporate

TABLE OF CONTENTS

Safety Notices ......................................................................................................1

Introduction ..........................................................................................................3Models ...............................................................................................................................4Features .............................................................................................................................4Optional Accessories .........................................................................................................5Specifications .....................................................................................................................5Theory Of Operation ..........................................................................................................7

Installation ............................................................................................................9Printer Connection .............................................................................................................9Serial Port Configuration ..................................................................................................10Connector Contacts .........................................................................................................10

Calibration ..........................................................................................................13Gathering A Sample Set ..................................................................................................13Samples Required For Calibration ...................................................................................13Sample Collection ............................................................................................................13Product Characteristics ....................................................................................................14Sample Moisture Content ................................................................................................14Sample Storage ...............................................................................................................15Developing Calibrations ...................................................................................................15Regression Data Collection .............................................................................................16Developing Calibrations With Computer And Regression Program .................................17

Sample Preparation ...........................................................................................19Grinding Samples ............................................................................................................19Mixing Samples ...............................................................................................................19Loading Standard Sample Cup (Dry Powder Samples) ..................................................19

Instalab Series 600 Analyzers11001-1360-200512

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TABLE OF CONTENTS

Operation ........................................................................................................... 23Operator Controls ............................................................................................................ 23Basic Operating Concepts ............................................................................................... 27Mode Selection ................................................................................................................30Analyzing Samples For Data Collection - Modes 1.0, 1.1, 1.2, and 1.3 .......................... 32Calibration Entry - Mode 2 ............................................................................................... 33Calibration Storage .......................................................................................................... 34Calibration Modification And Deletion - Mode 2 .............................................................. 35Product Name Assignment ..............................................................................................36Constituent Number Assignment ..................................................................................... 40Printing Products And Constituents With Stored Calibrations - Mode 2.1 ....................... 41Printing User Programmable Product Names - Mode 2.2 ............................................... 41Printing Programmable Constituent Names - Mode 2.3 .................................................. 42Printing Product Name Assignments - Mode 2.4 ............................................................. 43Collecting Reference Or Raw Sample Data - Mode 3 ..................................................... 43Testing Display, Printer, And Drawer Operation - Mode 3.5 ........................................... 44Continuous Reference Data Collection - Mode 3.6 ......................................................... 45Bias Adjustment ...............................................................................................................45Display Resolution Modification - Mode 4 ....................................................................... 46Reference Log Sequencing Selection - Mode 4.1 ........................................................... 47Entering and Storing Machine Title - Mode 6 .................................................................. 48Running Reference Logs And Base Gain Settings - Mode 8 .......................................... 49Disabling Printer Handshaking - Mode 9 ......................................................................... 50Enabling Printer Handshaking - Mode 9.3 ....................................................................... 50Date Entry - Mode -1 ....................................................................................................... 50

Troubleshooting ................................................................................................ 51

Maintenance ....................................................................................................... 55Checking Air Filter ...........................................................................................................55Cleaning Reference Disk And Sample Drawer ................................................................ 55Cleaning Aperture Glass ................................................................................................. 56Fuse Replacement .......................................................................................................... 57

Appendix ............................................................................................................. 59

Instalab Series 600 Analyzers11001-1360-200512

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OPERATOR’S MANUAL

SAFETY NOTICES

Safety notices are one of the primary ways to call attention to potential hazards.

This Safety Alert Symbol identifies important safety messages in this manual. When you see this symbol, carefully read the message that 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 the word CAUTION with the Safety Alert Symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Use of the word CAUTION without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in equipment damage.

!

Instalab 600 Series Analyzers11001-1360-200512

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OPERATOR’S MANUAL


2 SAFETY NOTICES

OPERATOR’S MANUAL

INTRODUCTION

Quality in design and construction of the Instalab 600 Series ensures the most reliable Near Infrared Reflectance (NIR) results available. The rotating sample cup virtually eliminates the problems associated with sample non-homogeneity - studies indicate up to 3 times better than integrating sphere and other types of data collection technology. Reliability is further enhanced by a reference design that incorporates the entire optical system. An exclusive DICKEY-john feature, Optigain®, enables the user to adjust the gain for low-reflectance samples. Another exclusive, thermoelectrically cooled detectors, maximizes both sensitivity and dynamic range.

The Instalab 600 Series is designed and built for trouble-free operation in virtually any environment - from the lab to the production line. The optics chamber is completely sealed and thermally isolated. An integrated, computerized self-test mode continuously monitors instrument performance and pinpoints errors. Calibrations are stored in a non-volatile EEPROM system that doesn’t rely on battery backup. Automatic self-test procedures verify correct operation after each sample.

The unique sampling system makes the Instalab adaptable to nearly any solid or semi-solid substance. Replaceable filters allow the instrument to be adapted, easily and economically, for nearly any substance and any constituent, making the Instalab 600 Series ideally suited for both development work and for dedicated instrument use. The replaceable filter feature also allows any change in filter configuration developed by a research scanning instrument to be easily implemented in satellite Instalabs for networking.

Near Infrared (NIR) technology offers an important alternative to wet chemistry, an alternative with a world of applications: control of incoming raw materials, process control, research, and many more. Virtually any solid or semi-solid material may be analyzed by the DICKEY-john NIR method.

With sufficient calibration data, the Instalab will provide accuracy comparable to laboratory results. In fact, in daily operation, the Instalab is much more repeatable and precise than typical laboratory testing since operator technique is less crucial and instrument error is minimal.


INTRODUCTION 3

OPERATOR’S MANUAL

Figure 1Instalab Unit

MODELS• MODEL 660A utilizes the universally accepted standard set of six

wavelengths commonly used to measure moisture, protein, starch, oil, etc. in food products.

• MODEL 610FGA includes ten selected filters designed specifically for use in measuring properties in feed and grain.

• MODEL 610SBA includes ten selected filters designed specifically for use in measuring properties in soybeans, wheat, and corn.

• MODEL 610MCA includes the ten most commonly used filters for NIR applications in food, feed, grain, meat, and dairy applications.

• MODEL 610A CUSTOM permits the user to choose four specific filters from a selection of over 50 available wavelengths to supplement the six standard filters, allowing dedicated calibration for special product applications.

FEATURESFeatures of the Instalab 600 Series Analyzer features include:

• Memory capabilities allow storage for 52 calibrations.• Selectable moisture basis constituent concentration may be give “as

is”, at dry basis, or at a preselected moisture basis. A combination of moisture basis may also be selected using the various formats available.

• Keyboard selected wavelengths.• Sample presentation system provides rotating sample cup for

averaging of sample reflectance and less susceptibility to particle size.• System provides for sample cup interchangeability.


4 INTRODUCTION

OPERATOR’S MANUAL

• Digital microprocessor circuitry provides fast, easy field changes to incorporate alternate data treatments as they become available.

• Circuitry ensures excellent long and short term stability due to elimination of electrical drift.

• Circuitry ensures stable, nonvolatile storage of calibration constants without dependence on an alternate power source such as batteries.

• Thermoelectrically cooled photo detector eliminates errors associated with temperature changes within the detector.

• Field-proven, long life tungsten-halogen light source.• Completely sealed optics chamber minimized effects of dust.• Modular construction for ease of service.• Self-test provision eliminates operator error, continuously verifies

operational status, and speeds servicing of the unit.• Diagnostic modes for fault isolation.• High speed operation.• OPTIGAIN® feature allows user to select optimum gain characteristics

for products with low reflectance characteristics.

OPTIONAL ACCESSORIESOptional accessories include:

• Printer - produces a permanent record of results and calibrations.• Regression and Data Collection Package - allows the operator to

develop custom calibrations (when used with IBM and IBM-compatible personal computers).

• Optical Filters - additional optical filters are available to provide greater flexibility over a wider range of constituents.

SPECIFICATIONSThe Instalab is a rugged, self-contained optical reflectance instrument, designed to quickly and accurately measure the percent of constituent concentration (moisture, protein, oil, starch, fiber, ash, etc.) in a wide range of commodities common to the grain, feed, and food industries.


INTRODUCTION 5

OPERATOR’S MANUAL

Figure 2Dimensions

• Weight - 65 lbs/29.5 kg• Dimensions - (Height) 13.62 in/34.6 cm, (Width) 22.25 in/56.5 cm,

(Depth) 16.35 in/41.5 cm• Power Requirements - 102-132 VAC, 47-63 Hz or 187-242 VAC,

47-53 Hz• Wavelengths - 6-10 (Customer Replaceable• Storage Capacity - 52 Constituent Matrix• Serial Computer Interface - Standards RS-232-C• Printer - Optional• Accuracy - Exceeds federal specifications for NIR instruments• Sample Integration Technique - Rotating cup• Filter Bandpass - 10 nm• Light Source - Tungsten Halogen• UL Listed/CSA Certified - yes (110v version)• Calibration Storage - Non-volatile EEPROM (Electrically Erasable

Programmable Read Only Memory)• Typical Analysis Time - 10 seconds• Detector - Thermoelectrically cooled lead sulfide• Reference Measurement - Through entire optical system, against

ceramic disk• Gain Setting - Customer-adjustable, using Optigain feature• Diagnostics - Self-test, automatically after every sample

16.35"

TOP VIEW

22.25"

FRONT VIEW

1.52"

19.25" 16.35" 3.50"

13.62"

SIDE VIEW


6 INTRODUCTION

OPERATOR’S MANUAL

THEORY OF OPERATIONThe Instalab uses NIR technology and a statistical math treatment to predict the percent of constituent concentration within a sample. Research has proven certain constituents absorb light energy at specific wavelengths. For instance, moisture absorbs the 1.94 µm (micrometer) band of near infrared light (NIR), protein absorbs the 2.18 µm band and oil, the 2.31 µm and 2.33 µm bands. By bombarding a sample with a very narrow band of light at a specific wavelength of NIR light, analysis of a sample can be predicted. The light energy absorbed by the sample is inversely proportional to the reflected light.

