CAS DataLoggers supplied the coffee roasting temperature profiling solution to a coffee brewer who makes his own product from his home to sell at local shops and through his website. Creating a good cup of coffee from scratch requires a lot of experimentation, so he sources green coffee beans from many different countries to make original blends. First, the beans are emptied into the roaster and then raised to temperatures up to 204°C (400°F). Afterward, the beans go into the grinder. After establishing a few unique blends, the brewer wanted to document his coffee roasting profiles to give his roasting process repeatability which ensures that the beans had the right taste with every new batch. Working with a limited budget, his business needed a data acquisition product to get an accurate temperature profile of his process, but he couldn’t afford many of the DAQ setups he looked at.

Installation

CAS DataLoggers provided him with a Brainchild 6-Channel RTD Input Module which he installed in his brewing room, mounting it on a DIN rail using the included clip. Designed for temperature data acquisition, the Modbus-based module featured analog inputs for 6 RTDs. The removable screw terminal connectors made for quick installation and the module’s small size and light 105g weight made mounting the module a breeze.

The brewer then connected half of the inputs to 3 PT100 RTD temperature sensors which were then placed evenly in the roasting racks. The RTDs record the process temperature at a higher accuracy than would be possible with thermocouples and can maintain temperature stability over several years of use. The module provides direct reading of temperature without the need for scaling and operates on a +12 VDC power supply. Each channel has a connection terminal and an LED status indicator channel. User-set sampling rates from the module log temperature readings from the RTDs in real-time at speeds of up to once every 2 seconds, useful for profiling each roasting cycle.

Usage

The module’s bright LEDs show the status of the inputs/outputs, communication, and power supply. In case the PC were to malfunction, the module’s watchdog timer can identify PC hardware/program errors, sending a signal to put the PC in safe mode, with the timer adjustable from 1 to 255 seconds. This provides a failsafe in case the owner isn’t around to respond in time.

Designed to communicate with a datalogger, PLC, SCADA or HMI via Modbus RTU protocol, the module supports RS485 communication with a baud rate up to 115200 bps. The module was easy to integrate into the user’s network, with his office PC acting as the Modbus master. An RS232 to RS485 converter handles communication between the module and the PC, and the address of the module is set up by using the module’s dip switches (allowing up to 127 addresses).

All the data is available for real-time viewing and analysis using the standard IO PC Studio Software which produces a temperature curve of the entire process. This helps ensure process repeatability, the most important aspect of his product quality. The DAQ software reads the Modbus registers which contain the data from the sensors. In this way, data is sent to the PC located in his office via serial communication and stored there. The software also enables the brewer to configure the module’s communication settings on the Modbus network, and diagnostic information is also available for troubleshooting. The software is inexpensive and easy to use, so his temperature monitoring project was quickly up and running.

Benefits

Using the data acquisition module to monitor his entire coffee roasting temperature process, the brewer is now able to record all the subtle temperature curves and reproduce them whenever he starts a new roast. By looking at the temperature curves from his office PC, he’s able to monitor process temperatures in the same way used by larger industrial processes (i.e. the leading brands). This guarantees that his coffee always lives up to customer expectations. The module and RTD sensors are an ideal solution for the brewer’s limited budget, giving him maximum data logging reliability and high accuracy. Now he can experiment with new flavors and reproduce his bestsellers to satisfy demand.

For further information on the new Brainchild Modbus modules for data acquisition of many different sensor types, coffee roasting temperature, or to find the ideal solution for your application-specific needs, contact a CAS Data Logger Application Specialist at (800) 956-4437 or request more information.

The post Coffee Roasting Temperature Profiling Solution appeared first on CAS Dataloggers.

CAS DataLoggers provided a digital chart recorder to a medical research laboratory performing experiments which required real-time temperature monitoring. For years staff relied on older paper chart recorders but these devices were getting increasingly difficult to support and maintain. In addition, they wanted to make the switch to digital data storage and avoid wasting time hunting for hardcopy. Initially, the cost of several of the systems they considered was beyond their budget.

Installation

After the lab called in and described the requirements of their application, CAS DataLoggers provided them with a low-cost Brainchild PR-10 6-Channel Paperless Chart Recorder. Technicians connect the data logger’s 6 analog input channels to their existing thermocouples, went through a simple set-up process and immediately began measuring and recording data. This digital chart recorder shows all current readings on its customizable 4.3’’ Color Touch Screen display. The model the lab chose includes the optional portable case for easy placement wherever needed.

Offering flexible screen configuration and multiple display styles, the Brainchild is a stand-alone real-time monitoring solution with an interactive dialogue and convenient touch screen enabling quick navigation so staff can scroll back to review historical trends. The digital chart recorder has a fast sampling rate up to 10 Hz, accepts a wide range of thermocouple types plus RTD, voltage and 4-20 mA current inputs. It also offers optional mathematical capabilities including statistics with instant, average, and min/max values.

