RayTek CS210 Instruction Manual
CS210
Kiln Shell Temperature
Monitoring System
Rev. B4 Feb 2015
58401
Raytek Corporation
European Headquarters
France
United Kingdom
Fluke Service Center
© Raytek Corporation.
Raytek and the Raytek Logo are registered trademarks of Raytek Corporation.
All rights reserved.
Worldwide Headquarters
Santa Cruz, CA USA
Tel: +1 800 227 – 8074
+1 831 458 – 3900
Fax: +1 831 458 – 1239
solutions@raytek.com
(USA and Canada only)
CONTACTS
Berlin, Germany
Tel: +49 30 4 78 00 80
raytek@raytek.de
Beijing, China
Tel: +86 10 6438 4691
info@raytek.com.cn
Internet: http://www.raytek.com/
Thank you for purchasing this Raytek product. Register today at www.raytek.com/register to
receive the latest updates, enhancements and software upgrades!
info@raytek.fr
ukinfo@raytek.com
Specifications subject to change without notice.
Every change of the standard system design must be acknowledged from Raytek;
WARRANTY
Raytek warrants this product to be free from defects in material and workmanship under normal use
and service for a period of two years from date of purchase except as hereinafter provided. This
warranty extends only to the original purchaser (a purchase from Raytek or Raytek’s licensed
distributors is an original purchase). This warranty shall not apply to fuses or batteries. Factory
calibration is warranted for a period of one year. The warranty shall not apply to any product which
has been subject to misuse, neglect, accident, or abnormal conditions of operation or storage. Should
Raytek be unable to repair or replace the product within a reasonable amount of time, purchaser’s
exclusive remedy shall be a refund of the purchase price upon return of the product.
In the event of failure of a product covered by this warranty, Raytek will repair the instrument when it
is returned by the purchaser, freight prepaid, to an authorize Service Facility within the applicable
warranty period, provided Raytek’s examination discloses to its satisfaction that the product was
defective. Raytek may, at its option, replace the product in lieu of repair. With regard to any covered
product returned within the applicable warranty period, repairs or replacement will be made without
charge and with return freight paid by Raytek, unless the failure was caused by misuse, neglect,
accident, or abnormal conditions of operation or storage, in which case repairs will be billed at a
reasonable cost. In such a case, an estimate will be submitted before work is started, if requested.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF
MERCHANTABILITY, FITNESS, OR ADEQUACY FOR ANY PARTICULAR PURPOSE OR USE.
RAYTEK SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES, WHETHER IN CONTRACT, TORT, OR OTHERWISE.
otherwise the warranty of the complete system will be lost!
The device complies with the requirements of the European Directives.
EC – Directive 2004/108/EC (EMC)
Content
Content .................................................................................................................................................................. 4
1. Safety Instructions ...................................................................................................................................... 8
2. Technical Data ............................................................................................................................................. 9
2.1 Specifications ............................................................................................................................................... 9
2.2 Scope of Delivery ........................................................................................................................................ 9
2.3 Weights and Dimensions ......................................................................................................................... 10
3. Description ................................................................................................................................................. 12
4. Pre-Installation .......................................................................................................................................... 13
4.1 Environment .............................................................................................................................................. 13
4.2 Scanner Distance to Kiln .......................................................................................................................... 13
4.3 Scanner Alignment ................................................................................................................................... 14
4.4 Trigger Bar ................................................................................................................................................. 14
4.5 Cable Requirements ................................................................................................................................. 14
4.6 PC Requirements ...................................................................................................................................... 17
5. Installation .................................................................................................................................................. 18
5.1 Mounting ................................................................................................................................................... 18
5.2 System Connection Box ........................................................................................................................... 20
5.2.1 Cable Entry System .............................................................................................................................. 21
5.3 Fibre Optic / RJ45 Ethernet Converter ................................................................................................... 22
5.4 Position Indicator ..................................................................................................................................... 23
5.5 Fibre Optic Converter Box ....................................................................................................................... 24
6. Configuration ............................................................................................................................................. 25
6.1 Software Installation ................................................................................................................................ 25
6.2 CS Configuration ...................................................................................................................................... 27
6.2.1 <General options>................................................................................................................................. 28
6.2.1.1 <General settings> Tab .................................................................................................................. 28
6.2.1.2 <Communications settings> Tab ................................................................................................... 29
6.2.1.3 <e-mail> Tab .................................................................................................................................. 32
6.2.2 <Colours and axes definition> .............................................................................................................. 33
6.2.2.1 <Colors> Tab ................................................................................................................................. 33
6.2.2.2 <Axes> Tab .................................................................................................................................... 33
6.2.3 <Kiln Settings> .................................................................................................................................... 34
6.2.4 <Position of Scanners / Pyrometers> .................................................................................................... 35
6.2.4.1 <Settings> for Scanner or Pyrometer ............................................................................................ 36
6.2.5 <Special Commands> ........................................................................................................................... 38
6.2.6 <Alarm zones> ...................................................................................................................................... 39
6.2.6.1 Repository of alarm zones configuration ....................................................................................... 39
6.2.6.2 Alarm Zone configuration detail ................................................................................................... 40
6.2.6.3 Alarm zone definition .................................................................................................................... 41
6.2.7 <Refractory> ......................................................................................................................................... 41
6.2.7.1 Repository of refractory configuration .......................................................................................... 41
6.2.7.2 Refractory configuration detail...................................................................................................... 42
6.2.7.3 Refractory zone definition ............................................................................................................. 43
6.2.8 <Historical management> ..................................................................................................................... 43
6.2.8.1 <Images> Tab ................................................................................................................................. 43
6.2.8.2 <Others> Tab ................................................................................................................................. 44
6.2.9 <LRM Configuration> .......................................................................................................................... 44
6.2.10 <Digital Output Management> .......................................................................................................... 46