Figure 3Operational Diagram

Detector

Glass

Broadband Light

Lens

Chopper Disc

Chopped Broadband Light

Filter Wheel

NIR Filter

Aperture

Narrowband Light

Reference Disc

Sample Drawer

(Side View)

Fixed Reference Disc

Sample Drawer

(Top View)

Rotating Sample

NIR Filters

Filter Wheel

Top View


INTRODUCTION 7

OPERATOR’S MANUAL

Figure 3 illustrates the basic mechanical functions used in irradiating a product sample. A broadband Tungsten-halogen lamp produces a light source that is rich in near infrared (NIR) wavelengths. Beneath the lamp, a lens aligns the light into parallel rays. A chopper wheel periodically interrupts the focused light beam, resulting in an alternating signal to the detector, thus enhancing the stability of the reading. The chopped light passes through NIR filters to allow only selected bands of near infrared light to pass and irradiate the sample. An aperture blocks all outside light and allows only a column of filtered light through to the sample. The sample absorbs part of the near infrared light while reflecting the remainder. A detector reads the amount of reflected light, amplifies the signal, and converts the voltage level into a digital form for further processing.

There are six optional NIR filters installed in the filter wheel on a standard Instalab unit. Up to four additional filters may be supplied on more advanced models or added later as field modifications. The filters are successively rotated into place over the sample to irradiate it with discrete wavelengths of near infrared energy. The measured reflectance energy for each filter is converted to a machine logarithm that is used along with the calibration constants to predict the constituent concentration.

Where:

KA is the bias adjustment for the calibration.

KO is the coefficient for the first filter position

LOG is the first filter’s machine logarithm of the reciprocal reflectance (absorption)

K1 is the coefficient for the second filter position

LOG is the second filter’s machine logarithm of the reciprocal reflectance (absorption)

The sample drawer has two sections. One section is used for the sample and one section is used for a Ceramic Reference Disk. When the sample drawer is open between analyses, all the optical filters that are used in the calibration are successively positioned over the Ceramic Reference Disk. The gathered reflectance data, at each of the selected wavelengths, is a measure of the total available light. When the drawer is closed, the light reflected from the sample at each of these wavelengths is measured again. The machine logarithms used in the regression equation are the log ratio of sample reflectance data to the reflectance data gathered from the ceramic reference disk.

% CONTITUENT = KA + KO X LOG ( ) + K1 X LOG (1/R0

1/R1

+ . . . + K n+ LOG ( )

1/Rn

1/R0

( )

1/R1

( )


8 INTRODUCTION

OPERATOR’S MANUAL

INSTALLATION

Prior to shipment, the unit was inspected and found to be free of mechanical and electrical defects. After the Instalab is unpacked, inspect the unit for damage that may have occurred during shipping. Save all packing materials until the inspection is complete. If damage is found, immediately file a claim with the carrier and notify your DICKEY-john sales representative.

The Instalab should be installed and maintained in a level position and in a location where it is protected from rapid changes in ambient temperature. Also, the Instalab and printer (optional) must not be used in hazardous (classified) locations as defined in Article 500 of the NFPA Handbook of the National Electrical Code.

If a printer (optional) is installed, it should be placed on the right side of the Instalab so as not to obstruct the air vents on the instrument.

Connect the power cord to a 3-wire (grounded) 120 VAC, 60 Hz outlet. If the unit is optionally configured for 220 VAC, 50 Hz, connect the power cord to an appropriate 220 VAC outlet.

Proper grounding must be made to ensure the safe and proper operation of the unit.

The grounding pin on the power cord plug is connected to the Instalab enclosure. If an adapter with a grounding wire is used, make sure that the grounding wire is connected to a good earth ground. Otherwise, a shock hazard may be present. Do not use a 3-pin to a 2-pin adapter.

PRINTER CONNECTIONThe optional printer connects to the Instalab through a connecting cable that is terminated at each end with a 25-pin connector. These connectors plug into receptacles at the rear of the printer and the Instalab. The printer has its own 3-wire power cord and plug.


INSTALLATION 9

OPERATOR’S MANUAL

SERIAL PORT CONFIGURATIONThe serial port conforms to the EIA/TIA RS-232-E standard and is configured as Data Communications Equipment (DCE). The data out is at RS-232-E levels and polarity with a 1200 Baud rate. Each ASCII character is described as consisting of a start bit, 8 data bits, no parity bit and 1 stop bit or 7 data bits space parity and 1 stop bit.

Figure 4ASCII Character Bit Identification

CONNECTOR CONTACTSEach line consists of 16 characters followed by a carriage return and a line feed. Each transmission is terminated by a line consisting of sixteen equal signs ( “=” ), a carriage return, and a line feed followed by 2 lines each consisting of sixteen blanks ( “ “ ), a carriage return, and a line feed.

Figure 5Connector Contacts

Space + 12 V

0V

Mark - 12V

Start Bit LSB Stop Bit

Space Parity

or Bit # 8

Pin 1Pin 13

Pin 14Pin 25


10 INSTALLATION

OPERATOR’S MANUAL

Figure 6Connector Pin Assignment

Pin Number Data Communications Equipment Signal Direction

1 Frame Ground Bidirectional

2 Data in (TXD) In

3 Data Out (RXD) Out

4 Request to Send/Ready for Receiving (RTS) In

5 Clear to Send (CTS) Out

6 Instrument ON (DCE Ready) (DSR) Out

7 Signal Ground Bidirectional

8 Instrument ON (Rec'd line signal detector) (DCD) Out

20 Ready (DTR) In


INSTALLATION 11

OPERATOR’S MANUAL


12 INSTALLATION

OPERATOR’S MANUAL

CALIBRATION

GATHERING A SAMPLE SETSatisfaction with the performance of the Instalab is largely dependent on the care taken in gathering, selecting, and preparing samples for calibration. The calibration process is essentially one in which the instrument is “taught” to relate specific reflectance data to know chemical reference analysis of a selected set of samples. If the Instalab is “shown” a sample with reflectance characteristics unlike those included in the selected sample set, less accurate predictions may result. It is also important that the calibration sample set include all combinations and concentrations of constituents, whether 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 present in the sample.

SAMPLES REQUIRED FOR CALIBRATIONThe number of samples necessary to perform a multiple linear (least square) regression varies. At least 30 samples are recommended for calibration and an independent set of samples (approximately the same number) are required to test the calibration.

SAMPLE COLLECTIONCalibration samples must be collected from the same point in the process that the Instalab monitors. It has been found that within a multistage process, the product may have different characteristics at different points in the process. If the Instalab is to monitor several different points of the process, separate calibrations may have to be developed for each point that is to be monitored.

For a processed product, a good time to collect samples (for a wide range of constituent concentration) is when the plant is running under abnormal conditions or the operation is just returning to normal. Taking samples at frequent intervals during these periods usually produces a sample set with a good range and combination of constituents not always found under normal plant conditions.

Selection of a sample set for calibration may frequently be aided by using a “rough” calibration such as a calibration for a similar product to segregate samples and to ensure a set of samples across the desired range of interest are collected. This technique reduces the number of samples that have to be analyzed by the more cumbersome reference methods.


CALIBRATION 13

OPERATOR’S MANUAL

PRODUCT CHARACTERISTICSVariations in product characteristics such as color, hardness, and the amount of hull or foreign material may necessitate separate calibration constants for determinations. The color and hardness may affect the amount of light that is absorbed by the product and the amount that is reflected. The amount of hull and foreign material may affect the particle distribution causing different sized particles to be unevenly distributed throughout the sample.

SAMPLE MOISTURE CONTENTThe moisture content of a sample is important since the concentration of the remaining constituents (expressed as a percentage of the total weight) is a function of the moisture content. Consider, for example, a product with the following analysis:

Moisture 7.0%

Oil 8.0%

Protein 72.0%

If this same sample is dried to 3% moisture, the analysis becomes:

Moisture 3.0%

Oil 8.34%

Protein 75.1%

If this change in moisture occurred between the time the laboratory reference analysis and Instalab analysis is performed, one would wrongly conclude that there is a 3.1% difference in protein determinations.

The prediction equation utilizes reflectance measurements at specific wavelengths to predict the moisture, protein, oil, etc., with as little interference from other parameters or constituents as possible. To minimize errors due to moisture changes, samples should be analyzed for moisture on the same day that they are analyzed by the Instalab. Other constituents may be analyzed later as long as the constituent concentration is expressed on the moisture basis of the original sample presented to the Instalab.


14 CALIBRATION

OPERATOR’S MANUAL

SAMPLE STORAGECare must be exercised in sample storage and handling to minimize moisture loss. Tins with “slip-fit” lids should be sealed with vinyl tape. Glass jars with tight fitting screw lids may be satisfactory, but it is desirable to choose jar sizes to minimize the dead air space above the sample. Some materials cannot be stored for long periods of time without undergoing changes in composition. This is especially true of some high oil products. Chemical and biological degradation of samples may be slowed by keeping the samples refrigerated. Refrigerated samples should be allowed to return to room temperature before analysis. If samples have been stored for a long period of time, it is advisable to redetermine the moisture and convert the analysis of the other constituents to a present moisture basis before using the sample for Instalab calibration or bias adjustments. Ziplock plastic bags (of at least .004” thickness) are recommended for sample storage when storage is necessary. For moisture levels of 16% or greater, double bag each sample.

DEVELOPING CALIBRATIONSThere are three ways to obtain a calibration. DICKEY-john has developed some universal calibrations for certain products. These may be obtained from your DICKEY-john sales representative. Calibrations may be developed by using the optional Regression and Data Collection Package, or the user may use their own computing facilities to develop a calibration.

UNIVERSAL CALIBRATIONSContact your DICKEY-john sales representative for specific information concerning the products that have universal calibrations. If there is a calibration that fits your particular needs, use the following procedure to enter, store, and test the calibration. Adjust the machine bias to make the predictions agree with the reference analysis.

1. Enter the calibration using Mode 2 (refer to OPERATION).2. Randomly gather 20 samples at different times of the day from the

same point of the operation the Instalab will be monitoring. 3. Grind and mix each sample and divide each mixed sample into three

parts: two parts for laboratory analysis and one part for the Instalab analysis.

4. Perform the laboratory analysis separately, comparing the results. Do not use samples whose laboratory analysis differ enough that the accuracy is suspected.

