Land Instruments International NIR Borescope User manual

NIR Borescope
Near-Infrared Borescope Thermal Imaging System
© Land Instruments International, 2014
Installation Guide
Publication Nº 807346
Issue 7
11 September 2014
Language: English

Health and Safety Information
Read all of the instructions in this booklet - including all the WARNINGS and CAUTIONS
- before using this product. If there is any instruction which you do not understand.
DO NOT USE THE PRODUCT.
Safety Signs
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
personal injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury to the user or users, or result in damage to the product or to property.
NOTE
Indicates a potentially hazardous situation which, if not avoided, could result in damage or the loss of
data.
Equipment Operation
Use of this instrument in a manner not specied by Land Instruments International may be hazardous.
Read and understand the user documentation supplied before installing and operating the equipment.
Protective Clothing, Face and Eye Protection
It is possible that this equipment is to be installed on, or near to, machinery or equipment operating at
high temperatures and high pressures. Suitable protective clothing, along with face and eye protection
must be worn. Refer to the health and safety guidelines for the machinery/equipment before installing
this product. If in doubt, contact Land Instruments International.
Electrical Power Supply
Before working on the electrical connections, all of the electrical power lines to the equipment must
be isolated. All the electrical cables and signal cables must be connected exactly as indicated in these
operating instructions. If in doubt, contact Land Instruments International.
Storage
The instrument should be stored in its packaging, in a dry sheltered area.
Unpacking
Check all packages for external signs of damage. Check the contents against the packing note.
Lifting Instructions
Where items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the
Technical Specication for weights. All lifting should be done as stated in local regulations.
IMPORTANT INFORMATION - PLEASE READ

Health and Safety Information
Read all of the instructions in this booklet - including all the WARNINGS and CAUTIONS
- before using this product. If there is any instruction which you do not understand.
DO NOT USE THE PRODUCT.
Safety Signs
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
personal injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury to the user or users, or result in damage to the product or to property.
NOTE
Indicates a potentially hazardous situation which, if not avoided, could result in damage or the loss of
data.
Equipment Operation
Use of this instrument in a manner not specied by Land Instruments International may be hazardous.
Read and understand the user documentation supplied before installing and operating the equipment.
Protective Clothing, Face and Eye Protection
It is possible that this equipment is to be installed on, or near to, machinery or equipment operating at
high temperatures and high pressures. Suitable protective clothing, along with face and eye protection
must be worn. Refer to the health and safety guidelines for the machinery/equipment before installing
this product. If in doubt, contact Land Instruments International.
Electrical Power Supply
Before working on the electrical connections, all of the electrical power lines to the equipment must
be isolated. All the electrical cables and signal cables must be connected exactly as indicated in these
operating instructions. If in doubt, contact Land Instruments International.
Storage
The instrument should be stored in its packaging, in a dry sheltered area.
Unpacking
Check all packages for external signs of damage. Check the contents against the packing note.
Lifting Instructions
Where items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the
Technical Specication for weights. All lifting should be done as stated in local regulations.
IMPORTANT INFORMATION - PLEASE READ
Contact Us
UK - Droneld
Land Instruments International
Tel: [phone]
Email: [email protected].uk
[email protected]
Web: www.landinst.com
USA - Pittsburgh
AMETEK Land, Inc.
Tel: [phone]
Email: [email protected]
[email protected]
Web: www.ametek-land.com
For further details on all LAND/Ametek ofces, distributors and representatives, please visit
our websites.
Return of Damaged Goods
IMPORTANT If any item has been damaged in transit, this should be reported to the carrier and to the
supplier immediately. Damage caused in transit is the responsibility of the carrier not the supplier.
DO NOT RETURN a damaged instrument to the sender as the carrier will not then consider a claim. Save
the packing with the damaged article for inspection by the carrier.
Return of Goods for Repair
If you need to return goods for repair please contact our Customer Service Department. They will be
able to advise you on the correct returns procedure.
Any item returned to Land Instruments International should be adequately packaged to prevent damage
during transit.
You must include a written report of the problem together with your own name and contact information,
address, telephone number, email address etc.
Design and Manufacturing Standards
The Quality Management System of Land Instruments International is approved to BS EN ISO 9001 for
the design, manufacture and on-site servicing of combustion, environmental monitoring and non-contact
temperature measuring instrumentation.
Approvals apply in the USA
This instrument complies with current European directives relating to Electromagnetic
Compatibility 89/336/EEC and Low Voltage Directive 73/23/EEC.
The Quality Management System of Ametek Motors (Shanghai) Co. Limited is approved to
ISO9001:2008 for the Design and Manufacturing of Motors and the Manufacturing of Gas
Analysers.
Operation of radio transmitters, telephones or other electrical/electronic devices in close
proximity to the equipment while the enclosure doors of the instrument or its peripherals
are open, may cause interference and possible failure where the radiated emissions exceed
the EMC directive.
The protection provided by both CE and IP classications to this product may be invalidated if alterations
or additions are made to the structural, electrical, mechanical or pneumatic parts of this system. Such
changes may also invalidate the standard terms of warranty.
Copyright
This manual is provided as an aid to owners of Land Instruments International’s products and contains
information proprietary to Land Instruments International. This manual may not, in whole or part, be
copied, or reproduced without the expressed written consent of Land Instruments International Ltd.
Copyright © 2013 Land Instruments International.

