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NBN Fluke CS400 Hardware Manual

Kiln shell temperature monitoring
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CS400 System
Kiln Shell Temperature Monitoring
Hardware Manual
PN 5259635, English, Rev. 1.0, Sep 2021
© 2021 Fluke Process Instruments. All rights reserved. Printed in Germany. Specifications subject to change without notice.
All product names are trademarks of their respective companies.
nbn Austria GmbH

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Summary of Contents for NBN Fluke CS400

  • Page 1 Kiln Shell Temperature Monitoring Hardware Manual PN 5259635, English, Rev. 1.0, Sep 2021 © 2021 Fluke Process Instruments. All rights reserved. Printed in Germany. Specifications subject to change without notice. All product names are trademarks of their respective companies. nbn Austria GmbH...

  • Page 2: Warranty

    Warranty The manufacturer warrants this instrument to be free from defects in material and workmanship under normal use and service for the period of four years from date of purchase. This warranty extends only to the original purchaser. This warranty shall not apply to fuses, batteries or any product which has been subject to misuse, neglect, accident, or abnormal conditions of operation.

  • Page 3: Table Of Contents

    Table of Contents Chapter Page ................................2 ARRANTY ..............................3 ABLE OF ONTENTS ............................... 6 IST OF ABLES ..............................7 IST OF IGURES ............................8 OMPLIANCE TATEMENT ............................... 9 AFETY NFORMATION ................................12 ONTACTS ............................... 13 ESCRIPTION ..............................14 ECHNICAL 2.1 Measurement Specification .....................................
  • Page 4 6.1.3 Driver Installation ....................................32 6.2 I/O Modules ........................................36 6.3 Tire Slip Monitoring – TSM (A-CS-TSM-KIT-485) ............................37 6.3.1 Delivery ........................................37 6.3.2 Functionality......................................37 6.3.3 TSM Remote Control ..................................... 37 6.3.4 Position Indicator ....................................38 6.3.5 Installation......................................39 6.3.6 Wiring ........................................
  • Page 5 9.2.1 Technical Data ....................................... 61 9.3 Fiber Optic / RJ45 Ethernet Converter................................62 9.3.1 Technical Data ....................................... 62 9.4 Connection Box for Accessories ..................................63 9.4.1 Technical Data ....................................... 63 9.4.2 Delivery ........................................64 9.5 Position Indicator (A-CS-SYSECPI)................................65 9.5.1 Technical Data ....................................... 65...

  • Page 6: List Of Tables

    List of Tables Table Page Table 3-1: Required Cables ......................................19 Table 6-1: LED Indicators ......................................32 Table 7-1: Troubleshooting ......................................46 Table 8-1: W1 – Power Supply 24 V, 3-pin ................................51 Table 8-2: W3 – Alarm, Trigger, 6-pin ..................................51 Table 8-3: W8 –...

  • Page 7: List Of Figures

    List of Figures Figure Page Figure 1-1: Linescanner....................................... 13 Figure 3-1: Distance D and Kiln Length L ................................... 17 Figure 3-2: Scanner Alignment ....................................18 Figure 3-3: Welding the Trigger Bar on the Kiln ................................18 Figure 4-1: 3-Axis Mounting Bracket for Protective Housing ............................21 Figure 4-2: Protective Housing with Protective Channel ............................

  • Page 8: Compliance Statement

    Compliance Statement The device complies with the requirements of the European Directives: EC – Directive 2014/30/EU – EMC EC – Directive 2014/35/EU – low voltage EC – Directive 2011/65/EU – RoHS Compliance amended by Directive (EU) 2015/863 (RoHS III) EN 61326-1: 2013 Electrical measurement, control, and laboratory devices - Electromagnetic susceptibility (EMC) EN 61558-1: 2006...