6.2.10.1 Repository of Digital Outputs ..................................................................................................... 46
6.2.10.2 Digital Output Management detail ............................................................................................. 46
6.2.11 <Daily Report> ................................................................................................................................... 47
6.2.12 <Management of Errors> .................................................................................................................... 48
6.2.12.1 Repository of errors ...................................................................................................................... 48
6.2.12.2 Error detail ................................................................................................................................... 48
6.2.12.3 Error list ...................................................................................................................................... 49
6.2.13 <Management of Alarms> .................................................................................................................. 50
6.2.13.1 Repository of alarms..................................................................................................................... 50
6.2.13.2 Alarms detail ................................................................................................................................ 51
6.2.13.3 Alarms list ................................................................................................................................... 51
6.2.14 <Users> ............................................................................................................................................... 52
6.2.14.1 Users Repository .......................................................................................................................... 52
6.2.14.2 User’s detail ................................................................................................................................. 53
6.2.15 <Update ReadScan> ............................................................................................................................ 56
7. Operation ..................................................................................................................................................... 57
7.1 ReadScan .................................................................................................................................................... 57
7.1.1 <Control> Tab ....................................................................................................................................... 58
7.1.2 <Scanners> Tab ..................................................................................................................................... 58
7.1.3 <Pyrometers> Tab ................................................................................................................................. 59
7.1.4 <LRM> Tab ........................................................................................................................................... 59
7.1.5 <OPC Server> Tab ................................................................................................................................ 60
7.1.6 <Log> Tab ............................................................................................................................................. 60
7.2 CS Runtime Software: Deneb .................................................................................................................. 61
7.2.1 <Main> <Real time> ............................................................................................................................. 61
7.2.2 <Main> <Historic time> <Short term> ................................................................................................. 64
7.2.3 <Main> <Historic time> <Long term> .................................................................................................. 66
7.2.4 <Main> <Reference image> ................................................................................................................... 66
7.2.5 <Secondary> <Internal temperatures> .................................................................................................. 66
7.2.6 <Secondary> <Burning zone graphic> .................................................................................................. 67
7.2.7 <Secondary> <LRM view> .................................................................................................................... 67
7.2.7.1 <Kiln view> Tab ............................................................................................................................. 67
7.2.7.2 <Vertical> Tab ................................................................................................................................ 68
7.2.7.3 <Horizontal> Tab ........................................................................................................................... 68
7.2.7.4 <Time trend> Tab ........................................................................................................................... 69
7.2.7.5 <Space trend> Tab .......................................................................................................................... 69
7.2.8 <Secondary> <Areas of Interest> .......................................................................................................... 70
7.2.9 <Secondary> <Errors> .......................................................................................................................... 70
7.2.10 <Secondary> <Alarms> ....................................................................................................................... 71
7.2.11 <Graphic> <Histogram> ..................................................................................................................... 73
7.2.12 <Graphic> <Trend> ............................................................................................................................. 74
7.2.13 <Graphic> <Difference between images> ............................................................................................ 75
7.2.14 <Reports> ............................................................................................................................................ 75
7.2.14.1 Report Production History .......................................................................................................... 75
7.2.14.2 Daily Report ................................................................................................................................ 76
7.2.15 Command Line Options for Deneb ..................................................................................................... 77
8. Database ...................................................................................................................................................... 78
8.1 Concept ...................................................................................................................................................... 78
8.2 Historic Review......................................................................................................................................... 78
8.3 File Naming Convention ......................................................................................................................... 78
8.4 Backing Up all Data .................................................................................................................................. 79
8.5 Restoring THR Data ................................................................................................................................. 79
9. Options ........................................................................................................................................................ 80
9.1 Start-up-Service......................................................................................................................................... 80
10. Accessories .............................................................................................................................................. 81
10.1 Hardware ................................................................................................................................................. 81
10.2 Software ................................................................................................................................................... 81
10.3 Serial RS485 / RJ45 Ethernet Converter ............................................................................................... 82
10.3.1 Technical Data ................................................................................................................................... 82
10.3.2 LED Indicators ................................................................................................................................... 83
10.3.3 Driver Installation ............................................................................................................................. 83
10.4 Fan Control .............................................................................................................................................. 86
10.4.1 Technical Data ................................................................................................................................... 86
10.4.2 Installation ......................................................................................................................................... 86
10.5 LRM – Live Ring Migration .................................................................................................................. 87
10.5.1 Functionality ...................................................................................................................................... 87
10.5.2 LRM Remote Control ......................................................................................................................... 87