Contents
1 System Components 6
1.1 Component Descriptions 1
2 Thermal Imaging System - Installation Overview 4
2.1 Ambient air temperature and cooling water temperature limits 4
3 Electrical Connections 5
4 Connection of Cooling Water and Purge Air 11
4.1 Cooling Water Connections 12
4.2 Purge Air Inlet 13
5 Installing the Protective Enclosure in the Standpipe 14
6 Principle of Operation 24
7 Specications 25
7.1 Nomenclature 25
7.2 Optical Performance 26
7.3 Imager Performance 26
8 Spares & Accessories 27
9 Cleaning 28
9.1 External surfaces 28
9.2 Lens 28

NIR Borescope
Thermal Imaging System
Installation Guide
1 System Components
2
1
3
4
5
6
9
8
10
11
13
7
12
7a

Page 1
Installation Guide NIR Borescope
Thermal Imaging System
1.1 Component Descriptions
Item Description Notes
1Mains Power Cable
Customer-supplied
Length: As required
Minimum bend radius: Refer to manufacturer’s
datasheet
Recommendedmountingmethod:Cablexings/
conduit
IP Rating: Refer to manufacturer’s datasheet
Ambient temperature limits: Refer to manufactur-
er’s datasheet
Services in: 110V - 240V ac mains
Connects to: TRACO Power Supply Unit
2
2
TRACO Power Supply Unit
Part Nº 805753
Dimensions: 174 x 93 x 56 mm (6.5 x 3.6 x 2.2 in)
Weight: 1.15 kg (2.5 lbs)
Recommended mounting method: 4 x mounting
holes Ø4.6mm (0.18in)
IP Rating: IP65
Ambient temperature limits: -40 to 85°C (-40 to
185°F)
Services in: Mains power in
Services out: 24V to Terminal Box
Connects to: Terminal Box
4
via 24V Power
Cable
3
324V Power Cable
Part Nº 807610
Length: 5 m (16 ft)
Minimum bend radius: 50 mm (2 in)
Recommendedmountingmethod:Cablexings/
conduit
IP Rating: IP65
Ambient temperature limits: -20 to 50°C (-4 to
122°F)
Connects: TRACO Power Supply Unit
2
and
Terminal Box
4
4
Terminal/Ethernet Box
Part Nº 807744
Dimensions: 230 x 200 x 115 (9.1 x 7.9 x 4.5 in)
Weight: 0.76 kg (1.7 lbs)
Recommended mounting method: 4 x mounting
holes Ø6.3mm (0.25in)
IP Rating: IP65
Ambient temperature limits: -20 to 50°C (-4 to
122°F)
Services out (Optional): Thermocouple 4-20mA,
Warning Alarm, Over-temperature alarm 7a
Connects to: Borescope Thermal Imager
8
via
8-Way Cable
5
and CAT6 Ethernet Cable
6
, and
Personal Computer 13 via RJ45 Ethernet Cable
7

