Utilizing the Direct-Digital MODBUS interface for ClearView db – OEM Applications

ClearView db is a modular filter photometer suitable for many OEM applications. By selecting up to six filters ranging from 420nm to 2100nm each with a dedicated detector, system integrators have successfully utilized ClearView db for real-time monitoring of liquids and gasses. Examples include: acid & OH number monitoring, detection of copper in acid baths, hydrogen peroxide vapor sterilization, NO2 gas sterilization, water content of solvent or gasses, or color. Additionally, the ClearView db can monitor up to 2 process locations using either flow cells or direct insertion probes.

Guided Wave provides OEM partners with a detailed MODBUS TCP/IP map and implementation examples. This data enables system integrators to quickly incorporate the ClearView db into their existing projects. MODBUS enables directional communication and remote operational control of the analyzer. Commands include: taking a reference, zero, or background scan; applying a slope and bias correction to the measurement result; and alarms or errors. For example, analyzer faults or off spec process alarms. ClearView db monitor does not require an external computer for configuration and operations, Modbus TCP/IP communication is completely integrated into the system and does not need extra software or hardware from a third party supplier

Ultimately by implementing the OEM ClearView db photometer with MODBUS, critical process monitoring information can be quickly delivered to process engineers and other end-users. Allowing your customers to make informed decisions in real-time.

Interested in learning more about the OEM process for the ClearView db?

Block Diagram of the OEM Clearview db

Understanding MODBUS Bit Fields in the ClearView db

The ClearView db does not implement MODBUS bit commands such as Read Coils, Write Coils or Read Input bits. To reduce computational time, the ClearView db instead employs the use of bit fields in unsigned 16 bit words. The table below displays a partial MODUS map for the ClearView db. A complete MODBUS map is provided to OEM partners.

ClearView db Modbus Address 40003 Read / Write Example

BitNameDescription
0RunThe Run bit is set at power up and should be set at all times except during configuration changes. This bit is cleared when the touch screen configuration menu is accessed and set upon exit from the configuration menu screen. When Run is cleared the analyzer will no longer calculate Transmission, Absorbance, Answers or update Analog Output values.
1Referencing ASetting this bit will cause the analyzer to Reference / Zero Channel A. The bit will auto clear when completed. The Run bit must be set for this command to work properly.
2Referencing BSetting this bit will cause the analyzer to Reference / Zero Channel B. The bit will auto clear when completed. The Run bit must be set for this command to work properly.
3Configuration ActiveThis bit is set by the touch panel when the configuration menus are being accessed and cleared when the configuration screens are exited.
4Program SaveSetting this bit will cause the analyzer to save all of the answer configuration settings currently in RAM into EEProm. This bit will auto clear when completed. The Run bit should be cleared before setting this bit and then set after completion.
5Program LoadSetting this bit will cause the analyzer to load all of the answer configuration settings from EEProm into RAM. This bit will auto clear when completed. The Run bit should be cleared before setting this bit and then set after completion.
6Hardware Save
Factory Use Only
Setting this bit will cause the analyzer to save all of the Factory configuration settings currently in RAM into EEProm. This bit will auto clear when completed. The Run bit should be cleared before setting this bit and then set after completion. Factory settings apply only to installed components that cannot be changed in the field.
7 - 14Not used
15Analog Output TestSetting this bit cause the analyzer to enter Analog Outputs Test mode. This test cycles the 4-20mA outputs continuously 4ma, 12mA and 20mA for several seconds each until cleared.

Wishing You Holiday Cheer!

Do you know these faces? Here are the names:

Our staff wishes you happy holidays (from left to right in the photo) – Top row: Katherine Hsu, Don Thomas, Steve Elam, Scott Shores, Janell Leysath, Ryan Lerud (masked-man revealed). Middle row: Justin Stirrat, Debra Hall. Bottom row: James Low, Lynn Williams, Alice Munteanu, Curtis Mau, Susan Foulk, Neil Quiroz. Camera Shy: Cheng Teurn, Dave Holland, Israel Tenorio, Ken Gruessing.

Greeting from BB Sarkar in our office in India
Greetings from Hans Buytaret from our European office

Thank you for your business, loyalty, and support this past year. We hope you can take off your mask for a bit and put on your holiday cheer!