5. When both analyses for the same samples are close enough to assure laboratory accuracy, average the two results.

6. Log the laboratory analysis and Instalab analysis on the INSTALAB BIAS ADJUSTMENT WORKSHEET.


CALIBRATION 15

OPERATOR’S MANUAL

Figure 7Example Of Instalab Bias Adjustment Worksheet

Twenty laboratory analyses were preformed and all were of sufficient accuracy. They were logged under STANDARD ANALYSIS. The Instalab analyses were also logged. Each column was added, then divided by the number of samples (SUM ™ N). The Instalab average is then subtracted from the laboratory’s analysis. This result, “.25” in the previous example, is the amount of Bias Adjustment required to make the Instalab percent analyses agree with the laboratory determinations. Refer to MODE 4 for procedures on adjustments.

REGRESSION DATA COLLECTIONRefer to the manual entitled REGRESSION AND DATA COLLECTION PROGRAM for specifics on how samples are gathered and prepared, then perform the regression as explained in the manual. After development is complete, calibration constants are entered into nonvolatile memory by using MODE 2 and stored by using MODE 5.

Instalab Bias Adjustment Worksheet

Date: _____________________________ Instalab Serial #: _____________________

Product: ___________________________ Grinder Serial #: ______________________

CONSTITUENT CONSTITUENT CONSTITUENT CONSTITUENT

Sample # (N) Standard

Analysis

(%)

Standard

Analysis

(%)

Standard

Analysis

(%)

Standard

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Sum

Average(Sum÷N)

Standard Average

Minus Instalab Average

Equals Bias Change Req'd

Hard Red Wheat

Protein (.2)

10.56

11.02

13.5712.2011.67

13.30

12.8211.6010.98

12.90

12.37

13.42

10.2011.0612.07

12.3513.50

11.1711.11

12.07

10.31

10.77

13.3211.9511.42

13.05

12.5711.3510.73

12.65

12.12

13.18

9.9510.8111.82

12.1013.25

10.9210.8611.82

239.95

12.0

234.95

11.75

12.0

11.75

.25


16 CALIBRATION

OPERATOR’S MANUAL

DEVELOPING CALIBRATIONS WITH COMPUTER AND REGRESSION PROGRAMWhen the user develops calibrations using his facilities, the machine logs become the independent variables. The laboratory reference analyses become the dependent variables. After allowing 48 hours for the Instalab to warm up, enter the Reflectance Data Collection Mode that provides the best data to obtain machine logs. Develop the Calibration Constants (KA, K0, K1, ... Kn). After calibration constants are developed, they are entered into nonvolatile memory using MODE 2 and stored using MODE 5.


CALIBRATION 17

OPERATOR’S MANUAL


18 CALIBRATION

OPERATOR’S MANUAL

SAMPLE PREPARATION

GRINDING SAMPLESAfter being collected, samples must be ground to a uniform particle size. Since the reflectance from a sample is inversely related to particle size, it is not surprising that particle size variations can contribute to testing or calibration errors.

Sources of error caused by particle size variations may be minimized with the uniformity of particle size. Obviously, the calibration sample set and the prediction set must be treated in the same manner and should be as nearly identical in particle size and the particle size distribution as possible. Products such as flour, vital gluten, and dry yeast do not require grinding to reduce the sample to a uniform particle size. Grain, soybean, and other meal products (gluten feed, corn grits, forage, silage, and oil seeds) do require suitable grinding prior to analysis.

Low oil and low moisture products may be ground by using a Udy Cyclone Mill (the belt driven model is preferred over the direct drive version). The Wiley Intermediate sample mill has also proved useful on a number of products. High oil products may 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 grinding method has been chosen, the grinding technique should be documented and care taken to ensure the technique is repeated exactly on all samples.

Do not grind samples too near the air intake as dust may be drawn into the unit.

MIXING SAMPLESSince the Instalab determines the total sample composition by irradiating less than one-half a cubic centimeter, that portion must be representative of the whole. All constituents present must be distributed equally throughout the sample. Typically, 15 to 20 complete turns of the ground sample with a steel spatula are adequate for sample uniformity.

LOADING STANDARD SAMPLE CUP (DRY POWDER SAMPLES)

1. Begin by clearing the window of the sample cup. Use a Scott lint free microwipe or equivalent. If necessary, dampen the wiper with isopropyl alcohol to remove oil residue. Brushing with a soft camel’s hair brush may be sufficient for non-oily products such as wheat or oats.

2. Place sample cup cover (part with window) on loading tray (refer to Figure 8). Place the cup with the glass window down and twist the cup clockwise until it locks into place.


SAMPLE PREPARATION 19

OPERATOR’S MANUAL

IMPORTANT: Do not get finger prints on glass window.

Figure 8Placing Cup On Loading Tray

3. Obtain a heaping scoopula of the sample from a well-mixed sample container using a sideways scooping motion. Dump the sample onto the center of the window. Slide the sample off the tip of the copula to form a conical pile. Do not disturb the pile with the tip of the scoopula. If the cup well is not filled up to the rim, take a second scoopula full of the sample and fill in all holes. The sample should form a mound in the center of the cup, about 1 cm above the level of the cup rim.

4. Gently tamp the sample into the cup. Starting at the center of the mound and proceeding to the sides, gently tamp the sample into the cup using the flat side of the scoopula. Pack the sample until the surface is flat and flush with the rim of the cup.

Figure 9Tamping Sample Into Cup

5. Brush off excess sample. Carefully brush off all sample excess from around the rim of the cup using the brushes supplied. Be very careful not to disturb the smooth surface of the sample in the cup.


20 SAMPLE PREPARATION

OPERATOR’S MANUAL

Figure 10Brushing Off Excess Sample

6. Place sample cup bottom cover over filled sample cup. Use slight downward pressure on the cup bottom while turning it clockwise. Release the pressure and then twist the cup bottom counterclockwise while lifting the filled sample cup from the loading tray.

Figure 11Placing Sample Cup Bottom Over Filled Cup

7. Clean remaining sample residue from sample cup. Thoroughly clean the loading try after loading the sample cup.

IMPORTANT: Do not touch and/or fingerprint the glass cover.


SAMPLE PREPARATION 21

OPERATOR’S MANUAL

Figure 12Cleaning Off Remaining Residue

8. After the test is completed, disassemble the sample cup. Press the two halves together and turn the cup top counterclockwise. Clean all sample material from the sample cup before reusing.


22 SAMPLE PREPARATION

OPERATOR’S MANUAL

OPERATION

OPERATOR CONTROLSAll operator controls, except the power ON/OFF switch, appear on the front control panel as illustrated in Figure 13. The power ON/OFF switch is located on the rear of the unit just above the power cord connection. The control panel provides a means for the operator to issue instructions to the unit’s computing circuits. The control panel is divided into three major components: the key switch, the step switch, and a 16-key touch switch keyboard.

Figure 13Operator Control Panel Layout

KEY SWITCHThis switch utilizes three operating positions: % ONLY, CALIBRATE, and STORE ONLY. The % ONLY position is used during normal operation. Access to the other two positions are made by turning the key. Removal of the key (when in the % ONLY position) eliminates unauthorized alterations of calibrations or adjustments to the bias. Refer to MODE SELECTION for a definition of the various modes and functions available to the operator through the use of the key switch.

KEYBOARDThe 16-key switches of the keyboard are pressure sensitive switch contacts requiring only light finger pressure to actuate. The keyboard is subdivided into six function keys and ten numeric keys (refer to Figure 14). Each valid keystroke generates a short tone burst when the key closure occurs.

Function keys include:

• Clear Key - clears data from the top digital display.• Prod Key - completes the selection of a product and one or more

constituents.• Mode Key - completes the selection of a desired mode of operation.

7 8 9

4 5 6

1 2 3

0

COMM

BIAS STORE

LOGS CONSTANTS TESTLOGS

%

. + - ENTER

MODE

PROD

CLEAR

STEP

CALIBRATE

%ONLY

STOREONLY

KEYBOARD

KEYSWITCH

STEPSWITCH


OPERATION 23

OPERATOR’S MANUAL

• Enter Key - enters information shown on the top display into the computing circuitry.

• +/- Key - changes the sign of the number entered on the top display.• Decimal/Arrow Key - changes the resolution of the percent readout

from tenths to hundredths to thousandths and also enters a decimal point.

Figure 14Keyboard Layout

NUMERIC KEYSThe function of the numeric keys is to enter numerical data into the computing circuits and to initiate selected mode sequences. The numeric keys are illustrated in Figure 14. Several number keys have secondary labels below the key number to indicate basic modes that are often selected during operation. This is useful as a quick reference when selecting specific modes.

STEP SWITCHThe basic function of this switch is to increment the Instalab display from one reading to the next. For example, this switch is useful when measuring multiple products or constituents to advance to the next log reading, or move from one memory position to the next to display values for calibration. This is a multipurpose switch with its specific being defined by the mode of operation selected. Each mode of operation provides instructions for the use of the step switch.

DISPLAY PANELThe display panel, illustrated in Figure 15, is divided into three digital displays and 15 backlit messages. The function of the display panel is to communicate visually to the operator the status of the unit, internal data in memory, and the analyzed results of calculated measurements.

7 8 9

4 5 6

1 2 3

0

COMM

BIAS STORE


%

. + - ENTER

MODE

PROD

CLEAR

STEP

CALIBRATE

%ONLY

STOREONLY

Changes resolution of percentand enters decimal point

Changes signon top display

Enters data on topdisplay into unit

Ends selectionof mode

Completes selectionof product orconstituent

Clears topdisplay


24 OPERATION

OPERATOR’S MANUAL

Digital displays read out values for operator use and include:

• TOP READOUT - consists of five digits, five decimal points, and a minus sign.

• MIDDLE READOUT - consists of three digits and two decimal points.• BOTTOM READOUT - consists of a single digit and a single decimal

point.

Displayed Messages indicate selections and modes of operation. Each of the 13 backlit messages convey the following information:

• % - indicates operation in the PERCENT READOUT mode (MODE O).• BIAS - indicates operation in the BIAS ENTRY/RESOLUTION

SELECT mode (MODE 4).• MOISTURE BASIS - indicates the displayed percent reading is

corrected by a moisture level correction factor. The moisture basis on the center display determines the result shown on the top display.

• LOG - indicates one of the DATA COLLECT modes is selected (MODES 1.0, 1.1, 1.2, 1.3, or 3).

• CONSTANT - indicates operation in the CONSTANT READ/ENTRY/ALTER/STORE modes (MODES 2 or 5).

