Operating Instructions - Instrumentation Systems & Services Ltd.
Contents
1. Vortex Cooler 1090 C 2000 F External Water Cooled Shield External Insulating Shield ambient rating of the linescanner which is 50 C 122 F In all cases the internal temperature of the enclosure must be below the maximum Vortex Cooler Air Filter for Vortex Cooler Oil Filter for Vortex Cooler Conduit 3 2 Pressure Integrated Shutter Scanner Air Purge Internal Cold Plates External Water Cooled Shield Vortex Cooler High Temperature Enclosure 93 200 F 49 C 120 F 49 C 120 F 600 C 1112 F 1 5 to 10 bar 22 to 145 PSI 1 5 to 3 bar 22 to 43 5 PSI 8 6 bar 125 PSI max 8 bar 116 PSI 5 5 to 6 9 bar 80 to 100 PSI Technical Data 3 3 Water Flow Internal Cold Plates External Water Cooled Shield 3 4 Air Flow Scanner Air Purge Vortex Cooler 3 5 Material Enclosure Conduit Internal Cold Plates External Water Cooled Shield External Insulating Shield Vortex Cooler 3 6 Weight Linescanner with air purge Enclosure without linescanner Internal Cold Plates Vortex Cooler External Water Cooled Shield min 1 l min 0 26 gal min min 7 6 l min 2 gal min 100 to 200 l min 25 and 50 gal min 1132 l min 300 gal min for heat dissipation of 820 W 706 kcal h 2800 Btu hr stainless steel 1 4301 AISI 304 and refractory lining base plate Aluminum AL 6061 T6 or equivalent coating HART COAT stainless steel hose 1 4404 AI2. 22 ENCLOSURE WITI VORTEX COOL Rzesza Ad A i a _______ 7 3 ENCLOSURE FULLY DEVELOPED Safety Instructions 1 Safety Instructions This document is part of the operating instructions for the Raytek MP150 linescanner All tips and notices regarding acceptable operation and safety must be read in addition to the technical 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 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 as accessory for the Raytek infrared linescanner 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 other purposes 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 Disposal of old instruments should be handled according to
3. 8 parallel thread RS of the air purge 2x taking care to insert the stainless steel gasket for 1 8 in in between 3 Insert tubing with pre swaged ferrules into the fitting body until the ferrule seats rotate the nut by hand to the pulled up position tighten 74 revolution with a wrench Note the orientation of the Air hose assembly the T fitting will be in front of you High Temperature Enclosure 11 Installation Stem sleeve To Couple Align stem with body Push stem into body until it clicks Stem Body sleeve To Uncouple Pull body sleeve toward stem 12 4 The Air supply hose can be connected to the Instrumentation Quick Connect at the enclosure wall High Temperature Enclosure Options 5 Options Options are items that are factory installed and must be specified at time of order The following are available e Internal Cold Plates XXXSYSENCICP 5 1 Internal Cold Plates A compact and cost effective solution where cooling needs are low to moderate the Internal Cold Plates are aluminum plates with stainless steel tubing through which the cooling water flows To provide optimum protection the Internal Cold Plates are mounted directly adjacent to the scanner Upon shipment the water connections are all in place and connection to plant cooling water is made outside the enclosure By this design if a leak occurs the water will not enter the process through the viewing windo
4. Base Plate 4 5 2 Enclosure with External Shields If either the External Insulating Shield or the External Water Cooled Shield is installed there will be a total of eight through holes which can be used to mount the assembly In this case the height of the assembly will increase by 32 mm 1 26 in if one shield is used or 64 mm 2 52 in if both are used Take care to use fasteners with sufficient thread length to accommodate this assembly For further details see Figure 9 Dimensions for the External Water Cooled Shield on page 16 4 6 Mounting the Cable Conduit The scanner will always require power and communication cable connections and in some circumstances an additional cable for alarm trigger functions is also connected It is strongly recommended to use high temperature cables for the scanner only The high temperature cables allow a maximum temperature of 180 C 356 F but need to be ordered separately 8 High Temperature Enclosure Installation It is recommended that the high temperature cables will be installed in the conduit The enclosure is equipped with a large opening 60 5 mm 2 38 in in diameter specifically for this purpose To further facilitate installation a 1 5 m 59 in stainless steel flexible conduit is supplied with the enclosure other lengths on request To assemble insert the conduit through the opening taking care to ensure that the washer and the nut is on the inside of the enclosure Washer and
