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Ametek Land NIR-B Installation Manual

Electrical auto retract
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NIR-B
Electrical Auto Retract
INSTALLATION GUIDE
PUBLICATION N
813705
O
LANGUAGE: ENGLISH
ISSUE: 1
DATE: 20 NOVEMBER 2019
Electrical Auto Retract System for NIR-B Borescopes
i
Q U A L I T Y C U S T O M E R S O L U T I O N S

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  • Page 1 813705 LANGUAGE: ENGLISH ISSUE: 1 DATE: 20 NOVEMBER 2019 Electrical Auto Retract System for NIR-B Borescopes Q U A L I T Y C U S T O M E R S O L U T I O N S...
  • Page 2 Observe precautions for handling electrostatic discharge sensitive devices. Equipment Operation Use of this instrument in a manner not specified by AMETEK Land may be hazardous. Read and understand the user documentation supplied before installing and operating the equipment. The safety of any system incorporating this equipment is the responsibility of the assembler.
  • Page 3 This manual is provided as an aid to owners of AMETEK Land’s products and contains information proprietary to AMETEK Land. This manual may not, in whole or part, be copied, or reproduced without the expressed written consent of AMETEK Land.

  • Page 4: Table Of Contents

    Thermal Imaging System NIR-B Borescope Electrical Auto Retract Contents Auto Retract System Overview System Component Specifications Installation Overview Manufacture of a Base Frame Mechanical Installation Sequence System adjustment and alignment to process Installing the ECU Installing the IMAGEPRO Software Operating the System Maintenance 10-0 Appendix - Installation Drawings Installation Guide...

  • Page 5: Auto Retract System Overview

    NIR-B Borescope Thermal Imaging System Electrical Auto Retract AUTO RETRACT SYSTEM OVERVIEW These installation instructions cover specific details of the NIR-borescope Auto Retract (AR) system – they are meant to be read in conjunction with the instructions for the NIR borescope itself, and the user guide to the Image Pro NIR-b software. 1.1 System Description The NIR-borescope Auto Retract (AR) system comprises a slide beam and camera support onto which is mounted the NIR-borescope (NIR-b) in its cooling jacket. When the NIR-b lens system is inserted into the hot process area, it requires air and water cooling to keep its components within operational limits. If the cooling fails and the lens system rises above its limit, damage to the lenses will occur. The AR system will remove the NIR-B from the process if: • the power is lost (it has battery back up to do this) • any of the cooling services (air/water) to the lens system are lost. For PLC firmware version 2.1 and above, the Auto Retract will operate when the water has been off for over three minutes • the NIR-B lens system temperature reaches its alarm level A Furnace Seal Assembly ensures that when the NIR-b is retracted from the process, the process view port is sealed off with a Furnace Seal Assembly and purge air. Water cooling first feeds through the rear of the water-cooled jacket to cool the borescope electronics and then passes along the length of the jacket to cool the lens section of the camera within the process. The installer must ensure there can be no access to moving parts and that the system meets local safety regulations. A combination of faults (i.e. the water flow stops, and the AR system fails to retract), could lead to a build-up of pressure within the water system and therefore the water system is fitted with pressure relief valves (6bar).

  • Page 6: System Component Specifications

    Thermal Imaging System NIR-B Borescope Electrical Auto Retract SYSTEM COMPONENT SPECIFICATIONS 2.1 NIR-B Borescope Thermal Imager Details of the camera can be found in the NIR-B Borescope Installation Guide. 2.2 Imaging Workstation Computer Details of the computer can be found in the NIR-B Borescope Installation Guide. 2.3 ECU Power Vac 90-132/180-264 VAC, auto select Iac 2.20/0.83 A 115/230 VAC typical Freq 50-60 Hz Temperature : 0 °C to 50 °C...
  • Page 7 NIR-B Borescope Thermal Imaging System Electrical Auto Retract 2.4 Auto-Retract System Power Supplied from ECU Temperature : 0 °C to 60 °C Size 2000 x 740 x 570 mm (1270 mm @ 30° angle) Weight NIR-B with auto-retract: 65 kg max • Probe: 5 kg • Water-cooled Jacket: 15 kg • Auto Retract: 45 kg (modular sections, Max 22 kg) • Main Body: 24 kg • Port Seal: 7 kg • Large Heat Shield: 5.7 kg • Sundries Total: 8.3 kg...

