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optris PI LightWeight kit Operator's Manual

Ir camera with recording box for flight applications
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Operator's Manual
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optris
PI LightWeight kit
IR camera with Recording box for
flight applications

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Summary of Contents for optris PI LightWeight kit

  • Page 1 Operator’s Manual ® optris PI LightWeight kit IR camera with Recording box for flight applications...
  • Page 2 Optris GmbH Ferdinand-Buisson-Str. 14 D – 13127 Berlin Germany Tel.: +49 30 500 197-0 Fax: +49 30 500 197-10 E-mail: info@optris.de Internet: www.optris.com...

  • Page 3: Table Of Contents

    Table of contents General notes ..........................8 Intended use ..........................8 Warranty ............................. 10 Scope of delivery ........................11 Maintenance ..........................12 1.4.1 Cleaning ............................12 Technical Data ..........................13 Recording box ..........................13 2.1.1 General specifications ........................ 13 2.1.2 Electrical specifications .......................
  • Page 4 2.2.2 Electrical specifications ....................... 19 2.2.3 Measurement specifications ....................... 19 2.2.4 Optical specifications ........................21 Installation ........................... 26 Physical installation ........................26 Mechanical Data PI 400/ PI 450 / PI 640 LW ................27 Dimensions Recording box ......................28 Functional interfaces Recording box ..................29 Recording box operating modes ....................
  • Page 5 3.5.4 Configuration for PI on HDMI output + GoPro on TV output ............34 Operation ............................ 35 Startup of the Recording box ...................... 35 Stand-Alone operation ........................ 36 Multifunction button ........................37 Start a recording ......................... 38 4.4.1 Recording control with an electrical switch ................. 38 4.4.2 Recording control with the Recording box multifunction button ..........
  • Page 6 Operation Display ........................44 Analyzing of radiometric videos on a PC ..................46 Recording box configuration ....................... 49 GoPro Camera ..........................52 Using a GPS ..........................54 4.10 Micro SD card ..........................57 4.11 LED indicators ..........................58 4.12 Using servo control ........................59 4.12.1 Servo connector wiring .......................
  • Page 7 Recorder Software Update ......................63 System Recovery ........................64 Calibration files and Time settings ....................65 Installing the calibration files through Internet ................65 Installing the calibration files with an USB flash memory ............65 Time settings ..........................67 Backup battery replacement ....................... 68 Basics of Infrared Thermometry ....................

  • Page 8: General Notes

    The Recording box works with a Linux operating system that allows on-flight recording of infrared videos with the maximum speed of the camera. The optris PI 400 LW, 450 LW or 640 LW measures the surface temperature based on the emitted infrared energy of objects [►Basics of Infrared Thermometry]. The two-dimensional detector (FPA - focal plane array) allows a measurement of an area which will be shown as thermal image using standardized color palettes.
  • Page 9 The PI is a precise instrument and contains a sensitive infrared detector and a high- quality lens. The alignment of the camera to intensive energy sources (e.g. devices which emit laser radiation or reflections of such equipment) can cause an irreparable defect of the infrared detector.

  • Page 10: Warranty

    Warranty Each single product passes through a quality process. Nevertheless, if failures occur contact the customer service at once. The warranty period covers 24 months starting on the delivery date. After the warranty is expired the manufacturer guarantees additional 6 months warranty for all repaired or substituted product components.

  • Page 11: Scope Of Delivery

    Scope of delivery  IR camera PI400 LW or PI450 LW or PI640 LW (LightWeight) with one lens and fixed mounted USB cable (40 cm)  Recording box (Linux computer)  Power supply (100-240 VAC / 24 VDC)  Power cable (with open ends) ...

  • Page 12: Maintenance

    Maintenance Never use cleaning compounds which contain solvents (neither for the lens nor for the housing). Take care that no foreign substances penetrate into the venting slots of the Recording box. 1.4.1 Cleaning The housing of the Recording box can be cleaned with a soft, humid tissue moistened with water or a water based cleaner.

  • Page 13: Technical Data

    Technical Data Recording box 2.1.1 General specifications Operating temperature: 0…50 °C Storage temperature: -20...75 °C Relative humidity: 10...95 %, non-condensing Material (housing): aluminum Dimensions: 96 mm x 67 mm x 47 mm (L x W x H) Weight: 172 g (without the four mounting bricks) Vibration: IEC 60068-2-6 (sinus shaped), IEC 60068-2-64 (broad band noise) Shock:...

