NOVA SERIES
MCT466 QuikCheck
RUGGED NIR TESTER FOR USE AT LINE
USER GUIDE MANUAL
Process Sensors Corporation
113 Cedar Street Milford MA 01757 USA
www.processsensors.com
Tel. (508) 473 – 9901
MCT466-QC User Guide Manual
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MCT466-QC User Guide Manual
USA:
Process Sensors Corp
113 Cedar Street, S1
Milford, MA 01757
Tel: (508) 473-9901
Fax: (508) 473-0715
info@processsensors.com
Europe:
Process Sensors Europe
Adelaide House, Unit 4
Corbygate Business Park
Corby, Northants NN17 5JG UK
Tel: (44) 015 36408066
Fax: (44) 015 36407813
infouk@processsensors.com
Eastern Europe:
Process Sensors Polska
Dr Ing. Tomasz Stachowiak
ul. Erazma z Zakroczymia 12 lokal 2
03-185 Warzawa
Tel: (48) 226739526
Fax: (48)226739527
Tomasz@processsensors.com
Edition
Date
Description
Firmware
Version
Writer’s
Initials
1.0
04/25/2014
MCT466-QC At Line NIR Tester User Guide
Manual’s First Edition
V3.03
M.J.
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MCT466-QC User Guide Manual
Warranty, Exclusions and Limitations
The workmanship and the materials of all products manufactured by
Process Sensors Corporation are warranted for a period of two years
from the date of shipment. This warranty covers parts and labor
required to correct defects within the scope of the Corporation’s
warranty.
Excluded from the warranty coverage are products a) which have
been subjected to electrical, mechanical or other misuse or abuse b)
which have been disassembled or repaired, or attempted to be, by
other than PSC or its authorized servicing agents.
The foregoing warranty shall be in lieu of all other warranties,
expressed or implied, and the Corporation expressly disclaims any
warranty for merchant ability or fitness for a particular purpose.
Unless otherwise agreed in writing by the Corporation, repairs and
replacement parts provided by the Corporation under its warranty
shall be guaranteed only for the non-expired portion of the original
warranty on the repaired product.
The liability of PSC to any purchaser or user of its products shall not
in any case exceed the cost of correcting defects in a product as herein
provided and, upon expiration of the two years from the date of sale,
all such liability shall terminate. In no event shall the Corporation be
liable for interruption of operations, loss of profit, or special or
consequential damages.
Software Updates
Future revisions of the software that correct errors will be made
available to customers at no charge. Improvements and enhancements
to the software will be available for a nominal fee.
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MCT466-QC User Guide Manual
Table of Contents
Chapter 1. Introduction
1.1. Using this manual
1.2. About the NIR tester
1.3. Unpacking
Chapter 2. Principal of Operations
Chapter 3. MCT466-QC NIR tester Description
3.1. MCT466-QC NIR tester Components
3.1.1. Light Source
3.1.2. Filter Wheel
3.1.3. Filter Wheel Motor
3.1.4. Detector
3.1.5. NIR tester Electronics
3.1.6. Smart User Interface
3.2. Smart User Interface (SUI)
3.2.1. Initiating a Test
3.2.2. Changing Product Codes
3.2.3. User Screen
3.2.4. Menu Protection Password
3.2.5. Menu Selections
3.2.6. Calibration Parameters
3.2.7. Calibration Routine
3.2.8. Diagnostics
3.2.9. Miscellaneous
3.3. Engineering Menu
3.4. Digital Outputs
Chapter 4. NIR tester Installation
4.1. Sitting the Tester
4.2. Temperature
4.3. AC Power Connection
4.4. Communication
Chapter 5. Accessories
5.1. Calibration Check Standard
5.2. Angle Support Bracket
5.3. Sample Bowl
Chapter 6. Guide To Calibration
Chapter 7. Technical Specifications
APPENDECIES
Appendix I Special Features
Appendix II Dry Basis
Appendix III Default Parameters
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Chapter 1. Introduction
1.1. Using this Manual
This manual is designed to assist you in setting up, operating, and maintaining Process Sensors
Corporation’s MCT466-QC NIR tester. The manual is broken into chapters as follow:
1) Principal of Operation
This section covers the Near Infrared (NIR) technology used in the MCT466-QC NIR tester to
make the different measurements.
