Fluke Datapaq Food Tracker User Manual
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Fluke Datapaq Food Tracker User Manual

Fluke Datapaq Food Tracker User Manual

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Food
Tracker
®
USER MANUAL
for use with
Issue 3
MA5040A

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Summary of Contents for Fluke Datapaq Food Tracker

  • Page 1 Food Tracker ® USER MANUAL for use with Issue 3 MA5040A...
  • Page 3 Food Tracker ® User Manual for use with Issue 3 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

    European Union Directives The following product types MultiPaq21 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 CO NTE NT S Introduction 13 Insight Setup 13 Installing/Removing Insight 14 Communications Setup 17 Hardware 17 Data Logger – the MultiPaq21 22 Thermal Protection – Barriers and Heatsinks 27 Thermocouple Probes 31 Food Tray 32 Thermocouple Jig 33 Carrying Cases 35 Running a Temperature Profile 35 Setting Up 35 Selecting the Thermal Barrier...
  • Page 7 51 Using Hardwired Telemetry 51 Running a Temperature Profile Using Hardwired Telemetry 54 Using Multiple Loggers 55 Humidity Measurements 55 Humidity Sensor Specifications 57 Humidity Sensor in Use 61 Troubleshooting 61 Logger Communications Problems 61 Stopping the Logger 61 Logger Download Error Messages 62 Checking the Data 62 Testing the Logger and Thermocouples 63 Printing Problems...
  • Page 9 Economy – Maximize the operating efficiency of your process to save on oven/ freezer running costs. Datapaq Food Tracker temperature profiling systems travel through the oven or freezer with the food product, making a complete record of the temperatures Introduction...
  • Page 10 reached by the product itself throughout the process. Data gathering is carried out by a MultiPaq21 data logger contained in a protective thermal barrier, and Insight software is used for detailed analysis of the data gathered during the process. Datapaq systems offer the only reliable means of measuring the true product and environmental temperature throughout the process, an essential requirement for process validation under HACCP regulations A Food Tracker system in use in a typical application.
  • Page 11 With real-time data monitoring, you can know immediately what is happening to your product while it is in the oven, and make instant decisions that affect safety, quality and profitability. The optional TM21 telemetry system uses a cable-free radio link to send temperature information directly from within the process to the PC running Insight Food Tracker software.
  • Page 12 Troubleshooting (p. 61) – Lists error messages and describes how to test the data logger and probes. Introduction FOOD TR ACK ER...

  • 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 MultiPaq21 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 time, Windows will display a ‘Found New Hardware’ message. After a few seconds, Windows will display ‘Datapaq Paq21 Logger’, and, after a further few seconds, ‘Your hardware is installed and ready to use’. If any warnings are displayed about driver-signing, confirm them (Datapaq drivers have been tested, and were installed when Insight was installed).
  • Page 16 The Communications Setup dialog for the MultiPaq21 logger, with Diagnostic section expanded. Setting Frequency of Electricity Supply To increase the efficiency of the logger’s noise rejection, and thereby provide more stable measurements, select the frequency of the local electricity supply as follows.
  • Page 17 Hardware The basic Food Tracker system hardware comprises: • Data logger (including communications lead and charger). • Thermal barrier. • Thermocouple probes. Data Logger – the MultiPaq21 The MultiPaq21 has been designed to withstand the most hostile of food- processing applications and to guarantee operating reliability day after day. The logger’s key features are: •...
  • Page 18 8-channel MultiPaq21 logger, shown from above and below. 1: Stop button, RED – p. 19 5: Transmitter aerial socket 2: Battery status LEDs – p. 20 6: Thermocouple sockets – p. 43 3: Start button, GREEN – p. 19 7: Humidity sensor socket – p. 55 4: Logger status LEDs –...
  • Page 19 Real-time monitoring Hardwired (serial) telemetry (via communications cable). Optional TM21 radio-telemetry system available for 8-channel loggers. Protection (without IP67 (submersion to 1 m in water for 30 min) with thermal barrier) thermocouples fitted. Sample interval 0.5 s to 50 min (standard use – temperature only). 2.0 s to 50 min (radio telemetry –...
  • Page 20 Logger LEDs The logger is equipped with two sets of LEDs: two LEDs show the status of the battery, and two show the status of the logger and its memory. Battery Status LEDs Yellow Meaning Battery on fast charge Off (after Fast charge complete.