  • Page 8: Installation Overview

    Attaching the port seal assembly to the main assembly. Fabricating and installing rear support frame to fix the rear AR bracket. Clamping the NIR-b and water-jacket to AR System and attaching port seal sundries. Connecting the water and purge air (both supplies, see installation drawing sheets 5 &...

  • Page 9: Manufacture Of Abase Frame

    NIR-B Borescope Thermal Imaging System Electrical Auto Retract MANUFACTURE OF A BASE FRAME WARNING Make sure that the base frame is fully supported during installation. Metallic surfaces may become hot (over 73 °C / 163 °F) during installation. Ensure that the correct Personal Protection Equipment (PPE) is worn). The AR must be supported so that: • The borescope aligns with the furnace hole and does not protrude from the furnace insulation (see installation drawing sheet 8) • The AR can be fixed to the front and rear supports using the front and rear axis support brackets provided. • The front support is seated close enough to the furnace wall to allow the port seal to mate to walls surface (see installation drawing sheet 2) •...
  • Page 10 Thermal Imaging System NIR-B Borescope Electrical Auto Retract The angle at which the NIR-b camera sits is dictated by the pivot point and the height of the rear customer support. Simple trigonometry can be used to approximate the distance required between the front and back supports in the horizontal and vertical axis where; • C=1600mm (constant) • A= the required angle to suit port hole • b = the resulting horizontal distance required between supports • a= the resulting height difference between supports (See Fig. 4-1) Fig. 4-1 4 - 2 Installation Guide...

  • Page 11: Mechanical Installation Sequence

    NIR-B Borescope Thermal Imaging System Electrical Auto Retract MECHANICAL INSTALLATION SEQUENCE Attach the supplied front bracket to the prefabricated support frame using M20 bolts. It is recommended that the support frame be made height adjustable (Minimum 200 mm / 8 in) for ease of installation. See installation drawing Sheet 2 for mounting details. Fig. 5-1 Attach the main body section to the bracket by resting the axis bar within the U sections of the bracket ensuring the body section sits between the bracket uprights. Fig. 5-2 Once seated, unscrew the M16 bolts and nut out as far as possible without completely removing them. Fig. 5-3 Installation Guide...
  • Page 12 Thermal Imaging System NIR-B Borescope Electrical Auto Retract Next, take the port seal section and slide the sides of the bracket over the through bolt and the M16 clamping nuts. The port seal box can be separated from its bracket by unscrewing the M12 bolts on each side if required. Fig. 5-4 Once in place, slide the bracket up and tighten the M16 nut and M16 bolts (Note: do not 30 Nm fully tighten at this point, connections should be tightened so the assembly can still pivot on the bracket). The purge air hose can be fitted at this point. 40 Nm Fig. 5-5...
  • Page 13 NIR-B Borescope Thermal Imaging System Electrical Auto Retract Assemble the camera jacket by undoing the red handle and opening the clamp, seating the body of the jacket and tightening the clamp. Attach the port seal by sliding it over the end of the tube and securing in position using the 4 x M6 bolts. This can be adjusted later as required. Fig. 5-8 Assemble the water and air sensor assemblies via the three connection points. Attach all three sections in the order shown using the ½ in BSPP swivel adaptors, two suitable spanners and PTFE tape. Make sure that the male ends of the sensor assemblies are pointing downward (these will be adjusted later if required). Fig. 5-9 10) Attach the water and air supply hoses from the sensors to the system. 3 Nm Mark a point on each hose section, approx. 820 mm / 32 in from one end. Secure this point...
  • Page 14 Thermal Imaging System NIR-B Borescope Electrical Auto Retract 11) The base shield is attached by two slots each featuring a large hole. The large hole simply fits over the M10 nut & bolt attached to the underside of the main assembly and then the shield is slid so the bolt sits within slot. Tighten the M10 bolt to secure the shield at both ends. Fig. 5-11 30 Nm 12) The front shield is connected by releasing the two front thumb screws, sliding the slots of the shield over the threads of the screws, and then tightening the thumb screws. Fig. 5-12 13) Remove the motor box lid and take the red and black wires from the air sensor as shown. Fig. 5-13 5 - 4 Installation Guide...
  • Page 15 NIR-B Borescope Thermal Imaging System Electrical Auto Retract 14) Feed the wires through the top gland, which feature a dual grommet, as shown. Connect the wires (Red to Red & Black to Black) via the terminal block, and replace the motor box lid. Fig. 5-14 15) Connect the black lead from the motor box to the water sensor as shown. Fig. 5-15 The customer air and water connections can be connected as per the installation drawings pages 5 & 6 and the system can be aligned/adjusted. Once the camera is in position, all bolts should be secured with hand tools. The bolts in step 5 should be secured only when the angle is correct. Installation Guide 5 - 5...