Usage

Users configured the paperless recorder’s alarms to get instant notification when temperatures suddenly go out of specification, a feature that was not available on the older paper recorders. This had the benefit of helping to ensure that experiments are completed with the correct conditions. The recorder lists all alarm records along with relevant information and can remind users of the alarm status in different colors. Users can browse through this alarm list or acknowledge alarms easily via the touchscreen.

Additionally, the digital chart recorder’s standard Ethernet interfaces enable operators to access stored data over the network using the Observer software supplied with the unit. Data from experiments can be easily downloaded and archived, eliminating the need for cabinets of paper records and the hassle of manual searching through them. For critical experiments, they could remotely view real-time temperature data over the network using the optional Observer II PC software package.

Being a digital chart recorder, the PR10 stores the measured data in 256 MB of internal, non-volatile flash memory, on a removable SD memory card or on a USB memory stick via one of the 2 USB host ports. The PR10 is one of a family of 3 paperless recorders which feature a flexible, expandable, modular architecture with up to 48 analog input channels plus options for digital I/O cards for DAQ and control applications, such as activating relays, reading switches or turning on warning light or buzzer.

Benefits

The Brainchild PR10 paperless recorder is already saving staff valuable lab hours since it enables instant visualization of the temperature data. Now users can monitor temperature remotely in real time to help ensure that their experiments are operating with the correct parameters. The recorder’s user-friendly setup and operation provides quick startup for new experiments. By storing data electronically, the recorder simplifies data archiving while integrating into users’ existing systems to improve accuracy and data accessibility. With all these capabilities, users are able to monitor, record, and evaluate the temperature data using the same system. In case the lab takes on more demanding applications, expanded models are available with up to 48 channels for bigger projects. Finally, if future regulatory needs dictate it an optional FDA CFR 21 part 11 option allows secure data storage.

For further information on the Brainchild PR-10 6-Channel Paperless Chart Recorder, other digital chart recorders, or to find the ideal solution for your application-specific needs, contact a CAS Data Logger Application Specialist at (800) 956-4437 or request more information.

The post Lab Goes Paperless With a Digital Chart Recorder appeared first on CAS Dataloggers.

In our latest Technical Article adapted from dataTaker, CAS DataLoggers shows you how to use a dataTaker DT80 Intelligent Datalogger with a Brainchild Digital IO-16DI Module. This is useful for adding extra inputs for applications involving monitoring or controlling a PLC or SCADA system via the Modbus RTU protocol. The process involves connecting the I/O module, setting up the DT80, connecting your sensors and writing a brief example program.

1–Prerequisites

•Nil

2–Required Equipment

•dataTakerDT80 range data logger (firmware version 8.08 or above)

•BrainChild IO-16DI Modbus Expansion Module

•Connecting wires

3–Process

3.1–Connect the Module to the dataTaker

The BrainChild module connects to the DT80 Serial Sensor port via RS485. In this exercise we will also power the BrainChild module using the 12V output terminal on the dataTaker.

Figure 1– RS485 Wiring Diagram

Table 1–RS485 Connection List

NOTE: If you are powering many modules, then you should use a separate power supply, as the dataTaker 12V output can only supply 150mA.

3.2–Set the Modbus Address of the Module

Use the DIP switches on the front of the BrainChild Module to select a Modbus address. In the example below we have chosen to use address number 1 (DIP1 on, others off).

Figure 2–Setting the Modbus Address (Address 1)

It is essential that each device connected to the same RS485 network is unique; otherwise conflicts will occur and your system will behave in an undesirable manner.

For a complete list of the available addresses and DIP switch settings, please consult the IO- 16DI user manual.

3.3–Set Up the DT80 Serial Sensor Port

If DIP0 is switched to off as shown in Figure 2 above, then the serial communications for the BrainChild Modules will be set to default (9600,8,1,N). It is thus necessary to configure the DT80 Serial Sensor port profiles to match this. You should also change the Modbus Server port to a known value.

Send the following profile commands to the logger:

PROFILE SERSEN_PORT BPS=9600

PROFILE SERSEN_PORT FLOW=NONE

PROFILE SERSEN_PORT DATA_BITS=8

PROFILE SERSEN_PORT STOP_BITS=1

PROFILE SERSEN_PORT PARITY=NONE

PROFILE SERSEN_PORT MODE=RS485

PROFILE SERSEN_PORT FUNCTION=MODBUS_MASTER

PROFILE MODBUS_SERVER SERSEN_ADDRESS=0

3.4–Activate the Regulated 12V Power Output

Activating the 12V power output requires one single command:

PWR12V=1

This command, if used within a program/configuration, should be placed in the immediate schedule (called “on logger activation” in dEX).

3.5–Attaching Sensors to the BrainChild Module

There are many types of sensors which can be connected to the module. However most will either be contact closure or transistor output types. The diagrams below are from the BrainChild IO-16DI user manual:

Figure 3–Contact Closure Type Input Options

Figure 4–Transistor-Type Input Options

NOTE: The numbers of the shown terminal block do not match the labels on the IO-16DI.

