Fluke Datapaq Furnace Tracker User manual

Datapaq
®
Furnace
Tracker
®
USER MANUAL
for use with
Insight™software
Issue 2a
MA5070A

Datapaq
®
Furnace Tracker
®
User Manual
for use with Insight™software
Issue 2
DATAPAQ PART NO. MA5070A
Datapaq is the world’s leading brand of
process temperature-monitoring
instrumentation, and maintains
this leadership by continual development
of its advanced, easy-to-use Tracker systems.
Europe & Asia
Fluke Process Instruments
Lothbury House, Cambridge Technopark
Newmarket Road
Cambridge CB5 8PB
United Kingdom
Tel. [phone]
[e-mail]
www.flukeprocessinstruments.com
North & South America
Fluke Process Instruments
6920 Seaway Boulevard
Everett
WA 98203
USA
Tel. [phone]
[e-mail]
www.flukeprocessinstruments.com

SAFETY
WARNINGS
For safe use of Datapaq equipment, always:
•Take care to follow its supplied instructions.
•Observe any warning signs shown on the equipment.
Indicates potential hazard.
On Datapaq equipment this normally warns of high temperature, but,
where you see the symbol, consult the manual for further explanation.
Warns of high temperatures.
Where this symbol appears on Datapaq equipment, its surface may be
excessively hot (or excessively cold) and may thus cause skin burns.
© Fluke Process Instruments, Cambridge, UK 2021
All rights reserved
Fluke Process Instruments 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. Fluke Process Instruments 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.
Fluke Process Instruments 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, Furnace Tracker and the Fluke Process Instruments logo are registered trademarks of
Fluke Process Instruments. Microsoft and Windows are registered trademarks of Microsoft Corporation.
Manual set in 10 pt Gill Sans.
User manuals are available in other languages; contact Fluke Process Instruments for details.

CONTENTS
7 Introduction
8 System Components
9 Basic Hardware
9 Thermal Barriers and Heatsinks
10 Selecting the Thermal Barrier
16 Care and Maintenance of Barriers and Heatsinks
19 Thermocouple Probes
20 Thermocouple Specifications
21 Thermocouple Cables
22 Datapaq Thermocouple Probes
23 Care and Maintenance of Thermocouples
25 Furnace Temperature Profiles: Creation and Use
26 The Furnace
26 Atmosphere
26 Specification
27 Thermal Mass of the Tracker System
27 Thermal Barriers, First Use
27 Probe Location and Attachment
28 Preparing the Logger
29 Installing the Logger in the Thermal Barrier
31 Placing the System in the Furnace
32 Removing from the Furnace and Downloading Data
34 Troubleshooting
34 Checking the Data
35 Testing the Logger and Thermocouples
35 Datapaq Service Department
36 INDEX

FURNACE TRACKER Introduction 7
Introduction
Datapaq
®Furnace Tracker ®, incorporating Insight™software, is a complete
system for monitoring and analyzing the temperature profiles of products within
all types of furnace processes. Power and flexibility make it a perfect tool for
process temperature monitoring, from commissioning and troubleshooting to
process optimization, ensuring consistent quality of product, consistent furnace
performance and maximum efficiency. Innovative analysis techniques help in
identifying problems, fine-tuning the process and reducing running costs.
Telemetry options allow full monitoring of temperatures in real time while a
job is actually in the furnace: hardwired telemetry is part of the standard system
(see the dedicated User Manual supplied with your data logger), and Furnace
Tracker can be specified to include the TM21 radio-telemetry system.
Statistical Process Control (SPC) allows easy analysis of the results of
profile runs over time, highlighting trends in the performance of your process,
and allowing potential problems to be identified and dealt with before they
occur.
Powerful reporting facilities allow the user to generate customized printouts,
including any or all of the analysis results or raw temperature data.
Systems can be specified to include additional or alternative hardware for a wide
range of different purposes – and in some cases additional software, including:
•Furnace Surveying – conduct and analyse wizard-driven temperature
uniformity surveys to assess the accuracy and uniformity of heating within a
furnace.
•CAB Surveyor – monitor the performance of a furnace by running a
standard instrumented survey jig through it to gather and analyse
temperature data.
This manual contains the following sections:
•Basic Hardware (p. 9) – The standard system’s thermal barriers and
thermocouple probes, their specifications and their care and maintenance.
•Furnace Temperature Profiles (p. 25) – All the stages of obtaining a
temperature profile from a typical furnace process, including setting up the
hardware, running the system through the process, and downloading the
data.
•Troubleshooting (p. 34).
From Reflow manual
OMT para
re. EOS
From Help,
Intro topic

