heat flux instrumentation operating manual...user manual page 7 of 58 to clean the equipment,...

Heat Flux Instrumentation

Operating Manual Issue 2.1 May 2012

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Table of Contents

1 Manufacturer & Contact Details ....................................................................................4

2 System Details .............................................................................................................4

3 Introduction ................................................................................................................5

3.1 Digitron VOYAGER ....................................................................................................5

3.2 What is HEAT FLUX? ..................................................................................................6

4 Safety .........................................................................................................................6

4.1 General Safety ..........................................................................................................6

4.2 User Replaceable Parts ..............................................................................................9

4.3 Operational Safety ....................................................................................................9

5 Introduction to Hardware ........................................................................................... 11

5.1 Components .......................................................................................................... 11

5.2 Equipment Check list ............................................................................................... 12

5.3 Modes of Operation ................................................................................................ 13

5.4 Equipment Details .................................................................................................. 13

5.5 Heat Flux Measurement .......................................................................................... 24

6 Introduction to Software ............................................................................................ 26

6.1 Versions ................................................................................................................ 26

6.2 Installation ............................................................................................................. 26

6.3 Data Management .................................................................................................. 27

6.4 Using the Software ................................................................................................. 27

7 Measurement Procedure ............................................................................................ 27

7.1 Pre-trial Preparation ............................................................................................... 27

7.2 Assembling the Equipment ...................................................................................... 27

7.3 ThermaFlux Configuration ....................................................................................... 28

7.4 Data Management .................................................................................................. 28

7.5 Measurement Procedure ......................................................................................... 29

8 Software ................................................................................................................... 31

8.1 Installation ............................................................................................................. 31

8.2 Initiating the Software ............................................................................................. 31

8.3 Test Tab ................................................................................................................. 32

8.3.1 Configure ................................................................................................................. 32 8.3.2 Check ready .............................................................................................................. 33 8.3.3 Download data ......................................................................................................... 33 8.3.4 Reset ....................................................................................................................... 34 8.3.5 Status ...................................................................................................................... 35 8.3.6 Product Lines ............................................................................................................ 35 8.3.7 Sensor Table ............................................................................................................. 37 8.3.8 S/N Groups ............................................................................................................... 37 8.3.9 Configuration names ................................................................................................. 38 8.3.10 Settings .................................................................................................................... 38 8.3.11 About ....................................................................................................................... 39

8.4 Analyse .................................................................................................................. 39

8.4.1 View Tests ................................................................................................................ 39 8.4.2 Filter tests ................................................................................................................ 41 8.4.3 Test info ................................................................................................................... 41 8.4.4 Set as Standard ......................................................................................................... 41 8.4.5 Remove as Standard ................................................................................................. 41 8.4.6 Show Standard ......................................................................................................... 41 8.4.7 Graphical Functions .................................................................................................. 41 8.4.8 Data grid visible ........................................................................................................ 44 8.4.9 Settings .................................................................................................................... 44

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8.4.10 Copy graph ............................................................................................................... 44

8.5 Report ................................................................................................................... 44

8.6 Utilities .................................................................................................................. 46

8.6.1 Import database ....................................................................................................... 46 8.6.2 Import flx file ............................................................................................................ 46 8.6.3 Import legacy database ............................................................................................. 46 8.6.4 View Data folder ....................................................................................................... 47 8.6.5 Unlock Logger ........................................................................................................... 47

9 Technical Specification ............................................................................................... 48

9.1 Voyager (ThermaFlux) Datalogger and Sensor Head Specification ................................. 48

9.2 Conditioning Unit Operating Conditions and Specification ........................................... 48

Appendix A: ThermaFlux Instruments .................................................................................. 49

Appendix B: Heat Flux – Benefits ......................................................................................... 51

Appendix C: Clearance Checks ............................................................................................. 52

Appendix D: Oven Profiling – Risk Assessment ...................................................................... 54

Appendix E: ThermaFlux Operating Limits – Voyager A & B ................................................... 57

Appendix F: Conversion Factors ........................................................................................... 58

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1 Manufacturer & Contact Details

2 System Details

Each system comes with the following information which is provided separately:

• Equipment Certificate;

• Calibration Certificate;

• Unlock code.

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3 Introduction

3.1 Digitron VOYAGER

Digitron VOYAGER is the generic name for a new family of heat flux datalogging instruments for

the measurement of heat flux and temperature profiles.

They are a development of the Digitron ThermaFlux range which are well established and proven

within the food industry. The remainder of this manual focuses on the new Voyager system.

However, further information on the ThermaFlux range is included in Appendix A.

The VOYAGER instruments are portable and battery operated, and designed for ease of use. They

are robustly packaged for demanding production environments, and are supplied with new, user

friendly, intuitive software. Key benefits include their modular nature and use of common

components, which adds both flexibility and affordability. This allows the systems to be easily

customised for particular applications and added to as requirements extend or change.

The instruments can be used in a number of situations but are most commonly employed in

continuous, travelling ovens. The unit sits on the oven band and travels through the thermal

process, ideally surrounded by product, recording the heat flux and temperature profiles as it

goes. The units are generally used in heating processes but can also be used in cooling processes,

including chocolate cooling tunnels.

A radio frequency remote control allows the user to precisely start and stop the unit, and with the

dedicated software, high resolution, accurate heat flux profiles can be obtained simply and

quickly. The units can also be manually started and stopped by using the button on the

datalogger.

A conditioning unit is an integral part of the system and, depending on the model, allows for

optimised pre-conditioning of up to 3 sensor heads. Unlike the ThermaFlux base station, the

Voyager conditioning unit only provides pre-conditioning of the sensor heads - no post process

conditioning (cooling) is provided.

The dedicated software incorporates comprehensive data management and analysis facilities,

including profile comparison, thus allowing expedient diagnostic analysis. The data lends itself to

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rapid product and process improvement, including optimisation of process and product

consistency, and reduction of waste, energy consumption and process downtime (Appendix B).

3.2 What is HEAT FLUX?

Heat Flux is a measure of the rate of heat energy transfer. In many thermal processing

applications it is the amount and rate at which heat is transferred to or from a product which

determines its characteristics. The measurement of process temperature alone does not give this

information. For some further information see section 5.5.

4 Safety

4.1 General Safety

EC DECLARATION OF CONFORMITY

This equipment is in compliance with the essential requirements and other relevant

provisions of the following Directives.

Electromagnetic Compatibility Directive

Low Voltage Directive

Conditioning unit: Cable lengths must not exceed 1.5 metres.

Datalogger: All input cables must be screened and must not exceed 1.5 metres.

This User Manual contains information and warnings that must be observed to keep the

equipment in a safe condition. The instrument should not be switched on if it is damaged and it

should not be used under wet conditions.

For correct and safe use of this equipment it is essential that both operating and service

personnel follow generally accepted safety procedures in addition to the safety precautions

specified.

Safety protection is likely to be impaired if, for example, the equipment shows visible damage or

fails to operate normally.

The process equipment gets HOT. Use protective, heat resistant, gloves and place equipment on

a heat resistant surface after use. Note that the sensor heads may be hot following pre-

conditioning (depending on selected temperature) and protective gloves should be worn as

necessary when transporting the equipment to the plant being measured.

