Fluke Datapaq Food Tracker User manual

Food
Tracker
®
USER MANUAL
for use with
Issue 3
MA5040A

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.
DATAPAQ PART NO. MA5040A
Food Tracker
®
User Manual
for use with
Issue 3
Europe & Asia
Datapaq Ltd.
Lothbury House, Cambridge Technopark
Newmarket Road
Cambridge CB5 8PB
United Kingdom
Tel. [phone]
Fax [phone]
Email [e-mail]
www.datapaq.com
North & South America
Datapaq, Inc.
3 Corporate Park Dr., Unit 1
Derry
NH 03038
USA
Tel . [phone]
Fax [phone]
Email [e-mail]
www.datapaq.com

© Datapaq Ltd., Cambridge, UK 2012
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 Food 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:
•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.
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
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).
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
9 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
37 Probe Selection and Placement
40 Preparing the Data Logger and Thermocouples
40 Resetting the Data Logger
43 Installing the Logger in the Thermal Barrier
45 Placing the System in the Oven
46 Recovering the System
48 Downloading Data
49 Specifying Oven Start
49 Completing the Documentation

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
63 Datapaq Service Department
65 INDEX

FOOD TRACKER Introduction 9
Introduction
Datapaq
®Tracker systems – incorporating Insight™software – are a complete
solution for monitoring the temperature profiles of products within a heat-
treatment process; accurate data acquisition and powerful analysis techniques
are combined with flexibility and ease of use. The Food Tracker
®system is
designed specifically for product temperature monitoring in the food processing
industry: for static or conveyorized cook/chill processes alike, Food Tracker
provides a complete historical record of the temperature reached by your
product – and by the oven environment – throughout the process, an essential
requirement for process validation under HACCP regulations.
•Proving/proofing and baking
•Drying/dehydration
•Steam cook
•Pasteurization
•Sterilization (retorts)
•Roasting
•Flash frying
•Blanching/boiling (full immersion)
•Blast freezing
•Spiral freezing
With accurate, repeatable product temperature guaranteed, achieve clear
benefits to your product and process:
Food safety – Create the HACCP documentary proof that your product has
achieved the cook/cool temperatures necessary to guarantee the quality and
safety of your cooked meats, poultry, bakery products and ready-meals.
Quality – Guarantee texture, taste, color and size through control of the
temperature profile.
Productivity – Optimize batch-cook programs or conveyorized line speeds to
maximize product throughput.
Product yield – Control processes to prevent overcooking so ensuring maximum
product yields and palatability, and eliminating waste.
Reduce downtime – Highlight immediately when and where process problems
occur (e.g. hot/cold spots), and have the data to solve them.
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

10 Introduction FOOD TRACKER
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.
Datapaq systems are designed for the harshest environments, including
steam cooking, deep fat fryers and blast freezers. You can monitor the product
temperature for the entire cook/freeze cycle in either static or conveyorized
ovens.
From one run and one logger, you may collect product/environmental
temperatures from up to eight locations, profiling your entire process rather
than just an isolated part of it (e.g. different racks in a batch oven or locations
across a conveyor belt).
Collect data for up to eight individual profile runs (multiple lines or repeat
optimization runs) in the memory of the data logger before there is any need to
transfer data to the computer. You can thus collect all the data you need in one
session, with no need to repeatedly scrub and gown-up between runs as you
move from production to office in order to access the PC.

FOOD TRACKER Introduction 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.
Alternatively, the basic Food Tracker system’s built-in hardwired telemetry
capability allows you to monitor conditions inside a batch oven and to watch the
temperature profile develop in real time.
The data logger is rated to IP67 with special waterproofed thermocouple
connections allowing use in the most hostile of environments (steam, water
showers and washing procedures) with the confidence of guaranteed reliability.
Select a thermal barrier ideally suited to your application. Whether your
need is low height clearance, fully-submersible use in a fat fryer, or high
temperature protection (300°C/572°F), the MultiPaq21 can be provided with a
barrier to suit.
Use thermocouple sensor types to suit the product being monitored, and
restrict consumable costs to the thermocouples alone – not the entire logger –
if damaged.
Using flexible thermocouple cables, the temperature sensor can readily be
located within the product (core or surface), without the data logger or its
mass influencing the response characteristics of the sensor.
Unlike other commercial systems, there is no need to protect the data logger
from the process’s environmental temperatures by placing it inside the product
and thus affecting the product’s heating characteristics.
This manual contains information for all Food Tracker users, from novice to
experienced. The chapters are arranged in logical order, explaining the Food
Tracker system and the sequence of events in setting up and conducting a
temperature profile run. There is also guidance on setting up the Insight
software; after it is installed, complete information on using the software is
available in the online Help system.
Insight Setup (p. 13) – How to install, remove and run the Insight software.
Hardware (p. 17) – Describes the system’s data logger(s), thermal barriers
and thermocouple probes.
Running a Temperature Profile (p. 35) – All the stages of obtaining a
profile, from positioning probes to downloading the data into the software.
Using Hardwired Telemetry (p. 51) – Monitoring conditions inside a
batch oven and watching a temperature profile develop in real time.
Humidity Measurements (p. 55) – Adding humidity data to your
temperature measurements.