10.5.3 Position Indicator ............................................................................................................................... 88
10.5.4 Wiring ................................................................................................................................................ 89
10.6 Shadow Monitoring ............................................................................................................................... 90
10.7 Burning Zone Monitoring ..................................................................................................................... 92
10.8 Internal Heater ........................................................................................................................................ 94
11. Auxiliary Software ................................................................................................................................ 95
11.1 Managing the CS Database with DBCheck ......................................................................................... 95
11.1.1 Starting the DBCheck application ...................................................................................................... 95
11.1.2 Connecting to the database ................................................................................................................. 95
11.1.3 Migrating pre-existing CS100 data ................................................................................................... 96
11.1.4 Import and export CS configurations ................................................................................................. 97
11.1.5 Creating a backup file ......................................................................................................................... 98
11.1.6 Reset database ..................................................................................................................................... 99
11.2 Remote Access from a Client PC ........................................................................................................ 100
11.2.1 Enabling Remote Access to Readscan .............................................................................................. 100
11.2.2 Remote Access .................................................................................................................................. 100
11.3 Device Testing Programme: PComm ................................................................................................. 101
11.3.1 <Check operation> Window .............................................................................................................. 101
11.3.1.1 Scanner ...................................................................................................................................... 101
11.3.1.2 Pyrometer .................................................................................................................................. 102
11.3.1.3 Digital Output .......................................................................................................................... 103
11.3.1.4 LRM .......................................................................................................................................... 104
11.4 Refractory Management ....................................................................................................................... 105
11.4.1 Configuration .................................................................................................................................... 105
11.4.1.1 Kiln State ................................................................................................................................... 105
11.4.1.2 Refractory Management ............................................................................................................ 106
11.4.1.3 Brick Manufacturers .................................................................................................................. 110
11.4.1.4 Brick Types ................................................................................................................................ 110
11.5 3D Real Time View ............................................................................................................................... 112
12. Troubleshooting ................................................................................................................................... 113
13. Drawings ............................................................................................................................................... 114
13.1 CS212 Installation without Accessories ............................................................................................. 114
13.2 CS212 Installation with Accessories ................................................................................................... 115
13.3 CS21x with Multiple Scanners............................................................................................................. 116
13.4 System Connection Box Wiring .......................................................................................................... 117
13.5 Fibre Optic Converter Box Wiring ...................................................................................................... 119
13.6 Position Indicator Wiring ..................................................................................................................... 120
13.7 Fan Control Wiring ............................................................................................................................... 121
13.8 LRM Wiring ........................................................................................................................................... 122
13.8.1 Terminal Wiring W8 ........................................................................................................................ 123
13.8.2 Terminal Wiring W9 ........................................................................................................................ 124
13.8.3 Internal Wiring for the Position Indicators 4, 5, 6 ........................................................................... 124
13.9 Shadow Monitoring Wiring ................................................................................................................. 125
13.10 Burning Zone Wiring .......................................................................................................................... 126
14. Appendix – Technical Data ................................................................................................................ 127
14.1 Protective Housing ............................................................................................................................... 127
14.2 Connection Box ..................................................................................................................................... 128
14.3 Fibre Optic / RJ45 Ethernet Converter ................................................................................................ 129
14.4 Connection Box for Accessories .......................................................................................................... 130
14.5 Position Indicator .................................................................................................................................. 131
14.6 Output Modules .................................................................................................................................... 132
14.6.1 Digital Output Module 7043 (16 channels) ..................................................................................... 132
14.6.2 Relay Output Module 7067 (7 channels) ......................................................................................... 132
15. Notes ....................................................................................................................................................... 133
Safety Instructions
o to Fluke’s website for
The instrument is equipped with a Class 2 laser. Class 2 lasers shine only within the
mW. Looking directly into the laser beam can produce
, temporary blinding effect, but does not result in physical injury or damage to the
eyes, even when the beam is magnified by optical aids. At any rate, closing the eye lids is
reflections of the laser beam. The laser functions only to locate and mark surface
Incorrect use of 110 / 230 V electrical systems can result in electrical hazards and personal
All instrument parts supplied with electricity must be covered to prevent physical
1. Safety Instructions
This document contains important information, which should be kept at all times with the system
during its operational life. Other users of this instrument should be given these instructions with the
instrument. 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.
Acceptable Operation
This instrument is intended only for temperature measurement and is appropriate for continuous use.
The instrument operates reliably in demanding conditions, such as in high environmental
temperatures, as long as the documented specifications are adhered to. Compliance with the operating
instructions is necessary to ensure the expected results.
Unacceptable Operation
The instrument should not be used for medical diagnosis.
Replacement Parts and Accessories
Use only original parts and accessories approved by the manufacturer. The use of other products can
compromise the operational safety and functionality of the instrument.
Instrument Disposal
Do not dispose of this product as unsorted municipal waste. G
recycling information.
Operating Instructions
The following symbols are used to highlight essential safety information in the operation instructions:
Helpful information regarding the optimal use of the instrument.
Warnings concerning operation to avoid instrument damage and personal injury.
visible spectrum at an intensity of 1
a slight
encouraged when eye contact is made with the laser beam. Pay attention to possible
measurement targets. Do not aim the laser at people or animals.
injury.
contact and other hazards at all times.