Sincere holiday wishes from,
all of us at Guided Wave

Holiday Dates Closed

Please note Guided Wave will be closed December 24 through January 3, 2021. We will be monitoring the Guided Wave sales and support team emails, but replies will be delayed.[email protected] and [email protected]

Hours of Operations

On January 4, 2021 we will continue our regular business operations of Monday through Friday, 8AM – 5PM Pacific Standard Time.

NIR-O and M508plus Process Analyzer Analog Inputs and Outputs

The NIR-O Full Spectrum Analyzer is a Dispersive NIR spectrometer with an IECEX/ATEX certified designed for Class 1 Div 1 and Div 2 environments. Every NIR-O comes equipped with Modbus for communicating with a  distributed control system (DCS). For customers that require 4-20mA outputs, or other analog or digital, I/O Guided Wave has engineered an optional accessory I/O enclosure.

The M508plus UV-VIS Process Spectrometer is an EX IIC T4 compliant design developed for the polymer industry. The IP65 rated enclosure can include up to 16 custom digital and analog I/O and Modbus. There is no need for an external accessory enclosure.

How Many Channels Are Included on Each Module?

Each Digital Input module can accept up to 4 input channels.

  • If you require only 1 digital input, then you need 1 Digital Input module. You will then will have the ability to add up to 3 more inputs in the future.

Each Digital Output module can process to 4 answers or outputs.

  • If you only have 2 measurement parameters, then 1 Digital Output module will meet your needs and allow up to 2 more outputs in the future.

Each Analog Input module can accept up to 2 input channels.

  • If you require only 1 analog input, a Wika RTD to monitor process temperature, then 1 Analog Input module will provide the ability to add up to 1 more input in the future.

Each Analog Output module can process up to 2 answers or outputs.

  • If you have 3 measurement parameters, then you need 2 Analog Output modules.

Configuring the I/O Part Number

The Fiber Glass Cabinet – I/O Enclosure includes the programmable logic controller, 16 position rack for I/O modules, and two power supplies (5V and 24V). The smart part number 40217-1XADO

X = the number of Analog Input modules
A = the number of Analog Output modules
D = the number of Digital Input modules
O = the number of Digital Output modules

PART NUMBERMODULES INCLUDED
40217-101331 x Analog Output, 3x Digital Inputs, 3x Digital Outputs
40217-101011 x Analog Output, 1x Digital Output
40217-106136x Analog Outputs, 1x Digital Inputs, 3x Digital Outputs

Need a Communication Protocol other than Modbus?

Be sure to mention this requirement when you request a quote and our Technical Sales Representatives will be sure to add the optional digital and analog I/O devices.

Announcing direct integration of EigenVector’s SOLO Predictor with Omniview V2.0 software

Eigenvector Research and Guided Wave have partnered to implement an API between the Omniview V2.0 software and Solo_Predictor. This enables NIR-O Full Spectrum Analyzer users who develop models using Eigenvector’s MATLAB® based PLS_Toolbox or stand-alone Solo to use the real-time prediction engine, Solo_Predictor. Contact Guided Wave or your local representative to access this free of charge software update.

Steps to for Existing NIR-O Users to Implement Solo_Predictor

Time needed: 15 minutes.

Steps to integrate Solo_Predictor and Omniview Software.

  1. Provide proof of runtime license for the Solo_Predictor program

  2. Download software update from Guided Wave onto built-in analyzer PC

    A zip file containing updated python scripts and a 64-bit Solo_Predictor version 4.0.4 installation executable will be provided by sharepoint or drop box.

  3. Follow the installation procedure

    The installation procedure for existing users, requires moving some files into place.

Purchasing a NIR-O and want SOLO_Predictor to be preinstalled?

Existing EigenVector customers just need to provide proof of the run-time license when placing their order with Guided Wave. This will allow our production staff to implement the API on the analyzer computer.

Probes and Flow Cells for High Temperature and Hazardous Polymer Measurements

Polymer manufacturing is a high-temperature process conducted under hazardous conditions. A safe and cost-effective method to monitor polymer synthesis is near-infrared (NIR) analysis. Using remote insertion probes connected to a NIR analyzer with intrinsically safe fiber optic cables, protects the operator from potential safety risks compared to the use of grab samples or sample conditioning systems. The single-sided insertion (SST) and shuttle probes were specifically designed to withstand these high temperatures and pressures with low maintenance requirements.

