How Power Factor Affects Your Utility Bill

Power Factor is measured on a scale of 0 to 1.0 (often expressed as 0% to 100%). It is classified as either leading or lagging, depending on the position of the current waveform relative to the voltage. You can think of it a bit like a kinked garden hose – if the hose is straight, water flows easily through it with minimal pressure drop but if the hose is kinked the pump must work harder to push the same amount of water through. In the case of a low PF, the utility must expend more energy to deliver the same amount of power (current x voltage) to the load.

The Cost of Inefficiency

Most utility providers mandate a PF threshold, typically between 95% and 96%. If a facility falls below this level, the provider imposes a Reactive Power Fee.

• Why the fee exists: A low PF indicates an inefficient load that draws “reactive” (non-working) power. The utility must generate and transmit this extra power, even though it performs no actual work, putting a strain on the grid infrastructure.
• The Alignment Principle: In an ideal AC circuit, voltage and current are perfectly aligned (Unity). However, inductive loads (like motors and transformers) cause the current to lag behind the voltage. This misalignment forces the system to draw more current to perform the same amount of work.

Calculating Power Factor: The Power Triangle

To calculate Power Factor, we must understand the relationship between three types of power:

• Real Power (P): The actual power used to perform work, measured in kilowatts (kW).
• Reactive Power (Q): The “non-working” power required to maintain magnetic fields in inductive equipment, measured in kilovolt-amperes reactive (kVAr). This is because physics says the current passing through an inductive load like a motor cannot change instantly i.e. the inductance “reacts” to changing currents by opposing the change.
• Apparent Power (S): The vector sum of Real and Reactive power, measured in kilovolt-amperes (kVA).

You can use these three aspects to derive the Power Factor. See Figure 1 below.

Figure 1 – Calculating Power Factor

In an electric power system, a load with a low power factor draws more current than a load with a high power factor (near 100%) for the same amount of useful power transferred. These higher currents increase the energy lost in the distribution system and also require larger wires and other equipment. In other words, your Power Factor percentage shows you how much of the total current is being used to do real work. For example, a PF of 0.80 means that only 80% of the current supplied to your facility is doing useful work, while 20% is being wasted as non-working reactive power.

The 6 Strategic Benefits of PF Correction

1. Direct Utility Savings: Eliminating penalty fees can reduce monthly bills by up to 20%. Many utilities calculate the penalty based on the Peak Demand (kVA) rather than a flat fee, meaning a low PF multiplier can exponentially increase the highest part of your bill.
2. Increased System Capacity: Improving PF reduces the current draw, effectively “freeing up” capacity on your existing transformers and switchgear.
3. Carbon Footprint Reduction: Higher efficiency leads to lower energy demand, directly reducing $CO2 emissions.
4. Reduced I2R Losses: Lowering the current reduces heat losses in cables and distribution equipment.
5. Equipment Longevity: Reduced heat in motors and transformers prevents premature insulation breakdown and extends service life.
6. Improved Voltage Regulation: PF correction reduces voltage drops in long cable runs, ensuring motors start reliably and operate within their rated specifications.

Diagnostic Phase: Using Power Data Loggers

Before implementing correction, you must conduct a Power Factor Study. A 3-phase Power Data Logger is used to monitor voltage and current channels simultaneously. These devices capture:

• Min/Max/Average values over time
• Harmonic Distortion profiles
• Load Profiles to identify when the PF is at its lowest

This data is the foundation of a successful energy efficiency analysis and ensures that correction equipment is sized accurately.

Corrective Techniques: Raising Your Power Factor

Correcting PF involves supplying reactive power of the opposite sign to cancel out the effects of the load.

Passive Correction

Linear loads with a low power factor can be corrected using a passive network of capacitors or inductors. In the electricity industry, inductors are said to consume reactive power and capacitors are said to supply it; these devices alter the phase relationship between the voltage and current during AC line cycle to force them back in phase. For example, you can offset the inductive effect of motor loads by using locally-connected capacitors. If a load has a capacitive value, connect inductors (also known as reactors in this context) to correct the power factor.

Capacitors prevent equipment from having to draw reactive power from the grid. Non-linear loads such as rectifiers distort the current drawn from the system. In such cases, you can use active or passive power factor correction to counteract the distortion and raise the power factor. The devices correcting the power factor may be located at a central substation, spread out over a distribution system, or built into power-consuming equipment.

• Capacitor Banks: Most industrial loads are inductive (motors). Adding locally connected capacitors supplies the necessary reactive power, preventing it from being drawn from the utility grid.
• Operational Changes: Before investing in hardware, ensure motors are not oversized for their loads and avoid running idling motors for extended periods.

Active & Advanced Correction

• Automatic PF Correction Units: These units use a controller to switch capacitor blocks in and out of the circuit based on real-time demand.
• Synchronous Condensers: Utilizing an unloaded synchronous motor to provide variable reactive power by adjusting field excitation to create a leading power factor.
• Static VAR Compensators (SVC) & STATCOM: For high-voltage or rapidly fluctuating loads, these solid-state electronic devices provide near-instantaneous compensation with lower maintenance than mechanical systems.

Engineering Note: Correction elements must be applied following a detailed engineering analysis. Improperly placed capacitors can cause harmonic resonance, voltage fluctuations, and system instability. In the US, IEEE 519 (the standard for harmonic control in electric power systems) provides the guidelines for design of PF control systems.

Summary:

Measuring and correcting Power Factor is one of the most effective ways to realize immediate energy savings and protect your electrical infrastructure. Through data-driven analysis with professional logging equipment, facilities can move toward “Unity,” ensuring every dollar spent on electricity is going toward productive work.

For more information on Current, Voltage and Power dataloggers, or to find the ideal solution for your application-specific needs, contact a CAS Data Logger Applications Specialist at (800) 956-4437 or request more information.

The post Understanding Power Factor and Its Impact on Industrial Utility Costs appeared first on CAS Dataloggers.

ADwin-Gold Data Acquisition System

CAS DataLoggers Sales Manager Pete Martin impresses exhibition attendees with a unique ADwin demonstration of balancing a highly unstable inverted pendulum. The demo highlights how to achieve microsecond response times with a measurement and control system while operating in the Microsoft Windows environment. At the start of the demonstration, the inverted pendulum is knocked off-balance so that its weight causes it to fall. Almost immediately, however, the pendulum starts to swing and return itself to its original inverted position. The demonstration video is available online on YouTube at https://www.youtube.com/watch?v=87sD1TI7Ujc.

The Demonstration Hardware

A variety of hardware was used to implement this demonstration, including a stepper motor controlled by an ADwin real-time data acquisition system. By means of a toothed belt, the stepper motor moves a metallic plate (carriage) on which a quadrature encoder is mounted. The pendulum itself is an aluminum weight at the end of a carbon-fiber arm, which is attached in turn to the axis of the quadrature encoder.

ADwin: Real-Time Performance Independent Of A PC

The ADwin line of data acquisition systems are equipped with their own local processors, running at up to 1 GHz of internal memory, digital and analog inputs/outputs, as well as an external trigger input. ADwin systems are suitable for a diverse range of applications demanding deterministic response times of a microsecond or less, including control of complex, high-speed test stands.

When viewing the pendulum demo online, note that an inherent real-time operating system and a control program arranged in several processes for the demo model are running on the ADwin system. The real-time operating system manages running each process simultaneously and guarantees short and reliable response times in order to accurately balance the pendulum.

Programming The Real-Time Control Loop

The control program for the demonstration is programmed in ADbasic, a user-friendly development environment under Windows. This environment allows users to program in a BASIC-like programming language so that various control and measurement applications can be carried out easily. Moreover, ADbasic offers the opportunity for online debugging and data transfer with the PC.

ADbasic compiles the control program and transfers it to the local ADwin processor, where it runs completely independent of the PC operating system. As the process is being compiled, great care is taken to ensure the shortest possible runtime. The PC is only needed for operating, visualization, and logging the measurement values.

A constantly-running communication process allows for continuous data transfer between the system and the PC, even during the highest speed acquisition, without any effect on the ADwin system’s reaction time.

Operation and Control of the Pendulum Program

The TestPoint application development package was used to create the graphical user interface for the operating program that starts, stops, and monitors the movements of the stepper motor. Users view a window monitoring the carriage position over a chosen period, showing the actual status of the carriage (blue line) and the target status (red line), independent of time.

