1 Year Warranty
Description
SensyCal FCU400-IR — Universal Measuring Computer (Contactless Temperature Monitoring)
Product Overview
The SensyCal FCU400-IR is a universal measuring computer from ABB’s SensyCal family, configured specifically as a contactless temperature monitoring system. It combines a compact, panel- or rail-mounting computer with up to twelve CS-type infrared sensors, continuously measuring the surface temperature of objects that cannot be reached with contact sensors — hot, moving, electrically live, or hazardous components. The product number series V18022 covers the FCU400 variants, of which the FCU400-IR is the infrared version.
The system’s operating principle is simple and effective: each infrared sensor measures the thermal radiation of a target in the 8–14 μm spectral band, the computer evaluates the readings from all twelve measuring points, and the highest measured temperature (Tmx) is compared against configurable pre-alarm and alarm limits. Three electrically isolated switching outputs drive the pre-alarm, the main alarm, and a device-error signal, so the unit can be wired directly into protection and annunciation circuits without a PLC in between. A four-wire Pt100 input measures ambient temperature (Ta1), allowing the unit to display and log the temperature difference between the measured surface and its surroundings — a useful indicator of developing thermal anomalies.
The FCU400-IR belongs to the same hardware platform as the FCU400-G gas flow computer, the FCU400-P differential-temperature computer, and the FCU400-S steam computer. This shared heritage shows in the metrology: a 20-bit analog front end, accuracy class 2 per EN 1434-1 / OIML 75, an integrated ring-buffer data logger, and M-Bus, optical, and MODBUS communication — instrumentation-grade features in what is nominally a monitoring device.
Technical Specifications
| 参数名称 | 参数值 |
|---|---|
| Product Model | SensyCal FCU400-IR |
| Manufacturer | ABB Automation Products GmbH (SensyCal / Bopp & Reuther line, Germany) |
| Product Type | Universal measuring computer — contactless temperature monitoring |
| IR Sensor Inputs | Up to 12 infrared sensors, CS type |
| IR Measuring Range | -20…350 °C (software-scalable; factory 0–250 °C) |
| IR Spectral / Optics | 8–14 μm; optical resolution 15:1 |
| IR Accuracy | ±1.5 °C or 1.5 % of measured value; reproducibility ±0.75 °C / 0.75 % |
| Pt100 Input | 1 × Pt100 IEC, 4-wire, -200…850 °C, 20-bit resolution (≈0.0012 K) |
| Outputs | 3 × digital isolated outputs: pre-alarm, alarm, error; open collector, optocoupler-isolated |
| Communication | M-Bus per EN 1434-3 (300–38,400 baud); front optical interface; RS232/RS485 MODBUS option |
| Power Supply | 24 V DC ±5 % or 24 V AC; 1–10 VA |
| Ambient Conditions | -5…55 °C operating; IP65 base (IP40 for FCU400-IR); vibration 2 g / 10–150 Hz |
| Mounting | Panel 144×72×117 mm (~0.5 kg) or DIN rail/wall 144×72×183 mm (~0.7 kg) |
SENSYCAL FCU400-IR
Key Features and Advantages
Contactless measurement where contact fails: The 8–14 μm spectral range and 15:1 optical resolution let the FCU400-IR measure surfaces that are too hot, too fast, electrically live, or simply unreachable — rotating shafts, energized busbars, oven walls, and hazardous zones — without interrupting the process or risking personnel.
Twelve measuring points, one protection decision: Up to twelve CS infrared sensors feed a single computer that evaluates the maximum temperature across all points. Because the alarm logic is based on the highest of twelve readings, one developing hot spot triggers the output while every other point stays normal — the behavior a thermal-protection system needs.
Protection-grade outputs without a control system: Pre-alarm, main alarm, and error outputs are electrically isolated open-collector channels that can drive annunciators, beacons, or a shutdown relay directly. The unit therefore works as a standalone thermal watchdog, not just a data source.
Ambient reference for real diagnostics: The four-wire Pt100 input measures ambient temperature, and the computer displays and logs the difference between the hottest measured surface (Tmx) and ambient (Ta1). Rising ΔT over time — not an absolute temperature that changes with seasons and load — is the signal that flags genuine thermal deterioration.
Metrology-grade front end: A 20-bit analog-to-digital converter and accuracy class 2 per EN 1434-1 / OIML 75 reflect the billing-grade heritage of the SensyCal platform. Temperature readings and alarm decisions carry instrumentation accuracy, not watchdog vagueness.
Built-in thermal history: The ring-buffer data logger stores counter readings, instantaneous values, and min./max./mean values with configurable log periods from one hour to three months, so maintenance can reconstruct exactly how a hot spot developed between inspections.
