Multi-View® HDC & HDT

Operation & Maintenance

Manual

A Comprehensive Operation and Maintenance

Guide for:

Multi-View HDC & HDT Systems

Published by Thermoteknix Systems Limited

All possible care has been taken in the preparation of this publication, but Thermoteknix
Systems Limited accepts no liability for any inaccuracies that may be found.
Thermoteknix Systems Limited reserves the right to make changes without notice both to
this publication and to the product that it describes.

No part of this document may be reproduced, stored in a retrieval system, or

transmitted in any form by any means electronic, mechanical, reprographic, recording or
otherwise, without the prior written permission of the copyright owner.

Information in this document is subject to change without notice and does not represent a
commitment on behalf of Thermoteknix Systems Ltd, who takes no responsibility for damages
incurred as a result of any changes made.

Thermoteknix®, the Thermoteknix logo and ThermaScope®

are registered trademarks of Thermoteknix Systems Ltd.
All Trademarks are acknowledged.

Thermoteknix products are protected by patents and design rights. Please refer to our patent
marking web page for more information: http://www.thermoteknix.com/patents/

Thermoteknix Systems Ltd

Teknix House,
2 Pembroke Avenue,
Waterbeach,
Cambridge,
CB25 9QR
England.

Tel: + 44 (0) 1223 204000

Fax: + 44 (0) 1223 204010

www.thermoteknix.com

Part Number: GT610001

Revision 7

Revision History

Revision 1 16th September 2015 Original Version

Revision 2 25th July 2016 Major Updates
Revision 3 5th January 2017 Removed software section
Revision 4 28th March 2017 Air section and Multi-View
Revision 5 16th August 2017 Updated maintenance section.
Added Air Receiver information
Revision 6 29th September 2017 Updated warnings to de-pressurise
air receiver
Revision 7 16th May 2018 Multi-View Specific Updates

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Comments or feedback on this manual should be sent to support@thermoteknix.com

Limitation of Liability

1. Thermoteknix will not be liable for any loss or damage of any kind whatsoever, including
without limitation
a. Loss of or corruption to data,
b. Lost profits
c. Other special, incidental, consequential or indirect damages arising out of the use
or inability to use the product however caused and whether arising under contract,
tort including negligence or otherwise, to the maximum extent permitted by law.

2. The limitation of liability will apply even if Thermoteknix or any Thermoteknix product
distributor has been advised of the possibility of such loss or damage.

3. In the event that any exclusion, disclaimer or other provisions contained herein shall be
held invalid for any reason and Thermoteknix becomes liable for loss or damage that
could otherwise have been limited, whether in contract negligence or otherwise,
Thermoteknix’ liability shall not exceed £2,000.

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 WARNING!
Failure to install, operate or service the equipment in accordance with the
installation and operation manuals will invalidate the warranty. All other parts of
the system as supplied are covered by a one year return to base warranty with
the exception of consumables which are expressly excluded.

SAFETY NOTICES AND CAUTIONS

ELECTRICAL SAFETY
It should be noted that the ThermaScope works off the mains electricity supply. All work carried
out on the ThermaScope HD MUST only be done by a qualified engineer, and all safety
precautions must be observed to avoid the possibility of electric shock

PRESSURISED AIR
The ThermaScope HD is cooled by air only. When servicing/maintenance/repair of the
ThermaScope is required, the ThermaScope MUST first be retracted from the kiln, and then the
air supply MUST be turned off to prevent any accidental insertion of the camera whilst it is being
worked on. As the system has an air receiver, it MUST be allowed to de-pressurise before
starting work. The quick release fittings should be removed from the frame assembly before
working around the frame. Further checks of the air system are detailed later on in this manual.

WEIGHT
The Thermoteknix Systems Ltd ThermaScope is a heavy piece of equipment. If it is required to
be moved from the mounting location, it is highly recommended that two people be used to
perform this task to avoid any potential back problems or injury.

Uninterruptable Power Supply (UPS)

The ThermaScope HD has a power failsafe to extract the camera on loss of supply; The
Camera Control Unit MUST NOT be connected to a UPS.

Key to Symbols used in this guide:

IMPORTANT - Do not proceed without taking note of the important information

contained in the following statement

NOTE – Advisory information follows

CAUTION
It is up to each INDIVIDUAL to ensure that he/she has complied with the safe working
practices locally prior to and during any work undertaken. Observe all safety precautions.

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Contents
SAFETY NOTICES AND CAUTIONS .......................................................................................... 4
TABLE OF FIGURES................................................................................................................... 6
1 INTRODUCTION............................................................................................................... 9
2 Maintenance.................................................................................................................... 12
2.1 Weekly Maintenance ................................................................................................... 12
2.2 Weekly Checklist – ‘7 Checks - Every 7 Days’............................................................. 12
2.3 Every 6 months – Bi-Annual Maintenance................................................................... 12
2.4 Every 1 Year - Annual Service Visit ............................................................................. 12
2.5 Every 2 Years – HDT Calibration................................................................................. 12
2.6 ThermaScope Weekly Inspection Checklist Record Sheet.......................................... 13
2.6.1 Check the camera extracts in under 5 seconds ................................................ 14
2.6.2 Check the Wall Sleeve Enclosure Door (cat flap) closes correctly.................... 14
2.6.3 Check the wall sleeve for clinker build up ......................................................... 14
2.6.4 Check sapphire window is clean ....................................................................... 15
2.6.5 Check the end cap condition............................................................................. 15
2.6.6 Check condition of all cables and hoses ........................................................... 16
2.6.7 Check the air filters are clean and there is no condensate in filter bowls .......... 16
3 HDT CAMERA CALIBRATION (NOT REQURED FOR HDC)......................................... 17
4 HARDWARE ................................................................................................................... 18
4.1 Wall Sleeve.................................................................................................................. 18
4.1.1 Wall Sleeve ....................................................................................................... 18
4.2 Wall Sleeve Enclosure................................................................................................. 19
4.2.1 Wall Sleeve Enclosure Door (“Cat Flap”) .......................................................... 19
4.2.2 Adjusting Counter Balanced Weight.................................................................. 20
4.2.3 Attaching Enclosure Supplementary Air............................................................ 20
4.2.4 Removing Underside Enclosure Inspection Plate ............................................. 21
4.3 ThermaScope HD Assembly........................................................................................ 22
4.3.1 ThermaScope Camera Tube Assembly ............................................................ 22
4.3.2 Camera Tube Assembly – Removal, Installation, Replacement and Adjustment
26
4.3.3 Camera Tube End Cap – Removal & Installation.............................................. 31
4.4 ThermaScope HD Frame Assembly ............................................................................ 35
4.4.1 Removing and Attaching the HD Frame Assembly ........................................... 36
4.4.2 Fall Back Arrestor (Optional)............................................................................. 37
4.5 Camera Power/Data Cable .......................................................................................... 38
4.5.1 Removal............................................................................................................ 39
4.5.2 Install................................................................................................................. 41
4.6 Control Unit.................................................................................................................. 42
4.6.1 Power Section................................................................................................... 44
4.6.2 Electronic Section ............................................................................................. 46
4.6.3 Air Section......................................................................................................... 53
4.6.4 Fibre Optic Cable .............................................................................................. 62
4.7 Receiver Unit ............................................................................................................... 63
4.7.1 Receiver Board ................................................................................................. 63
4.7.2 Receiver Unit Connections................................................................................ 64
4.8 Multi-View PC .............................................................................................................. 66
5 MULTI-VIEW ALARMS & TROUBLESHOOTING ........................................................... 67
5.1 Service Manager.......................................................................................................... 67
5.1.1 Status................................................................................................................ 67
5.1.2 Configuration..................................................................................................... 68
5.1.3 Alarms............................................................................................................... 68
5.2 HDC / HDT Alarm Troubleshooting.............................................................................. 69

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 5.2.1 Camera Over Temperature ............................................................................... 69
5.2.2 Lost Air Pressure / Air Alarm............................................................................. 69
5.2.3 CANBUS Connection Failure / Communications .............................................. 70
5.2.4 Communications between Control and Receiver Units ..................................... 71
5.2.5 No Video Signal ................................................................................................ 72
5.2.6 Control Unit Over Temperature / Board Temperature ....................................... 72
5.3 Software Diagnostic Reporting .................................................................................... 73
5.3.1 Contacting Thermoteknix .................................................................................. 73