• TEST - indicates the TEST LOGS mode (MODE 3).• STORE - indicates one of the STORAGE modes (Modes 4, 5, or 6).• INSERT SAMPLE - indicates the unit is ready for the sample drawer to

be closed and for the sample to be analyzed (MODES 0, 1, or 3).• PRODUCT AND CONSTITUENT - indicates the current calibration

selection.• CORRECTED TO STANDARD MOISTURE - indicates that the result

displayed is corrected to a specified moisture level.• TEMP - remains backlit until the optics temperature has stabilized or

may also indicate a malfunction. Once this message goes dark, the operator may begin operation.

• ENTER MOISTURE BASIS - indicates the selected calibration requires a keyboard entered moisture basis.

• CALC - indicates the calculator output formation (MODE 9.1) is selected.

• COMM - indicates the optional communication port is enabled.


OPERATION 25

OPERATOR’S MANUAL

Figure 15Display Panel Messages

SAMPLE DRAWERThe location of the sample drawer is in the lower left portion of the Instalab and swings open for access to the interior. The interior contains two divisions. The division to the rear contains a fixed ceramic reference disk that is used for reference readings while the drawer is open. These readings are retained and compared with the sample reading after the sample is inserted and read.

To make a measurement on any product (corn, wheat, soybeans, etc.), a sample must be prepared (refer to SAMPLE PREPARATION), placed in a sample cup, and located on a turntable inside the sample drawer. When prepared and placed in position, the drawer is closed and the test is started. The sample is rotated by the turntable while a lamp at the top of the unit directs a powerful light source downward through a lens, a chopper (rotating) disk, an optics filter, and then through an aperture opening to the sample in the drawer. The reflected light from the sample is detected by a photo detector and the signal is processed by the electronics circuits of the unit. The results are then displayed and printed (if an optional printer is used).


26 OPERATION

OPERATOR’S MANUAL

BASIC OPERATING CONCEPTS

POWER UPImmediate following power up, the Instalab automatically checks its stored program. The HELLO message will appear after the checks have been completed successfully. An error code will be displayed if a fault is encountered during power up. The TEMP message on the display will remain lit until the machine temperature stabilizes. The HELLO message on the top display will remain on until a mode of operation or a product is selected. When a product is selected, MODE O is automatically assumed (refer to MODE SELECTION). It is recommended that the unit be powered on for 3 hours before measurements are taken.

KEYBOARD ENTRIESAs numbers are entered via the keyboard, the results are displayed. The Decimal/Arrow key enters a decimal point and the +/- key changes the sign of the number from positive to negative or vice versa.

After a five digit number has been entered, the Instalab cannot accept any more entries until one of the function keys (CLEAR, PROD, MODE, or ENTER) has been pressed to complete a specific function. Pressing the Clear key deletes the number from the top display. After a machine operation is performed and a number (the percent analysis, a log, or constant) is displayed on the top display, pressing any numbered key will clear the top display and the new “keyed number” will appear in its place.

PRODUCT AND CONSTITUENT SELECTIONSelecting a product and one constituent is accomplished by entering the product number, decimal point, and constituent number. Press the Prod key. Definitions for product and constituent numbers are provided in Figure #. The selected product and constituent numbers will appear on the center display. The PRODUCT and CONSITUTENT messages will be backlit.

Selecting a product and multiple constituents (up to 4) is accomplished by entering the product number, decimal point, and constituent numbers. Press the Prod key as before. The center display will show the selected product number, a decimal point, and a bar (-) indicating multiple constants have been selected. The PRODUCT and CONSTITUENT messages will be backlit.

Selecting a product and all available constituents (up to 9) is accomplished by entering the product number and pressing the Prod key. The center display will indicate the selected product number. The decimal point and constituent digit will remain blank. The PRODUCT message will be backlit.

IMPORTANT: To obtain a readout of the second constituent analysis (or the corrected reading when As-Is and corrected readings are called for), press the Step switch.

+

.

Decimal/Arrow key

CLEAR

Clear key

PROD

Prod key

+/- key


OPERATION 27

OPERATOR’S MANUAL

ENTERING SAMPLE ID NUMBERSA sample ID number of up to five digits may be entered from the keyboard and printed with the analysis in MODES 0 and 1. The ID number may be entered only after the sample drawer has been opened or any time thereafter prior to the completion of the sample analysis. If the drawer is still closed and the operator failed to enter the ID number, wait until the analysis is printed, then, with the drawer still closed, enter an ID number. A duplicate analysis will print with the corrected ID. To enter the ID number, press the +/- key, the ID number, and the Enter key.

MODE SELECTIONMore than 20 different modes of operation are available to the operator to perform various tests and measurements using the Instalab. Each mode performs a specific function and is identified by a mode number. Mode selection is restricted by the position of the Key switch. If the Key switch is not in the correct position when selecting a specific mode, an ERROR 5 will be displayed and the unit will continue in the current mode of operation. Each machine mode and the correct Key switch position is outlined in Figure 17. Before any test function may be performed, a mode of operation must be selected. After deciding on a particular mode, three simple steps are required to complete the task.

1. Set the Key switch to the proper position.2. Enter the desired mode number (and a decimal point, as necessary).3. Press the Mode key to enter the selected mode.

There are several modes available that are not listed in Figure 17. These are reserved for service personnel. If one of these modes is accidently encountered, exit it immediately by turning the Key switch to the % ONLY position.

ENTER

+

+/- key

Enter key

Key switch

MODE

Mode key


28 OPERATION

OPERATOR’S MANUAL

Figure 16Mode Entry

7 8 9

4 5 6

1 2 3

0

COMM

BIAS STORE


%

. + - ENTER

MODE

PROD

CLEAR

STEP

CALIBRATE

%ONLY

STOREONLY

1. Set to proper position 2. Select and key in mode number

3. Press the Mode key


OPERATION 29

OPERATOR’S MANUAL

Figure 17Standard Modes Of Operation And Functions

MODE SELECTION

ANALYZING SAMPLES FOR PERCENT ANALYSIS - MODE 0MODE 0 predicts constituent concentration in a sample. MODE 0 is assumed and does not require entering when the Key switch is set to the % ONLY position. When MODE 0 is in effect, the % message, adjacent to the right end of the top display, is backlit. To analyze a sample using MODE 0, perform the following procedures:

1. Select the product and constituent(s) numbers and press the Prod key.2. Place the loaded sample cup into the sample drawer. If the calibration

format specifies a keyboard entered moisture basis, the ENTER MOISTURE BASIS message on the display panel will illuminate. Enter the moisture basis as requested and press the Enter key. If a sample ID number is used, press the +/- key, enter the ID number, and press the Enter key.

Key Position Mode Functional Description

% or CAL 0 Analyze sample and display/print the percent analysisCAL 1 Analyze sample data and display/print the reflectance logs

(calibration data)CAL 1.1 Optigain function; analyze samples and display/print the

improved difference logarithms (calibration data)CAL 1.2 Same as 1.1CAL 1.3 Same as 1.1CAL 2 Enter, modify, and display/print the calibration constantsCAL 2.1 Print a list of the currently stored calibrations, product numbers

and names, and constituent numbers and namesCAL 2.2 Print a list of the programmable product namesCAL 2.3 Print a list of the programmable constituent namesCAL 2.4 Print a list of the product name assignmentsCAL 3 Analyze reference disk or sample and display/print the logs

(reference data or raw sample data)CAL 3.5 Display, printer, and drawer testCAL 3.6 Continuously analyze reference disk or sample and print logsSTORE 4 Enter bias or change the percent display/print resolutionSTORE 4.1 Select reference log collection modeSTORE 5 Store calibration constantsSTORE 5.1 Store product name assignmentsSTORE 6 Enter machine titleSTORE 6.1 Enter programmable product namesSTORE 6.2 Enter programmable constituent labelSTORE 8 Store reference logs and base gain settingsCAL 9 Disable printer handshaking and test outputCAL 9.3 Enable printer handshakingCAL -1 Enter or change data

Key switch

PROD

ENTER

Prod key

Enter key


30 OPERATION

OPERATOR’S MANUAL

3. Close the sample drawer when the INSERT SAMPLE message is illuminated. After the sample is analyzed, the printout should appear similar to Figure 18.

Figure 18Sample Printout With Entry Meanings

If a printer is not available for use with the Instalab and if the selected product and constituents remain the same as those shown in Figure 18, 8.99% appears on the top display and 12.1 (the product and constituent number) appears on the center display. To increase the display resolution to the nearest thousandth of a percent, press the Decimal/Arrow key and then the Mode key.

To obtain the analysis for the next constituent (PROTEIN), press the STEP switch. 13.69% will appear, the as-is analysis will be displayed on the top display, and 12.2 will appear on the center display. Press the Step switch again and 13.24%, the corrected reading, will appear on the top display. The message CORRECTED TO STANDARD MOISTURE will be lit indicating the displayed value is a corrected one. Pressing the Step switch again will result in the corrected reading remaining on the top display and the moisture basis, 12.0% in this example, displaying on the center display. The MOISTURE BASIS message will be backlit indicating the value shown on the center display is the keyboard entered or stored moisture basis. The CORRECTED TO STANDARD MOISTURE message will remain backlit.

INSTALABPRODUCT ANALYZER

6/17/05

ID: 1

HARD WHEAT

MOISTURE 8.99%PROTEIN 13.69%PROTEIN 13.24%@ 12.0% M

= = = = = = = = = = = =

user entered title

user entered date

user entered sample ID

sample product

selected constituent (.1)selected constituent (.2)corrected analysiskeyboard entered or storedmoisture bias

ENTER

Enter key

.

Decimal/Arrow key

MODE

Mode key

STEP

Step switch


OPERATION 31

OPERATOR’S MANUAL

ANALYZING SAMPLES FOR DATA COLLECTION - MODES 1.0, 1.1, 1.2, AND 1.3The four data collection modes are used to collect reflectance data (logarithms) for developing or testing calibrations. The mode selected is typically determined by the reflectiveness of the sample selected. If the sample is a low reflectance in the near infrared spectra range, high logarithms result. The Instalab is most sensitive to changes in constituent concentration when the majority of the sample’s logarithms are between 100 and 300. If the logarithms are between 20 and 400, the accuracy is not adversely effected. For best measurements of non-reflective samples, an Optigain feature has been incorporated into the Instalab design. Its function is to adjust a sample’s logarithms so that the majority fall into the optimum range (100-300).

