RayTek CS210 User manual

CS210
Kiln Shell Temperature
Monitoring System
Rev. B4 Feb 2015
58401

CONTACTS
Raytek Corporation
Worldwide Headquarters
Santa Cruz, CA USA
Tel: [phone] – 8074 (USA and Canada only)
+1 831 458 – 3900
Fax: [phone] – 1239
solutio[email protected]m
European Headquarters
Berlin, Germany
Tel: [phone]
[e-mail]
France
[e-mail]
United Kingdom
[e-mail]
Fluke Service Center
Beijing, China
Tel: [phone]
[email protected]
Internet: http://www.raytek.com/
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© Raytek Corporation.
Raytek and the Raytek Logo are registered trademarks of Raytek Corporation.
All rights reserved.
Specifications subject to change without notice.

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.
Every change of the standard system design must be acknowledged from Raytek;
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
8 Rev. B4 Feb 2015 CS210
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
o to Fluke’s website for
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.
The instrument is equipped with a Class 2 laser. Class 2 lasers shine only within the
visible spectrum at an intensity of 1
mW. Looking directly into the laser beam can produce
a slight
, 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
encouraged when eye contact is made with the laser beam. Pay attention to possible
reflections of the laser beam. The laser functions only to locate and mark surface
measurement targets. Do not aim the laser at people or animals.
Incorrect use of 110 / 230 V electrical systems can result in electrical hazards and personal
injury.
All instrument parts supplied with electricity must be covered to prevent physical
contact and other hazards at all times.

Technical Data
CS210 Rev. B4 Feb 2015 9
2. Technical Data
2.1 Specifications
Linescanner
Type MP150HR linescanner
Temperature range: 100 to 650°C (212 to 1202°F)
Optical resolution (90% energy) 170 : 1 (IFOV = 5,9 mrad)1
Spot detection (50% energy) 510 : 1 (IFOV = 2,0 mrad)2
Spectral response: 3.5 to 4 µm
Scan angle (FOV): 90°
Accuracy: ± 0.5% of reading or ± 3°C (± 6°F) whichever is greater,
at 0 - 50°C (32 - 122°F) ambient temperature for the scanner
Repeatability: ± 1°C (± 2°F),
at 0 - 50°C (32 - 122°F) ambient temperature for the scanner
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
(for synchronized measurement)
Packaging: CS211: about 40 kg (88 lb)
CS212: about 80 kg (176 lb)
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
1at 20 Hz scan speed
2at 20 Hz scan speed

Technical Data
10 Rev. B4 Feb 2015 CS210
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)