TABLE OF FIGURES
Figure 1 - ThermaScope system overview................................................................................... 9
Figure 2 - Single Camera System Schematic ............................................................................ 10
Figure 3 - Dual Camera System Schematic ............................................................................... 11
Figure 4 - Camera IN/OUT switch location................................................................................. 14
Figure 5 - Wall Sleeve Enclosure............................................................................................... 14
Figure 6 - Wall Sleeve Enclosure Inspection Plate .................................................................... 14
Figure 7 - Camera Sapphire Window Lens ................................................................................ 15
Figure 8 – Typical End Cap Damage (Top). End cap damage due to no regular inspection over
long periods of time (Bottom) ..................................................................................................... 15
Figure 9 – Armoured cable and air hose on ThermaScope HD Assembly ................................. 16
Figure 10 - Air filter bowls and filters .......................................................................................... 16
Figure 11 – HDT (Straight) camera tube, removed for calibration.............................................. 17
Figure 12 – Wall Sleeve ............................................................................................................. 18
Figure 13 – Wall Sleeve Enclosure ............................................................................................ 19
Figure 14 – Counter Balanced Weight adjustment..................................................................... 20
Figure 15 – Supplementary Air Hose Attachment ...................................................................... 20
Figure 16 – Enclosure Inspection Plate...................................................................................... 21
Figure 17 - Wall Sleeve Enclosure Inspection Plate Orientation ................................................ 21
Figure 18 – ThermaScope HD Assembly................................................................................... 22
Figure 19 – LEFT: Kiln Camera (Straight). RIGHT: Cooler Camera (Angled) ........................... 22
Figure 20 – ThermaScope HD Camera Assembly (Cooler - Angled)......................................... 23
Figure 21 – ThermaScope HD Camera Assembly (Kiln)............................................................ 24
Figure 22 – Armoured Cable...................................................................................................... 25
Figure 23 – Armoured Cable Terminations ................................................................................ 25
Figure 24 – Frame Junction Box Rear Plate Removal ............................................................... 26
Figure 25 – Disconnecting Camera Cable ................................................................................. 26
Figure 26 - Armoured cable locknut removal ............................................................................. 27
Figure 27 - Armoured cable lock nut orientation ........................................................................ 27
Figure 28 - Camera Video and Power/Data Connections .......................................................... 27
Figure 29 - Camera tube disconnected from camera junction box............................................. 27
Figure 30 - Locknut fitted to prevent loss ................................................................................... 28
Figure 31 – Removing Air Purge Hose from Air Tube ................................................................ 28
Figure 32 – Marking the correct Camera Position ...................................................................... 28
Figure 33 – Removing the Air Tube ........................................................................................... 28
Figure 34 - Correct cooler camera aim....................................................................................... 30
Figure 35 – Air Tube Adjustment ............................................................................................... 30
Figure 36 - End cap spanner (Part Number OT830018) ............................................................ 31
Figure 37 - STRAIGHT Camera End Cap Removal ................................................................... 31
Figure 38 - ANGLED Camera End Cap Removal ...................................................................... 32
Figure 39 - ANGLED end cap fitment......................................................................................... 32
Figure 40 - 1mm sapphire window camera identification ........................................................... 33
Figure 41 - 2mm sapphire window camera identification ........................................................... 33
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Figure 42 – Sapphire Window Replacement.............................................................................. 34
Figure 43 – Frame Assembly Parts............................................................................................ 35
Figure 44 – Frame Assembly Removal ...................................................................................... 36
Figure 45 – Fall Back Arrestor Plunger and Plate ...................................................................... 37
Figure 46 – Fall Back Arrestor Air Connection ........................................................................... 37
Figure 47 - Camera Power/Data Cable Schematic .................................................................... 38
Figure 48 – Frame Junction Box Rear Plate Removal ............................................................... 39
Figure 49 – Disconnecting Control Unit Cable ........................................................................... 39
Figure 50 - Armoured cable locknut removal ............................................................................. 39
Figure 51 - Armoured cable lock nut orientation ........................................................................ 40
Figure 52 - Camera Video and Power/Data Connections .......................................................... 40
Figure 53 - Camera power/data cable disconnected from camera junction box......................... 40
Figure 54 - Locknut fitted to prevent loss ................................................................................... 41
Figure 55 - Camera video and power/data connections inside control unit ................................ 41
Figure 56 – Control Unit Sections .............................................................................................. 42
Figure 57 - Control Unit Schematic Diagram.............................................................................. 43
Figure 58 – Control Unit Power.................................................................................................. 44
Figure 59 – Power Supply Cover Removal ................................................................................ 45
Figure 60 – Power Supply Composition ..................................................................................... 45
Figure 61 – Control Board.......................................................................................................... 46
Figure 62 – BK030016 Power Down PCB fitted......................................................................... 47
Figure 63 – Control Switches ..................................................................................................... 47
Figure 64 - Camera OUT (Extracted) [Left] - Camera IN (Inserted) [Right] ................................ 48
Figure 65 - An example of the test pattern ................................................................................. 48
Figure 66 - Image rotation example ........................................................................................... 48
Figure 67 – External Status LED’s ............................................................................................. 49
Figure 68 - COAX_LOSS LED location...................................................................................... 50
Figure 69 – External Retraction Control ..................................................................................... 52
Figure 70 – Air Section............................................................................................................... 53
Figure 71 – Air Hose Colour Code ............................................................................................. 53
Figure 72 – Air Hose Connections ............................................................................................. 54
Figure 73 – 270 litre Air Receiver............................................................................................... 55
Figure 74 – Site Air Supply Connection to Air Receiver ............................................................. 55
Figure 75 - Air Receiver Fitting Kit Connection Schematic (Including Optional Air Drier System)
................................................................................................................................................... 56
Figure 76 – Air Connection into Control Unit.............................................................................. 57
Figure 77 – Air Supply ON/OFF ................................................................................................. 57
Figure 78 – Air Filters Removal.................................................................................................. 58
Figure 79 – Air Pressure Regulator............................................................................................ 58
Figure 80 - Air Pressure Switch ................................................................................................. 59
Figure 81 – Air Accumulator....................................................................................................... 59
Figure 82 – Air Solenoid............................................................................................................. 60
Figure 83 – CAMERA IN/OUT switch......................................................................................... 60
Figure 84 – Camera Speed Adjustment ..................................................................................... 61
Figure 85 – Fibre Specification .................................................................................................. 62
Figure 86 – LC connector........................................................................................................... 62
Figure 87 - Fibre Optic data path between Control Unit and Receiver Unit................................ 62
Figure 88 – Receiver Unit Front View ........................................................................................ 63
Figure 89 – Receiver board........................................................................................................ 63
Figure 90 – Receiver Unit Connections...................................................................................... 64
Figure 91 - Receiver Unit Schematic Diagram ........................................................................... 65
Figure 92 – Multi-View PC - Connections to Receiver Unit ........................................................ 66
Figure 93 - ThermaScope Service Manager .............................................................................. 67

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Figure 94 - Camera junction box PCB power indication LED..................................................... 70
Figure 95 - LC Fibre connection. Not seated correctly [Left] Seated correctly [Right] ............... 71
Figure 96 - Fibre Optic data path between Control Unit and Receiver Unit................................ 71

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1 INTRODUCTION
The ThermaScope HDC & HDT Multi-View system was developed by Thermoteknix Systems
Ltd to allow the user to view what is happening within their kiln or cooler. This operation and
maintenance document has been designed to enable the customer to get the very best out of
their ThermaScope HD Multi-View system, regardless of whether the customer is using HDC,
HDT or combined systems. The document is split into the following parts:

Section 2 – Maintenance

Section 3 – HDT CAMERA CALIBRATION

Section 4 – HARDWARE

Section 5 – MULTI-VIEW ALARMS & TROUBLESHOOTING

The system itself is made up of 2 sub systems;

a. Site Kiln/Cooler equipment consisting of:

· Wall Sleeve
· Wall Sleeve Enclosure
· ThermaScope Camera Assembly
· Control Unit (Air Services)

b. Control Room equipment consisting of:

· Receiver Unit/s
· PC

Figure 1 - ThermaScope system overview

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Figure 2 - Single Camera System Schematic

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Figure 3 - Dual Camera System Schematic

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2 Maintenance
2.1 Weekly Maintenance
The ThermaScope HD system should have the following features checked on a weekly basis to
ensure reliable operation of the system. A record of these checks should be made. The
following page has a checklist record sheet.

NOTE: Failure to check and maintain the condition of the ThermaScope HD system
and provide a completed check list sheet (see following page) may void warranty.

2.2 Weekly Checklist – ‘7 Checks - Every 7 Days’

1. Check the camera extracts in under 5 seconds [2.6.1]
2. Check the wall sleeve enclosure door closes correctly when the camera is out [2.6.2]
3. Check the wall sleeve enclosure for clinker build up and remove if necessary [2.6.3]
4. Check sapphire window is clean [2.6.4]
5. Check the end cap condition [2.6.5]
6. Check condition of all cables and hoses [2.6.6]
7. Check the air filters are clean and there is no condensate in filter bowls [2.6.7]

2.3 Every 6 months – Bi-Annual Maintenance

1. Inspect air filter housing for cracks.
2. Replace 2 x air filters in control unit [4.6.3.4 Air filters].

2.4 Every 1 Year - Annual Service Visit

· It is recommended that in order to ensure the longevity and reliability of the system, a
service visit is booked with support@thermoteknix.com. Updates to system software,
firmware and hardware can be applied to ensure you have the most up to date
system, ensuring long term operation for many years.
· 1 year spares packages are available from sales@thermoteknix.com which includes
Ø Replacement End Cap
Ø Replacement Sapphire Windows – Including screws and securing ring
Ø Control Unit air filters for a year
Ø Spare Fuses

2.5 Every 2 Years – HDT Calibration

· To ensure temperature accuracy is maintained, a 2 yearly service return of camera for

service and calibration (HDT only) [see section 3], email support@thermoteknix.com
for further information.

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2.6 ThermaScope Weekly Inspection Checklist Record Sheet
Camera Serial Number

Checklist Item
Cables Air filters
Camera Wall Wall Sapphire
Date End Cap and and
extracts sleeve cat sleeve free Window
Condition Hoses bowls
<5s flap closes of dust clean
Condition clean

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2.6.1 Check the camera extracts in under 5 seconds
Extract the camera from the kiln by operating the IN/OUT switch inside the camera control unit.

Figure 4 - Camera IN/OUT switch location

1. Select the IN/OUT switch to OUT to EXTRACT the camera from the kiln.
a. The camera will extract in 3-5 seconds.
b. The camera should extract smoothly without jumping or sticking
c. The camera end should not be touching the protective door or any other metal
when fully extracted

2. Switch the IN/OUT to IN to INSERT the camera into the kiln.

a. The camera will insert within in 3-5 seconds
b. The camera should extract smoothly without jumping or sticking
c. The camera should fully insert all the way forward into the kiln. The circular
flange at the rear of the camera tube should contact the wall sleeve enclosure.

If camera does not insert or extract correctly as described above refer to chapter 4.6.3.8.1 (Air
Solenoid) to adjust camera insert/extract speed. It is more important that the camera can retract
to protect the camera in the event of an alarm condition.

2.6.2 Check the Wall Sleeve Enclosure Door (cat flap)

closes correctly
1. Select the IN/OUT switch to OUT to EXTRACT the camera
from the kiln.
a. Check that the cat flap fully closes when the camera is
extracted from the kiln.
b. Ensure that the door opens and closes freely and does
not jam or stick.
Figure 5 - Wall Sleeve Enclosure

If the door does not close correctly, refer to chapter 4.2.1 (Wall Sleeve Enclosure Door) for
corrective actions.