To determine which of the data collection modes to use, perform the following tests. Start by selecting and loading two samples. Use MODE 1.0 to obtain the reflectance data for each of the two samples.

1. Make sure the key switch is in the CALIBRATE position and enter MODE 1.0 by pressing the 1 key, followed by the Mode key.

2. Place a loaded sample cup in the sample drawer. When the INSERT SAMPLE message is displayed, close the sample drawer. The printout from the printer should be similar to Figure 19.

Figure 19Data Collection Examples Using Mode 1.0

If no printer is available, use the Step switch to observe and record the logarithm for each filter position. The filter position is shown on the bottom display and its logarithmic value is shown on the top display.

Examples 1 and 2 above are logarithms obtained from Hard Red Winter Wheat. Note that in both examples, all except the logarithm for filter 5 are in the optimum sensitivity range and the filter 5 logarithms are in the usable range. Therefore, Mode 1.0 should be selected to obtain reflectance data.

Examples 3 and 4 are reflectance data obtained from Rape Seed samples. Note L0 and L1 in Example 3 are above the usable range (20 to 400) and in Example 4, L0, L1, L2, L3, and L4 are all above the usable range.

- EXAMPLE 1 -

MODE 1.0CALIBRATION DATA

= = = = = = = = = = = =

LO 174.60L1 131.97L2 143.31L3 160.55L4 152.12L5 66.83

ANALYSIS:

- EXAMPLE 2 -


= = = = = = = = = = = =

LO 182.31L1 141.79L2 156.13L3 167.29L4 160.01L5 72.20

ANALYSIS:

- EXAMPLE 3 -


= = = = = = = = = = = =

LO 493.68L1 421.85L2 397.53L3 367.21L4 342.06L5 252.97

ANALYSIS:

- EXAMPLE 4 -


= = = = = = = = = = = =

LO 497.36L1 454.28L2 462.70L3 431.67L4 435.07L5 301.02

ANALYSIS:

MODE

Mode key

STEP

Step switch


32 OPERATION

OPERATOR’S MANUAL

Figure 20Data Collection Analysis Comparing Modes 1.0 and 1.1

Examples 5 and 5A are reflectance data obtained from the same Rape SEed sample as in Examples 3 and 4. However, Example 5 was obtained using Mode 1.0 and 5A using the Optigain Mode 1.1. Examples 6 and 6A were obtained from another Rape Seed sample using Modes 1.0 and 1.1. Note how all the logarithms dropped in value when Mode 1.1 was used. This brings the majority of logarithms to within the maximum sensitivity range (100-300). Therefore, Mode 1.1 should be selected to gather reflectance data on further samples for calibration.

Mode 1.2 should be selected if the majority of logarithms were not yet within the maximum sensitivity range. If the reading still requires adjustment, use Mode 1.3.

CALIBRATION ENTRY - MODE 2The CALIBRATION ENTRY mode enters a calibration that consists of a format, both upper and lower percent limits, and calibration constants KA through Kn. A product and constituent number must be assigned to each calibration before entering. These numbers are entered along with the calibration and are used in selecting the calibration to perform percent analyses. A product name may be assigned to a selected product number to appear on the printout along with the percent analysis (refer to PRODUCT NAME ASSIGNMENT). Most of the more common constituent names have already been assigned to constituent numbers (refer to CONSTITUENT NUMBER ASSIGNMENT). If a printer is not available, the product number can be any number between 1 and 99 and the constituent number can be any number between 1 and 9.

1. Set the Key switch to CALIBRATE and enter MODE 2 by pressing the 2 key, followed by the Mode key. The top display will indicate the format number. The center display will show “0”. The bottom display will show “F” indicating the Instalab is prepared to accept the format entry.

2. Enter PRODUCT 0 by pressing the “0” key, followed by the Prod key. Product “0” is selected to protect against accidental erasure of entered constants before being stored in memory.

- EXAMPLE 5 -


= = = = = = = = = = = =

LO 493.68L1 421.85L2 397.53L3 367.21L4 342.06L5 252.97

ANALYSIS:

- EXAMPLE 5A -


= = = = = = = = = = = =

LO 367.68L1 296.35L2 273.03L3 242.71L4 216.81L5 128.22

ANALYSIS:

- EXAMPLE 6 -


= = = = = = = = = = = =

LO 497.36L1 428.17L2 403.70L3 382.67L4 367.29L5 301.02

ANALYSIS:

- EXAMPLE 6A -


= = = = = = = = = = = =

LO 372.61L1 302.97L2 279.20L3 258.17L4 241.79L5 176.02

ANALYSIS:

Key switch

MODE

Mode key

PROD

Prod key


OPERATION 33

OPERATOR’S MANUAL

3. Select a format. The format code number consists of four digits with a decimal point. The first digit specifies the mode that was used to obtain reflectance data for the calibration. The second digit determines the readout resolution. The third digit specifies the type of moisture correction applied (if any). The fourth “decimal” digit selects AS-IS or both AS-IS and moisture corrected readings. All the variations are illustrated in Figure 21.

Figure 21Format Code Number Guide

If, for example, the MODE desired to gather reflectance data from a sample is 1.1 with the displayed RESOLUTION set to the nearest hundredth of a percent, a keyboard entered MOISTURE BASIS, and the DISPLAY/PRINT set to “AS-IS and corrected analysis”, the proper format to select is 122.1.

4. Enter the format number and press the Enter key. A typical format number is 020.0. If the third digit of the selected format is “1”, the bottom display will show “c”, the MOISTURE BASIS message will be backlit, and the top display will show .000000. Enter the stored moisture basis and press the Enter key. “U” will appear on the bottom display, indicating the unit is ready to accept the upper percent limit.

5. Enter the upper limit and press the Enter key. The bottom display will show “L”, indicating the unit is ready to accept the lower percent limit.

6. Enter the lower limit and press the Enter key. The bottom display will show “A”, indicating the unit is ready to accept the value for KA.

7. Enter the KA value and press the Enter key. The bottom display will show “0”.

8. Enter the K0 value and press the Enter key. Repeat this process until all calibration constants (KA through Kn) have been entered. After entering all constants, verify the accuracy of each constant by checking the numbers on the display. This may be accomplished by pressing the Step switch and reading the constants on the top display.

CALIBRATION STORAGEAfter entering and checking the procedures for CALIBRATION ENTRY, calibrations are ready for storage.

9. Set the Key switch to the STORE ONLY position and enter MODE 5 by pressing the 5 key and the Mode key.

Mode Resolution Moisture Basis Display/Print

0 = Mode 1.0 1 = xx.x (tenths) 0 = AS-IS 0 = Only one reading1 = Mode 1.1 2 = xx.xx (hundredths) 1 = Stored Moisture 1 = AS-IS first, then

Basis (MB) corrected reading2 = Mode 1.2 3 = xx.xxx (thousandths) 2 = Keyboard entered MB3 = Mode 1.3 3 = Keyboard entered MB

for Dry Basis calibration

ENTER

Enter key

STEP

Step switch

Key switch


34 OPERATION

OPERATOR’S MANUAL

10. Enter the product and constituent numbers for which the calibration was developed. To enter the product number, press the Decimal/Arrow key, enter the constituent number, and press the Prod key.

11. Press the Step switch to store the calibration. Wait until the upper display shows the DONE message, then return the Key switch to the CALIBRATE position. The printer should print out the newly entered calibration and appear similar to Figure 22.

Figure 22Calibration Storage

CALIBRATION MODIFICATION AND DELETION - MODE 2

1. Set the Key switch to the CALIBRATE position.2. Enter MODE 2 by pressing the 2 key, followed by the Mode key. The

currently-stored calibration will print out and the bottom display will show “F” indicating the value on the top display is the currently-stored format.

3. Enter the product number, press the Decimal/Arrow key, enter the constituent number, and press the Prod key.


6/17/05

CALIBRATION 12.2HARD WHEAT

PROTEIN

FORMAT 22.1RESOLUTION .01

MB ENTEREDAS-IS ALSO

= = = = = = = = = = = =

HI LIM = 15.0LO LIM= 8.00

KA 10.29K0 0K1 0K2 .2000K3 - .1184K4 0K5 - .0938

Note: When MODE 1.0 is used togather reflectance data, the "0" isnot printed. If MODES 1.1, 1.2, or1.3 were used, 1, 2, or 3 would beprinted at the first number of theformat.

STEP

Step switch

Key switch

.

PROD

Decimal/Arrow key

Prod key


OPERATION 35

OPERATOR’S MANUAL

CALIBRATION MODIFICATION4. After performing steps 1 - 3, press the Step switch repeatedly until the

constant requiring change appears on the upper display.5. Enter the correct value and press the Enter key.6. Press the Step switch again and change additional constants as

necessary.7. After all corrections have been made, place the Key switch into the

STORE ONLY position and enter MODE 5. The USED message should appear on the top display.

8. Press the Step switch to store the calibration. Wait until the DONE message is displayed, then return the Key switch to the CALIBRATE position. The corrected calibration will print.

CALIBRATION DELETIONBegin by performing steps 1-3 as previously stated. Press the Step switch once. The bottom display will show a “U”.

1. Enter “0” by pressing the 0 key and press the Enter key.2. Set the Key switch to the STORE ONLY position and enter MODE 5.3. Press the Step switch and wait until the DONE message is displayed.4. Return the Key switch to the % ONLY position. ERROR 8 will be

displayed, indicating there are no calibration constants stored for the selected product and constituent.

PRODUCT NAME ASSIGNMENTThe user may select any number from 1 through 99 for a product number. A product name, which will appear on the percent analysis printout, may be assigned to the selected product number. Twelve product names have already been assigned product numbers at the factory, as illustrated in Figure 23.

STEP

Step switch

Key switch

ENTER

Enter key


36 OPERATION

OPERATOR’S MANUAL

Figure 23Preassigned Product Names/Numbers

If any of the product numbers are used, the product name adjacent to the number is printed out, along with the percent analysis. If desired, additional product names may be assigned to the pre-assigned numbers, or the same product names may be assigned to several product numbers.