Page 2
NIR Borescope
Thermal Imaging System
Installation Guide
Item Description Notes
5
8-way Cable (20m)
Part Nº 803971
Length:20m/66ft
Minimum bend radius: 50mm (2 in)
Recommendedmountingmethod:Cablexings/
Conduit (Insulate as necessary)
IP Rating: IP65
Connects: Terminal Box
4
and Borescope
Thermal Imager
8
6
Ethernet Cable CAT6 8-Way
(M12)
Part Nº 807686
Length:20m/66ft
Minimum bend radius: 50mm (2 in)
Recommendedmountingmethod:Cablexings/
Conduit (Insulate as necessary)
Connects: Borescope Thermal Imager
8
and
Terminal Box
4
7
Ethernet Cable CAT6 RJ45
Customer-supplied
Length: As required
Minimum bend radius: 50mm (2 in)
Recommendedmountingmethod:Cablexings/
Conduit
Connects: Terminal Box
4
and PC 13
7a Optional Outputs Thermocouple 4-20mA, Warning Alarm, Over-tem-
perature alarm
8
NIR Borescope Thermal
Imager
Part Nº 806612 (12 in Probe)
Part Nº 806610 (24 in Probe)
Part Nº 806611 (36 in Probe)
Recommended mounting method: Protective Enclo-
sure
Services in: 8-way Cable, Ethernet Cable
Connects to: Terminal Box
4
via 8-way Cable
5
and Ethernet Cable
6
9
Protective Enclosure, Air
Purge & Water-Cooled Tube
Dimensions: See Fig. A1-740-074 (Sheet 6 of 9)
Recommended mounting method: Fitted to Stand-
pipe
12
via Standpipe Flange
11
IP Rating: IP65
Ambient temperature limits:
Services in: Cooling water in, Purge air in
Services out: Cooling water out
Connects to: Back-cap 10 and Standpipe
12
via
Standpipe Flange
11
10 Back Cap
Part Nº 805947
Dimensions: See Fig. A1-740-074 (Sheet 6 of 9)
Weight:
Recommended mounting method: Attach to Pro-
tective Enclosure
9
via locking fasteners
IP Rating: IP65
Services in: 8-way cable
5
, Ethernet Cable
6
Connects to: Protective Enclosure
9

Page 3
Installation Guide NIR Borescope
Thermal Imaging System
Item Description Notes
11
Standpipe Flange
Part Nº - See Notes
Dimensions: See Fig. A1-740-074 (Sheet 6 of 9)
Recommended mounting method: Attach to
Protective enclosure and standpipe using supplied
ttings
Connects: Protective Enclosure
9
to Standpipe
12
Part N° 806920: 3in ANSI Flange & Gasket
Part N° 807405: PN16 DN80 Flange & Gasket
12
Standpipe
Part Nº - See Notes
Dimensions: See Fig. A1-740-074 (Sheet 6 of 9)
Recommended mounting method: Weld to furnace
wall
Connects to: Standpipe Flange
11
Part N° 806828: 12 in Standpipe, Stainless Steel
with 3 in ANSI Flange
Part N° 806923: 12 in Standpipe, Stainless Steel
withPN60DN80/90JIS10Flange
13
Personal Computer LAND Process Imaging Workstation 2
Processor: One Intel Xeon 2.5Ghz
or Greater
Memory: 4GB or Greater
First Hard Drive: 1TB or Greater
Second Hard Drive: 1TB or Greater
Hard drive controller: C1 All SATA Hard Drives,
NON-RAID for 2 Hard
Drives
OpticalDrive:  16xDVD+/-RW
Graphics Card: 256MB or Greater
Network:   Additional10/100/1000 
Ethernet Card
Display: 22” Monitor or Greater
Software: English Windows 7
Ultimate (32Bit)