2.6.3 Check the wall sleeve for clinker build up

1. In the base of the Wall Sleeve Enclosure is a removable panel. This
check is only required if no additional air supply is fitted.
a. Ensure Eye protection is worn for this operation.
b. Remove the panel shown (Right) to clear any clinker build up
that has accumulated inside the Wall Sleeve Enclosure.
c. Refit panel after clinker has been cleared.
Figure 6 - Wall Sleeve Enclosure Inspection Plate

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2.6.4 Check sapphire window is clean
1. Select the IN/OUT switch to OUT to EXTRACT the camera from
the kiln.
· Wait 1 minute to ensure the purge air has allowed the end
cap to cool to a safe level.
· Inspect the sapphire window. A mirror and torch is useful
for this inspection.
i. Check the window is fitted
ii. The window should be clean
iii. The window should not have any cracks/pitting

If the window is dirty, remove the camera tube as shown in chapter 4.3.2.1
(Camera Tube Assembly – Removal). Clean the window as described in
chapter 4.3.3.4.
Figure 7 - Camera Sapphire Window Lens

If the window cannot be cleaned and the image quality is still affected, the sapphire window
should be replaced as shown in chapter 4.3.3.5.

2.6.5 Check the end cap condition

Regular inspections of the end caps should be carried out for signs of wear or corrosion. If there
are any signs that the camera viewing hole in the end cap has got bigger or there are any holes
or cracks in the end cap, then it should be replaced. Discolouration of the tube is normal, which
normally occurs within the first few weeks of operation.

Crack

Enlarged hole

Figure 8 – Typical End Cap Damage (Top). End cap damage due to no regular inspection over long periods of time (Bottom)

If the end cap is found to be damaged, the camera SHOULD NOT BE INSERTED INTO THE
KILN. The end cap controls cooling air flow to the camera head and must be in good condition
to protect the camera correctly. A replacement end cap should be fitted as shown at section
4.3.3.

Failure to inspect the end cap at weekly intervals may void warranty.

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2.6.6 Check condition of all cables and hoses
It is very important that the cable and air hose condition is checked. Poor installation and/or
excessive heat in the environment can lead to damage to the camera system.

The following items should be checked on the ThermaScope HD Assembly and also between
the ThermaScope HD Assembly and Control Unit

Armoured Cables – x2
· Check that the cable is in good condition and the armour has not been crushed, bent
beyond limits or damaged
· Ensure the armour is secure at all connection points
· No exposed wire should be visible

Air Hoses – x4
· Check the pipes are in good condition and no leaks are present
· Ensure all connections are secure and not leaking air (Particularly both ends of the purge
air pipe on the moving camera assembly)

Earth Cable – x1
· Check the earth cable is secure at the camera and inside the control unit.
· Check no build up of corrosion is present a good connection is present.

Figure 9 – Armoured cable and air hose on ThermaScope HD Assembly

2.6.7 Check the air filters are clean and there is no condensate in filter bowls
There are two air filters on the air supply inlet to the camera system. They
are to prevent any contaminants from the air supply such as oil or dust
entering the camera system.

· Check the float bowls for cracks or other damage

· There should be no condensate or liquid build up inside the
transparent filter bowls
· The filters should be clean and dry

If any problems are found, the transparent filter bowls and filters can be
removed, cleaned and/or replaced by following the instructions at section
4.6.3.4.

Figure 10 - Air filter bowls and filters

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3 HDT CAMERA CALIBRATION (NOT REQURED FOR HDC)
The HDT camera is a calibrated radiometric instrument; In order to keep the temperature
readings accurate and reliable it MUST be sent back to Thermoteknix at least every 2 years for
service and re-calibration. Failure to adhere to this procedure may affect the accuracy and
reliability of the readings. Liability for damage to 3rd party equipment or property is excluded by
Thermoteknix Systems Ltd. to the maximum extent permitted by law.

It is advised that in order to minimise the impact of this procedure, plants should arrange return
of the camera to Thermoteknix during a shutdown. To arrange this, please contact
support@thermoteknix.com

This applies to the HDT (Angled) and HDT (Straight) temperature sensing camera version.

When returning a HDT camera to Thermoteknix, please return the complete camera assembly
as in Figure 11 below:

Figure 11 – HDT (Straight) camera tube, removed for calibration

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4 HARDWARE
4.1 Wall Sleeve
The wall sleeve for both the HDC and HDT consists of the Wall Sleeve and Wall Sleeve
Enclosure.

NOTE: All fasteners securing these parts should have high temperature ceramic
paste applied to their threads, to prevent them seizing.

4.1.1 Wall Sleeve

The wall sleeve consists of a 330mm length of stainless steel tube, outside diameter 73mm with
a welded flange. The wall sleeve should have been welded into position during a shutdown, the
end of the steel tube should be flush with the internal refractory and should not protrude into the
cooler or kiln. Once the wall sleeve is welded in position, there is no maintenance to be carried
out on this part of the system.

Figure 12 – Wall Sleeve

NEVER BE CUT OR SHORTEN THE WALL SLEEVE. The kiln or refractory must
be modified on the kiln if wall sleeve fitment is not the same depth as the
refractory. FULL DETAILS ON INSTALLATION ARE AVAILABLE IN THE
RELEVANT INSTALLATION MANUAL.

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4.2 Wall Sleeve Enclosure
The wall sleeve enclosure is located between the wall sleeve and the ThermaScope camera
assembly. It houses the internal cat flap door which is closed by a counter balanced weight.
The weight can be positioned at different angles if required. This is to ensure correct operation
when the wall sleeve is orientated at a non standard angle. The bottom of the enclosure has a
removable plate on the underside of the enclosure to assist with cleaning and maintenance and
has a ½” BSPP thread to attach a supplementary air supply if required.

The Wall Sleeve Enclosure is HOT! Always wear heat protective gloves when
working with the Wall Sleeve Enclosure.

Figure 13 – Wall Sleeve Enclosure

4.2.1 Wall Sleeve Enclosure Door (“Cat Flap”)

The wall sleeve enclose door (Cat Flap) has a number of functions. It opens as the camera
enters the kiln and closes when the camera extracts from the kiln. The door is to protect the
camera from excessive heat when the camera is extracted. It also helps to prevent clinker
exiting the kiln when the camera is extracted or removed.

The door should close automatically under gravity, but if this does not occur:
· Extract the camera from the kiln.
· Clean any clinker accumulation from the wall sleeve and wall sleeve enclosure.
· Open and close the door manually with the camera extracted until correct operation is
seen and the door closes correctly.

NOTE: Do not apply grease to the wall sleeve enclosure as this will attract
clinker and cause seizure of moving parts

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4.2.2 Adjusting Counter Balanced Weight

Depending on your installation, you may need to change the angle of the counter balanced
weight on the wall sleeve enclosure to keep the cat flap closed when the tube is retracted. This
would normally only apply to systems installed in bespoke applications that are at a steep angle
and does not apply for the majority of cameras which will be installed on a horizontal plane.

To do this, retract the tube. Remove the securing bolt as shown below (red); the weight can now
be removed from the octagonal stud (blue). The weight can now be moved into 8 different
positions on the stud in order to keep the cat flap closed (green). Once the weight is in the
correct position, tighten the securing bolt.

Figure 14 – Counter Balanced Weight adjustment

4.2.3 Attaching Enclosure Supplementary Air

The wall sleeve enclosure is fitted with a ½” BSPP thread to attach a supplementary air supply if
required. The hose or connector is not supplied with the system. To do this, simply screw in
the air hose to the bottom of the screw thread on the bottom plate of the enclosure as pictured
below:

Figure 15 – Supplementary Air Hose Attachment

NOTE: The supplementary air will help to deflect any dust or clinker away from
the front of the camera tube by creating a positive pressure through the wall
sleeve. It also provides additional heat protection to the camera tube.

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4.2.4 Removing Underside Enclosure Inspection Plate

The rear of the wall sleeve enclosure may accumulate clinker over time; in order to facilitate the
cleaning of the wall sleeve enclosure, the underside plate can be removed by removing the 4
bolts as shown below:

Figure 16 – Enclosure Inspection Plate

NOTE: The plate where the air hose attaches should have an air deflector flap
attached on the inside. Ensure that the plate is fitted in the correct orientation to
duct the air TOWARDS THE KILN. If the plate is fitted incorrectly, this will cause
the air flow to be ducted backwards may not allow the wall sleeve enclosure door to
close correctly.

Figure 17 - Wall Sleeve Enclosure Inspection Plate Orientation

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4.3 ThermaScope HD Assembly
The ThermaScope HD consists of a camera tube assembly and a HD frame assembly.

Figure 18 – ThermaScope HD Assembly

The following sections breakdown the two assemblies into their different parts.

4.3.1 ThermaScope Camera Tube Assembly

The ThermaScope camera tube assembly comes in 4 different varieties which are:

a) ThermaScope HDC kiln camera assembly (Straight)

b) ThermaScope HDC cooler camera assembly (Angled)

c) ThermaScope HDT kiln camera assembly (Straight)

d) ThermaScope HDT cooler camera assembly (Angled)

The difference between the kiln and cooler camera is the camera and tube. The kiln camera
uses a straight tube and camera. The cooler uses an angled tube and camera. The following
images show the two different tubes and cameras that are supplied for kiln and cooler
applications:

Figure 19 – LEFT: Kiln Camera (Straight). RIGHT: Cooler Camera (Angled)

ThermaScope HD also comes in two different options, HDC and HDT:

a) The HDC uses a non-radiometric camera which has no temperature reading

functionality. (HDC = High Definition Camera)

b) The HDT uses a radiometric camera which is calibrated depending on the application.
(HDT = High Definition Temperature Measuring Camera)

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ThermaScope Cooler (Angled) Tube Assembly

Figure 20 – ThermaScope HD Camera Assembly (Cooler - Angled)

1. Connector Plate Assembly – This is the rear end cap for the tube. It also has the air
hose connector and cable gland for the camera cable and air hose.

2. Tube Camera Bar – Links the connector plate assembly and the camera sub
assembly.

3. Screw M3 – Securing screws for tube camera bar to camera sub assembly (x2).

4. Camera Sub Assembly (Angled) – HDT or HDC 35 degree high definition camera.

5. Screw M6 – Securing screws for connector plate assembly to angled air tube (x4).

6. Camera Cable – Cable connecting the camera to the Control Unit.

7. End cap - Sacrificial air tube end cap for camera protection

8. Angled Air Tube – This houses and protects the HD camera.

9. End cap free nut – Secures the end cap to the tube

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4.3.1.1 ThermaScope Kiln (Straight) Tube Assembly

Figure 21 – ThermaScope HD Camera Assembly (Kiln)

1. Straight Air Tube – This houses and protects the HD camera.

2. Connector Plate Assembly – This is the rear end cap for the tube. It also has the air
hose connector and cable gland for the camera cable and air hose.

