FLIR ThermaCAM EX300, TermaCAM E45 User Manual
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ThermaCAM™ EX300
User’s manual
1558439Publ. No.
a156Revision
English (EN)Language
February 28, 2006Issue date
Warnings & cautions
1
Important note about this manual
2
Welcome!
3
Packing list
4
System overview
5
Connecting system components
6
Introduction to thermographic inspections of
electrical installations
7
Tutorials
8
Camera overview
9
Camera program
10
Electrical power system
11
Maintenance & cleaning
12
Troubleshooting
13
Technical specifications & dimensional drawings
14
Glossary
15
Thermographic measurement techniques
16
History of infrared technology
17
Theory of thermography
18
Emissivity tables
19
ThermaCAM™ EX300
User’s manual
Publ. No. 1558439 Rev. a156 – ENGLISH (EN) – February 28, 2006
Legal disclaimer
All products manufactured by FLIR Systems are warranted against defective materials and workmanship for a period of one (1) year from the
delivery date of the original purchase, provided such products have been under normal storage, use and service, and in accordance with
FLIR Systems instruction.
All products not manufactured by FLIR Systems included in systems delivered by FLIR Systems to the original purchaser carry the warranty,
if any, of the particular supplier only and FLIR Systems has no responsibility whatsoever for such products.
The warranty extends only to the original purchaser and is not transferable. It is not applicable to any product which has been subjected to
misuse, neglect, accident or abnormal conditions of operation. Expendable parts are excluded from the warranty.
In the case of a defect in a product covered by this warranty the product must not be further used in order to prevent additional damage. The
purchaser shall promptly report any defect to FLIR Systems or this warranty will not apply.
FLIR Systems will, at its option, repair or replace any such defective product free of charge if, upon inspection, it proves to be defective in
material or workmanship and provided that it is returned to FLIR Systems within the said one-year period.
FLIR Systems has no other obligation or liability for defects than those set forth above.
No other warranty is expressed or implied. FLIR Systems specifically disclaims the implied warranties of merchantability and fitness for a
particular purpose.
FLIR Systems shall not be liable for any direct, indirect, special, incidental or consequential loss or damage, whether based on contract, tort
or any other legal theory.
Copyright
© FLIRSystems, 2006. Allrights reserved worldwide.No parts of the softwareincluding source codemay be reproduced,transmitted, transcribed
or translated into any language or computer language in any form or by any means, electronic, magnetic, optical, manual or otherwise,
without the prior written permission of FLIR Systems.
This manual must not, in whole or part, be copied, photocopied, reproduced, translated or transmitted to any electronic medium or machine
readable form without prior consent, in writing, from FLIR Systems.
Names and marks appearing on the products herein are either registered trademarks or trademarks of FLIR Systems and/or its subsidiaries.
All othertrademarks, trade names or companynames referenced herein are usedfor identificationonly and are the propertyof their respective
owners.
Quality assurance
The Quality Management System under which these products are developed and manufactured has been certified in accordance with the
ISO 9001 standard.
FLIR Systems is committed to a policy of continuous development; therefore we reserve the right to make changes and improvements on
any of the products described in this manual without prior notice.
Patents
This product is protected by patents, design patents, patents pending, or design patents pending.
One or several of the following patents, design patents, patents pending, or design patents pending apply to the products and/or features
described in this manual:
Reg. No.StatusDesignation
00809178.1ApplicationChina
01823221.3ApplicationChina
01823226.4ApplicationChina
235308Design PatentChina
ZL02331553.9Design PatentChina
ZL02331554.7Design PatentChina
200530018812.0PendingChina
1188086PatentEPC
01930377.5ApplicationEPO
01934715.2ApplicationEPO
27282912ApplicationEPO
000279476-0001Design PatentEU
1188086PatentFrance
viii Publ. No. 1558439 Rev. a156 – ENGLISH (EN) – February 28, 2006
Reg. No.StatusDesignation
60004227.8PatentGermany
106017Design PatentGreat Britain
3006596Design PatentGreat Britain
3006597Design PatentGreat Britain
1188086PatentGreat Britain
DM/057692Design PatentInternational
DM/061609Design PatentInternational
2000-620406ApplicationJapan
2002-588123ApplicationJapan
2002-588070ApplicationJapan
1144833Design PatentJapan
1182246Design PatentJapan
1182620Design PatentJapan
2005-020460PendingJapan
PCT/SE01/00983ApplicationPCT
PCT/SE01/00984ApplicationPCT
PCT/SE02/00857ApplicationPCT
PCT/SE03/00307ApplicationPCT
PCT/SE/00/00739ApplicationPCT
0302837-0ApplicationSweden
68657Design PatentSweden
75530Design PatentSweden
518836PatentSweden
522971PatentSweden
524024PatentSweden
09/576266ApplicationU.S.
