Modline® 5
Series 52, 56, 5G and
5R Sensors
Infrared Thermometer
Operating Instructions
Rev. L6 Feb 2017
60401
Contacts
Fluke Process Instruments
Americas
Santa Cruz, CA USA
Tel: +1 800 227 8074 (USA and Canada, only)
+1 831 458 3900
solutions@flukeprocessinstruments.com
EMEA
Berlin, Germany
Tel: +49 30 478 0080
info@flukeprocessinstruments.de
China
Beijing, China
Tel: +86 10 6438 4691
info@flukeprocessinstruments.cn
Worldwide Service
Fluke Process Instruments offers services,
including repair and calibration. For more
information, contact your local office.
www.flukeprocessinstruments.com
© Fluke Process Instruments
Specifications subject to change without notice.
Warranty
IRCON, Inc. warrants equipment manufactured by it to be free from defects in materials and
workmanship for a period of one year from the date of shipment by IRCON. Customer-paid repairs are
warranted for 90 days from date of shipment. If within such period any such equipment shall be proved
to IRCON’s satisfaction to be so defective, such equipment shall be repaired or replaced at IRCON’s
option, provided the defective equipment is returned to IRCON, transportation charges prepaid by
purchaser.
This warranty shall not apply (a) to equipment not manufactured by IRCON, (b) to equipment which
shall have been repaired or altered by others than IRCON so as, in its judgment, to affect the same
adversely, or (c) to equipment which shall have been subject to negligence, accident or damage by
circumstances beyond IRCON’s control or to improper operation, maintenance or storage, or to other
than normal use or service. With respect to equipment purchased by IRCON but not manufactured by
IRCON, the warranty obligations of IRCON shall in all respects conform and be limited to the warranty
actually extended to IRCON by its supplier (the manufacturer). The foregoing warranties do not cover
reimbursement for transportation, removal, installation, or other expenses which may be incurred in
connection with repair or replacement.
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to any other obligations or liabilities whatsoever with respect to equipment manufactured by IRCON
or services rendered by IRCON.
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AND IMPLIED WARRANTIES EXCEPT WARRANTIES OF TITLE, INCLUDING BUT NOT
LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
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price of the product or part on which such liability is based.
IRCON Limited Use Software License Agreement and Limited
Warranty
Modline 5 ModView Configuration Software Distributed with Ircon Modline 5 Sensors
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IRCON and/or its software suppliers.
LIMITED WARRANTY
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will be free from defects in materials and workmanship under normal use and service. Your Limited
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reason, please write: Ircon, Inc., Customer Service, 1201 Shaffer Road, Building 2, Santa Cruz, CA 95060-
5731.
Content
1 SAFETY INSTRUCTIONS ........................................................................................................................... 11
2 PRODUCT DESCRIPTION .......................................................................................................................... 14
2.1 Modline 5 Sensors, Cable and Interface Accessories ................................................................................. 14
2.1.1 Preliminary Inspection ....................................................................................................................... 14
2.2 Modline 5 Description ................................................................................................................................ 15
2.2.1 Sensor Standard Features ................................................................................................................... 15
2.2.2 Optional Sensor Features ................................................................................................................... 15
2.3 Model Configuration and Required Selections ........................................................................................... 16
2.3.1 Model Configuration .......................................................................................................................... 16
2.4 Modline 5 Model Number Summary .......................................................................................................... 17
2.5 Accessories ................................................................................................................................................. 18
2.5.1 Interconnecting Cable – Required Accessory ..................................................................................... 18
2.5.2 Power and Interface Accessories ......................................................................................................... 19
2.5.3 Installation Accessories ...................................................................................................................... 19
2.6 Specifications ............................................................................................................................................. 20
2.6.1 Sensor Specifications .......................................................................................................................... 20
2.6.2 Accessory Specifications ..................................................................................................................... 21
3 SENSOR INSTALLATION .......................................................................................................................... 22
3.1 Mechanical Installation ............................................................................................................................... 22
3.2 Sensors ........................................................................................................................................................ 22
3.2.1 Sensor Parts ........................................................................................................................................ 23
3.3 Sighting Methods ........................................................................................................................................ 23
3.3.1 Sighting and Focusing ........................................................................................................................ 23
3.3.2 Visual Sight ........................................................................................................................................ 23
3.3.3 Laser Sight .......................................................................................................................................... 24
3.4 Sensor Optical Characteristics .................................................................................................................... 26
3.4.1 Optical Resolution .............................................................................................................................. 26
3.4.2 Lens Focusing Ranges and Optical Resolution Factor ....................................................................... 26
3.4.3 Table of Model and Lens Type Combinations with Focusing Ranges ................................................ 27
3.4.4 Spot Size and Viewing Distance ......................................................................................................... 27
3.5 Measuring Temperature with Brightness and Ratio Sensors ...................................................................... 29
3.5.1 Resolving Targets with Brightness Sensors ....................................................................................... 29
3.5.2 Obstructions in Cone of Vision .......................................................................................................... 29
3.5.3 Resolving Targets with Two Color Ratio Sensors .............................................................................. 29
3.5.4 Signal Reduction ................................................................................................................................ 30
3.5.5 Summary ............................................................................................................................................ 31
3.6 Sensor Installation Planning ....................................................................................................................... 31
3.7 Sensor Mechanical Installation ................................................................................................................... 32
3.7.1 Installation Accessories ...................................................................................................................... 32
3.7.2 Sensor Dimensions ............................................................................................................................. 33
3.7.3 General Installation Requirements ..................................................................................................... 34
3.8 DWD Installation Requirements ................................................................................................................. 34
3.9 Modline 5 Mounting, Cooling and Air Purging Accessories ...................................................................... 35
3.9.1 UAA – Universal Adapter Accessory Description and Dimensions .................................................. 35
3.9.2 RAM – Right Angle Mount Description and Dimensions ................................................................ 37
3.9.3 APA – Air Purge Accessory Description and Dimensions ................................................................ 39
3.9.4 MFL – Mounting Flange Large Description and Dimensions ........................................................... 40
3.9.5 MFS – Mounting Flange Small Description and Dimensions ........................................................... 42
3.9.6 WJA – Water Jacket Accessory Description and Dimensions ............................................................. 44
3.9.6.1 WJA Water Cooling Requirements ........................................................................................... 45
3.9.6.2 WJA Air Cooling Requirements. ............................................................................................... 46
3.9.6.3 Sensor Temperature Alarm ....................................................................................................... 46
3.9.7 BMA – Base Mount Accessory Description and Dimensions ............................................................ 47
3.9.8 ESA – Extension Sleeve Adapter Description and Dimensions ......................................................... 48
3.10 Accessory Combinations with Break-out Drawings ................................................................................. 50
3.10.1 Recommended Accessory Groupings ................................................................................................ 50
3.11 Installation Drawings and Illustrations ...................................................................................................... 54
3.11.1 Installation Drawing for the UAA – Universal Adapter for Tripod or Custom Mounting ............. 54
3.11.2 Installation Drawing for the RAM – Right Angle Mount ............................................................... 55
3.11.3 Installation Drawing using the WJA – Water Jacket Accessory with Flange Mounts .................... 57
3.11.4 Installation Drawing using the WJA Water Jacket Accessory with the Base Mount Adapter ......... 58
3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling) .............................................................. 60
3.12.1 M5WJ5 – Mounting Kit ................................................................................................................... 60