Figure 24 provides a list of product names that are stored in memory but have not been assigned product numbers.

Product Number Reference Number Product Namefor Product Name

10 16 Corn11 49 Soybeans12 36 Hard Wheat14 47 Soft Wheat15 41 Oats16 38 Meal17 13 Barley18 45 Rye20 48 Sorghum21 51 Sunflower22 55 White Wheat23 22 Durum


OPERATION 37

OPERATOR’S MANUAL

Figure 24Stored Product Names

Any of the names appearing on the list may be assigned to a product number by using the following steps.

1. Set the Key switch to the STORE ONLY position.2. Enter MODE 5.1. Enter 5.1 and press the Mode key.3. Enter the selected product number and press the Prod key.4. Enter the reference number for the product name shown in Figure 24

and press the Enter key.5. Return the Key switch to the desired position.

If the product name does not appear on the list, MODE 6.1 may be used to program a product name of up to 12 characters into memory. Nine programmable product name positions are available, with reference numbers 1 through 9 reserved.

PROGRAMMING PRODUCT NAMES1. Plot the product name and spacing on a sheet of paper. Plan the

product name and spacing as illustrated in Figure 25 for the name to be centered. If left justification is preferred, start the first character in position 1 and fill in any unused character positions at the end with

Reference ProductNumber Name

10 Alfalfa-Dehy11 Alfalfa12 Bakery Flour13 Barley14 Blood Meal15 Bone Meal16 Corn17 Corn Gluten18 Corn Grits19 Corn Meal20 Corn Starch21 Cotton Seed22 Durum23 Expel. Cake24 Feather Meal25 Feed26 Fish Meal27 Flour28 Flour 0-.4129 Flour .45-.5530 Flour .60-.9031 Flour .90-up32 Gluten Feed33 Gluten Meal34 Groats

Reference ProductNumber Name

35 Hard Flour36 Hard Wheat37 Hay38 Meal39 Meat Meal40 Millfeed41 Oats42 Patent Flour43 Poultry Meal44 Rape Seed45 Rye46 Soft Flour47 Soft Wheat48 Sorghum49 Soybeans50 Spent Flakes51 Sunflower52 Wheat Germ53 Wheat Gluten54 White Flakes55 White Wheat56 44% Meal57 47% Meal58 48% Meal59 49% Meal

Key switch

MODE

Mode key

ENTER

Enter key

PROD

Prod key


38 OPERATION

OPERATOR’S MANUAL

space codes up to and including character 12. To determine the proper code for each character position, including space codes, refer to Figure 26. After the plan is complete, proceed with step 2.

Figure 25Product Name Formatting

Figure 26Character Code Selection Chart

2. Set the Key switch to the STORE ONLY position.3. Enter MODE 6.1. Press 6.1 and the Mode key.4. Enter the selected product reference number (1-9) and press the Enter

key.5. Enter the code number for the first character and press the Enter key.6. Enter the code number for the second character and press the Enter

key. Continue keying in all code numbers until the twelve characters of the product name are entered. After the last character code number is entered, the printer will print out the product name.

7. Use MODE 5.1 to assign a product name to the number.

CORRECTING PRODUCT NAME ERRORSIf an error is made during programming, product name correction may be accomplished as follows:

8. Use the Step switch to step to the character position to be corrected.9. Enter the correct code number and press the Enter key.

Character # 1 2 3 4 5 6 7 8 9 10 11 12Character Code 40 40 40 27 01 14 16 25 24 40 40 40Product Label - - - W A L N U T - - -

Character CodeA 01B 02C 03D 04E 05F 06G 07H 10I 11J 12K 13L 14M 15N 16O 17P 20

Character CodeQ 21R 22S 23T 24U 25V 26W 27X 30Y 31Z 320 601 612 623 634 645 65

Character Code6 667 678 709 71@ 00[ 33~ 34] 35{ 36} 37SPACE 40! 41" 42# 43$ 44% 45

Character Code& 46' apostrophe 47( 50) 51* 52+ 53, comma 54- 55. 56/ 57: 72; 73< 74= 75> 76? 77

STEP

Step switch

Key switch

MODE

Mode key

ENTER

Enter key


OPERATION 39

OPERATOR’S MANUAL

10. Turn the Key switch to another position. The corrected product name will be printed.

CONSTITUENT NUMBER ASSIGNMENTThere are nine constituent numbers, 1 through 9, available for use. The most commonly used constituent names are programmed into positions 1 through 6 by the factory. Constituent number 1 is set for MOISTURE and may not be changed. Positions 2 through 9 are user programmable. The names and labels in these positions may remain as programmed or changed as desired with up to 8 characters.

Figure 27Programming Constituents

CONSTITUENT PROGRAMMINGTo enter a constituent name, use the same basic procedure used to enter product names. If it is desirable to add a constituent(s) not already included in the list, or to alter one of the programmable positions, use the following procedure:

1. Plot the constituent name using an eight-character line. Plan the constituent name and spacing as illustrated in Figure 28 to center the constituent name. If left justification is preferred, start the first character in position 1 and fill in any unused character positions at the end with space codes up to and including character 8. To determine the proper code for each character, include space codes, refer to the Character Codes Chart illustrated in Figure 26. After the plan is complete, proceed with step 2.

Figure 28Constituent Name Formatting

2. Set the Key switch to the STORE ONLY position.

Constituent Constituent ProgrammingNumber Name Status

1 Moisture Permanent2 Protein3 Oil/Fat programmed4 Startch but5 Fiber changeable6 Ash7 CONST 7 require8 CONST 8 programming9 CONST 9

Character # 1 2 3 4 5 6 7 8Character Code 40 40 16 01 15 05 40 40Character - - N A M E - -

Key switch


40 OPERATION

OPERATOR’S MANUAL

3. Enter MODE 6.2 and press the Mode key.4. Enter the selected constituent number (2-9) to be altered and press the

Enter key. The constituent name currently programmed will be printed.5. Enter the character code numbers for each of the eight character

positions and press the Enter key after each entry. Refer to Figure 26 for the code number of each character to be entered. After the last character code number has been entered, the printer will print the name.

CORRECTING CONSTITUENT NAME ERRORS6. Press the Step switch repeatedly until the character position number

requiring alternation appears on the center display.7. Enter the correct character code number and press the Enter key.8. Return the Key switch to the desired position. The constituent name

will be printed.

PRINTING PRODUCTS AND CONSTITUENTS WITH STORED CALIBRATIONS - MODE 2.1When using a printer, MODE 2.1 may be accessed to obtain a printed list of products and constituents having valid calibrations stored in memory. To obtain such a printout:

1. Set the Key switch to the CALIBRATE position.2. Enter MODE 2.1. The printout will appear similar to Figure 29.

Figure 29Sample Calibration List Printout

PRINTING USER PROGRAMMABLE PRODUCT NAMES - MODE 2.2By using the printer, MODE 2.2 may be entered to obtain a printout of product names that were programmed into memory by the user. NOT NAMED will appear in each of the nine programmable position if no product names have been entered. To obtain a printout:

1. Set the Key switch to the CALIBRATE position.2. Enter MODE 2.2. The printout should be similar to Figure 30.

CALIBRATION LIST

12 HARD WHEAT.1 MOISTURE.2 PROTEIN

= = = = = = = = = = = =-----------------------------

MODE

Mode key

ENTER

Enter key

STEP

Step switch

Key switch


OPERATION 41

OPERATOR’S MANUAL

Figure 30Sample Printout Of Programmable Product Names

PRINTING PROGRAMMABLE CONSTITUENT NAMES - MODE 2.3By using the printer, MODE 2.3 may be entered to obtain a printout of the constituent names currently stored in each of the eight user programmable positions. To obtain a printout:

1. Set the Key switch to the CALIBRATE position.2. Enter MODE 2.3. Press the 2.3 keys and then press the Mode key.

The printout should appear similar to Figure 31.

Figure 31Sample Printout Of Programmable Constituent Name Assignments

PROGRAMMABLEPRODUCT NAMES

1 WALNUT2 SASSAFRAS3 NOT NAMED4 NOT NAMED5 NOT NAMED6 NOT NAMED7 NOT NAMED8 NOT NAMED9 NOT NAMED

= = = = = = = = = = = =

PROGRAMMABLECONSTIT. LABELS

2 PROTEIN3 OIL/FAT4 STARCH5 FIBER6 ASH7 CONST. 78 CONST. 89 CONST. 9

= = = = = = = = = = = =

Key switch

MODE

Mode key


42 OPERATION

OPERATOR’S MANUAL

PRINTING PRODUCT NAME ASSIGNMENTS - MODE 2.4With the use of the printer, MODE 2.4 may be entered to obtain a list of product names that have been assigned to product numbers. To obtain a printout:

1. Set the Key switch to the CALIBRATE position.2. Enter MODE 2.4. Press the 2.4 keys and press the Mode key. The

printout will appear similar to Figure 32.

Figure 32Sample Printout Of Product Name Assignments

COLLECTING REFERENCE OR RAW SAMPLE DATA - MODE 3This MODE is used to collect ceramic reference logs and raw sample data. The raw sample data is uncorrected logs of the sample’s reflectance for each filter position. These are printed out (displayed) when the sample drawer is closed and are used solely for diagnostic purposes by service technicians. The ceramic reference logs are collected with the sample drawer in the open position. The logs are collected once each week and filed chronologically. Two consecutive printouts are necessary for each test. The ceramic reference data aids in the diagnosing of suspected machine malfunctions. The collection procedure is as follows:

1. Verify that the ceramic reference disk is clean.2. With the sample drawer in the open position, set the Key switch to the

CALIBRATE position.3. Enter MODE 3. Press the 3 key and the Mode key. The LOG and

TEST messages will be backlit. After approximately 10 seconds the printer will print the first set of test logs reference data. About 10

PRODUCT NAMEASSIGNMENTS

10 CORN11 SOYBEANS12 HARD WHEAT14 SOFT WHEAT15 OATS16 MEAL17 BARLEY18 RYE20 SORGHUM21 SUNFLOWER22 WHITE WHEAT23 DURUM

= = = = = = = = = = = =

Key switch

MODE

Mode key


OPERATION 43

OPERATOR’S MANUAL

seconds later, a second set will be printed. The printouts should be similar to Figure 33.

