Cool Tools: Thermal Imagers

One of the most valuable tools for electricians is the thermal imager—a handheld infrared (IR) camera used to detect higher-than-normal temperatures in electrical components.

Rob Milner, director of global business development at Teledyne Flir, Wilsonville, Ore., said that electrical equipment under load generates heat, but if it is not operating correctly, abnormal heat levels occur and can be detected and documented by a thermal imager.

“A thermal camera is ideally suited to locate, measure and save the severity of these issues by comparing the temperature of the issue to a reference component temperature,” he said. “Thermal imaging [thermography] is used for quickly detecting load imbalance, overheating connections, grounding issues, inductive heating, bad insulators, bad breakers and even for locating in-floor heating elements or hidden wiring.”

Milner said many electrical contractors use thermal cameras every day to prevent equipment failure and electrical fires at utilities, manufacturing facilities and commercial and residential buildings. Thermal imaging inspection is responsible for keeping the electrical grid operating. Professional users who specialize in this type of inspection are known as thermographers.

“The basics of thermal imaging have not changed much since we first introduced the commercial technology to the world in 1960,” Milner said. “But because of the reduction in price and size, and the performance improvements of cameras and software, the use of the technology has greatly expanded into areas that were once cost-prohibitive.”

Today, any electrician with a multimeter or clamp meter can access an infrared camera in the same device. Where once this technology was limited to high-voltage equipment inspections, now it’s a common tool used by electricians, home inspectors, HVAC technicians and auto mechanics.

Teledyne Flir’s line of handheld thermal cameras for electrical condition monitoring is available in a variety of model platforms.

“The majority of our thermal cameras for condition monitoring are fully compatible with our analysis and reporting software packages, including Flir Ignite, and the professional-grade Flir Thermal Studio,” Milner said.

The T-Series platforms are top of the line, preferred systems for professional thermographers because of features that maximize performance and time efficiency. The products have a tilting optical block that allows inspection over, under and around obstacles, as well as an available dual field-of-view lens called FlexView, which eliminates the need to change lenses in the field.

These products also have several firmware features to speed the user’s inspection, documentation, reporting and routing processes. Routing enables the thermographer to fully document all the points in a condition monitoring inspection route without requiring a notepad and transcription, making professional large report generation possible in seconds.

Teledyne Flir’s Exx-Series models are pistol grip-style systems with the same routing capability and most of the firmware features of T-series products, but it is in a package that trades off the flexibility of the tilting optical block for extreme ruggedness.

Exx- and T-Series products are part of the premium handheld product category with interchangeable lens capability. The Exx-Series doesn’t have the premium handheld features; users are more focused on the inspection and less on reporting.

Flir Ignite software is enabled to automatically transfer images from the camera to a desktop wirelessly, provide online image editing and reporting functionality.

The C-Series products are wallet-shaped, pocket-sized, lower-cost thermography cameras. This form factor enables a large screen to fit on a compact camera, making it easier for users to understand what is going on and make decisions. The newest member of the C-Series line is the Cx5.

The TG-Series is made to look and feel like a common single-spot temperature gun, while providing a full thermal image, which speeds the process of finding issues by as much as 90%.

The Flir One series works with smartphones and tablets. Teledyne Flir just launched the Flir One Edge Pro.

Teledyne Flir’s Infrared Training Center offers classroom and virtual training to everyone from the occasional user to the certified level 3 professional thermographer. Courses include camera and software operation, IR theory and application-specific programming.

Justin Sheard, principal engineer for new applications and solutions at Fluke Corp., Everett, Wash., said thermal imaging inspections are a good choice for electricians looking for new ways to generate income.

“Assets evaluated with IR cameras include transformers, switchgear components, breakers, fused disconnects, nonfused disconnects, conductors, terminations, contractors, control wiring terminations, bus duct (open and enclosed), distribution and branch circuit breaker panels, and motors. Electrical contractors are finding more opportunities in using thermal imaging in solar and at electric vehicle charging stations,” he said.

Sheard said in residential and commercial construction, electrical contractors are seeing more of a need to inspect small-scale solar. They are making IR inspections at installation, maintenance and troubleshooting, which provides immediate visibility of unexpected hot spots on the photovoltaic and service panels. Electrical contractors involved with solar installation and maintenance are beginning to expand IR inspections to use drones.

“Construction of [electrical vehicle supply equipment] offer thermal inspection opportunities that are likely to continue to grow for years to come,” Sheard said. “IR inspections for maintenance and troubleshooting will continue to be needed to ensure these stations remain operational and running properly.”

Sheard said more thermal camera options are coming into the market to fulfill the expanding needs of professional thermographers and electrical contractors adding IR inspections. Demand for small, pocket-sized cameras designed for pass-through inspections has increased. More than anything, there’s been a serious increase in the need for better image quality, making the 640 x 480 class of thermal cameras very appealing.

“Fluke has focused on providing a broad offering of thermal cameras for electricians, technicians and thermographers based on the work they do, the environments they typically work in and the level of visual clarity and temperature range they require,” Sheard said. “Thermal imaging is one of the least invasive ways to inspect electrical equipment and some mechanical equipment, and is quickly becoming one of the most common approaches used in installation, maintenance and troubleshooting services.”

Thermographers and electrical contractors want IR cameras that have intuitive user interfaces and features that help keep track of their work better for later reporting. Sheard believes features such as auto focus, note taking and asset identification are almost becoming standard in new cameras

“Software as a service is also taking off by offering better ways to manage images and develop actionable reports quickly,” he said. “Based on conversations with thermal camera customers, including electrical contractors, the time it takes to manage images and create reports are two areas they’ve found most frustrating in their day-to-day work.”

Sheard summarized the features of key product lines:

Fluke PTi120 Pocket Thermal Camera: Handheld pocket-sized camera with asset tagging and a temperature range of –20ºC to 150ºC (–4ºF to 302ºF). This camera is best for walk-through inspections and is recommended for plant managers.

Fluke TiS75+ Thermal Camera: Handheld pistol grip with color alarms, video recording and asset tagging with a temperature range of –20ºC to 550ºC (-4ºF to 1,022ºF). These types of thermal cameras are designed for professional thermographers and electrical contractors.

Fluke TiX580 Infrared Camera: Two-handed articulating camera with 640 x 480 IR resolution, color alarms and video recording, with a wide temperature range of –20ºC to 1,000ºC (-4ºF to 1,832ºF). The camera is best for scenarios where equipment being inspected is further out of range or of a higher voltage level.

Fluke thermal imager

Fluke TiX580 infrared camera
www.fluke.com/en-us

Fluke offers face-to-face camera familiarization, application-specific use and tips on improving product ROI, all provided by territory managers. Fluke partners with the Snell Group for certification training (half or full day) to ASNT IR/T Level 1, 2 Certification. The certification training can be done face-to-face, virtual or hybrid.

Fluke also offers many content resources, such as articles, videos, webinars, application recommendations and demonstrations, and product-specific tips and tricks for improved performance.

Sabrina Kalsi, product manager at Klein Tools, Lincolnshire, Ill., said thermal cameras today are more accurate, provide higher-quality images, are more compact, easier to use and more durable.

“Today’s tools have more options—from small, portable units, to phone attachments—but more important, there are more price points available. With $200 to $400 retail prices, and as prices go down, the products become more accessible, and the applications for them expand,” she said.

Klein Tools’ thermal imager line is designed for detecting hot spots in panels, on wiring or on parts of equipment; showing energy loss within a home/building; detecting moisture behind walls and flooring; clogs in pipes; and much more.