Fluke DATAPAQ Tracker XL2 User Manual
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Fluke DATAPAQ Tracker XL2 User Manual

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Oven
Tracker
®
XL2
USER MANUAL
Issue 1
MA5150A

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  • Page 1 Oven Tracker ® USER MANUAL Issue 1 MA5150A...
  • Page 3 Oven Tracker ® User Manual for use with Issue 1 Datapaq is the world’s leading manufacturer of process temperature-monitoring instrumentation. The company maintains this leadership by continual development of its advanced, easy-to-use Tracker systems. Europe & Asia North & South America Datapaq Ltd.

  • Page 4: Safety Warnings

    SAFETY WARNINGS For safe use of Datapaq equipment, always: • Take care to follow its supplied instructions. • Observe any warning signs shown on the equipment itself. Indicates potential hazard. On Datapaq equipment this normally warns of high temperature, but where you see the symbol you should consult the manual for further explanation.
  • Page 5 European Union Directives The following product types XL2 Thermocouple Data Logger manufactured by Datapaq Ltd. Lothbury House, Cambridge CB5 8PB, UK comply with the requirements of European Union directives as follows. Directive 2004/108/EC Electromagnetic Compatibility (EMC) Standards Applied EN61326-1: 2006 – Group 1, Class B equipment (emissions section only), and Industrial Location Immunity (immunity section only).
  • Page 6 C ONT E NT S Introduction 11 System Components 13 Insight Setup 13 Installing/Removing Insight 14 Communications Setup 17 XL2 Logger Specifications and Operation 19 Specifications 20 Logger LEDs 22 Dual Interface Block 23 Memory Capacity 23 Battery 26 Over-temperature Protection 26 Hardware Reset 27 Testing and Calibration 28 Disposal of Loggers...
  • Page 7 45 Running a Temperature Profile 45 Overview 46 Resetting the Data Logger 50 Using SmartPaq 53 Installing the Logger in the Thermal Barrier, and Starting the Logger 55 Placing the System in the Oven 55 Removing the System from the Oven 57 Downloading Data 60 Preparing the Data for Analysis 61 Logger Defaults and Details...
  • Page 9 Introduction Datapaq Oven Tracker – incorporating Insight software, and designed ® ™ specifically for use in the general coating and finishing industry – is a complete system for monitoring the temperature profiles of products within your oven; accurate data acquisition and powerful analysis techniques are combined with flexibility and ease of use.
  • Page 10 Using Hardwired Telemetry (p. 63) – Monitoring conditions inside a batch oven and watching a temperature profile develop in real time. Troubleshooting (p. 67) – Lists software error messages and describes how to test the data logger and probes. For a rapid overview of the features of the XL2 logger and its step-by-step use with the Oven Tracker system, see the Oven Tracker XL2 Quick Reference Guide.

  • Page 11: System Components

    For use of the StenterPaq and CoilPaq systems, and for use of the XL logger (including radio-telemetry), see the Oven Tracker User Manual (part no. MA5000A). System Components A typical Oven Tracker XL2 system comprises: • XL2 data logger (comprising MemoryPaq and Transducer Interface units), with communications lead and charger (p.
  • Page 12 Introduction OVEN TRACKER XL2...

  • Page 13: Installation

    Insight Setup Before the logger is used for the first time, you must: 1. Install Insight software. 2. Establish communication between the logger and the computer/software. Installing/Removing Insight Datapaq Insight used with the XL2 logger requires the following minimum computer specification. •...

  • Page 14: Using The Software

    ‘Communications Setup’ (below). Once this has been done, an operator will be able to use Insight with the logger connected to the PC without being in Administrator mode. Upgrading It is not necessary to remove an existing version of the software before installing a new one.
  • Page 15 Typical sources of problems with establishing communication • Communications lead not fully inserted – Check correct sockets are being used. • Damaged communications lead or connectors – Check for breaks and other damage. Replace the lead. • Battery not charged – Recharge the battery (p. 23), ensuring the charging LED is illuminated.
  • Page 16 If the logger is detected, its type and the port to which it is connected are displayed. SHORTCUT Pressing F4 on the keyboard opens the Communications Setup dialog, tests for communication with a logger, and displays the logger type and other data (equivalent to clicking Test in the dialog).
  • Page 17 XL2 Logger Specifications and Operation The basic XL2 data logger consists of two units: • Transducer Interface – Digitizes data received from the thermocouple probes. • MemoryPaq – Travels through the oven with the Transducer Interface, controls it, and stores the digitized data. An optional Dual Interface Block allows two Transducer Interfaces to be connected to the MemoryPaq to increase the number of thermocouple probes used.
  • Page 18 The logger’s key features are: • Transducer Interface available with either six or eight thermocouple channels. For maximum data collection on each run, any two interfaces may be attached via a Dual Interface Block. The logger can thus easily be configured for a maximum of six, eight, 12, 14 or 16 thermocouple channels.