  • Page 14: Electrical Specifications

    2.1.2 Electrical specifications Power supply: 10 to 48 VDC Power consumption: 12 W Cooling: active via integrated temperature controlled fan Module: ODROID-XU4 Processor: Samsung Exynos5422 (Cortex™ A15 2GHz and Cortex™ A7) Octa core Memory: 8 GB eMMC flash storage/ 16 GB Micro-SDHC card (not intended to be exchanged by user) RAM: 2 GB LPDDR3 RAM Ports:...

  • Page 15: Camera Pi 400 / Pi 450 / Pi640 Lw

    Camera PI 400 / PI 450 / PI640 LW 2.2.1 General specifications Environmental rating: IP40 Ambient temperature: 0...50 °C [PI 400 LW & PI640 LW] / 0...70 °C [PI 450 LW] Storage temperature: -40...70 °C [PI 400 LW& PI640 LW]] / -40...85 °C [PI 450 LW] Relative humidity: 10...95 %, non-condensing Material (housing):...
  • Page 16 Figure 1: Used standards...
  • Page 17 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 Number of directions (3 axes with 2 directions each) Duration 600 Shocks (100 Shocks each direction) Shock, half sinus 50 g –...
  • Page 18 Vibration, sinus shaped – testing Fc (acc. IEC60068-2-6) Frequency range 10-500 Hz Acceleration 29.42 m/s (3 g) Frequency change 1 Octave/ min Number of axes Duration 1:30 h (3 x 0.30 h) Vibration, broadband noise – testing Fh (acc. IEC60068-2-64) Frequency range 10-2000 Hz Acceleration...

  • Page 19: Electrical Specifications

    500-2000 Hz -6 dB/ Octave 2000 Hz 0,1245 (m/s (0,00126 g /Hz) Number of axes Duration (3 x 1 h) 2.2.2 Electrical specifications Power Supply: 5 VDC (powered via USB 2.0 interface) Current draw: Max 500 mA Digital interface: USB 2.0 2.2.3 Measurement specifications Temperature ranges: -20...100 °C;...
  • Page 20 Detector: UFPA, 382 x 288 pixels (PI4xx) / 640 x 480 pixels (PI640) Spectral range: 7.5...13 µm 13° x 10°; 29° x 22°, 38° x 29°; 53° x 40°, 62° x 49°; 80° x 58° [PI4xx] Lenses (FOV): 15° x 11°; 33° x 25°; 60°x 45°; 90° x 66° [PI640] System accuracy ±2°C or ±2 % Temperature resolution (NETD):...

  • Page 21: Optical Specifications

    2.2.4 Optical specifications Make sure that the focus of the infrared camera is adjusted correctly. For focusing turn the lens. Figure 2: Focusing of the lens (1 – lens)
  • Page 24 Figure 3: Example of measurement field of the infrared camera PI160 representing the 23° x 17° lens...
  • Page 25 ■ HFOV: Horizontal enlargement of the total measuring at object level ■ VFOV: Vertical enlargement of the total measuring at object level ■ IFOV: Size at the single pixel at object level ■ DFOV: Diagonal dimension of the total measuring field at object level ■...

  • Page 26: Installation

    Installation Physical installation The PI 400 LW/ 450 LW / 640 LW are 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 the ¼’’ photo tripod mount (also on bottom side).

  • Page 27: Mechanical Data Pi 400/ Pi 450 / Pi 640 Lw

    Mechanical Data PI 400/ PI 450 / PI 640 LW Figure 5: Dimensions PI400/ PI450 / PI640 LW (mm)

  • Page 28: Dimensions Recording Box

    Dimensions Recording box Figure 6: Dimensions Recording box (mm)

  • Page 29: Functional Interfaces Recording Box

    Functional interfaces Recording box Figure 7: Controls and connections Recording box (1)
  • Page 30 Figure 8: Controls and connections Recording box (2)
  • Page 31 Figure 9: Controls and connections Recording box (3)

  • Page 32: Recording Box Operating Modes

    Recording box operating modes The PI LightWeight Recording box features a modular conception which provides the possibility to use different configurations:  Infrared PI camera on HDMI video output only  Infrared PI camera on analog CVBS TV output only ...