  • Page 16: System Adjustment And Alignment To Process

    Thermal Imaging System NIR-B Borescope Electrical Auto Retract SYSTEM ADJUSTMENT AND ALIGNMENT TO PROCESS The system camera can be aligned to the port left to 6 Nm right by either moving the position of the front and rear bracket along the bolt slots or via the adjustable clamp base (Sheet 9 of the Installation Drawings). The camera can be adjusted forward and backward by using the 2 x M10 bolts or adjusting its position in the quick release clamp as shown on Sheet 9 of the Installation Drawings. If required, the front position switch (Fig. 6-1) can be moved easily by loosening the 2 x M5 Cap head bolts and sliding into the required position along the linear slide assembly. The rear switch can be adjusted in the same manner if required. Adjust/replace cable ties as necessary. Once adjusted, tighten the bolts to 6 Nm.

  • Page 17: Installing The Ecu

    7.1 Connecting Customer Mains to the ECU (Cable 1) CAUTION The ECU must be mounted in a location away from heat source, but must be in a position where the operator of the ECU can see the NIR-B Auto-Retract. Requirements •...
  • Page 18 Thermal Imaging System NIR-B Borescope Electrical Auto Retract Connect the mains cable wires to the terminal block as per the wiring schedule below (Fig. 7-3): Earth N (Neutral) L (Live) Fig. 7-3 7.2 Connecting the Motor Box to the ECU (Cable 2) Land-supplied 20 m cable - 809077 Pass the free end of the cable from the Motor Box through the MOTOR BOX cable port entry and secure it with the Cable Gland (Fig. 7-4). Connect the Motor Box cables to the X1 and X2 terminals on the DIN rail inside the ECU. Refer to the wiring schedule on the inside lid of the Terminal Box (Fig. 7-5).
  • Page 19 7.5 Connecting the Customer NIR-B Camera Lens status cable to the ECU (Cable 5) A cable gland on the ECU can be used to pass through a cable which connects the NIR Camera Lens status parameters to the control room • NIR Camera Lens temperature (4-20 mA) • NIR Camera Lens temperature Warning (NO) 7.6 Connecting Land NIR-B Camera cables to the ECU (Cable 6 & 7 ) Land-supplied 25 m cable - 810794 Land-supplied 25 m cable - 810795 Attach the Ethernet cable from the Thermal Imager to the ETHERNET IN cable connector on the Terminal Box (Fig. 7-9). Connect one end of the 8-way cable to the CAMERA connector on the Terminal Box.
  • Page 20 Thermal Imaging System NIR-B Borescope Electrical Auto Retract 7 - 4 Installation Guide...
  • Page 21 NIR-B Borescope Thermal Imaging System Electrical Auto Retract Grounding Scheme ECU door V+ V- CUSTOMER EARTH L N E CONNECTION ECU Gland Plate Fig. 7-11 ECU Grounding Scheme Installation Guide 7 - 5...

  • Page 22: Installing The Imagepro Software

    Thermal Imaging System NIR-B Borescope Electrical Auto Retract INSTALLING THE IMAGEPRO SOFTWARE Details of the IMAGEPro software can be found in its own User Guide, Publication Nº 813385 8 - 0 Installation Guide...