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To clean the equipment, disconnect all power sources and wipe lightly with a clean, soft cloth

dampened with water. The sensor surfaces may be gently wiped.

WARNING Before removing the cover of the conditioning unit for maintenance or repair, the mains supply

must be isolated. The cover should only be removed by suitably qualified personnel.

The datalogger cover should not be removed.

The sensor head assemblies should not be opened.

This equipment is specified for use as follows:

Indoor use only;

Pollution Degree 2;

Operating conditions (conditioning unit): 5-40°C;

Operating conditions (in use): see specification.

This equipment must be used in the manner described in this manual otherwise the protection

provided may be impaired.

CAUTION – Battery Replacement

When replacing batteries the correct type MUST be used and they MUST be orientated correctly.

There is a risk of explosion and/or damage to the equipment if these instructions are not adhered

to.

Battery Disposal: Used batteries should be recycled or disposed off as per local regulations.

Further Advice

• Treat the stainless steel cables with care and try to avoid damage or “kinking”;

• Take care when handling the stainless steel over-braid as there is a risk of some sharp

ends, particularly where the braid enters the connector;

• DO NOT allow the cables to loop upwards in the process as this can lead to the equipment

getting caught;

• The loaded transport case is heavy – take care when lifting and follow good manual

handling procedures. Use the wheels whenever possible.

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Symbols and Terms

The equipment carries a number of symbols and warnings. The following table gives an

explanation of their meaning. Any warnings should be strictly heeded.

CAUTION: Risk of danger, refer to user manual

CAUTION: Risk of electric shock. High voltages are present

CAUTION: Hot Surface. Failure to observe may result in burns

Refer to manual

Protective earth Ground

Earth Terminal

OFF (Power)

ON (Power)

Instrument Plates Conditioning Unit

The conditioning unit carries the model number and the serial number of the system.

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Sensor Heads

There are four plates on the sensor heads. One carries the serial number

the calibration constant(s) and some warning symbols.

third and fourth plates give cable connection details.

4.2 User Replaceable Parts

Description Mains Fuse

Channel Fuses – 1, 2 & 3

Datalogger battery

Remote trigger batteries

4.3 Operational Safety

It is recommended that a FULL RISK ASSESSMENT

measurements. A sample risk assessment is included in Appendix

conduct their own assessments based on their own specific circumstances.

The following are issued as guidelines

1. Communicate with appropriate members of staff:

- production may have to be stopped if unforeseen problems arise;

- check procedure for stopping plant should this be necessary;

- do not conduct trial work alone;

- ensure appropriate help is available

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plates on the sensor heads. One carries the serial number of the head

calibration constant(s) and some warning symbols. These symbols must be observed.

third and fourth plates give cable connection details.

User Replaceable Parts

Part 240V 2A T; HBC (FS1)

1, 2 & 3 240V 2A T; LBC (FS3, FS4, FS5)

1 x AAA Alkaline (1.5V); Non-rechargeable

Remote trigger batteries 2 x AA Alkaline (3V); Non-rechargeable

FULL RISK ASSESSMENT is undertaken before carrying

measurements. A sample risk assessment is included in Appendix D but each client should

conduct their own assessments based on their own specific circumstances.

The following are issued as guidelines only and DO NOT replace a full client assessment

Communicate with appropriate members of staff:

production may have to be stopped if unforeseen problems arise;

check procedure for stopping plant should this be necessary;

do not conduct trial work alone;

ensure appropriate help is available and is fully briefed in the procedure

of the head and another

mbols must be observed. The

rechargeable

rechargeable

undertaken before carrying out any heat flux

but each client should

nt assessment.

in the procedure;

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- check location of emergency stops;

- are there any access points through the process e.g. oven access doors;

2. Check access at entrance and exit of plant:

- can the equipment be safely loaded and retrieved;

- is guarding in place and secure;

- can equipment be reached at exit;

- will the equipment safely enter and exit the process;

3. Clearance checks:

- check there is sufficient clearance through the entire process for the equipment;

- clearance last time is no guarantee of clearance this;

- check entire width of process;

- see recommended clearance check procedure in Appendix C;

- different configurations may require different clearances. A higher clearance should be

allowed for the framework to allow for any distortions or warping of the oven band. As a

minimum, the following is recommended:

4. Check and agree procedure for loading equipment:

- is a gap required in production;

- how will the gap be made;

- who will make the gap;

5. On exiting the process the equipment may be VERY HOT – wear gloves. The sensor heads

may also be hot prior to entering the process depending on their pre-conditioned

temperature. Wear gloves as appropriate.

6. Extra care may be necessary depending upon the particular configuration being used, for

example when conducting cross band checks where multiple components are involved;

7. Ensure the equipment is cool before packing away (<45°C; 113°F);

8. The loaded transport case is heavy – take care when lifting and follow good manual handling

procedures. Use the wheels whenever possible.

Standard System Clearance: System depth + 10mm

Framework System Clearance: System depth + 15mm

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5 Introduction to Hardware

5.1 Components

One of the key advantages of the new Voyager system is its modular nature. The components

making up the Voyager range can be broken down into 3 categories:

a. Common or standard components e.g. datalogger;

b. Modular or non-standard components, where a choice of component is available;

c. Optional extras.

The image below shows a three channel system with three Voyager B sensor heads. The table on

the following page gives a complete component list.

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5.2 Equipment Check list

The Voyager system consists of the following:

Component Common Required Optional Extras Modular Items – Choice Comments

ThermaFlux datalogger � �

Thermal barrier � Depth of barrier: 25mm; 40mm

Conditioning unit � Number of channels: 1; 2 or 3 One channel per sensor

Mains lead – conditioning unit � �

Cables – Conditioning unit to sensor(s) � � Standard length: 600mm

Sensor head(s) – up to 3 � Current sensor options:

a. Voyager A: Single sided; Black/Black;

b. Voyager B: Single sided: Black/Silver

Depth: 25mm

Cables – Sensor(s) to logger � Customer defined lengths available Standard lengths: 500mm, 750mm, 1000mm

Framework � � Available for 25mm barrier; 1, 2 or 3 sensors

Bracket � � Available for 40mm barrier; 1 sensor only

RF remote control � � For UK and Europe only

Download cable – serial � �

Serial/USB converter (not supplied) � Not supplied

Gloves � �

CD – Software � �

CD – Unlock code � Unique to customer and system

Manual � �

Spares – Batteries, fuses � �

Transport case � �

Calibration certificate � Unique to customer and system

Equipment certificate � Unique to customer and system

Temperature probes (various) � � On request

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5.3 Modes of Operation

The system has three modes of operation:

i. Conditioning of the sensor heads – this involves heating the sensor blocks to a pre-

determined temperature prior to commencing any trial work;

ii. Logging – this takes place as the equipment travels through the process under test, for

example an oven;

iii. Downloading – upon retrieval from the process, the data is downloaded.

Warning: The conditioning unit and conditioning cables are bench top items and do not travel

through the oven.

5.4 Equipment Details

ThermaFlux Datalogger & its Operation

The datalogger is battery powered:

• Standard alkaline (non-rechargeable) AAA battery: 1.5V;

• See cautionary note re battery replacement and disposal in Section 4.1

Position C

Battery

compartmentAerial

Reset button

Position B Position A

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The battery is replaced by opening the battery compartment (indicated with a battery symbol) on

the side of the logger – quarter turn.