For example, terephthalic acid (TPA) and dimethyl terephthalic acid (DMT) can both be synthesized by reacting P-xylene with cobalt–manganese–bromide catalyst, acetic acid, and air. Realtime quantitative monitoring of this caustic reaction is possible with the Guided Wave ClearView db analyzer along with an SST probe. The SST probe can be installed directly into the reaction vessel for continuous process monitoring and optimization. Additionally, in an extremely corrosive environment, the sample probe can be constructed out of Hastelloy C276.

In batch polymerization, DMT reacts with ethylene glycol in esterification to form monomer alcohol, which then polymerizes with TPA. The continuous method, on the other hand, involves a polymerization between TPA and ethylene glycol, so DMT is not necessary. Both methods involve heating either DMT or TPA with ethylene glycol to about 536 ºF for 30 minutes at atmospheric pressure, and then the mixture spends 10 hours under vacuum. near-infrared analyzers such as the ClearView db and NIR-O Process analyzers can be used to provide in-situ monitoring of the cross-linking under vacuum conditions. Out of specification product can be detected with a high temperature shuttle probe and near-infrared monitoring during melt transfer. By monitoring the molten polymer stream for acid number, cost savings can be realized by preventing the off-spec product from reaching the extrusion or pelletizer.

Rugged sample interface designs built to withstand harsh polymer process conditions, as well as the low maintenance requirements make Guided Wave probes and flow cells a cost effective, smart choice to help optimize polymer production, improve yields, ensure consistent product quality and enhance profitability. While Guided Wave’s probes and flow cells are optically matched for use with Guided Wave NIR or UV-VIS analyzers to provide top system performance, they are also compatible with many other analyzer brands.

Improve and Determine Yield During Diisocyanate and Urethane Synthesis

Diisocyanates are a family of chemicals used to make a wide range of polyurethane products. The most widely used aromatic diisocyanates are toluene diisocyanate (TDI) and methylene diphenyl diisocyanate (MDI). Less widely used, but still important, are the aliphatic diisocyanates, including hexamethylene diisocyanate (HDI), hydrogenated MDI (H12MDI), and isophorone diisocyanate (IPDI).


• TDI is mainly used to make flexible polyurethane foam that can be found in a wide range of everyday products, including furniture, bedding, carpet underlay, and packaging.
• MDI is used primarily to make rigid polyurethane foams such as insulation boards.

Multiple process points during diisocyanate production can benefit from real-time monitoring with NIR analyzers. For example, the yield of TDI and MDI can be determined. Additionally, the concentration of water which can cause off-spec products to form in the reaction vessel can also be monitored. Once the reaction is complete, the acid number (polyol value) of the prepolymer can be monitored to ensure the product is on-spec. Determining the urethane yield can also be achieved by NIR.

During polyurethane synthesis, isocyanate is reacted with an alcohol to form a urethane. This reaction process creates the carbamate functional group which forms the links in polyurethane. Along with acid number (polyol value), NIR analyzers such as the ClearView db photometer can be used to monitor the conversion efficiency of isocyanate to urethane. By monitoring these properties with an NIR analyzer, problems can be quickly detected and corrected, and as a result reaction yields will improve.

Improve Operational Safety through Phosgene Leak Detection

HSFC, high Safety Flowcell
High Safety Flow Cell

When processes involve extremely toxic or hazardous materials such as hydrofluoric acid, phosgene, isocyanates, etc., safety is paramount. Having a sample interface with built-in leak detection can help save human lives. Consequently, it is recommended that a High Safety Flow Cell be used when monitoring these situations. Constructed out of stainless steel or Hastelloy C276 with Kalrez seals, this flow cell is rated for 250 ºC typical operation at 300 psi. The safety sniffer port provided between o-ring seals allows for a connection to a leak detection system to be used as an indicator of primary seal failure.