3. Camera Sub Assembly (Straight) – HDT or HDC straight high definition camera.

4. Air Tube End Cap – Sacrificial air tube end cap for camera protection.

5. Tube Camera Bar – Links the connector plate assembly and the camera sub assembly.

6. Screw M6 – Securing screws for connector plate assembly to angled air tube (x4).

7. Screw M3 – Securing screws for tube camera bar to camera sub assembly (x2).

8. Camera Cable – Cable connecting the camera to the Control Unit.

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4.3.1.2 Camera Cable Protection

The camera data cable is fitted with armoured protection between the air tube and the frame
junction box, and the junction box to Control Unit as seen below:

Figure 22 – Armoured Cable

The armour protects the cable from direct contact with clinker and excessive heat. The camera
data cable is physically connected to the armour so no attempt should be made to separate
them. The cable should always remain attached to the air cooled camera tube. To remove the
armoured cable from the junction box, undo the lock nut as shown in chapter 4.3.2.1, steps 1-
10.

Figure 23 – Armoured Cable Terminations

NOTE: This manual from now on shows the data cables without armour in order to
aid in illustrating the steps involved during remove replace tasks.

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4.3.2 Camera Tube Assembly – Removal, Installation, Replacement and
Adjustment

The ThermaScope is designed to retract far enough to enable inspection of the air tube without
removing from the ThermaScope HD frame assembly. There may be however situations when
this task is necessary such as replacing the end cap or the sapphire window.

Before working on the ThermaScope, always ensure that the AIR and POWER
are turned OFF at the Control Unit and quick release air couplings (Blue/Red)
removed from frame assembly. Note the air receiver contains pressurised air
after the on/off valve has been closed. Remaining air pressure in the system
can be viewed on the air pressure gauge inside the control unit.

4.3.2.1 Camera Tube - Removal

1. Retract the camera from the kiln or cooler using CAMERA IN/OUT switch in Control Unit.
2. Switch off electrical power and wait 30 seconds.
3. Switch off air supply to the air receiver in order to allow the camera tube to cool. Only
disconnect the air hose from the camera if the air pressure gauge in the control unit
shows 0MPa pressure.
4. Unscrew the 4 captive screws securing the plate to the frame junction box and remove:

Figure 24 – Frame Junction Box Rear Plate Removal

5. Unplug the camera BNC cable and electrical connector (Normally left side for camera,
right side for control unit)

Figure 25 – Disconnecting Camera Cable

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6. Using a 24mm spanner, undo and remove the camera harness locking nut.

Figure 26 - Armoured cable locknut removal

7. Make note of its orientation; the spiked surface should face towards the metal box
surface (shown in the green circle on the right).

Figure 27 - Armoured cable lock nut orientation

8. Pass the connectors one at a time through the nut.

Figure 28 - Camera Video and Power/Data Connections

9. Remove the harness through the hole in the junction box housing.

Figure 29 - Camera tube disconnected from camera junction box

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10. Secure the locking nut back onto the camera harness cable to prevent loss.

Figure 30 - Locknut fitted to prevent loss

11. Remove the air purge air hose from the back of the air tube. Using a 19mm spanner,
undo the air purge hose from the back of the air tube.

Figure 31 – Removing Air Purge Hose from Air Tube

12. Before removing the air tube, mark with a scribe or permanent marker, a line going
across the frame and the tube as shown in the picture below which will allow the camera
to be reinstalled in the same position:

Figure 32 – Marking the correct Camera Position

13. Remove the air tube by removing the 3x hex socket headed bolts as circled below in red.
The tube can now be slid rearwards and removed from the frame assembly.

Figure 33 – Removing the Air Tube

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4.3.2.2 Camera Tube – Installation (Existing Tube)
Follow this guide whilst referring to the pictures in the removal section (4.3.2.1).
1. To re-install the air cooled tube, slide the tube into the frame assembly.
2. Roughly line up the marking as previously added during the removal on the frame and
tube (Step 12). Screw in the three hex socket headed bolts. Check that the marking is
now aligned accurately before tightening the 3x hex socket head screws.
3. Attach the air purge hose to the air tube by hand until it cannot be turned anymore.
Using a 19mm, tighten the air purge hose (do not over tighten as it may shear off or undo
the brass fitting next time it is removed). Ensure air purge hose is not twisted.
4. Install the camera harness into the junction box. Remember to remove the locking nut
and re-install, ensuring the correct orientation with the spiked surface facing down.
Again do not over tighten the locking nut. Push in the green connector and twist the BNC
connector to connect the harness to the junction box.
5. Replace the junction box cover.
6. Reapply the power and air and test the system; ensure the image in the control room is
as it was before.

4.3.2.3 Camera Tube – Installation (Replacement Air Tube)

Follow this guide whilst referring to the pictures in the removal section (4.3.2.1).
1. To install the air cooled tube, slide the tube into the frame assembly.
2. If installing in the cooler, make note of where the window needs to be pointing within the
cooler and align the tube this way.
3. Screw in the three hex socket headed bolts.
4. Attach the air purge hose to the air tube by hand until it cannot be turned anymore.
Using the appropriate spanner, tighten the air purge hose (do not over tighten as it may
shear off or undo the brass fitting next time it is removed).
5. Install the camera harness back into the junction box, remember to remove the locking
nut and re-install following the correct orientation with the curved surface facing down.
Again do not over tighten the locking nut. Push in the green connector and twist the BNC
connector to connect the harness to the junction box.
6. Replace the junction box cover.
7. Reapply the power and air.
8. Have someone in the control room and someone at the camera. By communicating by
either radio or phone, ensure the image angle in the control room is correct.
9. If adjustment is required, retract the ThermaScope by selecting Camera OUT on the
Control Unit control circuit card.
10. Slightly undo the 3 x hex socket head bolts from the back of the air tube, adjust the tube
slightly in the required direction and tighten up.
11. Insert the camera by selecting Camera IN on the Control Unit control circuit card.
12. Check the image.
13. Repeat steps 9-12 until the desired image is achieved in the control room.
14. Once the desired image is achieved, mark the frame and camera tube as previously
described with a scribe or permanent marker for future reference.

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4.3.2.4 ThermaScope Camera Aim Adjustment (Cooler)

The ThermaScope cooler camera aim can be adjusted so that the correct image is obtained in
the control room.

· This can either be rotating the tube vertically as shown in section 4.3.2.5.
· If the camera is installed and looking in the wrong direction along the kiln, the tube can
be removed and rotated 180 degrees to point in the opposite direction. To remove and
refit the camera tube, see chapter 4.3.2.1.
· If the image is upside down, toggle the IMAGE ROTATION switch in the Control Unit
4.6.2.1.6.

A correctly aimed cooler camera is shown here with the

ceiling of the cooler at the top of the screen. The clinker
drop area is visible.
· If the camera is looking too high, the ceiling will
cover too much of the field of view and it will not be
possible to see the clinker cooling bed.
· If the camera is aimed too low, it may not be
possible to see the clinker drop area.
Figure 34 - Correct cooler camera aim

4.3.2.5 Vertical Adjustment

1. The angled air tube can be adjusted in the vertical axis to allow the user to view the
desired area of the cooler.
2. loosen the x3 screws slightly (Highlighted in the red circles)
3. Rotate the tube either clockwise or anti-clockwise and tighten the screws.

Figure 35 – Air Tube Adjustment

4. The image should now be checked in the control room and adjusted again if needed until
the image is correct. Once this is achieved, a mark should be put across the tube and
frame to mark the correct position (Figure 32 – Marking the correct Camera Position).

4.3.2.6 Camera Direction Change

1. Remove and refit the camera tube in the desired direction, as described in section
4.3.2.1 and 4.3.2.2, ensuring the air hose and cable are not twisted.
2. If the picture is upside down, it can be corrected by switching the IMAGE ROTATION
switch in the control unit shown in section 4.6.2.1.6.
3. Perform the image adjustment as described in section 4.3.2.5

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4.3.3 Camera Tube End Cap – Removal & Installation

The end cap of the Kiln camera is a sacrificial/consumable part of the system that is intended to
protect the camera from direct heat and clinker. Due to this it is expected that it will need to be
replaced at some point depending on its condition. This would typically be done every 6
months, however since different processes will subject the end cap to varying temperatures and
amounts of material wear, it should be checked every week to monitor when it will be due for
replacement.

Figure 36 - End cap spanner (Part Number OT830018)

· The ANGLED end cap ring is removed using the LARGER ring of the spanner
· The STRAIGHT end cap is removed using the SMALLER ring of the spanner

Before carrying out any work on the air tube, ensure that it has cooled down
sufficiently to avoid a burn injury or damage to the camera. Ensure the air
system is depressurised and the quick release fittings are disconnected from
the frame.

4.3.3.1 STRAIGHT End Cap – Removal and Installation

1. In order to remove the end cap, the air tube should be removed from the frame assembly
(Chapter 4.3.2.1).

Figure 37 - STRAIGHT Camera End Cap Removal

When undoing the cap, check that the camera assembly is not sticking or
caught and rotating. The WHITE CERAMIC IS VERY BRITTLE and will break if
excessive force is applied.

2. To remove the end cap, use the end cap spanner to unscrew anti-clockwise from the air
tube and remove CAREFULLY.
3. Inspect the camera and end cap for signs of damage and wear.
4. To install the end cap, CAREFULLY slide the end cap over the camera and screw
clockwise until a secure fit is ensured.

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4.3.3.2 ANGLED End Cap – Removal and Installation
1. In order to remove the end cap, the air tube should be removed from the frame assembly
(Chapter 4.3.2.1).