8 Rev. B4 Feb 2015 CS210
Technical Data
2. Technical Data
2.1 Specifications
Linescanner
Type MP150HR linescanner
Temperature range: 100 to 650°C (212 to 1202°F)
1
Optical resolution (90% energy) 170 : 1 (IFOV = 5,9 mrad)
Spot detection (50% energy) 510 : 1 (IFOV = 2,0 mrad)
Spectral response: 3.5 to 4 µm
Scan angle (FOV): 90°
Accuracy: ± 0.5% of reading or ± 3°C (± 6°F)
at 0 - 50°C (32 - 122°F) ambient temperature for the scanner
Repeatability: ± 1°C (± 2°F),
Detector: HgCdTe
Sampling rate: 1024 pixel per scan line
Standard focal distance: infinity
Mechanical scanning system: MTBF: 40,000 hours
Power requirement: 100 to 240 VAC (for the system connection box in the field)
Protection rate: IP65 (NEMA4) protection for linescanner
Ambient temperature range:
(for scanner with housing)
- without cooling: -40 to 45°C (-40 to 113°F), no direct sunlight
Warm-up time: 20 minutes
System
Scan lines: 200
Min. kiln speed: 0.02 rpm (for synchronized measurement)
Max. kiln speed: 6 rpm @ 200 lines @ 20 Hz scan speed
Packaging: CS211: about 40 kg (88 lb)
CS212: about 80 kg (176 lb)
at 0 - 50°C (32 - 122°F) ambient temperature for the scanner
(for synchronized measurement)
2
whichever is greater,
2.2 Scope of Delivery
The standard CS211 package includes:
Scanner: Linescanner MP150HR
(CS212: 2 units, CS213: 3 units, CS214: 4 units)
7.5 m (24.6 ft) Ethernet cable
7.5 m (24.6 ft) power cable
1
at 20 Hz scan speed
2
at 20 Hz scan speed
CS210 Rev. B4 Feb 2015 9
Technical Data
7.5 m (24.6 ft) alarm/trigger cable
7.5 m (24.6 ft) RS485 cable
Spare window
Protective Housing: XXXSYSPHSS, stainless steel box
(CS212: 2 units, CS213: 3 units, CS214: 4 units)
grommet kit
adjustable mounting bracket
Spare Window: for protective housing, XXXSYSPHSW
Position Indicator: High temperature inductive sensor with junction box
(XXXSYSSECPI)
System Connection Box (field) CS210CONBOX
(CS212: 2 units, CS213: 3 units, CS214: 4 units)
with:
Fibre Optic / RJ45 Ethernet Converter:
4x Ethernet, 2x fibre optic channels
and:
Power Supply 100/240 VAC to 24 VDC, 2.5 A
Fibre Optic patch cable with SC connector, 2 m (6.6 ft) - 2 pieces
Fibre Optic Converter Box XXXHSFICBOX (control room)
with:
Fibre Optic / RJ45 Ethernet Converter:
4x Ethernet, 2x fibre optic channels
and:
Power Supply 110/230 VAC to 24 VDC, 1.25 A
Ethernet patch cable, 2 m (6.6 ft)
Fibre Optic patch cable with SC connector, 2 m (6.6 ft) - 2 pieces
Tool Kit: Hex key wrench 2.5 mm
Hex key wrench 4 mm
Hex key wrench 5 mm
Wrench 7x8 and 10x13
Key for locking/unlocking enclosure doors
DVD: DataTemp CS Software (incl. manuals, presentations, tools)
Documentation: CS210 Manual,
MP150 Operating Instructions,
MP150 Protocol Manual (on DVD only)
2.3 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: 8 kg (17.6 lbs)
10 Rev. B4 Feb 2015 CS210
Technical Data
Protective Housing: Length: 452 mm (17.79 in)
(with mounting bracket Width: 496 mm (19.53 in
and protective sighting channel) Height: 450 mm (17.72 in)
Weight: 13 kg (28.6 lbs)
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 lbs)
Junction box: Length: 84 mm (3.31 in)
Length: 110 mm (4.33 in) with electronic tube
Width: 79 mm (3.11 in)
Height: 67 mm (2.64 in)
Weight: 0.7 kg (1.5 lbs)
System Connection Box: Width: 380 mm (15 in)
Height: 380 mm (15 in)
Deep: 210 mm (8.3 in)
Weight: 9.8 kg (22 lb) - netto
CS210 Rev. B4 Feb 2015 11
Description
3. Description
The Raytek CS210 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 MP150 linescanner and a powerful, industrial software package. The
system allows accurate monitoring of the kiln shell and early detection of hot spots indicating
damaged or missing refractory bricks, preventing costly kiln damage and
extending production runs.
The key component of the CS210 system is an infrared linescanner (CS212
system: two linescanners). The linescanner collects infrared energy, emitted
from the kiln surface allowing the system to measure the temperature along the
length of the kiln.
The CS210 system provides many features, which include full-color
thermograms of the kiln surface, user defined alarms, automatic fan control and extensive historical
data analysis capability. The CS210 system also adds OPC server functionality, a powerful SQL server
for database applications, and full integration of all available accessories. Most notably, additional
point sensors can be installed and configured to monitor portions of the kiln “shadowed” from the
main sensor by physical obstructions and the results displayed as one homogenous thermogram.
Similarly, a separate sensor is available to monitor the burning zone of the kiln and again the data will
be seamlessly incorporated into one common display in the control room.
Using a optical fibre cable from the scanner in the field to the PC Ethernet interface in the control room
is a reliable way for connecting. Using fibre optics, you can prevent electrical interference from
corrupting the CS210 system. The optical fibre cable supports high speeds and long distance
transmissions (up to 2 km / 1.2 mi). One fibre optic communication line only from the field to the
control room minimizes the installation efforts on-site.