  • Page 33: Configuration For Pi On Hdmi Output

    3.5.1 Configuration for PI on HDMI output Connect the PI imager to one of the USB3.0 interfaces. The GPS-Stick (U-Blox) can be connected with the USB2.0 interface whereas the HDMI interface is used as video output. 3.5.2 Configuration for PI on analog TV output The HDMI video output is forwarded to the micro HDMI by using the HDMI cable bridge (see Figure 9: Controls and connections Recording box (3)

  • Page 34: Configuration For Pi On Hdmi Output + Gopro On Tv Output

    This configuration offers the possibility to switch between infrared and visible image. The video signal can be acquired from the mini jack port (see chapter 0). 3.5.4 Configuration for PI on HDMI output + GoPro on TV output It is possible to have both images (IR & visible) simultaneously on the two video outputs: The infrared image is permanently available on the HDMI output The visible image is permanently available on the TV output (mini jack) Connect the PIxxx to an USB 3.0 port (blue), the GoPro Hero 3+ to the GoPro USB port (see...

  • Page 35: Operation

    Operation Startup of the Recording box To startup PI LightWeight, connect all the cables according to the desired operating mode and simply plug the provided power cable (powered from power supply or LiPo battery), there is no ON/OFF switch. Before to power on the Recording box, the HDMI output must be connected either to the Micro-HDMI socket, or to a powered monitor to ensure a correct initialization of the video output.

  • Page 36: Stand-Alone Operation

    Stand-Alone operation For a self-contained power supply, a lithium-polymer battery with a voltage from 11 to 25 VDC (LiPo 3S to LiPo 6S) is recommended. After powering the Recording box, the system boots and is ready in about 30 seconds. A video monitor connected to the system via the video adapter cable, shows the IR live picture of the camera in full screen mode.

  • Page 37: Multifunction Button

    Multifunction button The multifunction button (see ) has the following Figure 9: Controls and connections Recording box (3) functions: Context Function Recording box is running. Press > 5s => shutdown the system Recording box is running with IR image visible. Press for 1 s =>...

  • Page 38: Start A Recording

     A short press < 1 s can have no effect  1 s press functions are also duplicated by the servo control (left connector) and remote control contact (mini jack and screw connector) Start a recording There are four possibilities to start a recording: Using an electrical contact (open/ close) via the analog video cable Using the Recording box multifunction button Using a servo control (Uni, Graupner /JR) or...

  • Page 39: Recording Control With The Recording Box Multifunction Button

    The recording starts if the trigger is connected to GND during one second, and stops doing the same again. Figure 10: Video cable (Order No.: ACPILKVCB2) left, and video cable (Order No.: ACPILKVCB2C) right The second video cable (not supplied - Order No.: ACPILKVCB2C) can be used for a direct connection of the system to a monitor –...

  • Page 40: Recording Control With A Servo Control

    4.4.3 Recording control with a servo control By connecting a servo control (Uni, Graupner /JR, type) to the Recording box servo control input, it is possible to start and stop the recording via remote control. 4.4.4 Recording control via screw terminal block The external switch S2 of the right screw terminal is Low-active and must be connected to ground (a simple switch to ground is recommended) to start a recording (see 4.13).

  • Page 41: Recording Time Duration

    4.4.5 Recording time duration The maximum recording time depends on the camera and video mode (frame frequency). It is recommended to record directly on external memory (Firmware ≥ v1.1.3.0) as it avoids a copy process after recording. The given example refers to a 128 GB USB 3.0 Drive PI640 LW 32 Hz ~ 108 minutes (640 x 480 pixels) PI640 LW...
  • Page 42 On internal memory If the external memory is not connected the internal memory will be used automatically. After finishing the recording the data can be copied to an USB stick. If the USB stick is well detected by the system it displays “Mounting USB stick”. If there is at least one record to copy the data transfer to the USB stick starts.
  • Page 43 The USB 3.0 drive should feature a writing speed of at least 10 MByte/ s for PI4xx (27Hz) and 25 MByte/ s for PI4xx (80Hz)/ PI640 (32Hz). The internal SD card can only be used for recordings with a PI4xx (27Hz). USB 2.0 drives are supported for copying data, not for recording data.