  • Page 9: Safety Information

    Safety Information This document contains important information, which should be kept at all times with the instrument during its operational life. Other users of this instrument should be given these instructions with the instrument. Eventual updates to this information must be added to the original document. The instrument can only be operated by trained personnel in accordance with these instructions and local safety regulations.
  • Page 10 Safety Symbol Description Read all safety information before in the handbook Hazardous voltage. Risk of electrical shock. Warning. Risk of danger. Important information. See manual. Laser warning Earth (ground) terminal Protective conductor terminal Switch or relay contact DC power supply Conforms to European Union directive.
  • Page 11 To prevent possible electrical shock, fire, or personal injury follow these guidelines: • Read all safety information before you use the product. • Use the product only as specified, or the protection supplied by the product can be compromised. • Do not use the product around explosive gases, vapor, or in damp or wet environments. •...

  • Page 12: Contacts

    Contacts Fluke Process Instruments ⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯ America Everett, WA USA Tel: +1 800 227 8074 (USA and Canada, only) +1 425 446 6300 solutions@flukeprocessinstruments.com EMEA Berlin, Germany Tel: +49 30 478 0080 info@flukeprocessinstruments.de China Beijing, China Tel: +86 10 6438 4691 info@flukeprocessinstruments.cn Technical Support USA &...

  • Page 13: Description

    Description Measurement Specification 1 Description The CS400 system is a comprehensive temperature measurement system for the monitoring, control, and analysis of rotating kiln shells used in cement and lime production, mineral processing, hazardous waste incineration and other processes. This system is a unique combination of hardware centered on the industry-leading MP linescanner and a powerful, industrial software package.

  • Page 14: Technical Data

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 2 Technical Data 2.1 Measurement Specification Temperature range 100 to 650°C (212 to 1202°F) Spectral response 3.5 to 4 µm Detector HgCdTe Accuracy ± 0.5% of reading or ± 3°C (± 6°F) whichever is greater, at 0 to 50°C (32 to 122°F) ambient temperature for the scanner Repeatability ±...

  • Page 15: Weights And Dimensions

    Technical Data Weights and Dimensions 2.5 Weights and Dimensions Linescanner Length 180 mm (7.09 in) Width 120 mm (4.72 in) Height 200 mm (7.87 in) Weight 7 kg (15.4 lbs) Protective housing Length 300 mm (11.81 in) Width 300 mm (11.81 in) Height 300 mm (11.81 in) Weight...

  • Page 16: Scope Of Delivery

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 2.6 Scope of Delivery The scope of delivery for a CS400 system includes the following: CS400 Kit Linescanner (RAYTMP150HRR1) 7.5 m (24.6 ft) Ethernet cable 7.5 m (24.6 ft) power cable 7.5 m (24.6 ft) alarm/trigger cable Spare window for linescanner (reorder: S-MP-WK-HR) Protective Housing (A-MP-ENC) stainless steel box...

  • Page 17: Pre-Installation

    Pre-Installation Environment 3 Pre-Installation The customer is responsible for preparation of the sensor stand, installation of the position indicator with the trigger bar and the complete field wiring as indicated in the appendix. 3.1 Environment Please take note of the following: •...

  • Page 18: Scanner Alignment

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 3.3 Scanner Alignment The optimal scanner alignment is shown in the figure below. Figure 3-2: Scanner Alignment Scanner Kiln Scanner stand (dedicated tower or roof of a building) 3.4 Trigger Bar A position indicator is mounted on the colder end of the kiln and generates a trigger pulse once per revolution to supply the CS400 system with data on the rotational speed of the kiln.

  • Page 19: Cable Requirements

    Pre-Installation Cable Requirements 3.5 Cable Requirements The following cables are necessary for standard installations, see also system drawings given in section System Installation – with Accessories, page 48. • W1 power supply cable for scanner (preinstalled with system connection box) •...
  • Page 20 CS400 System Hardware Manual, Rev. 1.0, Sep 2021 7.5 m (25 ft.) Manufacturer < 2 km (1.2 mi) Fiber optic cable (outdoor), Customer Standard cable designation: 2 fibres, multi-mode, 62.5/125 µm or 50/125 A-DQ(ZN)B2Y… µm, equipped with SC connectors 2 m (6.5 ft.) Ethernet patch cable (CAT5, RJ-45) Manufacturer 5 m (15 ft.)

