NBN Fluke CS400 User manual

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

Warranty
The manufacturer warrants this instrument to be free from defects in material and workmanship under normal use
and service for the period of four years from date of purchase. This warranty extends only to the original purchaser.
This warranty shall not apply tofuses, batteries or any product which has been subject to misuse, neglect, accident,
or abnormal conditions of operation.
In the event of failure of a product covered by this warranty, the manufacturer will repair the instrument when it is
returned by the purchaser, freight prepaid, to an authorized Service Facility within the applicable warranty period,

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 the
manufacturer, 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. The manufacturer shall
not be liable for any special, incidental or consequential 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. This software may not work in combination with modified or emulated versions of Windows
operating environments, memory-resident software, or on computers with inadequate memory. The manufacturer
warrants that the program disk is free from defects in material and workmanship, assuming normal use, for a period
of one year. Except for this warranty, the manufacturer makes no warranty or representation, either expressed or
implied, with respect to this software or documentation, including its quality, performance, merchantability, or

(i.e., the User) assumes the entire risk as to its quality and performance. The liability of the manufacturer under
this warranty shall be limited to the amount paid by the User. In no event shall the manufacturer be liable for any
costs including but not limited to those incurred as a result of lost profits or revenue, loss of use of the computer
software, loss of data, the cost of substitute software, claims by third parties, or for other similar costs. The
d documentation are copyrighted with all rights reserved. It is illegal to make copies for
another person.
Every change of the standard system design must be acknowledged from the manufacturer; otherwise,
the warranty of the complete system will be lost!
This manual is available in different languages. In case of differences between the language versions, the
English manual is binding.

Table of Contents
Chapter Page
WARRANTY.............................................................................................................................................................. 2
TABLE OF CONTENTS................................................................................................................................................ 3
LIST OF TABLES ....................................................................................................................................................... 6
LIST OF FIGURES ...................................................................................................................................................... 7
COMPLIANCE STATEMENT ......................................................................................................................................... 8
SAFETY INFORMATION............................................................................................................................................... 9
CONTACTS............................................................................................................................................................. 12
1DESCRIPTION....................................................................................................................................................... 13
2TECHNICAL DATA................................................................................................................................................. 14
2.1 Measurement Specification.............................................................................................................................................................................14
2.2 Optical Specifications......................................................................................................................................................................................14
2.3 Electrical Specifications ..................................................................................................................................................................................14
2.4 Environmental Specifications..........................................................................................................................................................................14
2.5 Weights and Dimensions ................................................................................................................................................................................15
2.6 Scope of Delivery............................................................................................................................................................................................16
3PRE-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
4INSTALLATION...................................................................................................................................................... 21
4.1 Mounting..........................................................................................................................................................................................................21
4.2 System Connection Box..................................................................................................................................................................................23
4.2.1 Cable Entry System ...............................................................................................................................................................................25
4.3 Fiber Optic / RJ45 Ethernet Converter............................................................................................................................................................26
4.4 Position Indicator.............................................................................................................................................................................................26
4.5 Fiber Optic Converter Box...............................................................................................................................................................................27
5OPTIONS ............................................................................................................................................................. 29
5.1 Start-up-Service ..............................................................................................................................................................................................29
6ACCESSORIES ..................................................................................................................................................... 30
6.1 Serial RS485 / RJ45 Ethernet Converter (A-CS-CONV-ETH485) .................................................................................................................31
6.1.1 Technical Data.......................................................................................................................................................................................31
6.1.2 LED Indicators .......................................................................................................................................................................................32