10/476,217ApplicationU.S.
10/476,760ApplicationU.S.
466540Design PatentU.S.
483782Design PatentU.S.
484155Design PatentU.S.
5,386,117PatentU.S.
5,637,871PatentU.S.
5,756,999PatentU.S.
6,028,309PatentU.S.
6,707,044PatentU.S.
6,812,465PatentU.S.
Publ. No. 1558439 Rev. a156 – ENGLISH (EN) – February 28, 2006
Reg. No.StatusDesignation
29/233,400PendingU.S.
x Publ. No. 1558439 Rev. a156 – ENGLISH (EN) – February 28, 2006
Table of contents
11 Warnings & cautions ......................................................................................................................
32 Important note about this manual .................................................................................................
53 Welcome! .........................................................................................................................................
63.1 About FLIR Systems .............................................................................................................
83.1.1 A few images from our facilities ............................................................................
103.2 Comments & questions ........................................................................................................
114 Packing list ......................................................................................................................................
135 System overview .............................................................................................................................
156 Connecting system components ..................................................................................................
177 Introduction to thermographic inspections of electrical installations ......................................
177.1 Important note ......................................................................................................................
177.2 General information ..............................................................................................................
177.2.1 Introduction ...........................................................................................................
187.2.2 General equipment data .......................................................................................
197.2.3 Inspection .............................................................................................................
197.2.4 Classification & reporting ......................................................................................
207.2.5 Priority ...................................................................................................................
207.2.6 Repair ....................................................................................................................
217.2.7 Control ..................................................................................................................
227.3 Measurement technique for thermographic inspection of electrical installations ...............
227.3.1 How to correctly set the equipment .....................................................................
227.3.2 Temperature measurement ...................................................................................
247.3.3 Comparative measurement ..................................................................................
257.3.4 Normal operating temperature .............................................................................
267.3.5 Classification of faults ...........................................................................................
287.4 Reporting ..............................................................................................................................
307.5 Different types of hot spots in electrical installations ...........................................................
307.5.1 Reflections ............................................................................................................
307.5.2 Solar heating .........................................................................................................
317.5.3 Inductive heating ...................................................................................................
317.5.4 Load variations ......................................................................................................
327.5.5 Varying cooling conditions ...................................................................................
337.5.6 Resistance variations ............................................................................................
337.5.7 Overheating in one part as a result of a fault in another ......................................
357.6 Disturbance factors at thermographic inspection of electrical installations ........................
357.6.1 Wind ......................................................................................................................
357.6.2 Rain and snow ......................................................................................................
367.6.3 Distance to object .................................................................................................
377.6.4 Object size ............................................................................................................
397.7 Practical advice for the thermographer ................................................................................
397.7.1 From cold to hot ...................................................................................................
397.7.2 Rain showers ........................................................................................................
397.7.3 Emissivity ..............................................................................................................
407.7.4 Reflected apparent temperature ...........................................................................
407.7.5 Object too far away ...............................................................................................
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418 Tutorials ...........................................................................................................................................
418.1 Switching on & switching off the camera .............................................................................
418.1.1 Switching on the camera ......................................................................................
418.1.2 Switching off the camera ......................................................................................
428.2 Working with images ............................................................................................................
428.2.1 Acquiring an image ...............................................................................................
428.2.2 Freezing an image ................................................................................................
428.2.3 Saving an image ...................................................................................................
438.2.4 Deleting one or several images ............................................................................
438.2.5 Opening an image ................................................................................................
448.3 Working with measurements ................................................................................................
448.3.1 Laying out a spot ..................................................................................................
448.3.2 Laying out a measurement area ...........................................................................
458.4 Working with alarms .............................................................................................................
458.4.1 Setting up a color alarm .......................................................................................
458.4.1.1 Setting a color alarm using the menu system ..................................
458.4.1.2 Setting a color alarm without using the menu system .....................
468.5 Changing level & span .........................................................................................................