12 Introduction FOOD TRACKER
Troubleshooting (p. 61) – Lists error messages and describes how to test
the data logger and probes.

FOOD TRACKER Insight Setup 13
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.
•1 GHz processor.
•2 Gb RAM.
•Monitor resolution 1024 ×768, 256 colors.
•100 Mb free hard-disk space.
•DVD drive.
•1 free USB port.
•Microsoft Windows™ XP, Vista, 7, 8 or above.
•Microsoft Internet Explorer 4 or above.
The MultiPaq21 logger operates only with Datapaq Insight v.2.0 and above.
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:
•Your license agreement.
•The outside of the DVD case.
•The 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

14 Insight Setup FOOD TRACKER
‘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.
For use of Insight to reset the logger, see p. 40.
For downloading data from the logger, see p. 48.
Communications Setup
After Insight has been installed, it is necessary to establish communication
between the data logger and the PC, as follows.
The logger can be connected to the PC by either a COM (serial)port or a USB port.
Only one logger at a time can be connected to the PC’s USB ports: it is not possible
to connect simultaneously more than one logger to the PC using USB ports and then
to choose which one to use.
1. Using the communications lead supplied, connect the logger to a free COM
(serial) port or to a USB port on the PC (to minimize communications
problems, connect the lead first to the PC and then to the logger). The red
LED on the logger should flash five times to confirm that the connection
between the communications lead and the logger has been made.
If using USB, and if the PC is having a Datapaq logger connected for the first

FOOD TRACKER Insight Setup 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).
Typical sources of problems with establishing communication
•Damaged communications lead or connectors – Check for
breaks and other damage. Replace the lead.
•Communications lead not fully inserted – Check correct sockets
are being used.
•Wrong COM port selected – Follow the procedure below to
select the correct port.
•Battery not charged – Recharge the battery, ensuring the
charging LEDs are illuminated.
2. On the Insight software’s menu bar, select Logger > Setup to open the
Communications Setup dialog.
3. Select the type of port to which the logger is connected: USB port or COM
(serial or RS232) port. For a COM port, select the port number, or click
Detect to auto-detect the port in use.
4. Click Test .
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, looks for the
port currently in use, and displays the port and logger type (equivalent to clicking
Detect in the dialog).
For more information on the logger in use, click the Diagnostic button which
now appears. Additional data shown covers firmware version, maximum
permitted internal logger temperature, battery charge status, serial number and
temperature recording range. Current temperature of the probes (updated
every 5 seconds) is also shown – or open circuit (*OC*) if no probe is attached;
the temperature of the thermocouple cold junction is effectively the current
internal temperature of the logger.

16 Insight Setup FOOD TRACKER
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.
1. In the Insight software, select Tools > Options and click the ‘Logger’ tab and
then the ‘Advanced’ button.
2. Select 50 or 60 Hz frequency. 50 Hz is most widely used, but 60 Hz is used
in North America, several countries in South America, and in Japan and
Korea.