A look behind the scenes shows that several individual processes run once the ADbasic pendulum program begins. To establish a reference position for the pendulum, the pendulum is brought to a standstill. After this, a reference run is made to find the zero point of the carriage. Only then will the pendulum begin to swing up and balance. The carriage is moved around the target position as long as the pendulum arm is above the carriage. After approximately 13 seconds, the pendulum is balanced above the carriage.

During balancing, two processes are running simultaneously on the ADwin system:

1. Measurement and control of the pendulum: Runs at a repetition rate of 10 ms, a fairly modest rate for the ADwin system.
2. Control of the stepper motor: This requires exact timing of several microseconds and is divided into two sub-processes. One prevents the pendulum arm from falling down, while the other, which overlies the first, helps to keep the carriage in its target position.

The target position of the carriage can be adjusted with the scrollbar on the right side of the dialog window. The ADwin system reacts immediately to any change of the target position, moving the carriage to the specified position. In the demonstration model, the control process is made more visible and obvious by slowing it down—the new target position, roughly 1000 units away from the original one, is reached after five seconds.

Concurrent Operation With Windows

Dynamic Link Libraries (DLLs) are available for all Windows operating systems (Windows 10/11) for transferring data between the ADwin and the operating program on the PC.

When using an ADwin system, neither the choice of Windows operating system nor the control application on the PC has any influence on the real-time capability of the system. Given that the control application need not meet any real-time requirements, it can be developed very easily with any of a number of common Windows development systems, such as Visual Basic, Delphi, Visual C++, or with programs like TestPoint, MATLAB, DIAdem, or LabVIEW.

ADwin Applications In Industry And Engineering

While ADwin systems can easily handle simplistic applications like this pendulum demonstration, they were expressly developed for applications in industry and engineering, where they’ve long been popular choices. Typical ADwin applications in this field generally require very short response times, such as:

• Vibration Test Stands: Control of vibration test stands for testing exhaust pipes, motor bearings, couplings, car seats, steering wheels, etc. For example, a fast digital controller moves a hydraulic cylinder along a track and acquires and evaluates the response signals. Cycle times of less than 20 microseconds are necessary here.
• Scanning Tunneling Microscopes: Control and monitoring of scanning tunneling microscopes. The X-Y coordinates of a very thin needle are precisely and quickly controlled via two analog outputs, while the distance (Z-coordinate) of the needle is controlled via an analog input and held at a constant height above the sample. The cycle frequency for this application must be several hundred kilohertz.
• High-Speed Controllers and Filters: Implementation of applications requiring very fast digital controllers and filters up to 400 kHz. These are similar to digital P, PI, and PID controllers, allowing for observation of process deviations and real-time adjustment of control parameters.

Large amounts of data can be acquired and distilled by the ADwin processor, and only the calculated result is sent back to the PC to free up resources. Once a value is calculated, the ADwin system can react intelligently by changing the test sequence accordingly.

Although it may seem like a novelty, the pendulum demonstration is also instructive for the way it spotlights ADwin’s capabilities more clearly than any words or figures. It demonstrates how system response times of less than 1 microsecond are possible while using the Windows environment for the human-machine interface.

For more information on sophisticated data acquisition and control solutions from ADwin, or to find the ideal solution for your application-specific needs, contact a CAS Data Logger Applications Specialist at (800) 956-4437 or request more information.

The post Automated Pendulum Demo Shows ADwin Microsecond Response Time appeared first on CAS Dataloggers.

Portable data logging systems are essential tools used in various industries to monitor and record temperature, voltage, current, and other values Used for troubleshooting, quality control, process monitoring, and data collection, these compact devices require careful selection. This guide provides key questions when choosing the right portable data logging system for your needs.

• Number and type of inputs: How many channels do you need, and what sensors will you use?
• Measurement accuracy and resolution: How precise do your measurements need to be?
• Measurement speed: How fast do you need to sample the inputs?
• Sensor signal conditioning: Does the system need to amplify or filter the signals from your sensors?
• Alarms: Do you need notification if the measurements are outside of the expected range? What type of alarm is required, local or remote?
• Standalone operation vs. tethered operation: Do you need the system to operate independently, or will it be connected to a computer?
• Durability and environmental conditions: Will the system be used in harsh environments?
• Communication methods: How will you transfer data from the data logger’s memory to your computer?
• Software: What software is included with the system, and does it meet your needs?
• Calibration: How often will the system need to be calibrated?

By considering these factors, you can choose a portable data logging system that meets your specific needs and applications.

12 Questions for Selecting a Portable Data Logging System

Every day, hundreds of calls and emails come to data logger distributors and systems integrators asking: “Which product is best for my application?” Whether you’re a technician planning your latest project or you’re a buyer filling a requisition, the sheer number of data logger manufacturers and models can be overwhelming. To make your selection easier, here are ten questions to help you through the decision process:

1. What Are Your Data Logging Needs?

Typical data logging and Data Acquisition (DAQ) applications focus on collecting data to determine efficiency, maintenance timing, or R&D. These systems feature flexible programming and communications capabilities and include portable systems powered by battery or external power supply.

2. What Is The Required Sample Rate?

An important question to ask yourself is how often you need to record a measurement (i.e., the logger’s sampling rate). Most data loggers record data at rates as fast as 1Hz (once a second) or slower (once per hour or a few times per day). Data acquisition systems can sample hundreds or thousands of times per second but require more power and are more expensive. The maximum sampling rate (bandwidth) is a significant factor in the overall cost of the system. A higher sample rate captures more rapid changes in the signal but if the measured value only changes slowly, for example, the temperature of a large tank of water or lake, sampling once a second only generates a lot of redundant data.

3. How Many Inputs Do You Need?

Do you just need to log a single measurement value (such as temperature) or several types of measurement values (current and voltage)? Some models are designed to measure a single measurement, while multi-input loggers include models to monitor AC voltage/current, DC voltage/current, or temperature & humidity. Universal input data loggers are designed to record from almost any physical measurement sensor. Data loggers are also available in expandable configurations capable of handling anywhere from one to hundreds of inputs.

4. What Type Of Sensors Will You Need?

Knowing your sensor type is important when selecting a data acquisition system. These systems are useful for almost every industry, including food & beverage, life science, and manufacturing. The most common reason for needing a data logging system is to monitor and record temperature using thermocouples, RTD, or thermistors. Other possible options include current/voltage sensors for electrical applications, pressure sensors for liquids or gasses, flowmeters, digital inputs to monitor switches or relays, serial communications interfaces such as RS232, RS485, or SDI-12 for environmental monitoring, or connectivity to MODBUS or CAN-based devices and systems. Knowing the types of sensors to be used is crucial as it dictates the type of signal conditioning needed – either in the logger or externally.

5. How Much Memory Does The Logger Need?

Consider how much storage space you’ll need. Depending on your application, you may want to capture only a few minutes’ worth of data, several months’ worth, or to continually monitor and archive all the data. Depending on the data logger, there may be an internal memory limit, or the logger may offer the option of using external memory such as a USB memory stick.

6. Will You Need Alarm Capability?

Ask yourself if you need to receive an alarm when your measurement value goes outside of a specified range of values. If so, how do you want to be notified? Consider both local alarms available in systems with digital or relay outputs can give a warning via an LED or

audible alarm or more advanced options for remote notification available on network-connected systems which can provide alarms via SMS text message, email, and even voice call notifications!

7. Where Do You Plan to Install the System?

There are data logging systems designed for fixed installation and others for portable applications. If the system needs to be portable, size, weight, and power source will be important considerations. When considering how the logger will be used, ask yourself these questions:

• How will the system be powered? Battery, AC adapter, solar panel, etc.
• Does it need to be protected from moisture and dirt?
• Does the system need to be completely self-contained so that it can be used outside or in a hazardous environment? Will it need a NEMA-rated enclosure?

Before looking at communications options, first, decide how you’d prefer to retrieve the data. Do you plan to bring the device to an office PC to download data, or do you want a system to download it to your PC remotely? Communication with the data logging system for viewing and downloading data can be done in many different ways including:

• Serial RS-232/RS-485 interface connection for legacy systems
• USB interface
• Ethernet network connection
• Wireless interface including Wi-Fi, Bluetooth, and proprietary radio links
• Cellular modem for remote locations where network connectivity is not available
• Satellite modem – for extremely remote locations that lack cellular coverage

9. What Software Is Required?

Of course, the device will require configuration software to set up the inputs, sample rate, alarms, etc. You’ll also need a way to retrieve data either manually via an automatic download or a device like a USB stick. Do you need the ability to plot the data or export it in a format for use with other programs like Microsoft Excel? Make sure you understand how you will analyze the data to get the information you are looking for.