2) NIR tester Description
This section talks about the different components of the MCT466-QC NIR tester and
summarizes its features. Also covered in this section are the different MCT466-QC NIR tester
features and the Smart User Interface (SUI).
3) NIR tester Installation
This section covers the MCT466-QC NIR tester’s installation
4) Power Connections
This section explains the correct wiring for the MCT466-QC NIR tester.
5) NIR tester Calibration
This section explains how product samples are conditioned and then used to calibrate the
MCT466-QC NIR tester.
6) Accessories
This section lists the different accessories which could be used along with the MCT466-QC NIR
tester.
7) Technical Specifications
This section lists the technical specifications of the MCT466-QC NIR tester.
1.2 About the NIR tester
The MCT466-QC NIR tester is a reliable multi-constituent device enclosed in a rugged polycarbonate
enclosure for at line or in a lab environment. The MCT466-QC NIR tester is made up of 5 basic
components: a quartz halogen lamp, a filter wheel motor, filter wheel assembly, a Lead Sulfide detector
and a single “smart” circuit board. The MCT466-QC NIR tester is fully modular – each of these
components can be replaced in the field within minutes.
1.3 Unpacking
Remove the packing slip and check the actual equipment received. If you have any questions about your
shipment, please call your Process Sensors Corporation’s Representative. Upon receipt of shipment,
inspect the shipping box for any signs of damage in transit. Especially take note of any evidence of
rough handling. Report any apparent damage immediately to the shipping agent.
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Chapter 2. Principle of Operation
Molecular bonds such as O-H in water and C-H in the case of oils and organic coatings absorb NIR light
at discrete wavelengths in proportion to their concentration. Absorption is quantified by comparison of
the signal at the measurement wavelength with that obtained at one or more reference wavelengths
where there are no unique absorptions. Measurement is achieved by focusing light through NIR
measurement and reference filters within a rotating wheel. An internal and external voltage signal is
generated for each filter, the latter results from collection of back-scattered light onto a concave mirror
and reflection onto the detector. The ratioed external/internal filter signals provide a voltage that is due
to product, not NIR tester effects. Filter signals are combined within an algorithm to generate a
proportional output which when calibrated provides a direct reading.
Typical Constituents Include:
O-H for Moisture & Alcohol
C-H for Oils, Fats, Adhesives & Plastics
N-H for Proteins, Ammonia & Amines
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Figure 1: Inside of an MCT466-QC NIR tester
MCT466-QC User Guide Manual
Chapter 3. MCT466-QC NIR Tester Description
3.1. NIR tester Components
The MCT466-QC NIR tester is a reliable and sturdy at-line NIR device for use in harsh environments.
The MCT466-QC NIR tester is routinely used to measure moisture in samples taken from the production
line. However, other measurements can be made including oils, protein, film thickness, coating weights,
nicotine and sugars. The following are the main components of the MCT466-QC NIR tester:
3.1.1. Light Source
A quartz-halogen light bulb running at reduced voltage generates infrared energy.
3.1.2. Filter Wheel
Six infrared and visible filters are held in a circular disc. A single timing notch is machined in
the edge of the disc.
3.1.3. Filter Wheel Motor
A precision brushless DC motor is used to accurately rotate the filter wheel in front of the
infrared light beam.
3.1.4. Detector
A PbS (Lead Sulfide) detector is used to convert the infrared light energy into electrical pulses.
3.1.5. NIR tester Electronics
The MCT466-QC NIR tester contains the following electronic components:
Power Supply: A 90-260-volt auto selection supply provides DC power to operate the
NIR tester.
Main Board: Single PCB “smart” circuit board containing central processing system,
analog and serial communications.
3.1.6. Smart User Interface
High resolution 5.7” touch screen color display providing all set up, calibration and diagnostic
data from the tester. (Go to section 3.2 for details on the SUI)
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3.2. Smart User Interface
The Smart User Interface is used to configure, calibrate and diagnose the MCT466-QC NIR tester.
The SUI is made up of 2 major components: a 5.7” high resolution touch screen and a single “smart”
circuit board. The SUI is located at the front of the tester on the base of the tester.
