Fluke DATAPAQ XDL12 User manual

XDL12
Data
Logger
USER MANUAL
for Furnace Tracker
®
for use with
Issue 2
MA5800A

DATAPAQ PART NO. MA5800A
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.
XDL12
Data Logger
User Manual
for Furnace Tracker
®
for use with
Issue 2
Europe & Asia
Datapaq Ltd.
Lothbury House, Cambridge Technopark
Newmarket Road
Cambridge CB5 8PB
United Kingdom
Tel. [phone]
Fax [phone]
[email protected]
www.datapaq.com
North & South America
Datapaq, Inc.
3 Corporate Park Dr., Unit 1
Derry
NH 03038
USA
Tel. [phone]
Fax [phone]
[email protected]
www.datapaq.com

© Datapaq Ltd., Cambridge, UK 2009
All rights reserved
Datapaq Ltd. makes no representations or warranties of any kind
whatsoever with respect to the contents hereof and specifically
disclaims any implied warranties of merchantability or fitness for any
particular purpose. Datapaq Ltd. shall not be liable for errors
contained herein or for incidental or consequential damages in
connection with the furnishing, performance or use of the Datapaq
software, associated hardware or this material.
Datapaq Ltd. reserves the right to revise this publication from time to
time and to make changes to the content hereof without obligation to
notify any person of such revisions or changes.
Datapaq, the Datapaq logo and Oven Tracker are registered
trademarks of Datapaq. Microsoft and Windows are
registered trademarks of Microsoft Corporation.
Manual set in 10 pt Gill Sans.
User manuals are available in other languages;
contact Datapaq for details.
SAFETY WARNINGS
For safe use of Datapaq equipment, always:
xTake care to follow its supplied instructions.
xObserve 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.
Warns of high temperatures.
Where this symbol appears on Datapaq equipment, the
surface of the equipment may be excessively hot (or
excessively cold) and may thus cause skin burns.

European
Union
Directives
The following product types
XDL12 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).
CFR47: 2007 Class A – Code of Federal Regulations: Part 15
Subpart B, Radio Frequency Devices, Unintentional Radiators.
RoHS Compliance Datapaq temperature monitoring equipment
is exempt from EU Directive 2002/95/EC (restriction of the use of
certain hazardous substances in electrical and electronic equipment)
under category 9 Monitoring and Control Instruments. This Datapaq
product nevertheless uses RoHS-compliant components and
manufacturing processes.
Conforms to relevant South Korean EMC Standards.
Electromagnetic Compatibility Applies to use in
Korea only. Class A Equipment (Industrial Broadcasting &
Communication Equipment). This product meets
requirements for industrial (Class A) electromagnetic
wave equipment and the seller or user should take notice
of it. This equipment is intended for use in business
environments and is not to be used in homes.

CONTENTS
7 Introduction
9 Logger Specifications and Operation
10 Specifications
12 Stop/Start Button Actions
12 Logger LEDs
13 Battery
15 Best Practice with the XDL12
16 Testing and Calibration
19 Using the Logger with Insight Software
19 Installing/Removing Insight
21 Communications Setup
23 Running a Temperature Profile
28 Logger Defaults and Details
29 Using Hardwired Telemetry
29 Running a Temperature Profile Using Hardwired
Telemetry
33 Troubleshooting
33 Logger Communications Problems
33 Logger Download Error Messages
33 Checking the Data
34 Logger Diagnostics
35 Datapaq Service Department
37 INDEX

DATAPAQ XDL12 Introduction 7
Introduction
Datapaq
®Tracker systems, incorporating Insight™software, are a complete
solution for monitoring and analyzing the performance of your heat-treatment
process – the temperature profiles of products within it, and the performance
of the furnace itself; accurate data acquisition and powerful analysis techniques
are combined with flexibility and ease of use. The Tracker system’s power and
flexibility make it a perfect tool for process-temperature monitoring, from
commissioning and troubleshooting to process optimization, ensuring consistent
quality of product and maximum efficiency.
Current temperature characteristics can quickly be compared with previously
stored reference curves to detect operating abnormalities – and innovative
analysis techniques help in identifying problems, fine-tuning the process and
reducing running costs.
A powerful and flexible printing option allows the user to generate and
customize reports, including any or all of the analysis results or raw
temperature data.
The XDL12 logger has scope for wide application in heat-treatment processes
and is specifically designed for location outside the high-temperature
environment while monitoring and analyzing data in real time from
thermocouples placed inside the furnace. It is particularly suitable for use with
Datapaq Insight Furnace Surveying software, for assessing a furnace’s
accuracy and uniformity of heating and its compliance with the AMS 2750D or
other standards.
Hardware for a basic system using the Datapaq XDL12 data logger comprises:
xData logger (including communications lead and charger) (p. 9).
xThermocouple probes (for specifications, see p. 11; for usage, see the
relevant manual supplied with your system).
This manual is for Datapaq systems supplied with an XDL12 data logger, and
focuses on all aspects of using the logger. There is also guidance on setting up
the Insight software; complete information on using Insight – both Furnace
Tracker and Furnace Surveying – is contained in the online Help system
available when it is installed. For step-by-step instruction on how to use the
logger and other system hardware components to collect temperature data
during your process, see the dedicated system manual supplied.