3.13 Sensor Installation Checklist ..................................................................................................................... 62
4 SENSOR WIRING .......................................................................................................................................... 64
4.1 Modline 5 Components ............................................................................................................................... 64
4.2 Modline 5 Sensor System Interfacing ......................................................................................................... 64
4.3 Modline 5 Sensor Cable .............................................................................................................................. 65
4.3.1 Sensor Interconnecting Cable.............................................................................................................. 65
4.4 TSP Terminal Strip Plate ............................................................................................................................ 65
4.4.1 Dimensions and Installation ............................................................................................................... 65
4.5 Sensor Interconnecting Cable Preparation .................................................................................................. 66
4.5.1 Cable Preparation ................................................................................................................................ 66
4.5.2 Interconnecting Cable Assembly Continuity Check ........................................................................... 67
4.6 Terminal Strip Plate – Sensor Interconnecting Cable Installation ............................................................... 68
4.7 Connecting Device Cables to Terminal Strip Plate ..................................................................................... 68
4.7.1 Recommended Cable Types ................................................................................................................. 68
4.7.2 Grounding and Shielding .................................................................................................................... 69
4.7.3 System Connections ............................................................................................................................ 69
4.7.4 RS-485 Digital Communications ........................................................................................................ 69
4.7.5 Analog Output Temperature Signal ................................................................................................... 69
4.7.6 Converting the Analog Output from a mA output to a 10 Volt Output ............................................ 70
4.7.7 Current Input for Remote Emissivity, E-Slope or Laser Operation .................................................... 70
4.7.8 Current Input Terminal Connections for Remote Laser ..................................................................... 71
4.7.9 Peak/Hold Switch for Remote Peak Picker Reset, Track and Hold or Laser Operation. ..................... 72
4.7.10 Sensor Alarm Relay Contacts ........................................................................................................... 72
4.8 Selection of a Power Supply for Sensors used with TSP Terminal Strip Plates ......................................... 73
4.8.1 TSP Terminal Strip Plate DC Power Supply Connections ................................................................ 75
4.8.2 Power Supply Common Ground Connection ...................................................................................... 75
4.9 RS-485 Multi-Drop Network Power Supply and System Wiring ............................................................... 75
4.9.1 Computer Communications Requirements ......................................................................................... 76
4.9.2 TSP Terminal Strip Plates Multi-drop Wiring .................................................................................. 77
4.10 Sensor and Cable Connection ................................................................................................................... 78
4.10.1 Cable Plug and Sensor Receptacle ..................................................................................................... 78
4.11 System Grounding and Shielding .............................................................................................................. 79
4.11.1 Terminal Strip Plate Diagram .......................................................................................................... 79
4.12 Summary Caution and Warning ................................................................................................................ 80
5 OPERATION ................................................................................................................................................... 82
5.1 Sensor Rear Panel Setup and Operation ..................................................................................................... 82
5.1.1 Introduction ........................................................................................................................................ 82
5.2 Rear Panel Keyboard, Displays and Sight and Laser Aiming ................................ .................................... 82
5.2.1 Description ......................................................................................................................................... 82
5.3 Navigation and Menus ................................................................................................................................ 83
5.3.1 Enter and Up / Down Arrow Pushbuttons ........................................................................................ 83
5.4 Main Menus ................................................................................................................................................ 83
5.5 Warm-up and Initial Setup .......................................................................................................................... 85
5.5.1 Series 5R, 5G, 52 Power On and Warm-up ....................................................................................... 85
5.5.2 Series 56 Models Power On and Warm-up ........................................................................................ 85
5.5.3 Initial Rear Panel Display .................................................................................................................. 85
5.5.4 Initial Sensor Setup ............................................................................................................................ 85
5.6 ENGR – Setup of Engineering Functions ................................................................................................... 86
5.6.1 LOCK – Panel Lock Security .............................................................................................................. 86
5.6.2 MODL – Sensor Model Number ........................................................................................................ 86
5.6.3 F/C – Selection of Fahrenheit or Celsius Indication (°F or °C) .......................................................... 86
5.6.4 CHK – Initiate Manual System Check ............................................................................................... 87
5.6.5 HOUR– Automatic System Check ..................................................................................................... 88
5.6.6 CHK – Manual System Calibration for 56 Models ............................................................................ 89
5.6.7 HOUR– Automatic Calibration Check for 56 Models ........................................................................ 91
5.6.8 WRNL – Dirty Window Detector Option Warning Level ................................................................. 92
5.6.9 VER – Sensor Firmware Version ........................................................................................................ 92
5.6.10 iALM – Selects Ratio Invalid Measurement Condition as an Alarm ............................................... 92
5.6.11 ATTN – Selects Attenuation Alarm Threshold ................................................................................ 93
5.7 AOUT – Setup of Analog Signal Output Current Range and Temperature Scaling ................................... 93
5.7.1 Fatl – Analog Output Operation for Sensor or Dirty Window Detector Malfunction Alarms ......... 94
5.7.2 A–LO – Analog Output Low Temperature Alarm ............................................................................. 94
5.7.3 A–HI – Analog Output High Temperature Alarm ............................................................................ 95
5.8 COMM – Setup of RS-485 Digital Communication Configuration ........................................................... 95
5.8.1 CLCK – Communications Lock .......................................................................................................... 96
5.8.2 ADDR – Sets the Sensor Address ...................................................................................................... 96
5.8.3 BRAT – Baud Rate ............................................................................................................................. 96
5.8.4 LASR –Laser Operation (Sensor Firmware Versions 1.08 and Higher) ............................................ 96
5.9 HEAD – Setup of Sensor Operating Functions .......................................................................................... 96
5.9.1 R.T. – Response Time ......................................................................................................................... 97
5.9.2 COLR – Ratio Unit Operation Selection ............................................................................................ 97
5.9.3 E-SL – Ratio Unit Two Color Operation E-Slope Adjustment .......................................................... 97
5.9.4 Remote E-Slope Current Input ........................................................................................................... 98
5.9.5 EMIS – Emissivity Adjustment for Brightness Sensors .................................................................... 98
5.9.6 Remote Emissivity Current Input ...................................................................................................... 99
5.9.7 MTCH – E-Slope or Emissivity Selection Based on Temperature Match .......................................... 99
5.9.8 SIGL – Signal Conditioning Selection ............................................................................................... 99
5.10 PSEL – Peak Picker Functions ............................................................................................................... 100
5.10.1 D.R. – Decay Rate Function ........................................................................................................... 100
5.10.2 RSET – Manual Peak Picker Reset ................................................................................................. 101
5.10.3 External Switch for Remote Peak Picker Reset ............................................................................... 101
5.10.4 AUTO – Auto Peak Picker Reset .................................................................................................... 101
5.10.5 RBEL – Reset Below Temperature .................................................................................................. 101
5.10.6 DEL – Peak Picker Delay ................................................................................................................ 101
5.11 Laser Sighting Operation ........................................................................................................................ 102
5.12 Out of Range Displays and Error Codes ................................................................................................. 104