Below are some screen shots showing the different pages of the Smart User Interface with one or more
constituents:
Figure 2: Home Screen – Single Constituent
Figure 3: Home Screen – Two Constituents
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3.2.1 Initiating a Test
A sample test can be initiated by simply placing the bowl in place on the rotating turn table or by
touching the hand symbol located in the top right corner of the SUI. When test is initiated, the
MCT466-QC NIR tester will go through the following testing stages:
Stage 1: Initializing
In this stage, the turn table will not turn and the tester prepares to start sampling and
measuring the moisture level. Initialization time could be changed by going to the grab delay
feature in the engineering menu.
Figure 4: Home Screen – Three Constituents
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Figure 5: Tester’s SUI during initializing stage
MCT466-QC User Guide Manual
Stage 2: Sampling
In this stage, the bowl will start turning and the tester starts sampling to measure the moisture
level in the sample. Sampling time could be changed by changing the sample time.
Figure 6: Tester’s SUI during sampling stage
Stage 3: Sample Complete
In this stage, sample testing is completed and the moisture value is displayed on the SUI as
shown in Figure 7 below.
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Figure 7: Tester’s SUI when Sample Complete
MCT466-QC User Guide Manual
3.2.2 Changing Product Calibration
Selection of the Product Calibration is made by touching the Current product calibration (Product Cal
(1)). A product calibration selection window will pop up. Select the new product by touching the
desired product calibration followed by the SAVE key.
Figure 10 below shows the select Cal & Constituent page in which the NIR tester’s existing
product calibrations will be listed.
Figure 10: Product Selection Menu
3.2.3 User Screen
Touching the Home symbol on the top right corner of the main screen will allow you to access an
unprotected User Screen as shown in Figure 11 below. In this screen, the user may offset the NIR tester’s
zero setting, change the damp time and change the grab sample time.
In order to offset the MCT466-QC NIR tester, touch the “Adjust” number and use the pop up keypad to enter
the true moisture of a sample and on pressing the Enter key the NIR tester display will be adjusted to match
the value entered.
In order to change the grab sample time, touch the “Grab Time” number and use the pop up keypad to enter
the grab sample test time.
In order to change the damp time, touch the “Damp” number and use the pop up keypad to enter the new
damp value. The Damp Time is a global setting that applies to all Product Calibrations.
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Figure 11: User Menu Front Page
3.2.4 Menu Protection Password
To access the NIR tester setup menu, touch the blue pad next to ENTER SETUP on the LCD.
The Password request screen will pop up.
Enter the correct password and touch the ENTER key. This will allow access to the SETUP
Menu. The default password is 0000.
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Figure 12: Password Entry Page
MCT466-QC User Guide Manual
3.2.5 Menu Selections
After entering the correct Password the Select Menu will be presented. The select menu consists of two
pages. Page 1 of the user menu is shown in Figure 13 below and page 2 of the user menu is shown in Figure
14 below.
Figure 13: User Menu Page 1
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Figure 14: User Menu Page 2
MCT466-QC User Guide Manual
3.2.6 Calibration Parameters
By touching the calibration parameters button, shown in Figure 13 above, you will access the
Select Cal page (shown in Figure 15 below). The display will present the product calibrations saved
in the NIR tester.
You can simply select the product calibration by touching it. Touch the right arrow on the top
right corner to see the calibration parameters for the product being used as shown in Figure 16
below. Adding a new product is made by touching the NEW blue button.
Figure 15: Calibration Parameters Page 1
Figure 16: Calibration Parameters Page 2
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MCT Calibration Graph
10 *
*
8 *
*
Each Product Calibration has its individual span and zero settings.
To make a change to the values, touch the number, a numeric keypad will pop up. Type the new
number and touch the ENT key.
3.2.7 Calibration Routine
The Calibration Routine is a linear regression routine that adjusts the NIR tester’s calibration
parameters (span and zero) so that the NIR tester’s readings match the actual lab moisture readings.
This is done by using a series of representative product sample with moisture contents covering the
moisture range to be measured.
The objective of NIR tester calibration is to obtain a straight-line graphical relationship between the
tester’s reading and the true moisture value of a series of samples as shown in Figure 17 below.
Calibration Routine Process:
1- Select one of the unused Product Calibrations in the NIR tester.
2- Make or collect from the process a series of sample (up to 25) with moisture contents covering the
range expected in the process.
3- Set the Span value to 25.0, the zero to -20 and the damp time to a value of 1.0.