Users of Furnace Surveying will use this manual chiefly to gain familiarity with
the basic operation of the XDL12 logger. For use of the Furnace Surveying
software and the procedure of carrying out a temperature uniformity survey, users
will need to refer to the Furnace Surveying User Manual and – especially –
the Furnace Surveying software’s Help system.
8 Introduction DATAPAQ XDL12

Logger Specifications and
Operation
The XDL12 data logger is at home in a wide range of heat-treatment
applications where a logger is required to operate outside the high-temperature
environment. The XDL12’s capacity for 18,000 data readings over each of 12
data channels makes it a supremely powerful, accurate and in-depth data-
collection tool. Its capability for hardwired telemetry, in conjunction with
Datapaq Insight software, allows temperature profiles to be watched developing
– and be analyzed – in real time. A single instance of Insight will simultaneously
support up to three XDL12 loggers collecting data by hardwired telemetry,
allowing data from 36 channels to be gathered.
The XDL12 data logger. Thermocouple sockets are on the rear of the unit.
The logger’s key features are:
xTwelve thermocouple channels for maximum data collection on each run.
xIndividual loggers can be supplied with combinations of different
thermocouple types (see specifications, below).
DATAPAQ XDL12 Specifications and Operation 9

10 Specifications and Operation DATAPAQ XDL12
xHuge memory capacity: 18,000 data points on each channel for detailed
process analysis.
xHigh accuracy: ±0.3°C/0.5°F (with type K thermocouples) for compliance to
tight specifications.
xHot data protected by non-volatile memory or software warning if reset is
attempted before download.
xUSB communication capability.
xHardwired telemetry for monitoring in real time with full analysis functions
and alarms to warn the user if the process is out of specification.
xCapability for up to three XDL12 loggers to gather data by hardwired
telemetry simultaneously.
xFour LEDs to show the exact status of the logger’s activity and its batteries.
xStart and stop buttons for easy user control.
xPowered by rechargeable NiMH batteries.
xRugged case and electronics allow operation in dusty environments.
xProof against data-corruption from earth-loop problems.
xLightweight and portable.
Specifications
Each XDL12 logger is supplied to order, with combinations of up to three
different thermocouple types as required by the user (see below). For example,
there may be a need for nine type K or type N thermocouples (for furnace
measurements on a surveying jig) combined with three type R or type S
thermocouples (for control measurements).
Length (inc. handle) 340 mm/13.4 in.
Width 330 mm/13.0 in.
Height With computer rest: 80 mm/3.1 in.
Without computer rest: 60 mm/2.4 in.
Weight 6.5 kg/14.3 lb
Thermocouples Combination of up to three possible types, according to model
of logger supplied: J, K, N, R, S, T; see below for data.
Thermocouple sockets accept both standard and miniature
thermocouple plugs.
Operating temperature 0–55°C/32–131°F
Humidity range 0–85% non-condensing
Ingress protection IP50 (dust-resistant)
Real-time monitoring Hardwired telemetry via communications lead as standard.
Capability for up to three XDL12 loggers to gather data by
hardwired telemetry simultaneously.
Sample interval 1 s to 50 min. in 1-s increments

