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optris PI 160 Operator's Manual

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Operators manual
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optris
PI
160/ 200/ 230/ 400/ 450/ 450 G7/ 640/ 640 G7/ 1M
Infrared camera

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  • Page 1 Operators manual ® optris 160/ 200/ 230/ 400/ 450/ 450 G7/ 640/ 640 G7/ 1M Infrared camera...
  • Page 2 Optris GmbH Ferdinand-Buisson-Str. 14 13127 Berlin GERMANY Tel.: +49 30 500 197-0 Fax: +49 30 500 197-10 E-mail: info@optris.de Internet: www.optris.de...

  • Page 3: Table Of Contents

    Table of contents Table of contents Table of contents .............................. 3 General Notes ............................7 Intended use ............................7 Warranty ............................. 8 Scope of delivery ..........................9 Maintenance ............................9 1.4.1 Cleaning ............................9 Model overview ..........................10 Technical Data ............................11 General specifications ........................
  • Page 4 Measurement specifications ......................16 Optical specifications ........................19 Mechanical Installation .......................... 28 Dimensions ............................28 Mounting accessories (optional) ....................... 33 High temperature accessories ......................34 3.3.1 CoolingJacket ........................... 34 3.3.2 CoolingJacket Advanced ......................36 3.3.3 Outdoor protective housing ....................... 40 Electrical Installation ..........................
  • Page 5 Table of contents Example for a Fail-Safe monitoring of the PI with a PLC ..............49 USB cable extension ........................51 Software PI Connect ..........................53 Installation and initial start-up ......................54 Software window ..........................57 5.2.1 Basis features of the software PI Connect ................59 Basics of Infrared Thermometry ......................
  • Page 6 Appendix C – Quick start for serial communication ................... 76 Appendix D – Interprocess Communication (IPC) ..................78 Appendix E – PI Connect Resource Translator ................... 79 Appendix F – Wiring diagrams PIF ....................... 80 Appendix G – Declaration of Conformity ..................... 84...

  • Page 7: General Notes

    Thank you for choosing the optris PI infrared camera. The optris PI calculates the surface temperature based on the emitted infrared energy of objects [►6 Basics of Infrared Thermometry]. The two-dimensional detector (FPA - focal plane array) allows a measurement of an area and will be shown as thermal image using standardized palettes. The radiometric processing of the picture data enables the user to do a comfortable detailed analysis with the software PI Connect.

  • Page 8: Warranty

     Avoid abrupt changes of the ambient temperature.  Avoid static electricity, arc welders, and induction heaters. Keep away from very strong EMF (electromagnetic fields).  In case of problems or questions which may arise when you use the infrared camera, please contact our service department.

  • Page 9: Scope Of Delivery

    General Notes 1.3 Scope of delivery  PI 160, PI 200, PI 230, PI 400, PI 450, PI 450 G7, PI 640, PI 640 G7 or PI 1M incl. 1 lens  USB-cable: 1 m (standard scope of supply, no IP67 protection class) 1 m, 3 m, 5 m, 10 m, 20 m (optional, for industrial applications, with IP67) ...

  • Page 10: Model Overview

    1.5 Model overview The cameras of the PI-series are available in the following basic versions: Modell Model code Temperature range Spectral range Frame rate Typical applications PI 160 -20 to 900 °C 7.5 - 13 µm 120 Hz Surface measurements in industrial application 200 to 1500 °C (optional) PI 200/ PI 230...

