Super System HB1000 Installation Manual
HB1000 Thermal Barrier
User’s Manual
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060 800-666-4330
Fax: 513-772-9466
www.supersystems.com
Table of Contents
Overview .......................................................................................................................................... 2
Electronics Component ................................................................................................................... 2
Data Logger Electronics Specifications .......................................................................................... 3
Thermal Barrier .............................................................................................................................. 4
Elements of the Thermal Barrier ................................................................................................... 4
Thermal Barrier Specifications ...................................................................................................... 5
Using the Thermal Barrier with the Data Logging Electronics ...................................................... 6
Replacing Wear Strips .................................................................................................................... 7
Getting Started ................................................................................................................................ 8
HB1000 Software ...........................................................................................................................10
HB1000 Menu .................................................................................................................................10
Install Driver ...............................................................................................................................11
Device Settings ...........................................................................................................................12
Calibrations ................................................................................................................................13
Zero Calibration ......................................................................................................................13
Span Calibration .....................................................................................................................14
T/C Trim Calibration ...............................................................................................................14
Cold Junction Calibration .......................................................................................................15
SDS Reporter Software ..................................................................................................................16
Menu ...........................................................................................................................................16
Report Properties Tab ................................................................................................................17
Report .....................................................................................................................................17
Survey Parameters .................................................................................................................18
Survey Details .........................................................................................................................19
Thermocouples .......................................................................................................................19
Survey Box ..............................................................................................................................21
Furnace ...................................................................................................................................21
Controller ...............................................................................................................................22
User Defined ...........................................................................................................................22
Comparison Check .................................................................................................................23
Chart Tab ....................................................................................................................................25
Data Tab .....................................................................................................................................25
File Menu ....................................................................................................................................26
SDS Menu Options ......................................................................................................................29
SDS Manage Survey Templates .........................................................................................29
SDS Download Surveys and Data .......................................................................................29
Options Menu Options ................................................................................................................31
Options Show Labels On Chart ..........................................................................................31
Help Menu Options .....................................................................................................................31
Help Check for Updates .....................................................................................................31
Help About ..........................................................................................................................32
SDS Data Tags ............................................................................................................................32
Creating a Personalized Template .........................................................................................39
SDS Template Manager .............................................................................................................41
Description of Template Manager Screen Tabs .........................................................................44
Description of Template Manager Screen Fields ..........................................................................48
Line Diagrams ................................................................................................................................49
HB1000 Thermal Barrier Rev-
1
Overview
SSi’s HB1000 Series In-Furnace Data Logging Device provides data gathering capabilities in a
unit designed to withstand the stress of monitoring temperature from within a furnace. The
thermal barrier is constructed with a stainless steel exterior and insulating components that
protect the internal electronics for extended periods of time at temperature. The high accuracy
electronics component supports 10 type K thermocouples with a maximum battery life of 40
hours. Using the USB connection, data can be easily imported in to SSi’s SDS Reporter software
for AMS 2750 D compliant reports.
Electronics Component
The switch on the bottom of the box turns the power on and off. Next to the switch is the USB
port. When the electronics are not in use, the unit should be powered off and connected to a
computer to charge. Keeping the unit powered off while not in use will drastically improve its
battery life.
The functions of the LEDs are as follows, starting with the LED furthest from the switch:
1. Yellow LED. Blinking when power is on. Stops blinking but remains lit when connected to a
computer via USB, thus charging.
2. Red LED. Blinking when connected to a computer via USB.
3. Red LED. Blinking when datalogging.
4. Green LED. Blinking when data is being transmitted via USB.
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HB1000 Thermal Barrier Rev-
Data Logger Electronics Specifications
HB1000 Thermal Barrier Rev-
3
Thermal Barrier
Figure: HB 1015 unit. HB 1012 unit not pictured.
Elements of the Thermal Barrier
HB1000 Thermal Barrier Rev-
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There are several guidelines to follow that will ensure the longest life of the thermal barrier:
Temperature in
°F
Temperature in
°C
HB 1012 Max
Time at Temp
HB 1015 Max
Time at Temp
482
250
7hrs 30min
13 hrs
572
300
5hrs 45min
10hrs 30min
662
350
4hrs 45min
8hrs 35 min
752
400
4 hrs
7hrs 25min
842
450
3hrs 30min
6hrs 30min
932
500
3hrs 30min
5hrs 35min
1022
550
2hrs 50min
5hrs
1112
600
2hrs 30min
4hrs 40min
1202
650
2hrs 15min
4hrs 15min
1292
700
2hrs 10min
4hrs
1382
750
2hrs
3hrs 45min
1472
800
1hr 50min
3hrs 30min
1562
850
1hr 45min
3hrs 15min
1652
900
1hr 45min
3hrs
1742
950
1hr 30 min
3hrs
1832
1000
1hr 30 min
2hrs 50min
DO NOT OPERATE AT TEMPERATURES ABOVE 1832° F (1000° C)
1. Do not let the high temperature fabric in the lid and the base rub or abrade against any
surface. Keep the cloth facing upwards when the unit is open.
