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Predictive Maintenance Procedure # MPD-THERM-CAR-01

Procedure Name: Thermography Routes- Carrocerias

Purpose: To formalize a consistent procedure for the collection and documentation of thermographic data
collection route data in the body shop area.

Background Information
1) Inframetrics Thermacam PM250.
2) Digital Visual Camera
Data storage files
1) C:\My Documents\Mantenimiento Predictivo\Termografia.mbd
2) C:\My Documents\Mantenimiento Predictivo\Ordienes de trabajo.mdb
Route Collection Intervals
1) Portable Spot Welders 2 weeks
2) MIG welder SCRs, Motors and Mechanical Equipment 1 month
3) Electrical Panels 3 months
1) Any time that a work request is made, a thermal image and a visual image must be recorded for
insertion into the request form.
2) On start up of the thermographic camera press “SETUP” three times and select LOGO=OFF. Press
MODE to return to image mode. The camera will take about 5 minutes to get down to operating
temperature from normal ambient conditions.
3) Use range 2 to check welding equipment and range 1 for all other equipment checks (except when
checking abnormally high temperatures).

1. Identify the route to be collected and print the appropriate route from MS-Access.
2. Ensure that the camera lens is protected from weld sparks by fitting the lens shroud extension.
3. Ensure that camera batteries (3) are fully charged before commencement of work.
4. Portable Spot Welders
a) Check the transformer connection to the kickless cable - record the actual temperature on the work
sheet.. If the temperature is above 60C raise a work request for repair at priority 2. If
the temperature is above 80C raise a work request for repair at priority 1. If the
temperature is above 100C contact a supervisor immediately to arrange an emergency
b) Next check the length of the kickless cable for hot spots and heat striping. Raise a work request if
there is a temperature differential of more than about 10C.
c) Check the connection between the kickless and the weld gun / jumper cable - record the actual
temperature on the work sheet.. If the temperature is above 50C raise a work request for
repair at priority 2. If the temperature is above 65C raise a work request for repair at
priority 1. Check the rest of the weld gun and jumper for unusual temperature
distributions and raise a work request if necessary.
5. MIG Welder SCRs
a) The numbering convention to be adopted for SCRs in MIG welders is (from the cooling fan end of
the controller) 1,2 & 3 from left to right for the first row of SCRs and 3,4 & 5 left to right
for the second row of SCRs.
b) Remove at least one side cover from the MIG controller. Being careful not to touch any live
electrical connections, check the temperature at each SCR and record the temperature on
the work sheet. If there is a temperature differential of more than 10C across the SCRs
or if the temperature of any SCR is above 50C, a work request for repair must be raised.
c) Check all other connections in the controller for abnormal temperatures. It may be necessary to
remove more covers or use the 480 volt supply cover access to check other connections.
6. Mechanical and Other Equipment
a) Compare the current .temperature to previous temperatures recorded at the same point. If the
temperature has suddenly increased or a gradual trend is shown, raise a work request for
repair. Ensure that the temperature increase is not caused by normal operating conditions
such as a normal change in load for example.
7. After completing the route and recording all necessary data entries on the work sheet, enter the
data into the appropriate MS-Access database.
a) Open MS-Access in the “Termografia.mdb” database. From the main switchboard, open
“Adquisición de datos Valores de Medicion” by clicking on the adjacent button.
b) In the form now on the screen, enter the point ID (from the data collection form which you printed
earlier) in the leftmost field, the actual temperature recorded in the next and the data of
collection in the next. If the point had a defect then check the box and type the
appropriate comments in the rightmost box.
8. All images recorded by the thermographic camera are stored in the format A##.tif. Where
A = the directory in which the image is stored
## = the sequential number of the file
tif = the image storage format (tagged image format).
a) Remove the PCMCIA card from the camera and insert into the appropriate slot in the PC (a two
tone rising bleep will be heard). Using explorer, copy the images from the PCMCIA card
(“F:” drive) and copy into the appropriate directory on the “C:” drive. Note that all
thermographic images are stored under sub-directories of
b) Rename the image so that you can recognize the image in the future. Long file names (up to 255
characters) are acceptable.
9. Raise any work requests as per procedure MPD-OT-1.

Procedure prepared by: Ron Frend

4010 Page, Suite 200
Michigan Center, MI 49254
Phone: (517) 764-6800 Fax: (517) 764-6869
Date: 30 March, 1998