  • Page 11: Technical Data

    Technical Data 2 Technical Data 2.1 General specifications Environmental rating: IP67 (NEMA-4) Ambient temperature: 0...50 °C [PI 160/ PI 2xx/ PI 400/ PI 640/ PI 640 G7] 5…50 °C [PI 1M] 0...70 °C [PI 450/ PI 450 G7] Storage temperature: -40...70 °C (-40...85 °C [PI 450/ PI 450 G7]) Relative humidity: 10...95 %, non-condensing...
  • Page 12 Shock IEC 60068-2-27 (25 g and 50 g) Used standards for vibration and shock: Figure 1: Used standards Stress program (camera in operation): Shock, half sinus 25 g – testing Ea 25 g (acc. IEC 60068-2-27) Acceleration 245 m/s (25 g) Pulse duration 11 ms...
  • Page 13 Technical Data Number of directions (3 axes with 2 directions each) Duration 600 Shocks (100 Shocks each direction) Shock, half sinus 50 g – testing Ea 50 g (acc. IEC 60068-2-27) Acceleration 490 m/s (50 g) Pulse duration 11 ms Number of directions (3 axes with two directions each) Duration...
  • Page 14 Vibration, broadband noise – testing Fh (acc. IEC60068-2-64) Frequency range 10 - 2000 Hz Acceleration 39.3 m/s (4.01 g Frequency spectrum 10 - 106 Hz 0.9610 (m/s (0.010 g /Hz) 106 - 150 Hz +6 dB/ Octave 150 - 500 Hz 1.9230 (m/s (0.020 g /Hz)

  • Page 15: Electrical Specifications

    Technical Data 2.2 Electrical specifications Power Supply: 5 VDC (powered via USB 2.0 interface) Current draw: Max 500 mA AO: Output Process Interface (PIF out) 0 - 10 V (Main measure area, measure area, internal temperature, flag status, alarm, frame sync, fail-safe, external communication) [►Appendix F –...

  • Page 16: Measurement Specifications

    2.3 Measurement specifications PI 160 PI 200 PI 230 Temperature ranges -20...100 °C; 0...250 °C; 150...900 °C; Option: 200…1500 °C Spectral range 7.5 - 13 µm Detector UFPA, UFPA, UFPA, 160 x 120 pixel @ 120 Hz 160 x 120 pixel @ 128 Hz 160 x 120 pixel @ 128 Hz 640 x 480 pixel (visual camera) 640 x 480 pixel (visual camera)
  • Page 17 Technical Data PI 400 PI 450 PI 450 G7 Temperature ranges -20...100 °C; 0...250 °C; -20...100 °C; 0...250 °C; 200…1500 °C 150...900 °C; 150...900 °C Option: 200…1500 °C Spectral range 7.5 - 13 µm 7.9 µm Detector UFPA, UFPA, UFPA, 382 x 288 pixel @ 80 Hz 382 x 288 pixel @ 80 Hz 382 x 288 pixel @ 80 Hz...
  • Page 18 PI 640 PI 640 G7 PI 1M Temperature ranges -20...100 °C; 0...250 °C; 200…1500 °C …1800 °C (27 Hz mode) 150...900 °C …1800 °C (80 Hz and 32 Hz mode) …1800 °C (1 kHz mode) Spectral range 7.5 - 13 µm 7,9 µm 0,85 - 1,1 µm Detector...

  • Page 19: Optical Specifications

    Technical Data 2.4 Optical specifications Make sure that the focus of thermal channel is adjusted correctly. If necessary, focus the thermal imaging camera with the optics (Figure 2). The turning out of the optics leads to the focus setting "near" and the turning in of the lens to the focus setting "infinity". The visual camera (PI 200/230 only) is adjusted with the supplied focusing tool (Figure 3).
  • Page 20 The variety of different lenses offers the possibility to precisely measure objects in different distances. We offer lenses for close, standard distances and large distances. Different parameters are important if using infrared cameras. They display the connection between the distance of the measured object and the size of the pixel (Table 2).
  • Page 21 Technical Data ® Figure 4: Measurement field of the infrared camera optris PI representing the 23° x 17° lens...
  • Page 22 For individual configuration there are different lenses available. Wide angle lenses have a radial distortion due to their large opening angle; the software PIConnect has an algorithm which corrects this distortion. As an alternative to the tables below, the optics calculator can also be used on the optris website (http://www.optris.com/optics-calculator).
  • Page 23 Technical Data Table 2: * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 24 * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 25 Technical Data * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 26 * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 27 Technical Data * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.