4- Present the lowest moisture sample to the tester; adjust the zero setting to make the tester’s reading
agree with the true moisture content of the sample. Note the reading.
5- Present all of the samples to the tester in turn, and make sure to note the tester and actual lab
readings for each sample.
6- Tabulate the results as shown in Table 1 below:
Figure 17: Calibration Graph
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Tester
Lab
3.7
3.7
4.5
5.2
7.6
8.3
9.5
10.3
8.2
8.9
Table 1: MCT vs Lab Readings
7- Select the Calibration Routine button in the main menu page (shown in Figure 13). This will take
you to the calibration page as shown in Figure 18 below.
Figure 18: Calibration Routine Page
8- Touch the Lab Value, displayed in blue on the LCD, and enter the true moisture value for the first
sample.
9- Touch the MCT Value, displayed in blue on the LCD, and enter the NIR tester reading for the first
sample.
10- Repeat this procedure for all the samples.
11- When all sample pairs have been entered, touch the CALCULATE button. A window will pop up
with the regression statistics and the values of the zero and span setting that will correctly calibrate
the NIR tester. Touch SAVE to save the new calibration settings to the desired Product Calibration.
Please note that the up and down arrows are the page up and page down arrows. They are used to
scroll the page up and / or down.
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Linear Regression Statistics
The NIR tester’s calibration program calculates several statistics during its calibration routine; these
statistics give a measure of the accuracy and quality of the calibration.
Correlation Coefficient: This is an expression of how well the tester readings match the true moisture
values.
1 is perfect
Greater than 0.9 is acceptable
Less than 0.9 is not acceptable
Standard Error: This is an indication of the accuracy of the calibration. A perfect value is 0.0.
Acceptable values are in the 0.0 to 0.5 range depending on the moisture ranges being measured.
3.2.8 Diagnostics
All NIR tester diagnostic values may be viewed in this menu choice. To go to the diagnostics menu,
touch the DIAGNOSTICS blue button in the user menu shown in Figure 13 above. There are four
pages of Diagnostic parameters group, the first page is called Front end and is shown in Figure 19
below:
In the front end diagnostics page, the following are listed:
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Figure 19: Diagnostics Menu – Page 1
MCT466-QC User Guide Manual
Sensor STATUS: This presents the operational status of the NIR tester. The tester’s microprocessor
continually monitors up to 12 tester parameters. If all are correct the status will indicate OK. If any one
of the parameters is out of range then a warning message will be presented. A detailed SENSOR
STATUS diagnostics list is displayed on page 2 of the diagnostics.
Wheel Speed: This is the rotational speed of the filter wheel.
Internal Temperature: This is the internal temperature of the MCT466-QC NIR tester.
Filter Gain: This is the optical circuitry gain value.
Cooler Temperature: This is the actual detector’s temperature.
Page 2 of the diagnostics menu displays the status of a list of the MCT466-QC NIR tester components as
shown in Figure 20 below. The component tab is displayed in green when its status is ok and in red when
something is wrong.
Page 3 of the diagnostics menu displays the main voltages values off of the main board of the MCT466-QC
NIR tester as shown in Figure 21 below. Value is displayed in green when status is ok and in red when
status is not ok.
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Figure 20: Diagnostics Menu – Page 2
MCT466-QC User Guide Manual
Figure 21: Diagnostics Menu – Page 3
Page 4 of the diagnostics menu displays the filter values, as shown in Figure 22 below, which are used
to help balance the MCT466-QC NIR tester.
This presents the detector signal levels for the six filters that may be fitted to the filter wheel in the
MCT466-QC NIR tester. Values are given for both external and internal filters. A bar graph
comparison for each filters INT and EXT values may be presented by touching the F# of the filter.
The preamplifier gain value is also presented. This value is an indication of the amplification required
to bring the detector signals into the range required by the processing electronics.
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Figure 22: Diagnostics Menu – Page 4
Parameter
Nomin
al
Value
Min.
Value
Max.
Value
Warning Message
Internal Filters
3.0-8.0
0.5
10.0
Above 9.9 “High Signals”
External Filters.
