NBN Fluke CS400 Hardware Manual Download

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CS400 System

Kiln Shell Temperature Monitoring

Hardware Manual

PN 5259635, English, Rev. 1.0, Sep 2021

All product names are trademarks of their respective companies.

nbn Austria GmbH

Summary of Contents for Fluke CS400

Page 1: ...ardware 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 trademark...

Page 2: ...damages whether in contract tort or otherwise Software Warranty The manufacturer does not warrant that the software described herein will function properly in every hardware and software environment...

Page 3: ...Dimensions 15 2 6 Scope of Delivery 16 3 PRE INSTALLATION 17 3 1 Environment 17 3 2 Scanner Distance to Kiln 17 3 3 Scanner Alignment 18 3 4 Trigger Bar 18 3 5 Cable Requirements 19 4 INSTALLATION 21...

Page 4: ...nternal Heater A CS CAB HEAT 45 6 6 1 Technical Data 45 7 MAINTENANCE 46 7 1 Troubleshooting 46 8 DRAWINGS 47 8 1 System Installation without Accessories 47 8 2 System Installation with Accessories 48...

Page 5: ...ata 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 T...

Page 6: ...ble 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 Complete Terminal Wiring fo...

Page 7: ...Sensor 41 Figure 6 8 MI3 Circuit Board with Termination for Activating the Shunt 42 Figure 6 9 Installing the Burning Zone Pyrometer 44 Figure 6 10 Internal Heater 45 Figure 8 1 System Installation wi...

Page 8: ...surement control and laboratory devices Electromagnetic susceptibility EMC EN 61558 1 2006 Safety Requirements for power transformers power supplies reactors and similar products low voltage EN 61558...

Page 9: ...nt is intended only for the measurement of temperature The instrument is appropriate for continuous use The instrument operates reliably in demanding conditions such as in high environmental temperatu...

Page 10: ...Important information See manual Laser warning Earth ground terminal Protective conductor terminal Switch or relay contact DC power supply Conforms to European Union directive Disposal of old instrume...

Page 11: ...at persons or animals or indirectly off reflective surfaces Do not use laser viewing glasses as laser protection glasses Laser viewing glasses are used only for better visibility of the laser in brigh...

Page 12: ...Beijing China Tel 86 10 6438 4691 info flukeprocessinstruments cn Technical Support USA Canada 65 67995578 Europe 49 30478008444 Latin America 1 831 458 3900 Australia New Zealand 1 831 458 3900 Asia...

Page 13: ...s of the kiln surface user defined alarms I O module support and extensive historical data analysis capability The CS400 system also adds OPC server functionality and full integration of all available...

Page 14: ...Focus infinity 2 3 Electrical Specifications System power 100 to 240 VAC for the system connection box Ethernet TCP IPv4 protocol 10 100 MBit s electrically isolated auto negotiation IP address 192 1...

Page 15: ...ght 450 mm 17 72 in Weight 13 kg 28 6 lbs with mounting bracket and protective sighting channel Position indicator Sensor head Length 50 mm 1 97 in Diameter 50 mm M50 x 1 5 1 97 in Weight 0 3 kg 0 66...

Page 16: ...Ethernet 2x fiber optic channels Power Supply 100 240 VAC to 24 VDC 2 5 A Fiber optic patch cable with SC connector 2 m 6 6 ft 2 pieces Basic Hardware Kit Position indicator with junction box A CS SYS...

Page 17: ...the scanner For details on grounding the sensor stand please refer to the local building codes for lightning protection The housing of the linescanner and the system connection box must have the same...

Page 18: ...ution to supply the CS400 system with data on the rotational speed of the kiln The installer must mount a trigger bar onto the kiln shell as shown in the figure below The maximum ambient temperature f...

Page 19: ...ation cable for scanner preinstalled with system connection box W20 Fiber optic cable from system connection box to the control room and to the second scanner if used Fiber optic cable to be provided...

Page 20: ...60 Hz min 3 x 1 5 mm 16 AWG Customer NYY W25 2 km 1 2 mi Fiber optic cable outdoor 2 fibres multi mode 62 5 125 m or 50 125 m equipped with SC connectors Customer Standard cable designation A DQ ZN B...

Page 21: ...a rail carrier system on which the linescanner will be mounted Open the latches on both sides of the rail loosen the bolt on top of the carrier and take off the carrier Mount the linescanner onto the...