  • Page 21: Testing And Calibration

    Battery The logger’s battery is rechargeable NiMH. Battery life is about three years or 500 charge/discharge cycles. The logger must be returned to Datapaq for battery replacement. Charging 1. Plug the charger into the electricity supply. 2. Plug the communications lead into the logger (the lead can also be plugged into the PC or not).
  • Page 22 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 23 • Silicone lid seal, providing water resistance yet quick and easy logger access. • Strong catches. • Carrying handle. Thermal durations quoted are based on the barrier being in still air, and will vary depending on the actual environment, i.e. temperature, pressure and moisture levels, and conditions of high air velocity, steam or immersion in liquid.
  • Page 24 TB5009 Non-submersible – short bake/roast processes Temp °C −100 Temp °F −148 Duration (hours) 1.5 1.75 1.25 Dimensions Height Width Length Weight 60 mm 203 mm 389 mm 3.95 kg 2.4 in. 8.0 in. 15.3 in. 8.7 lb Heatsink None TB5010 Non-submersible –...
  • Page 25 The more severe conditions of chilling by shower or submersion in water or brine immediately after cooking require more robust probe seals and mineral- insulated probes. In this case use MI adaptor kit PA0960 (one kit per probe); see p. 45. TB5016 Submersible –...
  • Page 26 TB5816 Submersible – long fry/steam processes Temp °C −100 Temp °F −148 Duration (hours) – 1.75 Water/Oil – 0.75 Dimensions Height Width Length Weight 65 mm 238 mm 380 mm 5.66 kg 2.6 in. 9.4 in. 15.0 in. 12.5 lb Heatsink TB9707 ×...
  • Page 27 TB5821 Submersible, low-height – short fry/steam processes Front-loaded. Supplied with different face-plate plus logger-tray according to use: 6-channel, 8-channel, or 8-channel plus RF antenna. Temp °C −100 Temp °F −148 Duration (mins) – Dimensions Height Width Length Weight 40 mm 140 mm 318 mm 2.5 kg...

  • Page 28: Thermocouple Specifications

    R, S and T, each type being identified by its connector color. The standard thermocouple probe for food industry use is type T, although in some circumstances type K probes are used. Thermocouple Specifications Probe Cable Insulation Accuracy Standard Type Mineral insulation ±0.5°C/0.9°F or ±0.4% BS EN 60584.1...
  • Page 29 The important products from PTFE thermal decomposition are: 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 30 1: Food Core Probe – PTFE cable with exposed temperature sensor. Used for environmental monitoring or insertion into products in semi-solid/liquid state prior to cooking, e.g. bakery. 2: Short Needle Probe – PTFE cable with insertion probe. Needle length 40 mm (1.6 in.), diameter 1.6 mm (1/16 in.), with location barb to prevent probe movement.
  • Page 31 Probe Part Numbers and Compatibility Type T Type K Barrier Compatibility MI Needle Probe PA150x PA151x Standard Needle Probe PA146x PA147x Short Needle Probe PA144x PA145x Heavy Duty Probe PA142x PA143x Not TB5817, TB5815, TB5816, TB5821 Air Clip Probe PA154x PA155x Not TB5817, TB5815, TB5816, TB5821 Food Core Probe...
  • Page 32 nuggets, fillets and portions, and beef patties), especially where frequent profiles are required. See p. 39 for use of the food tray. Part numbers CS3043A – for use with barrier TB5815 CS3044A – for use with barriers TB5816, TB5009, TB5011 Tray weight 1.45 kg/3.2 lbs Width...