  • Page 23: Operating The System

    NIR-B Borescope Thermal Imaging System Electrical Auto Retract OPERATING THE SYSTEM WARNING Ensure that the cooling water supply and purge air supply are connected and operating at all times, especially before inserting the Borescope Thermal Imaging camera into a furnace. The Auto-Retract system cannot be commanded Forward until the water and air supplies are flowing. WARNING In the event of cooling water failure, the water in the cooling jacket may boil, causing a steam explosion hazard. Pressure relief valves are fitted. Ensure that they are vented to a safe area. WARNING The Borescope and Auto-Retract System is heavy. A suitable load- bearing frame is required to support the unit. WARNING The Auto-Retract can move unexpectedly. Ensure that the area in which the Auto-Retract system is installed is guarded to local safety regulations.
  • Page 24 Thermal Imaging System NIR-B Borescope Electrical Auto Retract 9.1 Commissioning sequence The unit is shipped with the Battery Box fuse disconnected. Remove the lid from the Battery Box. Insert the fuse into its holder in the Battery Box (Fig. 9-1).
  • Page 25 NIR-B Borescope Thermal Imaging System Electrical Auto Retract 9.2 Insert & Retract (ECU) WARNING After retracting the NIR-B from a furnace, the lens tube may be hot. Do not touch the tube until it has cooled down. Fig. 9-4 Before using the AR system, check that the system is installed correctly and all services such as cooling water and purge air are operating as required. Before advancing the camera using the ECU, the camera should be advanced or retracted using the Retract and Manual momentary switches located on the Motor Box (Fig. 9-5). The manual controls allow the camera to be slowly inserted into the process, allowing for fine adjustment. Once completed the system requires testing using the ECU controls. Manual/Auto To operate the AR system via the ECU, make Key Switch sure that the EMERGENCY STOP is released.
  • Page 26 Thermal Imaging System NIR-B Borescope Electrical Auto Retract 9.3 Retraction (Automatic) Note that the Auto-Retract system is Manual insertion and Auto/Manual Retraction In the event of a fault, the FAULT light will illuminate on the front panel (Fig. 9-4), and the borescope will be retracted from the process, if possible.
  • Page 27 NIR-B Borescope Thermal Imaging System Electrical Auto Retract 9.3.1 Changing the time delay for the water sensor Ensure the ECU is powered up and the PLC is running. Using the arrow keys on the SIEMENS LOGO PLC, press the DOWN arrow until the following screen is displayed (Fig. 9-7). Fig. 9-7 Siemens LOGO PLC Press the ESC key. and navigate down to the option Set Param and press OK. Using the UP / DOWN arrows, select Program and press OK. Fig. 9-8 Program option Using the UP / DOWN arrows, select Set Parameter and press OK.
  • Page 28 Thermal Imaging System NIR-B Borescope Electrical Auto Retract Using the UP / DOWN arrows, select WaterSen and press OK. Fig. 9-10 WaterSen option Using the UP / DOWN arrows, adjust the T parameter to the desired time. Fig. 9-11 shows the nominal 30 seconds. NEVER set to more than 3 minutes. Press OK. Fig. 9-11 WaterSen Parameter Press the ESC key to navigate back to the screen of Fig 9.7. Then press the UP key to return to normal operation. 9.4 LED Status (ECU) Colour Function BLUE MAINS ECU has power from the mains ECU power interrupted. Note:...
  • Page 29 NIR-B Borescope Thermal Imaging System Electrical Auto Retract 9.5 Motor Box Controls 9.5.1 Emergency Stop The Emergency Stop button can be used when you need to stop the AR system from moving immediately. To stop in an emergency, press the Emergency Stop button on the motor drive (Fig. 9-10). NOTE The AR system will now be locked in position. The FAULT light will illuminate on the Control Emergency Stop button Panel, and The Emergency Stop error message Fig. 9-10 will be displayed on the Siemens PLC inside the Control Panel. To reset the system after an Emergency Stop, turn the Emergency Stop button clockwise approximately a quarter turn and lift the button to its off position. On the Control Panel, turn the switch momentarily to the RESET position.
  • Page 30 Fig. 9-12 create steam when in contact with hot surfaces! 9.7 NIR-B Camera status info in the IMAGEPro software When the Borescope is installed and operating, the following points should be noted: • The thermal image obtained by the Borescope will be displayed in the IMAGEPro software (Fig.
  • Page 31 NIR-B Borescope Thermal Imaging System Electrical Auto Retract 9.8 ECU I/O signals The following I/O signals are available from the terminal rail within the ECU Lens temperature 4-20 mA, 0-200 ºC Lens ‘over-temperature warning’ relay @150 ºC lens temperature (retract operates @180 ºC) ‘System OK’ relay no fault in system ‘In position’ relay AR slide is in its forward working position 9.9 Battery Information The battery has been installed by AMETEK Land Instruments. The installation date is on a label within the battery enclosure. When the unit is under normal mains power, the battery is automatically tested every 20 minutes. If the battery is no longer suitable for use, a fault condition is indicated and the battery must be replaced. The ECU contains a battery charger which has been set optimally for 30 °C. At lower temperatures than this the battery will take longer to charge. The battery is located in a separate vented enclosure attached to the ECU – DO NOT block the vents of the enclosure. Installation Guide...