468.5.1 Changing level ......................................................................................................
468.5.2 Changing span .....................................................................................................
478.6 Changing system settings ....................................................................................................
478.6.1 Changing language ..............................................................................................
478.6.2 Changing temperature unit ...................................................................................
478.6.3 Changing date format ...........................................................................................
478.6.4 Changing time format ...........................................................................................
488.6.5 Changing date & time ...........................................................................................
498.7 Working with the camera ......................................................................................................
498.7.1 Removing the lens ................................................................................................
508.7.2 Adjusting the focus ...............................................................................................
508.7.3 Inserting & removing the battery ..........................................................................
518.7.3.1 Inserting the battery ..........................................................................
518.7.3.2 Removing the battery ........................................................................
539 Camera overview ............................................................................................................................
539.1 Camera parts ........................................................................................................................
579.2 Keypad buttons & functions .................................................................................................
599.3 Laser LocatIR ........................................................................................................................
609.4 LED indicator on keypad ......................................................................................................
6110 Camera program .............................................................................................................................
6110.1 Result table ...........................................................................................................................
6210.2 System messages ................................................................................................................
6210.2.1 Status messages ..................................................................................................
6210.2.2 Warning messages ...............................................................................................
6310.3 Selecting screen objects ......................................................................................................
6310.3.1 Selecting screen objects ......................................................................................
6310.3.2 Examples of selected screen objects ...................................................................
6510.4 Menu system ........................................................................................................................
6510.4.1 Navigating the menu system ................................................................................
6510.4.2 Meas. mode ..........................................................................................................
6510.4.3 Manual adjust/Automatic adjust ...........................................................................
6610.4.4 Emissivity ..............................................................................................................
6710.4.5 Palette ...................................................................................................................
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6710.4.6 Range (extra option) .............................................................................................
6710.4.7 Hide graphics / Show graphics ............................................................................
6810.4.8 File .........................................................................................................................
6910.4.9 Setup .....................................................................................................................
6910.4.9.1 Settings .............................................................................................
7010.4.9.2 Date/time ...........................................................................................
7110.4.9.3 Local settings ....................................................................................
7110.4.9.4 Camera info ......................................................................................
7110.4.9.5 Factory default ...................................................................................
7311 Electrical power system .................................................................................................................
7511.1 Internal battery charging ......................................................................................................
7611.2 External battery charging .....................................................................................................
7711.3 Battery safety warnings ........................................................................................................
7912 Maintenance & cleaning ................................................................................................................
7912.1 Camera body, cables & accessories ....................................................................................
7912.2 Lenses ...................................................................................................................................
8113 Troubleshooting ..............................................................................................................................
8314 Technical specifications & dimensional drawings ......................................................................
8314.1 Imaging performance ...........................................................................................................
8314.2 Image presentation ...............................................................................................................
8314.3 Temperature range ...............................................................................................................
8314.4 Laser LocatIR ........................................................................................................................
8414.5 Electrical power system ........................................................................................................
8414.6 Environmental specifications ...............................................................................................
8514.7 Physical specifications .........................................................................................................
8514.8 Communications interfaces ..................................................................................................
8514.9 Pin configurations .................................................................................................................
8514.9.1 RS-232/USB connector ........................................................................................
8614.9.2 Power connector ...................................................................................................
8614.9.3 CVBS connector ...................................................................................................
8714.10 Relationship between fields of view and distance ...............................................................
9314.11 Camera – dimensional drawings ..........................................................................................
9614.12 Battery charger – dimensional drawing ...............................................................................
9714.13 Battery – dimensional drawing .............................................................................................
9915 Glossary ...........................................................................................................................................
10316 Thermographic measurement techniques ...................................................................................
10316.1 Introduction ..........................................................................................................................
10316.2 Emissivity ..............................................................................................................................
10416.2.1 Finding the emissivity of a sample .......................................................................
10416.2.1.1 Step 1: Determining reflected apparent temperature .......................
10616.2.1.2 Step 2: Determining the emissivity ...................................................
10716.3 Reflected apparent temperature ..........................................................................................
10917 History of infrared technology ......................................................................................................
11318 Theory of thermography ................................................................................................................
11318.1 Introduction ...........................................................................................................................
11318.2 The electromagnetic spectrum ............................................................................................