The logger has 24 channels and these are divided across 3 sensor positions (A, B and C) as detailed

in the accompanying table. In the software these positions are referred to as 1, 2 and 3. The

connectors used for the system are lemos. The cables, which are all stainless steel braided, are

engraved (or colour coded) and the lemo connectors are keyed such that the system cannot be

assembled incorrectly. The lemo plugs and sockets also have red marks on them – when

connecting ensure that these red marks align.

Reset: An internal button, accessed through a very small hole in the side of the datalogger case

can be pressed (>2s) to reset the logger.

Datalogger – Connecting the Sensor Cables

Position on logger A or 1 B or 2 C or 3

Description on logger case A Tc A mV B Tc B mV C Tc C mV

Function Temp Heat flux Temp Heat flux Temp Heat flux

No of available channels 4 4 4 4 4 4

Engraved symbol T V T V T V

Colour code Yellow Black Yellow Black Yellow Black

Note: Conditioning Cable: Engraved symbol: C; Colour code: Red.

The supplied communication cable plugs into

the small black socket. The datalogger is a serial

device and therefore connects to a serial port.

If a serial port is not available then it can

connect into a USB port via a USB/serial

adapter.

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The logger can be operated in two ways, either with the remote trigger, which communicates via

the short white aerial, or manually. The logger is manually started (and stopped) by pressing the

small button next to the PC connector – see photo below.

There are a number of LEDs on the logger and these indicate the following:

LED Action Description

LED 1* On continuously Confirms communication (when connected to PC)*

LED 1 One flash and

then continuous

flashing

When the logger is started this green light flashes once and then

flashes continuously to confirm that logging is taking place. The rate

of flashing indicates the logging rate.

LED2 One flash When the start/stop button is pressed and released (or the remote is

used) this red light flashes once to confirm that logging has stopped.

At the same time the green light stops flashing.

This light can also indicate a configuration error. The logger should be

re-configured.

LED3 Continuous When an attempt is made to start the logger this red light comes on

to indicate that there is data in the memory which has not been

downloaded. The data should either be downloaded or “Reset”

should be selected from within the software.

LED4 Continuous Temperature of the logger is outside operating limits

LED3 LED4 Continuous Low battery

*If the green light does not come on when the comms cable is connected, then try the following:

• Check comms port on computer and in software – they must be the same;

• Replace battery.

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Remote trigger operation:

The remote trigger is battery powered:

• 2 x standard alkaline (non-rechargeable) AA batteries: 3V;

• See cautionary note re battery replacement and disposal in Section 4.1

Before using the trigger it is important that communication is established between the trigger and

the datalogger. This is done as follows:

a. Switch on remote control (Power On) and the red power light will come on;

b. Point remote control at the unit and press yellow button until the “Ready” light comes on.

This confirms communication. It may be necessary to hold the button in for a period of time,

or to release and press again;

c. On pressing the green button the green light will come on and the logger will start;

d. Pressing the red button will stop the logger – the red light will come on to confirm that the

“stop” message has been received. It is not necessary to re-establish communication (yellow

button) before stopping the logger.

Thermal Barrier

The datalogger is protected within a thermal barrier. There are currently 2 barriers available:

• 25mm: this locates within the framework or can be used on its own.

• 40mm: this can be supplied with an optional pre-fitted bracket.

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Software

The system is supplied with new, user friendly, intuitive software. Further details regarding the

installation and use of the software are contained in Section 6.

Conditioning Unit

The purpose of the conditioning unit is to

pre-condition the sensor blocks prior to

entering the line being measured.

Following conditioning the sensors may be

HOT – handle with care and use gloves as

necessary.

The sensor blocks are heated for three reasons:

a. to ensure a fixed and repeatable starting point;

b. to prevent the formation of condensation on the surface of the sensors, as this affects

their performance. A temperature above the dew point should be selected;

c. to allow for a reasonable temperature gradient between the sensor blocks and the

surrounding conditions, as this is a pre-requisite for the equipment operating correctly.

For the majority of oven applications a temperature of 80 - 85°C (176 - 185°F) works well. If the

conditioning unit is located some distance from the entrance to the oven then the temperature

should be raised slightly (perhaps 5°C) to allow for the cooling which will take place while

transferring the equipment to the oven.

As indicated above it is necessary for

there to be a temperature gradient

between the sensor block and the

surrounding conditions for the

equipment to be successfully used,

and if possible a gradient should be

maintained throughout the whole

process. When selecting a block

temperature it is important therefore

to consider the process conditions.

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As a general rule the difference in temperature between the surrounding conditions and the

sensor should be no less than 35 - 40°C, although this is not always possible, particularly towards

the end of a run where the last zone may be running at a fairly low temperature. Note also that a

temperature above the ambient temperature within the facility should be selected as the

conditioning unit does not have cooling facilities.

Given the above, it may be necessary to alter the sensor block temperature depending on the

particular process conditions. If, for example, the oven is especially humid then it may be

necessary to raise the sensor temperature to avoid condensation forming on the sensors. A

temperature of up to 95°C can be selected but extra caution should be exercised when handling

the equipment.

Alternatively, in a drying application, where the

process temperature may be around 90 – 100°C

(194-212°F), an initial block temperature of say

50°C (122°F) may be more appropriate.

It is also possible to use the equipment in cooling tunnels. Since the block will cool through the

process it is necessary that the starting temperature be relatively high. Thus, the sensor block is

heated before entering the process and again a temperature of 80 – 90°C (176-194°F) is normally

selected. When the sensors are cooling the heat flux is negative.

The sensor block temperature should never exceed 150°C.

Measuring bottom heat flux in a cooling tunnel is difficult due to the belt being generally solid and

plastic, and is not usually recommended. Although the sensor block does not make direct contact

with the belt the heat from the sensor can lead to heat distortion of the belt so precautions

should be taken. It is also recommended that when doing top measurements the sensor unit is

not placed directly on the belt as the casing will also be relatively hot and this may lead to some

distortion. Positioning the sensor on a piece of insulating material will alleviate such issues.

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The conditioning unit comes in 3 models depending on the customer’s requirements. The

simplest is a single channel version and conditions one sensor only. The other versions are 2 and

3 channel respectively with each channel operating independently.

These images show the front and back of

the 3 channel conditioning unit. There

are a number of warning labels on the

instrument and these must be adhered to.

Also, there are a number of labels

indicating the channel numbers, the switch positions,

socket codes and information on the fuses (codes and

sizes). Finally, there is an instrument plate on the

back of the unit giving the model and serial number

of the system, along with the electrical specification.

A stainless steel braided cable connects the conditioning box to a lemo on the sensor head. As

mentioned previously keyed lemos and identifying marks are used (Engraved symbol: C; Colour

coding: Red).

Operation of Conditioning Unit

The conditioning unit is operated as follows:

• Place conditioning unit on a flat surface and deploy the feet;

• Ensure access to rear panel is not restricted in order that unit can be disconnected from

the mains supply as required;

• Ensure ALL switches are set to “OFF”:

- Mains switch on rear panel;

- Channel switches on front panel;

• Insert mains lead and switch on mains power at socket. Switch on the unit (mains switch

on rear panel). A red light will illuminate on the front panel confirming that the unit is on.

