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Fluke Thermal Imaging
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Thermography Definition and Benefits How a Thermal Imager Works
Agenda Thermography Definition and Benefits How a Thermal Imager Works Thermography Physics How Does an Imager Measure Temperature Imager Optics IR-Fusion Technology Imager Features Ti10/25/32, & Ti5X Thermography Examples PC Software
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What is Thermography? Measurement of temperature
remotely and assignment of colors based on temperature. Very effective to inspect: Electrical equipment Electrical circuits Mechanical equipment Heating/cooling equipment Building envelope Electronic Other
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Thermal imaging Is the science of seeing heat patterns using special
electronic cameras Rather than seeing light, these remarkable instruments create pictures of heat. They measure infrared (IR) radiation and convert the data to images corresponding to the source temperatures.
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Fast, safe and accurate non-contact measurements
Can be obtained from objects even if they are: moving or very hot difficult to reach expensive to shut-down dangerous to contact contaminated or altered if contacted
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Advantages of infrared inspection programs
1. Safety - Avoid catastrophic failure or injury 2. Greater asset reliability - Reduces unscheduled outages 3. Increased revenue - More uptime, revenue is maximized 4. Reduced outage costs Planned maintenance saves 5. More efficient inspections Just looking for heat 6. Improved and less expensive maintenance 7. Reduced spare parts inventory - Fewer spares 8. Reduced operational costs
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Industry Sector Revenue/Hour
Downtime is expensive Industry Sector Revenue/Hour Chemicals $704,101 Construction and Engineering $389,601 Electronics $477,366 Energy $2,817,846 Food/beverage processing $804,192 Manufacturing $1,610,654 Metals/natural resources $580,588 Pharmaceuticals $1,082,252 Utilities $643,250 Source: Jacksonville Power Authority
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Thermal imaging Applies to most types of equipment and conditions
Is obtained without disturbing production Quickly identifies location of problems Allows for detection of problems before failure Can scan large areas quickly to identify areas of concern, a picture is worth 1000 words
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Proactive or reactive? Thermal Imaging can be used to both prevent problems from occurring and to troubleshoot them when they do. Thermal Imaging can make visible “the invisible” and help pinpoint potential problem areas faster than any other measurement tool.
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Exam. Of an invisible problem
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Thermal Imaging helps find/solve problems in electrical circuits
Overloaded systems or excessive current Loose or corroded connections Component failures Wiring mistakes Under-specified components Power quality problems like phase unbalance, overload or harmonic distortion Insulation failures The use of one technology does not exclude the use of another. Image shown here is Picture-In-Picture (PIP) mode where center ¼ of image is IR surrounded by ¾ visible
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Thermal Imaging helps find/solve problems in electric motors
Over-heating due to: - reduced cooling airflow - under sized - electrical insulation degradation in windings Bearing ware due to: - poor lubrication miss alignment excess belt tension
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Thermal Imaging helps find/solve problems of moisture in buildings
Water entering building structure through: leaks in building envelop failed and poorly installed plumbing Condensation caused by: improper construction poor building management air leakage All of which can cause health, comfort, safety and financial issues
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Thermal Imaging helps find/solve problems of air leakage
Poor construction Leaks around envelop penetrations like: Chimneys Plumbing vents HVAC lines Utility lines Leaks around window and doors Poorly installed siding and wraps Damaged and misfit heat ducts
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Infrared Radiation Is Not Dangerous
Infrared radiation is electromagnetic radiation with wavelengths longer than visible light but shorter than microwaves Infrared radiation is radiated heat that cannot be seen by our eyes but can be sensed by our skin All objects, whatever their temperature, emit infrared radiation The intensity of infrared radiation depends on the temperature and a surface property termed “emissivity”
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Temperature Temperature is a measure of hotness and/or coldness
It is a measure of the molecular vibration in an object relative to the molecular vibration in other objects Molecules vibrate faster in warmer objects and slower in cooler objects Fahrenheit and Celsius are the most commonly used temperature scales They use the freezing and boiling points of water as reference points
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Temperature Scales Kelvin Celsius Fahrenheit Rankin