Page 22: ...led and supplied along with the system connection box For running the cables through the protective housing open one grommet plate on the bottom of the protective housing by loosening the three Allen...

Page 23: ...be necessary The tubes used for water may be run through the second grommet plate 4 2 System Connection Box The system connection box connects all device field cables with the customer supplied optic...

Page 24: ...the cables for the accessories with the connectors of the line up terminal as described in section 8 4 System Connection Box Wiring page 50 After double checking all connections switch the power on Th...

Page 25: ...embling the connectors Snap on mounting3 Lay cable into appropriate grommet and provide strain relief where necessary using cable ties Use appropriate tool to punch through cover on base frame Set cat...

Page 26: ...re 4 6 Position Indicator The position indicator consists of two parts a high temperature sensor head and a junction box Since the maximum ambient temperature allowed is 230 C 446 F the sensor may be...

Page 27: ...its operation With each revolution of the kiln you should obtain a trigger pulse indicated by an LED in the junction box field 4 5 Fiber Optic Converter Box The Fiber Optic Converter Box is in the co...

Page 28: ...CS400 System Hardware Manual Rev 1 0 Sep 2021 28 Figure 4 8 Fiber Optic Converter Box...

Page 29: ...l be operational before the final acceptance and sign off by the customer The manufacturer does not provide construction erection mechanical electrical or building services Prior to the start up servi...

Page 30: ...clude 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 Shadow Monitoring A CS SM KIT...

Page 31: ...ta Ethernet Communications Speed 100 Mbit s Ports 2x Port connector RJ45 Protection built in 1 5 kV magnetic isolation IP address 192 168 42 10 default RS485 Communications Ports 4x Port connector DB9...

Page 32: ...the way to install a virtual COM port on the CS computer by using the Configuration Utility Software The virtual COM ports work like standard Windows COM ports so the CS software sees no difference b...

Page 33: ...function 6 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...

Page 34: ...2 is configured as RS485 type for communicating with the shadow monitoring to be wired at connector X4 in the system connection box In the example above port 2 is assigned to the virtual COM port 11 t...

Page 35: ...Accessories Serial RS485 RJ45 Ethernet Converter A CS CONV ETH485 35 6 Note It is not recommended to change the pre set configuration for the four ports of the serial device XXXSYSCS210CON...

Page 36: ...16DI Digital Output Module 750 1504 16 channels A IO 16DO Passive Isolator 857 452 A IO 2A ISO Analog Current Output Module 750 563 preset to 0 20 mA 2 channels A IO 2AOC 0 Analog Current Output Modu...

Page 37: ...essories page 48 6 3 1 Delivery The scope of delivery for the TSM accessory Position indicator with junction box 3 position indicators delivered for monitoring of 3 tires each further tire requires an...

Page 38: ...g 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 on...

Page 39: ...lip Monitoring TSM A CS TSM KIT 485 39 6 6 3 5 Installation Figure 6 4 Mounting the Position Indicator Figure 6 5 Trigger Bar details 20 mm 0 79 in Position indicator Junction box Flat Iron steel ST37...

Page 40: ...Requirements page 19 Note The position indicator for the kiln master must be wired to the kiln trigger labeled input on the terminal line of the TSM remote control box All subsequent TSM position ind...

Page 41: ...Technical Data Temperature range 40 to 600 C 40 to 1112 F Spectral response 8 to 14 m Accuracy 1 of reading or 1 C whichever is greater Optical resolution 10 1 90 energy Head ambient temperature 0 to...

Page 42: ...Example Optical resolution for the MI3 sensor 10 1 Distance to the kiln 5000 mm 200 in Resulting spot size 500 mm 20 in 6 4 4 Wiring For an installation of two or more shadow sensors in a network eac...

Page 43: ...600 to 1800 C 1112 to 3372 F Spectral response 1 m nominal Accuracy 0 5 Tmeasured 2 C Tmeasured in C Optical resolution 100 1 95 energy Protection rate sensor IP65 NEMA 4 Ambient temperature without...

Page 44: ...Installation Figure 6 9 Installing the Burning Zone Pyrometer 6 5 4 Wiring For detailed wiring of Burning Zone Monitoring see section 8 9 Burning Zone Wiring page 58 For recommended cables see sectio...

Page 45: ...result of the heater design The heater comes with plug in thermostat and is designed for permanent operation 6 6 1 Technical Data Voltage 100 to 240 VAC Heating capacity max 50 W 170 BTU hour Wiring...