Figure 33Sample Printout Of Test Log Reference Data

If no printer is available, the test logs may be obtained by successively pressing the Step switch and reading the top display for each position. To obtain the second set of test logs, reenter MODE 3 and run the same procedure a second time.

TESTING DISPLAY, PRINTER, AND DRAWER OPERATION - MODE 3.5MODE 3.5 tests the operation of the display panel, printer, and the sample drawer position sensors. To run the test:

1. Set the Key switch to the CALIBRATE position.2. Enter MODE 3.5. Press the 3.5 keys and then Mode key. As the test is

running, each of the sixteen display messages individually light in order beginning with the upper left-hand message. Then each segment of the nine digital displays individually lights. After these checks have finished, the printer will print an entire character set twice, separated by two blank lines (refer to Figure 34). An audible tone will sound for one second, and the top display will show OPEN if the sample drawer is open or CLOSE if the sample drawer is closed.

REFERENCE DATA

L0 58.07L1 150.98L2 125.16L3 110.85L4 62.88L5 42.76

= = = = = = = = = = = =

REFERENCE DATA

L0 58.00L1 150.95L2 125.15L3 110.89L4 62.90L5 42.75

= = = = = = = = = = = =

STEP

Step switch

Key switch

MODE

Mode key


44 OPERATION

OPERATOR’S MANUAL

Figure 34Sample Printout Of Character Set

CONTINUOUS REFERENCE DATA COLLECTION - MODE 3.6By using the printer, reference logs or raw sample data can be collected on a continuous basis using MODE 3.6. The collection procedure is the same as MODE 3 except for step 3. In step 3, enter MODE 3.6 instead of MODE 3. The LOG and TEST messages will light. After approximately 10 seconds, the printer will print the first set of reference data. The instrument will continue printing a new set of reference data every ten seconds until the Key switch is turned to %ONLY or a different mode is entered.

BIAS ADJUSTMENTAfter a calibration has been entered, it should be checked by comparing the Instalab analyses to laboratory analyses. If the Instalab analyses are found to be consistently higher or lower than the laboratory readings, the Bias Constant (KA) may be adjusted to correct for any discrepancies. To adjust bias:

1. Set the Key switch to the STORE ONLY position.2. Enter MODE 4. Press the 4.0 keys, followed by the Mode key.3. Enter the product and constituent numbers of the calibration requiring

correction and press the Prod key.4. Enter the amount of bias adjustment, use the +/- key to provide the

proper sign, and press the Enter key.5. Return the Key switch to the %ONLY position. The printer will print the

calibration for the selected product and constituent. The change in bias may be seen in the difference of the KA value. Figure 35 provides an example of before and after printouts showing the KA constant change with a bias adjustment of +.2%.

@ABCDEFGHIJKLMNOPQRSTUVWXYZ[~]{}

!"#$%&'()*+,-./0123456789:;<=>?

@ABCDEFGHIJKLMNOPQRSTUVWXYZ[~]{}

!"#$%&'()*+,-./0123456789:;<=>?

Key switch

MODE

Mode key

PROD

Prod key

ENTER

Enter key


OPERATION 45

OPERATOR’S MANUAL

Figure 35Before And After Printout Of Bias Adjustment

DISPLAY RESOLUTION MODIFICATION - MODE 4The display resolution and printed analysis may be changed to read out to the nearest tenth, hundredth, or thousandth of a percent by using MODE 4. To change the resolution:

1. Set the Key switch to the STORE ONLY position.2. Enter MODE 4. Press the 4.0 keys, followed by the Mode key.3. Enter the product and constituent numbers to be changed and press

the Prod key. The display will show .0, .00, or .000 depending on the resolution currently selected.

4. Press the Step switch to advance to either .0 (tenth of a percent), .00 (hundredths of a percent), or .000 (thousandth of a percent) as indicated by the top display.

5. Return the Key switch to the %ONLY position. The printer will print the calibration. Next to RESOLUTION on the printout, a .1, .01, or .001 will print indicating the selected resolution (refer to Figure 36). The format number is also modified.

BEFORE CHANGE


6/17/05


MOISTURE

FORMAT 20RESOLUTION .01

HI LIM = 15.0LO LIM = 7.00

KA 9.1300K0 0K1 0K2 - .0718K3 - .1325K4 .2067K5 0

================

AFTER CHANGE


6/17/05


MOISTURE


HI LIM = 15.0LO LIM = 7.00

KA 9.3300K0 0K1 0K2 - .0718K3 - .1325K4 .2067K5 0

================

MODE

PROD

Key switch

Mode key

Prod key

STEP

Step switch


46 OPERATION

OPERATOR’S MANUAL

Figure 36Before And After Printout

REFERENCE LOG SEQUENCING SELECTION - MODE 4.1MODE 4.1 is used to select the manner in which reference logs are gathered prior to percent analysis. When MODE 4.1 is entered, a 1 or 2 is displayed on the top display. If 1 is displayed, reference logs of all the filters in the calibration are gathered and checked prior to each sample analysis. When 2 is displayed, all filters used in the calibration have their reference logs checked when the calibration is first selected, then for a four minute period, only the first filter specified by the calibration has its reference log checked. This accelerates the percent analysis procedure and is useful in a high volume, rapid analysis operation. To select 1 or 2:

1. Set the Key switch to the STORE ONLY position.2. Enter MODE 4.1. Press the 4.1 keys followed by the Mode key. The

top display will show a 1 or 2 and the STORE message will be backlit.3. Press the Step switch if the desired number is not displayed.4. Return the Key switch to the desired position.

BEFORE CHANGE


6/17/05


MOISTURE


HI LIM = 15.0LO LIM = 7.00

KA 9.1300K0 0K1 0K2 - .0718K3 - .1325K4 .2067K5 0

================

AFTER CHANGE


6/17/05


MOISTURE


HI LIM = 15.0LO LIM = 7.00

KA 9.1300K0 0K1 0K2 - .0718K3 - .1325K4 .2067K5 0

================

Step switch

STEP

MODE

Key switch

Mode key


OPERATION 47

OPERATOR’S MANUAL

ENTERING AND STORING MACHINE TITLE - MODE 6By using the printer, a two line title consisting of up to 16 characters per line may be stored in memory. The stored title is printed with each percent analysis. Use Figure 37 to determine the correct layout. Plot the title and spacing in a similar manner to enter the title on the printout. Start with character position 1. Write in a code number for each space or character. Do the same for each character position, through 16, until the first line is complete. Begin the second line at character position 17 and fill in unused character positions with space codes up to and including character 32. Both lines must be complete even if only one line is needed. For the character codes to fill each location, refer to Figure 26.

Figure 37Stored Title In Memory For Printout

To enter a title:

1. Set the Key switch to the STORE ONLY position.2. Enter MODE 6. Press the 6.0 keys followed by the Mode key. The

STORE message will light. The top display will show the existing character code number for the character position shown on the center display.

3. Enter the code number for position 1 and press the Enter key. Refer to Figure 26 to determine the correct character code.

4. Enter the code number for position 2 and press the Enter key again. Continue to enter code numbers in this manner for all 32 positions. After the code number for position 32 is entered, the printer will print the title.

Character # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16Character Code 40 40 40 40 40 01 02 03 40 03 17 40 40 40 40 40Character A B C C O

Memory Locations - First Line

Character # 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32Character Code 40 40 01 16 31 27 10 05 22 05 40 25 23 01 40 40Character A N Y W H E R E U S A

Memory Locations - Second Line

Key switch

MODE

Mode key

ENTER

Enter key


48 OPERATION

OPERATOR’S MANUAL

RUNNING REFERENCE LOGS AND BASE GAIN SETTINGS - MODE 8The function of this mode is to collect and store reference logs and base gain settings for filters installed in the filter wheel. The only reason the following procedure should ever be performed is if an ERROR 6 persists during normal operation. This mode is used by the factory to initialize the unit and should never be reentered indiscriminately. Each time a MODE 8 procedure is performed, new values are reinserted into the nonvolatile memory. Performance of this procedure should be limited to an average of no more than once every six months or a maximum of four times in two years. If these restrictions cannot be maintained, contact the DICKEY-john Service Department for assistance. It is important that a detailed record is kept of the results each time this procedure is run. Record the date, reason, and the result of the before and after stored reference data.

To perform a MODE 8 procedure:

1. Be certain the ceramic reference disk inside the sample drawer is clean. After ensuring this, leave the sample drawer open and turn the power ON if the unit is not already on.

2. Allow a minimum warm up period of 48 hours to ensure all circuitry has stabilized before proceeding. Three hours is recommended for warm up. On power up, the HELLO message will appear on the upper display and the TEMP message on the display panel will be on to indicate insufficient temperature. An error code 0, 1, 6, or 7 is not uncommon in the first few minutes of warm up.

3. After warm up is complete, the TEMP message should be off (temperature stabilized). Press the Clear key to blank the upper display. A short beep will sound when the key stroke is made.

4. Set the Key switch to the STORE ONLY position.5. Enter MODE 8 by pressing the 8 key followed by the Mode key. An 8

will appear on the upper display and the LOG and STORE messages will light. After 20 seconds or more, the DONE message should appear on the upper display to indicate the reference log for each optical filter has been automatically stored in the nonvolatile memory. If an error code number is flagged on the upper display between the 8 and Mode key strokes, the mode is not achieved. If necessary, press the 8 and Mode keys in sequence rapidly.

6. After the DONE message is displayed, turn the Key switch to the CALIBRATE position. The printer, if available, will automatically print the stored reference data in three columns.– Column 1 displays the filter number (L number followed by a digit.– Column 2 displays the stored reference data (4 or 5 digits in length.– Column 3 displays the gain setting (typically a 0 or 1) for each

optical filter used.

CLEAR

Clear key

Key switch

MODE

Mode key


OPERATION 49

OPERATOR’S MANUAL

An example is provided in Figure 38. On the display panel of the unit, the STORE message will darken and the TEST message will illuminate. The three digit display will indicate the same information as is printed on the printer (if used). The first filter position number will appear on the lower display. The stored reference data number the that filter will be shown on the upper display. The middle display will indicate the gain setting. Pressing the Step switch once will increment the lower display to the next filter number. The upper and middle displays will advance to the appropriate data for that filter. Repeat the procedure for each filter, recording (or checking) the results of each. Data displayed should agree with the printout if a printer is used. Be sure to keep a complete record of the results, along with the date and reason for running a MODE 8 for later reference.