Page 4
NIR Borescope
Thermal Imaging System
Installation Guide
2 Thermal Imaging System - Installation Overview
The NIR Borescope Thermal Imaging System comprises a thermal imaging borescope
camera which is designed to be installed inside a protective enclosure.
The enclosure has air purging and water cooling facilities. This protective enclosure is
designed to be installed in a furnace via a standpipe assembly.
The installation procedure can be broken down into the following steps:
• Electrical connections to the NIR Camera;
• Installing the camera in the protective enclosure;
• Connectingthecoolingwaterandpurgeairtotheprotectiveenclosure/standpipe
assembly;
• Installing the protective enclosure in the standpipe;
• Installation of the LIPS NIR-B Software.
2.1 Ambient air temperature and cooling water temperature limits
Fig. 2-1 (below) shows the maximum recommended water temperature for a range
of ambient air temperatures. Make sure that the water temperature does not exceed
the value shown in the graph e.g. For an ambient air temperature of 110°C, the water
temperature must not exceed 25°C.
Alternatively, if you know the temperature of the water, make sure that the air
temperature does not exceed that shown in the graph e.g. If your water temperature is
95°F, make sure that the probe is not used in an ambient air temperature above 158°F.
20
30
40
50
60
70
80
90
100
110
120
20 25 30 35 40 45 50
Water Temperature (°C)
Water Temperature (°F)
Air Temperature (°C)
Air Temperature (°F)
68 77 86 95 104 113 122
68
86
104
122
140
158
176
194
212
220
238
Fig. 2-1

Page 5
Installation Guide NIR Borescope
Thermal Imaging System
3 Electrical Connections
The basic system electrical connections are as follows:
• Mains input to the TRACO Power Supply Unit;
• 24VoutputfromTRACOPowerSupplyUnittoTerminal/EthernetBox;
• 8-Way cable from Terminal Box to NIR Camera;
• EthernetCablefromNIRCameratoTerminal/EthernetBox
• RJ45EthernetCablefromTerminal/EthernetBoxtoPersonalComputerrunningthe
LIPS NIR-B Software.
The TRACO Power Supply Unit is supplied with a 3-pin
AC input connector (Fig. 3-1) and a 7-Pin DC output
connector. You will need to disassemble each connec-
tor to install the required cables.
1) Unscrew the cover from the mains Input on the
Power Supply Unit.
Fig. 3-1
Fig. 3-2
Fig. 3-3
2) The easiest way to disassemble the 3-pin AC
inputconnectoristorstscrewtheconnector
assembly onto the input socket (Fig. 3-2).
3) Grip the rear section of the input connector and
unscrew it from the Power Supply Unit (Fig. 3-3).
Connecting the mains input to the TRACO Power Supply Unit

Page 6
NIR Borescope
Thermal Imaging System
Installation Guide
Fig. 3-4
Fig. 3-6
The connection terminals inside the input connector
will now be revealed (Fig. 3-4).
4) Unscrew the connector front section from
the Power Supply Unit and disassemble the
remaining parts of the connector.
5) Slide the rear locking ring, gasket and shell
body over the mains input cable.
6) Strip back the mains cable wires to the
appropriate lengths and connect them to the
Input connector terminals (Fig. 3-5) as per
the wiring schedule below:
Pin 1 = Live
Pin 2 = Neutral
Pin3=N/C
E = Earth
7) The mains input cable connector is now ready
for re-assembly and connection to the Power
Supply Unit (Fig. 3-6). Re-assemble the mains
input connector.
Fig. 3-5
Fig. 3-7
8) Attach the mains cable to the Input connector
of the Power Supply Unit (Fig. 3-7).