  • Page 28: Mechanical Installation

    3 Mechanical Installation 3.1 Dimensions The PI is equipped with two metric M4 thread holes on the bottom side (6 mm depth) and can be installed either directly via these threads or with help of the tripod mount (also on bottom side). The tightening torque of the M4 screws for mounting the PI camera should be between 1 ...
  • Page 29 Mechanical Installation Figure 5: PI 160, dimensions [mm]...
  • Page 30 Figure 6: PI 200/ 230, dimensions [mm]...
  • Page 31 Mechanical Installation Figure 7: PI 400/ PI 450/ PI 450 G7/ PI 640/ PI 640 G7, dimensions [mm]...
  • Page 32 Figure 8: PI 1M, dimensions [mm]...

  • Page 33: Mounting Accessories (Optional)

    Mechanical Installation 3.2 Mounting accessories (optional) Figure 9: Mounting base, stainless steel, adjustable in 2 axes [Part No.: ACPIMB] Figure 10: Protective housing, stainless steel, Incl. Mounting base [Part No.: ACPIPH]...

  • Page 34: High Temperature Accessories

    3.3 High temperature accessories 3.3.1 CoolingJacket  The IR camera can be used at ambient temperature up to 50 °C (up to 70 °C with PI 450/ PI 450 G7). For higher temperatures (up to 180 °C) the CoolingJacket is provided. ...
  • Page 35 Mechanical Installation Figure 11: CoolingJacket – Dimensions...

  • Page 36: Coolingjacket Advanced

    Figure 13: CoolingJacket with mounting bracket Figure 12: CoolingJacket for PI [Part No.: ACPIxxxCJ] 3.3.2 CoolingJacket Advanced  The CoolingJacket Advanced is available as Standard Version and Extended Version.  The IR camera can be used at ambient temperature up to 50 °C (up to 70 °C with PI 450/ PI 450 G7).
  • Page 37 Mechanical Installation Standard Version Figure 14: CoolingJacket Advanced [Part No.: ACPIxxxCJAS], Standard Version - Dimensions...
  • Page 38 Extended Version The Extended Version is provided for applications of the PI series with the PI Netbox and industrial PIF or the USB Server Gigabit and industrial PIF. Both PI Netbox and industrial PIF or USB Server Gigabit and industrial PIF can be integrated in the CoolingJacket. Figure 15: Cooling Jacket Advanced (Extended Figure 16:Cooling Jacket Advanced (Extended Version) Version) with PI Netbox and industrial PIF...
  • Page 39 Mechanical Installation Figure 17: CoolingJacket Advanced [Part No.: ACPIxxxCJAE], Extended Version – Dimensions...

  • Page 40: Outdoor Protective Housing

    3.3.3 Outdoor protective housing  The infrared camera PI and the USB server can also be used for outdoor applications by using the outdoor protective housing.  The outdoor protective housing can be used for any PI camera (lenses up to 90 ° FOV) ...

  • Page 41: Electrical Installation

    Electrical Installation 4 Electrical Installation At the back side of the PI there are the two connector plugs. The left plug is for the USB cable. The right connector plug is only used for the process interface. Figure 19: Backside of the camera with connectors Plug for USB cable Plug for PIF cable...

  • Page 42: Process Interface

    4.1 Process interface The process interface (electronics within cable as well as industrial interface) must be powered separately (5-24 VDC). Before switching on the power the PIF cable must be connected to the camera. The PI is equipped with a process interface (cable with integrated electronics and terminal block), which can be programmed via the software as an Analog Input (AI) and Digital Input (DI) in order to control the camera or as an Analog Output (AO) in order to control the process.
  • Page 43 Electrical Installation Figure 20: Configuration Standard Process Interface (PIF) The standard process interface provides the following inputs and outputs: Name Description max range / status Analog input 0-10 V Digital input 24 V (active-low = 0…0,6 V) Analog output 0-10 V Alarm output 0/ 10 V Depending on supply voltage;...