8 Introduction FURNACE TRACKER
The dedicated User Manual supplied with your data logger should be read in
conjunction with this manual. It provides information on operating the logger,
including:
•Installing Insight and establishing communication between logger and PC.
•Resetting the logger with new data-collection parameters.
•Downloading the collected data to the PC.
•Use of hardwired telemetry.
•Troubleshooting logger problems.
For full details on use of the Insight software, refer to the online Help system
available when the software is installed.
System Components
A typical Furnace Tracker system comprises:
•Data logger, with communications lead and charger; logger with radio-
telemetry option includes internal transmitter.
•Receiver (radio-telemetry option only).
•Thermal barrier – to protect the logger during its time in the furnace.
•Thermocouple probes.
•Insight Furnace Tracker software.
•User documentation:
○Datapaq Furnace Tracker User Manual.
○Data logger User Manual (specific to the logger model).
○TM21 Radio-telemetry System User Manual (radio-telemetry option only).
Additional hardware, software and documentation are supplied with Furnace
Surveying, CAB Surveyor and other systems, as appropriate.
This manual, and other Datapaq user documentation, in various languages, is
available on the Insight installation DVD or USB key included with Datapaq systems.
During the software installation, you may select documents to be copied to your PC
for rapid on-demand viewing through Insight.

FURNACE TRACKER Basic Hardware 9
Basic Hardware
The standard Furnace Tracker system includes one or more thermal barriers
and appropriate thermocouples.
For use of the data logger, and for other special-purpose hardware,
see the documentation supplied with it.
Thermal Barriers and Heatsinks
The thermal barrier provides the thermal and mechanical protection
necessary for the data logger to survive in the hostile environment of an
industrial furnace.
WARNING
It is essential to use the correct Datapaq thermal barrier for your individual process,
as supplied and approved by Fluke Process Instruments. Failure to use the
appropriate approved barrier, or the use of a barrier in an unapproved manner (e.g.
using above the specified temperature, or for longer than the specified time, or with
insufficient opportunity for adequate cooling between profile runs), can cause
catastrophic damage to the data logger or to other equipment, can endanger
health, or (if lithium batteries are being used)may lead to severe injury or death.
For the same reasons, never use a damaged thermal barrier.
Ensure that all dimensions of your logger/barrier/accessory assembly are such that it
will fit comfortably within the furnace through all stages of the process. Pay
particular attention to handles, catches, etc., and to trailing thermocouples. Failure
to do this can cause the assembly to jam in the furnace with consequent
overheating and potentially-severe damage to the equipment. Resultant battery-
leakage, and the act of recovering the equipment, may cause skin burns and
respiratory irritation.
Microporous insulation covered by a Mullite fiber cloth provides the primary
thermal protection. Heatsinks – stainless steel containers filled with a non-
toxic, non-flammable phase-changing material – provide additional, secondary
protection when the system has to operate at high temperature for extended
periods. The phase-changing material absorbs the heat and maintains a
temperature of 58°C/136°F until all the material has changed from solid to liquid
state.

10 Basic Hardware FURNACE TRACKER
Heatsinks have a temperature-sensitive label to provide indication of the
maximum temperature experienced by the data logger, and a warning should
the temperature exceed 77°C/170°F. This warning is important: see p. 17.
The Microporous insulation material will absorb moisture if stored in a damp
environment. Although this will not result in damage to the thermal barrier, its
performance will be degraded until the moisture is removed.
All Datapaq thermal barriers for furnace use have an adjustable lid to
compensate for any shrinkage of insulation material, and TB4900 and most
TB4000 series barriers (see below) also have provision for renewal of the
Mullite fiber used to clamp the thermocouple cables (see p. 18). Thermal
barriers with lid secured by catches have adjustment in the catches to
compensate for shrinkage (see p. 17).
Materials used for any fasteners in the TB4900 series barriers (nuts and bolts)
are normally 310 stainless steel, and are selected to avoid seizure at high
temperature.
Selecting the Thermal Barrier
The selection of barrier type depends principally on the height and width
limitations of the furnace, the data logger type, process duration, temperature,
time at temperature, furnace atmosphere and whether the process includes a
quench cycle.
When assessing the barrier’s required thermal performance, include within the
overall process duration the time taken to retrieve the Tracker system from the
furnace and to remove the data logger from the barrier.
Consult Fluke Process Instruments for advice on selecting a thermal barrier.
When changing the parameters of your process, be aware that using your
thermal barrier for conditions other than originally specified (i.e. longer
durations and/or higher temperatures) may cause serious damage to all parts of
your Datapaq system. We strongly advise you to contact Fluke Process
Instruments to confirm that your system is suitable for your new process. You
will require the following information about the new process:
•Heating phase (time to reach soak temperature).
•Soak time and temperature.
•Cooling phase (time from soak temperature to end of process).
•Furnace atmosphere.
•Time from end of cooling phase to removal of the thermal barrier and
dismantling of the system.
Moved to here from
further down.
Delete section heading

