How LoggerFlex Combo Data Recorder and Real-time Alarm Systems Work

Bun and Block are dataloggers and alarm systems designed to measure, record, and transmit data for various environmental parameters. They are Internet of Things (IoT) devices that connect to existing WiFi or cellular networks without requiring additional gateways. Most members of both product families are capable of operating on battery for a long time. For instance, a LoggerFlex WiFi temperature datalogger can operate on battery for up to 6 years while recording temperature every 10 minutes and can send real-time email, text message, and automated phone call alarms to an unlimited number of recipients and upload all the records for remote access to the LF cloud online application. To survive for this long on the battery, the device benefits from a unique patented algorithm to optimize battery life, maximize the sampling rate, and make sending real-time alarms possible. The key to long battery life is syncing the records with the cloud in a smart way when it is necessary.

 

Key Adjustable Intervals in LoggerFlex Dataloggers

There are two key adjustable intervals in every LoggerFlex datalogger:

  1. Recording Interval: Also known as the sampling interval, this is the interval between two measurements. The datalogger hibernates between measurements to prolong its battery life. It wakes up based on the recording interval, measures the parameters it is supposed to monitor, compares the measurements with alarm criteria, and if a measured value is out of bounds, it goes into alarm mode. Otherwise, it records the measurement in its internal memory with a timestamp and returns to hibernation until the next designated recording time. The recording interval, like other parameters in the device, is adjustable by the user through the LF cloud web-based interface remotely. The recording interval can be as short as 1 minute (3 seconds by special order) and is set to 10 minutes by default. A BLOCK data recorder can continue recording for over 7 months (220 days) every 10 minutes without accessing the cloud, based on its internal memory size. If the device runs out of space in its internal memory, it will stop recording.

  2. Syncing Interval: Also known as the uploading interval, this is the interval at which all the records in the internal memory are synced with the cloud. After the device verifies that the records are correctly copied to the cloud, it erases them from its internal memory to continue recording indefinitely. Syncing intervals are typically longer than recording intervals and can be set to every hour (or down to every minute by special order) and up to once a week, or manual mode for devices intended to work offline as dataloggers. The default syncing interval is every 24 hours. This means if all measurements are within the user’s defined minimum and maximum bounds, the records, although taken at shorter recording intervals, will only be uploaded to the cloud and available for viewing or analysis based on the syncing interval.

Refrigerator Example

For instance, if a datalogger installed to monitor the temperature in a refrigerator is set to record temperature every 10 minutes and sync with the cloud every 24 hours, with a maximum temperature alarm set at 40°F (4.4°C), then if the temperature remains below 40°F (4.4°C) for the entire day (24 hours), new readings will only appear on the cloud every 24 hours. After syncing, all the records of the day (every 10 minutes) will be available for viewing, rendering in graph format, or extracting as raw data or automatic food safety reports according to FDA regulations.

 

Alarm Criteria & Handling Interrupt Alarms

Depending on the device model, minimum and maximum levels can be set for the alarm boundaries of some or all of the measured parameters. If a measured parameter is out of bounds, the device automatically enters alarm mode and remains in alarm mode as long as the measurements stay out of bounds.

There are other types of alarms that LoggerFlex dataloggers and alarm systems can detect and report, which are not measurement-based but interrupt-based, such as flood or dry contact alarm outputs from a third-party device, a duress button, a door magnet, or any other source of alarm. For example, if a flood occurs, the device will wake up immediately and sync with the cloud without delay, allowing the server to promptly send notification emails, texts, and calls to the recipients.

 

Alarm Mode

When entering alarm mode, the device reports the latest measurement to the cloud along with all unsynced records in its internal memory immediately, enabling the server to notify the user. Upon entering alarm mode, the recording interval shortens to 1 minute and the syncing interval to every hour, providing a more accurate picture of the events during the alarm and giving faster updates to the user. The user will be reminded of the emergency every hour as long as the alarm condition persists. When the parameters return within range, the device will sync again to report the latest conditions and revert to its original syncing and recording configuration.

Refrigerator Example

If the temperature exceeds 40°F (4.4°C), it will be detected in a maximum of 10 minutes (depending on the recording, not syncing, interval). Regardless of the syncing interval settings, alarms will be pushed to the recipients, and new data will be synced (60 records with each upload) every hour. In other words, the shorter syncing interval does not affect the latency of receiving the alarms but impacts the device's battery life.