Page 7
Installation Guide NIR Borescope
Thermal Imaging System
10) Open the lid of the Terminal Box to reveal the
connection terminals on the DIN Rail.
11) Strip back the wires of the free end of the 24V
DC Output cable to the appropriate lengths
and feed them through left-hand cable entry
gland on the Terminal Box (Fig. 3-9).
12) Connect the 24V cable wires to the terminal
block as per the wiring schedule below:
Pin 1 = Screen
Pin 2 = +24V (White)
Pin 3 = 0V (Black)
9) Attach the 24V DC output cable to the Output
connector of the Power Supply Unit (Fig. 3-8).
Fig. 3-8
Connecting the 24V output from the TRACO PSU to the Terminal Box
Fig. 3-9
Connecting the customer-supplied (RJ45) Ethernet Cable to the Terminal Box
Fig. 3-10
13) Unscrew the Cable Gland from the terminal
box and remove the Cable Seal Washer and
rubber Conduit Cable Seal from the cable
gland port.
14) Thread the Ethernet Cable through the Conduit
Gland and the Cable Seal Washer.
15) The rubber Conduit Cable Seal is split
lengthways and is designed to clamp
around the cable. Fit the Seal so that it
is approximately 120mm (4.7in) from the
Ethernet connector (Fig. 3-10).
16) Pass the Ethernet connector through the
cableportontheterminalboxandtitinthe
Ethernet socket on the DIN rail.
17) Push the Conduit Cable Seal into the cable
port.RettheCableSealWasherandtighten
the Cable Gland to secure the Ethernet Cable
(Fig. 3-11).
Note
The additional cable glands in the Terminal
box can be used to provide connection to the
thermocouple outputs (4 to 20mA linearaised
0 to 200°C, Warning Alarm, High Alarm). It
is recommended that you make use of these
outputs. Refer to the ‘Customer Electrical
Connections’ drawing.
Fig. 3-11

Page 8
NIR Borescope
Thermal Imaging System
Installation Guide
Fig. 3-14
18) Connect one end of the 8-way cable to the
connector on the terminal box. Note: Align the
red marker on the pre-wired plug with the red
marker above the keyway in the socket on the
terminal box and push in the cable (Fig. 3-12).
Connecting the cables from Terminal Box to NIR Camera
Fig. 3-15
21) Unscrew the M25 Conduit Gland and remove
the Cable Seal Washer and rubber Conduit
Cable Seal from the cable gland port (Fig.
3-15).
20) The NIR camera is designed to be installed
inside a protective housing. In order to attach
the cables to the Camera, each cable must
rstbefedthroughtheoneofthecablegland
ports on the rear of the protective back-cap
(Fig. 3-14).
Fig. 3-12
Fig. 3-13
19) Connect one end of the 8-way CAT6 Ethernet
cable to the connector on the terminal box
(Fig. 3-13).

Page 9
Installation Guide NIR Borescope
Thermal Imaging System
Fig. 3-16
22) Slide the M25 Conduit Gland and the Cable
Seal Washer over the free end of the 8-way
cable.
23) The rubber Conduit Cable Seal is split
lengthways and is designed to clamp
around the cable. Fit the Seal so that it is
approximately 150mm (6in) from the 8-way
connector (Fig. 3-16).
Fig. 3-17
24) Insert the 8-way cable into the gland port so
thattheConduitCableSealisttedsnuglyin
the gland port (Fig. 3-17).
Fig. 3-18
25) RettheCableSealWasherandtightenthe
M25 Conduit Gland to secure the 8-way cable.
24) TheEthernetCablemustalsobettedinthe
Back-cap at this stage.
Repeat the cable installation process (as
described in steps 21 to 24) and insert the
Ethernet cable in the other cable gland port.
(Fig. 3-19 & Fig. 3-20).
Fig. 3-19