Flexible integration: M-Bus per EN 1434-3, a front optical interface for handheld readout and the HP82240B infrared printer, and an optional RS232/RS485 MODBUS card connect the unit to building automation, SCADA, or an energy-management system. Parameterization runs through the FCOM200 ParaTool software.
Built for the plant floor: Operating temperature of -5…55 °C with permissible condensation, vibration rating of 2 g / 10–150 Hz, shock 30 g / 11 ms, and a polycarbonate housing — the FCU400-IR is specified for industrial environments, not office conditions.
Application Areas
The FCU400-IR answers a recurring industrial question: what is the temperature of something I cannot touch? In power distribution, it monitors energized busbars, switchgear connections, and transformer surfaces, where a rising contact temperature precedes failure and contact sensors are ruled out by live voltage. Pre-alarm and alarm outputs can be wired directly to trip or annunciate circuits.
In rotating machinery, it watches bearing housings, shafts, and couplings where mounting a contact sensor is impractical or where a non-intrusive measurement is preferred. The 15:1 optics allow a suitable standoff distance, and the aiming LED simplifies alignment during commissioning.
In thermal processes — dryers, ovens, kilns, and heated rollers — the unit tracks surface temperature without disturbing the product flow, while its data logger provides the trend record needed for process qualification and maintenance planning. In energy monitoring, the ambient-reference channel supports heat-balance and loss calculations, complementing the FCU400-P and FCU400-S variants on the same platform.
Wherever the application, the FCU400-IR performs the same role: continuous, non-contact thermal surveillance of up to twelve points, with local display, alarm outputs, logging, and communication — a complete monitoring station in a 144 × 72 mm instrument.
Related Products
- SensyCal FCU400-G — gas flow computer / gas volume correction variant of the same measuring-computer platform.
- SensyCal FCU400-P — high-precision differential temperature computer for heat-balance, leakage, and boiler-level applications.
- SensyCal FCU400-S — steam computer for superheated and saturated steam billing and heat-balance duties.
- SensyCal FCU200-T — two-channel current-pulse converter on the same hardware platform.
- SensyCal FCU200-W — heat-meter computer variant for thermal energy metering.
- CS infrared sensor — the stainless-steel M12 × 1 sensing head (8–14 μm, 15:1) that feeds the FCU400-IR.
- SensyTemp TSP300 — Pt100 Class A four-wire sensor compatible with the temperature inputs of the SensyCal computers.
- Extension module 105 — RS485/RS232 card adding MODBUS communication to the measuring computer.
Installation and Maintenance
Installation preparation: Select measuring points with an unobstructed line of sight — the 15:1 optics mean the target must fill the field of view: a 150 mm target at 2.25 m distance, or proportionally smaller at shorter standoff. Mount the CS infrared sensors with the M12 × 1 thread, orient the sensor head squarely at the target, and confirm the cable (10 m supplied) reaches the computer without strain. Before commissioning, set the emittance (0.1–1.1) to match the target surface; an incorrect emittance is the largest single source of infrared measurement error. Then configure the measuring range, response time (30 ms…2 s), and the pre-alarm/alarm limits. Install the computer in the panel cutout (139 × 69 mm) or on a DIN rail, connect 24 V DC or AC through the 0.8 A fuse, and wire the three digital outputs according to their function before powering up.
Maintenance advice: Keep the sensor lenses clean — the manual is explicit here: use only water-based, solvent-free cleaners and a soft damp cloth, and blow loose dust off with dry compressed air; solvents damage the lens coating and silently degrade readings. Periodically verify sensor alignment and the emittance setting after any surface change (paint, corrosion, new lagging), and check that the pre-alarm and alarm thresholds still match the process. Review the data logger periodically for rising ΔT trends between inspections, and confirm the error output is wired into the annunciation system so device faults are visible. Any work inside the housing — for example, fuse replacement — must be carried out by trained personnel with the power off and ESD precautions in place, since the calibration seal is broken when the device is opened.
Product Warranty
The SensyCal FCU400-IR is supplied as a factory-new unit or as a tested, configuration-checked spare, covered by warranty against manufacturing and materials defects. Because the FCU400-IR is part of ABB’s standard SensyCal product family with the V18022 type-code series, replacement computers, CS infrared sensors, extension modules, and accessories remain available from the regular supply chain, and the device can be delivered with its measured-value configuration (measuring range, emittance, alarm setpoints) preset before shipment. ABB documentation — the operating instruction 42/18-70-EN, data sheets, and the EC declaration of conformity covering EMC Directive 2004/108/EC and Low Voltage Directive 2006/95/EC — accompanies the unit, and application support covers measuring-point selection, emittance setting, and integration with M-Bus or MODBUS systems, keeping the contactless temperature monitoring system operational, documented, and maintainable over the life of the plant.