  • Page 19: Specifications

    Specifications MemoryPaq + MemoryPaq + Dual Interface Block + 2 × Transducer Interface 1 × Transducer Interface 6 or 8 channels 12, 14 or 16 channels Length 170 mm/6.7 in. 207 mm/8.1 in. Width 75 mm/3.0 in. 75 mm/3.0 in. Height 24 mm/0.9 in. 50 mm/2.0 in.
  • Page 20 Due to continuing product development, specifications are subject to change without notice. Logger LEDs To conserve battery charge, the logger will power-off temporarily (e.g. LEDs will stop operating) if it has been inactive for 5 minutes (see p. 24). On its front face, the logger is equipped with LEDs as follows. SmartPaq LED If SmartPaq parameters have been setup for a pass/fail analysis on removal from the oven (see p.

  • Page 21: Alphanumeric Display

    Alphanumeric Display Display Meaning Display Meaning Sample interval (in seconds). Internal error: reboot Sample intervals up to 9.9 s logger with default reset are shown to one decimal parameters (see p. 26). Number place. Contact Datapaq if (e.g. 0.5, 50) problem persists.
  • Page 22 LEDs and connectors on the XL2 MemoryPaq. A: SmartPaq LED. F: Socket for Transducer Interface or Dual Interface Block. B: Alphanumeric display. G: Charging socket and LED. C: Logger status LEDs. H: USB connector (on far end of unit). D: Battery status LED. E: Hardware reset switch (p.

  • Page 23: Memory Capacity

    To start logging when a Dual Interface Block is fitted, and plug-and-go is selected as the trigger mode (p. 49): 1. Ensure that both Transducer Interfaces, with their probes connected, are attached to the Dual Interface Block. 2. Plug the MemoryPaq into the Dual Interface Block. This sequence must be followed.

  • Page 24: Low Battery Level

    Charging status is shown by the LED next to the charging socket: red when charging is in progress, green when charging is complete. A full charge is delivered within 2 hours. No light when the charger is attached indicates a problem: there may be a connection problem or the battery may need replacing.

  • Page 25: Battery Life

    The logger will automatically come out of power-off mode when: • The communications lead (which is connected to a powered PC) is plugged in, or • A Transducer Interface is connected to the MemoryPaq, or • A hardware reset is performed (see below). On power-up, the logger will return to its pre-power-off state.

  • Page 26: Over-Temperature Protection

    Over-temperature Protection The XL2 and the Insight software work together to reduce the likelihood of corrupt or inaccurate data being recorded due to the logger’s internal temperature being too high. The logger measures its internal temperature within the Transducer Interface; the internal temperature of the MemoryPaq is not monitored.