100 212 672 32 492 373 273 -273 -460 Water Boiling Point Water Freezing Point Absolute Zero Kelvin Celsius Fahrenheit Rankin Thermal radiation from objects depends on the 4th power of the absolute temperature, thus boiling water radiates 3.5 times as much as ice
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Heat always transfers from hotter to colder
Heat Transfer Heat always transfers from hotter to colder Steady state heat transfer is when the heat flow is constant with time Example: A electric motor that has been operating continuously for a period of time Transient heat transfer is when the temperature is constantly and significantly changing Example: An engine starting up or cooling down Heat capacity of material must be considered in transient heat transfer
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Three Modes of Heat Transfer
Solids Conduction Fluids & Gasses Convection Electromagnetic Waves Radiation Ts Temperature of heated surface SURFACE
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Conduction Heat Transfer
Conduction is the transfer of heat from one molecule to another in a solid, sometimes in a fluid Higher temperature molecules vibrate faster and transfer their energy to adjacent cooler molecules that are vibrating slower If an object is totally isolated all the molecules will eventually come to thermal equilibrium and vibrate at the same rate Metals are good conductors of heat; they conduct heat by electron flow as well as molecule to molecule Nonmetals are generally poor conductors of heat Materials that entrap small pockets of dead air are very poor conductors and are called insulators
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Conduction examples Heat is conducted away from a corroded and high resistance connection showing a temperature gradient along the fuse Extruded rebar shows a lower temperature exiting the die because heat is conducted from the surface of the bar to the die And the bar surface temperature reheats down stream from internal heat conducted from the center of the bar to the surface
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Conduction examples Heat conducted through the ceiling shows missing insulation and joist pattern Heat is conducted along copper bus bar away from resistive connection
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Combined Conduction and Convection Examples
Heat from outside is conducted through siding, convected inside empty wall cavity, conducted through inside wall board and convected into air conditioned room Heat is convected onto inside wall and ceiling, conducted through insulation and stud structure and convected to the outside air Convection air currents don’t flow in corners very well causing cold spot at ceiling
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Convection mixing Warm water discharge from Power Plant is mixed with cooler river water
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Radiation Heat Transfer
Radiation is different from convection and conduction Radiation does not require a medium Conduction and Convection are linearly proportional to temperature difference Radiation from a surface is proportional to the four power of absolute temperature Heat exchange between two objects involves complex relationships of geometry, emissivity and surrounding objects
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Be aware wind can effect temperature
85F 76F 72F 117F 95F 81F No wind 15 mph wind T = 13F T = 36F
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Thermal Capacitance Heat capacitance can both confuse or aid an inspection because it affects the rate of temperature change Water heats and cools slowly because of its high heat capacity Air heats and cools rapidly because of its low heat capacity Which has the highest thermal capacitance? - Copper - Steel - Brick - Wood - Water
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Heat Capacity Thermal capacitance can help find the liquid level in a tank Also leaks in a flat roof, Sun heats roof and after Sun goes down dry insulation cools faster than higher heat capacity wet insulation
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Phase Change Material can exist in three states -- Solid, Liquid and Gas To change state, energy must be added or removed Energy required to heat one pound of water at different states is shown below 32F Ice (0.465 BTU/F) Liquid Water (1BTU/F) Steam (0.489 BTU/F) 143 BTU 970 BTU 212F Thermography takes advantage of water to vapor phase change
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Phase Change Provides Moisture Detection
Evaporation of the water into vapor draws heat from wall
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How do we get the picture?
Each of the thousands of elements, or pixels, contain an accurate temperature value. The Imager, through the use of a complex set of algorithms, assign specific colors that correspond exactly with the temperature value found at the specific X Y coordinate. Some cameras save a simple picture which does not actually contain any measurements. Fully radiometric cameras store the actual temperature measurements which can be brought into a PC later for analysis. XXX Elements XXX Elements
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Radiometric Imagers It’s like having Thousands of infrared thermometers in one instrument When a Fluke thermal imager captures an image, all the background data is also saved along with the picture allowing in-depth post processing analysis.