5.12.1 Summary ......................................................................................................................................... 106
6 RS-485 DIGITAL COMMUNICATIONS ................................................................................................. 107
6.1 Introduction ............................................................................................................................................... 107
6.2 Basic Operation ......................................................................................................................................... 107
6.3 Sensor Rear Panel Setup for RS-485 Communication .............................................................................. 108
6.3.1 CLCK – Communications Lock ......................................................................................................... 108
6.3.2 ADDR – Sets the Sensor Address ..................................................................................................... 108
6.3.3 BRAT – Baud Rate ............................................................................................................................ 108
6.4 Communication Protocol .......................................................................................................................... 108
6.4.1 Command Message Format ............................................................................................................... 108
6.5 Command Codes ....................................................................................................................................... 109
6.5.1 Introduction ...................................................................................................................................... 109
6.6 Engineering Function Command Codes .................................................................................................... 109
6.7 Analog Output Function Command Codes ............................................................................................... 112
6.8 Head Function Command Codes ............................................................................................................... 113
6.9 Measurement Condition and Alarm Command Codes .............................................................................. 115
6.9.1 Introduction ...................................................................................................................................... 115
6.10 Command Code Summary ...................................................................................................................... 117
7 MAINTENANCE .......................................................................................................................................... 119
7.1 Routine Maintenance ................................................................................................................................ 119
7.1.1 Maintenance Checklist ...................................................................................................................... 119
7.2 Sensor Optics Cleaning ............................................................................................................................. 119
7.2.1 Cleaning the Optics ........................................................................................................................... 120
7.2.2 Restoring the Sensor to Operation .................................................................................................... 120
7.3 Servicing ................................................................................................................................................... 121
7.4 Factory Calibration and Service ................................................................................................................ 121
7.5 Measurement Condition Displays, Error Codes and Troubleshooting ...................................................... 122
7.6 Status Displays and Error Code Details .................................................................................................... 124
7.6.1 Troubleshooting ................................................................................................................................. 127
8 APPLICATIONS GUIDE ............................................................................................................................ 129
8.1 Introduction ............................................................................................................................................... 129
8.2 Analog Outputs ......................................................................................................................................... 129
8.2.1 Analog Output Range Scaling Example ........................................................................................... 130
8.2.2 Measured Temperature Calculations ................................................................................................ 130
8.2.3 Analog Output Operation Notes ...................................................................................................... 131
8.3 Response Time .......................................................................................................................................... 131
8.3.1 Description ........................................................................................................................................ 131
8.3.2 Determining Response Time to Use .................................................................................................. 132
8.4 Emissivity Settings .................................................................................................................................... 133
8.4.1 Using Emissivity Tables ................................................................................................................... 133
8.4.2 Using Emissivity Thermocouple Test ............................................................................................... 134
8.4.3 Setting the Emissivity ....................................................................................................................... 134
8.4.4 Using Relative Readings ................................................................................................................... 134
8.4.5 Practical Limits on Emissivity .......................................................................................................... 134
8.5 Ratio Sensors............................................................................................................................................. 140
8.5.1 E-Slope Settings ................................................................................................................................ 140
8.5.2 Setting the E-Slope ............................................................................................................................ 141
8.6 Peak Picker Signal Conditioning ............................................................................................................... 141
8.6.1 Turning Peak Picker On and Off ...................................................................................................... 141
8.6.2 External Switch for Remote Peak Picker Operation ......................................................................... 142
8.6.3 Peak Picker Signal Conditioning ...................................................................................................... 143
8.6.4 Peak Picker Reset .............................................................................................................................. 143
8.6.5 Peak Picker Decay Rate .................................................................................................................... 143
8.6.6 Auto Peak Picker Reset with Reset Below ........................................................................................ 143
8.6.7 Peak Picker Delay ............................................................................................................................. 144
8.7 Track and Hold ......................................................................................................................................... 145
8.7.1 External Switch Control of Track and Hold ..................................................................................... 145
8.8 Avoiding Common Measurement Problems ............................................................................................. 146
8.8.1 Viewing Angle Limitations ............................................................................................................... 146
8.8.2 Background Interference ................................................................................................................... 146
8.8.3 Transmission Effects ......................................................................................................................... 147
8.8.4 Transmission Path Effects ................................................................................................................ 148
8.8.5 Reflectance Effects ............................................................................................................................. 148
8.9 Use of Mirrors .......................................................................................................................................... 149
8.10 Use of Windows ..................................................................................................................................... 150
8.10.1 Special Considerations for Ratio Units ........................................................................................... 151
8.11 Preventing Sensor Overheating .............................................................................................................. 152
9 NOTICES ....................................................................................................................................................... 154
Safety Instructions
Modline 5
Rev. L6 Feb 2017 11
1 Safety Instructions
This document contains important information, which should be kept at all times with the instrument
during its operational life. Other users of this instrument should be given these instructions with the
instrument. Eventual updates to this information must be added to the original document. The
instrument can only be operated by trained personnel in accordance with these instructions and local
safety regulations.
Acceptable Operation
This instrument is intended only for the measurement of temperature. The instrument is appropriate
for continuous use. The instrument operates reliably in demanding conditions, such as in high
environmental temperatures, as long as the documented technical specifications for all instrument
components are adhered to. Compliance with the operating instructions is necessary to ensure the
expected results.
Unacceptable Operation
The instrument should not be used for medical diagnosis.
Replacement Parts and Accessories
Use only original parts and accessories approved by the manufacturer. The use of other products can
compromise the operation safety and functionality of the instrument.
Safety Instructions
12
Rev. L6 Feb 2017 Modline 5
Safety Symbols
AC (Alternating Current)
DC (Direct Current)
Risk of danger. Important information. See manual.
Hazardous voltage. Risk of electrical shock.
Warning Laser
Helpful information regarding the optimal use of the instrument.
Earth (ground)
Protective earth (ground)
Chassis ground
Switch or relay contact
Conforms to European Union directive.
Disposal of old instruments should be handled according to professional and
environmental regulations as electronic waste.
Safety Instructions
Modline 5
Rev. L6 Feb 2017 13
Warning
To prevent possible electrical shock, fire, or personal injury follow these guidelines:
Read all safety Information before you use the product.