DO NOT assume that if the light is off that the unit is not powered up – a failed LED does

not prevent the unit powering up. If the LED has failed then it should be replaced

immediately;

• Connect the sensor(s) to be conditioned using the stainless steel cables provided. Once

connected, switch on the relevant channel(s) using the front panel switches. DO NOT

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CONNECT OR DISCONNECT the sensors from the conditioning unit while the relevant

channel is on as there is a risk of ELECTRIC SHOCK and fuse failure;

• Select conditioning temperature on the Eurotherm controller. Use the arrow keys to raise

and lower the set temperature. The set temperature can be changed slowly by

repeatedly pressing the button (for a short period of time) or to change temperature

rapidly, the button can be held in;

• The controller will display the actual temperature – this is the temperature from a probe

inserted within the sensor block. In order to see the set temperature press one of the

arrow buttons briefly. Pressing for too long will change the set temperature.

• When ready to perform a run (see software section) the sensors must be disconnected

from the conditioning unit – SWITCH OFF the relevant channels before disconnecting;

• On returning from a run, follow the above procedure to recondition the sensor heads;

• When the trial work is complete, drop the set temperature to approximately 20°C (or

lower) and allow the equipment to cool;

• The actual temperature should be below 45°C before the equipment is packed away;

• To pack away: Switch off channels; Disconnect sensors; Switch off conditioning unit

(mains switch); Switch off mains and unplug; Return all components to transport case.

Framework & Bracket

The framework and bracket are optional

items.

The bracket is an attachment for the

40mm thermal barrier onto which a

single sensor head locates. The sensor

can be positioned facing upward or

downwards as required.

There are two versions of the framework,

the original (Framework1) and a newly

developed version (Framework2), and

both are described here.

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Framework1

The original design, which is 600mm

wide and fully adjustable, has been

designed to take up to 3 sensor heads

in a variety of configurations. It also

takes the 25mm thermal barrier which

makes handling of the system

considerably easier. The barrier can

be positioned in the framework in two

ways as illustrated. The second method, with all lemo connectors on the same side (Orientation2)

allows for easier connection and routing of the cabling, but the logger sits slightly higher in the

framework and therefore higher clearance through the oven is required. It is recommended that

the cables follow the system through the oven rather than leading

Framework2

The new design, which is also 600mm

wide, introduces a number of new

features:

1. The unit has handles to allow for

easier retrieval from the oven band;

2. The components can be secured in

place with a number of easy to use

thumb screws;

3. The datalogger can only be

used in one orientation but

locates down in the

framework thus keeping

the height down to 25mm;

4. With the use of special

brackets the sensors can

also be positioned on the leading (or trailing) edge of the frame;

5. The unit uses aluminium cross pieces and is thus lighter in weight.

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Cabling

The sensors connect to the datalogger with cables which are engraved (or colour coded) and

keyed. Each sensor requires two cables, one for the voltage signals (heat flux) and the second for

the temperatures. The cables are stainless steel braided and very flexible and this allows for a

number of sensor configurations. They are also sufficiently flexible to route through the holes in

Framework1 if desired. Cable management is very important – the cables should not be allowed

to “kink” upwards as this can lead to the equipment getting caught inside the process with serious

consequences for both production and for the equipment.

Take care when handling the stainless steel over-braid as there is a risk of some sharp ends,

particularly where the braid enters the connector.

Sensor heads

There are currently 2 sensor heads in the range:

• Voyager A - Single sided; Black/Black; Measures total heat flux;

• Voyager B - Single sided; Black/Silver; Measures total (black) and convective (silver) heat flux.

Each sensor head has an integrated air thermocouple. With the earlier sensor heads the air

thermocouple was positioned in the middle of the sensing area, between the two sensors. For

later heads it has been moved to emerge from one of the side bushes. This allows it to be used

for both top and bottom measurements. Care should be taken to position it such that it doesn’t

contact any metalwork, including the oven belt, during a run as this can influence its behaviour

and response. Care should also be taken when

packing the heads in the transport case.

The sensor blocks are labelled as described in

Section 4.1.

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Each sensor head has 4 mounting bushes to allow it to locate in either of the frameworks or in the

bracket. The sensors can be located either facing upwards or downwards.

The heads have a rim on their top and bottom which minimises the contact area with the band.

This reduces the degree of heat conduction into the heads but also means that the sensing area is

protected from touching the band when measuring bottom heat. This has two advantages:

• It protects the sensors from physical damage;

• It holds the sensors a fixed distance from the band thus giving good repeatability.

The accompanying photographs show the sensor head connections, including the colour coding,

where appropriate (earlier heads).

Special housings have been machined into the sensor

heads (inside) to allow small magnets to be fitted, which

help to hold the heads in position on the band.

The latest sensor heads have an additional connector (X) which accommodates a temperature

probe. A selection of probes will be available. To use this channel the “Band T/C” option must be

selected when configuring the system (Section 8.3.1; Configure; Screen2).

The Voyager system has been designed to allow new sensors to be added in the future. A number

of sensors are under consideration included a double sided model and a much deeper and more

robust version for more extreme conditions.

Conditioning Unit

Logger - Temp Logger - Voltage

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The following table gives details of cable and equipment connections:

Engraved

Symbol

Colour

Coding

Connects sensor

head to:

Function Comments

C Red Conditioning

unit

Pre-conditioning

of sensor head

Output from conditioning unit: 24V DC.

The relevant conditioning channel

must be switched OFF before the

conditioning cable is connected or

disconnected otherwise an electric

shock and/or fuse failure may result.

V Black Datalogger Voltage signals

from sensor head

T Yellow Datalogger Temperatures

from sensor head

X N/A External probes Temperature Various external temperature probes

can be added to the system.

Additional Components

There are a number of additional components in the system as detailed earlier, including:

• Peli transport case – robust; lockable; waterproof; with extendable handle and wheels;

• Gloves;

• Comprehensive user manual.

5.5 Heat Flux Measurement

The sensor heads employ two fast-response, surface-mounted heat flux sensors attached to a

copper heat sink. The sensors are either both black (Voyager A), in which case they are wired

together and only one output is received by the datalogger, or they are black and silver (Voyager

B), and wired independently. Included is a fast response thermocouple for the measurement of

the air temperature through the process.

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Heat Flux is defined as the amount of energy passing through an imaginary surface of unit cross-

sectional area in unit time.

Heat Flux is measured with heat flux sensors, which consist of a series of thermocouples (a

thermopile) embedded within a layer of heat resistant material.

When heat passes through the sensor a temperature gradient is developed across it, which is

detected by the thermocouples. The output from each thermocouple is small but when a large

number are wired in series (a thermopile) the resulting voltage becomes large enough to

accurately measure.

There are a number of benefits of using heat flux sensors:

a. Fast response, due to being very thin and surface mounted;

b. Good resolution, giving good detail;

c. Directional.

Each sensor has a calibration constant and this is required to convert the voltage from the

thermopile into a meaningful heat flux figure. The system is calibrated prior to despatch and it is

recommended that the unit is returned on an annual basis for recalibration.