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InsideIR PC Software Image Analysis and Sharing
Input location name from your keyboard Change emissivity in post processing Adjust for background temperature Insert accurate point measurements or Min/Max/Average area measurements Turn on a temperature grid
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Array Sizes Most Imager manufacturers provide imagers with either 320 by 240 or 160 by 120 arrays Advantages 320 by 240 arrays have four times as many pixels and if they have the same overall array dimensions and all other things being equal the imager will have four times finer detail Imagers made with 160 by 120 arrays are less expensive but adequate for the majority of users/applications
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How does it work? Every object emits infrared energy / heat
12,280 / 19,200 / 76,800 sensors measure the energy emitted by the object and produce a digital thermal image Sensors can detect temperature changes as slight as 1/7th degree Fahrenheit The minimum temperature difference that a Thermal Imager can measure is called Thermal Sensitivity or Noise Equivalent Temperature Difference (NETD)
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Comparison of Detector Type
320 x 240 160 x 120
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Important temperature measurement variables
Surface Emissivity Surface thermal reflectivity Background temperature Thermal capacitance Angle of view System load Target distance Camera settings Heat transfer Solar and wind conditions
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Reflection, Absorption and Transmission
When IR radiation strikes an object surface only three things can happen Some can be reflected () Some can be absorbed as heat () Some can pass through the object () From 1st Law of Themodynamics + + = 1 From Kirchhoff’s Law: emissivity () = absorptivity () Therefore + + = 1 ρ
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Transmission Most materials are opaque (not transparent)
Some materials are partially transparent: Atmosphere IR Lens materials Thin film plastics For opaque materials = 0, = 1 - This relationship is fundamental to the operation of a thermal imager ρ = 0
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Imager Temperature Measurement
W W W TT TB Single detector element is focused on target spot receiving radiation emitted from target W, background radiation reflected off target W and transmitted radiation from behind target W Only emitted radiation tells us surface temperature and the imager must eliminate reflected and transmitted radiation to measure it
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Imager Temperature Measurement
W W W TT TB WTotal = Wemitted + Wreflected + WTransmitted = T TT4 + T TB4 + 0 T = 1 - T WTotal = T TT4 + (1 - T) TB4 The operator must tell the imager what is the emissivity and background temperature, then the imager can calculate target temperature
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Selecting the Correct Emissivity Value
Only emitted radiation tells us surface temperature and the imager must eliminate reflected and transmitted radiation to measure it Rules of thumb Use 0.95 for all painted target surface independent of color If unpainted or un-corroded metal use 0.2 or lower Values for common materials are found in the imager owners manual, in the PC software, internet sources and on some Imagers If the target emissivity is unknown use the Imager to measure it Use the tape method
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Background Temperature
Ways of estimating the background temperature Use room temperature Take images of the background Use an aluminum foil curtain Crumpled kitchen foil smoothed to act like a diffuse reflector Target Crumpled Aluminum Foil Curtain Camera
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Selecting Background Temperature
Background temperature is the temperature of the surround behind and to the sides of the camera where reflected radiation emanates from Often the background temperature has little effect on the target temperature measurement Target emissivity is high Target temperature is higher than the background WTotal = T TT (1 - T) TB4 >
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Selecting Background Temperature (cont’d)
For Example: TT = 70F, TB = 65F, and T = 0.95 WTotal = T TT (1 - T) TB4 But if the target temperature and emissivity are low, background temperature is very important For Example: TT = 20F, TB = 70F, and T = 0.10 What to do? Use tape making the emissivity 0.95 > 100 5 < 2.1 32.4
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Diffuse versus Specular Targets
If the target reflects diffusely the background radiation measured by the camera comes from all around If the target is specular (mirror-like) the background radiation comes from specific point
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Example of a Specular Target
Image of window shows high specular reflection Two hot spots are not in the window pane, they are reflections from hanging light fixtures To identify reflections from real hot or cold spots move camera; if spots move they are refections
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Measuring Emissivity Example
Hole with emissivity of 1.00 White tape Black tape Place electricians tape (any color) on surface and take image Record tape temperature using 0.95 emissivity In same image place cursor on target surface next to tape Adjust camera emissivity until the temperature reading equals that of the tape Label E Ave T A A A A
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Controlling “Level & Span”
Span = 20.1F Level = 80.55F
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Level and Span can be adjusted