Data storage 18,000 data-points per channel
Data-collection start Start button, Temperature rise, Temperature fall, Date/time
Pre-trigger data stored Yes (configurable; see p. 28)
Hot-data protection By non-volatile memory, and software warning if reset attempted
before download
Communications USB
PC/software compatibility See p. 19
Logger reset Possible after download by start button (using previous run
parameters)
Battery Datapaq NiMH rechargeable battery-pack + lithium AA
Battery life Over 60 hrs continuous use (see p. 13), depending on sample
interval and operating temperature
Battery charger All regions except Americas – CH0070
Americas – CH0075
Specifications for Specific Thermocouple Types
Type J Type K Type N
Normal
range
Accuracy *
0°C to 800°C
32°F to 1,472°F
±0.3°C
±0.5°F
−100°C to 1,370°C
−180°F to 2,498°F
±0.3°C
±0.5°F
−100°C to 1,300°C
−180°F to 2,372°F
±0.4°C
±0.7°F
Lower range
Accuracy *
–
–
−190°C to −100°C
−310°F to −180°F
±0.5°C
±0.9°F
−190°C to −100°C
−310°F to −180°F
±0.5°C
±0.9°F
Resolution 0.1°C/0.2°F 0.1°C/0.2°F 0.1°C/0.2°F
Socket color
(IEC 584)
Black Green Pink
Type R Type S Type T
Normal
range
Accuracy *
50°C to 1,760°C
122°F to 3,200°F
±1.1°C
±2.0°F
50°C to 1,760°C
122°F to 3,200°F
±1.1°C
±2.0°F
−100°C to 400°C
−180°F to 752°F
±0.3°C
±0.5°F
Lower range
Accuracy *
−40°C to 50°C
−40°F to 122°F
±1.8°C
±3.2°F
−40°C to 50°C
−40°F to 122°F
±1.7°C
±3.1°F
−196°C to −100°C
−321°F to −180°F
±0.5°C
±0.9°F
Resolution 0.1°C/0.2°F 0.1°C/0.2°F 0.1°C/0.2°F
Socket color
(IEC 584)
Orange Orange Brown
*
Using sample interval > 0.8 s over temperature range shown. For more details, contact Datapaq.
DATAPAQ XDL12 Specifications and Operation 11

Due to continuing product development, specifications are subject to change
without notice.
Stop/Start Button Actions
Action Results Notes
Press GREEN button. Starts logging. In telemetry mode, also starts sending data.
Press RED button. Stops logging. Data retained in memory. Logger cannot be restarted
until data downloaded. Red LED flashes every 5 s to
warn of data in memory. If in telemetry mode will
also send ‘end of run’ signal to end real-time run.
Press GREEN and RED
buttons together, and
hold for 3 seconds.
Turns logger
off.
Data retained in memory.
Press GREEN button
after downloading data.
Starts logging. Last re-set conditions (sampling interval, probe
selection, etc.) used as default.
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 Red Meaning
Flashing every
5 seconds
Off Battery is at 20% or less of maximum charge, and charger not
connected.
On On Battery on fast charge.
On Off Fast charge complete, or
Problem with battery – cannot be charged.
Off Off Charger not connected, and battery at more than 20% of
maximum charge.
On Flashing once
per second
Battery being preconditioned due to being too hot, too cold
or too deeply discharged (see p. 15).
Flashing
rapidly for
2 seconds
Off Battery level extremely low. See p. 15.
12 Specifications and Operation DATAPAQ XDL12

Logger Status LEDs
Red Green Meaning
5 flashes, alternating
with green LED
5 flashes, alternating with
red LED
Logger successfully reset
Flashing, alternating with
green LED, at sample
interval *
Flashing, alternating with red
LED, at sample interval *
Logger awaiting trigger
On Flashing at sample interval * Logger awaiting trigger but one or
more thermocouples is open circuit
Flashing together with
green LED, at sample
interval *
Flashing together with red
LED, at sample interval *
All probes are above trigger
temperature, and thus data-recording
cannot be triggered by rising
temperature (or, if falling trigger is set,
all probes are below trigger point)
Off Flashing at sample interval * Logger acquiring data
Flashes 5 times (once
per second)
Off Connection between communications
lead (attached to an active PC) and
logger has been made
Flashing every second Off Internal error
Flashing every 5
seconds
Off Logger has data in memory which has
not been downloaded
2 quick flashes every
second
Off Logger too hot to start logging (after
pressing Start button)
*
Flashing interval will actually fall in range 1–5 s.
Battery
The logger uses a pack of three rechargeable 1.2 V nickel-metal-hydride
(NiMH) cells. Only battery packs supplied by Datapaq are suitable.
Service life of the rechargeable NiMH battery is about three years or 1,000
charge/discharge cycles. The logger must be returned to Datapaq for battery
replacement.
For subsidiary power, the logger also contains a lithium AA battery. This will
normally last for the life of the logger, but, if replacement is needed, the logger
must be returned to Datapaq.
Battery Life
Battery life (discharge time) of NiMH rechargeable batteries is affected by the
following factors.
DATAPAQ XDL12 Specifications and Operation 13