Figure 38Typical Reference Logs And Base Gains Printout

DISABLING PRINTER HANDSHAKING - MODE 9When selecting MODE 9, the instrument disables the printer handshaking and ignores the state of the RTS lead (pin 4 of the RS-232 interface). When the instrument has a “new” record to output, any information remaining in the buffer from the previous record is erased or overwritten.

ENABLING PRINTER HANDSHAKING - MODE 9.3When the handshaking feature is disabled, an OFF (low) condition on the RTS lead (pin 4 of the RS-232 interface) inhibits the printer output of the unit. The remainder of the current record output is buffered inside the instrument until one of two conditions are satisfied. These conditions include 1) the status of the RTS lead changes to ON (high), allowing the output to continue until the output buffer is cleared, or 2) the instrument completes a new measurement or data cycle and has a new record to output. If the latter occurs, any information remaining in the buffer from the previous record is erased or overwritten.

DATE ENTRY - MODE -1The -1 MODE is used to enter the correct date for printing, along with the analyses.

1. Set the Key switch to the CALIBRATE position.

STORED REF. DATA

L0 89.14 1L1 46.69 1L2 117.39 0L3 102.84 0L4 45.41 0L5 41.55 0

STEP

Step switch

Key switch


50 OPERATION

OPERATOR’S MANUAL

2. Enter -1. Press the -1 key followed by the Mode key. The digit(s) on the right of the top display will indicate the day. The digit(s) on the left of the top display will indicate the month. The digit(s) on the center display will indicate the year. The decimal point on the right side of the top display will indicate the position ready for user input.

3. Enter the number(s) for the day and press the Enter key. The decimal point will move to the MONTH position.

4. Enter the number(s) for the month and press the Enter key. The decimal point will move to the center YEAR position.

5. Enter the last two digits of the year and press the Enter key. 6. Turn the Key switch to the %ONLY position to exit the DATE MODE.7. To advance the date by one day, press the Step switch. One day will

be added each time the Step switch is pressed.

MODE

Mode key

ENTER

Enter key

Key switch

STEP

Step switch


OPERATION 51

OPERATOR’S MANUAL


52 OPERATION

OPERATOR’S MANUAL

TROUBLESHOOTING

The Instalab performs a number of self-checks to verify proper unit operation. If a fault is detected due to an operator procedural error, a machine error, or a problem with the sample, an error code will appear on the top digital display. When an error code is displayed, the operator can refer to the Error Card, located in the pullout tray below the keyboard, for an explanation of the error condition. Error codes listed on the Error Card are also outlined as follows.

ERROR 0Probable Cause:

1. Sample not reflective.

Corrective Action:1. Clean sample cup or change the sample.


1. Sample too reflective.

Corrective Action:1. Clean sample cup or change the sample.


1. Drawer moved during measurement.

Corrective Action:1. Do not close the sample drawer until the INSERT SAMPLE message is

backlit. Do not move the drawer from its closed position until a reading appears on the digital display.


1. Drawer position error.

Corrective Action:1. Open drawer and wait for the INSERT SAMPLE message to appear.


TROUBLESHOOTING 53

OPERATOR’S MANUAL


1. Drawer closed too slowly. No more than 5 seconds may elapse between the fully open and fully closed positions when inserting a sample.

Corrective Action:1. Open the drawer and wait for the INSERT SAMPLE message to

appear. Close the drawer swiftly.


1. Operation prevented by Key switch position.2. Invalid MODE selected.

Corrective Action:1. Correct the Key switch position.2. Use the correct MODE number.


1. System or excessive reference log drift.

Corrective Action:1. If error does not self-correct, clean the reference disk and aperture

glass. If error continues, perform a Reference Logs and Base Gain Setting - MODE 8 procedure.


1. System noise.

Corrective Action:1. Typically self-corrects. If error persists, contact DICKEY-john Service

Department.


1. No constants for the selected product/constituent.

Corrective Action:1. Select another.

Key switch


54 TROUBLESHOOTING

OPERATOR’S MANUAL


1. Timing error. An error occurred during the stepping of the filter disk.

Corrective Action:1. Open the sample drawer. If error persists, contact DICKEY-john

Service Department.


1. An attempt was made to store a calibration having more than 6 non-zero constants.

Corrective Action:1. Select only a maximum of six filters per calibration.


1. Constant error. A constant has been altered in memory.

Corrective Action:1. Reenter proper constants into memory.


1. Constant storage error. Data being stored in nonvolatile memory has not stored properly.

Corrective Action:1. Reenter constants.


1. Program memory failed. Stored program for the computer altered.

Corrective Action:1. Turn unit OFF, then back ON. If error persists, contact DICKEY-john

Service Department.


TROUBLESHOOTING 55

OPERATOR’S MANUAL


1. Read/write memory failed.

Corrective Action:1. Turn the machine OFF, then back ON. Error should clear. If problem

persists, contact DICKEY-john Service Department.


1. Product/constituent selection requires additional wavelengths.

Corrective Action:1. Rerun sample.


1. Incompatible gain settings for the same product.

Corrective Action:1. Check the format entries.

ERROR UProbable Cause:

1. Percent reading displayed is higher than the upper limit stored in calibration. Accuracy cannot be guaranteed.


ERROR LProbable Cause:

1. Percent reading displayed is lower than lower limit stored in calibration. Accuracy cannot be guaranteed.



56 TROUBLESHOOTING

OPERATOR’S MANUAL

MAINTENANCE

The Instalab is designed for trouble-free service. However, a few preventive maintenance procedures are necessary to ensure long life of the unit.

CHECKING AIR FILTERThis procedure should occur on a daily basis. Turn the power OFF and open the filter door at the left side of the unit to gain access to the filter. This may be accomplished by lifting the door latch to the horizontal position and pulling outward. The air filter may be removed from the inside of the door for cleaning or replacement. If the air filter is not very dirty, striking the edge of the filter sharply against a table or bench may dislodge light accumulations of dirt. However, if the filter is significantly soiled, it must be replaced. Make sure an 8 x 10 x 7/8 inch fine mesh replacement is used.

IMPORTANT: The air flow arrow must point toward the Instalab.

CLEANING REFERENCE DISK AND SAMPLE DRAWERThe reference disk and the sample drawer must be cleaned on a daily basis in order to assure accurate, error-free operation. To access the reference disk, open the drawer and put in on the level as illustrated in Figure 39. Open the sample drawer completely and hold it in the open position.

Figure 39Accessing Drawer Components

MOVE LEVERTO OPEN TRAY


MAINTENANCE 57

OPERATOR’S MANUAL

Clean all residue from the sample cup holder, under the sample cup holder, and the tray. If an ERROR 7 message appears during normal operation, check the underside of the sample cup holder flange and posts for debris buildup, which may prevent the sample cup from resting flat on the posts.

Figure 40Cleaning Sample Drawer And Reference Disk

Use a soft brush or a soft, clean lintless cloth for cleaning of the reference disk.

Do not touch the surface of the reference disk. Never use a solvent to clean the reference disk.

CLEANING APERTURE GLASSThis procedure should occur on a weekly basis. The aperture glass is located inside the Instalab just above the reference disk when the sample drawer is in its normal open position.

Slide the Instalab forward to the edge of the table or other mounting surface. Swing the sample drawer out (as illustrated in 39), exposing the reference disk.

Refer to Figure 41 and with the sample drawer completely open, the aperture glass may be accessed as shown. Use a flashlight to illuminate the area and use a Q-tip or a soft artist’s brush to carefully clean any dust accumulation from the glass surface.

IMPORTANT: After cleaning the aperture glass, allow at least 15 minutes for the photo detector to stabilize before readings are taken or resumed.

Close the sample drawer to its normal position and reposition the Instalab on the table.


58 MAINTENANCE

OPERATOR’S MANUAL

Figure 41Cleaning Aperture Glass

FUSE REPLACEMENTThere is a 3-ampere (for 110 Vac), 2-ampere (for 22 Vac version), TYPE AGC fuse located in the rear of the Instalab. If a replacement is required, use only an exact replacement.

Do not use a fuse with a higher rating.

If the replacement fuse blows, contact the DICKEY-john Service Department.


MAINTENANCE 59

OPERATOR’S MANUAL


60 MAINTENANCE

OPERATOR’S MANUAL

APPENDIX A






Analysis

(%)

Standard

Analysis

(%)

Standard

Analysis

(%)

Standard

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Sum

Average(Sum÷N)

Standard Average




APPENDIX A 61

OPERATOR’S MANUAL






Analysis

(%)

Standard

Analysis

(%)

Standard

Analysis

(%)

Standard

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

Instalab

Analysis

(%)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Sum

Average(Sum÷N)

Standard Average




62 APPENDIX A

OPERATOR’S MANUAL

Instalab Calibration Record

Product Number: ______________________________

Product Name: ______________________________

Date: ______________________________

MOISTURE PROTEIN OIL/FAT OTHER

F

U

L

KA

K0

K1

K2

K3

K4

K5

F

U

L

KA

K0

K1

K2

K3

K4

K5

F

U

L

KA

K0

K1

K2

K3

K4

K5

F

U

L

KA

K0

K1

K2

K3

K4

K5


Date Change New KA Date Change New KA Date Change New KA Date Change New KA


APPENDIX A 63

OPERATOR’S MANUAL

Instalab Calibration Record

Product Number: ______________________________

Product Name: ______________________________

Date: ______________________________


F

U

L

KA

K0

K1

K2

K3

K4

K5

F

U

L

KA

K0

K1

K2

K3

K4

K5

F

U

L

KA

K0

K1

K2

K3

K4

K5

F

U

L

KA

K0

K1

K2

K3

K4

K5


Date Change New KA Date Change New KA Date Change New KA Date Change New KA


64 APPENDIX A

TABLE OF CONTENTS - DICKEY-john€¦ · Instalab 600 Series Analyzers 11001-1360-200512 INTRODUCTION 5 • Digital microprocessor circuitry provides fast, easy field changes to incorporate

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