to fixed span temperatures or to automatically rescale based on the maximum and minimum temperature in image Narrow span produces more thermal detail Wider span produces less thermal detail Saturation colors will appear when the image temperatures are above or below the manually set span For example: When viewing a face, the image will show much more detail if the span is held to 10°F with the level at 92°F to 94°F
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Building - “Level & Span”
Manually scaled with hottest spot saturated Auto Scaled including hot spot
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Level and Span (cont’d)
Manual scaling shows more IR colors on transformer and small saturated point Auto Scaled
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FOV, IFOV & IFOVm Field of View (FOV) is total target area seen by imager, usually expressed in degrees Detector Array Lens Focal Length Target Distance to target d
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FOV, IFOV & IFOVm (cont’d)
Instantaneous Field of Viewmeasured (IFOVm) is the target area required by a single detector to accurately measure the temperature of a target area, usually expressed in milli-radians IFOVm is usually 2 to 5 times larger than IFOV
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Interchangeable lenses
Standard (20mm) Suited for most applications Ideal for general purposes Wide angle (10.5mm) Sees a larger surface at shorter distances Ideal for cramped spaces Long distance (54mm) Sees more detail at longer distances Ideal for power line insulators/transformers
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Lens Options Wide Angle Standard Telephoto
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FOV, IFOV for 160 by 120 Imagers Distance to Target (feet) 30 25 20 15
10 5 40 50 60 70 80 90 100 Target Size (feet) -- FOV 3.0 2.5 2.0 1.5 1.0 0.5 Pixel Size (inches)-- IFOVm 10.5mm Focal Length (32.4° Vert, 42.4° Horz) 20mm Focal Length (17.4° Vert, 23.2° Horz) 54mm Focal Length (6.5° Vert, 8.6° Horz) 33.3 26.7 13.3 6.7 Horz Vert For example, an imager with 20mm lens at 20 ft has a FOV of 8 ft horizontally and 6 ft vertically and an IFOV of 0.06 inches square
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76,800 pixels shows additional small feature details
320 by 240 versus 160 by 120 320 by 240 160 by 120 76,800 pixels shows additional small feature details 19,200 pixels
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Spot Size > Target Area Spot Size < Target Area
Spot Size is the area on target seen by single detector similar to IFOV Usually used to spec point radiometers Expressed as a ratio, like 60:1 which means at 60 ft the measurement spot on the target is 1ft square or at 30 inches the spot is ½ inch square Spot Size Target Spot Size > Target Area Spot Size < Target Area
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Move closer to measure it!
IFOVm example Hot spot is seen but temperature may not be best accuracy because spot size includes surrounding area Move closer to measure it!
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Focus is CRITICAL Focusing an IR imager is less sharp than a visible camera far more elements in a visible detector array Infrared images are naturally less sharp IR wave lengths are more than an order of magnitude longer visible light cameras generally measure reflected radiation not emitted; IR imagers must measure emitted radiation to determine temperature sharp edges can exist between a black line and a white line but sharp edges can not exist between a hot line and a cold line Best focus is critical for accurate temperature measurements Anything but focus can be modified/optimized later with PC software
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Best Focus Practices Look for edges Use IR-Fusion Hold imager still
Some people find best results with gray scale -- human eye most often can focus best in black and white
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Checking your imager calibration
As with any sophisticated piece of equipment, having the calibration check is a good habit. Routinely check basic calibration before each scan. Here are a few simple test you can perform Check the tear duct of a work partner (recommend the same person) Check an ice bath to verify camera performance at 0º C Check boiling water to verify camera performance at 100º C Acquire a blackbody reference in one of your common temp ranges
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IR Fusion® IR Only Visible Only 50/50 Blend
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What is IR-Fusion® ? IR-Fusion only is available on Fluke Thermal Imagers Be aware of imitations ! IR-Fusion links the Thermal Image with the Visual Image Easier to understand what you are looking at See the context Read any markers/labels/text No laser pointer needed Easier to report findings to others No need to also take a picture with a normal camera Helps you focus the Thermal Imager better The Thermal Imager is focused correctly when the Thermal and Visual images are completely aligned
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IR Fusion® view modes Traditional full IR Blended full Full Visible
-full display is 100% infrared Blended full -full display is IR blended with visible Full Visible -full display is 100% visible
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Fluke Ti series For everyday troubleshooting and maintenance
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Ti features IR-Fusion® Technology Large crisp images Made for rough environments Easy-to-use Flexible data storage Voice annotation Free of charge, unlicensed PC software 2 year warranty The complete package
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IR-Fusion Imager viewing modes
Max IR (traditional Thermal Imaging) Mid IR Min IR PIP Max IR PIP Mid IR PIP Min IR Ti25 Only Ti25 and Ti10
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IR-Fusion Software Viewing Modes