6.1.3 Driver Installation................................................................................................................................................................................... 32
6.2 I/O Modules..................................................................................................................................................................................................... 36
6.3 Tire Slip Monitoring TSM (A-CS-TSM-KIT-485).......................................................................................................................................... 37
6.3.1 Delivery.................................................................................................................................................................................................. 37
6.3.2 Functionality........................................................................................................................................................................................... 37
6.3.3 TSM Remote Control............................................................................................................................................................................. 37
6.3.4 Position Indicator................................................................................................................................................................................... 38
6.3.5 Installation.............................................................................................................................................................................................. 39
6.3.6 Wiring..................................................................................................................................................................................................... 40
6.4 Shadow Monitoring (A-CS-SM-KIT-485)........................................................................................................................................................ 41
6.4.1 Technical Data....................................................................................................................................................................................... 41
6.4.2 Delivery.................................................................................................................................................................................................. 41
6.4.3 Mounting................................................................................................................................................................................................ 41
6.4.4 Wiring..................................................................................................................................................................................................... 42
6.5 Burning Zone Monitoring (A-CS-BZ-EN-KIT-485).......................................................................................................................................... 43
6.5.1 Technical Data....................................................................................................................................................................................... 43
6.5.2 Delivery.................................................................................................................................................................................................. 43
6.5.3 Installation.............................................................................................................................................................................................. 44
6.5.4 Wiring..................................................................................................................................................................................................... 44
6.6 Internal Heater (A-CS-CAB-HEAT) ................................................................................................................................................................ 45
6.6.1 Technical Data....................................................................................................................................................................................... 45
7MAINTENANCE......................................................................................................................................................46
7.1 Troubleshooting.............................................................................................................................................................................................. 46
8DRAWINGS...........................................................................................................................................................47
8.1 System Installation without Accessories ..................................................................................................................................................... 47
8.2 System Installation with Accessories .......................................................................................................................................................... 48
8.3 System Installation Multiple Scanners......................................................................................................................................................... 49
8.4 System Connection Box Wiring................................................................................................................................................................... 50
8.5 Fiber Optic Converter Box Wiring................................................................................................................................................................ 52
8.6 Position Indicator Wiring.............................................................................................................................................................................. 53
8.7 TSM Wiring.................................................................................................................................................................................................. 54
8.7.1 Terminal W8 Wiring............................................................................................................................................................................ 55
8.7.2 Terminal W9 Wiring............................................................................................................................................................................ 56
8.7.3 Internal Wiring for the Position Indicators 4, 5, 6 .................................................................................................................................. 56
8.8 Shadow Monitoring Wiring........................................................................................................................................................................... 57
8.9 Burning Zone Wiring.................................................................................................................................................................................... 58
9APPENDIX –TECHNICAL DATA ...............................................................................................................................59
9.1 Protective Housing (A-MP-ENC) .................................................................................................................................................................... 59
9.1.1 Technical Data....................................................................................................................................................................................... 59
9.1.2 Scope of Delivery .................................................................................................................................................................................. 60
9.2 Connection Box............................................................................................................................................................................................... 61

9.2.1 Technical Data.......................................................................................................................................................................................61
9.3 Fiber Optic / RJ45 Ethernet Converter............................................................................................................................................................62
9.3.1 Technical Data.......................................................................................................................................................................................62
9.4 Connection Box for Accessories.....................................................................................................................................................................63
9.4.1 Technical Data.......................................................................................................................................................................................63
9.4.2 Delivery ..................................................................................................................................................................................................64
9.5 Position Indicator (A-CS-SYSECPI)................................................................................................................................................................65
9.5.1 Technical Data.......................................................................................................................................................................................65

List of Tables
Table Page
Table 3-1: Required Cables........................................................................................................................................................................................ 19
Table 6-1: LED Indicators ........................................................................................................................................................................................... 32
Table 7-1: Troubleshooting......................................................................................................................................................................................... 46
Table 8-1: W1 Power Supply 24 V, 3-pin ................................................................................................................................................................ 51
Table 8-2: W3 Alarm, Trigger, 6-pin ........................................................................................................................................................................ 51
Table 8-3: W8 Complete Terminal Wiring for all Position Indicators....................................................................................................................... 55