Units of heat flux:

W/m2

or Btu/h.ft2

* see Appendix F for Conversion Factors

Heat sink

Thermopile

Sensor

temperature

Heat flux

sensor

Voltage

from sensor

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For the sensors to operate successfully it is necessary for a temperature gradient to exist across

them for the entire process. In certain circumstances this can limit the length of time over which

they can operate, as the heat sink temperature will rise through the process and may eventually

reach the process temperature.

6 Introduction to Software

6.1 Versions

The software comes in two versions:

a. ThermaFlux3

b. ThermaFlux4

ThermaFlux3 is the original version while ThermaFlux4 is the latest version. This manual

concentrates on the latest version only. Details on the original version can be obtained on

request.

6.2 Installation

The ThermaFlux system comes with dedicated software which must be installed before the

system can be used.

PC Requirements: Microsoft® Windows™ XP to Windows 7.

Installing software on your Computer

There are two ways of installing the software:

i. CD (included in the transport case);

ii. Website link (will be emailed).

It is recommended that the link is used as this will always give the latest version of the software.

From CD

Insert CD into disc drive. Select relevant drive on PC and double click on ‘ThermaFlux Setup.exe’

icon. This will automatically run ThermaFlux installation set up. Follow the on screen instructions

to install.

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On initiating the software for the first time the screen to

the right may appear asking for the Serial number of your

unit and your unique unlock code. These will be supplied

to you with your system. Should you need assistance

please contact Digitron on 01803 400382.

From Link

Follow link and follow instructions. When asked, select “Run”.

6.3 Data Management

The data is stored and managed through a fully searchable database. Within the database are

three primary categories, Plant, Line and Product, the combination of these being referred to as

the Product Line. It is important that these categories are carefully considered from the outset

and that a consistent naming protocol is adopted by all users.

6.4 Using the Software

Detailed operation of the software is covered in Section 8.

7 Measurement Procedure

7.1 Pre-trial Preparation

Before doing any profiling work it is absolutely imperative that a number of safety checks are

carried out. These are detailed under Safety, in Section 4, and are summarised below:

1. Communicate with appropriate members of staff;

2. Check access at entrance and exit of plant;

3. Check clearance;

4. Check and agree procedure for loading equipment;

5. When retrieving the equipment from the band use gloves – it may be HOT.

7.2 Assembling the Equipment

1. Identify a suitable working area:

a. in the vicinity of the plant being assessed;

b. flat and sufficiently large;

c. clean and dry;

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d. with access to a single phase power supply;

2. Place conditioning unit on the flat surface with the Eurotherm controllers facing the user.

Deploy the feet;

3. Ensure access to rear panel is not restricted in order that unit can be disconnected from

the mains supply as required;

4. Ensure ALL switches are set to “OFF”:

a. Mains switch on rear panel;

b. Channel switches on front panel;

5. Insert mains lead and switch on mains power at socket. Switch on the unit (mains switch

on rear panel);

6. Connect the sensor(s) to be conditioned using the stainless steel cables provided. Once

connected, switch on the relevant channel(s) using the front panel switches. DO NOT

CONNECT OR DISCONNECT the sensors from the conditioning unit while the relevant

channel is on as there is a risk of ELECTRIC SHOCK and fuse failure;

7. Select conditioning temperature on the Eurotherm controller. This should concur with

the software. The sensors will now heat.

While the sensors are conditioning the other components of the system can be prepared:

8. Position datalogger and computer near the sensors;

9. Connect sensors to datalogger;

10. Start computer and connect comms cable to computer;

11. Start ThermaFux software (see later);

12. Connect comms cable to logger – green light should come on;

13. Check that remote control powers up – red power light will come on.

14. Monitor live display.

7.3 ThermaFlux Configuration

Before conducting any trial work it is necessary to configure the equipment correctly.

7.4 Data Management

As mentioned in section 6.3 (Data Management), downloaded data is stored and managed within

a database structure, with the combinations of Plant, Line and Product being referred to as the

Product Lines. When a run has been completed it is vital that the data is stored in the correct

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Product Line. These setups contain additional information (e.g. zone lengths) and it is important

that this information is as accurate as possible.

Product Line exists

If the required Product Line already exists it can be selected from within the software.

Product Line does not exist

If the required setup does not exist then it must be created. Since it is important that the input

information is as accurate as possible it is recommended that some time is spent gathering the

necessary data:

• Name of plant;

• Name of line;

• Name of product;

• Number of zones in the process;

• Individual zone lengths;

• Process time;

• Etc.

For companies with a large number of line and product combinations it is suggested that a

Product Line Template Sheet might prove useful to assist with the gathering of the required

information.

7.5 Measurement Procedure

Having completed the above steps the procedure for taking measurements proceeds as follows:

Plant Measurements

1. Check that unit is ready for plant (Check Ready);

2. Disconnect comms cable from logger;

3. Disconnect the sensors from the conditioning unit – SWITCH OFF the relevant channels

before disconnecting;

4. Place logger into the thermal barrier, ensuring that the aerial is inside;

5. Locate sensors (and thermal barrier) in framework or in bracket, as required;

6. Take unit, gloves, stopwatch and RF remote control trigger to front of plant;

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7. Ensure air thermocouple is not touching any metalwork as this can influence its behaviour

and response; Switch on remote control and establish communication with logger;

8. Request a small space in production (as previously agreed) and place unit on band;

9. As unit enters the plant press the green button on the remote;

10. Start stopwatch and go to exit to await unit;

11. As unit exits the plant press the red button on remote;

12. Retrieve unit using gloves and return to work area.

Note: The remote trigger does not have to be used. If preferred the unit can be started and

stopped manually by pressing the button on the logger.

Downloading

13. Remove unit from thermal barrier and place barrier in a suitable place to cool, in

preparation for the next run;

14. Connect conditioning cables to sensors and switch on conditioning channels;

15. Connect comms cable;

16. Download data – check location for the saved files and add comments as wished.

Once the sensors have re-conditioned and the thermal barrier and logger have cooled, another

profile can be taken. Placing the barrier and logger on a metal surface aids cooling. The internal

temperature of the logger at the start of a run should not exceed 42°C. For particularly severe

baking conditions a lower temperature than this is preferred. The internal temperature of the

logger should never exceed 85°C.

When the trial work is complete, the following procedure should be followed:

1. Drop the set temperature on the conditioning unit to approximately 20°C (or lower) and

allow the equipment to cool. The sensors should be below 45°C before being packed

away;

2. Allow the logger and thermal barrier to cool;

3. Once sensors have cooled switch off all channels;

4. Switch off conditioning unit (main switch);

5. Switch off mains and unplug;

6. Disconnect all cabling;

7. Return to transport case.

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8 Software

8.1 Installation

For information on installing the software and on the general structure of the database refer to

Section 6.

8.2 Initiating the Software

On initiating the software the following screen appears:

Notice the following:

a. The software uses a modern ribbon interface, making the software intuitive and easy to

use;

b. There are four ribbons, each associated with a tab:

i. Test;

ii. Analyse;

iii. Report;

iv. Utilities.

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8.3 Test Tab

The “Test” tab deals with setting up and communicating with the datalogging equipment in

preparation for collecting trial data.

It is split into two sections, the first deals directly with the datalogger and requires the datalogger

to be connected, while the second relates to the general setup and does not require direct

contact with the logger.