  • Page 21: Installation

    Installation Mounting 4 Installation 4.1 Mounting The linescanner protective housing requires a solid vibration-free mounting stand. The protective housing comes with a mounting bracket, adjustable 90° in all 3 axes. To mount the protective housing onto the sensor stand, e.g. on a tower, make a mounting plate with two 8.5 mm (0.31 in.) diameter mounting holes, as shown below.

  • Page 22: Figure 4-2: Protective Housing With Protective Channel

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 Figure 4-2: Protective Housing with Protective Channel Protective housing Protective channel Linescanner Window holder 2x M6 nuts Installing the linescanner Open the back door. Insert the linescanner (with the mounted carrier) into the rail/carrier system. Lock in the linescanner in place with the latches and screw.

  • Page 23: System Connection Box

    Installation System Connection Box Figure 4-3: Cable Installation Grommet plate Using the 4 M5x25 screws, mount the grommet plate on the outside of the protective housing. Plug the cable connectors into the linescanner. Connect the socket and the plug for earth ground. Note If installing the system in a warm environment, water-cooling may be necessary.

  • Page 24: Figure 4-4: Opened System Connection Box

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 Figure 4-4: Opened System Connection Box Fiber Optic / Power Mains RJ45 Ethernet Supply Socket Converter Serial/Ethernet Fuse Converter (Accessory) Heater (Accessory) Installation The system connection box can be mounted up to 7 meters (23 ft) away from the scanner. However, to simplify aiming the scanner at the kiln it is the best that the connection box is mounted as close to the scanner as possible.

  • Page 25: Cable Entry System

    Installation System Connection Box 4.2.1 Cable Entry System The cable entry system is a split system that allows pre-assembled cables to be routed into the system connection box without disassembling the connectors. Snap-on mounting Lay cable into appropriate grommet and provide strain relief where necessary using cable ties.

  • Page 26: Fiber Optic / Rj45 Ethernet Converter

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 Lock the catch hooks with the rail. Press gently on grommet one more time. 4.3 Fiber Optic / RJ45 Ethernet Converter The Fiber Optic / RJ45 Ethernet Converter assures high reliability and stability in harsh environments, making it a robust bridge between enterprise fiber-optic backbones and Ethernet devices like the linescanner.

  • Page 27: Fiber Optic Converter Box

    Installation Fiber Optic Converter Box Note The trigger signal is only required if the accessory Tire Slip Monitoring is not used! Figure 4-7: Mounting the Position Indicator Kiln axis Rotation Kiln Trigger bar steel St37, sized 50 mm in square (2.16 in. in square) Distance: max.

  • Page 28: Figure 4-8: Fiber Optic Converter Box

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 Figure 4-8: Fiber Optic Converter Box...

  • Page 29: Options

    Options Start-up-Service 5 Options 5.1 Start-up-Service The start-up service includes the installation of the scanners into the protective housing boxes, checking all wiring, communications, and services from the scanners to the location of the computer. The scanner alignment will be checked and corrected as necessary.

  • Page 30: Accessories

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 6 Accessories Accessories include items that may be ordered at any time and added on-site. • Serial RS485 / RJ45 Ethernet Converter (A-CS-CONV-ETH485) • I/O Modules • Tire Slip Monitoring – TSM (A-CS-TSM-KIT-485) •...

  • Page 31: Serial Rs485 / Rj45 Ethernet Converter (A-Cs-Conv-Eth485)

    Accessories Serial RS485 / RJ45 Ethernet Converter (A-CS-CONV-ETH485) 6.1 Serial RS485 / RJ45 Ethernet Converter (A-CS-CONV-ETH485) The serial RS485 / RJ45 Ethernet Converter is a dedicated device server for connecting to four RS485 devices to a TCP/IP network. The serial RS485 / RJ45 Ethernet Converter must be installed in case of having either one or all accessories such as Burning Zone Monitoring, Shadow Monitoring, or Tire Slip Monitoring.