For example, plant safety can be improved by monitoring the purity or concentration of phosgene using Guided Wave’s High Safety Flow Cell which is compatible with all Guided Wave analyzers and many other analyzer brands. Built into a Class 300 flange, using welded construction, the High Safety Flow Cell uses double o-ring sealed sapphire windows and a weep or “tattletale” port to self-monitor for o-ring failure. This safety mechanism allows the flow cell to be serviced once the process chemicals are detected in the space between the first and second o-ring seals. Moreover, by installing a High Safety Flow Cell on the input side of the reactor vessel and the recovery line, deviations in the amount of phosgene consumed by the process can be monitored, potentially alerting personnel to a hazardous leak in the facility. Thanks to the dual seals and a sniffer port, polymer manufacturers dealing with hazardous or corrosive samples, such as phosgene, can improve operational safety with the High Safety Flow Cell.

This is also compatible with all makes and models of process FT-NIR analyzers.

Market Trends: Solutions for the Plastic/ Polymer Industry

With the outbreak of COVID-19, this has been a year of uncertainty and rapid change. Apart from the direct economic impact, it is clear that this pandemic will create a shift in future socio-economic behaviors with more people working from home, increased expenditure on health and wellbeing, preference for online shopping, and reduced discretionary expenditure. For example:

  • There is now a widely held view that plastic products are safer and cleaner than the recycled and reusable versions, thus performing more favorably to fight and contain the spread of the virus.
  • Packaging for all goods and services has now become a priority in handling nearly everything from shipping and incoming inspection to handling the end product. More remote activities also mean more automation, such as robotic and computer usage. This will result in a greater need for laminates and other polymers to properly coat electronics and circuit boards.
  • Plastics will also benefit from increased spending on household cleaning, hygiene, and personal protection products, as well as higher domestic food packaging use, and disposable products.
  • Plastics used in healthcare can be both advanced medical grade polymer materials that comply with regulatory standards specifically engineered for medical usage, or commonly found plastics used in consumer packaging.

Regardless of the current state of the world, plastics will be at the forefront, offering exceptional and innovative products. Guided Wave and online process monitoring provide unique solutions to cost-effectively measure and control plastic/polymer manufacturing. As the industry moves forward developing these new plastics and polymers, Guided Wave will be can help customers maintain their competitive edge by continuing to solve challenging industrial process problems and accommodate market needs.

There is almost an endless list of medical applications for plastics 1

  • Polyvinyl chloride (PVC) can be found in approximately 40% of all disposable medical devices, including flexible fluid bags, tubing, oxygen, masks, surgical gloves, etc.
  • Polycarbonate (PC) is the material of choice for medical devices and equipment, given its clarity and ease of sterilization, replacing glass in items such as blood oxygenators, hemodialyzers, intravenous connectors, and high-pressure syringes, in addition to safety glasses and face shields.
  • Polystyrene (PS) is used for a wide range of applications, including tissue culture trays, test tubes, petri dishes, diagnostic components, and housings for tests.

REFERENCE
1: https://ihsmarkit.com/research-analysis/how-is-polymer-demand-impacted-by-the-covid19-pandemic.html;
May 12, 2020, Authors: Kaushik Mitra Martin Wiesweg

The Guide Post Fall Newsletter

Guided Wave’s fall issue of its customer newsletter, “The Guide Post” was recently released. This issue focuses on current trends in the plastic/polymer industry.

Due to the current state of the world, plastics will be at the forefront, offering exceptional and innovative products, from health and wellbeing to home office and automation. This issue will explore the ability of Guided Wave and online process monitoring to provide unique solutions to cost-effectively measure and control plastic/polymer manufacturing.

IN THIS ISSUE:      

MARKET TRENDS  – Solutions for the Plastic/Polymer Industry

  • APPLICATION FOCUS
    • Multiple Monitoring Points for Polymer and Polyurethane Synthesis
    • Improving and Determining Yield during Diisocyanate and Urethane Synthesis
    • OH Application Note
  • SAMPLE INTERFACE
    • Probes and Flow Cells for Polymer Measurements
    • Improve Operational Safety through Phosgene Leak Detection
  • PEOPLE / PLACES           
    • European Office Manager Retires after 29 Years
    • New Distribution Offices Expand Service
  • PRODUCTS
    • New Full Spectrum Laboratory Analyzer

DOWNLOAD THIS ISSUE

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OmniView Process Software V2.5 – Lab Wizard Module

In June 2020, the engineering team completed testing on version 2.5 of the Omniview Process Control Software for the NIR-O Full Spectrum Process Analyzer. In addition to several bug fixes, this version introduces a wizard to help guided users on how to collect data for model creation and validation. The Lab Wizard is accessible from the analyzer setup window and acts as an alternative to Demand Scan functionality that has existed since version 1 of Omniview.

