Computrac Model MAX 4000XL Moisture Solids Analyzer User Manual

  AZI P/N 700-0111-K Last update February 2013  USER MANUAL COMPUTRAC® MAX® 4000/4000XL MOISTURE ANALYZER Firmware Rev 1.5X February 2013 ARIZONA INSTRUMENT LLC 3375 N Delaware Street | Chandler, AZ 85225 USA 800.528.7411 | 602.470.1414 | f 602.281.1745 www.azic.com Email: General – azi@azic.com International – intl@azic.com Customer Service – support@azic.com AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 2 of 104 Computrac® MAX® 4000 / 4000XL PROPRIETARY RIGHTS NOTICE This manual contains valuable information developed by Arizona Instrument LLC for use with the Computrac® line of moisture analyzers. No part of this manual can be reproduced or transmitted in any form or by any means, electronic, mechanical, or otherwise. This includes photocopying and recording or in connection with any information storage or retrieval system without the express written permission of Arizona Instrument LLC. ALL RIGHTS RESERVED ? Copyright 2008-2013 Arizona Instrument LLC PLEASE NOTE: There are 2 different instrument models in the MAX® 4000 series: the MAX® 4000 and the MAX® 4000XL, and features vary between the two models. Throughout this manual, MAX® 4000 is used to refer to both the MAX® 4000 and the MAX® 4000XL when describing common features or functionality. When there are specific differences between the two models, these are indicated through the usage of MAX® 4000XL for features that are only available in the MAX® 4000XL. Refer to the chart on page 13 for details regarding the feature differences between the models. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 3 of 104 1. HOW TO USE THIS MANUAL The Arizona Instrument Computrac® MAX® 4000 series moisture analyzers are advanced, highly customizable instruments. As a result, the manual for the MAX® 4000 is extensive, comprehensive and detailed. For best results, read this manual in its entirety and keep the manual available for reference during instrument operation. The manual is organized in distinct sections to facilitate easily locating the information needed when referring back to the manual. The sections and their descriptions are as follows: §2 TABLE OF CONTENTS starting on page 4 §3 WARNINGS AND SAFETY INFORMATION starting on page 6 To protect safety, health and property, this very important information should be read by anyone utilizing the MAX® 4000. §4 PACKING and SHIPPING INSTRUCTIONS starting on page 9 Refer to this section when unpacking the instrument and prior to shipping the instrument. §5 INTRODUCTION starting on page 11 An overview of the features of the MAX® 4000, a chart of the two different instrument models, a list of items included with the instrument, and a list of the optional accessories available. §6 INSTRUMENT SETUP starting on page 15 All of the setup instructions for the instrument, including selecting a location for the instrument, connecting a printer, computer or other accessory, utilizing the instrument keypad, and setting the display contrast are explained here. §7 MOISTURE ANALYSIS TESTING starting on page 34 This section provides a general overview of moisture analysis testing, details the steps involved in running a moisture analysis test on the MAX® 4000 and provides suggestions for dealing with specific sample types, such as liquids. §8 MAIN MENU starting on page 40 The options available from each menu in the MAX® 4000 are described here. §9 WEB SERVER starting on page 87 The usage of the optional Web Server package that allows the MAX® 4000XL to be accessed over a Local Area Network (LAN) or company intranet. §10 PERFORMANCE VERIFICATION starting on page 93 The MAX® 4000 contains several pre-programmed tests that can be run to verify continuing instrument function and performance, as detailed in this section. §11 ROUTINE MAINTENANCE starting on page 95 Maintenance and cleaning procedures necessary to maintain instrument performance and extend the life of the MAX® 4000. §12 INSTRUMENT PROBLEMS starting on page 98 A troubleshooting section to aid in resolving instrument related issues. §13 TEST RESULT PROBLEMS starting on page 99 A troubleshooting section to aid in resolving issues with Test Results. §14 MAX® 4000 SPECIFICATIONS starting on page 101 The technical specifications of the MAX® 4000 / MAX® 4000XL. §15 WARRANTY page 103 - This section details Arizona Instrument’s warranty policy. All section numbers, titles and page numbers in BOLD in this manual are hyperlinks and can be clicked to simplify navigation within the PDF version of the manual. The BACK button found in most PDF software programs is also very helpful when navigating using the hyperlinks. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 4 of 104 2. TABLE OF CONTENTS 1. HOW TO USE THIS MANUAL --------------------------------------------------------------------- 3 2. TABLE OF CONTENTS ----------------------------------------------------------------------------- 4 3. WARNINGS AND SAFETY INFORMATION --------------------------------------------------- 6 4. PACKING AND SHIPPING INSTRUCTIONS -------------------------------------------------- 9 5. INTRODUCTION --------------------------------------------------------------------------------------11 5.1. Hardware ..................................................................................................... 12 5.2. Instrument Models ........................................................................................ 13 5.3. Oven ............................................................................................................ 13 5.4. Inventory & Accessories ............................................................................... 14 6. INSTRUMENT SETUP ------------------------------------------------------------------------------15 6.1. Instrument Location ...................................................................................... 15 6.2. Interior of Test Chamber & Pan Support ...................................................... 16 6.3. AC Power Connection .................................................................................. 16 6.4. User Interface Operation .............................................................................. 18 6.5. Contrast Adjustment ..................................................................................... 19 6.6. Back Panel Connections .............................................................................. 20 6.7. Connecting a USB Printer ............................................................................ 21 6.8. Connecting a USB Drive .............................................................................. 22 6.9. Connecting a Computer (Windows® XP Only).............................................. 22 6.9.1 USB Driver Setup ............................................................................ 23 6.10. Connecting a USB Keyboard ....................................................................... 27 6.11. Installing the Nitrogen Purge Kit ................................................................... 28 6.12. Nitrogen Control Module .............................................................................. 30 6.13. Bar Code Reader ......................................................................................... 32 6.14. Installing & Removing the External Filter ..................................................... 33 7. MOISTURE ANALYSIS TESTING ---------------------------------------------------------------34 7.1. Performing a Test ......................................................................................... 36 7.2. Preparing Granular and Powdery Samples .................................................. 39 7.3. Preparing and Testing Liquid Samples ........................................................ 39 8. MAIN MENU -------------------------------------------------------------------------------------------40 8.1. Test Programs.............................................................................................. 41 8.1.1 Sample Name ................................................................................. 43 8.1.2 Temperatures .................................................................................. 44 8.1.3 Ending Criteria ................................................................................ 46 8.1.4 Sample Size Options ....................................................................... 47 8.1.5 Tare Options ................................................................................... 49 8.1.6 Result Display Options .................................................................... 51 8.1.7 Lift Compensation ........................................................................... 53 8.1.8 Linked Test Options ........................................................................ 54 8.2. Test Results ................................................................................................. 55 8.2.1 Graph .............................................................................................. 57 8.3. Calibration Menu .......................................................................................... 58 8.3.1 Balance Calibration Menu ............................................................... 58 8.3.1.A View Calibration Report ...................................................... 59 8.3.1.B Perform Span Calibration ................................................... 60 8.3.1.C Linearity Verification Setup ................................................. 61 8.3.1.D Perform Linearity Verification ............................................. 62 8.3.1.E Span Calibration Reminder Setup ...................................... 63 8.3.2 Temperature Calibration .................................................................. 63 AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 5 of 104 8.3.2.A View Calibration Report ...................................................... 65 8.3.2.B Verification Setup ............................................................... 66 8.3.2.C Calibration Module Setup ................................................... 66 8.3.2.D Perform Calibration ............................................................ 67 8.3.2.E Perform Verification ............................................................ 68 8.3.2.F Calibration Reminder Setup ............................................... 69 8.4. Setup Menu .................................................................................................. 69 8.4.1 Printer Setup ................................................................................... 70 8.4.2 Report Setup ................................................................................... 70 8.4.2.A Report Control Options ....................................................... 71 8.4.2.B Report Items to Print .......................................................... 72 8.4.2.C Company Name ................................................................. 72 8.4.3 Date/Time Setup ............................................................................. 73 8.4.4 Ethernet Setup ................................................................................ 73 8.4.5 Misc Options ................................................................................... 75 8.4.6 Nitrogen Control Module ................................................................. 76 8.4.7 Login Setup ..................................................................................... 77 8.4.8 Special Features ............................................................................. 