Use the product only as specified, or the protection supplied by the product can be
compromised.
Carefully read all instructions.
Do not use and disable the product if it is damaged.
Do not use the product if it operates incorrectly.
Do not look directly into the laser with optical tools (for example, binoculars, telescopes,
microscopes). Optical tools can focus the laser and be dangerous to the eye.
Do not look into the laser. Do not point laser directly at persons or animals or indirectly off
reflective surfaces.
Do not use laser viewing glasses as laser protection glasses. Laser viewing glasses are used
only for better visibility of the laser in bright light.
Use the product only as specified or hazardous laser radiation exposure can occur.
Product Description
14
Rev. L6 Feb 2017 Modline 5
2 Product Description
2.1 Modline 5 Sensors, Cable and Interface Accessories
The basic Modline 5 System consists of either a standard Sensor or Sensor with the Dirty Window
Detection option with an interconnecting cable and Terminal Strip Plate. Optional components include
the POI Power Supply/Signal Interface Box and the remote DPM Digital Meter operator interface.
2.1.1 Preliminary Inspection
The Modline 5 is delivered in plastic wrappings, cradled in foam inside rugged cartons. The Sensor and
any accessories you have ordered are shown on the packing list. The photograph below identifies
Modline 5 system components. See Section 3 Sensor Installation, page 22 to identify mounting, air
purging, water cooling and other mechanical accessories.
Figure 1: Sensors, Cable and Interface Accessories
Place all items on a workbench or desk before removing the plastic covers. Inspect each item carefully
to determine if any damage occurred in transit. If you find such damage, promptly inform the freight
agent delivering the components. Save the carton until you are sure you will have no further use for it.
Return items for repair in their original packaging. Contact Ircon before returning any products for
service. See the “Contacts” page at front of the manual on how to contact IRCON.
For Modline 56 sensors: occasionally, a calibration flag that operates during the Sensor
internal Calibrate test may move into the viewing area during shipment. If this occurs,
the viewing area will be dark and appear obstructed. This flag will be positioned
correctly when power is applied to the Sensor.
Product Description
Modline 5
Rev. L6 Feb 2017 15
2.2 Modline 5 Description
The IRCON Modline 5 is an Infrared Thermometer Sensor. State of the art digital circuitry and firmware
provide excellent measurement accuracy, repeatability and overall performance. New diagnostics check
the status of the Sensor (such as detector temperature, sensor failure) and some of its external
environment (such as analog current output open circuit condition and case temperature). An internal
function check is performed without the need to block the lens. The check tests for and internal circuit
and detector operation. Alarms and Error Codes are outputted when out of limit conditions are sensed.
The Patented Dirty Window Detector option checks the Sensors front window for loss of signal because
a buildup of contaminants.
An easy to read, bright LED alphanumeric temperature display and three pushbuttons on a keyboard
is located at the rear of the Sensor. Each Sensor has a full complement of easy to navigate rear panel
setup and operating functions. Operation as a standalone Sensor is accomplished simply by using its
rear panel keyboard to access and setup operating parameters. The Sensor can display and output
temperature signals, and operates with an external dc power source.
The Sensor optics and electronics are contained in a small, rugged stainless steel NEMA 4 (IP65) rated
housing. Modline 5 accessories for mounting, air purging and cooling the Sensor have been designed
to maintain a small installation footprint.
2.2.1 Sensor Standard Features
Through the lens visible rear focusing and sighting with standard or close focus lenses.
Field selected °F or °C measuring units.
Field selectable analog current outputs, 0 to 20 mA or 4 to 20 mA. Temperatures within the span of the
Sensor can be assigned to the Analog output Zero and Full scale current values to customize the
corresponding output temperature range.
Peak Picker and Track and Hold Signal Conditioning with remote switch input for Peak Picker Reset or
Track and Hold operation.
RS-485 Digital Communications allows interfacing with any RS-485 capable device to setup and operate
the Sensor remotely. This allows use of a Host computer, Programmable Logic Controller (PLC), etc.
with the Sensor
Analog current input for remote adjustment of Emissivity or E-Slope.
Sensor diagnostic Alarm relay contacts are brought out on the interconnecting cable.
2.2.2 Optional Sensor Features
The Dirty Window Detector and Laser Sight are optional features that can be ordered when the Sensor
is purchased.
These options are not field upgradeable.
Product Description
16
Rev. L6 Feb 2017 Modline 5
2.3 Model Configuration and Required Selections
2.3.1 Model Configuration
The Modline 5 Model number contains seven alphanumeric characters. The first two designate the
Sensor Series. The Series defines the type of Sensor, brightness or ratio, and the operating wavelength.
The next four digits define the Sensor’s temperature range and optical resolution with the standard lens
installed.
Selection of sight, Visible through the lens or optional Laser aiming, is next. Permanent factory
installation is required. Each is exclusive of the other.
The Dirty Window Detector Option (DWD) is the next required selection. Permanent factory installation
is required. The product is covered by Patent Number 5812270 when the Dirty Window Option is
installed.
A Sensor can also be ordered to be used a Transfer Standard to calibrate other Modline 5 Sensors.
ModView Calibration Software and an expanded Calibration Certificate are supplied with this Sensor
Model.
A lens selection is required. Lens types for each Sensor must be specified. Lenses are factory installed
and are not field changeable.
Series designation, temperature range, optical resolution, optional Laser and DWD information is
provided in the tables sections below. Lens focusing ranges are found in Section 3.4 Sensor Optical
Characteristics, page 26. Ordering information and Model Number examples follow the tables.
Two Digit Sensor Series Designation
Sensor Series
Sensor Type Spectral
Response in μ (microns)
52
Brightness
0.85 to 1.1
56 Brightness
Lowest Temperature Range 2.0 to 2.8
Other Ranges: 2.3 to 2.6
5G
Brightness
1.6
5R Selectable Modes: Ratio
or Brightness (1 Color Mode)
Ratio Mode: 0.75 to 1.05; 1.0 to 1.1
Brightness Mode: 1.0 to 1.1
Series 52: Sensor Model Numbers
Model
Temperature Range in °C and (°F)
Optical Resolution with Type 2A Lens
52-1410
500 to 1400°C (932 to 2552°F)
D/100
52-2020
600 to 2000°C (1112 to 3632°F)
D/200
52-3024
750 to 3000°C (1382 to 5434°F)
D/240
Product Description
Modline 5
Rev. L6 Feb 2017 17
Series 56: Sensor Model Numbers
Emissivity span is limited to 0.3 to 1.0 for the first 55°C (100°F) for all temperature ranges
Model
Temperature Range in °C and (°F)
Optical Resolution with Type 6A Lens
56-0315
50 to 300°C (122 to 572°F)
D/150
56-0415
100 to 400°C (212 to 752°F)
D/150
56-0815
200 to 800°C (392 to 1472°F)
D/150
Series 5G: Sensor Model Numbers
Emissivity span is limited to 0.3 to 1.0 for the first 55°C (100°F) for all temperature ranges
Model
Temperature Range in °C and (°F)
Optical Resolution with Type 2A Lens
5G-1007
250 to 1000°C (482–1832°F)
D/75
5G-1415
300 to 1400°C (572–2552°F)
D/150
5G-2024
350 to 2000°C (662 – 3632°F)
D/240
Series 5R: Sensor Model Numbers
Model
Temperature Range in °C and (°F)
Optical Resolution with Type RA Lens
5R-1410
600 to 1400°C (1112 – 2552°F)
D/100
5R-1810
700 to 1800°C (1292 – 3272°F)
D/100
5R-3015
1000 to 3000°C (1832– 5432°F)
D/150
Through the Lens Sight – Required Selection
Visible or Optional Laser Sighting.