5. assembly but without the linescanner installed can be exposed to the expected ambient conditions The external temperature needs to be measured at the surface Temperature can be also recorded inside the enclosure at a number of points 4 2 Water Cooling water will be required if either the Internal Cold Plates or the External Water Cooled Shield are installed Although the available cooling equipment is designed to tolerate typical plant cooling water cleanliness levels as much as is possible water should be clean and free from gross contaminants Where concern exists we recommend that a filter be installed and in all cases water condition should be monitored periodically 4 3 Air In general air lines should be as straight as possible to minimize potential for flow constriction and potential blockage Similarly flow restricting fittings such as quick disconnects should be avoided as much as possible We recommend an external self venting air valve to minimize pressure when uncoupling the linescanner Air is always required for both the integrated shutter actuator and the air purge for the scanner itself 4 4 Process Opening Before mounting the enclosure in an application an opening will need to be fabricated so that the scanner can have a clear view of the process If this opening is too large an excessive amount of heat will reach the enclosure and the cooling systems may not have sufficient capacity to remove this heat On the ot
6. for optimum heat resistance performance The scanner is firmly held in place with four thermally isolated locating columns to facilitate aiming The enclosure includes an opening for a 2 conduit opening 60 mm 2 36 in diameter which is the recommended means for conveying the power and communication cables to the enclosure An integrated shutter shields scanner from process to facilitate removal for service or calibration The shutter is actuated by an air cylinder The system is designed in the normally closed position so that in the event that air pressure is interrupted the shutter will close to protect the scanner The enclosure was designed with ergonomics in mind to facilitate installation cabling and maintenance No tools are required to remove the scanner and a handle is supplied to simplify removal of the scanner even when wearing heavy protective clothing 2 High Temperature Enclosure Technical Data 3 Technical Data 3 1 Ambient Temperature The ambient temperature specifies the maximum air temperature at the front plate shield of the enclosure Enclosure Standard 50 C 122 Enclosure Standard Scanner with Air Purging 80 C 176 F Enclosure Vortex Cooler External Insulating Shield 340 C 650 F Enclosure Vortex Cooler External Water Cooled Shield 590 C 1100 F Enclosure Vortex Cooler External Water Cooled Shield 760 C 1400 F External Insulating Shield Enclosure Internal Cold Plates
7. 0 20 15 194 63 5 2 500 V 000 21 8 705 000 12 069 22 SG VLS 2 91 GP 254 10 000 311 33 114 620 mm in 38 1 1 500 Water Inlet 1 Water Inlet 2 000 ve 9 609 000 8 02 001 61 VI 687 Water Outlet 1 Water Outlet 2 101 6 4 0001 406 4 16 000 Figure 9 Dimensions for the External Water Cooled Shield 16 High Temperature Enclosure Accessories 6 2 External Insulating Shield The Insulating Shield is a stainless steel envelope with a high performance refractory core The system is designed so that the Insulating Shield is placed closest to the high temperature process to prevent heat from reaching the enclosure This lessens the heat load upon the cooling elements such as the water plates and the vortex coolers The window opening is designed to prevent heat ingress while providing sufficient field of view 6 2 1 Dimensions 32 18 1 2611 tol LoT 63 5 2 500 266 7 10 500 90 B B 533 4 21 000 Figure 10 Dimensions for the External Insulating Shield High Temperature Enclosure 17 Accessories 6 3 Vortex Cooler The Vortex Cooler uses the density difference between hot and cold air to separate factory air into a high temperature stream and a low temperature stream which is then directed into the enclosure The Vortex Cooler is made from stainless steel and supplied with a maintenance unit particle