10. What About Calibration, Maintenance, And Repair?

Do you need to have the device calibrated to meet some internal or external reporting requirements? If so, what sort of calibration is required, NIST traceable, ISO, or A2LA accredited? How often does the logger need to be calibrated or serviced for normal maintenance such as battery replacement? Does the vendor offer repair services if the logger is accidentally damaged?

11. What Level Of Support Or Training Do You Need?

Do you have staff in your organization that can handle the wiring and configuration of the data logger or will you need outside help? Will you need training? What level of support does the vendor provide and is it free or do they charge for it? Some providers also offer value-added services such as customization, configuration, training, programming, etc.

12. Where Can You Get Additional Help?

Selecting the right portable data logging system is crucial for successful data collection and analysis. By spending a little extra time upfront and carefully considering these ten key questions to fully define your requirements, you stand a much better chance of ending up with a product that satisfies all your needs. You can download a copy of our requirements checklist here: Data Logger Requirements Checklist.

Given the large selection of systems on the market, make sure you speak with a knowledgeable solutions provider to find the most suitable device that meets your budget.

To learn more about portable data logging systems, or to find the ideal solution for your specific needs, contact a CAS Data Logger Applications Specialist at (800) 956-4437 or request more information.

The post Choosing the Right Portable Data Logging System appeared first on CAS Dataloggers.

Introduction:

Cloud computing has revolutionized industries across the globe, and the industrial sector is no exception. By leveraging the power of the cloud, organizations can streamline operations, enhance efficiency, and gain valuable insights from their data.
This article will delve into the benefits, challenges, and best practices of adopting cloud-based solutions for industrial applications. We will explore how cloud technology can empower businesses in various sectors, including life sciences, food, agriculture, laboratory, research, automation, HVAC, manufacturing, museum, oil/gas/mining, and utility.

The Power of Cloud Computing in Industrial Applications

Cloud computing offers a multitude of advantages for industrial organizations:

Reduced IT Costs:
• Eliminate the need for significant upfront capital expenditures on servers, storage, and networking equipment.
• Reduce ongoing maintenance costs, including power consumption, cooling, and physical security.
• Avoid the expense of hiring and managing on-premises IT staff.
• Pay only for the resources you consume, resulting in a more predictable and potentially lower overall IT budget.

Enhanced Agility and Scalability:
• Rapidly scale resources up or down to meet fluctuating demands, such as seasonal peaks or unexpected surges in production.
• Quickly deploy new applications and services, accelerating time-to-market for new initiatives.

Improved Disaster Recovery:
• Leverage cloud-based data centers and disaster recovery services to minimize downtime and ensure business continuity in the event of unforeseen disruptions.
• Reduce recovery time objectives (RTO) and recovery point objectives (RPO) significantly.

Improved Collaboration:
• Facilitate seamless collaboration among teams, regardless of their location
• Allow real-time interaction through cloud-based tools and platforms.

Data-Driven Insights:
• Utilize advanced analytics and AI tools to extract valuable insights from data
• Facilitate data-driven decision-making.

Addressing Common Cloud Computing Concerns:

While cloud computing offers numerous benefits, it’s essential to address common concerns:

Data Security and Privacy:

Data Breaches: Implement stringent security measures to protect sensitive data, including utilizing Virtual Private Network (VPN) connections, encrypting critical data both in transit and on-site, comprehensive access controls, and intrusion detection systems.
Compliance Adherence: Ensure compliance with industry-specific regulations and data privacy standards such as HIPPA and FDA CFR21 Part 11.
Data Sovereignty: Consider data residency requirements such as GDPR and choose cloud providers that offer data centers in specific regions.

Network Connectivity and Reliability:

• Reliable Network Infrastructure: Invest in reliable network infrastructure to ensure uninterrupted connectivity to cloud services.
• Redundancy and Failover Mechanisms: Implement redundant network connections and failover mechanisms to minimize downtime.
• Security: Protect network infrastructure from cyber threats through firewalls, intrusion detection systems, and other security measures. Look for data centers compliant with ANSI/TIA-942 standards for both electronic and physical access.

Data Integrity and Consistency:

• Data Synchronization: Establish robust data synchronization processes to maintain data consistency between on-premises and cloud-based systems.
• Data Backup and Recovery: Implement comprehensive data backup and recovery strategies to protect against data loss. Look for redundant data centers or offsite backups to guard against data loss due to a natural disaster like a hurricane, tornado, or flood.
• Data Validation and Quality Assurance: Implement data validation and quality assurance procedures to ensure data accuracy and reliability.

Vendor Lock-in:

• Mitigate risk: Choose cloud providers with open APIs and consider multi-cloud or hybrid cloud strategies to avoid vendor lock-in.
• Prioritize portability: Select applications and services that can be easily migrated between different cloud platforms.

Cost Optimization:

• Right-Size Instances: Select the appropriate instance types based on workload requirements to avoid overprovisioning.
• Utilize Cost Optimization Tools: Leverage cloud provider tools and third-party solutions to monitor and analyze cloud spending.
• Explore cost-effective options: Consider reserved instances, spot instances, and other cost-saving mechanisms.

Best Practices for Adopting Cloud Computing in Industrial Applications

1. Conduct a Thorough Needs Assessment:

• Analyze current IT infrastructure and identify potential areas for cloud migration.
• Define specific business objectives and desired outcomes for cloud adoption.
• Identify any related to a governing body like the FDA.

2. Choose the Right Cloud Model:

• Evaluate the suitability of different cloud computing models (IaaS, PaaS, SaaS) for specific workloads and applications.
• Consider a hybrid cloud approach to leverage the benefits of both on-premises and cloud computing environments.
• Select the appropriate cloud model (public, private, or hybrid) based on your security and compliance needs.

3. Partner with a Reliable Cloud Provider:

• Select a reputable cloud computing provider with a strong track record of delivering reliable and secure services.

4. Develop a Comprehensive Cloud Migration Strategy:

• Outline a phased approach to cloud migration, including timelines, budgets, and resource allocation.
• Develop a robust change management plan to ensure a smooth transition.

5. Prioritize Security and Compliance:

• Implement strong security measures throughout the entire cloud migration process.
• Regularly review and update security policies and procedures.

6. Monitor and Optimize Performance:

• Continuously monitor cloud performance and resource utilization.
• Identify and address any performance bottlenecks or cost inefficiencies.

7. Conduct Regular Security Audits:

• Ensure that both your organization and your cloud provider are maintaining compliance with the latest best practices
• Verify that any changes have not introduced new vulnerabilities.

8. Train Your Workforce:

• Provide adequate training to your workforce to enable them to effectively utilize cloud-based tools and applications.

9. Monitor and Optimize Performance:

• Continuously monitor cloud performance and resource utilization.
• Identify and address any performance bottlenecks or cost inefficiencies.

Conclusion:

By carefully considering the advantages, challenges, and best practices outlined in this guide, IT resource managers can leverage cloud computing to enhance operational efficiency, reduce costs, and drive innovation within their industrial organizations. Embracing the cloud empowers IT departments to become more agile, responsive, and data-driven, enabling them to support the evolving needs better and unlock new opportunities for your business.

This White Paper has been adapted from an article written by Novus Automation. NOVUS manufactures data loggers, like FieldLogger and LogBox Connect family, that send data to the Cloud with a timestamp to record the exact moment that data was read from the sensor. NOVUS also offers its cloud monitoring tool.

For further information on cloud computing for industrial applications, 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 Navigating the Cloud: A Guide for Industrial Applications appeared first on CAS Dataloggers.

One type of sensor that is seeing expanded use in a number of applications are solid-state temperature sensors. These devices are from the same family as transistors, integrated circuits and LED’s. Solid state sensors are ideal for many temperature monitoring applications, such as cold chain data loggers, temperature measurement in life sciences and environmental monitoring. In our latest White Paper, CAS DataLoggers covers the basics of solid-state temperature sensors and how they might benefit your application.

What are Solid-State Sensors?

Like other types of sensors such as thermocouples and RTDs, solid-state temperature sensors measure a physical value and then convert it into an electrical signal that can be measured. The sensor (as part of a probe) captures its temperature by means of a diode, transistor or voltage reference that has a well-established voltage vs temperature characteristic. They typically include signal-conditioning electronics to generate a scaled voltage or current output that is proportional to temperature. For example, the Analog Devices TMP35 transducer provides a linear output voltage of 10mV/°C with an output of 250 mV at -25°C.