Lens Types
Lens selection requires matching the lens to specific models. Lens types ending in A are considered
standard focusing range lenses. Lens types ending in B are considered close focus lenses. Lens types
ending in C are considered very close focus lenses. Complete lens focusing ranges and spot size
information are found in Section 3 Sensor Installation, page 22 of this manual.
Dirty Window Detector Option – Required Selection
The selection is Installed or None. The product is covered by Patent Number 5812270 when the Dirty
Window Detector Option is installed.
2.4 Modline 5 Model Number Summary
Modline 5 Model Number as Found on Serial Number Label
Product Description
18
Rev. L6 Feb 2017 Modline 5
Series
Model
Sighting:
Visible or Laser
DWD None or
Installed
Transfer
Standard
Lens Type
(Two Characters)
(Four Digits)
0 or 1
0 or 1
0 or T
(Two Characters)
Example and Explanation
5 R
1 4 1 0
1 1 0
RA Lens
5R
600 to 1400°C
D/100
Laser Sight
DWD Installed
This unit is not
a Transfer
Standard
Focusing Range:
13 inches to
infinity D/100
The Model Number explanation information provided above defines a Modline 5 Sensor having the
following characteristics and features:
Model 5R-1410 is a Series 5R Ratio Type Sensor with the temperature range of 600 to 1400°C (1112
to 2552°F) and D/100 Resolution.
The Sensor Sight is Laser through the lens (Visible sighting was not selected).
The Dirty Window Detector Option (DWD) is installed
The Sensor is not a Transfer Standard. (T = Transfer Standard)
The installed lens is for the 5R Series and provides the standard focusing range of 13 inches to
infinity. The Sensor Model and lens combination provide a D/100 Optical Resolution
2.5 Accessories
2.5.1 Interconnecting Cable – Required Accessory
An IRCON supplied interconnecting cable with the Sensor mating connector attached on end one and
termination prepared wires on the other end is required. Special assembly of the cable is required and
the cable is only sold with the Sensor connector attached.
Maximum cable length is 350 feet (107 meters). The cable length limitation is due to the power supply
voltage requirements of the Sensor. The power supply voltage drop across this length of cable is low
enough to provide proper Sensor operation. Power supply cable wires are 22 AWG (0.35 mm²). Input
and Output wires are 24 AWG (0.25 mm²).
RS-485, Alarm relay output, and analog outputs, can extend beyond the 107 meter limitation. See Section
4 Sensor Wiring, page 64 for more information.
Sensor Standard Teflon Interconnecting Cable
Maximum temperature: 200°C (392°F)
Maximum cable length: 107 meters (350 feet)
See Red Lion Bulletin PAX – P for completing the specifications for DPM.
The cable must be terminated into a Power Supply/Signal Interface Box (POI) or a
Terminal Strip Plate (TSP) to ensure that the Sensor and cable installation meets RF
immunity and emission standards for CE compliance. These items are described
below.
Product Description
Modline 5
Rev. L6 Feb 2017 19
2.5.2 Power and Interface Accessories
Model POI – Power Supply/Signal Interface Box.
This box includes a 24VDC power supply, interconnecting cable termination strip, and RF suppression
components. Input power is 100 to 240 VAC 50/ 60 HZ.
Model TSP – Terminal Strip Plate
This plate includes an interconnecting cable termination strip and RF suppression components.
Model DPM – Digital Panel Meter
Digital Temperature Indicator and RS-485 Communication Operator Interface. 85 to 250 VAC 50/ 60 Hz.
The DPM does not provide power to Sensor.
2.5.3 Installation Accessories
Details on the following standard accessories can be found in Section 3 Sensor Installation, page 22. An
extended family of accessories is available and they are referenced in Section 3.
Standard Modline 5 Accessories
Model – MFS Mounting Flange (Small Diameter Pattern)
Model – BMA Base Mount Adapter
Model – APA Air Purge Accessory
Model – WJA Water Jacket Accessory
Model – ESA Dirty Window Detector Extension Sleeve Adapter
(one included with Dirty Window Detector Option)
Model – UAA Universal Accessory Adapter
Model – MFL Mounting Flange Large
Model – RAM Right Angle Mount
Model – M5WJ5 Mounting Kit to mount Sensor in WJ-5 Water Cooling Jacket
Protective Window / Sight Accessory
The EP – 5 with a dimming filter is available for viewing very high temperatures. This window replaces
the standard rear protection / sight window supplied with the Sensor. This filtered window is for
viewing high temperature targets from 1200°C (2192°F) to 2300°C (4172°F).
Spare part standard protection windows are identified as the RPW, rear protection window assembly
with clear sight window. One of these is supplied with every Sensor.
Product Description
20
Rev. L6 Feb 2017 Modline 5
2.6 Specifications
1
2.6.1 Sensor Specifications
Spectral Response
Series 52 0.85 to 1.1 microns
Series 56 2.0 to 2.8 microns (Model 56 to 0315 only)
2.3 to 2.6 microns (All other models)
Series 5G 1.6 microns
Series 5R Ratio Mode: 0.75 to 1.05; 1.0 to 1.1 microns
Single Color Brightness Mode 1.0 to 1.1
* All specifications subject to change without notice.
Calibration / Blackbody Accuracy at 25°C
Sensor Series 52 Within 0.3% of reading plus 1°C up to 2800°C (5072°F)
indication up to 3000°C (5432°F)
Sensor Series 5G Within 0.3% of reading plus 1°C
Sensor Series 56 Within 0.3% of reading plus 1°C, or
2C (whichever is greater)
Sensor Series 5R Within 0.5% of reading plus 2°C up to 2800°C (5072°F)
indication up to 3000°C (5432°F)
Repeatability at 25°C Within 0.1% of full-scale temperature (+1 digit)
Response Time for Display and Outputs
Series 5R Adjustable from 0.01 to 60 seconds.
Series 52, 5G Adjustable from 0.0066 to 60 seconds.
Series 56 Adjustable from 0.020 to 60 seconds.