List of Figures
Figure Page
Figure 1-1: Linescanner...............................................................................................................................................................................................13
Figure 3-1: Distance D and Kiln Length L ...................................................................................................................................................................17
Figure 3-2: Scanner Alignment....................................................................................................................................................................................18
Figure 3-3: Welding the Trigger Bar on the Kiln..........................................................................................................................................................18
Figure 4-1: 3-Axis Mounting Bracket for Protective Housing......................................................................................................................................21
Figure 4-2: Protective Housing with Protective Channel ............................................................................................................................................22
Figure 4-3: Cable Installation ......................................................................................................................................................................................23
Figure 4-4: Opened System Connection Box .............................................................................................................................................................24
Figure 4-5: Connection to the Internal Alarm Relay of the Scanner...........................................................................................................................24
Figure 4-6: Position Indicator ......................................................................................................................................................................................26
Figure 4-7: Mounting the Position Indicator ................................................................................................................................................................27
Figure 4-8: Fiber Optic Converter Box ........................................................................................................................................................................28
Figure 6-1: TSM Remote Control Box.........................................................................................................................................................................38
Figure 6-2: Position Indicator ......................................................................................................................................................................................38
Figure 6-3: Position Indicator and Trigger Bar ............................................................................................................................................................38
Figure 6-4: Mounting the Position Indicator ................................................................................................................................................................39
Figure 6-5: Trigger Bar details ...............................................................................................................................................................................39
Figure 6-6: Wiring of TSM ...........................................................................................................................................................................................40
Figure 6-7: Recommended Alignment of Shadow 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 without Accessories................................................................................................................................................47
Figure 8-2: System Installation with Accessories.....................................................................................................................................................48
Figure 8-3: System Installation Multiple Scanners...................................................................................................................................................49
Figure 8-4: System Connection Box Wiring.............................................................................................................................................................50
Figure 8-5: Fiber Optic Converter Box Wiring..........................................................................................................................................................52
Figure 8-6: Position Indicator Wiring........................................................................................................................................................................53
Figure 8-7: Wiring Scheme for TSM Remote Control Box..........................................................................................................................................54
Figure 8-8: Terminal Wiring for the Position Indicator (Kiln Trigger) ..........................................................................................................................55
Figure 8-9: Terminal Wiring for the Position Indicator (Ring 1)...................................................................................................................................55
Figure 8-10: Wiring of W9 between TSM Remote Control Box and System Connection Box ...................................................................................56
Figure 8-11: Wiring for the Position Indicators 4, 5, 6.................................................................................................................................................56
Figure 8-12: Shadow Monitoring Wiring...................................................................................................................................................................57
Figure 8-13: Burning Zone Wiring............................................................................................................................................................................58
Figure 9-1: Protective Housing....................................................................................................................................................................................59
Figure 9-2: Connection Box.........................................................................................................................................................................................61
Figure 9-3: Connection Box for Accessories...............................................................................................................................................................63
Figure 9-4: Dimensions of Position Indicator and Junction Box .................................................................................................................................65

Compliance Statement
The device complies with the requirements of the European Directives:
EC Directive 2014/30/EU EMC
EC Directive 2014/35/EU low voltage
EC Directive 2011/65/EU RoHS Compliance
amended by Directive (EU) 2015/863 (RoHS III)
EN 61326-1: 2013 Electrical measurement, control, and laboratory devices -
Electromagnetic susceptibility (EMC)
EN 61558-1: 2006 Safety Requirements for power transformers, power supplies, reactors, and similar
products (low voltage)
EN 61558-2-6: 2010 Safety Requirements for power transformers, power supplies, reactors, and similar
products for use up to 1.1 kV (low voltage)
EN 50581: 2012 Technical documentation for the evaluation of electrical products with respect to
restriction of hazardous substances (RoHS)

Safety Information
This document contains important information, which should be kept at all times with the instrument during its
operational life. Other users of this instrument should be given these instructions with the instrument. Eventual
updates to this information must be added to the original document. The instrument can only be operated by trained
personnel in accordance with these instructions and local safety regulations.
Acceptable Operation
This instrument 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 temperatures, as
long as the documented technical specifications for all instrument components 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 operation safety and functionality of the instrument.

Safety Symbol
Description
Read all safety information before in the handbook
Hazardous voltage. Risk of electrical shock.
Warning. Risk of danger. Important information. See manual.
Laser warning
Earth (ground) terminal
Protective conductor terminal
Switch or relay contact
DC power supply
Conforms to European Union directive.
Disposal of old instruments should be handled according to professional and
environmental regulations as electronic waste.
International Ingress Protection Marking
IP65