11418.3 Blackbody radiation ..............................................................................................................
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11518.3.1 Planck’s law ..........................................................................................................
11618.3.2 Wien’s displacement law ......................................................................................
11818.3.3 Stefan-Boltzmann's law .........................................................................................
11818.3.4 Non-blackbody emitters .......................................................................................
12118.4 Infrared semi-transparent materials .....................................................................................
12319 Emissivity tables .............................................................................................................................
12319.1 References ............................................................................................................................
12319.2 Important note about the emissivity tables ..........................................................................
12319.3 Tables ....................................................................................................................................
139Index ................................................................................................................................................
xiv Publ. No. 1558439 Rev. a156 – ENGLISH (EN) – February 28, 2006
1 Warnings & cautions
10474103;a1
■ This equipment generates, uses, and can radiate radio frequency energy and if
not installed and used in accordance with the instruction manual, may cause interference to radio communications. It has been tested and found to comply with the
limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules,
which are designed to provide reasonable protection against such interference
when operated in a commercial environment. Operation of this equipment in a
residential area is likely to cause interference in which case the user at his own
expense will be required to take whatever measures may be required to correct
the interference.
■ An infrared camera is a precision instrument and uses a very sensitive IR detector.
Pointing the camera towards highly intensive energy sources – such as devices
emitting laser radiation, or reflections from such devices – may affect the accuracy
of the camera readings, or even harm – or irreparably damage – the detector. Note
that this sensitivity is also present when the camera is switched off and the lens
cap is mounted on the lens.
■ Each camera from FLIR Systems is calibrated prior to shipping. It is advisable that
the camera is sent in for calibration once a year.
■ For protective reasons, the LCD (where applicable) will be switched off if the detector
temperature exceeds +60 °C (+149 °F) and the camera will be switched off if the
detector temperature exceeds +68 °C (+154.4 °F).
■ The camera requires a warm-up time of 5 minutes before accurate measurements
(where applicable) can be expected.
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1 – Warnings & cautions
2 Important note about this manual
As far as it is practically possible, FLIR Systems configures each manual to reflect
each customer’s particular camera configuration. However, please note the following
exceptions:
■ The packing list is subject to specific customer configuration and may contain more
or less items
■ FLIR Systems reserves the right to discontinue models, parts and accessories, and
other items, or change specifications at any time without prior notice
■ In some cases, the manual may describe features that are not available in your
particular camera configuration
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2 – Important note about this manual
3 Welcome!
Thank you for choosing the ThermaCAM™ EX300 infrared camera!
The ThermaCAM™ EX300 IR camera measures and images the emitted infrared radi-
ation froman object. The factthat radiation is a function of object surface temperature
makes it possible for the camera to calculate and display this temperature. The
camera system also features a laser pointer, a 2.5" color LCD, an IR lens, a removable
battery and a range of accessories.
The camera is very easy to use. It is operated by using a few buttons which are conveniently placed on the camera, allowing fingertip control of major functions. A builtin menusystem alsogives easyaccess toan advanced,simple-to-use camerasoftware
for increased functionality.
To document the object under inspection it is possible to capture and store images
to the camera’s internal memory. The images can be analyzed either in the field by
using the real-time measurement functions built into the camera, or in a PC using
FLIR Systems ThermaCAM Reporter software by downloading the images from the
camera using ThermaCAM™ QuickView.
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3.1 About FLIR Systems
With over 40 years experience in IR systems and applications development, and over
30 000 infrared cameras in use worldwide, FLIR Systems is the undisputed global
commercial IR industry leader.
10380703;a2
Figure 3.1 FLIR Systems, Boston, USA, FLIR Systems, Danderyd, Sweden, and FLIR Systems, Portland,
USA.
10570303;a2
Figure 3.2 Indigo Operations, Niceville, USA, and Indigo Operations, SantaBarbara, USA. Indigo Operations
is a division of FLIR Systems.
As pioneers in the IR industry, FLIR Systems has a long list of ‘firsts’ the world of infrared thermography:
■ 1965: 1st thermal imaging system for predictive maintenance (Model 650).
■ 1973: 1st battery-operated portable IR scanner for industrial applications predictive
maintenance (Model 750).
■ 1975: 1st TV compatible system (Model 525).
■ 1978: 1st dual-wavelength scanning system capable of real-time analog recording
of thermal events (Model 780). Instrumental in R & D market development.