8.3.1 Configure

Prior to doing a test the datalogger must be configured correctly. On selecting configure,

communication is established with the logger and a set of 3 screens appear. These require to be

completed by the user:

The first screen involves selecting the Product Line.

If it doesn’t exist then it needs to be created (see

Section 8.3.6).

The second screen involves selecting the equipment

being used for the run and the exact orientation

and positioning of that equipment. The sensor

heads are selected from the Sensor Table using

their serial number. If they are not in the Sensor

Table then they must be added. If using the “X”

option on the sensor head then the Band T/C

channel must be switched on.

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The third screen covers the logging rate and the

conditioning temperature of the sensor heads. A

logging rate of 4 per second is recommended,

although this may not always be possible. The

temperature should match the selected

temperature on the Eurotherm controller.

On completion of the 3rd

screen this information is then sent down to the logger whereupon it is

stored in the logger’s memory.

The software allows up to 3 heads to be used. Any positions without a head should be disabled.

8.3.2 Check ready

Before entering the process the sensors are pre-heated. The temperature is set on the

conditioning unit but is also entered into the software (see above). When selecting “Check

Ready” the software compares the actual

top sensor temperature with the expected

figure from the configuration. If the unit is

at the correct temperature this message

appears:

If the unit is not ready an error message

appears. The is a warning message only and

does not prevent the unit from being used.

However, it is recommended that the user

ensures that the unit is at the correct

temperature before proceeding.

8.3.3 Download data

This function enables the data to be downloaded from the unit into the database. The following

screens appear which allow the user to check, and if necessary to alter, where the data file is to

be stored. Additional information can also be added:

• Measured bake time;

• Normal run or Trial run (Trial run appears pink in database);

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• Time or distance to start of plant. It is suggested that this figure is left at zero and that

the data is “topped and tailed” in the Analyse section.

On completing the information and pressing “Save”, the newly downloaded data is displayed.

Checking the channel boxes on the legend hides or displays these traces on the graph. “Internal”

refers to the internal temperature of the logger.

8.3.4 Reset

If the system has been used and has fresh information in its memory it will not run again until this

information has been downloaded or the unit has been reset. This is a security feature to prevent

the loss or accidental overwriting of potentially valuable information.

If the operator is satisfied that the information is not required the unit can be reset ready for the

next run, thus avoiding the need to download.

Note: The most recent set of data is retained in the memory (even after downloading or resetting)

until logging starts again, at which point it is no longer available to download.

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8.3.5 Status

Gives a live display from the instrument:

8.3.6 Product Lines

This option allows new Plant, Line and Product configurations to be created and added to the

system.

In the following example the chosen location already exists (Plant 1) but the particular line and

product are new to the system. Selecting “New” for these categories and then “Edit Product Line”

allows the new information to be input:

Information can be input to the white boxes only and there are a number of drop-down boxes to

help. As the number of zones is increased additional zone boxes will open. It is advisable to

ensure that the information input at this stage is as accurate as possible as it is used in the graphs

and in the analyses.

On completing the entries “Save Product Line” creates the new plant details.

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The following screen shows a completed Plant Setup.

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8.3.7 Sensor Table

The Sensor Table contains valuable information on the sensor heads. When configuring the

system the appropriate heads are selected using their serial number and hence it is important

that the information held on them is accurate. A customer will only see details in the Sensor

Table of heads available to them. This is a customer specific table. On selecting Sensor Table the

following window opens:

New sensors are added to the system via this screen. Also, sensor details, including new

calibration figures are managed through this section. A head can only be used in the plant that is

specified. If it is to be used in a number of plants then the “All plants” option should be selected.

8.3.8 S/N Groups

This section allows the owners of a number of pieces of equipment (specified by logger serial

number) to be identified and grouped. This is for reference and filtering purposes and will prove

useful as the number of systems increases.

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8.3.9 Configuration names

This menu allows the names of individual channels to be changed. This should only be used if

absolutely necessary. Care should be taken as the function of a channel cannot be changed, only

its name.

8.3.10 Settings

This opens the following screen, where there are a number of important features including:

1. The colours for the various

channels can be changed;

2. The preferred units can be

selected;

3. The start of recording correction

preference can be selected. This is

the distance or time between the

unit being started and actually

entering the line.

4. The Comm Port number may need

to be changed to facilitate

communication with the

instrument. The port that the instrument is on (as determined by the PC) and the port

number specified here in the software must match;

5. Switching on the “Mains filter” eliminates mains noise;

6. There are also a number of useful Miscellaneous check boxes, the second one allowing

Product Line information to be edited.

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8.3.11 About

Pressing “About” brings up the following screen which gives details on the version of software

being used and a telephone number for Digitron technical support.

8.4 Analyse

The second tab (“Analyse”) deals with the handling of the data held within the database.

All of the graphical and analyses functions are contained within this section.

8.4.1 View Tests

When selecting “View Tests” a list of the tests contained within the database appears. These can

be ordered in a number of different ways by clicking on the column name e.g. by Plant. In

addition to the test listing, another ribbon, divided into 3 main sections, also appears.

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Display: Graphs the selected file(s). A number of files (up to 10) can be viewed together by

checking “Overlay” boxes. The main file should not be checked but should be highlighted thus:

View or Edit: Allows viewing or editing of the particular Test or Product Line details;

Locate standard: Finds the Gold Standard for the particular Product Line combination selected.

Delete test: Deletes the selected test(s) from the database;

Filtering: This becomes very valuable as the database

grows in size. Particular criteria can be selected and the

files not meeting those criteria are filtered out;

Export database: The entire database can be exported to a file (.adb). This file can then be

imported into someone else’s database via the “Utilities” section. This is a way of consolidating

data into one database or of simply sharing data. Alternatively, it is possible to select particular

files to be exported by using the filtering options. The files to be exported must appear by

themselves in the listing, otherwise all files will be exported. See below – the files with a checked

box have been selected and only these 3 will export.

Export Excel: This option sends the selected files across to Excel where each file opens in a new

worksheet. This is useful if further manipulation of the data is required.

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8.4.2 Filter tests

This allows the filtering to take place before going into the database listing, which allows the

particular files to be found more quickly.

8.4.3 Test info

This does the same as “View or Edit” in the “View Tests” section.

8.4.4 Set as Standard

This option allows the profile which is currently being viewed to be set as the standard. It is then

highlighted in the database in gold (Gold Standard). The standard can be changed – setting a new

standard deselects any previous selection. For each Product Line combination only 1 standard

can exist at any one time.

8.4.5 Remove as Standard

This removes the Gold Standard status from a file. It does not remove the file from the database.

8.4.6 Show Standard

This allows the comparison of the currently selected file with its associated Gold Standard.

Clicking again switches it off - it is still highlighted in the database but is not visible on the screen.

8.4.7 Graphical Functions

The remaining series of symbols under the Analyse tab relate to the graphing functions.

Graph1 (G1): This plots the raw data. On the graph two vertical lines appear: a green one

towards the front of the profile and a red one towards the end. Moving the green line moves

both lines together while the red line can be moved independently. This allows the data to be

“topped and tailed”. The green line should be moved to the start of the profile and the red one to

the end. The discarded data does not appear in any of the subsequent graphs and is not used in

any of the analyses. This is a very powerful function and should be fully utilised in order to

achieve accurate analysis of the data.