8. High Temperature Enclosure for the MP150 Linescanner Operating Instructions aiRaytek A Fluke Company Rev B 01 2010 58601 FAT Tel 01943 602001 WWW ISSLTD CO UK Fax 01943 816796 FB WARRANTY The manufacturer warrants this instrument to be free from defects in material and workmanship under normal use and service for the period of two years from date of purchase This warranty extends only to the original purchaser This warranty shall not apply to fuses 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 provided manufacturer s examination discloses to its satisfaction that the product was defective The manufacturer 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 WARRAN
9. Nut Securing Cable Conduit view insight box Flexible Conduit Stainless Steel Figure 5 Conduit Connection 4 7 Mounting the Scanner Handle For ease of insertion and removal of the scanner from the enclosure a mounting handle is provided Before installing the scanner into the enclosure attach the handle to the scanner with the four M3 x 20 fasteners provided Grounding point Handle M3 Fasteners Figure 6 Handle Assembly High Temperature Enclosure 9 Installation 4 8 Grounding the Scanner To ground the linescanner simply connect the yellow grounding cable to the M3 screw which fixes the blind caps on the back of the scanner grounding point To disconnect quickly the linescanner in the field pull out the quick connect pin at the grounding point 4 9 System Assembly After the opening has been prepared in the process and the mounting studs or bolts have been installed the enclosure and various cooling accessories should be assembled In cases where the External Insulating Plate is use this should always be located closest to the process The cooling concept is that it is better to prevent the heat from reaching the enclosure by using the insulating plate than it is to try to remove it with either air or water After mounting the External Insulating Shield and if ordered the External Water Shield the Enclosure and base plate can be lowered onto the studs and the asse
10. SI 316 L braiding 1 4301 AISI 304 Aluminum plates with stainless steel stainless steel 1 4301 AISI 304 stainless steel 1 4301 AISI 304 packed with refractory stainless steel type 316 7 kg 247 oz 21 kg 740 oz 1 5 kg 53 oz 2 3 kg 81 oz 12 4 kg 437 oz High Temperature Enclosure Technical Data External Insulating Shield 10 0 kg 352 oz 3 7 Scope of Delivery The enclosure package XXXSYSENC includes the following e Stainless steel enclosure with base plate and mounting aperture for high performance vortex cooler e Integrated fail safe shutter e 2 cable conduit 1 5 m long 59 in High Temperature Enclosure 5 Technical Data 3 8 Dimension J8HNUS 0 NI eqni do Jeuueog 0 eqni dO yojebems 18 009 X9110A noui perjddns si yno ddng pue ejqe Figure 3 Dimensions for Standard Enclosure 6 High Temperature Enclosure Installation 4 Installation 4 1 Ambient Temperature In many cases there is a very poor understanding of the actual temperatures at the site where the enclosure is mounted While process temperatures are typically very well monitored and controlled there is ambient conditions around the process have no bearing on product throughput or quality and therefore remain unknown It is recommended to perform considerable testing In a first step the enclosure and the entire
11. TY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR ILIED INCLUDING BUT NOT LIMITED TO ANY 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 Specifications subject to change without notice TABLE OF CONTENTS TSAFETYINSTRUCTONS a iw ai R GA Oak 1 PQ BB Shes EU feel By Jn O AN LE ME 2 2 1 1 ENCOUN O isr n E E OG O Oo 2 oo vd atenta aue 3 S LAXMBIENT TEMPERATURE pci dI LU COE oai 9 IA T PES Bg c e 3 RONA P D OP 4 IAAT ELO W C M E 4 2I MATERIA D UU UT TER 4 oM eI M NWN 4 SCORE OF DELIVER Y gt 5 ODMINSION A SM R E 6 TINS PA EEA TOON Za al aa kid Do aaa Fin Pe 7 ZI AMBIENT A RO 7 A RZA d aer n M 7 cuu e cM C Eu ML MEM 55 OPENING re 7 NOU TN GC EOL secet tastes O a O Lu eme DM eM DEM DE IDEE 8 T