3.0-8.0
0.5
9.9
Above 9.9 “High signals”
+ 5 V
5.00
4.8
5.2
Outside Min/Max “VCC
Fault”
+ 15 V
15.00
14.0
16.0
Outside Min/Max “VP
Fault”
- 15 V
15.00
14.0
16.0
Outside Min/Max “VN
Fault”
Motor Speed
1500
950
3500
Outside Min/Max
“High/Low Motor”
Filter Wheel
Slot
No slot switch input for > 400 ms
“Motor Stopped”
Gain
X5-X10
1
100
Above X64 “Low Signals”
Cooler Drive
15%
0.1%
100%
Above 75% “Cooler Fault”
Pre-Gain
1 0 2
None
Cooler Temp
20
0.2
65
0.0 “Detector Fault
Internal Temp
35
0.0
100
Above 65 “High Board
Temperature”
Ranges of Diagnostic Parameters:
The following table gives the range of values for each of the diagnostic parameters:
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Table 2: Diagnostics Parameters Ranges
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3.2.9 Miscellaneous
The miscellaneous menu, shown in Figure 23 below, provides access to change the password of the user
menu and the readings decimal places. It also lists the MCT466-QC NIR tester’s information such as the
sensor version, board type and the interface version.
3.3. Engineering Menu
The MCT466-QC NIR tester contains a ‘hidden’ engineering menu that presents several other
customization functions of the NIR tester.
Please note that this menu should only be accessed by people experienced in the setup of the
MCT466-QC NIR tester for specific applications. Also, the engineering work is always done in the
factory prior to shipping and is all based on the customer’s specifications / application.
Access to the Engineering Menu is gained by using a special password.
At the password request enter the number 2882 and press ENTER. This will allow access to the
engineering menu, shown in Figure 24 below, in which multiple different engineering pages could be
accessed. Touch the blue boxes to access each of the different engineering settings.
Figure 23: Miscellaneous Page
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The engineering functions are separated into six different sub menus and they are as follows:
1- AGC Engineering Page:
This submenu helps the user control the MCT466-QC signal’s gain for better performance. The Gain is
also presented in the diagnostics menu to help balancing the MCT466-QC NIR tester. The pregain is a
user selectable gain factor that is used to adjust the size of the reflected filter signals.
Figure 24: Engineering Menu
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Figure 25: Engineering Menu – AGC Page
MCT466-QC User Guide Manual
Signal Gain System
The MCT has a software adjustable preamp gain factor. This factor is the gain applied to the filter
signals coming from the detector.
The amplification applied is split into two components:
Pre-Gain: This is a manually settable course gain factor that selects a pre-amp gain resistor to amplify
the detector signals.
Gain: This is a fine, software controlled, gain that amplifies the detector signal to achieve a value of
4.5v on the largest filter value.
Pre-Gain and Gain adjustments:
The Pre-Gain feature allows the pre-amplifier gain to be adjusted to allow the MCT to operate on a wide
range of differing colored products.
Very dark products do not reflect well and will need a higher pre-gain setting. Very white or light
products reflect light well and will need a lower pre-gain setting.
The Pre-Gain has four manually adjustable settings:
Pre-Gain Gain Factor
0 x1
1 x10 (Default)
2 x15
3 x20
4
The Gain setting is a fine gain that is controlled by the microprocessor. It is automatically adjusted to set
the filter values at a level of 7.0volts. If the gain value on the product goes above x10 then the Pre-Gain
value needs to be increased.
2- TEC Engineering Page:
This page (Figure 26) allows for the setup and adjustment of the thermo cooled detector fitted to the
NIR tester.
The TEC Engineering page also displays the following parameters:
Detector cooler drive
NIR tester’s internal temperature
Detector temperature
Detector temperature set point. This is adjustable between 10 degrees C and 30 degrees C.
Cooling the detector will increase its sensitivity to NIR light.
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3- Constituents’ Engineering page:
Below in Figure 27 is a screen shot of the Constituents settings page. This engineering page allows the
end user to enable and / or disable constituents, change the reading type to Dry basis and other features
shown in the screen shot below.
Figure 26: Engineering Menu – TEC Page
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Figure 27: Engineering Menu – Constituents’ page
MCT466-QC User Guide Manual
FunctAtro (Dry): This sets the MCT466-QC NIR tester to readout in moisture computed on a dry
weight basis.
Algorithm (Log): This sets the MCT466-QC NIR tester to readout using a logarithmic calculation.
Lin Mode: This changes the linear regression calibration to a “look up” table calibration.