Figure 38 - ANGLED Camera End Cap Removal

5. To remove the end cap, use the end cap spanner to unscrew the securing collar anti-
clockwise from the air tube and CAREFULLY remove. The camera is spring loaded so
ensure that the end cap does not twist when removing the securing ring.
6. CAREFULLY slide the end cap off of the camera
7. Inspect the camera and end cap for signs of damage and wear. Hold the end cap up to a
light and inspect for pin holes of light.
8. To install the end cap, CAREFULLY slide the end cap over the camera and ensure that
the camera is centralised on the camera tube.
9. The end cap needs to be held securely so that the spring is compressed.
10. Ensure the end cap keyway is engaged correctly.
11. Install the securing ring screw clockwise until a secure fit is ensured. Check the camera
is centrally aligned and the securing ring is not cross threaded.

Angled end cap keyway Incorrect end cap fitment Correct End Cap Fitment
Figure 39 - ANGLED end cap fitment

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4.3.3.3 ThermaScope Sapphire Window – Cleaning and Replacement

The sapphire window is a high temperature material that protects the camera from the direct
heat radiated from the kiln, whilst allowing the required wavelength through to the camera.

NOTE: There are two sizes of Sapphire Windows available. It is important to

identify the type that you have in your system so that the correct part is used. It
is not possible to use a 1mm lens in a 2mm camera and visa versa.

1mm Sapphire Window

These are used on older ThermaScope systems

Figure 40 - 1mm sapphire window camera identification

2mm Sapphire Window

These are used on newer ThermaScope systems

Figure 41 - 2mm sapphire window camera identification

The white ceramic section of the camera is very brittle and should be handled
with care. DO NOT OVER TIGHTEN sapphire window retaining screws (Item 2,
Figure 24) as the ceramic thread is VERY FRAGILE.

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4.3.3.4 Sapphire Window Cleaning/Inspection
The sapphire window can become dirty or damaged, causing the image to become blurred or
poor quality. If the window is dirty, initially the customer should try cleaning the window using a
limescale remover.

If the window cannot be cleaned and the image quality is still affected, the sapphire window
should be replaced. The procedure is the same for the kiln and cooler cameras.

4.3.3.5 Sapphire Window - Removal

1. Disconnect and remove the camera tube (4.3.2.1 Camera Tube Assembly – Removal)
2. Take the camera tube to a CLEAN WORKING ENVIRONMENT
3. Remove the end cap of the camera tube (4.3.3 Camera Tube End Cap – Removal &
Installation)
4. Remove the 2x M2x5 Torx head screws (2) securing the HD window holder (1).
5. Remove the HD window holder (1) from the face of the HD camera.
6. Remove the Sapphire window (3) from the HD window holder (1).

Figure 42 – Sapphire Window Replacement

4.3.3.6 Sappire Window - Installation

1. Place the Sapphire window (3) into the HD window holder (1).
2. Using the 2x M2x5 Torx screws (2) secure the HD window holder (1) complete with
Sapphire window (3) to the face of the HD camera. DO NOT OVER TIGHTEN, as the
screw threads directly into ceramic material and is very brittle.
3. Clean the Sapphire window to remove any finger prints or smudges.
4. Refit the camera tube onto the frame assembly (4.3.2.2).
5. Check the image in the control room.

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4.4 ThermaScope HD Frame Assembly
The ThermaScope HD frame assembly provides the interface between the kiln, camera and
services. The outer shell of the frame is made from stainless steel which protects the air tube
from direct contact with clinker and heat. The air tube is only accessible via the underside of
the frame which guards against accidental exposure of the camera. The HD frame assembly is
the same for all 4 variants of ThermaScope systems. The below drawing shows a breakdown of
the HD frame assembly:

Figure 43 – Frame Assembly Parts

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4.4.1 Removing and Attaching the HD Frame Assembly

The ThermaScope HD Frame Assembly is secured to the wall sleeve enclosure which is bolted
to the kiln or cooler.

Figure 44 – Frame Assembly Removal

1. Loosen the two bolts a few turns at the top of the frame (DO NOT REMOVE).

2. Remove the two bolts at the bottom of the frame.

3. Store the two bolts on the opposite side to ensure they are not lost.

4. Stand close to the frame, using two hands, lift the ThermaScope in an upwards motion; the
frame should come clear of the wall sleeve enclosure. If not, repeat step 1 and try again.

To reattach the frame to the wall sleeve assembly, repeat the steps above in reverse order.

- 36 -
4.4.2 Fall Back Arrestor (Optional)

The fallback arrestor is only used in installations where the ThermaScope is fitted at an acute
downward angle. The fallback arrestor mechanism will prevent the ThermaScope tube from
moving forward under gravity, this is particularly important should there be an air supply failure.
The arrestor itself is just a simple spring plunger that retracts upon insertion of the air tube.

Figure 45 – Fall Back Arrestor Plunger and Plate

A supply of air is fed from the rear of the carriage mechanism into the plunger cylinder when the
ThermaScope tube is inserted which causes the plunger to retract into its housing. When the
camera is retracted, the spring loaded plunger is released back up allowing the stop plate to
slide over the plunger which locks the air tube in the retracted position.

Figure 46 – Fall Back Arrestor Air Connection

It can be seen that the attachment for the arrestor mechanism goes into the lower connection
space. If no arrestor is fitted, there will be an empty space instead.

- 37 -
4.5 Camera Power/Data Cable
The camera data cable connects the ThermaScope HD Assembly junction box to the Control
Unit. It is composed of a shielded co-axial cable for transmitting the video data and signal
control wires for camera control via a CANBUS data link (Blue/White) and 24VDC power
(Black/Red). These are enclosed within an armoured shell to protect the cable from damage.

Figure 47 - Camera Power/Data Cable Schematic

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4.5.1 Removal

Before working on the ThermaScope, ensure that the AIR and POWER are turned
OFF.

1. Retract the camera from the kiln or cooler using CAMERA IN/OUT switch in Control Unit.
2. Switch off electrical power and wait 30 seconds.
3. Unscrew the 4 captive screws securing the plate to the frame junction box and remove:

Figure 48 – Frame Junction Box Rear Plate Removal

4. Unplug the camera BNC cable and electrical connector (Normally right side for control
unit, left side for camera,)

Figure 49 – Disconnecting Control Unit Cable

5. Using a 24mm spanner, undo and remove the camera harness locking nut.

Figure 50 - Armoured cable locknut removal

- 39 -
6. Make note of its orientation; the spiked surface should face towards the metal box
surface (shown in the green circle on the right).

Figure 51 - Armoured cable lock nut orientation

7. Pass the connectors one at a time through the nut.

Figure 52 - Camera Video and Power/Data Connections

8. Remove the harness through the hole in the junction box housing.

Figure 53 - Camera power/data cable disconnected from camera junction box

- 40 -
 9. Secure the locking nut back onto the camera harness cable.

Figure 54 - Locknut fitted to prevent loss

10. To remove the data cable from the Control Unit, first unplug the BNC connector and
green connector from the control board as shown below.

NOTE: There are fragile fibre optic cables in the Control Unit. Care must be
taken so that these cables are not damaged or bent beyond their minimum
bend radius.

Figure 55 - Camera video and power/data connections inside control unit

11. Next, undo the lock nut securing the cable to the control unit using a 24mm spanner.
12. Pass the connectors one at a time through the nut.
13. Remove the harness through the hole in the Control Unit.
14. Secure the locking nut back onto the camera harness cable.

4.5.2 Install

To install the camera data cable, simply follow the removal instructions in reverse order.

- 41 -
4.6 Control Unit
The control unit provides the necessary services required by the system at the kiln or cooler. It
measures 500mm x 500mm x 250mm approx. It is broken down into 3 sections; POWER,
ELECTRONICS and AIR. The power supply provides the required voltages used by the system
from the 110/240V site supply. The electronics control the ThermaScope unit at the kiln or
cooler and transmit the video signal to the control room via fibre optic cable. It also houses the
air accumulator, air filters and associated valves and pipe work to supply the air cooling and
insertion and retraction mechanism.

Figure 56 – Control Unit Sections

Uninterruptable Power Supply (UPS)

The ThermaScope HD has a power failsafe to extract the camera on loss of supply;
The Camera Control Unit MUST NOT be connected to a UPS.

- 42 -
Figure 57 - Control Unit Schematic Diagram

- 43 -
4.6.1 Power Section

It should be noted that the ThermaScope works off the mains electricity supply. All
work carried out on the ThermaScope HD MUST only be done by a qualified
engineer, and all safety precautions must be observed to avoid the possibility of
electric shock or death.

The power section converts the 110/240V site supply to the voltages required by the system
hardware.

Figure 58 – Control Unit Power

· The site supplied power should be a constant supply between 110/240V single phase, 50-
60Hz AC. If the supply is lost to the Control Unit, the ThermaScope will automatically retract
from the kiln or cooler.

· The master power switch is used to turn on or isolate the power to the Control Unit. It has
two positions, ON and OFF. The switch can be locked in the OFF position by a padlock if
maintenance is being carried out by up to 3 padlocks; this is to prevent accidental switch ON
of the equipment which may cause injury or death. This should be used in conjunction with
the site’s Health and Safety procedures.

· The utility socket fuses are for the Control Unit utility socket. This is for use by Thermoteknix
engineers and does not affect the system operation.

· The Control Unit fuses protect the system from over voltage/current situations. If the system
does not power up, these fuses should be checked. Both supply and return are fused to
account for different countries power supply arrangements.

In the event that access is required to the Control Unit power supply, the protective cover will
need to be removed. To do this, first ensure that any fibre optic cable is removed from the
- 44 -
plastic cable tidy fitted to the front of the protective cover. Loosen the 3 screws shown circled in
red in Figure 59 (do not remove). The protective cover should slide to the left and the cover can
be removed. It is replaced by carrying out the above instructions in reverse order.

Figure 59 – Power Supply Cover Removal

Figure 60 – Power Supply Composition

· The utility socket is for use by a Thermoteknix engineer and provides mains voltage.

· The AC-DC converter converts the AC supply to a DC level used by the system.

· The EMI filter protects the electronic circuitry from electronic interference transmitted via
the site supply.

· The double pole switch is used to turn the mains power on or off as supplied into the
system via the site supply.