Page 10
NIR Borescope
Thermal Imaging System
Installation Guide
Connecting the Cables from the Terminal Box to the Camera
Fig. 3-21
This procedure will complete the installation of the
Camera in the protective enclosure.
26) Connections to and from the camera are made
viathe2cablesttedinsidetheBack-cap(Fig.
3-21).
27) The cable connections are on the rear of the
NIR camera. Connect the Ethernet cable to
the M12 connector, and the 8-way power cable
to the 8-way socket (Fig. 3-22).
Fig. 3-23
28) Attach the back cap to the thermometer jacket
and secure it via the locking clips on the top
and bottom of the Back-cap.
The Borescope Camera is now ready for
connection of the water cooling and air purging
services.
Fig. 3-20
25) Onceagain,ensurethatthesealisttedthat
it is approximately 150mm (6in) from the
Ethernet connector (Fig. 3-20).
 TheBack-capisnowreadytobettedtothe
protective housing.
Fig. 3-22

Page 11
Installation Guide NIR Borescope
Thermal Imaging System
4 Connection of Cooling Water and Purge Air
Warning
Refer to Installation Drawings Sheets 4 and 5 for details of Pressure Relief Valves.
Ensure that the water inlet is always below the water outlet during operation.
Ensure that the cooling water supply is connected and operating before inserting
the Borescope Thermal Imaging camera into a furnace.
Ensurethattheowofwaterthroughthecoolingtubesismaintainedatall
times.
Iftheowofcoolingwaterorpurgeairstops,removetheNIRandwater-cooled
protective housing from the process immediately. The LIPS NIR-B software will
display a high temperature warning (measured by the integral thermocouple in
the probe) if there is a problem with the cooling of the probe.
Fig. 4-1 below shows a graph of the maximum recommended cooling water temperature
versus the ambient air temperature.
20
30
40
50
60
70
80
90
100
110
120
20 25 30 35 40 45 50
Water Temperature (°C)
Water Temperature (°F)
Air Temperature (°C)
Air Temperature (°F)
68 77 86 95 104 113 122
68
86
104
122
140
158
176
194
212
220
238
Fig. 4-1

Page 12
NIR Borescope
Thermal Imaging System
Installation Guide
Fig. 4-3
The cooling water connections to the protective enclosure
aremadeviathe1/2inNPTfemaleconnectorsonthe
protective housing (Fig. 4-3).
Youwillneedtwo1/2inNPTmalestainlesssteelttings
(not supplied) to connect to the Water in and Water out
connectors.
Water Supply Requirements
• Water pH level must be within 5-8pH
• Max Water Pressure = 3 bar
• Max Water Temperature at inlet : 40°C (104°F)
Suggested Flow Rates:
•20l/minforapplicationsupto1800°C(3272°F)
•10l/minforapplicationsupto1200°C(2192°F)
•4.5l/minforapplicationsupto600°C(1112°F)
4.1 Cooling Water Connections
Water cooling is not only required by the lens system but also by the housing which
encloses the camera electronics.
Land supply a single feed system (Fig. 4-2) where the cooling water for the electronics
housing is ‘tapped off’ from the water out from the lens cooling
Fig. 4-2

Page 13
Installation Guide NIR Borescope
Thermal Imaging System
4.2 Purge Air Inlet
Fig. 4-4
Thepurgeairinletisviaa1/2inchNPTttingontheside
of the protective enclosure (Fig. 4-4).
Air Supply Requirements
•Clean,lteredandregulatedinstrumentair
• Max Air Temperature at inlet : 40°C (104°F)
Suggested Flow Rates:
•450l/minforapplicationsupto1800°C(3272°F)
•250l/minforapplicationsupto1200°C(2192°F)
•50l/minforapplicationsupto600°C(1112°F)

Page 14
NIR Borescope
Thermal Imaging System
Installation Guide
5 Installing the Protective Enclosure in the Standpipe
Refer to the Installation Drawings in this section for details of installing the Borescope
Protective Housing into a furnace via the Standpipe.
Warning
Ensure that the cooling water supply is connected and operating before inserting
the Borescope Thermal Imaging camera into a furnace.
Ensurethattheowofwaterthroughthecoolingtubesismaintainedatall
times.
Iftheowofcoolingwaterorpurgeairstops,removetheNIRandwater-cooled
protective housing from the process immediately.