  • Page 32: Led Indicators

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 6.1.2 LED Indicators There are LEDs display the power status, network status, and serial communication status located on the front panel of the Serial RS485 / RJ45 Ethernet Converter, each of them has its own specific meaning as shown in the table below.
  • Page 33 Accessories Serial RS485 / RJ45 Ethernet Converter (A-CS-CONV-ETH485) Right click the serial device <XXXSYSCS210CON> and select the “Auto Mapping” function. The serial ports that can be assigned to virtual COM will be shown in the following window. Click the <Select All> button and press <Map Selected Ports> button. All selected serial ports will be mapped to virtual COM ports in sequential order.
  • Page 34 CS400 System Hardware Manual, Rev. 1.0, Sep 2021 The configuration for the four ports of the serial device <XXXSYSCS210CON> are preset in accordance with the available CS accessories, e.g. port 2 is configured as RS485 type for communicating with the shadow monitoring to be wired at connector X4 in the system connection box.
  • Page 35 Accessories Serial RS485 / RJ45 Ethernet Converter (A-CS-CONV-ETH485) Note It is not recommended to change the pre-set configuration for the four ports of the serial device <XXXSYSCS210CON>!

  • Page 36: I/O Modules

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 6.2 I/O Modules The CS400 system supports a flexible approach to implement Ethernet based I/O modules with the following individual components: • Basic Kit (A-IO-BASICKIT), contains: Fieldbus Coupler 750-352, Supply Module 750-602, End Module 750-600 •...

  • Page 37: Tire Slip Monitoring - Tsm (A-Cs-Tsm-Kit-485)

    Accessories Tire Slip Monitoring – TSM (A-CS-TSM-KIT-485) 6.3 Tire Slip Monitoring – TSM (A-CS-TSM-KIT-485) To avoid kiln deformation that can damage refractory kiln torsion must be kept within certain limits. Kiln shell torsion is greatly affected by the degree of clearance between the tires and the kiln shell. The simplest and most accurate procedure is to measure the kiln shell’s rotational speed as compared to the rotational speed of the tires.

  • Page 38: Position Indicator

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 Figure 6-1: TSM Remote Control Box TSM – For more technical data, see section 8.7 Wiring, page 54. 6.3.4 Position Indicator Temperature resistant inductive proximity switches are used to trigger the PLC counter rotation time. The trigger bar for the position indicator is welded directly onto the tire.

  • Page 39: Installation

    Accessories Tire Slip Monitoring – TSM (A-CS-TSM-KIT-485) 6.3.5 Installation Figure 6-4: Mounting the Position Indicator 20 mm (0.79 in) Position indicator Junction box Figure 6-5: Trigger Bar – details – Flat Iron (steel ST37) Angle Iron welded...

  • Page 40: Wiring

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 6.3.6 Wiring Figure 6-6: Wiring of TSM Position Indicator (Kiln) Position Indicator Position (TSM) Indicator Position Junction (TSM) Indicator (TSM) Junction Junction Junction TSM – For the detailed wiring of the TSM see section 8.7 Wiring, page 54.

  • Page 41: Shadow Monitoring (A-Cs-Sm-Kit-485)

    Accessories Shadow Monitoring (A-CS-SM-KIT-485) 6.4 Shadow Monitoring (A-CS-SM-KIT-485) The linescanners can be hindered from monitoring the complete kiln by physical obstructions and by shadows from the tires. With the shadow monitoring kit additional pyrometers can be installed and configured to monitor these “shadowed”...

  • Page 42: Wiring

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 It is important that the sensor is mounted at a distance from the target, sufficient to be able to "see" the entire area of interest. For this reason, the manufacturer provides a field of view calculating software called "Spot Size Calculator", which allows the calculation of the resulting spot size for a given sensor model and based on a specific mounting distance, see https://www.flukeprocessinstruments.com/SpotSizeCalculator/index.htm...