  • Page 44: Pin Allocation

    4.1.1 PIN allocation 1 VCC 1 INT 2 GND 2 SDA (I²C) 3 SCL (I²C) 4 D - 4 DGND 5 D + 5 3.3 V (Out) Figure 21: Rear side of the camera...
  • Page 45 Electrical Installation If the process interface of the camera is directly connected to external hardware (without using the supplied PIF cable) an activation of the field „Support proprietary PIF cable” in the menu Tools/ Configuration/ Device (PIF) in the PIConnect software is necessary. Figure 22: Support proprietary PIF cable Consider that the input of the PIF is not protected if there is a direct PIF connection! A voltage >...

  • Page 46: Industrial Process Interface (Optional)

    4.1.2 Industrial Process Interface (optional) For use in industrial environment the industrial process interface with 500 V AC isolation voltage between PI and process is available (connection box with IP65, 5 m, 10 m or 20 m standard or high temperature cable Appendix F –...
  • Page 47 Electrical Installation The industrial process interface provides the following inputs and outputs: Name Description max range / status A IN 1 / 2 Analog input 1 and 2 0-10 V Digital input D IN 1 24 V (active-low = 0…0,6 V) AO1 / 2 / 3 Analog output 1, 2 and 3 0-10 V...
  • Page 48 The process interface has an integrated fail-safe mode. This allows to control conditions like interruption of cables, shut-down of the software etc. and to give out these conditions as an alarm. Controlled conditions on camera and software Standard Process interface Industrial Process interface ACPIPIF ACPIPIF500V2CBxx...

  • Page 49: Example For A Fail-Safe Monitoring Of The Pi With A Plc

    Electrical Installation 4.2 Example for a Fail-Safe monitoring of the PI with a PLC Figure 24: Fail-Safe monitoring states Fail-Safe monitoring states Breakdown of PIF power supply Malfunction of PI Cable break of fail-safe cable Breakdown of PI power supply/ Interruption of USB cable Interruption of cable PI-PIF Malfunction of PIConnect software...
  • Page 50 Figure 25: Fail-Safe monitoring states Fail-Safe monitoring states Breakdown of PIF power supply Malfunction of PI Cable break of fail-safe cable Breakdown of PI power supply/ Interruption of USB cable Short circuit of fail-safe cable Malfunction of PIConnect software Interruption of cable PI-PIF...

  • Page 51: Usb Cable Extension

    Electrical Installation 4.3 USB cable extension The maximum USB cable length is 20 m. For greater distances between PI and computer or for stand-alone solutions the optional PI NetBox or the USB Server Gigabit is provided: Figure 26: Ethernet direct communication with PI Netbox Figure 27: Ethernet network communication with PI Netbox...
  • Page 52 Figure 28: Stand-Alone operation with PI Netbox Figure 29: USB Server Gigabit...

  • Page 53: Software Pi Connect

    Software PI Connect 5 Software PI Connect Minimum system requirements:  Windows Vista, Windows 7, Windows 8, Windows 10  USB interface  Hard disc with at least 30 MByte of free space  At least 128 MByte RAM  CD-ROM drive A detailed description is provided in the software manual on the software CD.

  • Page 54: Installation And Initial Start-Up

    5.1 Installation and initial start-up  Uninstall previous versions of the PI Connect before installing the new software. To this use the Uninstall icon in the start menu.  All drivers are booted via Windows OS automatically. A driver installation is not necessary. ...
  • Page 55 Software PI Connect At the initial start the software asks for the calibrations files which are available via internet or on the CD. 5. Install the calibration files at first start of the software. Figure 30: Calibration data transfer...
  • Page 56 After the calibration files have been installed the live image from the camera is shown inside a window on your PC screen. 6. Choose the desired language in the menu Tools → Language. 7. Adjust the focus of the image by turning the exterior lens ring at the camera.