  • Page 44: Operation Display

    Operation Display The video output of the Recording box shows a live stream of the thermal imager. The temperatures are indicated by a color palette. The color palette can be altered by the user (see section 4.7). By default, a hot spot (red), cold spot (blue) and center spot (white) is displayed with temperature information for supporting the drone pilot.
  • Page 45 Figure 11: Display if no imager is connected or Figure 12: Display, if imager is connected calibration files missing...

  • Page 46: Analyzing Of Radiometric Videos On A Pc

    Analyzing of radiometric videos on a PC The recorded files contain raw thermal IR energy data and geo data which needs to be converted. Extension of these files is *.raw and they have to be first converted by PIConnect software to the *.ravi format to enable further analysis in PIConnect.
  • Page 47 Then you get a message window: Validate, and there is the conversion window displayed:...
  • Page 48 The conversion needs to be finalized by providing a file name of the converted RAW file. The record file is automatically played by the imager software: Figure 113: Screenshot of PIConnect displaying the GPS data embedded in radiometric file.

  • Page 49: Recording Box Configuration

    Recording box configuration There are different parameters of the Recording box which can be adjusted by the user. The recording box can operate different imagers (only one at the same time). Each imager can be configured individually:  Recording speed (27 or 80 Hz for a PI4xx camera; 32 or 125 Hz for a PI640) ...
  • Page 50 To change the Recording box parameters you first have to generate a configuration file in PIConnect software. This file has to be loaded then into the Recording box. 1) Connect the PI camera to the PC where PIConnect software is installed, 2) If the imager is connected the first time to this PC it is necessary to load the calibration files from the internet, 3) Adjust the configuration in PIConnect as desired,...
  • Page 51 5) Connect the PI camera and the USB stick to an USB 3.0 USB port of the Recording box, the configuration file is automatically loaded to set the parameters. For generating the Recording box configuration file it is required to connect the imager to a PC where PIConnect is installed.

  • Page 52: Gopro Camera

    GoPro Camera The GoPro camera cannot just be used to as video source. The Recording box provides the possibility to transfer the GoPro video files automatically when the IR recording has been stopped. Therefore, the USB-bridge cable must be attached as well as the mini-USB cable for the GoPro camera. Assure the GoPro camera is switched on.
  • Page 53 The following points need to be considered when using a GoPro camera: GoPro4 data transfer and video mode is supported by firmware version ≥ v1.1.3.0 GoPro data transfer relies on USB 2.0 data transfer rate. Large video files requires a long transfer time to USB Stick. To avoid automatic data transfer to USB drive, remove USB bridge cable from Recording box.

  • Page 54: Using A Gps

    Using a GPS The PI LightWeight system can work with U-Blox USB GPS chipsets to embed the geo data in the radiometric video file. The locational information are stored as string using the the NMEA conform GPRMC format. Locational information for each frame can be exported manually with PI Connect Software (≥...
  • Page 55 Field number: 1. Universal Time Coordinated (HHMMSS.SS) 2. Status, (V=invalid data; A=Valid) 3. Latitude (ddmm.mmmm) 4. N or S (N=North / S=South) 5. Longitude (dddmm.mmmm) 6. E or W (E=East / W=West) 7. Speed over ground, (knots) 8. Track made good, (degrees true) 9.
  • Page 56 If a compatible GPS is connected to the USB 2.0 port, and detected, and before valid GPS data are received, the message “No GPS device attached” is displayed. As soon as valid GPS “sentences” are received, the incomplete “RMC” frame is displayed at first (left figure): only UTC time and date are present.

  • Page 57: Micro Sd Card

    4.10 Micro SD card The Recording box is provided with a 16 GB micro SDHC card embedded in the computer. The card hosts a recovery system. In addition, the memory card can be used as internal memory for recordings. The memory card is part of the operating system. Modifications and exchange can cause system damage! SD card can be exchanged in case of damage or if additional internal memory for record is required.

  • Page 58: Led Indicators

    4.11 LED indicators The Recording box is equipped with a total of 6 LED indicators: 5 status LEDs (L0-L4, above the multifunction button) see Figure 9: Controls and connections Recording box (3) Function LED is ON, if: Power indicator Recording box is powered via a power supply/ battery Flight-recorder service Software basic functions are running PI camera status...

