Proven tandem: OPUS 20E and MCPS 8

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The demand for open systems in indoor air quality monitoring is steadily increasing. More and more users want to benefit from intelligent sensors without having to completely replace their existing analog systems immediately. For such cases, a hybrid solution is suitable, which can process and treat both analog and digital signals equally.

The basis of such a solution is often a versatile data logger that can handle both digital and analog measuring instruments. A proven example of this is the OPUS 20E, which the experienced sensor manufacturer Lufft GmbH offers as a compact all-purpose tool for various applications from pharmaceuticals to food production to electronics in its portfolio. The "E" stands for external, as the OPUS 20E comes with a total of six connections for external sensors. Four digital inputs are available for temperature and humidity sensors, along with two inputs for analog sensors such as differential pressure meters or particle counters. A clearly readable display completes the OPUS 20E as a complete solution for indoor air quality monitoring.

The FDA Guideline 21 CFR 11

Differential pressure, airflow, and air purity play a crucial role, especially in cleanrooms. Sensitive applications in production rooms, research laboratories, workshops, or museums, where even small deviations in indoor climate can jeopardize entire batches, would be unthinkable without reliable monitoring of various microclimatic parameters. Additional requirements are set by a guideline from the FDA, the U.S. Food and Drug Administration. Known as 21 CFR Part 11, it regulates replacing traditionally paper-based records with electronic documentation. 21 CFR 11 requires, among other things, managing individual batches to trace the production conditions of a specific lot. Access rights for the data are also clearly defined.

Good software reduces a lot of work

To meet these requirements without having to undertake enormous effort, the use of suitable software for recording and analyzing measurement data is recommended. Proven in combination with the data logger OPUS 20E is the monitoring software MCPS (Multi Channel Process System), which is now available in its eighth version and is widely used in the pharmaceutical industry. MCPS 8 processes both digital and analog signals, manages up to 1000 individually configurable measurement channels, and allows measurements to be conducted separately for different areas such as production, storage, laboratory, etc. The software includes comprehensive alarm monitoring and enables compliant monitoring of indoor air quality according to 21 CFR 11 guidelines. It encrypts each access electronically and, in case of an alarm, also records the measures taken by the user. Additionally, MCPS 8 helps to visualize data in a user-friendly and versatile manner, facilitating analysis and processing of measurement results. This includes, for example, evaluation clients or the integrated web server for online data.

Various fields of application

Thanks to the ability to connect any analog sensors and seamlessly integrate data with digital measurements, the combination of the data logger OPUS 20E and the MCPS 8 software is suitable for virtually any indoor climate application and can be customized to individual needs. It allows both continuous monitoring and individual batch recording, alarm setting, access logging, and user-friendly data visualization. Two example application areas are highlighted here.

Pharmaceuticals – Research and Production

The development and manufacturing of medicines and cosmetics are subject to strict guidelines. From research laboratories to production, encapsulation, and warehouse shipping, specific atmospheric parameters are defined. Besides typical measurements such as temperature and humidity, in cleanrooms, contamination of the air and differential pressure between different rooms play a significant role. MCPS 8 can also calculate the Mean Kinetic Temperature if desired.

Food Production – Processing, Manufacturing, and Cooling

For understandable reasons, strict guidelines and clearly defined production conditions apply to processing and manufacturing. Even minimal deviations from the ideal temperature or humidity can destroy or spoil a batch. The combination of Lufft OPUS 20E is used in production halls, cooling rooms, and ultra-cold chambers with temperatures down to minus 50 degrees Celsius.

Multichannel Data Logger for Analog Signals

There are cases where many sensors are concentrated in one location. For such applications, for example, a cooling room with many individually monitored cooling units, the modular data logger PFC200 is suitable as a data collector. It has a central unit with an Ethernet interface and SD card. Any measurement modules can be connected, such as for signals in the range of 4-20mA and 0-10V, resistance thermometers (RTD), thermocouples, digital inputs, pulse signals, etc. Alarms or indicator lights can be switched via digital outputs. The central unit automatically records all data and encrypts it on the SD card. In case of network failure, the data is not lost and can be automatically reloaded later by MCPS.

Conclusion: Analog and digital systems can be combined

There is no longer any reason to forego the advantages of digital measurement technology in indoor air quality monitoring. The calibration curve integrated into digital sensors greatly simplifies calibration and sensor replacement. Additionally, digital signals can be transmitted losslessly over longer cable lengths, making digital sensors more flexible. However, analog measuring devices are not rendered obsolete by the use of smart sensors. They can be easily integrated into a suitable system consisting of a flexible data collector like the OPUS 20E and intelligent software. In some cases, a modular data logger like the PFC200 may be the preferred choice, especially when many sensors are used in a confined space.