3.6–Modbus Commands

There are four Modbus commands which will be used in this section:

1. Read a digital state
2. Activate counters
3. Read counters
4. Set/reset counters

3.6.1 Read a Digital State

Reading a digital state is straightforward and only requires a simple command:

1MODBUS(ADX,R1:N)

where:

• X  is the address of the BrainChild module
• N   is the digital input number which is to be read

Example:

1MODBUS(AD1,R1:14)

(Read the state of digital input #14 on the module with address #1)

3.6.2 Bulk Reading Digital States into Channel Variables

It is also possible to read several consecutive states into a list of channel variables. This would be performed for the purpose of speed and sometimes to simplify the program.

1MODBUS(ADX,R1:N,=p..qCV)

where:

• X is the address of the BrainChild module
• N is the first digital input number which is to be read
• p is the first channel variable to store a value
• q is the last channel variable to store a value

NOTE: The number of values read from the module depends on the range of channel variables specified in the command. This means q-p+1 values are read from the slave.

Example:

1MODBUS(AD1,R1:5,=1..5CV)

(Read the state of digital inputs 5-9 into channel variables #1-5)

3.6.3—Change Counter Mode

Each input on the IO-16DI can be used as a counter, but these are disabled by default. To change the counter mode we need to write a value to register type 4, number 101.

1MODBUS(ADX,R4:101)=N

Where:

• X is the address of the BrainChild module
• N is the counter mode, which can be either:
  • 0 = disabled
  • 1 = enabled (standard upward counter)
  • 2 = enabled (up/down counter)

In counter mode 2 the inputs will act as up/down counters. Input 1 will increment counter 1 while input 2 decrements counter1. In the same way, inputs 3 and 4 operate counter 2; inputs 5 and 6 operate counter 3 and so on. A consequence of using this counter mode is halving the total number of counters.

Example:

1MODBUS(AD1,R4:101)=1

(Activate the standard upward counter on the module with address number 1)

3.6.4–Read Counter

Reading a counter is much like reading a digital input, however the returned value is a 32-bit integer, so its value spans across two registers, which are each 16-bits wide. For this reason we use the MBL channel option, which automatically converts the two 16-bit registers into a single 32-bit value.

NOTE: The module returns a 32-bit unsigned integer value, which potentially stores numbers up to 4,294,967,296 however the dataTaker uses 32-bit signed integer values, which means only the lower 31 bits can be used (since the highest bit changes the sign). In short, this means you should reset the counters before they reach a value of 2,147,483,648.

1MODBUS(ADX,R4:N,MBL)

Where:

X is the address of the BrainChild module

• N is the register number, which is related to the counter number using the equation ((2xC)+1), where C is the counter number

Example:

1MODBUS(AD1,R4:33,MBL)

(read counter number 16 [ (2 x 16)+1=33] )

3.6.5 Set/Reset Counter

Counters may need to be set to a starting value or zeroed. To do this you will use the following command:

1MODBUS(ADX,R4:N,MBL)=M

Where:

• X is the address of the BrainChild module
• N is the register number, which is related to the counter number using the equation ((2xC)+1), where C is the counter number
• M is the value which you would like to assign to the counter

Example:

1MODBUS(AD1,R4:31,MBL)=0

(Reset counter number 15 [ (2 x 15)+1=31] to zero)

4. –Putting it Together

The example program below will set up the Modbus port, read digital inputs 1-5 every 5 seconds, read a counter on channel 6 every 10 seconds and reset that counter at midnight every day.

BEGIN“IO16DI”

‘====================================================

‘    DEVICE SET UP

‘–PROFILES—

PROFILE SERSEN_PORT BPS=9600

PROFILE SERSEN_PORT FLOW=NONE

PROFILE SERSEN_PORT DATA_BITS=8

PROFILE SERSEN_PORT STOP_BITS=1

PROFILE SERSEN_PORT PARITY=NONE

PROFILE SERSEN_PORT MODE=RS485

PROFILE SERSEN_PORT FUNCTION=MODBUS_MASTER

PROFILE MODBUS_SERVER SERSEN_ADDRESS=0

‘–POWER OUTPUT—

PWR12V=1

‘–ACTIVATE COUNTERS—

1MODBUS(AD1, R4:101)=1

‘====================================================

‘====================================================

‘     Schedule A (Read digital inputs)

‘           – Runs every 5 seconds

‘====================================================

RA(“B:”,ALARMS:OV:10KB,DATA:OV:1MB)5S LOGONA

1MODBUS(AD1,R1:1,=1..5CV,W)

1CV(“Digital 1”)

2CV(“Digital 2”)

3CV(“Digital 3”)

4CV(“Digital 4”)

5CV(“Digital 5”)

‘====================================================

‘     Schedule B (Read counter input)

‘     – Runs every 10 seconds

‘====================================================

RB(“B:”,ALARMS:OV:10KB,DATA:OV:1MB)10S LOGONB

1MODBUS(“Counter 6”,AD1,R4:13,MBL)

‘====================================================

‘  Schedule C (Reset Counter)

‘ – Runs every day at midnight

‘====================================================

RC(“B:”,ALARMS:OV:10KB,DATA:OV:1MB)1D LOGONC

1MODBUS(AD1,R4:13,MBL)=0

END

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