- 45 -
4.6.2 Electronic Section

The Control Unit of the ThermaScope provides all the necessary data and interconnections for
controlling both the ThermaScope and the video/data for the Multi-View PC to display.
It also ensures that the user is able to locally retract and extract the ThermaScope should the
need arise. There is a second PCB BK030016 T’Scope HD Power Down PCB that fits over the
main control board BK030006. This disconnects the 24V supply to the camera in the event of
loss of purge air, to avoid excessive heat load on the camera. This board BK030016 is not
shown in some of the following photos for clarity.

There are no differences between the HDT and HDC control unit.

Figure 61 – Control Board

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 Figure 62 – BK030016 Power Down PCB fitted.

4.6.2.1 Control Switches

The control switches are located on the right hand side of the control board in the control unit.
They consist of 2 push buttons and 4 toggle switches; the toggle switches have two positions.
The purpose of this is for facilitating maintenance, testing and setting up of the image.

Figure 63 – Control Switches

4.6.2.1.1 ALARM RESET

If an alarm occurs in the system, the ThermaScope will retract from the kiln or cooler. The
event will be logged in the memory, which will keep the camera in the retracted position.

If an alarm occurs, ALWAYS inspect the camera and end cap condition BEFORE
resetting the system and inserting the camera into the kiln.

Pressing the alarm reset button, clears the alarm cache. This forces the system to clear its
memory of any old alarms and will allow the ThermaScope to be re-inserted into the kiln or
cooler. In the event that pressing this button does not send the camera back into the kiln or
cooler, it indicates that the original fault has not been fixed.

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4.6.2.1.2 ALARM OVERRIDE:
If an alarm is triggered where the camera cannot be re-inserted into the kiln automatically or by
resetting the alarms; the alarm override button can be pressed. This will send the camera into
the kiln regardless of any alarms but only for as long as the button is held. The camera will
operate depending on the toggle switch positions. This should only be used to test which parts
of the system are working and should not be used to insert the camera for any length of time as
damage may occur to the camera and tube. The cause of the fault should be identified and
repaired before the camera will insert into the kiln for normal operation.

The ThermaScope HD camera should never be sent into a hot kiln/cooler if there is a
low air pressure alarm. For Control Unit software version 6.13 and later, the alarm
override does not send the camera in if there is a LOW AIR PRESSURE alarm.

4.6.2.1.3 CAMERA IN/OUT:

The CAMERA IN/OUT toggle switch inserts or retracts the camera from the kiln/cooler. This
switch will override any control to insert/extract the camera, to prevent the PC operating the
camera whilst maintenance is being undertaken on the system.

Figure 64 - Camera OUT (Extracted) [Left] - Camera IN (Inserted) [Right]

4.6.2.1.4 REMOTE/LOCAL: NO FUNCTION

4.6.2.1.5 TEST PATTERN:

The test pattern switch generates a test pattern from the camera
head. This allows the system testing and the signal to be traced to
test the cables integrity. This would normally be performed with
assistance from Thermoteknix during fault finding and is not for
normal use of the camera.
Figure 65 - An example of the test pattern

4.6.2.1.6 IMAGE ROTATION:

The image rotation toggle switch is used to rotate the image by 180 degrees. This switch will be
used with cameras in coolers where the camera can be installed on either side of the cooler or
in coolers where the customer wants the camera to face in the opposite direction from where
the clinker is falling. This will be set up at commissioning by the Thermoteknix Service
Engineer.

Figure 66 - Image rotation example

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4.6.2.2 External Status LED’s

There are LED’s externally on the side of the control unit, that give the user the current status of
system. The LED’s should be checked in the event of a system fault or alarm in order to identify
what has caused this.

Figure 67 – External Status LED’s

There are 3 distinct areas of the panel, ERROR, 24V POWER and CAMERA TEMPERATURE.
The error section consists of various events that could occur with the ThermaScope system.
The LED will either be off which indicates no error, or red which indicates an error related to that
particular event. Any one of these errors will result in the camera retracting automatically from
the kiln or cooler.

1. CAMERA OVER TEMPERATURE - This LED will illuminate when the camera sensor
temperature is above 95 degrees Celsius (203 degrees Fahrenheit). The camera will
automatically retract to protect the camera from excessive heat damage. It will not be
possible to reinsert the camera until the camera cools down below this temperature.

2. CONTROL UNIT OVER TEMPERATURE - This LED will illuminate if the control board in the
control unit reaches a critical temperature. If this occurs, efforts should be made to cool the

- 49 -
 control board immediately to prevent permanent failure and the control unit should be
switched off. The Control unit location should be protected or the unit position moved away
from heat sources if this LED is illuminated.

3. LOW AIR PRESSURE - This LED will illuminate if the incoming air pressure to the control
unit drops below 0.05MPa [0.5Bar] below site supply air pressure (0.3MPa/3Bar minimum
pressure on older systems) – as set on the pressure switch.

4. CANBUS COMMUNICATION FAILURE - This LED will illuminate if communication is lost

between the camera and the control unit.

5. FIBRE OPTIC COMMUNICATION FAULT - This LED will illuminate if communication is lost
between the control unit and receiver unit in the control room.

6. NO VIDEO SIGNAL – The function of this LED is performed by the COAX_LOSS LED inside
the Control Unit as shown below. If the video from the camera is being received by the
Control Unit, the COAX_LOSS LED will be GREEN. If the Video is not being received, the
COAX_LOSS LED will illuminate RED.

Figure 68 - COAX_LOSS LED location

7. CONTROL UNIT EXTERNAL RETRACT LINK OPEN - This LED will illuminate when the
external retract function is operated. For details see section 4.5.2.3.

8. CONTROL UNIT PCB IN/OUT SWITCH - This LED will illuminate when the camera IN/OUT
switch is set to OUT. It extinguishes when the camera is sent in.

9. CONTROL UNIT PCB 24V - The LED will be green in normal operation which is when the
board is powered up with 24V from the power supply. If no 24V supply is present, the LED
will be off and the camera will retract from the kiln or cooler.

10. CAMERA TEMPERATURE MAXIMUM LIMIT - This red LED will illuminate if the cameras
internal temperature is above 95°C (185°F) and will illuminate in conjunction with LED 1. It
will extinguish once the cameras temperature drops below this temperature.

- 50 -
11. CAMERA TEMPERATURE HIGH - This amber LED will illuminate if the camera
temperature is between 75 and 85 degrees Celsius (167-185 degrees Fahrenheit). The LED
will be off when the temperature is below this range and the camera will not retract at this
temperature.

12. CAMERA TEMPERATURE NORMAL (High Range) - This green LED will illuminate when
the camera temperature is between 65 and 75 degrees Celsius (149-167 degrees
Fahrenheit). When the camera temperature is below this range, the LED will be
extinguished; the camera will not retract.

13. CAMERA TEMPERATURE NORMAL (Low Range) - This green LED will illuminate when
the camera temperature is below 65 degrees Celsius (149 degrees Fahrenheit). When the
camera temperature is above this range, the LED will be extinguished.

- 51 -
4.6.2.3 External Retraction Control

The control board in the Control Unit has a connector that is used to externally retract the
camera from the cooler or kiln. This feature can be integrated into site equipment to enable a
retract override situation to protect the camera from potential damage (Kiln over pressure
sensor for example). The connector consists of 4 pins; pins 3 and 4 should be shorted together
when the ThermaScope is in normal operation. To retract the camera, pins 3 and 4 should be
open circuit. When not using the user retract feature, pins 3 and 4 should be shorted together.
Thermoteknix supply a shorting connector as standard with all systems.

Figure 69 – External Retraction Control

Pins 1 and 2 are not used on the connector so these should not be used.

NOTE: Some early systems required pins 3 and 4 to be shorted together to RETRACT
the camera. If in doubt, please contact support@thermoteknix.com to confirm which
version you have.

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4.6.3 Air Section
No attempt should be made to connect/disconnect an air hose to the
ThermaScope with the main air supply supplied the control unit.

ALWAYS ensure that the air supply is OFF when working on the ThermaScope
hardware and the system is DE-PRESSURISED.

The air section of the Control Unit is comprised of the filters, gauges and air switches for
conditioning, distributing and monitoring the ThermaScope air supply.

Figure 70 – Air Section

4.6.3.1 Air Hose Connections

Air connections from the Control Unit to the camera tube (air purge) and the pneumatic cylinder
assembly are made using the ¼” bore hoses. The connections to the control unit are by 90
degree ¼” BSPP fittings and are colour coded. The connections to the pneumatic cylinder are
by quick release couplings, which are colour coded and keyed. The air purge connector at the
camera tube is a 90 degree ¼” BSPP. The hoses are supplied in 10 metre lengths as standard.

MK030072 Camera In: 90 deg 1/4" BSPP x 10m long hose x RED quick release
MK030073 Camera out: 90 deg 1/4" BSPP x 10m long hose x BLUE quick release
MK030071 Air Purge: 90 deg 1/4" BSPP x 10m long hose x 90 deg 1/4" BSPP

Figure 71 – Air Hose Colour Code

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 Figure 72 – Air Hose Connections

The air hose locations are colour coded on both the Control Unit and the HD frame assembly.
The hoses are also colour coded so identification is straight forward.

4.6.3.2 Site Air Supply

The ThermaScope HD camera uses compressed air for cooling. The air supply to the
ThermaScope HD camera should be between 5-8 Bar and capable of supplying 300 litres/min
at Standard Temperature and Pressure (STP).

To avoid damage if the air supply is suddenly lost or if an operator accidentally switches the air
supply off, a 270 litre air receiver (reservoir) should be fitted on the supply side or the air inlet to
the Control Unit. Thermoteknix supply the air fittings and hose connection, but the customer
should supply the air receiver so that it meets all applicable pressure vessel safety legislation
and site requirements.
See Figure 75 - Air Receiver Fitting Kit Connection Schematic (Including Optional Air Drier
System) for the air system schematic.

NOTE: The site should ensure the air receiver complies with all applicable pressure
vessel safety legislation. It should have a pressure relief valve, a pressure gauge
and a condensate drain valve. It should also be suitable for the site requirements,
including the maximum pressure of the compressed air system.

The air receiver should be mounted securely at a suitable location close to the Control Unit. It
should be out of direct sunlight and protected from other sources of heat.