The lab wizard supports two use cases. The first mode is for the collection of data which will be used to create a new NIR calibration. The second mode is for QC operations and enables users to scan a series of samples with an existing NIR calibration. In both modes, the multiple scans can be exported into a single csv file for post-processing or manual submission to a LIMS system.

Overview

The Lab Wizard module was designed to allow users with a NIR-O process analyzer to collect on-demand scans and export them into a single file that is accessible by other software (Unscrambler© software, LIMS systems, etc.). The functionality of the Lab Wizard runs in parallel to the normal process software functionality. Changing channel configuration settings such as the number of scans to average (coadds) will also change the settings for the spectral data collected by the Scheduler. Additionally, the Scheduler can remain active while the Lab Wizard is running. This enables users to collect on demand scans on specific channels with minimal impact to ongoing operations.

Using the Lab Wizard

1) To enable the Lab Wizard button, click the Lock button,in the Analyzer window.

Omniview V2.5 screen shot of analyzer setup
Omniview V2.5 screen shot of analyzer setup

2) Click the Lab Wizard button to begin,

Omniview V2.5 screen shot of analyzer setup

3) The Setup tab of the Lab wizard allows for the general scope or data-set of the on-demand scans to be defined. A user with Technician level privileges can only select a previously defined data-set from the drop down list. A user with Engineer level privileges can select an existing data-set or create a new data-set by clicking the plus button.

Omniview V2.5 screen shot of lab wizard tab1

Parameters that define a dataset include: file name prefix, file path to export scans to, selecting which channel spectra will be collected on, if any lab reference values will be supplied, if any existing models/methods should be called.  Additionally, lab required meta information such as the time that a sample was pulled can be entered as a lab reference value. The Procedure drop down list is currently a place holder

Omniview V2.5 screen shot of lab wizard tab 1 defining datasets

4) Once a data-set is selected, click the Next button to proceed to the Scan Setup tab.

5. The Scan Setup tab allows for modification by a user with Engineer privileges to change the channel configuration.  

Omniview V2.5 screen shot of lab wizard tab 2

6. The ZERO Scan tab allows for the collection of ZERO scans and follows the same logic as the ZERO Wizard. Both Technician and Engineer users can collect a new zero or proceed with the existing zero scan.

Omniview V2.5 screen shot of lab wizard tab 3

7) The Collect Scans tab allows for data to be collected as defined by the previous tabs. If reference values were setup on the data configuration tab, the user will be prompted for them once the scan is completed. If a sample collection time is to be entered use the date format. Additionally, users will be prompted to provide a comment.  The comment can be a sample name or any other information that may be useful.  Both fields can be left blank. To collect a scan click the Perform Scan Button.

Omniview V2.5 screen shot of lab wizard tab 4

7) The lab reference value or sample scan time can be entered in the popup:

Omniview V2.5 screen shot of lab wizard - defining reference value

8) Once a scan is complete the spectrum will appear in the chart and tabulated data in the table above it. Additional scans added to the collection will appear in both the table and chart.

Omniview V2.5 screen shot of lab wizard populating a data collection

9) To export the collection of scan to a file, click the Export Collected Scans button.  The collection of scans and tabular information will be exported according to the previously selected file format (csv, gwj, etc)

10) Selecting scans in the table enables the deletion button. Scans removed from a collection are still stored in the database. Removing a scan simply removes it from the collection.  The entire collection can be deleted using the Clear Collection button.

Omniview V2.5 screen shot of lab wizard exporting data collection

11) A trend chart of Lab Wizard answers can be displayed by opening the Answer window and selecting the data from the list of available answers. At this time, lab reference values cannot be displayed inside of the OmniView process software. To generate a ‘Predicted vs Actual value chart, use the exported file of the collection.

Omniview V2.5 screen shot of answers trend chart

For more information on how to use OmniView software see our YouTube Channel.