  • Page 32: Maintenance

    Thermal Imaging System NIR-B Borescope Electrical Auto Retract MAINTENANCE 10.1 Operational Checks WARNING Make sure that the base frame is fully supported during installation. WARNING If, for any reason, the water jacket is to be removed from the AR System, this task must be undertaken by a minimum of two competent personnel. It is recommended that the AR system is tested once a month The full test involves retracting the borescope, and then applying each of the failure modes in turn - checking that the correct error message is displayed on the PLC & the operation of the indicator lights. WARNING The test involves opening the door of the retract ECU whilst the unit is powered. As such, it should only be performed by suitably trained and...
  • Page 33 NIR-B Borescope Thermal Imaging System Electrical Auto Retract For PLC firmware version 2.2, the retract will operate when water has been off for 30 seconds, or whatever time has been programmed using the procedure described in Section 9.3. Observe that a fault is indicated (Red light on the front panel). Observe that the PLC display shows “Water Flow Failure” Restore the water flow as soon as the fault has been observed. Clear the fault by operating the retract control. Turn off the mains supply at the mains circuit breaker. The equipment will continue to operate from battery for the next 60 seconds. Observe that a fault is indicated (Red light on the front panel). Observe that the PLC display shows ”Power Failure”. Restore the power. Clear the fault condition by operating the retract control. Turn off the purge air briefly. Observe that a fault is indicated (Red light on the front panel). Observe that the PLC display shows “Purge Air Failure” Restore the air flow as soon as the fault has been observed. Clear the fault by operating the retract control 10) Operate the Forward control. Observe that the shutter opens without blockage. Observe that the slide moves slowly into its operating position. Observe that the green light on the front panel lights. 10.2 Cleaning 10.2.1 External surfaces External surfaces can be cleaned with a clean, damp cloth. 10.2.2 Lens The purge system should keep the lens clean from process contamination.
  • Page 34 Thermal Imaging System NIR-B Borescope Electrical Auto Retract 10.3.2 Battery Replacement It is recommended that only insulated tools are used. Remove metallic objects from hands / wrists / neck. Isolate the mains from the ECU, then wait until the UPS is OFF. Remove the battery fuse. Disconnect the battery module at the battery terminal strip Loosen the four screws, and remove the battery. Write the commissioning date on the new battery. Ensure that the new battery wires are reconnected correctly. Insert the battery and tighten the four screws Reconnect the battery to the terminal strip. Insert the battery fuse and switch on the mains. Dispose of the old battery (sealed lead acid battery) according to local regulations or return to AMETEK Land for disposal. 10 - 2 Installation Guide...
  • Page 35 NIR-B Borescope Thermal Imaging System Electrical Auto Retract APPENDIX INSTALLATION DRAWINGS Installation Guide Appendix - 1...
  • Page 46 For a full list of international offices, please visit our website www.ametek-land.com Copyright © 2019 LAND Instruments International. Continuous product development may make it necessary to change these details without notice. NIR-B Borescope Electrical Auto Retract Installation Guide, Issue 1, 20 November 2019...

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