12. filter oil removal filter The cooler should be mounted on the top only vertically 6 3 1 Installation Compressed air lines should be sized to hold pressure drops to a minimum When installing supply lines use 1 4 pipe for runs up to 3 m 10 ft Use 3 8 pipe for runs up to 15m 50 ft and 1 2 pipe for runs over 15 m 50 ft If using compressed air hose consider 3 8 inner diameter hose to be the same as 1 4 pipe and 1 2 inner diameter hose to be the same as 3 8 pipe Do not use restrictive fittings such as quick connects as they can result in excessive pressure drop The Vortex Cooler is provided as a kit with a silencer cold muffler air filter including manometer and oil removal filter To insure long trouble free operational life please install each of these components and take all precautions possible to provide clean air to the device The oil removal filter should be used downstream from the automatic drain filter separator Filters should be used close to the Vortex Cooler within 3 to 4 6 m 10 to 147 ft is the best Maximum temperature rating of filters is 49 120 The silencer can be easily installed on the cold air discharge inside the enclosure With this muffler installed the noise level is less then 75 dBA NEMA abinet CG Figure 11 Vortex Cooler and Silencer Once the air supply line has been prepared and the filters etc have been installed make the final connection to t
13. he Vortex Cooler via the 1 4 NPTF connection on the side of the unit If the Vortex Cooler is not producing cold air check the pressure by installing a gauge at the compressed air inlet of the cooler Large pressure drops are possible due to undersized lines restrictive fittings and clogged filter elements 6 3 2 Dimensions A detailed drawing for the assembled enclosure you can find in the appendix 7 2 Enclosure with Vortex Cooler on page 20 18 High Temperature Enclosure Appendix 7 Appendix 7 1 Enclosure with Internal Cold Plates 10 41 64 1 8 8 58 21 5 12 145 2 4 58 116 2 14 79 7 o oo n D o 2 5 D X c o T eu n won o 20 0 MX pa 5 5 n On n O I 1 Figure 12 Enclosure with optional Internal Cold Plates High Temperature Enclosure 19 Appendix 7 2 Enclosure with Vortex Cooler 10 41 264 3 8 58 217 8 4 58 116 2 9 06 1 45 189 2 mm in 6 60 02 el 1 59 1192 7 Figure 13 Enclosure with Vortex Cooler 20 High Temperature Enclosure Appendix 7 3 Enclosure Fully Developed 1311 80 rm E EE Oe kk uM Figure 14 Enclosure with Internal Cold Plates Vortex Cooler External Water Cooled Shields and External Insulating Shield High Temperature Enclosure 21
14. her hand if the opening is too small it may block the field of view between the scanner and the process and result in part of the process being shielded from the scanner during operation For optimum performance we recommend an opening 381 mm 15 long and 119 mm 4 7 wide Of course to ensure that the scanner is properly oriented the shorter dimension should be in line with process flow The scanner has field of view of 90 As such the further the distance from the scanner mounting location the wider the physical scan line becomes When mounting the enclosure on surfaces where the wall of the process is very thick perhaps due to large amounts of insulation take care to ensure that the opening has sufficient angle so that it does not block the edges of the scanner field of view High Temperature Enclosure 7 Installation 4 5 Mounting Holes 4 5 1 Enclosure Standard Depending on the accessories selected there are a number of ways of mounting the enclosure to the process In this modular system s most simple configuration only the enclosure and base plate will be provided In this case there are four through holes 11 mm 7 16 in diameter located one on each corner of the base plate In this case the base plate can be mounted with bolts studs as desired Recommended size of customers process opening Recommended size of customers process opening not scaled view mm in Figure 4 Bottom View of the Enclosure s