  • Page 27: Testing And Calibration

    Thus, a hardware reset can also be used as a way of quickly restoring the default data-collection parameters without connecting the logger to a PC. Unlike a normal reset, a hardware reset will preserve in memory all data already collected – it will not be deleted. To perform a hardware reset: 1.
  • Page 28 Always adhere to the applicable statutory regulations for recycling and waste disposal. For details of recycling Datapaq products within the European Union, see www.fluke.co.uk. Under the European Union WEEE Directive, users should return all loggers (whether or not containing batteries) to Datapaq for disposal at the end of their useful life.
  • Page 29 Thermal Protection – Barriers and Heatsinks A Datapaq thermal barrier provides the thermal and mechanical protection necessary for the data logger to survive in the hostile environment of an industrial oven. Ceramic insulation covered by a ceramic fiber cloth provides the primary thermal protection, and a heatsink filled with a non-toxic, non-flammable phase- changing material provides additional, secondary protection allowing the system to operate at high temperatures for extended periods.
  • Page 30 TB0090 and TB0091 barriers have been independently tested by an automotive paint laboratory, and proven to be non-crater-forming in both solvent and water-based paint processes. • Angled heatsink (TB0090) holds logger securely in open barrier, even if vertical, and allows strain- free routing of cables out of the barrier.
  • Page 31 TB0091 Low-height XL2 Typical applications: 2-piece can manufacture – internal-bake ovens, low-height mesh-belt ovens, portable system for travelling paint reps. With Heatsink Temp °C Temp °F Duration (mins) Dimensions Height Width Length Weight 104 mm 187 mm 291 mm 3.2 kg 4.1 in.
  • Page 32 TB0081 Long-duration XL2 (with Heatsink) Typical applications: aluminum age-hardening, long low-temperature cure, automotive single-pass; possible to send the system through the complete paint process in an uninterrupted run – electrocoat (E-coat), primer, base and clear coat. Temp °C Temp °F Duration (hours) 24 –...
  • Page 33 TB5010-XL IP65 Waterproof XL2 (with Heatsink) Typical applications: dry-off ovens, processes with water-shower rinse. This barrier is not silicone-free. Temp °C Temp °F Duration (mins) Dimensions Height Width Length Weight 100 mm 219 mm 393 mm 6.0 kg 3.9 in. 8.6 in.
  • Page 34 3. Divide the sum of the temperatures by the number of verticals to calculate the average temperature. Modify this temperature as follows: 4. Add 15% if the maximum temperature is reached in the first third of the process. 5. Add 10% if the maximum temperature is reached in the first half of the process.

  • Page 35: Thermocouple Specifications

    Thermocouple Probes Thermocouple probes utilize the Seebeck effect, discovered in the nineteenth century, by which an e.m.f. is produced in any electrically conducting material that is not at uniform temperature. The actual voltage measured is proportional to the temperature difference between the thermocouple’s ‘hot’ and ‘cold’ junctions (the hot junction being the measurement junction, and the cold junction being the junction of thermocouple and measurement instrumentation).
  • Page 36 Thermocouple Cable Insulation The practical operating temperature of the thermocouple probes is limited by the cable insulation material’s temperature characteristics. Insulation Upper Temperature Limit Glass fiber, thin 500°C/932°F Glass fiber, thick 500°C/932°F continuous, 700°C/1,292°F peak Mineral insulation (MI) 1,250°C/2,282°F PTFE 265°C/509°F Glass-fiber-insulated probes are available in both thin and thick forms.
  • Page 37 At Temperatures Greater Than Product 400°C/752°F See note* 430°C/806°F Tetrafluoroethylene 440°C/824°F Hexafluoropropylene 475°C/887°F Perfluoroisobutylene 500°C/932°F Carbonyl fluoride*, which, in moist air, converts to the acid gas hydrogen fluoride * May also be produced if PTFE tape is kept at 400°C/752°F for an extended time. Health-hazard Data •...
  • Page 38 High-temperature adhesive tape For securing exposed-junction thermocouples. Pressure-sensitive silicone adhesive. Maximum 400°C/752°F. HT0090 9 m/29.5 ft Silicone-free High-temperature Kapton Sheet For securing exposed-junction and patch probes in automotive applications. Pressure-sensitive acrylic adhesive. Maximum 200°C/392°F. Cut to size and remove backing paper before use. CS2090 200 ×...
  • Page 39 Air Magnetic Thermocouple Attaches directly to ferrous substrate to measure air/ environmental temperature. PTFE-insulated cable. Maximum 265°C/509°F. PA0055 1.5 m/5 ft PA0056 3.0 m/10 ft PA0059 6.0 m/20 ft Washer Thermocouple Screwed directly to large heavy metal substrate. PTFE- insulated cable. Maximum 265°C/509°F. PA0081 1.5 m/5 ft PA0082 3.0 m/10 ft Clamp Surface Thermocouple...
  • Page 40 IRMag Surface Thermocouple Magnetic attachment (maximum 300°C/572°F), to measure surface temperature of ferrous substrate in infra-red cure oven. Easy attachment and fast thermocouple response. High-temperature glass-fiber-insulated cable with stainless- steel outer braid prevents damage from infra-red heaters (maximum 400°C/752°F). Ideal for automotive infra-red repair ovens.
  • Page 41 Hanging Strap Mild-steel strap to be hung from thermal barrier. Clamp or magnetic thermocouples can be attached to it for easy transport of the system – or use to attach thermocouples between runs. PA2052 Working with Thermocouple Probes Datapaq probes cover a huge range of possible usages. Choose suitable types for your process, and for the individual probes’...
  • Page 42 In assessing oven performance, to ensure repeatability and ease of use, test- pieces or test-fixtures with permanently mounted thermocouples should be used whenever possible. The presence of a probe on the product will inevitably affect the product’s temperature: it adds to its thermal mass and thus changes, however slightly, the rate of heating and cooling.
  • Page 43 repeatable measurements. Attach to the product, test-piece or test-fixture using a bolt or self-tapping screw. • Clamp-on A quick and easy method suitable for ferrous and non-ferrous materials. The product must have a thin, flat surface to ensure good thermal contact.
  • Page 44 Communications Setup dialog), may be broken. Inconsistent readings may indicate an intermittent short circuit. 2. If a satisfactory ambient reading is recorded, apply heat to the thermocouple-tip via fingers or other heat source. An increased temperature should register: ○ If the reading does not change, the thermocouple is short circuit and must be replaced.