  • Page 33: Carrying Cases

    Carrying Cases A soft, lightweight case (part no. CC0048) is available for transporting the logger and accessories (excluding barriers). Hardware FOOD TR ACK ER...
  • Page 34 Hardware FOOD TR ACK ER...

  • Page 35: Running A Temperature Profile

    Running a Temperature Profile This chapter describes all the stages of setting up for a temperature profile – from preparing the data logger and thermal barrier, to how and where to place the probes and installing the complete system in the oven. (To run a profile using hardwired telemetry, see p.
  • Page 36 Dry Environments 1. Plot a graph of the temperature versus time characteristics of the process. 2. Divide the horizontal axis into 10 equal increments and draw verticals. Read the temperature at each vertical. A typical temperature profile. The average temperature is 350°C. 3.
  • Page 37 Probe Selection and Placement Probe Selection Selection of thermocouple type and insulation (see p. 27 for the range available) is based on the product and the process environment. Product size is a prime consideration. In general, suitability is as follows: Needle probes –...

  • Page 38: Air Temperature

    • Probe needles should be inserted to such a depth that most of the needle lies within the product. This minimizes the effect of heat being conducted along the probe into the product (stem effect). • Probes should be inserted to the same depth each time. •...
  • Page 39 Use of Food Tray See p. 31 for sepecification. • Attach thermal-barrier-securing bracket to tray using Allen bolts supplied. • Using Allen bolts, fix probe-positioning bracket to suit product, i.e. to give appropriate probe height and horizontal or vertical orientation. •...
  • Page 40 Preparing the Data Logger and Thermocouples The logger should be inspected externally before every profile run, as follows. • Look for any signs of salt crystals or dirt, particularly in and around the sockets and communications port. Remove carefully with damp tissue or cotton-bud, and dry thoroughly.
  • Page 41 collect. The shorter the sample interval the better you will be able to record short-term variations in your temperature regime – but the total recording time available to you will be reduced, and the data will take longer to download to the PC after the run. Restrictions apply to the sample intervals allowed, depending on use of the humidity sensor.
  • Page 42 logger’s memory size. The time available may be further limited by the level of battery charge. Probe Temperatures Current temperature measured on each of the logger’s channels is shown, updated every 5 seconds. This serves as a useful check that thermocouples are working properly. (Probe temperatures, and the logger’s internal temperature, are also shown in the Communications Setup dialog, p.
  • Page 43 3. After clicking OK, the logger is reset and a message box confirms the sample interval and trigger mode you have set. 4. Disconnect the communications lead from the logger; the logger’s status LEDs briefly flash red and green alternately to confirm logger reset. Replace the dust-cap on the communications port.
  • Page 44 Use of Thermcouple Plug Shroud 1. Insert thermocouple plugs (and blanking plugs if used) into appropriate positions in shroud. 2. Slide retaining rod through length of shroud to fix plugs in place within shroud. Lock rod with Allen key. 3. With all plugs in place in shroud, align against logger and press firmly into place.
  • Page 45 • To aid insertion and removal of the logger, a length of adhesive tape can be attached to the logger to act as a simple handle. • When lowering the logger into the cavity of the barrier, make sure that no thermocouples pull out of their sockets.

  • Page 46: Recovering The System

    Load the product so that it enters the oven before the thermal barrier and logger. If convenient, use a hanging hook (part no. TB9800) to hang the barrier from the oven rack, etc. If subject to an environment of high-pressure water showers, use a hanging hook to locate the barrier with its probe exit away from the direct water flow.
  • Page 47 If the process involves brine, be sure to keep thermocouple connectors away from any residual liquid that may be on the barrier or in the working area. Salt on the connectors will cause the thermocouples to fail in a very short time. Allow the barrier (with lid open), heatsinks and logger to cool to ambient temperature before further use;...