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 Figure 73 – 270 litre Air Receiver

Figure 74 – Site Air Supply Connection to Air Receiver

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Figure 75 - Air Receiver Fitting Kit Connection Schematic (Including Optional Air Drier System)

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The following image shows where the air supply should be connected to the Control Unit:

Figure 76 – Air Connection into Control Unit

The Air Receiver contains pressurised air after the air supply has been switched
off/isolated. Any user must ensure the system has fully de-pressurised before
starting work on the system.

4.6.3.3 Air on/off switch

Some older Control Units have an air switch located within the Control
Unit. However using this to switch negated the benefit of the air
receiver, so it should not be used. It should always be in the open
position where ‘SUP’ (Supply) is displayed. The air should be switched
off using the valve between the site supply and the air receiver.

Figure 77 – Air Supply ON/OFF

NOTE: The ThermaScope safety mechanisms should not be tested by switching the
air off.

Even if the air supply is switched off, the air receiver and air accumulator in the
Control Unit retains pressurised air, so the camera tube is still capable of moving.
The BLUE and RED quick release fittings to the camera frame should always be
removed before working on the camera.

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4.6.3.4 Air filters

The air filter section consists of two inline air separators. The filters will
separate small amounts oil or water from the site supplied air. If the site
supplied air is heavily contaminated with moisture or oil, a pre filter
should be provided before the air enters the control unit; these are not
supplied by Thermoteknix. The filters are fitted with a drain tube which
drains outside of the Control Unit which is gravity fed. If there is too
much contamination in the air supply for the filters to handle an air dryer
will be required (available separately through your normal sales
channel).

ALWAYS ensure that the air supply is OFF when working on

the ThermaScope hardware and the system is
DE-PRESSURISED.

Figure 78 – Air Filters Removal

4.6.3.4.1 Remove/Replace Filter

1. Set the CAMERA IN/OUT switch to OUT to extract the camera from the kiln.
2. Wait 2 minutes to allow the camera to cool.
3. Turn the air supply off to the camera system and allow any pressure to dissipate from the
air reservoir (This may take another two minutes). You should see the system pressure
slowly drop.
4. Check the air supply pressure is 0MPa on the pressure regulator gauge
5. Remove by pulling the grey centre tab down and pull the whole filter down at same time
then twist to release the transparent filter bowl.
6. The filter can be removed by unscrewing.
· The White filter is fitted to the inlet filter (Right)
· The Black filter is fitted to the secondary filter (Left)
7. Fit new filters by screwing into place, ensuring they are not loose.
8. Refit the transparent filter bowl by inserting off centre and twist so that the grey locking
tab locates in the centre (A ‘click’ should be heard if seated correctly)

4.6.3.5 Air Pressure Regulator

The air pressure regulator allows the air pressure to be set for the
ThermaScope air supply. The pressure should be adjusted to 0.5 and 0.8 MPa
(5-8 Bar) as indicated on the pressure gauge. To do this, pull down on the cap
on the bottom of the regulator to unlock the adjuster. Turn the cap clockwise or
anticlockwise to increase or decrease the pressure. When the correct pressure
is displayed on the gauge, the cap should be pushed up to lock the adjuster
and stop accidental adjustment of the regulator.

Figure 79 – Air Pressure Regulator

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4.6.3.6 Air Pressure Switch

The air pressure switch is attached between the air pressure regulator
and the air accumulator. It is electrically connected to the control board
within the control unit. In the event of the air pressure to the system
falling 0.05 MPa (0.5 Bar) below the site supply pressure, the air pressure
switch will operate and switch over the air supply to the air accumulator
which will retract the ThermaScope camera from the kiln or cooler. This
will enable the camera to be safely withdrawn to avoid heat damage. A
loss of power will also retract the camera.

On Control Units with the Power Down PCB fitted, the camera power will
also be disconnected in the event of a low pressure air alarm (ERROR 3).
This will also illuminate ERROR 4 on the camera Control Unit warning
panel.

On older systems, the Air Pressure Switch is set to 0.3 MPa (3 Bar).

Figure 80 - Air Pressure Switch

4.6.3.7 Air Accumulator

The air accumulator is an air reservoir which stores enough air

pressure to retract the ThermaScope in the event of air or
power failure. It holds enough air to retract the camera
once from the kiln or cooler so cannot be used again until
it is recharged from the site air supply. This is carried out
when the air supply is reapplied to the system. There is no
maintenance to be carried out on the accumulator.

NOTE: The air accumulator is supplied via a non-return

valve, so it still contains pressurised air after the air
inlet valve has been closed.

Figure 81 – Air Accumulator

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4.6.3.8 Air Solenoid

The air solenoid controls the insertion and retraction mechanism for the camera.
· The speed of the insertion and retraction can be adjusted to allow the smooth operation
of the air tube in and out of the kiln or cooler.
· It has a 24V LED showing that the unit has power. If the LED is illuminated, the camera
air supply will insert the camera into the kiln. The LED will extinguish when the camera is
extracted from the kiln.
· There is a button which allows the camera to be inserted into the kiln or cooler (see
Figure 82). The button is mechanical in nature and can be operated with or without
power. Holding the button in inserts the camera, releasing the button retracts the
camera.

The blue manual button on the solenoid should NEVER be pressed to send the
ThermaScope HD camera into a hot kiln/cooler if there is a LOW AIR PRESSURE,
or CAMERA OVER TEMPERATURE alarm.

Figure 82 – Air Solenoid

To set the insertion/retraction speed of the camera, the Camera In/Out button on the Control
Unit PCB should be used to check the camera travel speed.

Figure 83 – CAMERA IN/OUT switch

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4.6.3.8.1 Adjusting the Insert/Retract Speed

If the ThermaScope becomes too slow on either insertion or retraction, the following procedure
will enable the user to adjust the speed of the ThermaScope travel. To increase or decrease
the speed in which the ThermaScope goes in and out of the kiln or cooler, the two exhaust
valves in Figure 84 are used.

1) Insert the ThermaScope into the kiln by switching to IN (Figure 83) and check the speed,
it may well be OK and not need altering. Then switch to OUT and monitor the out speed.
If either of the speeds need changing (The travel should be smooth with no ‘jumping’. It
should not be too quick which can cause damage, nor too slow so that it looks like the
camera is not inserting/retracting) follow the rest of these instructions. The camera
should insert or retract within 5 seconds.

2) To adjust the IN speed loosen the lock nut just behind the plastic rotary switch, this is a
locking device and needs to be loosened in order to allow free movement of the plastic
knob. You may find the plastic knob rotates with the collar, in order to stop this hold the
plastic knob whilst turning the metal collar in an ANTI-CLOCKWISE direction.

3) Now adjust the plastic knob Clockwise or Anti-clockwise depending on whether you want
to increase the speed or decrease the speed. Only a slight adjustment say ¼ of a turn is
necessary each time before retesting the speed by following instructions in number 1.
CLOCKWISE REDUCES the speed ANTI-CLOCKWISE INCREASES the speed.

4) Continue adjusting and switching as per instructions in 1, 2 and 3, until desired speed is
reached. Then holding plastic knob and ensuring it does not move rotate the locking
collar clockwise to lock the knob in place.

5) Repeat the above for the OUT speed. The camera should extract from the kiln in less
than 5 seconds.

Figure 84 – Camera Speed Adjustment

NOTE: If camera does not retract from the kiln/cooler for any reason, disconnect the
quick release fittings from the frame (Blue & Red) and pull the camera out by hand.
Ensure suitable gloves are worn.

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4.6.4 Fibre Optic Cable

The cable comes complete with terminated LC connectors, which are protected in a section of
conduit when the cable is pulled. The specification is listed below:

Fibre Optic Cabling Specification

Cable Maximum Length Maximum Allowable Loss Budget
9/125µm Single Mode 2000m <0.4dB/km @1310nm
Figure 85 – Fibre Specification

4.6.4.1 Connection of Fibres

The fibre connects between the PCB in the Control Unit, to the receiver unit in the control
room/server room. The fibre is supplied with two spare fibres for redundancy should one
become damaged. It is vital that a note is made of the colour of the Fibre and to which port on
the board it is connected to, as this MUST be reversed on the receiver unit.

Figure 86 – LC connector

NOTE: Thermoteknix do not recommend the use of fibre patch panels. End to end
connectivity should be achieved using the fibre cable provided.

Figure 87 - Fibre Optic data path between Control Unit and Receiver Unit

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4.7 Receiver Unit
The ThermaScope HD Receiver Unit converts the fibre optic signal sent from the control unit
back to a digital signal used by the Multi-View PC. It is a 2U rack mountable unit that can also
be placed on a desk top, measuring W445xD272xH85mm.

Figure 88 – Receiver Unit Front View

The unit is standard for both HDC and HDT systems so comes with the connections required for
either. The connections that are used will be explained further in this chapter. The unit is also
supplied with a country specific mains lead. The standard length of the supplied HDMI cable is
5 metres so this should be taken into account when locating on a desktop. If installing in a rack
in a server room, a 20m HDMI cable can be supplied as an optional extra if required.

4.7.1 Receiver Board

The receiver board is housed within the Receiver Unit; it converts the incoming optical signal
from the control unit back to the analogue signal used by the PC. The unit has a built in power
supply which is mains powered and the same as in the Control Unit.

Figure 89 – Receiver board

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4.7.2 Receiver Unit Connections

The ‘USB’ connects to the Multi-

View PC and carries system data
and status
+24V – 24V supply to board is good when lit
+5V – 5V supply to board is good when lit
+3.3V – 3.3V supply to board is good when lit
LDO GOOD – power to LDO is good when lit

The ‘HDMI’ connector can output HDC video

to a monitor via HDMI cable (optional)

The ‘SDI VIDEO’ connects to the Multi-View PC and carries the

camera video signal. Ensure that the BURNER and/or COOLER
cables are connected to the correct Multi-View PC BNC cards.
They will be labelled for easy identification.

