Furnace Camera System Operator s Manual. Version

Transcription

1 Furnace Camera System Operator s Manual Version

2 Contents 1. Introduction Description Model Nomenclature Specifications Confirmation of Camera Field of View Location and Mounting Sensor Location Installation and Mounting Notes Sensor Mounting Operation Controls Maintenance Regular Maintenance Returns of the FCS FCS Junction Box Layouts... 9 P a g e 1

3 1. Introduction The Logika Technologies Furnace Camera System, is designed for use in steel, aluminum and other metal mill production lines, allowing operators to observe materials in furnaces. It can also be used to monitor combustion in power and boiler operations. It includes a rugged enclosure protecting a high resolution camera and will withstand the harsh ambient conditions present in heavy industrial environments. The Unit includes water cooling and air purge to enable the camera to work in the hostile environments around industrial furnaces. Temperature sensors and an Automatic Retraction System provide insurance against overheating and the local electrical and pneumatic panels simplify installation. Applications include: Steel Blast, Melt and reheat Furnaces Cement Clinker Cooler, Rotary Kiln Power Generation Combustion Monitoring Glass Float Glass Line Waste Combustion Grate Firing Clay and Ceramics Kiln Monitoring 2. Description 2.1 Model Nomenclature Record your Furnace Camera System s complete Model Number here: FCS - - Base Model Power Input Mount Angle Wall Thickness FCS 110: 110 VAC Customer 220: 220 VAC Furnace Dependent Customer Furnace Dependent Serial Number P a g e 2

4 2.2 Specifications Operating Temp Temperature inside the furnace 2000 o C Auto-exit device 90 o C, control system 70 o C Air Supply Compressed air, inlet pipe diameter G 1/2, pipeline diameter G 3/4 Power Input 110VAC 60Hz, 220V 50 Hz <120W Output Hi resolution NTSC color composite signal Compressed Air Pressure MPa (15 to 100 psi) depending on the temperature inside furnace Flow: m3/min (3.5 to 14 cfm) Inlet temperature of compressed air 35 o C (95 o F) Lens Special high-temperature resistant pinhole lens Image Index Resolution 650 lines (976 x 572 pixels), Signal-to-noise 42 db Visual angle (diagonal line) 80 o diagonal, Image Sensor 1/3 Signal to Noise Ratio >50 db, sensitivity 0.1 lux Auto Retract The probe will automatically retract from Furnace Chamber at overtemperature, regardless of pneumatic loss (add UPS to cover electrical power loss as well) Weight Auto-exit device about30 kg; furnace wall cover about 30 kg Dimensions Auto-exit device 1280 (L) 320 (W) 480 (H) mm (50 L x 12.6W x 19 H) Furnace Hole ø 140 mm, 120 o horn-like hole on interior wall of furnace P a g e 3

5 2.3 Confirmation of Camera Field of View Calculation Formula for Field of View: Where: f= (focal length of pinhole lens) = 3.5 mm H = (height of field of view) (m) W = (width of field of view) (m) L = (the distance between the lens and target) (m) h = (1/3 height of camera sensor) = 3.6 mm w = (1/3 width of camera sensor) = 4.8 mm L(m) H (m) W (m) P a g e 4

6 3. Location and Mounting 3.1 Sensor Location Figure 3.1: Installation Layout P a g e 5

7 In order to maximize the proportion of the monitored target in the monitoring image, it is suggested to bore the hole on the furnace wall as near to the monitored target as possible. 3.2 Installation and Mounting Notes 1. The pitch angle should be confirmed on ordering. 2. After the equipment is installed for the air supply to the furnace door, the user should tie in G 1/2 pipe for laying to the FCS. The air inlet to the filtration tank should be 0.5 m away from the filtration tank and G1/2 outer thread is remained. 3. The standard distance between the pneumatic control box and auto-retract device is 2 m; additional pipe is necessary if the distance is greater. 4. The pipeline inside the dashed frame in Figure 3.1 is to be provided by the customer. 5. Bore 140 mm hole in furnace wall, with a flared opening toward the interior. 6. The embedded parts should be welded and fixed to the outer skin (steel plate) of the furnace wall and full welding is required. The ceramic pipe and the hole gap on the furnace wall should be filled with fire clay. 7. For proper installation and operation of this equipment, a 500 mm clearance radius around the center of the bored hole is required 8. Bolt or weld the Electric and Pneumatic Control Panels solidly into place close to the Auto- Retract Device but out of the way for maintenance operations. 9. Required Air Pressure: MPa 10. Required Air Flow: m3/min 11. Required Air Temperature: 35 o C 12. Temperature inside the furnace: 2000 o C 13. Air source: compressed air 14. From Figure 3.1: Cables (1), (2), (3), (4) should be provided by the customer. (1) Video cable SYV 75-5 (RG-6) (2) Control cable RVV (3) (4) power cable RVV 3 1 (5), (8), (9) are the (included) cross-over pipes of the equipment with G 1/4 fittings. (6), (7) are the (included) connecting cables of the equipment. 15. The customer installs G 1/2 rigid pipe for the cooling water to within 0.5 m of the embedded parts, terminated with a shutoff with G 1/2 male fitting. Similarly, the customer installs G 1/2 rigid pipe for the cooling water return to within 0.5 m of the embedded parts, terminated with a shutoff with G 1/2 male fitting. 16. Before the air is applied to the equipment, close shutoff valves S1 and S2, open S3 and S4 for ventilation. After the pipes have been completely blown out, close S3, S4 and open S1, S2. The equipment is then ready for normal operation. 3.2 Sensor Mounting P a g e 6

8 4. Operation 4.1 Controls The Control Box will be located with the monitor in the Control Room. It will allow the operator to retract or insert the camera probe at will. P a g e 7

9 5. Maintenance 5.1 Regular Maintenance Diagnostics- Normally, the FCS does not require maintenance at a fixed period. Regular attention to the following will ensure steady operation of the sensor: Lens Cleaning- Routinely check the FCS sensor s pinhole lens for dust or oil residue. Open the lens shield at the front of the sensor by unscrewing the fastening hardware on the shield and clean the lens with alcohol and lens paper or lint-free cloth. Detector- The pneumatic filters should be inspected and replaced as necessary according to the plant maintenance schedule. 5.2 Returns of the FCS Contact us with the Serial Number of your sensor before you return our product. If we are unable to solve the problem by phone or , we will then provide you with a return authorization number. Do not return the FCS without an authorization number. If the product is out of warranty, we will provide a repair estimate and then complete the repairs after your approval. P a g e 8

10 6. FCS Junction Box Layouts Figure 6.1: FCS Pneumatic Junction Box Layout P a g e 9

11 Figure 6.2: FCS Electrical Junction Box Layout P a g e 10