Selectable Analog Current Output 0 to 20 mAdc or 4 to 20 mAdc
600 Ω maximum load including cable resistance
Output is not isolated from power supply common.
Digital Communications RS-485 Digital Interface
Emissivity Range Emissivity is 0.10 to 1.00.
Series 52, 56, 5G and 5R (single color mode)
Emissivity Limitations for Series 5G and 56
Emissivity span is limited to 0.3 to 1.0 for the first 100°F
(55°C) for all temperature ranges of these models
E-SLOPE Range Model 5 R (Two color Ratio Mode) 0.800 to 1.200.
Signal Reduction Range Tolerated Sensor Series 5R will tolerate 95% reduction in radiation
intensity caused by low emissivity, non-resolved or obscured
1
All specifications subject to change without notice.
Product Description
Modline 5
Rev. L6 Feb 2017 21
targets or combinations of these conditions above target
temperatures of 1500°F (800°C).
System ALARM Relay Contacts 24 V AC/DC at 1 Amp. Resistive
Peak Picker Rise Time Same as selected Response Time
Peak Picker Decay Rate Adjustable 0.00 to 300 degrees F (0.00 to 166 degrees C)
per second
Peak Picker Reset: Internal Reset has two Modes: Manual and Auto.
External Reset: Contact closure greater than .08 second
Track and Hold Tracking Mode is elected with external contact closure
Power Requirements 24 VDC +/- 5%, 8 Watts Maximum
Operating Ambient Temperature
Sensor Series 52, 56, 5R and 5G: 0 to 55°C F (32 to 130°)
With WJA Accessory Air Cooling 0 to 105°C (32 to 220°F)
With WJA Accessory Water Cooling: 0 to 200°C (32 to 400°F)
Sensor Environmental
Sensor Housing NEMA 4 (IP65).
Sensor Cable Plug and
Housing Connector NEMA 4 (IP65).
Humidity 10 to 90% non-condensing
Sensor Dimensions See dimensional drawings in section 3.7.2 Sensor Dimensions,
page 33.
Weight 4 lbs. (1.8 kg) approximate, Model and option dependent
Laser Sight Option Laser: Class II Less than 1 mw at 635 nm
Shock IEC 68 - 2-27
Vibration IEC 68 -2-6
2.6.2 Accessory Specifications
POI Power Supply/Signal Interface Box
Ambient Temperature: 0 to 55°C (32 to 130°F)
Environmental: NEMA 4 (IP65)
Power Requirements: 100 to 240VAC 50/ 60 HZ, 40 VA.
DPM Digital Panel Meter
Ambient Temperature: 0 to 50°C (32 to 122°F)
Environmental: NEMA 4X (IP65) Sealed Front Bezel
Power Requirements: 85 to 250 VAC 50/60 HZ, 15VA.
Terminal Strip Plate
Ambient Temperature: 0 to 55°C (32 to 130°F)
Sensor Installation
22
Rev. L6 Feb 2017 Modline 5
3 Sensor Installation
3.1 Mechanical Installation
This section provides instructions for installing the Modline 5 Sensor. Sighting, aiming, focusing and
resolving targets are explained. Mounting and protection of the Sensor in hot and dirty environments
using installation, air purging and water cooling accessories are presented.
3.2 Sensors
Figure 2: Standard Sensor Figure 3: Sensor with Dirty Window Detector
Two Sensors types are available in the Modline 5 Series, standard Sensor or Sensor with the Dirty
Window Detector option. The front of the standard Sensor consists of a front objective lens only. The
Sensor with the Dirty Window Detector option has internal components and an external protection
window located in front of the objective lens. A hooded mirror extends out in front of protection
window. The sensors are illustrated in the photographs above and below.
The Patented Dirty Window Detector option, IRCON, inc. Patent Number 5812270, checks the Sensors
front window for loss of signal caused by a buildup of contaminants. A Coarse or Sensitive level of
signal loss can be selected. Visual Alarms and a relay output are provided to indicate window
contamination.
Dimensions for the Sensor with the DWD are slightly different because of the additional components.
Measurement of the optical working distance on the standard Sensor is made from the front surface of
the unit. The working distance determination on the Sensor with DWD requires a simple calculation.
Measurement is made from the front tip of the hooded mirror and 66 mm (2.6 inches) is added to the
distance to compensate for the extended optics.
Figure 4: Standard Sensor Lens and Lens with DWD
Standard Sensor Lens
Sensor with DWD
Mirror
Window
Sensor Installation
Modline 5
Rev. L6 Feb 2017 23
3.2.1 Sensor Parts
The photograph below illustrates the Sensor parts called out in this manual.
Figure 5: Sensor Parts
The EP – 5 Protective / Visual Sight Window with a dimming filter is available for
viewing very high temperatures. This replaces the standard rear protection and sight
window shown above.
3.3 Sighting Methods
The Modline 5 Sensor is a precision electro-optical instrument that senses infrared radiation. This signal
is processed by the unit’s digital circuits to provide an output proportional to the temperature being
measured. The Sensor’s linear analog current output and RS-485 digital temperature signals are brought
out through a connector on the bottom of the Sensor with a shielded cable. The output signals are then
connected to compatible devices within the process measurement system.
3.3.1 Sighting and Focusing
The Modline 5 is a variable focus instrument that features visual through-the-lens sighting by means of
a viewing sight at the rear panel of the Sensor. An optional internal Laser for through-the-lens aiming
is available. Focusing with either the visible or laser sight is accomplished using the rotating rear section
of the Sensor.
3.3.2 Visual Sight
The Modline 5 visible sight is aimed and focused onto the target to be measured as simply as an ordinary
camera. The rear focus is smooth, utilizing almost one turn of the focusing section.
A circular reticle is contained within the Sensor’s optical system and is visible when viewing through
the sight. During temperature measurement, the target image is superimposed on the reticle. Focusing
is performed by adjusting the rear focusing section while viewing the scene until the target area is clear
and well defined. Illustrated below is a properly focused Sensor viewing an induction heated rod. The
visible sight rear panel is shown below.
Rear Rotating Focusing Section
Focuses the Sensor optical
system on the target.
Lens Lock Thumb Screw
Locks the focusing section in
place after focusing.
(Do Not Use Tools)
Rear Protection / Visual Sight
Window. Threads on focusing
section to cover rear panel
display and keypad. Provides
NEMA 4 (IP65) environmental
rating. See note below about
EP-5 window.
UAA Universal Adapter
Accessory for mounting
Cable Connection, Match
Red Dots to connect
NEMA 4 (IP65)
environmental rating
Sensor Installation
24
Rev. L6 Feb 2017 Modline 5
Figure 6: Visible Sight Figure 7: Reticle
When properly focused, the area of the target within the reticle will be measured. The Sensor infrared
detector will “see” the same image seen defined by the reticle. Approximately 97% of the measured
energy will come from the area defined by the reticle.