  • Page 43: Burning Zone Monitoring (A-Cs-Bz-En-Kit-485)

    Accessories Burning Zone Monitoring (A-CS-BZ-EN-KIT-485) 6.5 Burning Zone Monitoring (A-CS-BZ-EN-KIT-485) With Burning Zone Monitoring a two-color point sensor (Endurance ratio pyrometer) can be installed looking into the burn zone of the kiln to monitor the temperatures in this very important area. The two-color unit will essentially “see”...

  • Page 44: Installation

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 6.5.3 Installation Figure 6-9: Installing the Burning Zone Pyrometer Water ¼” NPT 6.5.4 Wiring Burning Zone – For detailed wiring of Burning Zone Monitoring see section 8.9 Wiring, page 58. For recommended cables see section 3.5 Cable Requirements, page 19.

  • Page 45: Internal Heater (A-Cs-Cab-Heat)

    Accessories Internal Heater (A-CS-CAB-HEAT) 6.6 Internal Heater (A-CS-CAB-HEAT) The internal heater is for the use in the system connection box for ambient temperatures below 0°C (32°F). The surface temperatures on the accessible side surfaces of the housing are kept down as a result of the heater design. The heater comes with plug-in thermostat and is designed for permanent operation.

  • Page 46: Maintenance

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 7 Maintenance You can find a troubleshooting guide for common system problems in the Linescanner manual. System specific problems you can find listed below. 7.1 Troubleshooting Table 7-1: Troubleshooting Checkpoint Possible Cause / Solution Kiln Trigger The system has lost synchronization due to missing signals from the position indicator: •...

  • Page 47: Drawings

    Drawings System Installation – without Accessories 8 Drawings 8.1 System Installation – without Accessories Figure 8-1: System Installation – without Accessories For more detailed information see section 3.5 Cable Requirements, page 19.

  • Page 48: System Installation - With Accessories

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 8.2 System Installation – with Accessories Figure 8-2: System Installation – with Accessories For more detailed information see section 3.5 Cable Requirements, page 19.

  • Page 49: System Installation - Multiple Scanners

    Drawings System Installation – Multiple Scanners 8.3 System Installation – Multiple Scanners Figure 8-3: System Installation – Multiple Scanners The drawing above shows the principal design of a system with 4 scanners. The detailed wiring is the same for all scanners.

  • Page 50: System Connection Box - Wiring

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 8.4 System Connection Box – Wiring Figure 8-4: System Connection Box – Wiring...

  • Page 51: Table 8-1: W1 - Power Supply 24 V, 3-Pin

    Drawings System Connection Box – Wiring Table 8-1: W1 – Power Supply 24 V, 3-pin Description Color (6 wires) power ground brown not connected + 24 VDC input for + 24 VDC power supply voltage white shield black Table 8-2: W3 – Alarm, Trigger, 6-pin Description Color (6 wires) Relay contact...

  • Page 52: Fiber Optic Converter Box - Wiring

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 8.5 Fiber Optic Converter Box – Wiring Figure 8-5: Fiber Optic Converter Box – Wiring...

  • Page 53: Position Indicator - Wiring

    Drawings Position Indicator – Wiring 8.6 Position Indicator – Wiring Figure 8-6: Position Indicator – Wiring Position Indicator Junction Box System Connection Box Note The W8 cable for the position indicator is only to be wired to the system connection box like shown above for the cement system! In case of using the TSM accessory the position indicator is connected to the TSM connection box in the field directly!

  • Page 54: Tsm - Wiring

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 8.7 TSM – Wiring Figure 8-7: Wiring Scheme for TSM Remote Control Box 20 2 22 23 24 2 26 2 30 3 32 33 34 3 36 3 Note The internal wiring for the position indicators 4, 5, 6 – the dotted lines – does not come as factory default.