4- Constants Engineering Page:
The constants page shown in Figure 28 below displays the current algorithm of the MCT466-QC NIR
tester. This page is used to change the NIR tester’s algorithm for all constituents measured.
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Figure 28: Engineering Menu – Constants Page
5- Clocks and Resets Engineering Page:
Clocks and resets generator screen shot is shown below in Figure 30.
MCT466-QC User Guide Manual
Watch Dog: This is a log of how many times the CPU resets itself.
Clock Monitor: This is a log of how many times the CPU’s timing clock goes out of tolerance.
3.4. Digital Outputs
The MCT466-QC provides a choice of serial output formats, RS232, RS485 and USB. RS232
is suitable for a single NIR tester to computer connection over a distance of up to 100 feet (30
meters). USB is optional and used for direct connection to a laptop PC.
Serial Requirements:
RS232/485:
Baud Rate: 9600 to 38400 (9600 default)
Parity: None
Data Bits: 8
Stop Bits: 1
Cables:
RS 232: 9 pin ‘D’ serial cable wired pin to pin
RS 485: Shielded twisted pair.
Figure 30: Engineering Menu – Clocks & Resets Page
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Chapter 4. NIR tester Installation
The MCT466-QC NIR Tester is a plug and play device which will be ready for use after being calibrated for
the different products / measured constituents. The built in Smart User Interface makes the end user’s job
easier than ever.
4.1. Sitting the Tester
The MCT466-QC NIR Tester is suitable for mounting on a countertop in a laboratory or on a
tabletop at-line in the production environment as shown in Figure 31 below.
Figure 31: MCT466 QuikCheck being used in a laboratory environment
4.2. Temperature
The MCT466-QC NIR Tester is designed to give satisfactory measurements within a temperature
range of 32 to 120 degrees F (0 to 50 degrees C).
4.3. AC Power Connections
The MCT466-QC NIR tester is powered using the 6-foot (2 meters) power cord connected to the
rear of the tester. The input is auto ranging and accepts 90-260VAC volts, 15 amps.
4.4. Communication
The MCT466-QC NIR Tester will communicate with the PC software installed on a remote PC
by using the RS232 port or the USB located on the back of the tester.
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Chapter 5. Accessories
5.1. Calibration Check Standard
The Process Sensors Calibration Check Standard provides users of the MCT466-QC Series NIR
Transmitters with a quick way of verifying that the tester’s calibration has not altered over time.
The standard simulates moisture levels as follows:
Low Moisture
High Moisture
Connection of the Standard to the MCT Tester
Locate the standard on the light shroud. Make sure that the key on the Standard mates with the slot on
the light tube and then tighten the hand screw to ‘lock’ the standard in place.
How to Use the Calibration Check Standards
The Check Standards should be used on a periodic basis, daily, weekly or monthly, to check that the
tester is remaining stable and thus giving the correct moisture values.
The standards may be used in two ways:
a) As a quick low/high check of the tester’s reading. In this manner it allows users to gain
confidence in the stability of the tester and in the accuracy of the initial calibration.
b) As a way of transferring the calibration from one tester to another. In this manner a newly
purchased or repaired tester can be quickly put into operation without the need for actual samples of
product.
Quick Calibration Check
Using the standards to check the stability of the MCT466-QC requires that it be correctly calibrated
using samples of the product(s) on which it is measuring. As soon as the tester is satisfactorily
calibrated, the reading of the low and high sides of the standard should to be noted.
1. Clip the standard onto the light tube.
2. Rotate the standard selector knob to the LOW position and tighten the locking nut.
3. With the MCT set on the same CAL Channel as used to measure the product, make a note of the
MCT reading
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4. Rotate the standard selector knob to the HIGH position and lock into place. Note the MCT466-
QC reading.
At any time in the future, inserting the check standard, and selecting the respective reflectors, will give
the same values as previously noted above. If the MCT does not give the same readings to +/- 0.2, then
the calibration of the MCT466-QC may be in error.
Using the Check Standards with multiple calibration channels
When the MCT466-QC is operating with multiple calibration codes, it is important to only use the check
standard on the same Cal Channel. The differences in the calibration coefficients for the various
products (zero & span) will give different readings for the check standards.
Users may wish to use a vacant Cal Channel as a designated ‘CAL CHECK CHANNEL’. Doing this
will allow two convenient values to be setup for the low and high standards.
