CALPlex DataLogger Support

• The first port of entry is via the RS-232 communications port. If an electrical spike enters the communication port then your computer has also taken the spike since it had to travel through your computer's COM port to the CALPlex datalogger. It is not very common for spikes to travel this route, but it has occurred
• The second port of entry is the grounding wire. Under normal circumstances, CALPlex's grounding wire will dissipate electrical spikes. However, stray voltage from a welding unit could result in errors in the temperature readings, or damage to the CALPlex's internal circuitry. Never use the CALPlex on the same circuit or connect the grounding wire to a common ground that is being used simultaneously by a welding unit.
• The third port of entry is through CALPlex's connection to its power supply. However, the datalogger is protected very well against such entry since the spike must pass through a surge protector (if one is being used), the AC-DC converting power supply and a fuse before reaching any board level components of the datalogger. It is unlikely, but not impossible, for damage to occur to the CALPlex from electrical spikes entering via the power supply.
• The fourth and most common cause for damage from an electrical spike is when the spike enters the datalogger via a thermocouple lead. There is no protection from this type of spike within the datalogger.

How do the spikes traveling via a thermocouple lead occur?
The most common source for these spikes is from welding! If a lead wire is connected to the datalogger and its hot junction is touching the retort shell, or something metal with the retort, then welding anywhere in the plant that is in anyway connected to the retort via a conductor can cause electrical spikes to enter the datalogger.

Also, some users have forgotten to disconnect leads before welding their hot junctions which will definitely "fry" the datalogger.

What can you do to avoid spikes entering the datalogger via thermocouple leads?
To avoid "frying" your datalogger:

• Make sure that there is no welding going on in the vicinity around the datalogger while free leads could be in contact with the retort shell.
• It is recommended that you disconnect all wires from the datalogger if you are leaving your equipment set up overnight. You never know when work will be going on in a food plant.
• If you are going to repair a thermocouple lead wire or weld a hot junction onto the tip of the lead wire, always unplug the lead wire from the CALPlex datalogger.

While the CALPlex datalogger is designed to withstand very harsh environments (high temperatures, high humidity), it is not completely "water tight" and cannot withstand being doused with water.

How can the datalogger get doused with water and what can be done about it?
We have seen many different instances where a datalogger was doused with water. Two of the most common are:

• Water forced through lead wires drips continuously into the datalogger. This scenario can be avoided by splitting the Teflon overwrap of the lead wires somewhere between the retort packing gland and the datalogger. Splitting the overwrap allows the water to drip before it reaches the datalogger.
• Valve diaphragm blows/pipe breaks and CALPlex is sprayed with water. This scenario can be avoided by carefully picking out the space to set up your equipment. Sometimes you can't avoid setting up too close to the retort and you have to hope nothing breaks that can ruin your datalogger and/or computer.

• Always be sure the green grounding wire is grounded to a device that has an earth ground. An improperly grounded unit may produce erratic or inaccurate readings. One suggestion is the cold water line entering the retort.
  
• It is recommended to turn on the CALPlex unit at least 30 minutes prior to using it. This will allow the CALPlex unit to warm up and equilibrate to the process room temperature.
  
• Never use the CALPlex on the same circuit or connect the grounding wire to a common ground that is being used simultaneously by a welding unit. Stray voltage from a welding unit could result in errors in the temperature readings, or damage to the CALPlex's internal circuitry.
  
• Always unplug all wires connected to the CALPlex box at the completion of your tests. This includes the power source, the grounding wire, and the thermocouple lead wires. The reason for this precaution is most maintenance tasks performed in a production facility are performed in-between shifts (e.g., at night). Be careful what you use as a grounding source for the CALPlex unit. Equipment such as welding machines that are connected to the source used for grounding the CALPlex unit may damage the unit, even when it is turned off.

• Is the data logger turned on?
• Check the AC-DC power supply brick to see if the green light on it is illuminated. If it is on, proceed. If it is not on, then either the power supply is bad or the datalogger is plugged into an outlet that has no power to it.
• Check the connection between the power supply and the CALPlex box. If you wiggle the connection and the power comes on then the connector on the power supply may need to be replaced.
• Check the fuse by unscrewing the fuse cap and removing the fuse (see Figure A-1). If it is blown, insert a new fuse into the slot and replace the cap.
• If the above fails, then the CALPlex unit needs to be sent in for repair - it is likely that the power supply board is not working. The power supply board can be damaged by excessive power spikes, direct exposure to water or voltage spikes that have bypassed entry through the power supply and have come through the thermocouple wires. It is imperative that the datalogger not be connected to a retort where welding is occurring, since electrical spikes may enter the "back door" by traveling through the thermocouple wires into the datalogger.

Learn more about how electrical spikes can enter the CALPlex datalogger.

I am getting "Communication Failure" within CALSoft when trying to collect data.