  • Page 57: Software Window

    Software PI Connect 5.2 Software window Figure 31: Software window...
  • Page 58 IR image from the camera Toolbar Temperature of measure area: Analyses the temperature according to the selected shape, e.g. average temperature of the rectangle. The value is shown inside the IR image and the control displays Control displays: Displays all temperature values in the defined measure areas like Cold Spots, Hot Spots, temperature at cursor, internal temperature and chip temperature Alarm settings: Bar showing the defined temperature thresholds for low alarm value (blue arrow) and high alarm value (red arrow).

  • Page 59: Basis Features Of The Software Pi Connect

    Software PI Connect 5.2.1 Basis features of the software PI Connect Extensive infrared camera software  No restrictions in licensing  Modern software with intuitive user interface  Remote control of camera via software  Display of multiple camera images in different windows ...
  • Page 60 Video recording and snapshot function (IR or BI-SPECTRAL)  Recording of video sequences and detailed frames for further analysis or documentation  BI-SPECTRAL video analysis (IR and VIS) in order to highlight critical temperatures  Adjustment of recording frequency to reduce data volume ...
  • Page 61 Software PI Connect Automatic process control  Individual setup of alarm levels depending on the process  BI-SPECTRAL process monitoring (IR and VIS) for easy orientation at point of measurement  Definition of visual or acoustic alarms and analog data output ...

  • Page 62: Basics Of Infrared Thermometry

    6 Basics of Infrared Thermometry Depending on the temperature each object emits a certain amount of infrared radiation. A change in the temperature of the object is accompanied by a change in the intensity of the radiation. Searching for new optical material William Herschel by chance found the infrared radiation in 1800. Figure 32: William Herschel (1738-1822) He blackened the peak of a sensitive mercury thermometer.
  • Page 63 Basics of Infrared Thermometry noticed the increasing temperature from violet to red. The temperature rose even more in the area behind the red end of the spectrum. Finally he found the maximum temperature far behind the red area. Nowadays this area is called “infrared wavelength area”. Figure 33: The electromagnetic spectrum and the area used for temperature measurement For the measurement of “thermal radiation”...
  • Page 64 Figure 34: Main principle of non-contact thermometry Infrared thermometers basically consist of the following components:  Lens  Spectral filter  Detector  Electronics (amplifier/ linearization/ signal processing) The specifications of the lens decisively determine the optical path of the infrared thermometer, which is characterized by the ratio Distance to Spot size.
  • Page 65 Basics of Infrared Thermometry The advantages of non-contact thermometry are clear - it supports:  temperature measurements of moving or overheated objects and of objects in hazardous surroundings  very fast response and exposure times  measurement without inter-reaction, no influence on the ...
  • Page 66 Figure 35: Non-contact thermometry...
  • Page 67 Basics of Infrared Thermometry Application field: Monitoring of electronic R&D of electronics R&D of electronic parts Process control extruding cabinets plastic parts Process control Process control at R&D of mechanical parts Monitoring of cables manufacturing solar calendering modules...

  • Page 68: Emissivity

    7 Emissivity 7.1 Definition The intensity of infrared radiation, which is emitted by each body, depends on the temperature as well as on the radiation features of the surface material of the measuring object. The emissivity (ε – Epsilon) is used as a material constant factor to describe the ability of the body to emit infrared energy.
  • Page 69 Emissivity Figure 37: Spectral emissivity of several materials: 1 Enamel, 2 Plaster, 3 Concrete, 4 Chamotte If the emissivity chosen is too high, the infrared thermometer may display a temperature value which is much lower than the real temperature – assuming the measuring object is warmer than its surroundings. A low emissivity (reflective surfaces) carries the risk of inaccurate measuring results by interfering infrared radiation emitted by background objects (flames, heating systems, chamottes).