  • Page 48: 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 49 Specifying Oven Start If you have not applied a process file, or if the process file you applied did not specify that the oven start position be adjusted, you may want to adjust the oven start position now: from the menu bar, select Process > Adjust Oven Start, or use the right-click menu.
  • Page 50 Running a Temperature Profile FOOD TR ACK ER...
  • Page 51 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 it, 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 52 Resetting and Starting the Logger When Using Hardwired Telemetry The logger is reset and started exactly as for a normal (non-telemetry) profile run (see p. 40), except that: • In the Reset dialog, select Hardwired Telemetry. • After completing your selections in the Reset dialog, leave the communications lead attached to the logger and PC.
  • Page 53 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 54 the run, the autosaved version of the data is displayed 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.

  • Page 55: Humidity Measurements

    Humidity Measurements The MultiPaq21 data logger makes it possible to complement temperature measurement data with in-process humidity measurements. This is ideal for baking applications such as proving/proofing, and will also be of interest in general food processing where the humidity measurements can be used to validate oven control and to optimize yields and product quality.

  • Page 56: Sensor Accuracy

    Temperature operating range Sensor head −100 to 200°C/−148°F to 393°F Sensor electronics −50 to 85°C/−58°F to 185°F Humidity units (sensor) Standard: relative humidity (%RH) Humidity units (software) Relative humidity (%RH) Moisture by volume (%Mv) Parts per million (ppm) Dew-point temperature (°C or °F) Accuracy at 23°C/73°F ±0.8%RH, ±0.1°K Response time...
  • Page 57 Sensor Cap The humidity sensor is supplied as standard with a metal cap (part no. PA20041) fitted with a removable PTFE filter (PA2041). The sensor filter is provided to protect the sensor but may affect its responsiveness during measurements; thus, if responsiveness is important, the cap without a filter should be used.
  • Page 58 The humidity sensor connection cable, in Sensor electronics in position in the two sections. thermal barrier’s humidity-probe retainer. The barriers are provided with an external mounting bracket for positioning the sensor, screwed to the barrier-lid splash guard (see photograph p. 55). When fitting the sensor, ensure that all cables are carefully located through the barrier’s probe-exit slot so that they are not trapped under the barrier lid.
  • Page 59 The display panel shows the heater’s current temperature, factory-set to °C or °F. Press and hold the  button to toggle the display between the temperature units and the heater’s target temperature. Humidity sensor conditioner, CS3050. To heat the humidity sensor: 1.

  • Page 60: Humidity Compensation

    Note that the conditioner remembers the last target temperature set, so it is necessary to re-set it only if a new temperature is needed. WARNING The inside of the conditioner’s heating chamber can get very hot. The conditioner should only be used for heating humidity sensors. Humidity Compensation One of the inputs to the relative humidity measurement is temperature.

  • Page 61: 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. • Wrong COM port selected – See ‘Communications Setup’ (p. 14) to select the correct port.

  • Page 62: Checking The Data

    Checking the Data Thermocouple probes are generally reliable, but damage resulting from inappropriate use or handling can produce erroneous readings. If you suspect that invalid data may have been introduced into your temperature profile (paqfile), select the View Data tab in the Insight software’s Analysis Window to view the raw data as downloaded from the logger.

  • Page 63: Printing Problems

    Proceed as follows. 1. Note readings first at ambient temperature: thermocouples registering no data in Insight, or an open circuit with a digital thermometer (*OC* in the Communications Setup dialog), may be broken. Inconsistent readings may indicate an intermittent short circuit. 2.
  • Page 64 Troubleshooting FOOD TR ACK ER...
  • Page 65 I N D E X Open circuit 62 Oven, removing system from 46 Alarms 48 Oven start position 49 Carrying case 33 Paqfile 49 Communications lead 61 notes 48, 49 Communications with computer Paqfile Properties dialog 49 problems 15, 61 Printed report 49 COM port 14 Printing problems 63...

  • Page 66: North & South America

    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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