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:
•Temperature and (on 8-channel logger only) humidity profiling.
•Up to eight temperature channels with interchangeable thermocouples.
•Operating temperature −40°C to 85°C/−40°F to 185°F.
•Accuracy to ±0.2°C/0.36°F.
•IP67 water-resistance rating to guarantee reliability/data integrity.
•Programmable (start trigger, sample interval, etc.).
•USB and serial RS232 communication capability.
•Multi-run capability (up to eight separate profiles before download).
•RF telemetry option (on 8-channel logger only).
•Rechargeable NiMH battery (120 hours at 0.5-s sample interval).
Four versions are available: with six and eight data channels, and suitable for
type T and type K thermocouples (see specifications, below).
The MultiPaq21 logger achieves ingress protection standard IP67, which
specifies that, when immersed in water to a depth of 1 m for 30 minutes, water
must not enter in any harmful quantity. The rating is achieved in the logger’s
operational state with thermocouples (or blanking plugs) connected; these are
provided with O-ring seals. As an illustration of this (although not
recommended for normal use), the unit has been shown to operate successfully
submerged in water at room temperature without any protection from a water-
resistant thermal barrier.
FOOD TRACKER Hardware 17

18 Hardware FOOD TRACKER
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 – p. 20 8: Communications port with dust-cap – p. 14
The logger is not designed for use without an external barrier in hot-water
applications or in an environment of rapidly changing temperature; the accuracy of
data cannot then be guaranteed. Although able to record at − 40°C/ − 40°F, it is
recommended that, for freezing applications, even above this temperature, a
thermal barrier (TB5011)be used to overcome thermal shock errors.
MultiPaq21 Logger Specifications
Logger Types
DP2162A 6 channels, type T thermocouples.
DP2166A 6 channels, type K thermocouples.
DP2182A 8 channels, type T thermocouples.
Humidity option on one channel, and RF telemetry option available.
DP2186A 8 channels, type K thermocouples.
Humidity option on one channel, and RF telemetry option available.
Accuracy ±0.2°C/0.36°F
Resolution ± 0.1°C/ 0.18°F
Measurement range Type T −196°C to 400°C/−320.8°F to 752°F
Type K −150°C to 1,370°C/−238°F to 2,498°F
Operating temperature −40°C to 85°C/−40°F to 185°F
(without thermal barrier)
Humidity option Available on 8-channel system.

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 – temperature only).
2.0 s to 50 min (temperature and humidity measurement).
Memory 1.81 Mb = 16 hours data collection (8 thermocouples and 0.5-s
sample interval).
Communications Serial cable (RS232) – CI1025.
USB cable – CI1026.
Thermocouple plug shroud To plug thermocouples into the logger in one action,
guaranteeing the correct thermocouple is plugged into the
correct channel (see p. 44).
6-channel plug shroud – CS1130 (supplied as option).
8-channel plug shroud – CS1131 (supplied as standard).
Blanking plugs DP1213A (for thermocouple sockets), DP1920A (for humidity-
sensor socket) – inserted into unused channels to give
protection to the connector from dirt, etc., and to provide
water-resistance.
Operation Up to 8 individual runs before download.
Data collection start Start/stop button, temperature rise/fall, date and time.
Battery Rechargeable NiMH (recharge time 2.5 hours).
Battery life Temperature only (0.5-s sample interval) = 120 hours.
(full charge) Temperature only (10-min sample interval) = 250 hours.
Telemetry (2.0-s sample interval) = 65 hours.
Humidity (2.0-s sample interval) = 120 hours.
Battery charger CH0070B power-supply unit: input 90–264 V AC, 50–60 Hz,
400 mA.
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 re-
started 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 s.
Turns logger
off.
Data retained in memory.
Press GREEN button
after downloading data.
Starts logging. Last re-set conditions (sample interval, probe
selection, etc.) used as default.
FOOD TRACKER Hardware 19

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
On On Battery on fast charge
On Off (after
being on)
Fast charge complete. Can also occur if battery overheats
during fast charge.
On Flashing once
per second
On applying charger power when battery is too hot/cold or
too deeply discharged. Battery is charged at 1/16 of fast-charge
rate, until safe to start fast charging.
Off Off Charger not connected or no power connected
Flashing once
per second
Off Battery is at 20% or less of maximum charge
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
Flashing together with
green LED
Flashing together with red
LED
Probe temperature is above trigger
point and cannot trigger (or, if falling
trigger is set, temperature is below
trigger point)
Off Flashing at sample interval Logger acquiring data
Two flashes together with
green LED, then pause,
then repeat
Two flashes together with
red LED, then pause, then
repeat
Logger waiting for next run to be
started (only during multiple runs)
Flashes 5 times (once per
second)
Off Connection between communications
lead 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
20 Hardware FOOD TRACKER