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As well as the graph a number of tables and figures appear in the data grid at the top of the

screen. These include the following:

1. A general Time and Coordinates table, containing the actual bake time taken directly from

the graph (time between the green and red lines);

2. Channel information table;

3. Zonal Averages table (click to open);

4. Zonal Energy Density table (click to open);

Comments can be added to the Zonal tables.

Another usful feature is the highlighting of individual traces in the graph when the cursor hovers

over them (the pointer arrow). The accompanying line in the legend also highlights thus allowing

traces to be easily identified. The coordinates at the pointer location are also given.

The series of graphs shown here are for a Voyager B head with only the heat flux channels

selected. Using the check boxes in the legend to the right of the graph the user can select as

many (or as few) channels as wished. Be aware that selecting too many channels can lead to a

graph that is difficult to interpret.

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Graph2 (G2): This shows the data re-plotted with the excess data discarded. Notice the accurate

positioning of the zone breaks.

Graph3 (G3): This shows the zonal cumulative energy (the area under each zone of the graph),

with the total figure at the end giving the total area under the graph.

Graph4 (G4): This graph shows the zonal averages.

Graph5 (G5): This graph shows the zonal energy density figures (area under each zone).

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Graph6 (G6): This graph can only be plotted if an Operator side (OS) and Non-operator side (NOS)

file have been selected, as this graph shows the difference between them. This can be

particularly valuable when conducting cross band checks on a line. The NOS is always subtracted

from the OS.

8.4.8 Data grid visible

This switches on and off the tabular information at the top of the page.

8.4.9 Settings

As before (8.3.10)

8.4.10 Copy graph

This copies the current graph to the clipboard, from where it can be pasted.

Additional Icons

There are a number of additional icons on this ribbon.

Two vertical and two horizontal lines can be dropped onto the graph to pick out particular details

and this information is then displayed in the “Channels” table and in the “Time & Coordinates”

table. The units for the horizontal line can be selected (TP: Temperature or HF: Heat Flux).

Clicking on the vertical and horizontal lines switches them on and off. Clicking on the arrow icon

returns the pointer.

8.5 Report

The third tab in the series is “Report” which allows reports to be automatically generated. The

user selects the information to be included in the report from a drop down list.

A number of additional pages have been included to allow a full and detailed report to be

generated. The user can add their own comments to a number of pages and each of these pages

can be saved as an individual template for future use.

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The image below shows a sample Title Page. The particular

trial details can be changed each time the template is

brought in prior to generating the report and this ensures a

standardised report is issued each time. This also speeds up

the report generation. A Last Page has also been included

and this can contain a summary of the trial or

recommendations for further work.

Once a template has been created it can be saved (“Save”).

Saved templates are brought in using the “Load” option.

Note that a template is for one page of the report only. It is

recommended that a series of standard templates are created for: Title Page; Intro Page; Last

Page. It is likely that a single template will suffice for the other pages.

There are a number of “Copy” options on the ribbon. These can be used to bring in specific

details about the test. The information is copied to the clipboard and from there can be simply

pasted into the chosen page of the report.

Once all required comments have been added and the relevant pages selected the report can be

generated using the “Create report” command. The following window appears, from which a

number of further options are available, including saving and printing the document.

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8.6 Utilities

The “Utilities” tab deals with database functions including importing data into the database from

elsewhere.

8.6.1 Import database

This function allows a database to be imported from elsewhere, for example, another factory

within the Group.

8.6.2 Import flx file

This function allows a file from a previous version of software to be brought into the new version.

These files have a “.flx” extension.

8.6.3 Import legacy database

This function allows an entire database from a previous version of software to be brought into the

new database. These files are named: “TFLX_database.dat”.

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8.6.4 View Data folder

This function takes the user to the folder (ThermaFlux data) where the test data is stored.

8.6.5 Unlock Logger

On occasions it may be necessary to unlock the

datalogger. The serial number of the logger

must be input (e.g. 118) along with its unique

unlock code.

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9 Technical Specification

9.1 Voyager (ThermaFlux) Datalogger and Sensor Head Specification

VOYAGER SYSTEM EQUIPMENT WHICH PASSES THROUGH PROCESS

GENERAL

Classification Class 3 product; Portable equipment; Pollution Degree 2; Indoor use only

Heat Flux sensors Voyager A: Black/Black; Voyager B: Black/Silver

Other sensors 1 air temperature; 1 sprung band temperature

Accuracy +/- 2% of full scale

Response time T60 less than 0.1 seconds

Sampling Multi-channel sampling from 8 samples/sec (4/s is recommended)

Software Compatible with Windows ’95 to Windows 7

DIMENSIONS/WEIGHTS

Thermal Barrier 25mm: 150 x 150 x 25mm (0.6kg); 40mm: 240 x 205 x 40mm (1.9kg)

Sensor Heads Without bushes: 130 x 70 x 25mm (0.8kg)

Framework 600 x 230 x 20mm (1.7kg)

Transport case (1650) 781 x 520 x 295mm (25kg)

OPERATING LIMITS

Operating limits See accompanying graphs – Appendix E

Operating range -15,000 to 15,000 W/m2 over a temperature range of -50 to 400°C

Humidity limit Dew point: 90°C

Oven cables The cables are rated to 250°C but will operate at 300°C for short periods

Datalogger The internal temperature of the logger must not exceed 85°C

Sensor Heads The sensor blocks should not exceed 150°C

Conditioning cables The conditioning cables are only rated to 40°C

9.2 Conditioning Unit Operating Conditions and Specification

Classification of Equipment:

• Class 1 product;

• Bench top equipment;

• Pollution Degree 2;

• Indoor use only.

CONDITIONING UNIT Channels: 1 2 3

Supply volts 100-240V ac

Output volts 24V dc

Current 0.2A 0.38A 0.52A

Supply frequency 50 / 60Hz

Power rating 48W 92W 125W max

Mains fuse rating & type 240V 2A T; HBC (FS1)

Channel Fuses 240V 2A T; LBC (FS3, FS4, FS5)

Operating temperature range 5°C to 40°C (-41°F to 104°F)

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Appendix A: ThermaFlux Instruments

There are currently 4 instruments within the ThermaFlux range:

1. Standard;

2. Cake & Bread (CAB);

3. Differential – Mid range (Mid Diff);

4. Differential – Slimline (Slim Diff).

A number of bespoke instruments also exist.

1. The standard unit is a slimline instrument of height 25mm, which is used largely within

the biscuit and snack industry. It employs a single top sensor and a separate bottom

sensor which allows the top and bottom heat flux levels to be measured simultaneously.

The air temperature through the process is also recorded and an additional temperature

channel is provided for the optional measurement of band or product temperature.

2. The Cake & Bread system (CAB), which is 95mm deep, was designed for use within the

bread industry where the standard unit is unable to cope with the more severe baking

conditions, including the increased bake time. It too has top and bottom heat flux

sensors, an air temperature thermocouple and an additional temperature channel.