To use this method, decide on a low reading for the low standard, say 2.0 and a high value for the high
standard, say 8.0.
Now use the calibration development routine to calculate the zero & span values that make the
MCT466-QC NIR tester read the 2.0 and 8.0 values. As the Cal Development routine requires 3 data
pairs, one set of values needs to be entered twice.
Finally store this zero & span value in the CAL CHECK CHANNEL, say # 9.
When using the standards, make sure that this CAL CHECK CHANNEL is selected prior to inserting
the standards.
Calibration Transfer
Once the values given by the two standards are known for a specific product calibration, they can be
used as ‘stable samples’ for calibrating other testers.
The known values for the standards should be used as the LAB values in the Cal Development routine.
1. For a new or repaired tester set the span to 25.0.
2. Select the Low standard and note the MCT466-QC reading.
3. Select the High standard and note the MCT466-QC reading.
4. Select the CAL DEVELOPMENT routine.
5. Enter the data pairs of MCT reading and known standard values. Enter the High standard twice
to get the 3 data pairs.
6. Compute the zero and span values that will make the tester read the values of the standards.
7. Save these settings in the desired Cal Channel.
5.2. Angle Support Bracket
The angle support bracket, shown in Figure 32 below, is used to support a reflective sample, typically
glass, film, paper etc… at an angle to the tester to eliminate specular (surface) reflections from entering
the tester’s sensing head.
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The angle bracket support is a pressed steel angled holder with circular “cut-out” and passive reflector
on the bottom surface.
5.3. Sample Bowl
There are different sizes sample bowls due to the diverse physical structure and shape of the different
products. Figure 32 below shows the MCT466-QC NIR tester with a larger size bowl.
Figure 31: MCT466 QuikCheck with Angle Bracket Support
Figure 32: MCT466 QuikCheck with a larger size sample bowl
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Chapter 6. Guide To Calibration
calibration
If it is possible to collect samples over the full moisture range from the production line, and retain the
moisture level by placing them in airtight containers over a 24 hour period this will provide the best
calibration and is preferable. It will ensure that all parameters vary, not only the moisture or constituent
of interest, making the calibration more robust over time.
If not possible, collect a bulk sample from the production line when the moisture level is low.
Condition samples to higher moisture levels over the moisture range ( minimum moisture range of
1.0%) by adding a fine mist of water through a spray bottle.
Conditioning samples
Condition a minimum of two or three samples (each approximately 50 cm3 ) to install an approximate
calibration, seven or more for a full calibration. Two samples are at the lower and two samples are at
the upper limits of the moisture range are required in order to establish the tester’s sensitivity (span) and
set the bias (zero). The fifth sample is used as a mid-point to check the linearity over the calibration
range, or as an additional high or low sample to provide confidence in the span.
Obtain a bulk sample from the line, allow time for the sample to cool. Use a thermal balance on a 10g
sub-sample to establish the approximate moisture level. Calculate the grammage of moisture that needs
to be added to achieve the required moisture levels. Place the conditioned samples in an airtight bags/
small containers ensuring there is minimum head space. Allow the contents of all bags to equilibrate
over a minimum of 24 hours.
Gauging samples
NIR tester each of the samples using the default calibration (Span = 25, Zero= -20). If the sample is
non- homogeneous or varies in particle size, NIR tester the sample at least twice, returning it to its
container between measurements. Record the MCT/ average MCT values. If there is little or no
difference in the reading between the highest and lowest moisture sample, double the default span and
re-run the samples. Perform reference tests on each sample immediately following gauging. Oven
testing is preferable to the thermal balance as all samples undergo the same test conditions.
Once all the reference values are recorded, the data pairs (NIR tester and corresponding reference value)
can be entered either into the Cal Routine sub menu on the Smart User Interface or within the PC
software. A graph can be accessed showing the existing values and calibrated values. Examine the
graph and manually remove any data points that appear to be outliers (outliers have a residual value >
twice the standard deviation of all the residuals). Click “Calculate” to access the calibration statistics
and new Span and Zero. You can save this new calibration file.