FURNACE TRACKER Basic Hardware 11
A lower process temperature can still result in serious damage to your system if the
duration has been increased.
Two ranges of barrier are available:
•TB4000 Series, standard range – For use in environments free from
carbon and where maximum temperature does not exceed 800°C/1,472°F.
•TB4900 Series, for severe environments – For environments where
carbon is present and maximum temperatures do not exceed 1,000°C/
1,832°F in normal combustion atmospheres. Also recommended for
applications where temperatures change rapidly (such as gas quench) as this
range of barrier utilizes Datapaq Floating PlateTM technology to minimize
distortion of the thermal barrier’s base and lid. Also recommended where
height tolerances are critical. The barriers feature 310 stainless steel
(including catches), round edges and a replaceable thermocouple wear-strip.
Due to continuing product development, specifications are subject to change
without notice.
TB4000 Series – Standard Thermal Barriers
TB4000 series thermal barrier (TB4005 shown)
From barrier
dbase
From next
section

12 Basic Hardware FURNACE TRACKER
TB4005
Temp °C 200 250 300 400 500
Temp °F 392 482 572 752 932
Duration (hrs) 65421.5
Dimensions Height Width Length Weight
125 mm 248 mm 504 mm 12.0 kg
4.9 in. 9.8 in. 19.8 in. 26.3 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 × TB1001
TB4012
Temp °C 200 300 400 600 800
Temp °F 392 572 752 1,112 1,472
Duration (hrs) 15.5 10 6.5 4 2
Dimensions Height Width Length Weight
170 mm 297 mm 526 mm 20.0 kg
6.7 in. 11.7 in. 20.7 in. 44.1 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 x TB1066 (TP6100/TP3000)
1 × TB1069 (DP5x60/DQ1860)
TB4015
Temp °C 200 300 400 600 800
Temp °F 392 572 752 1,112 1,472
Duration (mins) 200 140 110 70 50
Dimensions Height Width Length Weight
100 mm 247 mm 509 mm 11 .7 kg
3.9 in. 9.7 in. 20.0 in. 25.8 lb
Logger DP5x60 or DQ1860
Heatsink 1 × TB1001

FURNACE TRACKER Basic Hardware 13
TB4026
Temp °C 200 400 600 800
Temp °F 392 752 1,112 1,472
Duration (hrs) 24 12 8.5 6
Dimensions Height Width Length Weight
250 mm 357 mm 543 mm 31 .0 kg
9.8 in. 14.1 in. 21.4 in. 68.4 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 x TB1066 (TP6100/TP3000)
1 × TB1069 (DP5x60/DQ1860)
TB4056
Temp °C 200 400 600 800
Temp °F 392 752 1,112 1,472
Duration (hrs) 84.25 2.75 2
Dimensions Height Width Length Weight
150 mm 275 mm 504 mm 15.0 kg
5.9 in. 10.8 in. 19.8 in. 33.1 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 2 x TB1001
TB4900 Series – Severe-environment Thermal Barriers
TB4905
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 621.25 10.8
Dimensions Height Width Length Weight
129 mm 248 mm 534 mm 13.8 kg
5.1 in. 9.8 in. 21.0 in. 30.3 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 × TB1001.