15. le levels typically found in manufacturing facilities 6 1 1 Installation Inlet water pressure must be limited to a maximum of 8 bar 116 PSI The flow rate should never be less than 7 6 l min 2 gal min It is highly recommended that a flow meter be installed to monitor the cooling water flow rate Under no circumstances should pressure be applied unless the External Water Shield is assembled Without rigid surfaces on either side there is a risk that the pressure could cause the water shield to deform For similar reasons care should be taken to insure that the water inlets and outlets are properly connected and that there is no potential for blockage of the outlets Optimum performance will be achieved when the cooling water ambient temperature is 25 C 77 F or lower The External Water Cooled Shield is equipped with four 3 4 NPT externally threaded pipe fittings It is important to note that the shield itself is essentially a large thin box divided internally into two isolated parallel passages Since there is no connection between the two halves if the directions are not followed it is possible to provide water pressure to both fittings on one circuit and drains on both fittings on the other This error could go unnoticed and would result in severe damage to the External Water Cooled Shield if water pressure were allowed to build beyond the recommended limit High Temperature Enclosure 15 Accessories 6 1 2 Dimensions 38 1 1 50
16. mbly completed with nuts and lock washers Air supply for air purging Air supply for shutter Figure 7 Enclosure Air Connections Install the flexible stainless steel conduit provided with the enclosure into the conduit opening Run the power communication and if required trigger cables leaving approximately 300 mm 12 in inside the enclosure for connection to the scanner at a later point in the process At this point you will be ready to make the cooling water connections as necessary External air connections can be made to the integrated shutter assembly and the scanner s air purge If the Vortex Cooler has been ordered remove plates from the circular opening in the top of the enclosure and install the Vortex Cooler using the locknut provided Connect the air as indicated in section 6 3 Vortex Cooler on page 18 Once all of the cooling facilities are connected it is strongly recommended that you run the enclosure with all cooling options operational for one hour minimum to reduce the ambient air temperature within the enclosure After this period make the electrical and air purge connections to the scanner outside the enclosure and gently lower it into place using the handle provided 10 High Temperature Enclosure Installation 4 10 Integrated Shutter The integrated shutter actuator is a pneumatic piston with a normal closed position Compressed air or nitrogen at a pressure of 1 5 bar 22 PSI is required to ope
17. n the integrated shutter External air supply connections are made to fittings on the outside of the enclosure Looking at the rear of the enclosure the shutter connection is located at the upper right corner see Figure 7 Enclosure Air Connections on page 10 Factory air can be connected at this point with a typical 1 4 outer diameter tube Internal connection to the shutter actuator is pre installed We recommend an external self venting air valve for the purpose of closing the integrated shutter when the linescanner is being replaced 4 11 Scanner Air Purge The scanner air purge is always required to keep dust and debris from settling on the lens and obscuring the field of view Required airflow rates are between 200 to 400 l min 50 and 100 gal min The maximum recommended pressure is 3 bar 43 5 PSI External air supply connections are made to fittings on the outside of the enclosure Looking at the rear of the enclosure the air purge connection is located at left center see Figure 7 Enclosure Air Connections on page 10 Factory air can be connected at this point using a typical compression fitting sized for 1 4 outer diameter tube Stainless steel braided hoses are provided for connection to the scanner to provide air for the air purge function If you need to assemble the air hose to the scanner in the field you need to do the following 1 Disassemble the elbow T fitting 2 Screw the straight connector into the 150228 G1