Page 46: ...trigger bar for a reliable signal generation Check the wiring Note The trigger signal can be verified by a blinking LED on the junction box located close to the position indicator Ethernet Communicat...

Page 47: ...Installation without Accessories 47 8 8 Drawings 8 1 System Installation without Accessories Figure 8 1 System Installation without Accessories For more detailed information see section 3 5 Cable Requ...

Page 48: ...W W22 W20 W2 W Fibre ptic Converter in ousing Accessory Modules W24 W24 W24 00 240 AC 00 240 AC Cable e uirements W power supply cable for scanner W3 trigger alarm between linescanner and W cable from...

Page 49: ...n 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 The posit...

Page 50: ...CS400 System Hardware Manual Rev 1 0 Sep 2021 50 8 4 System Connection Box Wiring Figure 8 4 System Connection Box Wiring...

Page 51: ...oltage white shield black Table 8 2 W3 Alarm Trigger 6 pin Description Color 6 wires 1 Relay contact Potential free relay contact capacity max 30 V 1 A brown 2 Relay contact Potential free relay conta...

Page 52: ...CS400 System Hardware Manual Rev 1 0 Sep 2021 52 8 5 Fiber Optic Converter Box Wiring Figure 8 5 Fiber Optic Converter Box Wiring...

Page 53: ...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 conne...

Page 54: ...7 TSM Wiring Figure 8 7 Wiring Scheme for TSM Remote Control Box Note The internal wiring for the position indicators 4 5 6 the dotted lines does not come as factory default 2 3 4 6 0 2 3 4 6 20 2 22...

Page 55: ...sition Indicators Position Indicator Ring 1 Pin Ring 2 Pin Ring 3 Pin Ring 4 Pin Ring 5 Pin Ring 6 Pin Shield 16 20 24 28 32 36 24 VDC 13 17 21 25 29 33 Out 14 18 22 26 30 34 GND 15 19 23 27 31 35 Jun...

Page 56: ...al wiring by your own The complete wiring for the TSM Remote Control Box is given below Figure 8 11 Wiring for the Position Indicators 4 5 6 30 29 28 27 26 25 top 42 41 40 39 38 37 shield gnd Kiln Tri...

Page 57: ...Drawings Shadow Monitoring Wiring 57 8 8 8 Shadow Monitoring Wiring Figure 8 12 Shadow Monitoring Wiring Next Box MI Connection Box System Connection Box...

Page 58: ...CS400 System Hardware Manual Rev 1 0 Sep 2021 58 8 9 Burning Zone Wiring Figure 8 13 Burning Zone Wiring Endurance Connection Box System Connection Box...

Page 59: ...ing Air purging and or water cooling is available if required Multiple scanner systems contain one protective housing per scanner Figure 9 1 Protective Housing 9 1 1 Technical Data Material Box Stainl...

Page 60: ...tor 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 adjustable mounting bracket allowing aiming...

Page 61: ...ta Box sheet steel powder coated Temperature range 0 to 50 C 32 to 122 F 30 C 22 F with internal heater A CS CAB HEAT for the system connection box Dimensions W x H x D 380 x 380 x 210 mm 15 x 15 x 8...

Page 62: ...lti mode 62 5 125 m or 50 125 m Distance max 2 km 1 24 mi Mechanics Dimensions W x H x D 37 x 140 x 95 mm 1 45 x 5 5 x 3 7 in Mounting DIN rail Power Power input 12 to 48 VDC redundant dual inputs Pow...

Page 63: ...ferent internal electrical wiring The connection box is used for the following items Endurance connection box for Burning Zone Monitoring MI connection box for Shadow Monitoring Figure 9 3 Connection...

Page 64: ...CS400 System Hardware Manual Rev 1 0 Sep 2021 64 9 4 2 Delivery Connection box Cable grommet plate Set of grommets for different cable sizes...

Page 65: ...range position indicator 25 to 230 C 13 to 446 F junction box 25 to 70 C 13 to 158 F Length of cable 5 m 15 ft Protection rate IP67 Output No 2 active 24 V 300 mA max short circuit protected Junction...

Page 66: ...2021 66 nbn nbn at www nbn at Tel 43 316 402805 Fax 43 316 402506 Riesstra e 146 8010 Graz nbn Austria GmbH Aufgrund laufenderWeiterentwicklungen sind nderungen der Spezifikationen vorbehalten Alle An...

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