These devices only require a simple voltage or current measurement and linear calculation to convert the output signal to temperature.

Taking their name from the family of semiconductor electronic devices, solid-state sensors have no moving components (unlike transducers, switches etc.) and incorporate additional circuitry to provide an easy to use output. As a good alternative to thermocouples, solid-state temperature sensors are also an effective way to capture the temperature data of a specific product or to continually monitor an industrial process (for alarm purposes, etc.). As an additional benefit, newer devices come pre-calibrated with traceable data. This means that:

1. There is no need for an additional initial calibration step.
2. If there are multiple sensors in a system, they can be interchanged without a loss of calibration
3. If the sensor ever fails, it can simply be replaced with a new one and the calibration of the temperature measurement system is maintained.

Why Use Solid-State Temperature Sensors?

By relying on the same technology as other mass produced electronic devices we rely on every day such as computers, cell phones and TV’s, solid-state temperature sensors are very inexpensive especially given their high degree of accuracy. Consider using semiconductor sensors when price is a factor and you have a very specific temperature range in mind. Three of the most common types of these sensors are the AD590 series from Analog Device which provides a current output of 1 uA/ °K, the LM 35 series from Texas Instruments which provides a 10 mV/°C output and the TMP36 from Analog Device which also provides a 10 mV/°C output. In addition to these, there are several other types such as silicon diode sensor for ultra-low temperature measurements.

Solid-state sensors are also ideal for less tech-savvy users, being straightforward in operation. They’re easy to connect to a datalogger, noise-resistant, and don’t require additional signal conditioning in the form of expensive add-on devices. This sensor type is also easy to use with most types of digital measurement systems like meters or single board computers.

Naturally there are a few considerations to keep in mind when using these devices (i.e. potential drawbacks). Like thermistors, solid-state sensors lack the wide temperature measurement range of many thermocouples, so you may need to use the latter if your need to measure very low or very high temperatures.  Additionally, other types of temperature sensors like thermocouples or RTD’s are more common, there are more styles available which may be better suited to the mounting requirements for your particular application.

Table 1. Comparison of various temperature sensors

How Do You Measure These Sensors?

Dataloggers are available in many different styles which are able to measure and record electrical data from external temperature sensors including thermocouples, RTD’s and semiconductor sensors. When selecting a data logger for use with solid-state sensors, make sure to select one that is designed to accept the type of output signal from the temperature probes and your specific sensor type. Most devices will incorporate software to allow you to scale the raw signal to temperature as it is being recorded. Also, be aware that most of these sensor will require some sort of external power such as 3.0 to 5.0 VDC either from the data logger, power supply or battery. From some applications for just one or 2 measurements, a simple voltage datalogger like the TandD MCR-4V may be all you need. Consider a universal input data logger like the dataTaker DT80 If you want a multi-channel system to log several temperature inputs and other parameters at the same time.

Conclusion

Solid-state temperature sensors offer an attractive solution for a wide range of temperature monitoring applications. Their affordability, ease of use, and compatibility with various data logging systems make them a practical choice many projects. While they may not possess the wide temperature measurement range of thermocouples, their accuracy, reliability, and straightforward operation make them ideal for many common applications.

By understanding the benefits and limitations of solid-state temperature sensors, users can make informed decisions to optimize their temperature monitoring strategies and achieve accurate and reliable results. If you’re seeking a cost-effective and user-friendly temperature sensing solution, solid-state temperature sensors are certainly worth considering.

The Data Logging Experts:

As one of the largest datalogger distributors in North America, CAS DataLoggers has sold automated monitoring solutions and real-time systems to customers since 2001 and has been in business for over 20 years. Customers can select from hundreds of different models from over 16 trusted manufacturers to tackle all manner of data recording applications.

Users can select from many models of temperature dataloggers which can read the signals from thermocouple sensors including wired and wireless models, lightweight and compact units, power over Ethernet loggers, etc.

For further information on Temperature Data Loggers, water flow monitoring solutions, 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 Solid-State Temperature Sensors: Reliable & Affordable appeared first on CAS Dataloggers.

Many hospital and pharmaceutical technicians know that they need to establish an environmental monitoring plan for their cleanroom. Still, Centers for Disease Control and Prevention (CDC) regulations are many and varied. How do you tie together the requirements to monitor, alarm, and document the data?

If you work in a cleanroom monitoring application such as a product fill cleanroom, in a non-sterile manufacturing area, or in a medical cleanroom, this White Paper from CAS DataLoggers can help you get started on an actionable cleanroom monitoring plan.

Environmental Monitoring Basics:

Whether you’re a Surgical Technician, Quality Engineer, or Pharmaceutical Microbiologist, passing your standards audit will require a comprehensive monitoring plan. CDC guidelines on environmental measurement in cleanrooms and isolated areas state: “Do not conduct random, undirected, microbiologic sampling of air, water, and environmental surfaces in health-care facilities” (CDC Report, 2003). Rather, a targeted sampling process that follows a written well-defined protocol for sample collection, scientific analysis and interpretation of the results, and corrective actions based on the results should be employed.

The main risk to cleanrooms is the loss or reduction of sterility assurance and the subsequent microbiological contamination that follows. Environments are monitored to protect pharmaceutical products from contaminants and to prevent Out of Specification (OOS), Out Of Limit (OOL), and Out Of Trend (OOT) alarm events from occurring. This is the equivalent of the modern healthcare industry placing its emphasis on prevention rather than cure.

Isolated areas require both air and surface cleanroom monitoring to verify sterilization/decontamination. Without recourse to historical data in the form of stored measurements, technicians lack any reliable way to determine sterilization effectiveness. Carefully consider the requirements of your specific class of cleanroom as they relate to measurement collection. For example, when working in isolated environments graded Class A, C, and D, personnel should routinely sample the air and swab the surfaces. If your class mandates the daily use of particle counters (Grade A esp.) then consider using an automated monitoring system with remote monitoring capability for instant access to alarms.

Note that settle plates, although often used as a simple way to roughly gauge the level of microbial contaminants, are not by themselves sufficient to ensure sterilization or to pass an audit. If you plan on using an environmental monitoring system, be sure to set it to monitor even throughout the duration of settle plate use. The CDC’s guidelines state: “Do not use settle plates to quantify the concentration of airborne fungal spores” (CDC Report, 2003).

An especially high risk to cleanrooms is posed by gram-negative bacteria which contaminate water and produce most toxics found in the microclimate. It’s a common problem in aseptic processes, generating endotoxins that cause disease. Product-fill cleanrooms in particular are a good breeding ground for these bacteria since there are often multiple exposed petri dishes located throughout the cleanroom for research purposes.

This and other risks can be addressed by developing your incubation regime, which in many cases requires specialized equipment. For example, the CDC recommends: ”Use standard cleaning and disinfection protocols to control environmental contamination with antibiotic-resistant, gram-positive cocci (e.g., methicillin-resistant Staphylococcus aureus, vancomycin-intermediate sensitive Staphylococcus aureus, or vancomycin-resistant Enterococcus [VRE])” (CDC Report, 2003).

Before you consider the further details of your cleanroom monitoring plan, ask yourself, are you planning on taking measurements manually or automatically?

Manually: A significant source of contamination in labs can be caused by personnel taking frequent manual measurements. The more frequent these manual samples are, the higher the chance of microbial contamination.
Automatically: Automated monitoring systems can provide your business or organization with the technology to cut labor costs, save time, and measure your critical values at high accuracy. Full regulatory compliance with patient privacy and electronic documentation standards is possible using all the advanced archival and documentation capabilities available with system software.

Monitor, Alarm, And Validate

Regular environmental measurements, whether taken manually or performed by an automated monitoring system, form the foundation of your risk assessment strategy. When conducted at the appropriate times and frequencies, these measurements give personnel time to take remedial action before product quality and/or environmental sterility are threatened. For instant notification, many environmental monitoring systems feature on-line communication, giving users the ability to remotely receive alarms and monitor data in real-time. This capability is especially useful for maintaining Grade A cleanrooms and other areas with gram-negative bacteria.

Accurate data measurement is also useful for OOL and OOS investigations, which determine why a given alarm went off. Finally, monitoring systems save all data for documentation and audit/validation purposes.