 

Delayed Alarms

Sometimes, exceeding the limits for a short while is not critical. In such cases, a delay for pushing the alarms can be configured for each data recorder, and alarms will only be sent if the measurements remain out of bounds for more than a certain period. The delay can be set from immediately to over 96 hours.

Refrigerator Example

If the alarm is set to 40°F (4.4°C) with a 30-minute delay, and the temperature exceeds 40°F (4.4°C) briefly, the device will not send any notifications. It will only send alarms if the temperature remains over 40°F (4.4°C) for more than 30 minutes. This way, the device can filter out many false alarms caused by fluctuations such as door openings and closings or automatic defrost cycles.

 

Advanced Alarms: Drift Detection and Long Exposure

LoggerFlex dataloggers are equipped with unique functions that make them ideal tools for predictive maintenance. In addition to standard min/max alarms and delayed (persistence detection) alarms, all dataloggers can monitor slow drift in measurements and send email notifications upon detecting a drift.

For each parameter, users can define alarm criteria based on a percentage increase or decrease over a configurable time period. For example, if a 15% increase in the Time Weighted Average of measurements for a parameter is detected over the last 24 hours, the device can notify the user via email. This feature enables LoggerFlex dataloggers to effectively monitor long-term equipment conditions and predict failures before they occur. Early signs of issues in compressors, electric motors, pumps, or evaporators can be identified long before failure, allowing users to take proactive measures. By monitoring the direction of the drift, devices can notify users promptly, eliminating the need for constant expert monitoring.

Another advanced function, implemented in BLOCK CO2 dataloggers, is the Long Exposure Rules and Alarms. This feature continuously monitors environmental parameters, such as CO2 levels, and tracks the duration of exposure to deviations. Users can set specific threshold values for parameters and define the maximum allowable exposure time. When a monitored parameter exceeds the set threshold for longer than the allowed duration, an alarm is triggered. All exposure events are logged for detailed analysis and reporting, and users can adjust thresholds and exposure durations through an intuitive web application.

Power Management and Battery Life

Utilizing existing connectivity infrastructure like WiFi and cellular networks instead of using a gateway that is always plugged into power, while operating on battery for a long time, is only possible with smart and efficient power management. Battery life can be impacted by user configurations and environmental conditions. These are the three most important parameters:

 

  • Syncing Interval: The syncing interval significantly impacts battery life, although it does not affect the maximum latency for receiving alarms. For example, for a typical temperature and humidity sensor, the impact of the syncing interval can exceed 1000 times that of the recording interval.

  • WiFi/Cellular Coverage and Signal Quality: Signal strength directly affects data transmission time and battery consumption. A stronger signal reduces transmission retries, preserving battery life. Operating in alarm mode without adequate WiFi signal can drain the battery up to 20 times faster compared to having a stable connection. Optimizing signal strength can be achieved by orienting the datalogger towards the router, positioning it higher and free from obstacles, and placing it closer to the router for better coverage.

  • Ambient Temperature: Battery performance is notably poorer in colder temperatures, resulting in reduced battery life. Lower temperatures can significantly shorten battery lifespan, necessitating considerations for operational environments.

Syncing Current Measurements and Receiving New Configurations

Since the device syncs with the cloud only when necessary, any changes to configurations such as intervals or alarm criteria made on the web-based application require user action to update the device. The user can either:

  1. Manual Sync: Press the sync button on the device to immediately sync with the cloud and receive the latest settings.

  2. Scheduled Sync: Wait for the next designated syncing time or an alarm event for the device to sync with the cloud and apply the new settings.

If the latest settings have not yet been received by the device, it will appear in blue on the website, indicating that there are unsynced settings.

 

Lost Connection or Missing Upload Notification Emails

In the realm of IoT devices, no news is often good news! If all measurements fall within their designated bounds and the device successfully connects to the cloud at scheduled times, no notifications are sent to users. However, if the device fails to connect to the cloud at the designated time, the server will promptly send a "missing upload" email notification to the user.

A missing upload can occur for various reasons, ranging from unavailable WiFi networks to a depleted battery. While devices typically send low battery email alarms beforehand, a "missing upload" alarm specifically indicates that the device has failed to sync with the cloud at the scheduled time and warrants immediate attention.