xOperating Temperature – Essentially, the higher the ambient
temperature the battery operates in, the shorter will be the life. Batteries
that operate for a large part of the process cycle at relatively low
temperatures will have a longer life than those that operate for the majority
of the process cycle at higher temperatures.
xSample Interval – The shorter the sample interval, the shorter will be the
battery life. This is because power is being consumed each time the logger
takes a reading. A short sample interval will achieve the maximum amount
of information, but this must be balanced against the greater battery charge
required.
xProgramming and Downloading the Data – When these operations
are carried out it is necessary to connect to the computer via a
communications cable, and power is consumed as soon as the cable is
plugged into the logger. The software warns the user to disconnect from
the PC, but if the logger is left connected this will affect battery life.
Given the factors that can affect the life of a battery it is obviously difficult to
predict accurately, but a fully-charged battery can typically achieve over
60 hours of data-collection using a 30-second sample interval. The LEDs on the
logger will give the best indication of when the battery is low. In the user’s own
conditions, experience will quickly indicate typical battery life, and a log should
be kept for the first few runs, noting sample interval.
Sample Interval No. of Channels Battery Life (hrs)
1 s 12 30
5 s or more 12 60
Charging
Recharge the battery as follows.
1. Plug the charger into the electricity supply.
2. Plug the charger lead into the charger socket on the logger.
A full charge is delivered in about 2 hours. Indication of battery/charging status
is provided by colored LEDs on the logger (see p. XX).
14 Specifications and Operation DATAPAQ XDL12

The logger intelligently monitors the battery, ensuring it is never overcharged.
Thus, by leaving the charger connected to the logger, the logger will always be on
charge and ready for use. This will not damage the battery or reduce its service life.
If the logger’s battery is low when the logger is required quickly, it can be
connected to the electricity supply via the charger and used immediately. The
battery will then charge while the logger is running. However, to ensure the highest
level of accuracy, it is recommended that the logger is not connected to mains
electricity during data-collection (see p. 16).
New batteries – or ones which have been unused for several months –
should be charged for 24 hours before use.
NiMH batteries discharge slowly even when not in use and will need
charging if left for more than three weeks.
If the logger is not in regular use, the battery should be charged at least
every 3 months. If this is not done, the battery may drain to a level where it
cannot successfully be recharged.
Where batteries are too cold (below 0°C/32°F), too hot (over 45°C/113°F) or
too deeply discharged, they must be pre-conditioned before fast charging can
begin. Pre-conditioning (slow charging) occurs automatically if it is required, and
is shown by the battery status LEDs (steady yellow + flashing red). If the
battery is still being pre-conditioned after 5 hours, there may be a fault; contact
Datapaq.
In extreme cases of low battery charge, the logger may not operate at all
(yellow LED will flash rapidly for 2 seconds). If this happens:
1. Disconnect the communications lead from the logger.
2. Turn the logger off (press green and red buttons together, and hold for
3 seconds).
3. Connect the charger.
The logger should then operate normally while recharging – though pre-
conditioning may be necessary, as above.
Low Battery Level
When the battery’s charge drops to 20% of the full level, this will be shown by
the logger LEDs (p. 12) and (if connected to the PC) by the Insight software.
DATAPAQ XDL12 Specifications and Operation 15

Auto Power-off
When the logger contains data from a previous run which has not been
downloaded, or is indicating an error, the logger-status red LED will be flashing.
If the logger is left in this state there is potential for the battery to flatten, and
the logger will therefore power-off automatically after five minutes. On
subsequent power-up, the logger will either return to its pre-power-off state
or, if the communications lead is connected, be ready to communicate with
the PC.
Best Practice with the XDL12
The XDL12 is a highly accurate logger which utilizes a specially-designed cold-
junction compensating unit to minimize errors. But note that…
…the following guidelines must be observed to ensure
maximum accuracy.
Temperature Stabilization
xWhen carrying out a survey, let the logger stabilize at the ambient
temperature in the area where it will be used (i.e. near the furnace) for
1 hour before starting data-collection. This is especially important when
bringing the logger from an air-conditioned office to a warm workshop, or
from a warm office to a cool workshop.
xDo not place the logger where there may be sudden temperature
changes, e.g. where there may be a draught from an opening door or
where hot air may issue from a furnace.
Powering the Logger
xWhile a survey is in progress, whenever possible run the logger only
from its battery – i.e. if it is avoidable, do not use the battery charger as a
means of powering the logger from mains electricity. A fully-charged battery
will last at least 60 hours with a sample interval of 30 seconds, and this is
generally far longer than is required for a survey.
Using and Connecting Thermocouples
xFor ease of use, the XDL12 utilizes standard thermocouple sockets. To
ensure the highest accuracy, extension cables and compensating cables
supplied by Datapaq have plugs from the same manufacturer as the sockets.
16 Specifications and Operation DATAPAQ XDL12