3. The first differential unit (Mid Diff) is a mid-range instrument of height 50mm and has a

number of advanced and enhanced features. The main difference is that it has 2 top heat

flux sensors, one black and one silver, which allows the heat to be differentiated into its

component parts of convection and radiation. The black sensor measures the total heat

while the silver one measures the convection only (assumes the emissivity approximates

to 0), thus allowing the radiation to be determined. A second enhancement is the nature

of the bottom sensor, which can be used in either contact or non-contact mode with the

belt, band or baking tray. The air temperature is again measured and 3 additional

temperature channels are provided for product and/or band measurement.

4. The second differential unit (Slim Diff) is essentially an enhancement of the standard unit.

It is a slimline instrument of height 25mm and has 2 top sensors – a black and a silver. It

has a standard bottom sensor, an air thermocouple and an additional temperature

channel.

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The selected unit travels through the thermal process, ideally with the product, recording the

heat flux and temperature profiles as it goes. The units are generally used in heating processes

(e.g. travelling ovens) but can also be used in cooling processes (e.g. chocolate cooling tunnels).

A radio frequency remote control allows the user to precisely start and stop the unit and with the

dedicated software, high resolution, accurate heat flux profiles can be obtained simply and

quickly. The units can also be manually started and stopped by using the button on the

datalogger.

A base station provides rapid pre and post conditioning of the instrument, cooling (or warming)

the datalogger and optimising the sensor head for intensive repetitive use.

To use the ThermaFlux unit, software must be installed. It is preferable, although not imperative,

that a portable computer is used, and if possible, one dedicated to the instrument. The software

incorporates comprehensive data management and analysis facilities, including profile

comparison, thus allowing expedient diagnostic analysis. The same software, which has recently

been significantly enhanced, will run all 4 systems.

The data allows rapid product and process improvement, including optimisation of process and

product consistency, and reduction of waste, energy consumption and process downtime

(Appendix B).

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Appendix B: Heat Flux – Benefits

4. Quality.

5. Profile comparisons:

- product transfers;

- new equipment assessment;

- product launches.

2. Trouble shooting:

- product variations;

- operational issues;

- preventative maintenance.

1. Knowledge and understanding:

- what is the profile.

3. Efficiency and reduced cost:

- profile optimisation;

- waste reduction;

- energy savings (Kyoto);

- turn of scale.

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Appendix C: Clearance Checks

It is vitally important that a complete and rigorous clearance check is made before sending a

VOYAGER unit (or any other logging equipment) through the process being assessed. This is to

ensure that the equipment will safely pass through the process and that there are no obstructions

which could catch or dislodge the equipment. Potential issues include: temperature probes;

burner support bars; inter-zonal baffles or curtains; and collapsed roof panels or tiles.

Note also that regular clearance checks should be undertaken – things can and do change and a

successful trial in the past on a particular plant does not necessarily guarantee a successful future

trial.

When conducting clearance checks it is important that the entire width of the band is assessed.

The recommended method for doing this is as detailed below.

The procedure for checking the available height within the process should not itself cause any

problems. It is recommended that whatever is passed through will itself not get stuck. The

recommended method is to use stacks of biscuits where a problem should simply cause the stack,

or part of the stack, to become dislodged, as illustrated below.

The stacks should be comfortably higher than the instrument. The instrument to be passed

through should be carefully measured and an extra 10mm added to this.

Continuous Plant

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Thus, for an instrument of height 25mm (1.0in.), a stack height of at least 35mm (1.4in.) is

recommended.

Deeper units will require a higher clearance.

The entire width of the band must be covered and this is done by staggering the stacks and

making sure that there is no gap between them in the lateral direction (across the band).

The blue line in the above diagrams indicates the centre of the band. The first check should

extend from one side (e.g. control side or operator side) to just beyond the centre line and the

second check from the other side to just beyond the centre line.

The equipment should not be positioned too close to the edge of the band as there are often

obstructions in this area. There are magnets on some of the instrument to hold it on the band. In

cases where the band is non-magnetic or it is warped or demonstrates band-bounce, extra care

should be taken.

No gap between stacks across band

Centre of band

Direction of travel

Centre of band

Direction of travel

Stack of biscuits 35mm (1.4”)

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Appendix D: Oven Profiling – Risk Assessment

Description of Activity

Oven profiling involves sending datalogging equipment through an oven to measure the

conditions inside. This can be done either on an empty oven where there is no product, or on a

fully loaded oven where a small space must be made to accommodate the equipment on the

band.

The equipment is positioned directly on the band at or near the entrance of the oven and is

removed at or near the exit of the oven.

Prior to conducting any measurements a full risk assessment should be carried out.

Equipment

• Digitron VOYAGER;

• ThermaFlux;

• Any other oven profiling equipment.

Risk Assessment

There are a number of areas where a potential risk exists and these should be examined and

assessed accordingly.

Communication (including any emergency procedures)

• Communicate with appropriate members of staff;

• Ensure appropriate help is available should this prove necessary;

• The plant and/or production may have to be stopped if unforeseen problems arise;

• Check and agree procedure for stopping plant and/or production should this be

necessary;

• Check location of emergency stops;

• DO NOT CONDUCT TRIAL WORK ALONE.

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Oven Access – Entrance, Exit, Access Doors

• Check access at entrance and exit of plant;

• Can the equipment be safely loaded and retrieved;

• Can the equipment be reached at the exit;

• Are steps required – if so, ensure these are dedicated to the task and will not be

removed;

• Is guarding in place and secure;

• Are there any nip points;

• Are there any unguarded moving parts - e.g. drive chains;

• Will the equipment safely enter and exit the plant;

• Does anything need to be removed or raised - e.g entrance/exit curtain/flap;

• Does anything need to be switched off to protect the equipment – e.g. sugar sprinkler;

• Are there access points (windows, doors) through the process.

Clearance Checks – See Appendix C

• Check there is sufficient clearance through the entire process for the equipment;

• Clearance last time is no guarantee of clearance this time;

• Check entire width of process;

• The different units require different clearances;

• See full procedure in Appendix C.

Trial Procedure – Loading and Unloading

• Check and agree procedure for loading equipment;

• Check and agree procedure for unloading equipment;

• Is a gap required in production;

• How will this gap be made;

• Who will make the gap;

• Does anything need to be switched off – who will do this;

• Does anything need to be removed or raised – who will do this;

• Are steps required – if so, ensure these are dedicated to the task and will not be

removed.

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Heat

• Prior to entering the oven some parts (e.g. sensor heads) may be hot – take care;

• On exiting the oven the entire system WILL BE HOT – wear heat resistant gloves.

Manual Handling

• When using multi-component systems, take care. Note that the sensor heads locate

within the framework and on the bracket, but are not secured;

• Transport cases are heavy – take care.

Electrical Issues

• Mains electricity is required for conditioning the sensor heads and for running the

computer;

• The usual electrical safety procedures apply.

Clearance Checks

See Appendix C.

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Appendix E: ThermaFlux Operating Limits – Voyager A & B

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Appendix F: Conversion Factors

PARAMETER CONVERSION FACTOR

Length 1m = 39.37in. =3.28ft; 1mm = 0.039in.

Heat Flux 1 W/m2 = 0.3171 Btu/h.ft

2

Mass 1kg = 2.20lb

Temperature °C = 5/9 ( °F -32)

heat flux instrumentation operating manual...user manual page 7 of 58 to clean the equipment,...

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