Your environmental monitoring plan should contain these three key factors:

1. Determine Your Monitoring Points: Your facility’s monitoring point layout depends on the size and area of your isolated environment. First determine where you need to take readings or install sensors in your given cleanroom, hospital corridor, surgery, or other area. Your layout also depends on the level of risk to patient health or product quality, for example, whether you have an open or closed process. As a good guideline, you’re safer having more monitoring points rather than less. Before placing sensors, it’s critical to determine the area’s risk level using a designation of Low, Mid, or High. In high-risk cases such as gram-negative bacteria applications, your installed sensors need high sensitivity to address the main risk of losing sterility through microbiological contamination.

Prioritize these areas:

• Areas with higher travel/population (corridors, surgery prep areas, etc.)
• Areas with longer work or incubation durations
• Dirty or wet areas
• Any significant variations within rooms

Putting this type of forethought into sensor placement helps you to determine how best to detect specific fungi/bacteria in operation-dependent regimes. This includes not only surface measurements but also active air sampling (volumetric air-samplers, particle counters, etc.). To accommodate a wider sensor grid, cleanroom monitoring systems are available in configurations with anywhere from one to hundreds of inputs. This makes them ideal for monitoring filling machine cleanrooms, ISO 5 product fill cleanrooms, test sample incubation, non-sterile manufacturing, and many other applications.

2. Choose Monitoring Frequencies:

Also known as sampling rate, your monitoring frequencies should generally be performed frequently, at minimum recording a reading at each batch filling, at defined intervals, or immediately after sanitizing isolated & sterile areas.

You should also take a reading following:

• Essential maintenance
• Monthly/quarterly monitoring
• Incubation of test samples
• Critical times and temperature windows of operation-dependent regimes.

Monitoring systems can also accommodate different sampling rates for different cleanroom types. Your particular monitoring frequency will often depend on your cleanroom class, rated by the International Organization for Standardization (ISO). Example classes include:

ISO 5: Common examples are applications with specified filling points in liquid containers. Monitoring frequency needs to be either daily or at the end of each batch, whichever is higher.
ISO 7: This class includes gowning rooms and other applications that have surrounding areas rated at ISO5; here a weekly monitoring frequency is indicated.

Monitoring Systems and Sampling Rate:

As we covered in an earlier article, ‘How Fast Should You Sample on Your Thermocouples?’ sampling rate is highly dependent upon your individual application needs. Modern environmental monitoring systems can sample data once every second, which is more than enough for most cleanroom applications. Note that a high sample rate is inversely tied to power consumption/battery life and the specifications of the specific device chosen. Available recording duration can be determined by dividing the data logger’s memory capacity by its sample rate.

In most cleanroom applications, your temperatures won’t fluctuate several times a second. With this in mind, you can configure your data loggers at a lower sampling rate (say, once every five or ten minutes depending on the measurement value). This helps to save device memory space and time spent trending data during analysis. Applications that may require faster sampling rates include advanced scientific research, high-speed equipment tests, etc.

3. Documentation and Validation:

Full data documentation and subsequent validation is the third major component of an effective cleanroom monitoring regimen. For audit and standardization purposes, all your data and methodology needs to be recorded and validated, both for your use and for inspectors. As part of this process, be sure to itemize your monitoring plan to give to auditors later.

Trending Environmental Data:

Armed with several months or a year’s worth of collected environmental data, you can, in many applications, examine it all in trend format to determine your plan’s effectiveness. Whether your regime is working as intended and you can consequently reduce the sampling rate, or whether you find that your plan needs to be reconsidered, validation is a key reason to trend your data. Also, be sure that your assembled data is easily accessible to inspectors on short notice.

All cleanroom validation solutions need to be able to automatically record, store, and trend your environmental data. By using software provided by the monitoring system, you can view historic data by specific filters. This is an easy way to view all alarm violations over a given period, which helps in OOS/OOL investigations to discover why alarms are triggered in the first place.

To learn more about Cleanroom Monitoring Solutions, 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 How to Establish a Cleanroom Monitoring Plan appeared first on CAS Dataloggers.

Your Guide to Cold Chain Temperature Monitoring

• Do perishable product losses due to equipment or power failures concern your business?
• Is your company required to comply with FDA, USDA, or other safety regulations?
• Is temperature monitoring necessary for your products or specific areas?

The cold chain system is an essential process for ensuring the safety and quality of perishable food, beverages, and medicines. Whether you’re a small business owner, transportation manager, warehouse supervisor, or purchasing agent, you stand to benefit from ensuring the integrity and transparency of your food product’s cold chain. But what exactly is the cold chain, and how can you best manage it? At CAS DataLoggers we’ve put together this introductory guide covering the basics of cold chain management using a typical temperature monitoring system so you can choose which is best for your application.

Introduction: What is the Cold Chain?

First and foremost, it’s crucial for every business to identify its major safety risks. For a food or beverage business, it only takes one missed alarm or power failure to lose your entire inventory. Managing this risk is a key priority at every link in the cold chain.

So what exactly is the cold chain? Also known as the temperature cold chain, the food supply chain, and other names, it’s the journey that temperature-sensitive products take from their point of origin through production and packaging to the final point of sale—i.e. from ‘farm to fork.’ Every ‘link’ or step of the cold chain must be monitored for temperature, from manufacturing to storage to shipping—all the way to the customer—to ensure product quality and safety.

Major Cold Chain Risks Include:

• Refrigerator/Freezer equipment failures
• Power failures
• Alarm events occurring outside of work hours (weekends, nights)
• Human error (leaving the freezer door open, etc.)

According to a study by the London-based Institution of Mechanical Engineers, up to half of the world’s food is wasted due in part to poor storage and transport methods. This is especially common when shipping food to vendors. That’s why an effective cold chain needs to extend beyond just your plant or warehouse, going all the way to the receiver.

Which Regulations Impact Your Business?

As every food manufacturer and shipper knows, regulatory compliance is vital to stay operating and to ensure product quality. According to the US FDA “The FDA Food Safety Modernization Act (FSMA), the most sweeping reform of our food safety laws in more than 70 years, was signed into law by President Obama on January 4, 2011. It aims to ensure the U.S. food supply is safe by shifting the focus from responding to contamination to preventing it.” Among other regulatory pressures, FSMA mandates that Food & Beverage manufacturers monitor and document their products’ entire temperature history.

Another widespread regulation, Hazard Analysis and Critical Control Points (HACCP) is a general, industry-adopted form of best practices that many businesses closely adhere to. As with FSMA above, the emphasis is on hazard prevention through measurement and documentation rather than just product recalls. HACCP is effective because it applies to each link in the cold chain. Before sourcing a cold chain solution, be sure to first identify the specific regulations your business is subject to, be it for meat and poultry, milk and dairy, pet food, etc. Once you know your exact requirements, you can determine which temperature data logger is right for your application.

What is a Temperature Data Logger?

What is a temperature data logger? Data loggers are stand-alone electronic devices— often palm-sized or smaller and inexpensive– typically battery-powered and designed to collect and store temperature or other measurement values, independent of a PC.

Data loggers are much more reliable and accurate than manual measurements, and their automated operation frees up employees for other work. Ideal for use in the cold chain, temperature logger can have internal sensors or connect to external sensors and record readings to their internal memory or an external storage device, such as an SD card. They also feature automated alarm capabilities to provide an immediate indication of a problem making them an all-in-one system.

Many Cold Chain Temperature Data Loggers are designed for a specific use, such as for monitoring refrigerators and freezers, food preparation areas, and more. Increasingly businesses are using these specialized devices to safeguard their products and satisfy regulatory demands. Whether you need a simple single-channel unit to log temperature in a case of food or a multi-channel system to monitor the temperature in a large refrigerated warehouse along with other parameters at the same time, you can find a data logger to meet your exact needs.

Why Use Data Loggers?

Proof of Best Practices to Regulators: You need an easy way to document the entire temperature history of your product without having workers spend time taking manual temperature measurements. Replacing outdated, manual temperature data collection with automated data logging provides more accurate data that is automatically archived with no human intervention required. This electronic documentation also helps ensure that you have a quick way to give proof to regulators that your product or environment was kept in temperature spec for the entire storage or trip duration.

Alarm Notification: Data loggers also serve as a reliable, dependable alarm system. Simple models can be programmed with the appropriate thresholds and provide immediate indication via an LED if the limit has been exceeded. More sophisticated models incorporate network connectivity such as Ethernet, WiFi, cellular, or LoRaWAN and can send notifications via email, push notification, or even voice message phone calls. This is especially useful on weekends so that you don’t return on Monday morning to find that your freezer failed overnight!