2. Store the thermal barrier in the pelican case it is shipped in. If it cannot be stored in the
pelican case, it should be kept in a dry location. In this case, it is recommended that the
thermal barrier be kept inside a plastic bag.
3. Replace the wear strips with new ones before the high temperature fabric is damaged. The
high temperature fabric should not come in contact with the sensor cables.
4. The start temperature of the thermal barrier should be less than 77° F (25° C).
5. If possible, keep the barrier unbuckled during storage.
6. When the thermal barrier has just come out of the furnace and is hot, open the lid and keep
the unit on a perforated surface to let it cool down. Handle with high temperature gloves.
7. Any time the unit is unbuckled, it should be prevented from sliding to reduce wear on the
matting.
8. When placing the upper half on top of the lower half, keep the wear strips clear of the sensor
outlet guide.
9. When locking the thermal barrier, place all four toggle clamp arms into the engagements
before pressing the toggle clamps down to lock. Similarly, when unlocking, loosen all four
clamp arms before pulling apart from the engagements.
10. NEVER EXCEED THE THERMAL CAPACITY ( TEMP / TIME CAPACITY ). Refer to chart below.
Neither unit should be used at temperature above 1832° F (1000° C) for any amount of time.
Thermal Barrier Specifications
5
HB1000 Thermal Barrier Rev-
Using the Thermal Barrier with the Data Logging Electronics
1. Open the thermal barrier and set the halves next to each other.
2. Insert the data logger into a plastic/polythene bag.
3. Set the heat sink up so that the pocket faces upwards, and insert the data logger into the
pocket.
4. Lean the heat sink onto the edge of the thermal barrier as shown in picture 2 and route
the thermocouple wires through the sensor outlet guides.
5. Place the upper half on top of the lower half, keeping the wear strips clear of the sensor
outlet guides. Fasten all four toggle locks.
HB1000 Thermal Barrier Rev-
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Replacing Wear Strips
To replace the wear strips, simply unscrew the locking plate and put the new wear strip in
place. Screw the locking plate back on.
HB1000 Thermal Barrier Rev-
7
Getting Started
To begin using the HB1000, first load the SDS Reporter software provided with the unit onto a
computer.
Connect thermocouples to the data logger. Channel one must be connected in order to collect
data. The thermocouples can be connected using a mini adaptor. When connecting the
thermocouples, the positive side is down and is the smaller of the two terminals.
Next, connect the data logging electronics to the computer with a USB cable. Verify that the
USB Connection Active LED is blinking red. Instructions for installing the driver for the HB1000
can be found under Install Driver on page11. Assign the on and off data logging temperatures
for the unit. For continuous data logging, the on temperature should be set to 0°F or C and the
off temp to the maximum temperature, which is 3276°F (1802°C). Instructions for setting the on
and off temperatures can be found under Device Settings on page12. Thermocouple one
controls the on and off status of the data logging; this cannot be assigned to any other
thermocouple. Once the on and off temperatures are assigned, disconnect the unit from the
computer. If the on temperature is below ambient temperature, the Data Logging In Process
LED should be blinking red.
At this point, the data logger setup is complete. The data logger can be placed into the heat
sink with the thermocouple wires facing out. Please see the section Using the Thermal Barrier
with the Data Logging Electronics to ensure proper arrangement of the parts.
Once the HB1000 has come out of the furnace, pull the electronics component out of the
thermal barrier as quickly as possible. The thermal barrier should be handled with heat
resistant gloves. After removing the electronics, turn the switch OFF and connect the unit to a
computer with a USB to charge. This will discontinue data logging. Keeping the unit turned off
or charging when it is not in use will greatly prolong the battery life of the electronics.
Before beginning a new survey, the electronics must always first be connected to the computer
and scanned by the Uniformity Box software if the device has been turned off. Once the device
has been found, it will have the same On and Off temperatures assigned from the previous
survey, and it can be disconnected from the computer at that time to begin data logging.
Downloading a Survey
Connect the electronics to the computer with a USB cord. Verify that the USB Connection Active
LED is blinking red. To download a survey, go to SDS Download Surveys and Data, and select
the unit from the SDS drop down menu. Hit the Download button. The program will download
every job (survey) on the unit each time this operation is performed. To delete old jobs from the
device, use the Erase Jobs button on the Device Settings menu. Erasing jobs is discussed
further in the Device Settings section.
Once the jobs are downloaded, close the window. Select File New. The Report Properties
tab will open. The first box on this page is labeled Data Sources. Click the button with three
dots next to the Data field. This will display the Load Survey Data window. Select the
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HB1000 Thermal Barrier Rev-
appropriate job; the most recent job performed will be at the top of the list. Once the job is
highlighted, a template can be used by clicking the Attach Template to Survey button in blue
located just below the list of jobs. This will display the Open Template File window with the
option to open a local survey template file located on the computer. Hit the Browse button,
select the appropriate template, and press Open. Hit the Open File button at the bottom of the
Open Template File window. This will display the Select Template window. Highlight the
appropriate template, and hit Ok. Now, press the Use button in the Load Survey Data window.
For more information on creating a template, please see the section SDS Template Manager.