• Is the communication cable connected to the correct port on the computer? If so, is CALSoft set up to communicate with that port? To find out what port CALSoft is set up to communicate with, open the CALSoft software, chose the Edit | Preferences from the drop-down menu, and choose the Collect tab. Under COM Port select the Detect button to have CALSoft check COM1 - COM4 and report back to you if it finds a CALPlex datalogger on any port.
• Is the communication cable in good shape? Could the cable be broken? Is there excessive rust/oxidation on the cable connections into the computer and/or CALPlex datalogger? Try scraping the connections if rust or gunk appears.
• Is the port in the computer enabled. Some newer laptops disable COM ports so that Infrared ports may be enabled. If you have an infrared port check your computer's guide to see if the COM port needs to be enabled.
• Are you running your computer off of battery power? With some of the new energy saving computers there may not be enough power when running off of battery to power the serial port to send and receive signals from the CALPlex datalogger. Therefore, you should try running your computer off of AC.
• If all fails, your datalogger may need repair. It is possible that the communication chip has gone bad or has been affected by a voltage spike.

Learn more about how electrical spikes can enter the CALPlex datalogger.

I am getting varying temperatures back from the datalogger from scan to scan.

• The most likely problem here is grounding. You need to be sure that your CALPlex datalogger is properly grounded. Grounding is especially critical when collecting data on vessels that have large electro-mechanical motors on them (i.e. rotational retorts, steam-air retorts). There is no definitive way to know that you have a good ground other than to see the temperatures stop varying as they are doing. Follow these steps:
  • Be sure both ends of the ground cable are free of oxidation.
  • Begin by connecting the retort end of the cable to the cold-water pipe. If the pipe is painted be sure to scrape away some of the paint so that a good connection can be made.
  • If grounding to the cold-water pipe does not work, try moving the ground to other parts of the retort.
• If you believe that you have a good ground, or that grounding is not what is causing you erratic/varying readings, then look at the following:
  • Are your lead wires in good shape? Try a different set of wires to see what happens.
  • If you are collecting through a slipring, has the slipring been cleaned lately?
  • Are your connections in the wire tight?
• If erratic readings persist, you may need to send you CALPlex unit in for repair.

The datalogger is scanning but I am getting no temperatures on any channels.

THIS REQUIRES A REPAIR.

If the datalogger is scanning, it is likely that an internal electronic component on the CALPLex main board (a "mux chip") has gone bad and the datalogger will have to be sent in for repairs.

I am getting no temperatures (0) back from the datalogger on eight channels.

THIS REQUIRES A REPAIR.

If this is occurring in a bank of eight channels as follows: 1-8, 9-16, 17-24, and/or 25-32, then it is likely that an internal electronic component on the CALPLex main board (a "mux chip") has gone bad and the datalogger will have to be sent in for repairs.

My datalogger got wet, what should I do?

• First, if the datalogger gets doused with water:
  • Immediately stop using it, turn it off and unplug it from its power source.
  • Move the datalogger to a dry environment and let it sit there until it completely dries.
  • Once it is dry, try the datalogger to see if it works.
• If it still does not work after drying, your CALPlex may need to be repaired.
  Learn more about how water can get into your CALPlex datalogger.

The readings from CALPlex are not agreeing with my MIG thermometer.

• The most likely problem here is grounding. You need to be sure that your CALPlex datalogger is properly grounded. Grounding is especially critical when collecting data on vessels that have large electro-mechanical motors on them (i.e. rotational retorts, steam-air retorts). There is no definitive way to know that you have a good ground other than to see the temperatures stop varying as they are doing. Follow these steps:
  • Be sure both ends of the ground cable are free of oxidation.
  • Begin by connecting the retort end of the cable to the cold-water pipe. If the pipe is painted be sure to scrape away some of the paint so that a good connection can be made.
  • If grounding to the cold-water pipe does not work, try moving the ground to other parts of the retort.
• If you are sure that you do not have a grounding problem, then it is likely that your MIG thermometer is not far enough into the retort to report accurate temperatures.
• If the readings are still not in agreement, your CALPlex unit may need to be calibrated. A common cause for this problem is calibration inaccuracy in the CALPlex unit and/or the thermocouple wires. Both are referred to as "calibration errors". The CALPlex unit, if recently calibrated, is accurate to + 0.2°F (0.1°C). The special limits of error for new thermocouple wire is the greater of 0.9°F (0.5°C) or 0.4% of the reading. At a thermocouple reading of 250°F (121.1°C), the error could be 1.0°F (0.56°C).

One solution would be to make sure your CALPlex unit has been calibrated within the past 12 months. If not, we suggest sending your CALPlex unit in for calibration. Simply click "Create RMA" on the left of this page to get an RMA number from TechniCAL and shipping instructions. Another solution is to make sure that you have properly calibrated your data collection system (CALPlex, thermocouple lead wires, and thermocouples) against the known reference MIG thermometer installed on your retort.

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I am getting communication failures when my computer is running off of its battery, but all is fine when it is running off of AC.

• With some of the new energy saving computers there may not be enough power when running off of battery to power the serial port to send and receive signals from the CALPlex datalogger. Therefore, you should try running your computer off of AC.
• If the problem still persists, you may need to send in your CALPlex for repair.

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