14 Basic Hardware FURNACE TRACKER
TB4912
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 14.5 6.5 42.1 1.75
Dimensions Height Width Length Weight
174 mm 296 mm 531 mm 21.0 kg
6.9 in. 11. 7 in. 20.9 in. 46.3 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 x TB1066 (TP6100/TP3000)
1 × TB1069 (DP5x60/DQ1860)
TB4912 severe-environment thermal barrier with heatsink and data logger.
TB4915
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 3.3 1.8 1.2 0.8 0.7
Dimensions Height Width Length Weight
104 mm 247 mm 529 mm 12.6 kg
4.1 in. 9.7 in. 20.8 in. 27.8 lb
Logger DP5x60 or DQ1860
Heatsink 1 × TB1001

FURNACE TRACKER Basic Hardware 15
TB4926
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 24 12 8.5 64.5
Dimensions Height Width Length Weight
254 mm 358 mm 563 mm 32.0 kg
10.0 in. 14.1 in. 22.2 in. 70.6 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 x TB1066 (TP6100/TP3000)
1 × TB1069 (DP5x60/DQ1860)
TB4933
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 27 18 10.5 8.5 7. 5
Dimensions Height Width Length Weight
304 mm 406 mm 613 mm 44.0 kg
12.0 in. 16.0 in. 24.1 in. 97.0 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 x TB1066 (TP6100/TP3000)
1 × TB1069 (DP5x60/DQ1860)
TB4938
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 18 95.5 3.75 2.5
Dimensions Height Width Length Weight
217 mm 291 mm 522 mm 26.0 kg
8.5 in. 11. 5 in. 20.6 in. 57.3 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 1 x TB1066 (TP6100/TP3000)
1 × TB1069 (DP5x60/DQ1860)

16 Basic Hardware FURNACE TRACKER
TB4950
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 27 18 10.5 8.5 7. 5
Dimensions Height Width Length Weight
154 mm 275 mm 529 mm 17.4 kg
6.1 in. 10.8 in. 20.8 in. 38.3 lb
Logger TP6200 or TP3300
Heatsink 1 x TB1066 or 1 x TB9840
TB4956
Temp °C 200 400 600 800 1,000
Temp °F 392 752 1,112 1,472 1,832
Duration (hrs) 84.25 2.75 21.25
Dimensions Height Width Length Weight
154 mm 275 mm 529 mm 17.4 kg
6.1 in. 10.8 in. 20.8 in. 38.3 lb
Logger TP6100 or TP3000 or DP5x60 or DQ1860
Heatsink 2 × TB1001
Care and Maintenance of Barriers and Heatsinks
Cooling
Placing a hot thermal barrier directly onto a cold surface will probably cause the
barrier to distort due to the different cooling rates of the surfaces. Thus, place
the hot thermal barrier on a Datapaq barrier stand. Alternatively use spacers, a
ceramic fiber blanket or refractory material to ensure uniform cooling.
Fluke Process Instruments will not be liable for damage caused by distortion due to
incorrect handling of a barrier while cooling.
The heat absorbed by the thermal barrier will continue to affect the
temperature of the heatsink and logger: remove them from the barrier as soon as
the test is completed, and leave them in the open to cool before further use; in
most cases, cooling overnight is sufficient.

FURNACE TRACKER Basic Hardware 17
Examination
Compare the heatsink’s thermometer-strip with the following possible
scenarios.
In this ideal scenario the heatsink has not reached 71ºC/160ºF. On
cooling, the phase-change material will re-crystallize. Your system and
process are compatible.
A possible problem: the temperature has exceeded 77ºC/171ºF.
Allow the heatsink to cool to room temperature (about 15ºC/59ºF)
before placing in a freezer at −20ºC/−4ºF to cool overnight. You must
do this to ensure the phase-change material crystallizes, as it may not
do this at room temperature. After freezing, allow the heatsink to
return to room temperature. Be aware that your process is near the limit
of the barrier’s capacity. If the heatsink’s thermometer-strip has
recorded a temperature greater than 77°C/171°F, replace it before further use;
a self-adhesive replacement is supplied with the Tracker system.
A definite problem: the heatsink has been exposed to a process
beyond the system’s thermal capacity. You must follow the procedure
described immediately above, and also contact Fluke Process
Instruments for advice.
If the heatsink phase-change material leaks, contact Fluke Process
Instruments. It is a non-toxic wax-like substance that dries hard powdery white
and has a slight acidic smell. Wait until it is dry before scraping off any material
that has leaked onto the surface of the barrier.
Examine the cooled thermal barrier and heatsinks for damage before storing in
a dry environment to avoid the insulation absorbing water.
Check the thermal barrier’s seals and closing mechanism, and rectify any
damage before further use.
Sealing Catches
Barriers’ catches may require some adjustment, but can easily be set by hand.
Spare parts for catches are available from Fluke Process Instruments.
WARNING
For optimum performance, barriers with damaged catches should be returned to
Fluke Process Instruments for repair.
DEL1-sentence
para above re
examining
Move this to
here from below