  • Page 55: Terminal - W8 Wiring

    Drawings TSM – Wiring 8.7.1 Terminal – W8 Wiring Figure 8-8: Terminal Wiring for the Position Indicator (Kiln Trigger) Junction Box TSM Remote Control Box Position Indicator (System) Kiln trigger ground Kiln trigger input Kiln trigger VDC Shield Figure 8-9: Terminal Wiring for the Position Indicator (Ring 1) Position Indicator Junction Box TSM Remote Control Box...

  • Page 56: Terminal - W9 Wiring

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 8.7.2 Terminal – W9 Wiring Figure 8-10: Wiring of W9 between TSM Remote Control Box and System Connection Box TSM Remote Control Box System Connection Box 8.7.3 Internal Wiring for the Position Indicators 4, 5, 6 The internal wiring for the position indicators 4, 5, 6 does not come as factory default.

  • Page 57: Shadow Monitoring - Wiring

    Drawings Shadow Monitoring – Wiring 8.8 Shadow Monitoring – Wiring Figure 8-12: Shadow Monitoring – Wiring MI Connection Box Next System Connection Box...

  • Page 58: Burning Zone - Wiring

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 8.9 Burning Zone – Wiring Figure 8-13: Burning Zone – Wiring Endurance Connection Box System Connection Box...

  • Page 59: Appendix - Technical Data

    Appendix – Technical Data Protective Housing (A-MP-ENC) 9 Appendix – Technical Data 9.1 Protective Housing (A-MP-ENC) To protect the linescanner from the high temperatures and poor air quality near the kiln, the scanner is enclosed in a rugged stainless-steel protective housing. Air purging and/or water-cooling is available, if required. Multiple scanner systems contain one protective housing per scanner.

  • Page 60: Scope Of Delivery

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 Air purge Connector outer diameter 8 mm (0.315 in.) Pressure 1.5 to 3 bar (air must be cleaned) 9.1.2 Scope of Delivery • stainless steel box with air purge and all mounting parts •...

  • Page 61: Connection Box

    Appendix – Technical Data Connection Box 9.2 Connection Box The connection box is used for the following items: • System connection box in the field • Fiber Optic Converter Box in the control room • TSM – Tire Slip Monitoring (A-CS-TSM-KIT-485) Figure 9-2: Connection Box 9.2.1 Technical Data sheet steel, powder-coated...

  • Page 62: Fiber Optic / Rj45 Ethernet Converter

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 9.3 Fiber Optic / RJ45 Ethernet Converter 9.3.1 Technical Data Ethernet Communications Ports Port connector RJ45 Distance max. 90 m (295 ft) Fiber Optic Communications Ports Port connector SC type Fiber multi-mode, 62.5/125 µm or 50/125 µm Distance max.

  • Page 63: Connection Box For Accessories

    Appendix – Technical Data Connection Box for Accessories 9.4 Connection Box for Accessories The connection box connects the cables of a field device (shadow pyrometer, burning zone pyrometer) with the customer cables in the field. All connection boxes come with the same housing but have different internal electrical wiring. The connection box is used for the following items: •...

  • Page 64: Delivery

    CS400 System Hardware Manual, Rev. 1.0, Sep 2021 9.4.2 Delivery • Connection box • Cable grommet plate • Set of grommets for different cable sizes...

  • Page 65: Position Indicator (A-Cs-Sysecpi)

    Appendix – Technical Data Position Indicator (A-CS-SYSECPI) 9.5 Position Indicator (A-CS-SYSECPI) Figure 9-4: Dimensions of Position Indicator and Junction Box Position indicator Junction box Mounting hole d=5.2 mm (0.205) PG9 cable gland for field cable Mounting hole d=5.2 mm (0.205) Electronic component with cable to the sensor head 9.5.1 Technical Data...
  • Page 66 Aufgrund laufender Weiterentwicklungen sind Änderungen der Spezifikationen vorbehalten. Alle Angaben vorbehaltlich Satz- und Druckfehler. nbn Austria GmbH Riesstraße 146, 8010 Graz Tel. +43 316 40 28 05 | Fax +43 316 40 25 06 nbn @ nbn. at | www. nbn. at...

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