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Chapter 7. NIR Tester Specifications
MCT466-QC NIR Tester Specifications:
Measured NIR Constituents: 1, 2 or 3 simultaneously
Moisture Range: Min. 0.1%, Max. 95%
Coatings Range: Min. 0.1gr./m, Max. 200 gr./m
Fats & Oils: Min. 0.1%, Max. 50%
Repeatability: +/- 0.2%
Calibration Codes: 200.
Power: 90-260VAC, 50/60 Hz, 40 watts
Construction: Hygienic Polycarboante
Ambient Temperature: 0-50 °C (32-120˚F)
Accuracy:
Moisture: +/- 0.1%
Coatings: +/- 0.1 gr./m
Fats/Oils: +/- 0.2%
Repeatability: +/- 0.2%
Smart User Interface Specifications:
Display: 5.7 inch Color Touchscreen LCD
Languages: User Selectable
PC Software:
Software: Windows-based program or OPC-DDE Server
Maintenance:
Warranty: 24 months Parts / labor
Routine Cleaning: During Scheduled Plant Maintenance
Calibration Confirmation: Calibration Check Standard
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Backdoor Password
If the password for the MCT466-QC has been forgotten or is unknown then a special ‘backdoor’
password will allow the user/engineer to view and change the old password.
To use this ‘backdoor’ system proceed as follows:
At the Password request enter the number 6811, and then press ENTER.
This will allow access to the SETUP SELECT Menu; then select the MISCELLANEOUS menu.
View or change the current PASSWORD.
Language Shortcut
To return the MCT screens to English from any other selected language enter 9999 at the password
request. This will instantly set the language used on all screens to English.
Appendix I
Special Features
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Appendix II
Dry Basis
It is common for some industries, particularly the wood panel industry to calculate the moisture in the
wood particles as a percentage of the dry material rather than a percentage of the wet material.
Wet % = Wet Weight – Dry Weight
Wet Weight
Dry % = Wet Weight – Dry Weight
Dry Weight
Conversion from Wet % to Dry % is as follows:
% Dry = % Wet x 100
(100-% Wet)
Conversion from % Dry to % wet is as follows:
% Wet = % Dry x 100
(100 + % Dry
The MCT466-QC may be configured to present moisture on a dry basis by selecting DRY: Y in the
Engineering Menu.
This selection does the following to the tester parameters:
1. The displayed moisture readings are presented in the Dry Basis.
2. An asterisk appears in front of the ‘Moisture’ word in the display to alert users
that the tester is in the DRY mode.
3. The Calibration routine is modified to allow dry basis values to be used.
Offset Adjustments
When operating in the Dry Basis Mode, a change to the Zero parameter of the calibration will not make
the same adjustment to the moisture reading. This is because the moisture reading is being modified by
the wet to dry conversion factor.
To allow users to make a simple trim adjustment to the tester’s reading and additional calibration
parameter is presented in the Cal parameters when in the Dry Basis Mode.
This is: OFFSET.
The default setting for it is 0.00.
To make a reduction in the displayed moisture reading of 0.5, make the OFFSET be –0.5.
To make an increase to the moisture reading of 0.8, make the OFFSET be + 0.8
When initially calibrating a tester ALWAYS set the OFFSET to 0.00
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User Parameters – No Password needed
Sample Value 0.0
Avg Time 10.0 secs
Trend Time 60 min
Calibration and Set Up Parameters – Password needed
Parameter Moisture Constit 1 Constit 2
Zero -20.0 -40.0 -20.0
Span 25.0 50.0 25.0
Damping 1 1 1
Cooler Target 20C
Pre Gain X1
Password 0000
Inst ID 9
Digits 1
Prod Code Lock OFF
Solids OFF
Heater Control
Target 25
Prop 10
Int 0.6
Deadband 0.2
Engineering Parameters – Special Password needed
General
Damp Mode Yes
Bench OFF
Max Cal 50
Pre Gain 1
Dead Band 0.1
Cooler ON
Appendix III
MCT466-QC NIR tester Default Parameters
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Constituents
Moisture ON
Atro OFF
Log OFF
Constituent 2 OFF
Log OFF
Constituent 3 OFF
Log OFF
Temperature OFF
Constants
Moisture Constituent 2 Constituent 3
K1 = 1.0 K6 = 1.0 K4 = 1.0
C2 = 0.3 C5 = 1.0 C2 = 1.0
C3 = 0.7
All others 0.0 All others 0.0 All others 0.0
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