To check or adjust focus, slowly move your head slightly from side to side or up and down. Note
whether the target appears to move with respect to the reticle. If it does, adjust the lens focusing section,
until there is no perceived motion between the reticle and target (hence eliminating parallax between
the two). The instrument is then in sharp focus. Lock the lens rear focusing section in place using the
locking thumbscrew on the bottom of the Sensor.
If looking through a sight tube or sight hole, position, align and rotate the Sensor and Sight tube to
center the reticle in the field of view.
For Modline 56 sensors: occasionally, a calibration flag that operates during the Sensor
Calibrate test may move into the viewing area during shipment. If this occurs, the
viewing area will be dark and appear obstructed. This flag will be positioned correctly
when power is applied to the Sensor.
3.3.3 Laser Sight
With the optional Laser sight, a laser light spot is projected onto the target and used to aim the Sensor.
The same rear focusing method applies and is to be used to adjust for the smallest laser light spot. The
projected focused laser image will be approximately the same diameter “spot” as measured by the
detector. See Section 3.4 Sensor Optical Characteristics, page 26 for determining spot size.
The Laser image is reflected from the target surface. The image can easily be seen on most targets at
distances of 10 feet and further. The visibility of the reflected image is dependent on the reflection
characteristics of the target material as well as the intensity of the ambient lighting. When viewing hot
glowing targets, the visibility of the image also depends upon its temperature. The color and intensity
of a hot glowing object may override the reflected Laser image.
Use of the laser on distant targets or poorly reflecting targets may require some white paint on the target
or a white substitute target such as a sheet of paper to accomplish focusing. Ambient light dimming
may be required for targets that reflect poorly. For difficult conditions, pre-focus the Sensor optics while
aiming the laser at a white reflective target. Then use the Laser to aim the pre-focused Sensor on to the
target.
Sensor Installation
Modline 5
Rev. L6 Feb 2017 25
Figure 8: Laser Sight
If looking through a sight tube or sight hole, position, align and rotate the Sensor and Sight tube to
center the laser image in the field of view.
The Sensor is a Class II Laser Product with the Laser Sight option installed, see section 5.11 Laser
Sighting Operation, page 102 of this manual for safe and full operating instructions. Install Sensor and
setup Laser operating procedures so that personnel are not exposed to the laser beam at any time
whether the Laser is energized remotely or at the Sensor Rear Panel.
Figure 9: Sensor Laser Label
The sensor label is shown in detail in Figure 10.
Figure 10: Sensor Laser Label in Detail
Warning Label
Sensor Installation
26
Rev. L6 Feb 2017 Modline 5
3.4 Sensor Optical Characteristics
3.4.1 Optical Resolution
The Sensing Head is sensitive to infrared radiation in the area indicated by the Cone of Vision in the
illustration below.
Figure 11: Cone of Vision and Spot Size Formula
The diameter of the cone at any point will determine the area of measurement at that point. Any part of
the target or other intervening object positioned within the cone will be imaged on the detector.
Anything seen by the detector will become part of the measurement.
When the Sensor is sighted on an object, you are “aiming” or positioning the cone of vision on the object.
When you focus, you are adjusting the optical system elements so the focal point is at the surface of the
object. The measurement area, as seen by the detector, will then be outlined in the reticle. The reticle
only defines the measured area (spot size) in the focused condition.
The formula d = D/F defines the spot size at the focal point. Simply divide the Working Distance (D),
measured from the front of the Sensor to target by the Resolution Factor (F) to determine the Spot Size
(d). Resolution factors for Sensor Model and Lens combinations are provided in the table on the
following page. The focusing range for each lens type is also provided in the table. The focusing range
defines the allowable range for the Working Distance.
For Sensors with the Dirty Window Detector Option, the Working Distance (D) is
calculated by measuring the distance from the front tip of the protruding hood to the
target and then adding 2.6 inches (66 mm).
3.4.2 Lens Focusing Ranges and Optical Resolution Factor
The table below lists Lens Type and Focusing Ranges for the Modline 5 Series 52, 56, 5G and 5R. Two
ranges are shown. The first range is for a Sensor without the Dirty Window Detector Option (DWD)
option. The distance is measured from the front metal surface of the standard Sensor.
d = D / F
where:
d = diameter of cone at focal point
D = distance from front of Sensor to focal point.
For Sensors with DWD Option,
add 2.6 inches (66 mm) for distances
measured from tip of front hood.
F = Resolution Factor of Sensor Model and
Lens combination
Cone of Vision
Sensor
Sensor Installation
Modline 5
Rev. L6 Feb 2017 27
The second range is for a Sensor with the DWD option. This distance is measured from the tip of the
front mirror hood. Very close lens types that include alpha character C are not useable with the DWD
option.
Some installation, cooling and air purging accessories will limit some of the usable close focus range
accessory.
The Model number and installed lens type is found on the Sensor Model number tag. Range tolerance
of is ±10%.
3.4.3 Table of Model and Lens Type Combinations with Focusing Ranges
The Optical Resolution Factor for each Model and Lens combination is given in the table. Use the
formula: d = D / F to calculate the spot size at any working distance within the specified range. The
smallest spot size can be determined using the closest distance within the range.
Model Number
Lens
Type
Focusing Range in inches “ and millimeters (mm)
Standard Sensor
Sensor with DWD Option
Resolution
Factor
52-1410, 5G-1007
2A
13” to infinity (330 mm to infinity)
10.4” to infinity (264 mm to infinity)
D/100, D/75 (5G)
52-2020, 5G-1415
2A
13” to infinity (330 mm to infinity)
10.4” to infinity (264 mm to infinity)
D/200, D/150 (5G)
52-3024, 5G-2024
2A
13” to infinity (330 mm to infinity)
10.4” to infinity (264 mm to infinity)
D/240
52-1410, 5G-1007
2B
6 to 12 “ (152 mm to 305 mm)
3.4 to 9.4” (86 to 239 mm)
D/90, D/67 (5G)
52-2020, 5G-1415
2B
6 to 12 “ (152 mm to 305 mm)
3.4 to 9.4” (86 to 239 mm)
D/180, D/135 (5G)
52-3024, 5G-2024
2B
6 to 12 (152 mm to 305 mm)
3.4 to 9.4” (86 to 239 mm)
D/216
52-1410, 5G-1007
2C
2.25 to 2.75“ (57 to 70 mm)
Not Available with this lens.
D/80, D/60 (5G)
52-2020, 5G-1415
2C
2.25 to 2.75“ (57 to 70 mm)
Not Available with this lens.
D/160, D/120 (5G)
52-3024, 5G-2024
2C
2.25 to 2.75“ (57 to 70 mm)
Not Available with this lens.