18 Basic Hardware FURNACE TRACKER
Adjust each catch (as
below) such that it
shows no slack when
closed, and only light
thumb pressure is
required just before it
shuts tight.
•TB4000 Series (Standard) – Use a screwdriver to turn the adjusting screw (A)
under the catch-lever.
•TB4900 Series (Severe Environments) – Manually rotate the adjusting thumb
screws (B) between each thumb-catch.
Thermocouple Wear-strips
The Mullite fiber wear-strips in the base and lid can be replaced by the user as
follows.
In the barrier base . ..
1. Undo the screws
retaining the bracket that
secures the wear-strip
inside the barrier (C–D).
2. Remove the old Mullite
fiber wear-strip (B).
3. Thread the new Mullite
fiber wear-strip over the
small-diameter bar inset
from the carrying handle (A), and over the face of the inside insulation.
4. Fasten the ends of the new wear-strip with the bracket and screws (C– D).
In the barrier lid . ..
1. Unscrew the six retaining
screws (C–D), and
remove the insulation
layer and metal plate.
2. Remove the old Mullite
fiber wear-strip (B).
3. Thread the new Mullite
A B

FURNACE TRACKER Basic Hardware 19
fiber wear-strip over the small-diameter bar inset from the carrying handle
(A).
4. Fasten the ends of the new wear-strip by replacing the insulation and metal
plate. Replace the six screws (C–D).
Thermocouple Probes
Thermocouple probes utilize an effect 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).
Datapaq thermocouple probes.
The practical implementation of thermocouples requires sophisticated
electronics to eliminate potential measurement errors which include poor
linearity over the measurement range, and inaccuracy due to temperature
variations at the cold junction.To accommodate these the electronics in the
measuring system must simulate a temperature of 0°C/32°F at the cold
junction, as well as compensating for any non-linearity over the range of
thermocouple operation.
Over the years, ‘standard’ thermocouple types have been developed using
materials chosen for sensitivity, linearity (consistency of sensitivity over the
useful temperature range), price and availability.
From Reflow manual
DEL last 2 sentence re. types
DEL section re reflow t/cs
Order table rows as here
Order table cols as here

20 Basic Hardware FURNACE TRACKER
Probe
Type
Typical
Application
IEC
Plug/Socket Color
Previous
Plug/Socket Color
BKiln Gray White
KGeneral purpose Green Yellow
NFurnace, kiln Pink Orange
R/S Kiln Orange Green
The standard probes for furnace operation are type K: they have a hot junction
combining nickel-chromium alloy and nickel-aluminum alloy.
International specifications for type K define a sensitivity and linearity over the
range 0–1,370°C/32–2,498°F (see below). The practical operating range is
limited by the properties of the cable insulation (normally PTFE, mineral or
ceramic fiber; see below) or metallic sheathing.
WARNING
Never connect thermocouples to mains electricity. This could cause major injury
or death.
Take care when handling thermocouple cables to avoid accidental damage to the
eyes by sharp thermocouple-tips.
Thermocouple Specifications
Probe
Type
Temperature
Range*
Cable
Insulation
Accuracy of Datapaq
Probes
Notes
BContact Fluke
Process Instruments
K0°C to 1,370°C/
32°F to 2.498°F
PTFE,
ceramic,
mineral
insulation,
glass fiber
0–1,250°C ±1.1°C/
32°F to 2,282°F ±2°F
or ±0.4%, whichever is greater
(ANSI MC96.1)
Datapaq probes
are Nicrobell™
sheathed for
high-temperature
operation
N0°C to 1,300°C/
32°F to 2,372°F
Mineral
insulation
only
0–1,300°C ±1.1°C/
32°F to 2,372°F ±2°F
or ±0.4%, whichever is greater
(ANSI MC96.1)
R/S 0°C to 1,760°C/
32°F to 3,200°F
Ceramic
tube
0–1,000°C ±1.1°C; 1,100–
1,600°C ±1°C +
0.003(t−100)°C, where
t = measurement temperature
Not available
from Fluke
Process
Instruments
* The cable insulation material limits the actual operating temperature (see below).
Para from end of
t/c chapt
DEL 2nd part of
sentence re. heating
elementsto
Add asterisk