Improved Product Quality: Just as coffee brewers use temperature sensors to experiment with different roasting temperatures, similarly you can improve and fine-tune your own product quality by using temperature data loggers. Taking a look at this temperature history gives you the hard data you need to see actual conditions at every step of your cold chain, from field to manufacturing to storage to shipping.

Where Should You Monitor Temperature?

• Refrigerators and Freezers
• Walk-in Coolers and Deli Freezers
• Warehouses
• Refrigerated Compartments in Trucks

What Kind of Data Logger Should You Consider?

Whether you’re a purchasing agent or a small business owner who’ll be using the logger, you can help find the right device by first deciding what features you need. Typically data loggers use internal or external temperature sensors to record temperature data. While some of these loggers are dedicated to a certain input or sensor type (such as thermocouples), others are programmable and scalable for different sensor types. The sensor type is determined by several factors including the range of temperature measurements, the required accuracy, and any physical requirements such as does it need to be immersed in a liquid or inserted into the product being measured.

Many data loggers are more than accurate enough to suit cold chain applications, but some situations benefit from higher-accuracy models capable of measurement to within one-tenth of a degree. Most devices for industry and individual use are battery-operated, while some intended for a more permanent installation, for example in a warehouse, can be powered externally. Thinking beforehand about these details will help you decide what kind of logger you need and will also give you a baseline when you speak to an experienced cold chain solutions provider.

Should You Go Wired or Wireless?

Communication with the data logger can be handled in many different ways, including USB or Ethernet interface, wireless capability including Wi-Fi and proprietary radio links, Bluetooth, cellular modem, and more.

Often your selection will already be made for you depending on your particular facility’s wired or wireless setup.

4 Common Types of Temperature Monitoring Systems:

Standalone Transit Data Loggers operate independently of computer. They collect the measurements and store them in internal memory. Typically these devices are for a single temperature or temperature/humidity measurement. They either use USB or Bluetooth for data retrieval. Some models feature the ability to automatically create a PDF report file when connected, eliminating the need for special software to retrieve the data. There is also a choice between low-cost single-use loggers which are good for a limited duration and then can be thrown away or recycled or more durable multi-use models that will continue to reliably operate for at least a year. Standalone devices are widely used in the transportation industry to track shipping conditions inside a truck, rail car, or cargo plane. They are the ideal choice when:

• The manufacturer, shipper, and end customer are all different organizations and the device is going on a one-way trip.
• Cost is a major concern.
• The data is primarily for verification and alarming is a secondary.

Wired Data Loggers utilize a central data logger with a wired connection to sensors placed in different locations. With a wired device, you don’t have to worry about wireless range, which can unexpectedly complicate matters if you haven’t considered it beforehand. These systems can be used in production facilities or warehouses where the initial cost of installing cabling can be amortized over a long period of time. Having all the measurements brought back to one point simplifies data management and allows for centralized alarming. In addition, the logger can be connected to the LAN to provide the features of the networked data loggers (below).

Wired systems are the ideal choice when:

• Your facility has too many obstructions (or otherwise limits wireless range)
• You have an existing wired network that you plan to use
• You’re able to run cabling and have specific concerns about wireless devices and data integrity.

Wireless Data Loggers have two parts, one or more measurement devices that collect and transmit the data and a wireless base station or gateway that receives the data, processes it, and then uploads it to a PC, server, or cloud-based site. By using proprietary wireless protocols they can offer a range of 500 feet or more between the transmitters and the base station making them suitable for large warehouses. These devices can provide data and alarms in near real-time giving personnel time to save food products.

Wireless systems are the ideal choice when:

• You have several distributed points where you need to measure the temperature
• It would be difficult or expensive to run wires from your measurement points back to a central location
• Data needs to be collected and transmitted from a truck or other vehicle while it’s in motion, preventing the use of wired sensors

Data and/or alarms need to be collected from a site that’s difficult to access or does not offer regular internet connectivity. Some layouts make wireless system deployment difficult. As a quick exercise, look around the area you need to monitor. Consider whether the units would have a clear line of sight to a gateway or a repeater, or if their communication would be obstructed by walls, floors, or objects.

Networked data loggers use a LAN or Wi-Fi connection to automatically transmit their data over your facility’s network to an office PC, server, or to a cloud-based service. They can provide near-instantaneous alarms via email, SMS, or even a voice call. Network-connected devices are quickly becoming universal in the food and beverage industry as a way to help businesses and organizations pass inspections and ensure product quality. They are ideal for applications where the cost of lost product or risk is very high. Networked loggers include individual 1 or 2-channel data loggers with a LAN connection that can be distributed around a facility.

How Do You Want to Receive Alarms?

Alarms are a standard feature of temperature data loggers that provide immediate notification of temperature excursions in your product or environment. Specifically, these devices alert you through a variety of methods whenever their configurable temperature limits are exceeded.

Alarm delivery methods include:

1. Audible Alarms— If you know that personnel will be in the vicinity or if you’re in no danger of losing product, an audible alarm might be enough for your purposes. Just be sure that there are no consequences for missing an alarm! A good rule of thumb is to assume that someone won’t be in the room every time the alarm goes off.
2.  Visual Indicator— First ensure that the temperature logger is located somewhere with high traffic so personnel have a fast response time. These are useful for transit applications where the receiving party can immediately determine if the product remained within the required temperature range during shipment by looking at the indicator on the logger.
3. Emails— Email alerts are equally convenient. For critical applications, you’ll want to ensure that you’re aware of when you’re emailed. Many users use their mobile devices to give them an audible notification when they have an incoming alarm email.
4. SMS Text Message— SMS text alerts are a popular way to get an instant heads-up on alarm events. Once configured, the data logger automatically sends alarms out to specified personnel.
5. Phone Calls— Some systems provide dial-out capability to a landline or cell phone, enabling immediate notification virtually anywhere. An example of these monitoring products is the Accsense Monitoring family of wireless temperature, humidity, and environmental monitoring systems.

Temperature Monitoring Kits:

If you want to simplify your search, we have a number of Refrigerator and Freezer Monitoring Systems for the cold chain monitoring of temperatures in refrigerators and freezers. These kits provide a simple and effective solution that is easy to install and provides temperature alarm functionality. Based on wired Ethernet, Wi-Fi, or wireless hardware, we have the solution to your temperature monitoring problem.

Each kit is made up of temperature sensors and a data logger or network-connected device to record and transmit data to either a cloud-based server or to a location on your internal network. The sensor is placed inside the refrigerator or freezer cavity with the electronics located outside. Data and current temperatures are available from the included software or by using a web browser to the cloud server. Many of these solutions require little to no IT department involvement.

How Often Do You Need to Collect Data?

After determining what temperature range you need to log in and where you need to log it, it helps to decide how often you need the data logger to take a reading. In most temperature monitoring applications, users only need to take a temperature sample once every 15 or 30 minutes just to keep tabs on a specific product or environment. Depending on your temperature recording application, you may need to only capture a few hours or days’ worth of data or you may need the logger to store months’ worth of readings.

Concerning the specific data logger, there may be a limit based on the total amount of internal memory, or the logger may offer the option of using external memory such as a USB memory stick. Be sure to check the logger’s spec sheet for its battery life. Nowadays, many data loggers ensure that recorded data is kept in non-volatile memory so it will remain safe if the battery fails or power is lost.

What Software Features Do You Need?

Data logger software is used to control the operation of the system. Software features include:

1. Configuration/Setup—This is an area where a user-friendly interface really pays off. You want to be able to quickly move through naming sensors and setting temperature limits, and sample rates. Wireless data loggers now offer remote configuration and setup.
2. Data retrieval—You’ll want to be able to retrieve your data as quickly and easily as possible—as above, intuitive software really helps here.
3. Alarm management—Here you’ll choose who will receive alarms and how they’ll be notified, whether over email, text message, or even landline phone calls with some models.
4. Charting—Useful for identifying and displaying data trends such as temperature profiles or temperature spikes. Depending on your product, this feature may help you to increase product quality as well.
5. Report Generation—The ability to easily generate compliance reports may be necessary for proof of your best practices to the FDA or other regulatory bodies. Some devices offer the ability to directly export PDF reports which greatly simplifies documentation and record keeping.

Conclusion:

Effective cold chain management is crucial for ensuring the safety, quality, and integrity of perishable products. By implementing a robust temperature monitoring system, businesses can mitigate risks, comply with regulatory standards, and ultimately enhance their bottom line. Data loggers provide valuable insights into the temperature history of products, enabling proactive measures to prevent spoilage and product recalls. As technology continues to advance, cold chain solutions are becoming increasingly sophisticated, offering greater accuracy, reliability, and convenience. By investing in a comprehensive cold chain management strategy, businesses can safeguard their reputation and deliver high-quality products to their customers.