For a complete system overview see section 13.2 CS212 Installation with Accessories, page 115.
12 Rev. B4 Feb 2015 CS210
Pre-Installation
L
2
1
D ≥
D
L
Scanner
Kiln
4. 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.
4.1 Environment
Please take note of the following:
• The maximum ambient temperature for the scanner within the protective housing is 45°C (113°F).
If necessary, add an additional shaded roof to protect the protective housing from direct sunlight
or provide water direct to 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 potential.
(Check for good electrical contact at grounding wire connection).
4.2 Scanner Distance to Kiln
The standard system, CS211, is a one-scanner system and is suited for small to medium length kilns
up to 60 m (200 ft) in length. For longer kilns the CS212, a two-scanner system, will be required.
The linescanner has a 90° scan angle. The distance between the scanner and the kiln required for
complete coverage of the kiln length can be calculated as follows:
where:
D … Distance between scanner and kiln
L … kiln length (required scan width)
Figure 1: Distance between Scanner and Kiln
CS210 Rev. B4 Feb 2015 13
Pre-Installation
Scanner stand
(dedicated tower or
roof of a building)
Scanner
Kiln
Kiln axis
Rotation
Kiln
Trigger bar
Trigger
bar
4.3 Scanner Alignment
The optimal scanner alignment is shown in the figure below.
Figure 2: Alignment of Scanner
4.4 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 CS210 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 for the position indicator is 230°C (446°F). For installing the
position indicator see section 5.4 Position Indicator, page 23.
4.5 Cable Requirements
The following cables are necessary for standard installations, see also system drawings given in
section 13.1 CS212 Installation without Accessories, page 114.
– W1 power supply cable for scanner (preinstalled with system connection box)
– W2 RS485 communication cable for scanner (preinstalled with system connection box)
– W3 trigger/alarm cable for linescanner (preinstalled with system connection box)
– W8 from the junction box of the position indicator to the system connection box (standard
– W9 from the LRM remote control box to the system connection box. This six-wire-cable is used for
14 Rev. B4 Feb 2015 CS210
Figure 3: Welding the Trigger Bar on the Kiln
installation) or to LRM remote control box (when used with accessory Live Ring Migration).
data communication, power supply, and trigger pulse.
Pre-Installation
All copper cables must be shielded! The wires from W9, W10, W14, and W15 must be a
– W10 from the fan control output module to the system connection box. This four-wire-cable is
used for data communication and power supply to the output module.
– W14 from the MI connection box to the system connection box and between MI connection boxes
when more than one shadow sensor is installed. This four-wire cable is used for data
communication and power supply to the pyrometer.
– W15 from the MR connection box to the system connection box. This six-wire cable is used for
data communication and power supply to the pyrometer.
– W16 MI sensing head cable.
– W17 MR sensing head cable.
– W18 Ethernet communication cable for scanner (preinstalled with system connection box)
– W20 Fibre optic cable from system connection box to the control room and to the second scanner
(if used). Fibre optic cable to be provided by customer.
– W22 Ethernet cable from fibre optic converter (control room) to the PC.
– W23 from the position indicator head to the junction box.
– W24 Power supply cable 100 to 240 VAC.
– W25 Fibre optic cable from the first scanner to the second scanner (if used). Fibre optic cable to be
provided by customer.
twisted pair! Local building codes should be observed when selecting cables!
CS210 Rev. B4 Feb 2015 15
Pre-Installation
Cable
Distance
Cable features
Supplied from …
Example / Remarks
W1, W2,
W3
7.5 m (25 ft.)
preinstalled
Raytek
W8
350 m (380 yd)
3 x 0.25 mm²,
24 AWG, 3 conductor, shielded
Customer
(N)YLHCY-J 3 × 0.25 mm²
Manhattan/CDT, P/N M13233
W9
350 m (380 yd)
3 x 2 x 0.25 mm²,
24 AWG, 3x twisted pair, shielded
Customer
LifYCY 3 × 2 × 0.25 mm²
W10
350 m
(380 yd)
2 x 2 x 0.25 mm²,
24 AWG, 2 x twisted pair, shielded
Customer
W14
350 m (380 yd)
2 x 2 x 0.5 mm²,
20 AWG, 2 x twisted pair, shielded
Customer
max. 5 pyrometers
350 m (380 yd)
2 x 2 x 1.5 mm²,
16 AWG, 2 x twisted pair, shielded
Customer
max. 14 pyrometers
W15
350 m (380 yd)
3 x 2 x 1.5 mm²,
16 AWG, 3x twisted pair, shielded
Customer
W16
8 m (26 ft)
preinstalled
Raytek
W17
15 m (49 ft.)
preinstalled
Raytek W18
7.5 m (25 ft.)
Raytek
W20
< 2 km (1.2 mi)
Fibre optic cable (outdoor),
connectors
Customer
Standard cable designation:
W22
2 m (6.5 ft.)
Ethernet patch cable (CAT5, RJ-45)
Raytek W23
5 m (15 ft.)