The ‘TEST’ toggle switch gives the user the ability to switch the test
pattern ‘on’ or ‘off’. The test pattern is used to prove there is a signal
being sent to the PC from the receiver unit.
Figure 90 – Receiver Unit Connections

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Figure 91 - Receiver Unit Schematic Diagram

- 65 -
4.8 Multi-View PC
The Multi-View PC uses a SDI/HDMI Mini Recorder Capture Card (GX040381) to process the
raw video data from the camera.
· The PC is connected to the receiver unit via BNC terminated co-axial cable. This cable
connects between the SDI connections on the PC capture card, to the Receiver Unit.
· A USB connection between the Receiver Unit is used for non-video data such as alarms
and camera calibration.

Figure 92 – Multi-View PC - Connections to Receiver Unit

NOTE: If two cameras are used, ensure the receiver units are connected to the correct
SDI cards on the PC, as labelled and shown in the photos above.
Connect Burner to Burner. Connect Cooler to Cooler.

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5 MULTI-VIEW ALARMS & TROUBLESHOOTING
When the camera system experiences a fault, it will be displayed on the Multi-View timeline.
Details on how to view the timeline are contained in the Multi-View Application Manual supplied
with your system (EN) Application Manual.pdf.

5.1 Service Manager

Live system status is available via a separate program called Service Manager. Service
Manager Software is also able to provide more system information to help troubleshoot a
problem. Select the Burner Receiver Unit or Cooler Receiver Unit to display the system
status for that camera.

Figure 93 - ThermaScope Service Manager

The Service Manager software should be connected to the Receiver Unit during normal
operation to allow it to relay alarms from the Control Unit. If not connected, select the correct
receiver unit from the ThermaScope device dropdown menu and press Connect.

5.1.1 Status

RU Fibre Fault – The Receiver Unit is not receiving communications from the Control
Unit via the Receiver Unit inbound fibre optic cable.
CU Fibre Fault – The Control Unit is not receiving communications from the Receiver
Unit vai the Receiver Unit outbound fibre optic cable.
Low Air Pressure – The air pressure has fallen below the set air pressure alarm level
Tube Retracted – This alarm will become active if the camera insert solenoid is not
activated. This signal may experience a delay and take up to 10 seconds to update.
RU Voltage Fault – Supply voltage has deviated by more than 10% of the expected
value.
CU Voltage Fault - Supply voltage has deviated by more than 10% of the expected
value.
External Retract – The camera has been retracted using the external retract connection,
see (4.6.2.3 External Retraction Control)
Software Retract – The camera has been retracted using the Multi-View software
No link camera⇒RU – There are no communications between the camera and Receiver
Unit (CANBUS)
Sensor (°C) – Camera sensor temperature
Tube (°C) – Camera board temperature

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5.1.2 Configuration

RU Test Pattern – The test pattern switch has been turned on at the Receiver Unit, see
(4.7.2 Receiver Unit Connections)
CU Test Pattern – The test pattern switch has been turned on at the Control Unit, see
(4.6.2.1 Control Switches)
Alarm Reset – The alarm reset button at the Control Unit has been pressed, see (4.6.2.1
Control Switches)
Alarm Override – The alarm override button is being depressed at the Control Unit, see
(4.6.2.1 Control Switches)
Keep Camera Out – An error is stopping the camera from being inserted

Image Rotate – The image rotate switch has been turned on at the Control Unit, see
(4.6.2.1.6 Control Switches)
Calibrated – The software has access to a calibration table for the camera (HDT Only)

5.1.3 Alarms

Sensor too hot – The camera sensor has exceeded maximum of 95°C
Camera too hot – The camera circuit board has exceeded maximum of 85°C
Control Unit too hot – The Control Unit has exceeded maximum of 70°C
Low Air Pressure – The air pressure has fallen below set air pressure alarm level
No link CU⇔camera – There are no communications between Control Unit and the
camera
No link RU⇒CU – There are no communications between the Receiver Unit and
Control Unit

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5.2 HDC / HDT Alarm Troubleshooting

Once an alarm condition has been raised the ThermaScope will retract, and it will be necessary
to push the Alarm Reset button on the control board to reinsert it (see section 4.6.2.1 Control
Switches).

NOTE: Before replacing cables and boards it is recommended that Thermoteknix

support are involved through raising a support ticket by emailing
support@thermoteknix.com

5.2.1 Camera Over Temperature

The primary temperature sensor has surpassed 95°C, or the backup temperature sensor has
surpassed 85 °C; the camera requires further cooling.

Check Condition of camera end cap and lens.

Check air purge hose (Figure 72 – Air Hose Connections - Green Identification Markings)
connections are secure and no leaks are present
Ensure 0.5MPa (5 Bar) Minimum is being supplied to the system (Figure 79 – Air
Pressure Regulator)
Increase the air pressure being supplied to the camera (Figure 79 – Air Pressure
Regulator)
Fit a supplementary air supply to the wall sleeve (4.2.3 Attaching Enclosure
Supplementary Air).
After all checks have been carried out and ONLY IF THERE IS NO DAMAGE TO THE
CAMERA system, press the Control Unit ALARM RESET button to resume normal
operation.
If operation is not correct contact support@thermoteknix.com

5.2.2 Lost Air Pressure / Air Alarm

The instantaneous air pressure has fallen below 0.05 MPa (0.5 Bar) below site supply pressure

Check Condition of camera end cap and lens.

Increase the air pressure being supplied to the camera (Figure 79 – Air Pressure
Regulator).
Check that the pressure switch connector is correctly connected onto the controller board
(4.6.3.6 Air Pressure Switch).
If the ThermaScope shares an air source with other equipment and the air pressure is
regularly dropping more than 0.05 MPa (0.5 Bar) below site supply pressure, it may be
necessary to investigate external causes of the pressure drop.
After all checks have been carried out and ONLY IF THERE IS NO DAMAGE TO THE
CAMERA system, press the Control Unit ALARM RESET button to resume normal
operation.
If operation is not correct contact support@thermoteknix.com

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5.2.3 CANBUS Connection Failure / Communications

The data connection between the Camera and Control Unit has been interrupted.

F/W v6.13 and later - Press the Control Unit ALARM RESET button to reset
communication and resume normal operation (4.6.2.1.1 ALARM RESET).
F/W v6.12 or earlier – Reset the Control Unit power, using the master power switch
(4.6.1Figure 58 – Control Unit Power).
Open the camera Junction Box and check that the power LED is illuminated.

Figure 94 - Camera junction box PCB power indication LED

Perform a resistance check on the x4 wires in the cable between the Control Unit and
Camera junction box (Figure 25 – Disconnecting Camera Cable and Figure 55 - Camera
video and power/data connections inside control unit).
o Red - +24VDC
o Black - 0VDC
o Blue - CANBUS Camera Data
o White - CANBUS Camera Data
If operation is not correct contact support@thermoteknix.com

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5.2.4 Communications between Control and Receiver Units

There are no communications between the Control Board and Receiver Board.

Ensure the LC fibre plugs are correctly seated inside the Control Unit and Receiver Unit.
The connectors should click when inserted and the locking device engaged. The
connection on the left is not fully seated. The connector on the right is correctly seated.

Figure 95 - LC Fibre connection. Not seated correctly [Left] Seated correctly [Right]

Power reset the Control Unit using the master power switch (4.6.1 Figure 58 – Control
Unit Power).
Power reset the Receiver Unit (Figure 90 – Receiver Unit Connections).
Swap the fibres at both the Control Unit and Receiver Unit for the redundant fibres
(4.6.4.1 Connection of Fibres).

Figure 96 - Fibre Optic data path between Control Unit and Receiver Unit

Test the fibre optic cable for end to end connectivity to verify whether it has been
damaged and replace if necessary.
If operation is not correct contact support@thermoteknix.com

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5.2.5 No Video Signal

The control unit is not receiving a video signal from the camera.

Check the camera is inserted into the kiln/cooler.

Check condition of sapphire window and ensure clean.
Check for the alarm condition on the INSIDE of the control unit (Figure 68 - COAX_LOSS
LED location) to see if the problem is between the control and receiver units or between
the control unit and camera. LED Green = Video received. LED red = Video not received.
Push the Alarm Reset button on the control board (4.6.2.1.1 ALARM RESET).
Power reset the Control Unit using the master power switch (4.6.1 Figure 58 – Control
Unit Power).
Power reset the Receiver Unit (4.7.2 Receiver Unit Connections).
Investigate the external camera video and data cables for damage, replace if necessary
(4.5 Camera Data Cable).
If operation is not correct contact support@thermoteknix.com

5.2.6 Control Unit Over Temperature / Board Temperature

The Control Board has reached 70°C. The camera will retract. Check for alarm ‘Control Unit
over temperature’ on the outside of the control unit (0 External Status LEDs).

Provide a means of cooling the Control Unit.

Relocate the Control Unit to a cooler location.

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5.3 Software Diagnostic Reporting
When investigating a problem, it is often the case that we (Thermoteknix) do not know in
advance what information might be useful. It may not be obvious to you (as an end-user) which
part of the system is misbehaving. There may be features of your computer or network which
are unusual and relevant, but we may not know to ask about them and you may not realise that
they are relevant. To address these difficulties, we have produced a Diagnostic Reporting tool
and made it easily available from both the simple and advanced viewers.

If you are reporting a problem to Thermoteknix, we may ask you to run a report on your system
and send us the results. The report is in MHTML format and can be viewed in most web
browsers, so you may find it useful even before contacting Thermoteknix.

Instructions on how to generate a diagnostic report are in the Multi-View Configuration

Manual, at chapter 3.

5.3.1 Contacting Thermoteknix

Whilst we obviously hope that your Multi-View system always performs perfectly, and also hope
that the user manuals and other documentation provided with the product answer every
question, we recognise that you will probably need to contact Thermoteknix at some point in the
lifetime of the product.

More information on support options is provided at http://www.thermoteknix.com/support/.

Thermoteknix Support can be contacted at support@thermoteknix.com.

Please ensure that you provide the following information to ensure a swift resolution of
the issue:

Company
Site Name/Location
System Type
System Serial Number (Serial number located on rear of camera carriage
assembly)
Kiln Number (If applicable)
A FULL description of the issue. Photos and screenshots are VERY helpful!!

Thermoteknix are able to examine your system remotely if the camera PC is connected to
the internet and software downloaded via a special link provided by Thermoteknix. This
enables system fault investigation to be completed more swiftly. For details contact
Thermoteknix support on the email address above.

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