For more info on data loggers, or cold chain temperature monitoring, or to find the ideal solution for your application-specific needs, contact a CAS Data Logger Applications Specialist at (800) 956-4437 or request more information.

The post What is the Cold Chain? appeared first on CAS Dataloggers.

In today’s data-driven world, the integrity and reliability of isolated measurement systems are critical. Electrical isolation, a protective design feature, plays a crucial role in ensuring the accuracy and safety of data acquisition systems. By separating measurement signals from different sensors from each other and the data processing circuitry, isolation prevents electrical interference and protects both the system’s components and the collected data.

This white paper explores the concept of electrical isolation, its benefits, and the potential risks associated with non-isolated systems. We’ll delve into specific applications where isolation measurement is essential and provide insights into why you should consider using isolated data acquisition systems and data loggers in your process-critical applications.

What is Electrical Isolation?

Electrical isolation is a protective design feature of many data loggers and data acquisition systems. Isolation is implemented to separate measurement signals from each other to keep them from interacting and causing electrical issues. The essential design feature is to keep each section of the circuit independent such that there is no current path between different sections of the measurement system including the signal conditioning, measurement, and data communication circuitry. Isolation can be implemented by several techniques such as optical isolation, transformer isolation, or specialized ICs that decouple the inputs and outputs to break any grounds or other current paths.

For example, a specific type of isolation, galvanic isolation, can be used to separate the analog signal processing and measurement circuits from the digital data processing and communications circuits to cut off current flow among them. This protects the system’s electrical components by eliminating the potential for issues such as ground loops while still allowing for communication and data exchange per usual between electric circuits. For example, you can use opto-isolators, ICs that use light to transfer data between system components. By allowing no ground or DC paths, galvanic isolation keeps unintended current from flowing between the system segments.

Your existing data acquisition equipment may already have isolation; if unsure, check the device’s specification sheet. If your system is multiplexed (combining several signals into one), it may already feature a level of isolation between channels. This will normally be called out in the specifications as channel-to-channel isolation resistance or maximum common mode voltage. Devices with greater communication capability often have (or require) galvanic isolation owing to their greater need to safeguard data.

Why Isolate Your Systems?

Isolation is often required in real-time data acquisition applications such as:

• Automotive manufacturing
• Machine monitoring (turbines, motors, etc.)
• Food processing operations
• Materials Engineering (alloys, etc.)
• Many other heavy industrial uses

One excellent reason to use isolated data acquisition systems is to protect yourself or your personnel from electrical accidents. In particular, galvanically isolated systems protect operators from being exposed to unintended current paths or high voltage in the case of a fault.

Another good reason to use isolated measurement systems is to ensure that your measurements are free (as much as possible) from signal noise. In electronic equipment, noise is a prevalent wiring issue that corrupts your devices’ program signals, leading to data distortion or drops. Signal noise is caused by unintended current carried by a ground loop, which is in turn formed when two or more connected electrical systems are accessing more than one path to the ground. Resistance changes these currents into voltage fluctuations, causing the problem.

As mentioned in our earlier White Paper, ‘Seven Ways Signal Noise Can Impact Your Electrical Equipment,’ applications with high signal noise and electromagnetic interference can greatly benefit from system isolation. Many manufacturers of data acquisition systems offer several different models of their basic product, featuring different levels of isolation such as channel-to-channel, galvanic, etc.)

While it’s true that all measurements have a certain amount of inaccuracy, if you’re working in a high-accuracy application then you’ll need to reduce errors and interference for external sources as much as possible. An isolated design helps to prevent signal noise by eliminating potential ground loops caused by different ground points for different sections of the measurement systems.

Galvanic isolation offers an additional benefit in the form of common-mode voltage rejection, which reduces signal noise by ignoring those signals (voltages) that are common to both the + and – input connections.  This is especially useful if you’re trying to record accurate measurements in areas where the output voltage of a sensor may be floating concerning the earth’s ground.

What Risks are Posed by Non-Isolated Systems?

While isolated measurement systems are fractionally more costly than non-isolated products, you may find that the cost of repairing or replacing your system is much higher!

For the average user of a data acquisition system, the most likely risk is that the analog/digital signals will be corrupted or that the system will be damaged as a result of unintended ground current flow. For example, your system’s circuits can be damaged in an instant by currents caused by a fault if this threat is not mitigated beforehand by isolation. For all practical purposes, non-isolated systems also restrict your choice of input signal types.

However, Ground loops pose one of the greatest threats, both to measurement signals and to users themselves:

• Data Loss: Networked data systems lacking isolation are at great risk of losing data through signal degradation. Isolation safeguards data from signal degradation while also helping to protect your initial investment in your data acquisition system. A very common example is noise inducted in a USB-connected measurement system that does not provide isolation between the USB interface and the analog measurement circuits
• Physical harm: Users of non-isolated systems face a real risk of harm caused by high current or voltage.

Isolation prevents these ground loops from forming, thereby protecting the system and measurement signals. If you need to take additional precautions, galvanic isolation prevents ground loops by preventing the current paths that cause current to flow between units in the first place (i.e. by breaking the loop).

If you’re working on a process application, you’ll want isolation as an extra precaution against measurement and control system failures, which can cause a costly process delay or shutdown.

If you’re a systems integrator or contracted purchaser, you should consider isolating your data acquisition systems to avoid complaints or even lawsuits from customers whose systems were damaged from ground loops and other electrical issues. By supplying systems with built-in isolation, you can also gain a reputation for quality products in the heavy industrial market.

Summary:

No matter what application you’re considering sourcing a data acquisition system or data logger for, we highly recommend you first consider whether or not you’ll need a system with built-in isolation. If so, the marginally higher cost is well worth it considering the potential for lost data, damaged components, and physical risk to the operator. If you’re not sure whether or not your application requires isolation, be sure to address this with a trusted solutions provider.

For more info on Data Acquisition Systems, or to find the ideal solution for your application-specific needs, contact a CAS Data Logger Applications Specialist at (800) 956-4437 or request more information.

The post Why You Should Consider Using Isolated Measurement Systems appeared first on CAS Dataloggers.

Personnel installing new temperature monitoring systems in their refrigerators and freezers are often surprised to see the temperature vary up and down unexpectedly. Our temperature data loggers and fridge monitoring systems provide significantly faster response time and significantly more data than conventional thermometers which often leads to the observation of temperature behavior that was previously missed. We have put together this quick guide to help you investigate potential causes and suggest some solutions so that over time you can identify the source and control the stability of the temperature in your fridge or freezer.

There are 3 common reasons the recorded temperatures can periodically change:

1. Frequent Door Opening

The first and simplest cause of unstable temperature readings is caused by staff opening the door, which almost immediately causes a change in the value of the refrigerator/freezer’s temperature as reported by the sensor. Please note that the actual temperature of the products stored inside is not changing this rapidly, only the air temperature as recorded by the sensor. The sensors used by electronic data loggers have much faster response times than traditional mercury thermometers and will display rapid temperature increases of as much as 5-10 degrees which might be interpreted as a problem with the system. If the presence of these jumps in temperature is an issue for your organization, you can add a thermal buffer, a small bottle of glycol or glass beads, or a nylon block, to the probe. If you take a look at the CDC Vaccine Storage and Handling Toolkit, they recommend using a buffered thermal probe. The thermal buffer provides thermal mass which will dampen the system’s response time and eliminate the temperature spikes caused by opening the door. Thermal buffers also have the benefit of making the reported temperature more closely mimic the actual temperature of the refrigerated product.

2. Refrigerator/Freezer Compressor Cycling

The second source of temperature variation arises from the normal cycling of the compressor used to cool the refrigerator/freezer. Again, if the temperature displayed by your thermometer is being compared to the temperature reported by your electronic monitoring system, the response time of the thermometer may be masking the actual temperature fluctuations inside the cabinet. By looking at a graph of temperature vs. time, this cycling will be revealed by a regular, periodic change in temperature. We occasionally find the probe for the monitoring system placed very close to the evaporator coil or directly in the airstream of the coil fan. These locations aren’t ideal since they experience the greatest change in temperature as the compressor turns on and off, so relocating the probe to a spot away from the coil or out of the airstream will usually help reduce variation amplitude.