Raytek
W24
Power supply cable 100 to 240 VAC,
50 / 60 Hz, min. 3 x 1.5 mm² (16 AWG)
Customer
NYY
W25
< 2 km (1.2 mi)
Fibre optic cable (outdoor),
connectors
Customer
Standard cable designation:
The cable length causes a certain voltage drop on the power cable. In case of using
it must always be ensured, that the sensor will be supplied with the minimal voltage
Linescanner: min. 18 VDC
2 fibres, multi-mode, 62.5/125 µm or
50/125 µm, equipped with SC
2 fibres, multi-mode, 62.5/125 µm or
50/125 µm, equipped with SC
multiple sensors (MI shadow pyrometers via W14), longer cable lengths, or less gauges
power!
MR burning zone pyrometer: min. 20 VDC
MI shadow pyrometer: min. 12 VDC
A-DQ(ZN)B2Y…
A-DQ(ZN)B2Y…
16 Rev. B4 Feb 2015 CS210
4.6 PC Requirements
software exclusively on the PC! Other
TCP/UDP Port
Server
Client
Remark
16500
CS Readscan
CS Deneb
1433
CS SQL database
CS Config, CS Readscan
25
CS Mail (SMTP)
CS Readscan
default
2727
Linescanner Communication
CS Readscan
default
5048, 5058
Serial RS485 / RJ45 Ethernet Converter
CS Readscan
as accessory only
23
Telnet
for service only
Minimum Hardware requirement for CS211 and CS212:
− Processor: Intel i5 quad core series CPU or comparable
− 8 GB RAM system memory
− 1280 x 1024 pixel graphic card and monitor
(for displaying one scanner with 1024 pixel per line)
2560 x 1600 pixel graphic card and monitor
(for displaying two scanners with 2048 pixel per line)
− OpenGL 2.1 graphics adapter (when using the 3D Real Time View)
− 50 GB hard disk
− DVD drive
− Ethernet, TCP/IP protocol, 100 Mbit/s
Minimum Software requirement:
− Windows
®
XP or Windows 7 3 with latest Service Pack
It is strongly recommended to run the CS
applications could affect function and performance.
Pre-Installation
For the CS system it is necessary to disable Windows' default power management
settings in order to avoid that the computer goes to sleep automatically.
Make sure that a possible firewall does not block the following ports:
3
Windows Vista should work but it is not guaranteed.
CS210 Rev. B4 Feb 2015 17
Installation
Bottom view
Protective Housing
Bottom view
5. Installation
5.1 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. The mounting bracket is 150 mm (5.9 in) high.
Figure 4: Protective housing’s 3-axis mounting bracket
Preparing the protective housing to be mounted on the sensor stand
Open the protective housing from the back to access to the internal components. On the bottom of the
box, there is 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 carrier using the 4 M6 x 12 screws provided. Connect the earth ground to the top of the
linescanner. To install the ground on the left mounting thread, use a M6 x 12 hex head screw with
washer and lock washer.
Mounting the protective channel and the window
Open the front door of the protective housing. Mount the protective field-of-view channel on the front
side by using 6 M4 x 12 bolts. The slotted side of the protection channel faces downwards. The bolts
must be inserted from inside the box (i.e. the nuts are outside).
Make sure that the drain hole for rain water in the protective channel faces downwards!
18 Rev. B4 Feb 2015 CS210
Installation
Window holder
2 nuts – M6
Protective
housing
Protective
channel
Linescanner
Figure 5: Protective housing with protective channel
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.
Electrical Installation
For best performance, the electrical installation of the CS210 System should correspond to one of the
recommended installation configurations illustrated in section 13.1 CS212 Installation without
Accessories, page 114.
Connecting the cables
The cables W1, W2, W3, and W18 (located between the linescanner and the system connection box) are
factory preinstalled 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-bolts. Use an appropriate grommet by considering
the different cable outer diameters:
• Cable W1 (power supply): Ø 5 mm (0.2 in)
• Cable W18 (Ethernet): Ø 6 mm (0.24 in)
• Cable W2 (RS485) and W3 (Alarm/Trigger): Ø 7 mm (0.28 in)
Feed the cable through the grommets so that grommet is approximately 400 mm (15.7 in) away from
the linescanner connectors (round plugs). Place the grommet plate over the grommets as shown in the
figure below. Be careful to have the cable identification plates pointed toward the system connection
box (longer end of the cables). Close unused holes with the blind grommets then close the grommet
plate.
CS210 Rev. B4 Feb 2015 19
Installation
cooling may be necessary.
Mains
Plug
Fuse
6 A
Power
Supply
Serial/Ethernet
Fibre Optic /
Heater
Grommet plate
Figure 6: Cable installation
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.
If installing the CS210 system in a warm environment, waterThe tubes used for water may be run through the second grommet plate!
5.2 System Connection Box
The system connection box connects all device field cables with the customer supplied optical fibre
cable. The system connection box includes the Fibre Optic / RJ45 Ethernet Converter, the 24 VDC
power supply and the Serial/Ethernet converter for supporting the accessories (if used).
The box is supplied with quick installation line-up terminals. For more technical data, see section
14.2 Connection Box, page 128.
RJ45 Ethernet
Converter
Converter
(Accessory)
(Accessory)
20 Rev. B4 Feb 2015 CS210
Figure 7: Opened System Connection Box
Installation
Lay cable into appropriate grommet and provide strain relief
Use appropriate tool to punch through cover on base frame.
Pin 18
Pin 17
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. The cables between the linescanner and the connection box needs to be protected
from mechanical damage.