  • Page 45: Running A Temperature Profile

    Running a Temperature Profile A temperature profile can be acquired by two means: • Without telemetry – After the logger and product have been in the oven, data is downloaded from the logger into the PC to be displayed and analyzed by the Datapaq Insight software.
  • Page 46 2. Reset the logger so that its memory is emptied and it is ready to receive fresh data; in the process of doing this you will also be able to set the sample-collection interval, the method used to trigger the start of data collection, and whether to use multiple- or single-run mode, and to check the logger’s battery status.
  • Page 47 It is not necessary to go through the reset procedure if the previous data- collection parameters are to be re-used for the next profile run and (when the logger is in multiple-run mode, see p. 48) if data from nine or fewer profile runs is stored in the memory.
  • Page 48 already running or the popup feature has been disabled (see p. 46), open the Logger Reset dialog (click on the Insight toolbar, or press function key F2, or select Logger > Reset from the menu bar) and specify your reset options as follows.
  • Page 49 limited by the level of battery charge and by the performance of the thermal barrier used. The Reset dialog for the XL2 logger. Battery Status The charge indicator gives both the current percentage of full charge held by the logger battery, and a color-coded report: GREEN Sufficient charge to perform a run.
  • Page 50 Plug-and-Go Data-recording starts immediately the reset is complete and a Transducer Interface (or Dual Interface Block) is attached to the MemoryPaq. Rising Temperature Data-recording starts when the temperature of any probe rises to the specified value. SmartPaq For instant quality assurance, click the button to enable or disable SmartPaq, or to create or edit the pass/fail criteria (see below for details).
  • Page 51 SmartPaq calculations will be performed on data from all the thermocouples that are specified in the SmartPaq setup (see below). The SmartPaq result will be a fail if: • One or more of the chosen parameters (see below) is outside the limits specified for any of the thermocouples .
  • Page 52 Select whether to test the calculated Datapaq Value against minimum and/or maximum values, and enter those values (for guidance, see Data Analysis > Datapaq Value in Insight’s online Help system). (See also ‘Process File’, below.) The SmartPaq Setup dialog. Time at Temperature Enter data for temperature thresholds (up to three thresholds with Oven Tracker Professional, one threshold with Over Tracker Basic) and whether to test the times spent above those temperatures against minimum and/or...
  • Page 53 Maximum Temperature Enter a maximum permitted temperature. By default, the value will be the maximum temperature entered for Datapaq Value calculations. (See also ‘Process File’, below.) Probe Selection Probe selections can be set separately for each of the SmartPaq analyses. Click on probe numbers to exclude them from the SmartPaq calculations.
  • Page 54 1. Plug the thermocouples into the logger’s numbered sockets. If you are using a process file, ensure that the probe/socket numbers on the logger correspond to those used to define probe numbers and locations in that file (see the Insight software for an introduction to process files: press function key F1, or select Help >...
  • Page 55 4. Fit the lid, ensuring a good seal around the thermocouple cables. Secure the lid’s catches with the locking pins, if fitted. The Tracker system is designed to pass through the oven after the product has been coated. Any coating which has become attached to the probes during a previous run will influence the measurements, and it must be removed before the next run starts.
  • Page 56 Stop data-collection by separating the MemoryPaq from the Transducer Interface. A slowly-flashing red LED indicates that the logger holds data that has not yet been downloaded to the PC. It is normally convenient to leave the thermocouple probes attached to the Transducer Interface.