  • Page 59: Using Servo Control

    4.12 Using servo control Two remote control inputs are available with the Recording box, see Figure 7: Controls and connections Recording box (1) Left socket allows to remotely control the start and stop of the recording Right socket allows to remotely toggle the analog CVBS video output between infrared image from PI camera, and visible image from the GoPro camera 4.12.1 Servo connector wiring Left (black)

  • Page 60: Screw Connectors Interface

    4.13 Screw connectors interface The Recording box is equipped with two screw block terminals: Figure 13: Screw block terminals Left connector Four connections, from the left to the right: GND | +5V output (100 mA max.) | GND | Video in (visible camera) The analog NTSC Video IN can be used for alternative video cameras.
  • Page 61 Right connector Four connections, from the left to the right: S3 | S2 | GND | TVout The external switches S2 and S3 are Low-active and must be tied to ground (a simple switch to ground is recommended). Start and Stop recording switch IR or visible cam (e.g.

  • Page 62: System Update And Recovery

    System Update and Recovery The Recording box can be updated by the user. Beside of system updates also a system recovery can be done. System updates System updates can improve the amount of features or enhance the stability of the operating system. ...

  • Page 63: Recorder Software Update

    Recorder Software Update The Recorder Software is responsible for the main functionality of the Recording box.  To update the system, the update files need to be copied to the root directory of an USB- Stick (FAT32 formatting).  Start the box, wait until the box is up and the splash screen is visible. ...

  • Page 64: System Recovery

    System Recovery For a system recovery the SD-card needs to be removed from the Recording box.  Remove the cover which protects the SD-card. Unscrew only the central screw (of three).  Remove the SD-card.  Download the new SD-card image (ask your local distributor for a download link). ...

  • Page 65: Calibration Files And Time Settings

    Calibration files and Time settings The PI cameras are not only infrared imagers, they are mainly thermal measuring devices and so they need calibration files to work properly. These calibration files are specific to each camera and lens and are installed at factory on the Recording box, but after a recovery it is necessary to install them again in the system.
  • Page 66 2/ Use PIConnect software to copy automatically the correct calibration files corresponding to the PI camera currently connected to this PC: Menu “Tools/ Extended/ Config Recording box, check “Copy calibration data” and select the USB flash memory where you want to copy these files. Press OK.

  • Page 67: Time Settings

    Time settings For automatic time synchronization, the Recording box needs to be connected to a local network with internet access. Reassure the local network is granting access to internet for loading calibration files and synchronizing time. Usually company networks are protected, especially for devices which are not part of a company domain.

  • Page 68: Backup Battery Replacement

    Backup battery replacement The Recording box is equipped with a Real Time Clock supplied by a 3V lithium battery (CR 1632). The battery can be exchanged if necessary. Unscrew the four screws on the bottom of the Recording box and remove the cover. Remove the battery from mount carefully using a thin screw driver.

  • Page 69: Basics Of Infrared Thermometry

    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 15: William Herschel (1738-1822)
  • Page 70 He blackened the peak of a sensitive mercury thermometer. This thermometer, a glass prism that led sun rays onto a table made his measuring arrangement. With this, he tested the heating of different colors of the spectrum. Slowly moving the peak of the blackened thermometer through the colors of the spectrum, he noticed the increasing temperature from violet to red.
  • Page 71 Infrared thermometers are optoelectronic sensors. They calculate the surface temperature on the basis of the emitted infrared radiation from an object. The most important feature of infrared thermometers is that they enable the user to measure objects contactless. Consequently, these products help to measure the temperature of inaccessible or moving objects without difficulties.
  • Page 72 The specifications of the lens decisively determine the optical path of the infrared thermometer, which is characterized by the ratio Distance to Spot size. The spectral filter selects the wavelength range, which is relevant for the temperature measurement. The detector in cooperation with the processing electronics transforms the emitted infrared radiation into electrical signals.
  • Page 73 Figure 18: Contactless thermometry...
  • Page 74 Application fields: Monitoring of electronic Process control extruding R&D of electronics R&D of electronic parts cabinets plastic parts Process control Process control at R&D of mechanical parts Monitoring of cables manufacturing solar calendering modules...
  • Page 75 Emissivity: 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. It can range between 0 and 100 %.
  • Page 76 Figure 20: Spectral emissivity of several materials: 1 Enamel, 2 Plaster, 3 Concrete, 4 Chamotte...

  • Page 77: Ce Conformity

    CE Conformity...

This manual is also suitable for:

Pi 400 lwPi 640 lwPi 450 lw

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