18. nect the air from the linescanner air purge collar by removing the quick connecting fittings 4 Remove the power and communication fittings from the linescanner along with the grounding cable and remove the linescanner from the enclosure using the handle provided 5 With the scanner removed four M6 x 25 cap screws become accessible on each side holding the Internal Cold Plates in place 6 Remove these screws to release the cold plates and remove from the enclosure The replacement plates can be installed by reversing the directions above High Temperature Enclosure 13 Options Remove 4x M6 x 25 to release Cold Plate Figure 8 Replacing the Internal Cold Plates 5 1 3 Dimensions A detailed drawing for the assembled enclosure you can find in the appendix 7 1 Enclosure with Internal Cold Plates on page 19 14 High Temperature Enclosure Accessories 6 Accessories Accessories include items that may be ordered at any time and added on site e External Water Cooled Shield XXXSYSENCWCS e External Insulating Shield XXXSYSENCIS e Vortex Cooler XXXSYSENCVT 6 1 External Water Cooled Shield The External Water Cooled Shield is a stainless steel construction with oversize fittings designed for optimum performance at relatively low water pressure but high water flow rates Internal baffling creates serpentine flow pattern for optimum heat removal Oversized fittings and flow channels prevent system fouling due to high sca
19. o E E OE DLL aa an OSA WO A OKA ACE 8 AOD Euosure qui 8 4 6 MOUNTIN GTNECABPLECONDUMN 8 47 MOUNTING THE SCANNER HANDLE head _6_6__ _____ 9 40 GROUNDINGENESCANNER za AR RAA A 10 2 9 SYSTEM ASSEMBLY 2t pdt Ak GA ai o Kodi Bi Ai oi w GR Od 10 4 10 INTEGRATED SHUTTER 11 d PESGANNERZNEP ORC 11 AEGEE 13 2 PINTERNABPCOFPDREAT a AR W 13 VALOR LA ORL GERE O a Ga 13 2 12 ERE DORT CONE WAP kkk 13 Be Wd OS MU ES EL 14 G6 ACCESSORIES iota o b si 15 Ol EXTERNAL WATER COOLED SHIELD iGO A and mated s 15 E ONA Atel AO b 15 CERDD S O T PR gt 16 OZ PEXIBRNADTNSUPEATING SHIELD oc dote e Ra 17 AI BUE IS Rc 17 V ORTE COOLER veena a e a E SA 18 COA A OT NE NER NEC 18 0 922 DEOS sanen ar a A a R A W d ALONG 18 ZALDEND DOS o E ON T 19 7 1 ENCLOSURE WITH INTERNAL COLD PLATES aa eset ee ae rae Ye vow eode Sv eve vau eu ee ba eue vae Ya er Eod O A 19
20. professional and environmental regulations as electronic waste 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 Warnings concerning operation to avoid personal injury High Temperature Enclosure 1 Description 2 Description 2 1 1 High Temperature Enclosure The modular high temperature enclosure system is specifically designed to protect the linescanner from exposure to ambient temperature up to 1090 C 2000 F While protected in this enclosure the linescanner can operate comfortably in high temperature processes such as those seen in processing steel and other metals as well as glass and a variety of minerals Base Plate Figure 1 Standard Enclosure with Base Plate By design the high temperature enclosure system is modular in nature The standard enclosure while insulated provides only minimal heat resistance Additional cooling elements include an external insulation plate an external water plate smaller internal water plates and a vortex cooler Vortex Cooler Connections for Internal Cold Plates External Water Cooled Shield External Insulating Shield Figure 2 Enclosure with Accessories The enclosure is fabricated from stainless steel and is lined with high performance refractory material
21. w The ergonomic design permits rapid replacement in the event that the plates become fouled due to contaminated cooling water 5 1 1 Connecting a Water Line The Internal Cold Plates are fabricated such that the piping extends through the wall of the enclosure itself When the enclosure is viewed from the rear four 3 8 stainless steel pipes can be clearly seen Using 3 8 compression fittings connect the factory water supply and check for leaks The Internal Cold Plates require water flow rates not to exceed 7 6 l min 2 gal min pressure should not exceed 8 6 bar 125 PSI It is recommended that the water supply and drain to from the Internal Cold Plates be isolated from the supply for the External Water Shield if used This will allow the Internal Cold Plates to be disconnected to facilitate removal without interrupting supply to the External Water Shield Such an interruption could lead to extremely high temperatures within the enclosure making the working environment uncomfortable and requiring significant cool down time before the scanner can be reinstalled 5 1 2 Replacing the Internal Cold Plates In the event that the Internal Cold Plates should become clogged we recommend that they be removed and replaced The cold plated may be removed in situ as described below Removing existing Cold Plates 1 Isolate both the water supply and drain 2 Onthe outside of the enclosure disconnect the water inlet and outlet connections 3 Discon
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