79 8.5. Balance Mode .............................................................................................. 79 8.6. Parameter Expert ......................................................................................... 80 8.6.1 Develop New Test Program ............................................................ 80 8.6.2 Optimize Existing Test Program ...................................................... 83 8.7. Sample Foils ................................................................................................ 85 8.8. Audit Log ...................................................................................................... 86 9. WEB SERVER-----------------------------------------------------------------------------------------87 9.1. Calibration Report ........................................................................................ 88 9.2. LCD View ..................................................................................................... 89 9.3. Test Programs.............................................................................................. 90 9.4. Test Results ................................................................................................. 91 9.5. Audit Log ...................................................................................................... 92 10. PERFORMANCE VERIFICATION ---------------------------------------------------------------93 10.1. The Weight Test ........................................................................................... 93 10.2. Sodium Tartrate Test ................................................................................... 94 10.3. Retained Samples ........................................................................................ 95 11. ROUTINE MAINTENANCE ------------------------------------------------------------------------95 11.1. Heat Chamber Cleaning ............................................................................... 95 11.2. Balance Shaft Check .................................................................................... 96 11.3. Heater Cleaning ........................................................................................... 96 11.4. Pan Support Cleaning .................................................................................. 97 11.5. Lithium Battery Replacement ....................................................................... 98 12. INSTRUMENT PROBLEMS & ERROR MESSAGES --------------------------------------98 13. TEST RESULT PROBLEMS ----------------------------------------------------------------------99 14. MAX® 4000 SPECIFICATIONS ----------------------------------------------------------------- 101 15. WARRANTY ----------------------------------------------------------------------------------------- 103 AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 6 of 104 3. WARNINGS AND SAFETY INFORMATION The MAX® 4000 moisture analyzer complies with the Underwriter Laboratories Inc. standards and European Council Directives for Electrical Equipment for Laboratory Use, electromagnetic compatibility, and the stipulated safety requirements. The MAX® 4000 and its accessories pass Class A emissions. However, improper use or handling of the instrument can result in damage to the equipment and/or injury to personnel. The MAX® 4000 is Equipment Class I, Pollution Degree 2, and Installation Category II. The Temperature Calibration Interface (TCI) is ESD sensitive. Read these operating instructions thoroughly before using your instrument to prevent damage to the equipment. Keep these instructions in a safe place. An up-to-date electronic copy of this manual can be found on the AZI web site at http://www.azic.com. The following instructions will help to ensure safe and trouble-free operation of your MAX® 4000. • Use the instrument only for performing moisture/solids analysis of samples. Any improper use of the instrument can endanger persons and may result in damage to the instrument or other material assets. • Do not use this instrument in a hazardous area/location; operate it only under the ambient conditions specified in these instructions. • Although the instrument is simple to operate and is very user friendly, it should only be operated by qualified persons who are familiar with the properties of the sample being analyzed. • Ensure, before getting started, that the voltage rating printed on the manufacturer's label is identical to your local line voltage (See section 6.3 AC Power Connection on page 16). • The MAX® 4000 is provided with a power cord that has a protective ground conductor. Do not operate the instrument without the supplied three-wire power cord or an identical recognized equivalent that meets all applicable standards. • AZI does not recommend the use of an extension cord. However, if one must be used, use an extension cord that meets all applicable standards and has a protective ground conductor. • Do not remove the protective grounding wire from the power supply circuit. • With the power switch off, power is still applied to the power entry module. Remove the power cord from the MAX® 4000 to ensure complete power removal from the instrument. • Position the power cable so that it cannot touch any hot areas of the instrument. • Use only AZI supplied accessories and options with the MAX® 4000 and check with AZI before using any third party accessories, such as printers and analytical balances, to verify compatibility. • If there is visible damage to the MAX® 4000 or its power cord, unplug and isolate the instrument first and then call AZI Customer Service. • Do not open the housing of the MAX® 4000. There are no user serviceable parts or adjustments inside the instrument. Any maintenance inside the instrument is to be performed by factory-trained technicians only. Any unauthorized inspection and/or maintenance of the MAX® 4000 will make the warranty null and void. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 7 of 104 LITHIUM COIN CELL BATTERY The MAX® 4000 contains a lithium battery to keep power on the clock when the instrument is turned off. CAUTION – The battery may explode if mistreated. Do not recharge, disassemble, or dispose of in fire. PREVENT EXCESS HEAT BUILD-UP AROUND THE INSTRUMENT • When setting up the instrument, leave enough space to prevent heat from building up and to keep your instrument from overheating. Leave 20 cm (8 inches) around the instrument and 1 m (3 feet) above the instrument. • Do not put any flammable substances on, under or near the instrument, as the area around the instrument will heat up. • Use extreme care when removing the sample from the chamber. The heating chamber, the sample itself, the sample pan, and the heating element can still be extremely hot. HAZARDS FOR PERSONS OR EQUIPMENT POSED BY USING SPECIFIC SAMPLES: Flammables; explosives; substances that contain flammables, explosives, solvents; and/or substances that release flammable or explosive gases or vapors during the drying process. • The user shall be liable and responsible for any damage that arises in connection with the MAX® 4000 and potentially harmful substances. • Substances containing toxic, caustic, or corrosive substances may be analyzed with the instrument in an appropriate fume hood only. The fume hood must keep the work area below the lower toxic limit established by appropriate standards. • Substances that release caustic vapors such as acids should be analyzed in the smallest sample size possible to still achieve satisfactory results. If vapors condense on the MAX® 4000 housing parts, stop the testing, wipe the surface clean with a suitable neutralizer and place the instrument in a fume hood capable of removing the vapors. • The user has the responsibility for carrying out appropriate decontamination if hazardous material is spilled on or inside the MAX® 4000. CLEANING • Clean the MAX® 4000 according to the cleaning instructions only. Use of strong detergents and “oven cleaners” will damage the case and heater housing of the MAX® 4000. • Before using any cleaning or decontamination method except those recommended by Arizona Instrument, check with AZI Customer Service to ensure that the proposed method will not damage the equipment. • The outside housing of the MAX® 4000 should be cleaned with a mild household detergent such as Formula 409? and a soft, lint-free cloth. Paper towels should never be used, as they will scratch the instrument’s finish and the clear lens over the display. If methods that are more stringent are required, call AZI Customer Service for recommendations. • Every precaution has been taken to prevent contaminants from entering the instrument. However, if liquids or powders do enter the case, call AZI Customer Service for recommendations. The user shall be liable and responsible for any damage that arises in connection with this instrument. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 8 of 104 ENVIRONMENTAL CONDITIONS • STORAGE AND SHIPPING o Temperature should be between 0 °C and +40 °C (+32 °F and +104 °F). o Relative Humidity should be between 10% and 80%. • OPERATIONAL CONDITIONS – INDOOR USE. o Optimum results will be achieved when the instrument is set on a smooth, level, non-vibrating surface in a non-condensing, non-explosive environment of 0 - 40 ºC at 50% relative humidity or 0 - 30 ºC at 80% relative humidity. o Do not expose the instrument unnecessarily to extreme temperatures, moisture, shocks, blows or vibration. WARNING SYMBOLS Protective Ground: Identifies the connection on the chassis and power inlet module for the safety ground (green/yellow) wire connection. Warning: Observe information or procedures Electrical Shock Hazard: Observe all steps of the procedure to prevent electrical shock. Warning - Hot surface or area of possible severe burns: Use listed precautions when opening the oven lid and handling samples to prevent injury. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 9 of 104 4. PACKING AND SHIPPING INSTRUCTIONS IMPORTANT Movement, handling, and packaging of the instrument must be done with EXTREME CARE to avoid permanent, expensive internal damage. The MAX® 4000 uses a delicate and very sensitive electronic force balance to measure small weights and weight losses. The balance is capable of measuring weight to a resolution of 0.1 milligrams. Careful handling is necessary to prevent damage to the balance. With proper care, the instrument will provide years of dependable service. UNPACKING • Unpack the instrument carefully and set it down gently. Select a place where it will be safe from bumping, jarring, excessive air currents, and vibration. • Check the instrument immediately for any visible damage resulting from rough handling during shipment. • Retain the box and all packaging materials for any future shipment of the instrument. If the instrument is returned to AZI for any reason, place it in the original packaging materials. Only the original packaging materials have been tested and proven effective during shipment. • Install the pan support: o Open the lid by lifting the handle just above the display. o Remove the yellow tape, pan support and packing foam. o Save the foam so that it can be taped in place when the instrument is returned to the factory for annual calibration. o Gently but firmly install the pan support into the balance stem. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 10 of 104 REPACKAGING FOR SHIPMENT • Call AZI Customer Service for Return Material Authorization (RMA) information prior to returning an instrument. • Boxes and packing materials are available from AZI for all shipments. • Pack the MAX® 4000 in a Computrac® MAX® 4000 shipping container. Use the packing diagram below that matches your shipping system as a guide. If using the foam on the right below, orient the bottom foam tray as shown. A packing guidance diagram is also included on one of the box flaps. • Be sure to place the foam block underneath the pan support when packing the instrument. See UNPACKING (on the previous page) for pictures and more information. AZI WILL NOT BE RESPONSIBLE FOR SHIPPING DAMAGE. IF YOU RETURN THE INSTRUMENT IMPROPERLY PACKAGED OR SHIPPED, YOU SHOULD INSURE IT FOR FULL VALUE. j j MAX® 4000 AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 11 of 104 5. INTRODUCTION The Computrac® MAX® 4000 and MAX® 4000XL are high performance programmable loss-on-drying analyzers with the following features: • Typically, the instrument results are precise to better than: 0.002% SD typical for < 0.020% moisture (MAX® 4000XL only) 10% RSD from 0.020% - 0.100% moisture (MAX® 4000XL only) 2.0% RSD from 0.100% - 100% moisture (MAX® 4000 and MAX® 4000XL) • Programming is through the front panel keypad with a user friendly menu system. • A color LCD that is easy to read and provides color graphing. • Arizona Instrument's pioneering prediction method that can automatically end a test to provide accurate results in the shortest possible time. • Test temperatures that can be set at one degree increments from 25 ºC to 275 ºC on the MAX® 4000XL. (25 ºC to 225 ºC on the MAX® 4000). • Programmable for 250 Test Programs for different materials, including 245 user programs and 5 factory programs on the MAX® 4000XL. (The MAX® 4000 has 6 user programs and 4 factory programs.) • Test Results: o On the MAX® 4000XL, the last 1,000 Test Results are stored in the instrument along with the last 100 Test Graphs. (The MAX® 4000 stores 2 Test Results and does not have Test Graphs.) o Tests Results can be viewed, printed, and downloaded using Internet Explorer® (with the optional Web Server only available on the MAX® 4000XL), or sent to a PC over a USB or serial port. o The mean, standard deviation and relative standard deviation can be calculated for test results. o Moisture graphs can be viewed and printed. (Only available on the MAX® 4000XL) • A lid fan that rapidly cools the heat chamber to reduce time between tests to increase overall throughput. • In addition to moisture analysis, the instrument can function as an analytical balance. • Periodic balance and temperature calibration to maintain accuracy. • Balance linearity verification across the full range of the balance. (Only available on the MAX® 4000XL). • A Parameter Expert feature (only available on the MAX® 4000XL) that assists a user with the development of a Test Program that will produce results that match a reference method. • An optional Web Server (only available on the MAX® 4000XL) allows a user with Internet Explorer® to: o Download a complete calibration report. o View the LCD screen o Download and upload Test Programs. o Download Test Results and Test Graph data o Download the Audit Log • An Audit Log that tracks test program changes, calibrations, test result deletions, system errors, and power on events. (Only available on the MAX® 4000XL). AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 12 of 104 • A User Login function that, if activated, can be used to restrict access to calibration functions and instrument and test configuration options except by authorized users, preventing unwanted changes to operating parameters. When User Login is active on the MAX® 4000XL, a user is required to login prior to testing, and the user name is recorded with each test result. • On 21 CFR, Part 11 compliant instruments, the Delete Test Results and Delete Audit Log Events functions are disabled throughout the system. For those familiar with moisture analysis instruments, the MAX® 4000 should be simple to operate. However, please read all of the sections in this manual before attempting your first analysis. Contact AZI Customer Service if you have any questions about the following instructions. An up-to-date electronic copy of this manual can be found on the AZI web site at http://www.azic.com. 5.1. Hardware The MAX® 4000 series instruments consist of: • A small oven that dries the sample. • A precision balance weighing mechanism with a resolution of 0.001 gram (0.0001 gram on the MAX® 4000XL) and a full scale range of 40 grams that continuously weighs the sample. • An input power module that can be set to 100-120 VAC or 220-240 VAC. • A large backlit color graphic LCD. • A 32-bit microprocessor that controls the test process, data handling, communications, and performs all necessary calculations. • A lid fan that rapidly cools the heat chamber to reduce time between tests to increase overall throughput. • A small fan in the lower chassis that maintains the electronics at a stable and low temperature. • Connectors on the back panel include: o A USB Type A / Host port for connecting a USB printer, a USB keyboard, a Nitrogen Control module, a bar code reader, and/or other accessories. o An RS-232 serial port for PC connection and Temperature Calibration Interface (TCI) module connection. o An Ethernet connection for using the optional Web Server. (MAX® 4000XL only). o A USB Type B / Slave port for connecting a computer to the MAX® 4000. The MAX® 4000 is designed to remain powered up at all times. From a cold start, the instrument requires a 60 minute warm up period for optimum accuracy. When the instrument is not in use, select a test with an idle temperature of 25 ºC and keep the lid down. The oven will remain cool and the LCD backlight will turn off after a period of inactivity to conserve energy. Press any key or open or close the lid to restore illumination to the LCD. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 13 of 104 5.2. Instrument Models There are 2 different instrument models in the MAX® 4000 series, the MAX® 4000 and the MAX® 4000XL, which have various feature differences, as detailed below. Throughout this manual, MAX® 4000 is used to refer to both the MAX® 4000 and the MAX® 4000XL when describing common features or functionality. When there are specific differences between the two models, these are indicated through the usage of MAX® 4000XL for features that are only available in the MAX® 4000XL. Refer to the label on the front of the instrument, the splash screen displayed during power-up or access the Special Features menu (see page 79) to determine which model instrument you have. FEATURE MAX® 4000 MAX® 4000XL Moisture Range 0.1 to 99.9% 0.005 to 100% Balance Resolution 0.001g 0.0001g Test Result Storage Count 2 1000 Factory Test Program Count 4 5 User Test Program Count 6 245 Max Test Temperature 225 275 Test Temperature Rate Control No Yes Test Ending Criteria Rate or Prediction All Minimum Rate Setting for Rate Ending Criteria 0.01%/minute 0.0010%/minute Custom Result Equations No Yes Result Resolution (decimal points) Fixed At 2 Adjustable Linked Tests No Yes Allow Moisture Gain No Yes Graphing No Yes Perform Temperature Calibration & Verification No Requires Temp Calibration Kit Perform Balance Linearity Verification No Yes Parameter Expert No Yes Web Server No Optional Audit Log No Yes User Login Yes Yes Contact your technical sales representative for more information on the different models. 5.3. Oven The sample oven is designed to remove volatile components from the sample as quickly as possible, while maintaining accurate temperature control to prevent sample degradation. Oven temperature is measured with a Resistance Temperature Device (RTD), mounted in a rugged metal tube to prevent damage and dislocation. Temperature control accuracy is within one degree of the set value after equilibrium is reached, and the 700-watt heater reaches equilibrium in 90 to 180 seconds, depending on the difference between the starting and setpoint temperatures. Closed loop feedback control assures a constant temperature even if power line voltage varies during the test. After a test is completed, the heating system is turned off and the lid cooling fan is turned on. If desired, open the lid after testing to speed cooling before performing the next test. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 14 of 104 5.4. Inventory & Accessories Carefully unpack the instrument and locate the following items: Part Name AZI Part Number MAX® 4000 MAX® 4000XL MAX-4000 / MAX-4000XL Pan Support Assembly 600-0152 Accessory Kit: Y990-0209 Line Cord, 110 VAC 200-0002 or Line Cord, 220 VAC (Europe) 200-0233 or Line Cord, 220 VAC (UK) 200-0234 Test Weights (NIST Class F): 3 grams 5 grams 20 grams 690-0003 690-0004 690-0007 Tweezers 690-0012 Hex wrench for pan support 690-0016 User Manual 700-0111 Quick Guide 700-0120 Sample Pans, Waffle XT (100 Pcs) 990-0233 Optional Accessories Bar Code Reader 990-0231 DC to AC Inverter Kit Y990-0251 IQOQPQ Validation Package (for MAX® 4000XL) Y990-0228 Nitrogen Purge Kit 990-0046 Nitrogen Control module Y990-0214 Null modem cable for PC connection 6000-1044 Color Printer Kit (includes printer & USB cable) Y990-0212 Black & White Mini-Printer Kit (includes printer, USB cable & thermal paper) Y990-0252 (Add’l Paper: 6100 0050) Rear Port Dust Covers Kit Y990-0250 Sample Basket 600-0137 Shipping Container 751-0011 Temperature Calibration Kit, 110V Y990-0156 Temperature Calibration Kit, 220V Y990-0160 Test Weight – 10 gram (NIST Class F) 690-0005 USB Cable for Printer or PC connection 200-0165 USB Keyboard 990-0230 USB Flash Drive 990-0241 USB Hub 990-0232 Web Server Y990-0232 Consumables: External Filter 800-0071 Filter Paper 990-0003 Sample Pans, Flat Bottom (100 Pcs) 990-0010 Sample Pans, Waffle XT (100 Pcs) 990-0233 Sodium Tartrate (500 gram bottle) 800-0037 Spare Parts: 4 Amp Fuse 190-1002 8 Amp Fuse 190-1001 AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 15 of 104 6. INSTRUMENT SETUP Review and perform all necessary setup steps in section 6 (including its subsections). After setting up the instrument, complete the following three items before testing any samples with the instrument: • Perform a balance span calibration (See section 8.3.1.B Perform Span Calibration on page 60). • Perform weight tests to verify proper performance and to get familiar with instrument operation (See section 10.1 The Weight Test on page 93). • Set up a test program to run material tests (See section 7 MOISTURE ANALYSIS TESTING starting on page 34.) 6.1. Instrument Location The MAX® 4000 is designed to provide reliable results under normal ambient conditions in the laboratory and on the production floor. Compliance with the following guidelines will help ensure optimum accuracy and minimum test times: • Locate the instrument on a firm and level surface that is free from vibration that will affect the balance measurements. • Locate the instrument close to an isolated power outlet that will provide dedicated electrical power. • Locate the instrument away from a fan, heating/air-conditioning vent, or drafts from a window/door that might produce force on the balance. • Maintain an operational clearance of 20 cm (8 inches) around the instrument and 1m (3 feet) above the instrument. • Keep all cables as short as possible (less than 2 meters (6 feet) in length if possible). • Avoid placing the instrument in close proximity to a heater or otherwise exposing it to heat or direct sunlight. • Avoid exposing the instrument to extreme temperature fluctuations. • Keep the instrument protected from dust, liquids, and caustic vapors as much as possible. • Do not expose the instrument to saturated humidity environments. Moisture in the air can condense on the surfaces of a cold instrument whenever it is brought into a substantially warmer place. If you move the MAX® 4000 to a warmer area, make sure to condition it at room temperature by disconnecting it from AC power for at least 2 hours or until moisture condensation no longer occurs. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 16 of 104 6.2. Interior of Test Chamber & Pan Support CAUTION - Do not, at any time, attempt to spin the pan support as it may result in damage to the force balance. Avoid excess pressure on the pan support from the top or sides, which can damage the force balance. If not already installed, gently but firmly install the pan support into the balance stem. Check the clearance between the pan support arms and the shroud gasket by observing the space between the arms and the shroud gasket. The clearance should be between 1.9mm (the thickness of an American nickel) and 3mm (the thickness of a nickel and a dime stacked). If the clearance is considerably different, or the pan support appears to be crooked, call AZI Customer Service. 6.3. AC Power Connection The MAX® 4000 can be used with a 100-120 VAC or a 220-240 VAC input power source. Check the setting on the fuse holder, located at the rear of the instrument, and make sure it is set for the correct voltage for your environment. Ensure that the power entry module (where the power cord connects to the instrument) is set for the correct voltage for your environment. To change the voltage from 110 to 220VAC or 220 to 110VAC: • Remove the power cord. • Pry the fuse holder from the power entry module. • Ensure only 8 amp timed fuses are installed for 100-120 VAC operation or only 4 amp timed fuses are installed for 220-240 VAC operation. (Note: There are four fuses in the power entry module: Two in the fuse holder clips and two spares in the slide out compartments.) • Rotate the fuse holder 180º and reinstall it in the power entry module, making sure that the arrow on the power entry module is pointing to the proper voltage for your environment. Connect power to the instrument: • Ensure that the power switch, located on the power entry module in the back of the instrument, is set to off (O). • Remove the power cord from the packing material and insert the rectangular end into the power entry module. • All accessory equipment, printer, computer, etc., should be connected before applying power to the instrument. See sections 6.7 Connecting a USB Printer on page 21 and 6.9 Connecting a Computer on page 22 to connect a printer and/or computer. Power Requirements: 100-120 VAC, 50/60 Hz @ 8 Amps – fuse is F8A T250V 220-240 VAC, 50/60 Hz @ 4 Amps – fuse is F4A T250V Fused on/off switch is part of an EMI power entry module AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 17 of 104 For best results, AZI recommends that the instrument is provided with its own DEDICATED electrical power outlet. Do not put it on a circuit with motors, blenders, heaters, coolers, grinders, or other high current electrical devices. The power source outlet that is used by the MAX® 4000 MUST BE GROUNDED. (If you are not sure if the socket is grounded, check with your plant electrician before proceeding). The MAX® 4000 will appear to function correctly even if the socket is not grounded, but there is a danger of possible electrocution If grounded outlets are not available, consider using a ground fault interrupter to protect personnel against electrical shock. • Plug the power cord into a dedicated electrical power outlet. Line noise on the power lines may affect accuracy. A dedicated AC power line or an isolation transformer for the MAX® 4000 may be beneficial in eliminating this noise. • Turn on the instrument by flipping the switch on the power entry module on the back of the instrument; the instrument is designed to remain powered up at all times. • From a cold start, allow the instrument to warm-up for 60 minutes before testing. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 18 of 104 6.4. User Interface Operation • After power up, the Main Test screen shown below appears. (It may be necessary to press the [ESC] key to clear any calibration reminders). The keypad button functions are as follows: • [START] - Begins a test using the currently selected Test Program. • Left and Right Arrow Keys: o Move the cursor to the prior or next item on edit screens. o Move the cursor one page prior or following on list screens. • Up and Down Arrow Keys: o Move the cursor to the prior or next item on edit screens. o Move the cursor one line up or down on list and menu screens. o Move the cursor up or down while editing a list of items. • Numeric Keys: o Select the numbered item on menu screens. o Move to the item on list screens. The last numeric digit of the item is used when the choices are two digit numbers. For example, the 7 key could be used to select 7, 17 or 27, etc., depending on the choices displayed on the instrument. • [ENT] (for ENTER): o Selects most items. o Toggles Yes/No, On/Off, and Checked (v) items. • [ESC] - Exit a menu or screen. Items that are Yes/No or On/Off choices are saved when the [ESC] key is depressed to end editing of the item. • Soft Keys are located below the instrument’s display and the functions that they perform are indicated by the titles located above each soft key on the display. These functions are related to the current operating mode of the instrument and will vary accordingly. Soft Keys AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 19 of 104 To begin editing an item either: • Press [ENT] to edit the existing value. • Press an Alphanumeric or Numeric key to overwrite the existing value with a new value. Typical keys during item editing are: • Left and Right Arrow Keys – Move the cursor one position left or right. • Alphanumeric Keys – For alphanumeric items, press the key repeatedly to scroll through the listed characters plus a blank space (similar to cell phones). After a short delay, the alphanumeric digit is saved to the item allowing a new digit to be added. For example, press the 2 key once for an “A”, twice for a “B”, thrice for a “C”, four times for a “2”, and five times for a blank space. After the blank space, repeated button presses start the cycle over at “A”. Note, the 0 (zero) key contains the dash and percent symbols. • Numeric Keys – For numeric items, add a numerical digit. • [?DEL] or [DEL?] – Delete the character to the left or right of the cursor. • [CLEAR] – Erases all characters in the item. • [+/-] - Change the polarity (positive or negative sign) of a number. This is only displayed when applicable. • [ENT] – Save the edited value and advance to the next item, if one is present. • [ESC] – Exit an item edit without saving the value (unless it is a Yes/No or On/Off item). 6.5. Contrast Adjustment If necessary, adjust the display contrast controls for better viewing of the display. At the Main Test screen, the leftmost soft key below the display has the word CONTRAST above it. Press this key and the display changes to instructions on setting the contrast. Use the up and down arrows on the key pad until the display is acceptable and press the [ESC] key to save the setting and exit back to the Main Test screen. During normal operation, the LCD will darken after a few minutes of inactivity but will brighten with any key press or lid opening or closure. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 20 of 104 USB Type B 6.6. Back Panel Connections In addition to the AC power connection, these connections are also available from the back panel of the instrument: • RJ-45 Ethernet Connection (marked ETHERNET) o The Ethernet port is used primarily to connect the MAX® 4000XL to a Local Area Network (LAN) for use with the optional Web Server. See section 9 WEB SERVER on page 87 for more information. • Temperature Calibration Interface and RS-232 serial port (marked TCI) o The TCI port is used primarily to connect the Temperature Calibration Interface when performing Heater Temperature Calibration on the MAX® 4000. See Temperature Calibration on page 63 for more information. This port is also used to connect to a PC using a serial cable. See Connecting a Computer on page 22 for more information. • USB Type B / Slave Connection (marked PC) o The USB Type B connection is used to connect the MAX® 4000 directly to a PC using a USB A to B cable (AZI P/N: 200-0165). See Connecting a Computer on page 22 for more information. (Windows® XP only) • USB Type A / Host Connection (marked USB) o The USB Type A connection can be used to connect various accessories, including a USB printer, a USB drive, a USB keyboard, a bar code reader or a Nitrogen Control module. An icon (shown below) will appear in the bottom left corner of the main screen indicating the type of USB device connected. To connect more than one accessory at one time, a USB hub is required. Some accessories, such as the Nitrogen Control module, require a powered USB hub that connects to AC power in order to function. For best results, if a USB hub is used with the MAX® 4000, a powered hub (AZI P/N: 990-0232) is recommended. o For additional information on these accessories, see: 6.7 Connecting a USB Printer on page 21 6.8 Connecting a USB Drive on page 22 6.10 Connecting a USB Keyboard on page 27 6.12 Nitrogen Control Module on page 30 6.13 Bar Code Reader on page 32 USB Type A AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 21 of 104 6.7. Connecting a USB Printer Two optional graphics capable printers are available from AZI: • Color Printer Kit AZI P/N: Y990-0212 • Black and White Mini-Printer Kit AZI P/N: Y990-0252 The printers connect to the USB Type A / Host port (marked USB) on the back panel. Test Programs, Test Results and graphs, and calibrations can be printed. The reports can be custom configured through the menu system. These same reports can be directed to a computer through the USB Type B / Slave port (marked PC) or RS-232 TCI serial port on the back panel. To set up the printer: • Unpack the printer and cable. • Load the ink cartridges (if any) and paper according to the printer instruction manual. • Plug the USB Type B square connector of the printer cable into the printer’s mating socket and the Type A rectangular connector of the cable into the MAX® 4000’s mating socket (marked USB). If other USB devices are being used, a USB hub is needed to connect multiple devices to the MAX® 4000. • Plug the power cord into the printer, and into a GROUNDED power receptacle. • Turn on the printer. • Turn on the MAX® 4000. • When a printer is connected, a printer icon will appear in the bottom left corner of the main screen, above the CONTRAST soft key. The icon varies depending on which printer is connected: o Standard Printer o Mini-Printer • To configure the MAX® 4000 for printer use, go to section 8.4.1 Printer Setup on page 70. • To configure test report options, go to section 8.4.2 Report Setup on page 70. • Verify printer operation by printing a test result or calibration. For example: o Begin at the Main Test screen and press [MENU], (the center soft key below the display) to access the Main Menu. o Select the CALIBRATION MENU item and press [ENT]. o Select the BALANCE CALIBRATION MENU item and press [ENT]. o Select the VIEW CALIBRATION REPORT item and press [ENT]. o Select the [PRINT] soft key and verify the report prints. • If the printer runs out of paper while printing, printing to the printer will cease and the print job will be purged. Printing to the PC, USB drive or a 2nd attached printer will not be affected. To continue, refill the printer with paper and reprint the desired print job. If you have any questions about connecting a printer to your MAX® 4000, call AZI Customer Service. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 22 of 104 6.8. Connecting a USB Drive If you wish to monitor testing using a USB drive (AZI P/N: 990-0241), one can be connected to the USB Type A / Host port (marked USB) on the back of the MAX® 4000. For best results, use AZI Flash Drives (AZI P/N: 990-0241) that have been validated for use with the MAX® 4000. Compatibility with non-AZI USB drives cannot be guaranteed. See section 8.4.1 Printer Setup on page 70 for instructions on configuring the instrument to send reports to the USB drive. USB drives that contain the U3 program are not compatible with the MAX® 4000 and should not be used. The MAX® 4000 can send data to a computer, a USB drive, and a printer port at the same time. However, graphs that can be printed by the printer are not formatted for display by the computer or USB drive. Therefore, graphs are not sent to the computer or USB drive. When a USB drive is connected, the USB drive icon will appear in the bottom left corner of the main screen, above the CONTRAST soft key. If you have any questions about connecting a USB drive to your MAX® 4000, call AZI Customer Service. 6.9. Connecting a Computer (Windows® XP Only) If you wish to monitor testing with a PC, a PC can be connected to the MAX® 4000 with a USB cable (AZI P/N: 200-0165) or a null modem cable (AZI P/N: 6000 1044). Before connecting the MAX® 4000 to a PC with a USB cable, install the USB driver first. See section 6.9.1 USB Driver Setup on page 23. To use a null modem cable, connect the TCI serial port on the MAX® 4000 back panel to a PC serial port. For either a null modem or USB connection: • Use any serial port communications program on your PC to read the reports transmitted from the MAX® 4000. (Most pre-Vista Windows® PC’s come with HyperTerminal in the PC’s Start/Accessories/Communications menu). Configure the PC to use 115.2kbits/s, 8 data bits, no parity, 1 stop bit, and no flow control. • The MAX® 4000 does not test to see if the computer is actually connected or ready to receive data. It does not respond to a request from the computer for status information. • The MAX® 4000 can send data to a computer, a USB drive, and a printer port at the same time. However, graphs that can be printed by the printer are not formatted for display by the computer or USB drive. Therefore, graphs are not sent to the computer or USB drive. If you have any questions about connecting a computer to your MAX® 4000, call AZI Customer Service. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 23 of 104 6.9.1 USB Driver Setup Before using the computer to receive information from the MAX® 4000 through the USB port, the USB driver must be installed on the PC. The USB driver is on the CD with this manual and on the Drivers page of the AZI website at http://www.azic.com. The driver works with Windows® XP (32-bit). If the CD is available: • Insert the CD in the PC’s CD-ROM drive. • Use Windows® to browse to the CD, locate the driver file (AZI_USB_Driver.zip), and copy it to your desktop. If the CD is not available: • Download the driver file from the Drivers page at http://www.azic.com and save it to your desktop. If you received these instructions and the driver in an email, save the attached file (AZI_USB_Driver.zip) to your desktop. Once the driver file (AZI_USB_Driver.zip) is on your desktop: • Double-click the file to open it. • Drag the “Driver Install” directory from the zip file to the desktop. • Double-click the "Driver Install" folder to open it. • Double-click the "Install Driver" shortcut. This will launch the AZI Driver Installer wizard. Follow the instructions in the AZI Driver Installer wizard. • Click Next. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 24 of 104 Windows® may display a message indicating that the driver has not passed Windows® Logo Testing. The driver being installed is a generic Communications Port driver that is part of Windows® (usbser.sys), so it is safe to ignore this warning. • Click “Continue anyway” to install the driver. • Click Finish AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 25 of 104 • Connect the MAX® 4000 to the target computer using a USB cable, and then power on the MAX® 4000. Windows® will detect the MAX® 4000 and automatically start the New Hardware wizard. The following pictures and descriptions apply to a Windows® XP installation. • If the following dialog box appears, DO NOT connect to Windows® Update to get the driver. Select “No, not this time” and click Next. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 26 of 104 • Select “Install the software automatically”, and click Next Again Windows® may display a message indicating that the driver has not passed Windows® Logo Testing. This driver being installed is a generic Communications Port driver that is part of Windows® (usbser.sys), so it is safe to ignore this warning. • Click “Continue Anyway” to install the driver. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 27 of 104 Windows® will copy a file and finish the wizard. • Click Finish. Windows® will then indicate that the driver has been successfully installed 6.10. Connecting a USB Keyboard An optional keyboard is available from AZI (AZI P/N: 990-0230) that allows easier text entry. It connects to the USB Type A / Host port (marked USB) on the back panel. The keyboard can be used as a substitute for the alphanumeric keypad, and the arrow, [ESC] and [ENT] keys, and the keyboard function keys F1?F5 can be used to activate the soft keys. However, the keyboard cannot substitute for the [START] button. • Unpack the keyboard. • Plug the end of the keyboard cable into the MAX® 4000’s mating USB socket (marked USB). If other USB devices are being used, a USB hub is needed to connect multiple devices to the MAX® 4000. • When the keyboard is connected, the keyboard icon will appear in the bottom left corner of the main screen, above the CONTRAST soft key. Note, however, that the bar code reader also acts like a USB keyboard and only one keyboard device can be connected to the MAX® 4000 at a time. To use the keyboard, the bar code reader must first be disconnected from the instrument or USB hub, and vice versa. For more information on the bar code reader, see section 6.13 Bar Code Reader on page 32. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 28 of 104 6.11. Installing the Nitrogen Purge Kit CAUTION - Use of nitrogen or other inert carrier gas does not create an explosion-proof system. Some applications may require the use of a nitrogen purge to remove volatiles from the chamber. In addition to the Nitrogen Purge Kit (AZI P/N: 990-0046), the following materials are required for the nitrogen purge setup: • Nitrogen source/cylinder or other supplied inert gas source. • Two-stage regulator capable of regulating pressure to 5 psi: o For cylinder applications: Multi-stage Gas Regulator for Compressed Air Cylinder, VWR #55850-420 or equivalent. o For supplied gas sources: Matheson Gas Products Model 3471 Single Stage Line Regulator or equivalent. • Tubing with a 1/8" (.31 cm) inside diameter (I.D.) and, 1/4" (.625 cm) outside diameter (O.D.) - Vinyl tubing (VWR #63013-029), or Nalgene clear plastic tubing (Nalgene #8000-0020, VWR #63015-368) • Connector, 1/8" I.D., 1/4" O.D. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 29 of 104 Install the kit: • Open the lid and remove the plug that is centered in the heater ring. • Install the air diffuser and seal into the opening that was created by the plug removal. Caution – Tighten to finger tight only to prevent breakage. • Close the heater lid. • From the back of the instrument, remove the plug located in the upper left corner (as viewed from the rear) of the heater lid. • Install the .007 orifice fitting (it has the green insert), supplied with the Nitrogen Purge Kit, into the opening created when the plug was removed. • From the back of the instrument, remove the plug from the lower portion of the instrument. • Install the .012 orifice fitting (it has the black insert), supplied with the Nitrogen Purge Kit, into the opening created when the plug was removed. • Connect the regulator to the gas source/cylinder per the regulator manufacturer's instructions. • Use tubing to connect the outlet of the regulator to the “Y” connector supplied with the Nitrogen Purge Kit. • Connect tubing from the “Y” connector’s two outlets to the fittings on the rear of the instrument. • Check that all fittings are gas tight and secure. The valve should be turned off until the start of a test to conserve gas. Flow rates will be sufficient with the pressure set to between 4 and 5 psi. Remove plug and install air diffuser Remove plugs and install .007 and .012 orifice fittings MAX® 4000 AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 30 of 104 6.12. Nitrogen Control Module The Nitrogen Control module (AZI P/N: Y990-0214) is an optional accessory that is used in conjunction with the Nitrogen Purge Kit to conserve nitrogen. The module turns on nitrogen to the instrument prior to a test and turns off the nitrogen after a test. This is especially helpful when using a limited supply of nitrogen (bottled nitrogen). The module also monitors the nitrogen pressure and alerts the user when the nitrogen source is depleted. The incoming pressure must be between 4 and 20 psi inclusive. The module connects to the USB Type A / Host port (marked USB) on the back panel. • Unpack the module. • Plug the Type A flat end of the included cable into the MAX® 4000’s mating socket (marked USB). If other USB devices are being used, a USB hub is needed to connect multiple devices to the MAX® 4000. (The hub must be self-powered, i.e. use an external power adapter, or the Nitrogen Control module will not function correctly). • Connect the Type B square end of the cable to the mating socket on the Nitrogen Control module. • The module is enabled through the SETUP menu (See section 8.4.6 Nitrogen Control Module on page 76). • When the module is connected, the module icon will appear in the bottom left corner of the main screen, above the CONTRAST soft key. The module’s flow connectors are connected into the nitrogen supply just after the regulator in the standard nitrogen purge setup. • Connect the input to the regulator, as shown. • Connect the output to the Y-Connector, as shown. MAX® 4000 AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 31 of 104 The module has two LEDs for informational purposes: • The GREEN LED on the right: o Solid Green indicates good pressure and nitrogen not currently flowing. o Blinking Green indicates good pressure and nitrogen currently flowing. • The RED LED on the left indicates inadequate pressure. The trigger pressure for the module has been factory set to 3 psi +/- 0.2 psi. It takes at least this pressure to trigger a good pressure reading. If necessary, the trigger pressure can be adjusted through the capped hole on the top of the module. Once a good pressure is triggered, the pressure must drop to around 0.5 psi to trigger a low pressure reading. To adjust: • Set the incoming nitrogen pressure to the desired trigger pressure. • Remove the cap from the hole on the top of the module. • To set the module to trigger at this pressure, insert a regular screwdriver through the hole and turn the screw on the top of the pressure sensor. Turn the screw counterclockwise to lower the trigger pressure and clockwise to raise the trigger pressure. As detailed above, the LEDs indicate good and inadequate pressure. An audible click also occurs when the pressure sensor triggers. • To verify proper adjustment, watch the LED’s while disconnecting and re-connecting the nitrogen. Make fine adjustments as necessary. • Re-install the cap into the hole. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 32 of 104 6.13. Bar Code Reader An optional bar code reader (AZI P/N: 990-0231) is available from AZI that allows rapid data entry. Alphanumeric data can be entered into the MAX® 4000 using the instrument keypad, a USB keyboard, or, if the data is in a bar code format, by using the bar code reader. When the item to be input is highlighted on the instrument, simply scan the barcode to populate the item. For example, if the samples to be tested are labeled with bar codes, the bar code reader is useful if entering the LOT NUMBER and PRODUCT ID at the start of a test. See section 8.4.5 Misc Options on page 75 for more information on LOT NUMBER and PRODUCT ID input. The bar code reader connects to the USB Type A / Host port (marked USB) on the back panel of the MAX® 4000. Note, however, that the reader acts like a USB keyboard and only one keyboard device can be connected to the MAX® 4000 at a time. To use the bar code reader, the keyboard must first be disconnected from the instrument or USB hub, and vice versa. • Unpack the bar code reader. • Plug the rectangular cable end into the MAX® 4000’s mating socket (marked USB). If other USB devices are being used, a USB hub is needed to connect multiple devices to the MAX® 4000. The hub must be self-powered i.e. use an external power adapter or the reader will not function correctly. • When the bar code reader is connected, the keyboard icon will appear in the bottom left corner of the main screen, above the CONTRAST soft key. Try out your bar code reader here ? AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 33 of 104 6.14. Installing & Removing the External Filter An optional External Filter (AZI P/N: 800-0071) is available to keep dust and other particulates from entering the interior of the instrument. If the filter is being used, it should be inspected regularly for debris build-up and replaced when dirty. The filter can be installed and removed without placing the instrument on its side. However, if the instrument is going to be placed on its side, power off the instrument and remove the pan support first, and lay down a soft cloth or piece of cardboard to avoid scratching the finish on the side of the instrument. If the instrument is going to be laid on its side: • Power off the instrument. • Remove the pan support. • Lay the instrument on its side on a piece of soft cloth or cardboard to protect the finish. • After removal/installation is complete, set the instrument right side up before replacing the pan support and powering on the instrument. To install the filter: • Slide the filter into the retaining brackets with the wire lattice pattern towards the instrument as shown. Orientation is also indicated by the Air Flow arrow on the side of the filter; the arrow points towards the instrument when the filter is installed. To remove the filter: • Push the filter from one side and pull from the other side to remove it. • If the filter is dirty, discard it and install a clean filter (AZI P/N: 800-0071). AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 34 of 104 7. MOISTURE ANALYSIS TESTING The Computrac® MAX® Series loss-on-drying moisture analysis system takes advantage of leading edge technology to reduce test times and increase precision over standard vacuum oven or convection oven drying procedures. Prior to testing, a Test Program is created with the parameters to be used for testing the sample. The instrument then controls the test using this Test Program, as explained in more detail in the following pages. Within each Test Program, the test temperature can be programmed between normal room temperature (25 ºC) and 225 °C (275 °C on a MAX® 4000XL). Using the linked test functionality available on the MAX® 4000XL, a multi-step temperature contour can be set up across several linked Test Programs. In the test chamber, an aluminum sample pan rests on a pan support coupled to a sensitive electronic force balance. The sample is added to the sample pan and the force balance registers the initial weight of the sample before testing. The heater located on the underside of the test chamber’s lid then heats the sample, and a Resistance Temperature Device (RTD) monitors the temperature in the test chamber. The temperature readings from the RTD are sent to the microprocessor, and under the microprocessor's control, the heater element is cycled on and off to bring the test chamber to the programmed temperature. As the sample is heated according to the Test Program selected for the test, it loses weight due to moisture evaporation. The balance records that weight loss and transmits the data to the microprocessor for evaluation. The balance readings are averaged to eliminate signal interference or erroneous data. The microprocessor interprets the information and compares the sample's weight loss to a standard drying curve. The sample's decreasing weight is compared to the initial sample weight and the calculated moisture concentration appears on the display. The final moisture concentration is extrapolated from the curve and results are available within minutes. A typical drying curve is shown at the right. Section (A-B) represents the sample's weight loss as it heats from room to testing temperature. Section (B-C) is linear, representing moisture loss from the interior of each particle of the tested sample. Section (C-D) is exponential in nature and represents the final evolution of moisture from within the particle. The point at which no additional weight loss occurs (E) represents the complete evolution of water from the original sample. Section (D-E) is the longest and most time-consuming portion of the entire testing process. The time for a sample to reach zero residual moisture in an oven can take from one to possibly 24 hours depending upon the sample, sample preparation, and testing temperature. When using the Predict ending criteria, the MAX® 4000’s loss-on-drying system calculates the sample's moisture concentration through mathematical extrapolation from the exponential (C-D) portion of the curve. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 35 of 104 The microprocessor monitors the sample's weight loss during the entire testing process. Simultaneously, if using the Predict ending criteria, the microprocessor is predicting a final moisture concentration based upon the sample's rate of weight loss compared to the exponential portion of a standard drying curve. Testing continues until the predicted moisture concentration agrees within a certain percentage of the actual moisture concentration appearing on the display. The percent agreement between the predicted and the actual moisture concentrations will vary depending upon the system's programming and the moisture level of the sample. The MAX® 4000 is an extremely flexible instrument. This flexibility means that some time is required to determine the best set of parameters for a particular application. The determination of the proper parameters requires a series of tests and good laboratory procedure. Call your AZI technical sales representative for assistance developing Test Programs for your samples. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 36 of 104 7.1. Performing a Test A Test Program for your material must be developed prior to using the MAX® 4000 for production testing: • See section 8.1 Test Programs on page 41 for guidance setting up a Test Program. This section helps you determine the proper test temperature, ending criteria, sample size, and other parameters. • The Parameter Expert feature (MAX® 4000XL only, see section 8.6 Parameter Expert on page 80) automatically selects most test parameters based on your reference method results and then guides you through a series of tests to determine the proper test temperature and ending criteria. • AZI technical sales can develop Test Programs for your material. After a new Test Program is developed, run 5 or more tests to obtain reliable information about the standard deviation of a typical result. Each test result is automatically saved, and the instrument can calculate the mean, standard deviation, and relative standard deviation through the Test Results menu. Note, the MAX® 4000 only stores 2 Test Results. To perform a test: • If a clean pan is not already installed, then place a new/clean sample pan on the pan support. • Close the lid. • If not at the Main Test screen, press [ESC] repeatedly until the Main Test screen is displayed. • If the desired Test Program is not currently active, press the [PROGRAM] key, then highlight the desired Test Program from the list. • If desired, press [ENT] to view the test parameters for the highlighted Test Program prior to starting the test. A screen similar to this one will be displayed. The test parameters cannot be edited from here, as indicated by the lock icons. Press [ESC] when done to return to the TEST PROGRAM SELECT screen. • From the TEST PROGRAM SELECT screen, press [START] to begin a test using the highlighted Test Program. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 37 of 104 • The instrument will tare (zero out) the pan. This will occur instantly if the lid has been closed and the balance is stable. • Open the lid and quickly load the sample, taking care to evenly distribute it across the entire pan surface in a thin layer to get the fastest and most accurate results. While loading the sample, the weight is displayed graphically with the acceptable target window in green and in grams at the screen bottom. Add sample so that the sample weight is centered in the graph; an audible signal indicates when the sample weight is acceptable. Once the desired amount has been added, the pan can be removed from the test chamber to evenly distribute the sample. The sample should be distributed over the surface of the pan by gentle shaking or tapping, or for very viscous samples, spreading with a spoon or knife. An even layer of sample across the pan will reduce test times and increase precision of results. To load difficult samples more easily, remove the sample pan from the instrument after the correct amount of sample has been placed on the pan, place the filled pan on a level work surface, spread the sample with a small flat brush or spatula (depending on the consistency of the sample), and then replace the loaded sample pan on the pan support. Do not spread granular products with a spoon as the particles compress even under gentle pressure affecting test times and results. Transport samples in an airtight container to prevent moisture gain or loss through contact with air. If performing WEIGHT tests: The weight test simulates moisture loss with the removal of one of two known weights, and is used to verify the balance is responding properly. Select (Factory) WEIGHT as the Test Program to perform the weight test, then wait approximately three minutes for the chamber to heat to 80 °C before starting the test. Instead of adding sample material to be tested, carefully place both the included 5-gram and 3-gram weights near the center of the sample pan when prompted. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 38 of 104 • Close the lid, and the instrument weighs the sample. • The test proceeds to dry the sample. For a WEIGHT test only, immediately after the instrument weighs the sample, gently open the lid, carefully remove the 3-gram weight, and gently close the lid. • The test finishes once the ending criteria has been met, as shown below left. If performing WEIGHT tests: When the WEIGHT test completes, the final test result screen indicates Pass or Fail by a Green or Red background respectively and a PASS or FAIL below the result, as shown below right. • Open the lid and remove the sample. • Place a new/clean sample pan on the pan support to get ready for the next test. • Close the lid when the heat chamber is cool. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 39 of 104 7.2. Preparing Granular and Powdery Samples The MAX® 4000 can be used to test a wide range of products from finely ground, low-moisture powders to high-moisture slurries. For best results, the sample should be of a uniform particle size distributed evenly over the sample pan. If sample material is collected into a jar or sampling bag, shake the jar or bag to produce a more thorough mixture. Note, however, if there is a large variation in particle size, shaking will tend to distribute larger particles to the top. Liquid samples should also be mixed or shaken to ensure a more homogeneous mixture. Large chunk samples, such as charcoal or cookies, should be crushed or ground to smaller pieces approximately 1/4" or less in diameter. For best results, take care not to over-grind the sample, causing it to heat up and causing moisture loss. Some samples, such as dried vegetables, may also need to be ground. The smaller pieces will easily release moisture during testing, leading to shorter test times and more repeatable results. Solid, granular sample material should be shaken onto the pan from a spoon; shaking sample directly from the collection jar will usually deposit only the larger granules, not a representative mixture. Samples should be evenly distributed over the sample pan. 7.3. Preparing and Testing Liquid Samples Some liquid samples will dry slowly, even at high temperatures. Drops or puddles may form on the pan and dry slowly as the sample concentrates. A skin may form which limits evaporation from the interior. Long test times (greater than 25 minutes) and low percent moisture (or high percent solids values) suggest incomplete drying. Pre-dried glass-fiber filter paper (AZI P/N: 990-0003) and flat-bottomed pans (AZI P/N: 990-0010) are recommended to successfully test samples such as these. Call AZI consumable parts sales for more information. The glass-fiber filter paper serves as a support for the liquid sample. The sample is absorbed through the paper for more even and rapid evaporation to reduce test times. Waffle-bottom sample pans are not recommended for use with filter paper; the liquid sample may soak through the filter paper and collect in puddles in the pan's depressions. Liquid samples or slurries can be spooned or poured onto the sample pan; however, a pipette or sampling straw will collect a uniform mixture of the sample. Samples should be evenly distributed over the sample pan. Occasionally, some samples cannot be absorbed into the filter paper. At the end of the test, examination of the sample pan shows the sample sitting high above the filter paper with a thick crust. The crust may be singed from the heat or even show bubbling where vapor has been trapped beneath the surface. Percent solids results will be high or percent moisture results will be low. Samples such as these are treated differently: After the sample has been added to the sample pan, remove the pan from the test chamber and place it onto a flat surface. Grasp part of the filter paper (tweezers are suggested) and flip it over so that the sample lies between the pan and the paper. Squash the sample with a flat-bottom glass or jar to a uniform layer. Return the sample pan to the test chamber and close the lid. The upper filter paper surface absorbs moisture from the sample and minimizes bubbling and spattering to produce more accurate, reproducible results. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 40 of 104 8. MAIN MENU Pressing the MENU soft key on the Main Test screen provides access to the MAX® 4000 menu system. To get here, press: [MENU] The first and second levels of the menu system are shown below, and are explained in detail in this section of the manual. Throughout this section, the key presses necessary to get to the indicated menu are shown at the beginning of each subsection. Note that all menus are accessed by first pressing the MENU soft key from the Main Test screen. After making changes in the SETUP MENU, press [ESC] until back at the Main Menu to save the changes. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 41 of 104 8.1. Test Programs Test Programs are test parameter sets. They are sequentially numbered from 1 to the total number of programs entered into the instrument. The figure below shows program 1 selected, as indicated by the yellow arrow. The 1/20 in the upper right hand corner indicates that a total of 20 test programs have been defined and the blue cursor bar is on number 1 out of 20. The “(Factory)” programs are for standard tests to check the performance of the instrument. The MAX® 4000XL has 245 user programs and 5 factory programs, while the MAX® 4000 only has 6 user programs and 4 factory programs. (The (Factory) DRIFT test is only available on the MAX® 4000XL.) To get here, navigate: [MENU]?TEST PROGRAMS TEST PROGRAMS allows access to the test parameter sets. This is where the contents of the Test Programs may be printed or changed. The keypad functions are: • Up and Down Arrow Keys move the cursor one line at a time. • Left and Right Arrow Keys move the cursor one page at a time. • [START] key selects the highlighted Test Program and immediately begins a test. • [ENT] – Select and edit the highlighted Test Program. Press [ESC] when done to return to the TEST PROGRAM EDIT screen. This program will now be selected. • [CUT] – Copy the current program into temporary memory and delete it from the list. The program can be optionally inserted at another location. Use this carefully. The “(Factory)” programs cannot be deleted with this option. • [COPY] – Copy the current program into temporary memory, which can be optionally inserted at another location. • [INSERT?] or [INSERT?] - Insert the program that is in temporary memory into the list either above or below the current program. The following programs are moved down, and multiple copies can be made with multiple insertions. • [I/O] – Displays the [SAVE], [LOAD], [PRINT], and [MOVE] soft keys. These soft keys are used to upload, download or print Test Programs, as shown on the next page. To add a new Test Program: • Highlight an existing Test Program and press [COPY], • Use the arrow keys to scroll to the desired location in the list for the new program, • Press one of the insert keys to insert a copy of the Test Program. • Edit the inserted Test Program to reflect the desired parameters, as explained in the following pages. When the MAX® 4000 is powered on, it will immediately begin heating to the IDLE TEMPERATURE of the first Test Program in the list. When shipping from the factory, the default first Test Program in the list is the (Factory) IDLE Test Program, which has an IDLE TEMPERATURE of room temperature (25 °C) to avoid undesired heating. To change the default Test Program upon power up, insert the desired Test Program at position 1 in the list of Test Programs. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 42 of 104 The following soft keys are available after pressing the I/O soft key on the TEST PROGRAM EDIT screen: • [SAVE] – Save a copy of any or all of the Test Programs to a USB drive. After pressing [SAVE], follow the onscreen instructions to plug in a USB drive, select the desired programs and save them to the USB drive. • [LOAD] – Load the Test Programs saved on a USB drive into the MAX® 4000. After pressing [LOAD], follow the onscreen instructions to plug in a USB drive and select where in the list of Test Programs the new ones should be loaded. The Test Programs will be loaded starting below the selected location. • [PRINT] – If a printer is connected, [PRINT] is used to print a summary of the stored Test Programs. An example print-out is shown below. The “(Factory)” programs do not print. • [MOVE] – Changes the soft keys back to [CUT], [COPY], [INSERT?], [INSERT?], and [I/O], as shown on the previous page. COMPUTRAC MAX 4000 TEST PROGRAM REPORT COMPANY: AZI Preferred Customer INSTRUMENT #: 400000 —————————————————————————————————————————————————————————————————————————————— # ID TST IDL HST SSZ SWN LFT LINK EC MODE —————————————————————————————————————————————————————————————————————————————— 5 Program 5 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 6 Program 6 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 7 Program 7 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 8 Program 8 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 9 Program 9 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 10 Program 10 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 11 Program 11 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 12 Program 12 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 13 Program 13 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 14 Program 14 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 15 Program 15 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 16 Program 16 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 17 Program 17 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 18 Program 18 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 19 Program 19 160 25 25 8.0 1.0 100 No Rate 0.1000%/min 20 Program 20 160 25 25 8.0 1.0 100 No Rate 0.1000%/min The column headings are abbreviations for the following: # Number of the Test Program ID Name of the Test Program TST Test Temperature IDL Idle Temperature HST High Start Temperature SSZ Sample Size SWN Sample Window LIFT Lift compensation amount LINK Indicates if this Test Program is linked to the next one (MAX® 4000XL) EC MODE Ending Criteria AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 43 of 104 A Test Program may be edited by moving the cursor to the desired program and pressing the [ENT] key. There are 8 categories of test parameters for each Test Program, as shown, each explained in more detail in the following pages. Refer to section 6.4 User Interface Operation on page 18 for instructions on how to edit items. 8.1.1 Sample Name To get here, navigate: [MENU]?TEST PROGRAMS?[ENT] to edit a program?SAMPLE NAME Use any name or number to identify the product under test. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 44 of 104 8.1.2 Temperatures The temperature parameters control the test result, speed, and repeatability. If the moisture of the sample material is known, as determined by a reference method, the MAX® 4000's temperature can be adjusted until test results correlate with the established moisture concentration. If the moisture is not known, prepare a moisture versus temperature curve to decide the proper test temperature for a particular sample. An appropriate curve can be prepared by running multiple tests of the sample material at temperatures increasing in five-degree increments. The starting temperature is usually the standard or reference method temperature for the particular sample. Results for each increasing temperature will usually rise to a plateau where several temperature increases do not change the results significantly. Beyond this plateau, results can rise dramatically. A sample tested at these increased temperatures may show burning or charring. Results along the plateau usually correlate well with the standard or reference method results. Repeated testing should be done at temperatures in this range. Several tests are performed using the same sample size and test parameters. Results from these repeated tests are tabulated to calculate the mean, or average, and the standard deviation (S.D.). Analysis of the mean and standard deviation, and their comparison with reference method results, determines if the proper test temperature has been used. If mean values do not compare well, or if the standard deviation is too large, test at another temperature along the plateau. Higher temperatures generally result in faster test times and less repeatability. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 45 of 104 To get here, navigate: [MENU]?TEST PROGRAMS?[ENT] to edit a program?TEMPERATURES The following options are available: • TEST TEMPERATURE – Set to a value that correlates well to the reference method and gives good test times and repeatability. The maximum test temperature is 225 ºC on the MAX® 4000 and 275 ºC on the MAX® 4000XL. • TEST HISTART TEMP - When active, the HISTART TEMP is used at the start of the test, and the test continues at that temperature for at least one minute. When the rate of moisture loss falls to half of its peak value, the instrument then changes to the TEST TEMP for the remainder of the test. This shortens a long test without affecting the results and may be useful for tests longer than 15 minutes. When used, try a HISTART TEMP that is 25 ºC above the TEST TEMP. To deactivate the HISTART feature, set the HISTART TEMP to 25 ºC. • IDLE TEMPERATURE – This is the temperature that is maintained by the instrument between tests. This speeds testing throughput by decreasing the time required to heat the sample chamber at the beginning of the test and reducing the cool down time between tests. An appropriate idle temperature can save 10 to 120 seconds of test time and several minutes of cool down time if properly used. A common idle temperature value is 50 ºC or 80 ºC for most products. For plastics, a 100 ºC idle is desirable. Any value between 25 °C and 150 ºC can be used. Too high a value causes low results because the sample is evaporating while the starting weight is being measured at the beginning of the test. Experiment to see what value is best for your application. • TEMP RATE - The temperature is controlled to the specified rate while ramping to the setpoint. This can be used to slow the heating of a sample to determine at what temperature the sample releases volatiles. The Temp Rate can be set from 1 to 99 °C per minute and has a range of control from 40 to 275 °C. During the ramp, temperatures are maintained to within 1% of the instantaneous temperature determined by the temp ramp rate. Set TEMP RATE to 0 to disable temperature ramp control. Note: only the MAX® 4000XL has Temp Rate Control. • START TEMPERATURE CONTROL - Prevents a test from starting if the chamber temperature is more than five degrees hotter or colder than the IDLE TEMPERATURE. Once the temperature has stabilized at the IDLE TEMPERATURE, the instrument will allow the test to be started. This feature can improve the standard deviation of results of some temperature-sensitive materials. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 46 of 104 8.1.3 Ending Criteria To get here, navigate: [MENU]?TEST PROGRAMS?[ENT] to edit a program?ENDING CRITERIA The ending criterion is used by the instrument to automatically end a test. This feature makes it unnecessary for the operator to monitor the instrument while it is performing a test. All ending criteria are available on the MAX® 4000XL, but only PREDICTION and RATE are available on the MAX® 4000. The decision of which ending criterion to use is application dependent. Best results are typically given with PREDICTION or RATE, rather than TIME. Experiment with your particular sample to determine which criterion is best for your product. For PREDICTION, the MAX® 4000 predicts what the final result should be by extrapolating the current moisture loss curve. Prediction begins about a minute after peak rate loss. The test ends when the actual moisture loss is within X% of the predicted value, where X is typically 90; this is the “reliability” value listed in the Test Results. Prediction can reduce test times by 1 to 5 minutes. Set X to a higher value if 90 is not producing good results. If the moisture loss curve shape does not fit the Prediction model, then it will produce poor results; Prediction does not work on all samples. For RATE, the MAX® 4000 ends the test after the sample weight loss rate has fallen below a preset value. This is the most common ending criteria and works well with samples that show a consistent moisture rate loss at some point in the process. The parameter may be set for values from 0.0010% to 9.9999% loss rate on the MAX® 4000XL. (0.01% to 9.99% on the MAX® 4000). A good value to use is the (Expected Moisture Result) / 30, but do not use a value outside the range 0.0050% to 0.5%. For example, if the Expected Moisture Result is 3.00%, then use a Rate EC of 0.100%/minute. Note: A test with a RATE ending criteria will always last at least one minute, however, the test will end in 4 minutes if a peak rate of at least 0.0010% is not detected. The MAX® 4000 assumes that the sample contains volatile material that will completely evaporate after some time. It further assumes that the rate of moisture loss (or weight change) will increase to a maximum point and then gradually decrease to zero. Selecting some threshold rate values will cause the test to end before the sample is completely dry. Rate is useful to profile a sample's weight loss. Some testing applications are faster using the rate ending criteria, while others are faster using the prediction ending criteria. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 47 of 104 Some samples contain more than one volatile material, such as nylon resins with large amounts of unpolymerized material (Caprolactam). In these cases, the rate will fall to some fixed value when all the moisture has evaporated but while the monomer is still evaporating. The GRAPH display available from the Main Test screen is of great help in visualizing these cases. The rate ending criteria, if set above the rate of monomer volatilization, may give the best results. For TIME, the MAX® 4000XL ends the test after a preset time (up to 120 minutes) has past. TIME may be useful for conducting sample characterization tests and other development purposes. For TIME or RATE, the MAX® 4000XL ends the test after the sample weight loss rate has fallen below a preset value or after a preset time. The TIME or RATE may be useful to quickly end a test for a sample that is much wetter than expected and the final result is not necessary. Use the “TEMP THEN …” ending criteria (TEMP?PREDICT, TEMP?RATE, and TEMP?TIME OR RATE) to prevent a test from ending before the temperature reaches within 2 degrees of the preset test temperature. Generally, this is not needed. The MAX® 4000 will end a test after 120 minutes regardless of the selected ending criteria. 8.1.4 Sample Size Options To get here, navigate: [MENU]?TEST PROGRAMS?[ENT] to edit a program?SAMPLE SIZE OPTIONS The sample size options are used during sample loading to restrict the sample load to a desirable amount. Sample sizes can be programmed from 0.2g to 39.9g. The sample window must be at least ±0.1g and the total of the sample size plus the sample window must be less than or equal to 40g maximum. Note: Samples as small as 100mg (or as large as 40g) can be tested by using a sample size of 0.2g (or 39.9g) with a sample window of 0.1g. The available options are: • SAMPLE SIZE – Set as discussed above. • SAMPLE WINDOW – Set the allowable sample size tolerance. A smaller tolerance produces more repeatable results, but makes it more difficult to load a sample. Generally, pick a window size = 10% of SAMPLE SIZE and less than 1g. • INSIDE LIMITS AND OUTSIDE LIMITS - Selections of no sound, one beep, two beeps or three beeps may be programmed to have the instrument indicate when the weight of the sample is inside or outside the sample weight tolerance. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 48 of 104 Each particular sample will have its own optimum sample size. Best results will be obtained if the sample consists of a single layer of particles, as long as this is sufficient to develop a weight loss of 10 milligrams or more. A good rule of thumb is "the lower the moisture, the larger the sample." A larger absolute weight change between the initial and final sample weights gives more accurate, repeatable results, but a smaller sample size gives faster tests. Generally, it is best to use a thin layer of sample that just covers the surface of the pan. Very light, or very expensive, test materials may necessitate weighing as little as 150 milligrams. (With a sample size of 0.2g and a sample window of 0.1g, samples as small as 0.1g can be tested.) Note, however, that the standard error will be larger for samples this small, unless the moisture content is sufficient to cause a weight change of at least 10 milligrams for each test. If the first result is too low, increase the sample size or raise the temperature. If it is too high, decrease the sample size or lower the temperature. General recommended sample sizes are as follows: • High volatile materials, such as coatings, typically require a smaller 1 to 3g sample. Larger samples can be used to increase accuracy, but test times will increase. • Materials that are 2% to 98% moisture typically require around a 5g sample. • Low moisture materials (< 2%) require around a 10g sample. • Ultra low moisture materials (< 0.1%), such as plastic resins, typically require larger sample sizes. The instrument is optimized for ultra-low moisture testing with a 30g sample size. Contact your AZI technical sales representative for assistance with appropriate sample sizes. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 49 of 104 8.1.5 Tare Options To get here, navigate: [MENU]?TEST PROGRAMS?[ENT] to edit a program?TARE OPTIONS The following options are available: • PAN TARE records the empty pan weight after ensuring that its weight is sufficiently stable over a programmable period of time. Pan Tare continues until the weight is found stable (= 0.2mg deviation) over the programmable period of time. Temperature fluctuations occur in the test chamber, dependent on a number of different criteria such as previous test temperature, the amount of cool down time between tests, and the current idle temperature. The temperature fluctuations cause the balance readings to drift and are reflected as an error in the result. Because the conditions that cause the temperature fluctuations are not always constant, the error often appears as a higher standard deviation on higher moisture samples. Obtaining an accurate Pan Tare is crucial for low moisture samples. If the lid has been closed prior to starting the test and the balance is near zero (-0.1 to 0.1g), then Pan Tare usually occurs instantly unless something has recently upset the balance readings. The following options are available: o Standard is good for most materials. o Extended may improve results for low moisture materials. AZI Sales/Customer Service 800-528-7411 or 602-470-1414 or support@azic.com Page 50 of 104 • SAMPLE TARE waits a fixed time after lid closure and records the starting sample weight. Obtaining an accurate Sample Tare is crucial for low moisture samples. The following options are available: o High Volatile is used for high volatile materials that evaporate during the Sample Tare. During the Sample Tare, the rate of evaporation is measured, the rate is used to calculate the amount that has evaporated during the tare, and the amount is added back into the starting weight to produce a more accurate Sample Tare. o Standard is used for most samples. o Ultra Low Moisture can be used for samples with < 0.1% moisture. • SPECIAL TARE options are: o Normal Tare is used for most samples. o Syringe Tare is used to obtain an accurate sample tare for materials that rapidly evaporate during the sample loading process. To use this feature, an external balance with 0.0001 gram (0.1 mg) resoluti