Figure 1. Typical temperature cycling behavior measured at several locations inside a typical refrigerator over 2 hours.

3. Electrical Noise

The final cause is due to electrical noise in the monitoring system. This can often be identified from the temperature data in the form of random jumps in temperature from 0.5 to 5 degrees or more happening over a very short period (such as seconds). The most common cause of electrical noise is the placement of wires running from the sensor to the actual measurement instrument. The signal levels generated with some of the common types of sensors are often in the millivolt or microvolt range. If the wires carrying these signals pass near wires carrying AC line voltage power signals for motors or other devices, it’s easy to get stray voltage induced on the temperature signal from the sensor. To fix this, make sure to carefully route wires from the temperature sensor away from any wires away from wires carrying AC power, use twisted pair wiring, and use shielded cable for the sensor wires, ensuring that the shielded cable is connected to good earth ground at just one end.

Summary

Utilizing these suggestions with your fridge monitoring system, you should be able to minimize or remove the majority of temperature fluctuations in your medical refrigerator, perishable freezer, or any fridge/freezer/cooler unit you rely on to keep your product safe.

For more information on Fridge Monitoring Systems or to find the ideal solution for your application-specific needs, contact a CAS DataLogger Application Specialist at (800) 956-4437 or request more information.

The post 3 Ways Temperature Fluctuates in Fridge & Freezer Monitoring appeared first on CAS Dataloggers.

In today’s world, precise temperature monitoring is vital across many industries. From ensuring food safety in restaurants to maintaining the efficacy of medications in pharmacies, even slight temperature fluctuations can have significant consequences for the products that are being stored there. This is where temperature monitoring systems (TMS) come into play. This comprehensive guide delves into the six key components of a TMS, empowering you to make informed decisions when choosing a system that best safeguards your products and adheres to regulations.

This comprehensive guide delves into the six key components of a TMS, empowering you to make informed decisions when choosing a system that best safeguards your products and adheres to regulations.

Part 1: The Starting Point – Temperature Probes

At the heart of every TMS lies the temperature probe, the silent sentinel that captures crucial temperature data. These sensors come in various types, each with its strengths and weaknesses:

• Thermocouples: The most widely used probes, they offer affordability, come in many different styles and provide a wide temperature measurement range. However, their accuracy is lower compared to other options.
• RTDs (Resistance Temperature Detectors): These probes deliver high accuracy but have a narrower operating range. They are ideal for applications requiring precise measurement within a specific temperature window.
• Thermistors: Boasting the highest accuracy, thermistors excel in scenarios demanding exceptional precision. However, their limited operating range and highly non-linear response necessitate specialized measurement systems.

Choosing the right probe depends on your specific needs. Consider factors like the required temperature range, desired accuracy level, and budget constraints. Most sensor manufacturers offer a variety of probe types, including:

• Stainless steel probes: Ideal for general-purpose applications and high temperatures
• Immersion probes: Sealed for use in liquids.
• Magnetic surface contact probes: Perfect for attaching to metal surfaces.

Part 2: Smoothing the Response – Thermal Buffers

Imagine a probe taking a temperature reading in a refrigerator. When the door opens, a surge of warm air momentarily disrupts the internal temperature. While the actual products inside might not experience such a drastic change, the probe’s faster response time can cause the reading to spike. This is where thermal buffers come in. Thermal buffers are essentially thermal masses (materials or liquids) attached to the probe. They act as a damper, slowing down temperature fluctuations and providing a more accurate reflection of the product’s actual temperature. Common types include:

• Glycol bottles: Filled with a specific type of antifreeze, these buffers are ideal for cold storage applications.
• Nylon blocks: A cost-effective option for various temperature ranges including LN2.
• Vials filled with glass beads: Offer excellent thermal conductivity and response time.

Part 3: The Brain of the Operation – Measurement Devices

The measurement device provides a key function of a TMS. It connects to the probes, converting the raw sensor output into digital values. These devices come in various forms, each catering to different needs:

• Standalone data loggers: These self-contained units store data internally and often feature an LCD-display for viewing current temperatures. They are ideal for situations where network connectivity is unavailable or not required.
• Networked/LAN/Wi-Fi measurement devices: These devices connect to a network, allowing for remote data access and monitoring. They are perfect for multi-location setups or applications requiring real-time data analysis.
• Wireless measurement devices: Employing wireless technologies (Cellular, Bluetooth, LoRa, SigFox, or proprietary protocols), these devices offer flexibility in probe placement and eliminate the need for wired connections. They are well-suited for monitoring areas with difficult wire routing or constantly moving objects like trucks in transit.

Choosing the Right Measurement Device:

Here are some key factors to consider when selecting a measurement device:

• Sensor Input Type: The measurement device must provide inputs that are suitable for the sensor type described in Part 1. Each sensor type has unique measurement requirements that need to be taken into account.
• Sampling Rate: How often the device takes temperature readings. Higher sampling rates provide more detailed data but require more storage space.
• Measurement Accuracy: The level of precision required by your application.
• Battery Life (if applicable): Crucial for standalone devices. Battery life depends on factors like sampling rate and chosen battery type (rechargeable or non-rechargeable). •
• Communication Interface: How the device connects to a network (Ethernet, Wi-Fi) or other devices (USB).

Part 4: Keeping Track of History – Data Storage

The data collected by your TMS serves as a historical record, providing valuable insights into temperature fluctuations over time. The amount of storage you need depends on how long you want to retain data and the sampling rate. The time window can be simply when you are not in the office like weekends or holidays or it may be dictated by the need to provide monthly or annual temperature reports to auditors or 3rd party accreditation bodies. Here are the common data storage options:

• Internal Memory: Most devices offer some internal storage, but capacity is limited.
• Local Base Station (for wireless systems): Acts as a central hub for data collection and storage before potentially forwarding it to a network or cloud.
• Local PC: A traditional and cost-effective method, but requires manual data retrieval and management.
• Cloud Storage: Offers remote access to data and eliminates the need for on-site storage solutions. Some cloud services provide additional features like data analysis and reporting tools.

Part 5: Making Sense of the Data – Software for Management and Analysis

The software component of a TMS transforms raw temperature data into actionable insights. User-friendly interfaces are crucial for navigating and interpreting the information effectively. Here’s a breakdown of the software’s functionalities:

• System Configuration: Allows you to set up the system, define the measurements for the probes and configure any communications interfaces.
• Alarm Management: Enables you to set alarm thresholds for minimum and maximum temperatures. The software can trigger visual or audible alarms on the device itself, or send notifications via email, text message, or phone call.
• User Management: Allows for assigning different user roles with varying levels of access and permissions within the system.
• Data Visualization: Retrieve live or stored data and present it in various formats, including charts, graphs, and tables. This enables you to identify trends and patterns easily.
• Data Analysis and Reporting: Provides comprehensive reports on temperature history, highlighting critical events like fluctuations or equipment malfunctions.

Choosing the Right Software:

• Scalability: Consider the potential growth of your monitoring needs. Choose software that can accommodate additional probes and devices.
• Security: Ensure the software offers robust security features to safeguard your sensitive temperature data.
• Compliance Requirements: If your industry has specific regulations regarding data storage and audit trails, choose software that meets those requirements.
• Integration Capabilities: Does the software integrate with existing business systems like inventory management or building automation software?

Part 6: Keeping You Informed – Alarm Systems

The alarm system is the final piece of the TMS puzzle, ensuring you’re promptly notified when temperatures deviate from acceptable ranges. These systems can operate in various ways:

Visual Alarms: LEDs on the device itself or a central display can flash or change color, indicating an out-of-range temperature.

Audible Alarms: The device can emit a loud beep or siren to grab your attention.

Remote Notifications: The software can send email, text message, or phone call alerts to designated personnel. This is crucial for situations where staff might not be physically present near the monitoring location.

Advanced Alarm Features:

Silence/Acknowledge Alarms: Allows authorized personnel to silence or acknowledge alarms after investigating the issue.

Multi-Level Notifications: Trigger alerts to different recipients based on the severity of the temperature deviation.

Escalation Procedures: Automatically notify higher-level personnel if alarms are not addressed within a predefined timeframe.

Conclusion

By understanding the six key components of a TMS and considering your specific needs, you’re well-equipped to choose a system that safeguards your products, ensures regulatory compliance, and empowers you to make informed decisions based on real-time temperature data. Remember, a well-designed TMS can significantly impact your operations, minimizing product loss, optimizing energy usage, and ultimately, enhancing your bottom line.

For further information on temperature monitoring systems, 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.

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