Mount the connection box in a convenient location. The cables W1, W2, W3, and W18 are factory
preinstalled. Insert the cable W20 using the grommet plate taking care to select the correct grommet
size for the cable diameter.
Connect the cables for the accessories with the connectors of the line-up terminal as described in
section 13.4 System Connection Box Wiring, page 117.
After double-checking all connections, switch the power on. The 24V-LED indicates the ON/OFF
status (see terminal pin 8 in the system connection box). Check the trigger signal coming from the
position indicator (see terminal pin 40 in the system connection box).
Pins 17 and 18 of the terminal in the system connection box connect to the internal alarm relay of the
scanner. The contacts are potential free, the maximum load is 30 V / 1 A. To configure the alarm relay,
see section 6.2.4.1 <Settings> for Scanner or Pyrometer, page 36.
Figure 8: Connection to the internal Alarm Relay of the Scanner
5.2.1 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
4
where necessary using cable ties.
4
Illustrations: © Murrplastik
CS210 Rev. B4 Feb 2015 21
Installation
Set catch hooks into the sides of the cut-out.
Insert rail completely.
Set the rail onto the catch hooks and press on.
Lock the catch hooks with the rail. Press gently on grommet one
The grommet must produce a continuous seal on the back side.
more time.
5.3 Fibre Optic / RJ45 Ethernet Converter
The Fibre Optic / RJ45 Ethernet Converter assures high reliability and
stability in harsh environments, making it a robust bridge between enterprise
fibre-optic backbones and Ethernet devices like the linescanner. Using fibre
optics, you prevent electrical interference from corrupting the CS210 system.
The Fibre Optic / RJ45 Ethernet Converter supports fast speed and high
distance transmissions. Copper based Ethernet communication is very
limited in length without using a repeater.
The Fibre Optic / RJ45 Ethernet Converter in the system connection box is
converting up to 4 Ethernet channels to support one or two scanners and the
CS210 accessories. The Fibre Optic / RJ45 Ethernet Converter in the control
room is converting the glass fibre signals back to TCP/IP Ethernet again. For further technical details
see appendix 14.3 Fibre Optic / RJ45 Ethernet Converter, page 129.
22 Rev. B4 Feb 2015 CS210
Installation
In the case of a non-existing trigger signal, the system switches to the non-synchronized
software will blink
5.4 Position Indicator
The position indicator is a temperature resistant inductive proximity
switch used to synchronize the scanning system with the kiln rotation.
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 mounted near the kiln’s
surface. For the junction box a maximum ambient temperature of 70°C (158°F) is allowed. For further
technical details see appendix 14.5 Position Indicator, page 131.
Both components, sensor and junction box, are connected via a high temperature cable (length: 5 m /
15 ft). Protecting the cable against mechanical stress is recommended. Since the position indicator is
necessary to generate a trigger pulse for the CS210 system, a trigger bar must be welded onto the
“colder“ end of the kiln and if possible close to the drive ring (see Figure 9).
The distance between the trigger bar and the position indicator is a very important parameter for
correct operation. If the distance is too small, the trigger bar can destroy the sensor head. On the other
hand, if the distance is too big, the position indicator will be unable to detect the trigger bar. Thus, it
will not be able to generate the trigger pulse for the system.
mode. In this mode, a yellow bar on the top area in the CS
continuously. Non-synchronized thermograms are not stored in the database!
In multi-scanner systems, the trigger signal may be associated with any scanner!
CS210 Rev. B4 Feb 2015 23
Installation
Kiln axis
Rotation
Kiln
Trigger bar
steel St37
square (2.16
Trigger bar
Distance: max. 20 mm (0.79 in.)
Position indicator with
mounting pla
PTFE cable, 5 m (15 ft.)
Junction box
Cable W8 to system connection box
, sized 50 mm in
in. in square)
te
Figure 9: Mounting the Position Indicator
Adjustment of the position indicator:
1. Mount the trigger bar.
2. Mount the position indicator mounting plate .
3. Check the distance between position indicator and trigger bar.
4. Lock the position indicator in place and monitor its’ operation. With each revolution of the
kiln you should obtain a trigger pulse indicated by an LED in the junction box (field).
5.5 Fibre Optic Converter Box
The Fibre Optic Converter Box is located in the control room and connects the fibre optic cable from
the field to the Ethernet interface of the computer. For more technical data, see section 14.2 Connection
Box, page 128.
24 Rev. B4 Feb 2015 CS210
Figure 10: Fibre Optic Converter Box
Configuration
The software installation requires the user as local administrator with full permission
It is strongly recommended to update the Windows operating system before installing
Make sure that the default SQL port 1433 is not in use; otherwise you will be not able to
c shutdown,
6. Configuration
The following sections of this manual describe the operation of the CS software. Complete
configuration requires the following steps:
1. Install the software.
2. Configure the system.
a. Provide detail of certain general options.
b. Define detail of visual appearance options.
c. Define temperature reading instruments (scanners and pyrometers).
d. List alarm zones and refractory details.
e. Need for controlling of fans
f. Provide detail of the LRM system installation.
g. Define preferences for storing historical data.
Before proceeding with the following sections please ensure that the physical installation
(communication and power wiring, air, water if necessary, etc.) is completed and working
satisfactorily.
6.1 Software Installation
whereby the administrator requires a dedicated password (network and non-password
accounts do not work).
the CS software!
install the software.