All modes – Full and PIP with infinite blending, and Color Alarm are available in the PC software
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IR-Fusion Software Viewing Modes
Traditional Full IR PIP Full IR Color Alarms Blended IR/Visual PIP Blended IR/Visual Full Visual Infinite blend from 100% IR to 100% visible
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On-camera display and operation
Ti25/TiR1 Ti10/TiR
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Large widescreen display
3.5 inch 640 x 480 pixels resolution Crystal clear images
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For rough environments
Engineered and tested to withstand a 6.5 ft drop Withstands dust and water: IP 54 rating Integrated protective lens cover No string to get in the way or cause dangerous situations close to rotating equipment Works in ambient temperatures from 14ºF to 122ºF and measures up to 662ºF
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Easy to use Intuitive, three button menu Single handed operation
Easy to use with gloved hand Single handed operation Important when standing on heights Improved safety Adjustable (left or right) hand-strap makes imager convenient to hold Supports 16 different languages
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Flexible data storage SD Memory card stores images:
>1000 images as *.is2 with all temperature data and visual image included in one image file With the included software you can modify anything but the focus >3000 images as *bmp Upload *is2 images into PC with included card reader and Smartview software
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Voice annotation (Ti25/TiR1 only)
Record and save commentary with stored images Up to 1 minute with every image No need to write down comments Playback (review) on Imager or with the software
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On-board analysis Spot temperature indicators
Center point High and low marker (Ti25/TiR1 only) Max and min temperature on image Emissivity correction (Ti25/TiR1 only) Select from table or enter manually
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Powerful software Fluke Software is included at no additional charge, with no license agreement and no costly upgrades The Fluke Thermal Imager stores all radiometric data to allow full analysis capability All parameters can be adjusted except focus if image is saved as an is2 file The report wizard makes it easy to create professional reports quickly
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2 year warranty Twice the time of other manufacturers in the market today Standard on all new Fluke imagers Covers all components
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One Complete Package Included with every Ti: Rugged hard case
Portable soft case Adjustable handstrap 2 GB SD memory card SD memory card reader Internal rechargeable battery AC charger/power supply Smartview analysis and reporting software
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Range, Level and Span adjustment
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Color Palettes Choose from 6 different palettes
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Imager settings
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Fluke Flexcam series For professionals demanding the best
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Flexcam features IR-Fusion® Technology
Extra large high-resolution display 180º articulating lens Easy-to-use High thermal sensitivity and broad temperature range Interchangeable lenses On-board analysis Auto capture Flexible data storage Free of charge, unlicensed PC software 2 year warranty The complete package
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IR-Fusion® Imager Viewing Modes
Traditional Full IR PIP Full IR Color Alarms Blended IR/Visual PIP Blended IR/Visual Full Visual
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Can be changed on the camera and with the software
Blending Can be changed on the camera and with the software 100% 75% 25% 50%
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IR-Fusion operation Blending Bar
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Color Alarm Infrared colors show area inside specified temperatures
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Extra large display >40% larger than other Imagers
320x240 pixel resolution Crystal clear images Sunlight readable
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180º articulating lens For areas with poor accessibility
Easy to scan floors and ceilings without looking down or up Select any angle that works for you
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Easy to use Single hand focus and image capture
Windows CE based interface Mouse “on screen” operation Programmable function buttons
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Thermal sensitivity and range
Flexcam can be used in most applications: Measure temperature differences as low as 0.05ºC (depending on the model) Measure temperatures as low as -4ºF and high as 1200ºF (depending on the model)
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Interchangeable lenses
Standard (20mm) Suited for most applications Ideal for general purposes Wide angle (10.5mm) Sees a larger surface at shorter distances Ideal for confined spaces Long distance (54mm) Sees more detail at longer distances Ideal for power line insulators/transformers
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On camera measurements (depending on model)
On-board analysis On camera measurements (depending on model) Center point Center box : Max, Avg and Min Hot and Cold marker Max and min temperature on image Cursor measurements (up to 3 points) Color alarm
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Example Thermograms
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Thermography found loose connections
Connections hotter than normal