  • Page 57: Downloading Data

    Downloading Data The procedure described here uses the Insight software’s Logger Download dialog. If you are less sure of the process, you can instead use the Logger Download Wizard to guide you, step-by-step, through this stage of running a profile: click on the Insight toolbar, or select Tools >...
  • Page 58 Downloading data from multiple profile runs stored in the XL2 logger (Oven Tracker Professional only): here, all profiles except no. 8 are selected for download; profile no. 2 has already been downloaded, but will now be downloaded again; the profiles will not be merged. 4.

  • Page 59: Open Circuits

    you to see the temperature profile in relation to the oven zones as the profile appears on screen during the run. See the Insight software for an introduction to process files: press function key F1, or select Help > Contents from the menu bar, and click the section ‘Process Files: Oven, Recipe, Product’.) If you will normally not wish to apply a process file to the results, you can opt not to have the Select Process dialog displayed immediately after a download (from the...
  • Page 60 Logger in single-run mode: • When starting the next profile run, the data held in the logger will be deleted automatically (this is prevented if the data has not yet been downloaded), so there is no need to reset the logger unless you wish to change the data-collection parameters.
  • Page 61 if a linear relationship is assumed between adjacent temperature values, appropriate corrections can then be applied to all data within the calibrated temperature range. Insight stores these correction factors in a ‘correction factor file’, and correction is achieved simply by applying this file to the data. For details of the creation and use of correction factor files, see the topic ‘Correction Factors’...
  • Page 62 If the logger does not reach the temperature required to start data-logging, Insight will always download the pre-trigger data, in order to aid the user in determining why triggering did not occur. For further features of the Insight software – particularly data analysis and the use of process files –...
  • Page 63 Using Hardwired Telemetry In addition to the standard off-line analysis, real-time analysis by hardwired telemetry is possible with Insight software when used with an intermittent or periodic oven (a batch process). Thus, with thermocouples trailing from the oven and attached to the logger outside the oven, data being gathered by the logger is transmitted via the communications lead directly to the PC, and the temperature profile can be watched developing in the Insight software as data is received, i.e.
  • Page 64 • After completing your selections in the Reset dialog, leave the communications lead attached to the logger and PC. • The Select Process dialog then appears in order that you may choose a process file to apply to the results. If the process file and its components have been given names, these are shown when the process file is selected in the list.
  • Page 65 You may zoom the display as when viewing a paqfile (see the online Help system), except that: • Double-clicking on the graph (or selecting Real Time Zoom from the View menu or right-click menu) shows only the most recently received portion of the data on the scrolling graph (see above).
  • Page 66 automatically when Insight is next run, and you may then choose to save it as a paqfile. When the run is complete, ensure that data received by Insight has been saved as a paqfile. If you wish, you may download the data held in the logger (p. 57), though it should normally be adequate simply to save, as a new paqfile, the data already received.

  • Page 67: Troubleshooting

    Troubleshooting Logger Communications Problems • Communications lead not fully inserted – Check correct sockets are being used. • Damaged communications lead or connectors – Check for breaks and other damage; replace the lead. • Batteries not charged – Recharge the batteries, ensuring the charging LEDs are illuminated (see p.
  • Page 68 *LO* Temperature measured was below the range of the logger. *HI* Temperature measured was above the range of the logger. Calculation cannot be performed (not necessarily because the data are invalid). Does not appear in View Data analysis mode. Probes with an intermittent open circuit may produce spiky, erratic profiles. Note that spikes are inevitable when probes are disconnected from a running data logger.
  • Page 69 I N D E X Barrier – See Thermal barrier communication problems 15, 67 Cable – See Communications lead, communications setup 14 Thermocouple probe correction factors 60 Case 34 Datapaq Value 51 CoilPaq 11 Help system 14 Communications lead 67 installing 13 Communications setup –...
  • Page 70 Europe & Asia Datapaq Ltd Lothbury House Cambridge Technopark Newmarket Road Cambridge CB5 8PB United Kingdom Tel. +44-(0)1223-652400 Fax +44-(0)1223-652401 sales@datapaq.co.uk North & South America Datapaq, Inc. 3 Corporate Park Dr., Unit 1 Derry, NH 03038 Tel. +1-603-537-2680 Fax +1-603-537-2685 sales@datapaq.com China Datapaq Ltd...

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