■ 1983: 1st thermal imaging and measurement system with on-screen temperature
measurement.
■ 1986: 1st TE (thermo-electrically) cooled system.
■ 1989: 1st single-piece infrared camera system for PM (predictive maintenance)
and R & D (research & development) with on-board digital storage.
■ 1991: 1st Windows-based thermographic analysis and reporting system.
■ 1993: 1st Focal Plane Array (FPA) system for PM and R & D applications.
■ 1995: 1st full-featured camcorder style FPA infrared system (ThermaCAM).
■ 1997: 1st: uncooled microbolometer-based PM/R & D system.
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3 – Welcome!
■ 2000: 1st thermography system with both thermal and visual imaging.
■ 2000: 1st thermography system to incorporate thermal/visual/voice and text data
logging.
■ 2002: 1st automated thermography system (model P60) to feature detachable re-
motely controllable LCD, JPEG image storage, enhanced connectivity including
USB and IrDA wireless, thermal/visual/voice and text data logging.
■ 2002: 1st low-cost ultra-compact hand-held thermography camera (E series).
Revolutionary, ergonomic design, lightest IR measurement camera available.
■ 2003: 1st low-cost, ultra-compact infrared camera for fixed installation intended for
automation and security applications. Exceptionally user-friendly due to standard
interfaces and extensive built-in functionality.
■ 2004: 1st camera models specially designed for building thermography (B1, B2
and B20)
10401603;a3
Figure 3.3 LEFT: FLIR Systems Thermovision® Model 661. The photo is taken on May 30th, 1969 at the
distribution plant near Beckomberga, in Stockholm, Sweden. The camera weighed approx. 25 kg (55 lb),
the oscilloscope 20 kg (44 lb), the tripod 15 kg (33 lb). The operator also needed a 220 VAC generator
set, and a 10L (2.6 US gallon) jar with liquid nitrogen. To the left of the oscilloscope the Polaroidattachment
(6 kg/13 lb) can be seen. RIGHT: FLIR Systems ThermaCAM Model E2 from 2002 – weight: 0.7 kg (1.54
lb), including battery.
With this tradition of unparalleled technical excellence and innovative achievements,
FLIR Systems continues to develop new infrared products, educational venues and
applications expertise to meet the diverse demands of thermographers worldwide.
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3 – Welcome!
3.1.1 A few images from our facilities
10401303;a1
Figure 3.4 LEFT: Development of system electronics; RIGHT: Testing of an FPA detector
10401403;a1
Figure 3.5 LEFT: Diamond turning machine; RIGHT: Lens polishing
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3 – Welcome!
10401503;a1
Figure 3.6 LEFT: Testing of IR cameras in the climatic chamber; RIGHT: Robot for camera testing and
calibration
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3 – Welcome!
3.2 Comments & questions
FLIR Systems is committed to a policy of continuous development, and although we
have tested and verified the information in this manual to the best of our ability, you
may find that features and specifications have changed since the time of printing.
Please let us know about any errors you find, as well as your suggestions for future
editions, by sending an e-mail to:
documentation@flir.se
➲ Do not use this e-mail address for technical support questions. Technical support
is handled by FLIR Systems local sales offices.
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3 – Welcome!
4 Packing list
The ThermaCAM™ EX300 and its accessories are delivered in a hard transport case
which typically contains the items below. On receipt of the transport case, inspect all
items and check them against the delivery note. Any damaged items must be reported
to the local FLIR Systems representative immediately.
Qty.Part NumberDescription
21 195 106Battery
11 195 102Battery charger
11 195 221Hand strap
11 120 987Lens cap for camera body
11558439Operator’s manual
11 909 528Power supply
1Configuration-dependentThermaCAM™ EX300 infrared camera with
lens
11 195 494TrainIR CD
11 195 128USB cable
11 909 775Video cable
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4 – Packing list
5 System overview
This system overview shows all accessories that are possible to order for a ThermaCAM™ EX300.
10582303;a2
Figure 5.1 System overview
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5 – System overview
6 Connecting system components
10438203;a2
Figure 6.1 How to connect system components
Figure 6.2 Explanations of callouts
ExplanationCallout
Power supply cable (11–16 VDC)1
USB / RS-232 cable2
Video cable (CVBS, i.e. composite video)3
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6 – Connecting system components
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