DATAPAQ XDL12 Specifications and Operation 17
If providing your own connecting cables, make every effort to ensure that
all cables and terminating plugs are from the same manufacturer.
xThe XDL12 will accept sub-miniature thermocouple plugs, but for highest
accuracy standard plugs are recommended.
xUse high-quality extension cables and compensating cables from
the logger to the external furnace connection, preferably from the same
batch.
xIf using type-R or type-S noble-metal thermocouples, compensation cable
can be used, but only noble-metal wire will ensure full accuracy. This
is particularly important if significant temperature variation may occur down
the length of the cable.
xWhen using mineral-insulated thermocouples in a vacuum furnace at
relatively high temperatures, ensure that the diameter of the cable is big
enough to avoid breakdown of the magnesium oxide insulation but small
enough to allow the cable to be bent around the test jig. These
requirements are generally met by 2-mm diameter, type-N, mineral-
insulated thermocouples.
xMinimize the number of plug and socket or other connections in
the extension cables or compensating cables. In vacuum furnaces and
autoclaves it is not possible to avoid such connections, but always check the
condition of the sockets on the inner wall of the furnace, and clean with a
small-diameter wire brush if oxidized.
xReplace any of the connections on the inner or outer walls of the
furnace if in poor condition or where the connection seems loose.
Testing and Calibration
It is recommended that the logger is tested and calibrated by Datapaq at least
once a year. To comply with the AMS 2750D standard, loggers should be
calibrated every three months. The Datapaq calibration procedure comprises:
xInspection of the logger, externally and internally.
xBattery- and charge-testing.
xStability testing, using a stable temperature source and varying ambient
temperatures.
xCalibration and updating of the logger’s firmware.
xIssue of certificate, which can be traced back to national calibration
standards.
No other company can offer this degree of in-depth testing as well as a full
calibration service. To calibrate your logger, please return it to the Service
Department at Datapaq (see title page for contact details).

It is possible for users to check calibration of the logger themselves if they have
a secondary standard instrument that complies with the requirements of
AMS 2750D Table 3.
18 Specifications and Operation DATAPAQ XDL12

Using the Logger with
Insight Software
See your dedicated system manual for full details on:
xChoosing appropriate thermocouple probes.
xConducting a temperature-profile run of your process.
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.
Before each profile run, you will:
3. Reset the logger to prepare it to receive fresh data.
After the profile run is complete, you will then:
4. Download the data from the logger.
These stages are described below.
Installing/Removing Insight
Datapaq Insight used with the XDL12 logger requires the following minimum
computer specification.
x1 GHz processor.
x2 Gb RAM.
xMonitor resolution 1024 u768, 256 colors.
x100 Mb free hard disk space.
xDVD drive.
x1 free USB port.
xMicrosoft Windows™ XP, Vista, 7, 8 or above.
xMicrosoft Internet Explorer 4 or above.
The XDL12 logger operates only with Datapaq Insight v.6.0 and above.
DATAPAQ XDL12 Using Insight Software 19

Installation
Ensure you are logged into Windows in Administrator mode.
For most systems, installation will start automatically on placing the Insight
DVD in the drive. (If installation does not start, click the Windows Start button
and select Run; browse to your DVD drive, and run Setup.exe.)
Follow the on-screen instructions. You will need your license number to hand,
which is to be found on:
xYour license agreement.
xThe outside of the DVD case.
xThe outside of the system packaging.
Insight’s link with the logger must also be made while Windows is in
Administrator mode, and it is thus best to do this now, as part of the Insight
installation: connect the logger to the PC and follow the procedure under
‘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. Settings and data files used with the current installation
will be maintained.
Removal
From the Windows Start button menu, select Settings and then Control Panel.
Double-click Add/Remove Programs, select Datapaq Insight and click Add/
Remove.
Using the Software
Full details on using the Insight software are contained entirely within its online
Help system: access this by clicking Help, and then Contents, on Insight’s main
menu. Then, within Help, click on Contents headings and topics to expand and
read them.
You may also click the Help button in any dialog – or press the F1 key – to
bring up help information relevant to the task being performed.
20 Using Insight Software DATAPAQ XDL12