Disable all energy saving functions of the operating system like automati
energy saving modes, and hard drive spin down!
Insert the software DVD in the DVD drive and double click on the <Setup.exe> file. The install setup
application will start, showing the following steps in a screen window.
• When the install setup starts up, a welcome screen will show, letting you select the default
language for the application. Once you have selected the language, click on <Next> to
continue.
• Next, select the path where you want to install the application and the folder where you want
the database to be installed. When finished, click on <Next>.
CS210 Rev. B4 Feb 2015 25
Configuration
Figure 11: Installation screen
• Once you have completed selecting your preferences, you can click on <Install> to proceed
with the installation.
• In one of the next screens, you have to give a valid <user name> and <password> for an
administrative user for a domain on the installation computer to allow the SQL database
server to be executed.
Figure 12: Administrative User for the Computer Domain
In case of installation problems uncheck the <Try to install SQL Server automatically>
item!
• On the last installation screen, you can activate the check box to import an old CS100
configuration and a CS100 database into CS software. After closing the install setup you will
be guided through the migration procedure.
26 Rev. B4 Feb 2015 CS210
Configuration
In addition, you find also the check box to start automatically ReadScan when Windows
starts. It is strongly recommended to keep this check box enabled!
Figure 13: Installation finished
• If the installation is successful, all necessary shortcut icons will appear in your PC desktop
screen and in the Start-menu (Start\Programs\Raytek\DataTemp CS).
For Windows Vista and Windows 7 operating systems, the user data will be stored in
the dedicated <My Documents> folder separately from the program files!
6.2 CS Configuration
To configure the DataTemp CS software, select the start menu, activate the CS program group and
click on the icon <CS Config> (alternatively you can also find the icon on the desktop). You will be
prompted to enter a password.
Figure 14: Authentication screen
At this point, a valid user and password must be entered for the selected profile. If this is the first
login, a single profile will be seen, and that profile is normally <Raytek>.
Predetermined user for CS Config (valid also for the program components CS Deneb and ReadScan):
Username: <ADMIN>
Password: {empty}
CS210 Rev. B4 Feb 2015 27
Configuration
When ReadScan is active, any changes made in the configuration settings won’t be
ctive until ReadScan restarts automatically later. For more information on this topic
uested physical units (distance and
The configured scanner data format <points per line> applies to all scanners and
database backups. The data format (256 pixel / 512 pixel / 1024 pixel, 1 byte / 2 byte and
200 lines) must not be mixed. The same resolution is used for every scanner
Once these 3 boxes are correctly filled, the user will proceed to a new screen and select the different
menu options.
effe
see section 7.1.1 <Control> Tab, page 58.
6.2.1 <General options>
6.2.1.1 <General settings> Tab
This tab allows the user to configure the general aspects of the system, such as description, language,
maximum and minimum temperature to be seen from Deneb, the amount of lines formed per
thermogram and metric or imperial units. In standard installations the scanner communicates via
Ethernet, there are no speed restrictions to consider.
Figure 15: General options: <General Settings> Tab
It is strongly recommended to select the req
temperature) before all others changes!
100 /
connected and all database backups loaded into the system!
28 Rev. B4 Feb 2015 CS210
Configuration
The number of lines per thermogram is a parameter that can only be modified when the
western European languages (Turkish, Russian) it is strongly
Points per line
Bytes per point
Minimum serial speed
256 1 115 kBaud
512 1 115 kBaud
database is empty, (i.e. when the database does not contain any images)!
For running of nonrecommended to use a Windows Operating System in that desired language!
Non-western European languages can also be displayed by setting the Windows codepage
accordingly.
• Go to <Start> <Settings> <Control Panel> <Regional and Language Settings>
• Under <Regional Settings> select the desired language
• Under <Advanced> select the same desired language for programmes not supporting Unicode
fonts
For old systems only, running with RS485 communications:
The number of data points per line and the number of bytes per data point needs to be considered in case of running the
scanner via the serial RS485 communication line. The table below shows the recommended configurations.
<Points per line> defines the number of data points per line provided by one scanner.
<Bytes per point> defines the number of bytes per one data point.
Figure 16: Recommended Configurations for the Serial RS485 Communication
6.2.1.2 <Communications settings> Tab
On this tab the user can configure general communication settings for the serial devices.
The <command timeout> is the maximum time to wait after sending one command to a device. If the
device doesn’t answer in less than the time stipulated, the system will consider it as a communication
error.
The <communication timeout> is the time period between a communication error with a device and
the systems attempt to retry the communication.
<Retries for communication> defines the number of automatic trials to re-establish the communication
to a lost serial device.
By labeling the checkbox <OPC Server active>, the CS software runs as OPC server for one or more
OPC clients within a network. For interfacing to other control systems this option allows the remote
monitoring of the process.
OPC (OLE for Process Control) is an industrial standard for the data exchange between applications
based on the DCOM model from Microsoft. For further information see
http://www.opcfoundation.org/
The CS OPC server supports Data Access in version 2.0 only!
CS210 Rev. B4 Feb 2015 29
Configuration
Figure 17: General Options: <Communication settings> Tab
<Send DTR signal with alarms> enables the output of a system alarm signal via the CS interface box
(for scanners communicating via COM) or a digital output module (for scanners communicating via
Ethernet).
30 Rev. B4 Feb 2015 CS210
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