  • Page 70: Determination Of Unknown Emissivity

    7.2 Determination of unknown emissivity ► First determine the actual temperature of the measuring object with a thermocouple or contact sensor. Second, measure the temperature with the infrared thermometer and modify the emissivity until the displayed result corresponds to the actual temperature. ►...
  • Page 71 Emissivity ► Cove a part of the surface of the measuring object with a black, flat paint with an emissivity of 0.98. Adjust the emissivity of your infrared thermometer to 0.98 and take the temperature of the colored surface. Afterwards, determine the temperature of a directly adjacent area and modify the emissivity until the measured value corresponds to the temperature of the colored surface.

  • Page 72: Characteristic Emissivity

    7.3 Characteristic emissivity In case none of the methods mentioned above help to determine the emissivity you may use the emissivity table ► Appendix A and Appendix B. These are average values, only. The actual emissivity of a material depends on the following factors: ...

  • Page 73: Appendix A - Table Of Emissivity For Metals

    Appendix A – Table of emissivity for metals Appendix A – Table of emissivity for metals...

  • Page 75: Appendix B - Table Of Emissivity For Non-Metals

    Appendix B – Table of emissivity for non-metals Appendix B – Table of emissivity for non-metals...

  • Page 76: Appendix C - Quick Start For Serial Communication

    Appendix C – Quick start for serial communication Introduction One special feature of the PI Connect software contains the possibility to communicate via a serial COM-Port interface. This can be a physical COM-Port or a virtual COM-Port (VCP). It must be available on the computer where the PI connect software is installed.
  • Page 77 Appendix C – Quick start for serial communication Command list The command list is provided on the software CD and in the PI Connect software (Help → SDK). Every command must expire with CR/LF (0x0D, 0x0A).

  • Page 78: Appendix D - Interprocess Communication (Ipc)

    The ImagerIPC2.dll will export a bunch of functions that are responsible for initiating the communication, retrieving data and setting some control parameters. The main difference to the former Version 1 (ImagerIPC.dll) is the support of more than one Optris PI via multiple instances of Optris PI Connect.

  • Page 79: Appendix E - Pi Connect Resource Translator

    Appendix E – PI Connect Resource Translator Appendix E – PI Connect Resource Translator A detailed tutorial is provided on the CD. PI Connect is a .Net Application. Therefore it is ready for localization. Localization as a Microsoft idiom means a complete adaption of resources to a given culture. Learn more about the internationalization topics consult Microsoft’s developer documentation on http://msdn.microsoft.com/en-us/goglobal/bb688096.aspx.

  • Page 80: Appendix F - Wiring Diagrams Pif

    Appendix F – Wiring diagrams PIF Analog Output: Figure 41: Analog output For voltage measurements the minimum load impedance must be 10 KOhm. The analog output can be used as a digital output too. The voltage for “no alarm” and “alarm on” is set within the software.
  • Page 81 Appendix F – Wiring diagrams PIF Digital Input: Figure 42: Digital input The digital input can be activated with a button to the PI GND-Pin or with a low level CMOS/TTL signal: Low level 0…0.6 V; High level 2…24 V Example Button: Figure 43: Button...
  • Page 82 Analog input (usable voltage range: 0 … 10 V): Figure 44: Analog input Relay output at industrial PIF [Part No.: ACPIPIF500V2CBxx] The analog output must be set to “Alarm”. The voltage level for AO1-AO3 can be set in the software (no alarm: 0 V/ alarm: 2-10 V) REL1-3 (DO1-DO3): = 30 VDC...
  • Page 83 Appendix F – Wiring diagrams PIF Figure 45: Relay output at industrial PIF...

  • Page 84: Appendix G - Declaration Of Conformity

    Appendix G – Declaration of Conformity...

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