At this point, the data from the job performed as well as the data fields that correspond to the
selected template will be populated. Any other necessary information can be entered by
clicking through the Report Properties tabs. For more information on this, please see the
section SDS Reporter Software. The chart for the survey can be viewed by clicking the Chart
tab.
To create a report using this job, click the button next to the Report Template field,
located on the Report tab of Report Properties. Select the appropriate report file, and hit Open.
Go to File Print Preview Print Preview Report to view the report. The report can be printed
from here. For more information on creating a Report Template, please see the section
Creating a Personalized Template.
HB1000 Thermal Barrier Rev-
9
HB1000 Software
The HB1000 software provides a simple interface for accessing data collected by the uniformity
box.
Open SDS Reporter and
choose SDS Uniformity Box
settings.
HB1000 Menu
The HB1000 Menu consists of three
buttons: Calibrations, Device
Settings, and Install Driver.
At any point, clicking the red X in the
top right corner will bring the
operator back to this menu screen.
HB1000 Thermal Barrier Rev-
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Install Driver
First, connect the unit to the computer via a USB cord. Select Install Driver. This will bring up
the following screen:
Click the Start Driver Installation button. This will allow the software to recognize the device.
There will be messages stating the driver
installation has started and has been
successful. Click the red X to return to
the Menu.
HB1000 Thermal Barrier Rev-
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Device Settings
Pressing the Scan for Devices button
will display a list of the devices on the
network in the top left corner. If the
device has been given a serial
number, this is how it will be
displayed, along with the port it is
communicating to. Select the
appropriate device. The settings
displayed will include the Device Time,
the On Temp, the Off Temp, and the
Serial Number. On the right hand side
of the Device Settings window, there
are four buttons which allow the
operator to change the settings.
Channel one will always control the on
and off temperature. The device must
be selected before changes can be
made.
The Set Time button will change the time on the device to match the time on the computer it is
connected to.
The Set On Trigger button will change the On Temp for the HB1000. When thermocouple one,
which controls data logging, reaches this temperature, the controller will begin data logging.
The Set Off Trigger button will change the Off Temp for the controller. When thermocouple one
reaches the off temp, a timer will count down from 10 minutes. After this timer is finished, once
the temperature falls below the off temp, the data logger will stop recording data. For
continuous data recording, it is recommended that the on temp be set to 0° and the off temp be
sent to the maximum of 3276°.
The Set Serial Number button allows the operator to name the device. This can be a name
using letters, numbers, or a combination of the two.
The Erase All Jobs button will erase all of the data from the device. This will erase all jobs from
the device; it is not possible to choose only certain jobs to erase and to keep others. Erasing the
jobs will take 60 seconds, and a timer will count down during this operation.
HB1000 Thermal Barrier Rev-
12
Calibrations
There are four types of calibrations for the HB1000. All of the thermocouple channels must be
calibrated at the same time.
Zero Calibration
To calibrate the voltage properly, both a zero and a span calibration must be performed. For
zero and span calibrations, only
regular copper wire should be
used – not T/C wire. Connect
each positive input to its
corresponding negative input or
connecting a calibrator and
outputting 0.0 volts DC (VDC).
Once the connections are made,
press the Start Calibration
button. Theoretically, this
should yield 0.0 VDC, however
many times it is close but not
quite 0. Now a span calibration
should be performed.
HB1000 Thermal Barrier Rev-
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Span Calibration
Following a zero calibration, perform a span calibration. For zero and span calibrations, only
regular copper wire should be
used – not T/C wire. To
perform a span calibration,
hook up a calibrator to each
input. From the calibrator,
output 72 millivolts. Set the
Calibration Value to 72 mV on
the computer software. The
voltage range should be set to
80 mV for a type K
thermocouple. Press the Start
Calibration button. More often
than not, the scaled voltage
will read something slightly
off from 72 mV, for instance
72.09 instead of 72. The
voltage is then calibrated
according to the results of the
zero and span calibrations.
T/C Trim Calibration
For the T/C Trim calibration, T/C wire should be used. The T/C trim calibration is performed by
connecting a thermocouple
calibration device to each
input and outputting a trim
temperature that is used be
equal to the expected
operating temperature. For
example, the calibration could
be completed using an output
temperature of 1700°F. After
the zero, and span
calibrations, the temperature
may read about 1701.5°F
instead. This type of
calibration should be used in
lieu of the regular cold
junction calibration unless the
cold junction temperatures
are reading a temperature
that is much too high for what
the ambient temperature could possibly be. A cold junction calibration can be used in this
instance when need be, but the T/C Trim Calibration is preferred.
HB1000 Thermal Barrier Rev-
14
Cold Junction Calibration
The purpose of the Cold Junction Calibration is to calibrate the ambient temperature at each of
the 10 connectors. The ambient
temperature can be determined
by holding a probe near the
connectors and reading that
value. The operator should then
enter the ambient temperature
into the box labeled Calibration
Value. Press the Start
Calibration button to run a Cold
Junction calibration. Each input
will then be reading the ambient
temperature. A message will be
displayed stating that the
calibration is successful.
HB1000 Thermal Barrier Rev-
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