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Thermography found hidden overheated part
Heat from hidden part produces elevated temperature on outer surface via heat conduction
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Thermography works especially well with multiple units
Far-right compressor is obviously off
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Thermography helped make house greener
Large air leak causes cold spot on ceiling
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Thermography helped plumbers find water leak in church heating system
Plumbing leak in cement floor caused hot spot
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Thermography helps inspect power plant equipment
Baseline for feed water pump
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Thermography helped distinguish between loose connection and overloaded circuit
Loose connection, fuse hot on one end only Overloaded circuit fuse hot on both ends
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Thermography helped identify overheated pole transformer
Transformer problem easily identified from a distance
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Thermography helped identify a worn belt
Hot v-belt stressed due to wear and/or misalignment
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Thermography helped identify tank fill levels
Subject to warming from the Sun the high heat capacity of oil keeps tank wall lower temperature than the lower heat capacity of air above the oil
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Poor Electrical Contact
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Three Phase Fuse Phase imbalance
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Loose Fuse Socket Extra resistance at one end of fuse socket
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Transformer Cooling Some cooling tubes appear to be plugged
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Overheated transformer, P1 was 350F due to cooling oil leak had exposed top of coil
Near catastrophic failure! Found and managed until normal factory shut down
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Most likely caused by high resistance or corrosion on the connector
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Motor control centers Inspect lug connections and also look for subtle patterns that may be caused by internal contacts or connections to the bus
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Wrong washer used in 3 phase connection on 150 HP motor
3-Phase connection with copper washer 3-Phase connection with galvanized steel washer 3-phase connection box
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Motors Uneven heating in an electrical motor will reduce the life and efficiency of the motor if not properly addressed For each 10ºC (18ºF) rise over maximum rated temperature, approximately ½ the life of a motor is lost due to insulation failure!
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Natural Gas Compressor
Uneven temperatures on cover of lower left cylinder alerted maintenance to investigate and find faulty valve in natural gas compressor
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Small bearings No other method is as effective or fast for small bearings Small bearing failures can result in fire, mechanical stress, belt wear, and increased electrical loads
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Bearings/couplings May be difficult to see if guard is in place
Temperature varies depending on type
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Rotating cement kilns
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Steam Traps Determine valve on/off and leakage
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Process monitoring Example of spray cooling
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Liquid Tank Levels Sludge buildup found at bottom of tank
Fill level clearly identified
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Solid Tank Levels Dry grain fill levels can be seen in elevator storage Location of wet and possibly spoiled grain can also be seen
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Roof inspection Wet spots under roof membrane
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Typical patterns Patterns vary with:
Roof type Insulation type Deck Conditions Non-absorbent insulation types are more difficult to inspect
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Air infiltration Air Infiltration
Clearly shows air infiltration through poor door seal
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Bridge Deck / In-Floor Heating
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Subsurface Anomalies Locate lines and utilities in walls, floors or underground
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Building Envelope Moisture remaining in wall after 2 days of extensive drying Missing insulation
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Located missing cement fill in block wall
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Software solutions SmartView software InsideIR software
For Ti-series and Flexcam series Imagers InsideIR software For Ti20 Both Software packages are free of charge, unlicensed and with free of charge upgrades
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Fluke Smartview Software
Free of charge Unlicensed Free upgrades Easy to use Extends the Thermal Imager’s functionality Makes reporting easy
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Powerful software Fluke Software is included at no additional charge, with no license agreement and no costly upgrades The Fluke Thermal Imager stores all radiometric data to allow full analysis capability All parameters can be adjusted except focus if image is saved as an is2 file The report wizard makes it easy to create professional reports quickly
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