D192
56 – All Models
6A
12” to infinity (305 mm to infinity)
9.4” to infinity (239 mm to infinity)
D/150
56 – All Models
6B
6 to 12 “ (152 mm to 305 mm)
3.4 to 9.4” (86 to 239 mm)
D/ 135
56 – All Models
6C
2.25 to 2.75“ (44 to 57 mm)
DWD Not Available with this lens.
D/105
5R-1410, 5R-1810
RA
13” to infinity (330 mm to infinity)
10.4” to infinity (264 mm to infinity)
D/100
5R-3015
RA
13” to infinity (330 mm to infinity)
10.4” to infinity (264 mm to infinity)
D/150
5R-1410, 5R-1810
RB
7 to 14“ (178 mm to 355 mm)
4.4 to 11.4” (112 to 289 mm)
D/90
5R-3015
RB
7 to 14“ (178 mm to 355 mm)
4.4 to 11.4” (112 to 289 mm)
D/135
5R-1410, 5R-1810
RC
2.25 to 2.75 “ (57 to 70 mm)
Not Available with this lens.
D/80
5R-3015
RC
2.25 to 2.75 “ (57 to 70 mm)
Not Available with this lens.
D/120
Table 1: Model and Lens Type Combinations with Focusing Ranges
3.4.4 Spot Size and Viewing Distance
Viewing distance and spot size is demonstrated in the Distance and Spot Size illustration. A Sensor with
a Resolution Factor of F = 100 is focused on a 0.5 inch (12.7 mm) rod at three distances. The drawings at
the left for each example illustrate a large circle that represents the total area visible in the Sensor sight.
The smaller circle represents the reticle.
Sensor Installation
28
Rev. L6 Feb 2017 Modline 5
Figure 12: Distance and Spot Size Illustration
In top example A, the rod is 100 in. (2540 mm) away. The spot is 1 inch (25.4 mm) in diameter. The one
half inch diameter rod does not fill the reticle in the viewing sight. Middle example B illustrates a
viewing distance of 50 inch (1270 mm). The spot is 0.5 inch (12.7 mm) in diameter, the same size as the
rod. Bottom example C illustrates a viewing distance of 25 inch (635 mm). The spot size is 0.25 inch (6.35
mm) one half the one half inch target size. The view in the eyepiece shows the target completely resolved
by the reticle.
Resolution Factor F = 100
A: Target smaller than Spot Size.
Sensor measures part target and part
background
Move closer and Refocus!
B: Target equal to Spot Size.
Any shift of target or sensor will
cause sensor to view part target
and part background.
Move closer and Refocus!
C: Target twice Spot Size.
Excellent!
Target is safely resolved.
Sensor
Sensor Installation
Modline 5
Rev. L6 Feb 2017 29
3.5 Measuring Temperature with Brightness and Ratio Sensors
3.5.1 Resolving Targets with Brightness Sensors
When using single color Series 52, 56 and 5G brightness Sensors, best results are obtained when the
resolved portion of the target is two times the diameter of the reticle.
The Sensor measures the average temperature of the target or object seen in the reticle. Targets smaller
than the reticle will result in low temperature readings if the background (object within the cone of
vision beyond the target) is lower that the target temperature. If the background temperature is higher
than the target, the averaged temperature indication will be higher.
Low temperature indications can also be caused by other factors. An out of focus cool object cutting the
cone of vision anywhere between the target and Sensor, or a small target may shift position and move
partially out of the measurement cone.
3.5.2 Obstructions in Cone of Vision
Errors can be caused by objects positioned between the Sensor and target. Evaluate the Sensor’s “Cone
of Vision” and if there is any possibility that an intervening object is within the cone, select a different
viewing position. An object inside the Cone of Vision will be visible to the detector and may cause an
error in the temperature measurement. Obstructions in the cone of vision, whose temperatures are
lower than the target temperature, will generally cause lower temperature readings when using single
color brightness units. The obstruction may not be seen clearly in the instrument sight if it is some
distance away from the target and out of focus. Such an obstruction is illustrated below.
High temperatures can be caused by an out of focus hot object cutting the cone of vision anywhere
between the target and Sensor.
Two color ratio units are usually not affected by obstructions that are significantly lower in temperature
than the target. Ratio units are affected by hot objects in the cone of vision that are much higher in
temperature than the target. If too high, the hot targets can dominate the measurement. If the object
temperature is the same, the measured temperature is not affected.
Figure 13: Cone of Vision Obstruction
3.5.3 Resolving Targets with Two Color Ratio Sensors
Modline 5 Series 5R Ratio Sensors utilize a dual detector assembly that measures temperature by
comparing infrared radiation levels in two wavelength bands (0.85 to 1.05 microns and 1.0 to 1.1
microns). Temperature readings are based on the ratio of the two signals in these bands.
Obstruction
Target
Cone of Vision
Sensor Installation
30
Rev. L6 Feb 2017 Modline 5
Because Series 5R Sensors measure the ratio of radiation intensities at two wavelengths rather than the
absolute intensity of radiation at a single wavelength, they are almost immune to error caused by loss
of signal. Small targets that do not fill the field of view and partial obstructions from bursts of steam,
dust and solid objects in their sight path can be tolerated.
3.5.4 Signal Reduction
Three causes contribute to the loss of signal:
Low target emissivity.
The measured object is too small to fill the reticle as seen in the Sensor sight and is not completely
resolve.
Partial obstruction of the optical path caused by smoke, steam, dust, dirty window or a solid
object.
The total reduction in signal is the sum of the losses from all three causes.
Example: Assume the target emissivity is 0.45. The reduction in signal due to low emissivity is 55%. If the
instrument can operate with a 95% signal reduction, another 40% can be lost due to an unresolved target and/or
obstructions in the cone of vision such as smoke, steam, dust, a dirty window or partial blockage by solid objects.
Figure 14: Invalid Measurement Conditions
When you reach the maximum allowed reduction, the Sensor will indicate “Invalid”. An Invalid
measurement condition also occurs, without any obstructions, if the target temperature signal is below
a level that can be accurately measured by the instrument.
Signal Reduction Tolerated
The Series 5R Sensors have a limit as to how much the signal from a hot target can be reduced. The
reduction in the signal can be as high as 95% with target temperatures above 800C (1500F). The
Target Emissivity = 0.45
Target
Valid Measurement Conditions
Target
Target
Invalid Measurement Conditions
Total Signal Loss Greater than 95 %
1.
Intense Smoke in Sight Path
2.
Target too small for Spot Size
3. Low Emissivity
Cone of Vision
Smoke in Sight Path
Sensor Installation
Modline 5
Rev. L6 Feb 2017 31
amount of signal reduction that the Series 5R Sensors will tolerate depends upon the Sensor temperature
range and the target temperature. The signal reduction tolerated is less in the bottom portion of the
range. The Sensor will indicate invalid when the measurement is not possible.
3.5.5 Summary
The spot size and target size relationship is not as critical for Series 5R Sensors which use the two color
ratio method. Avoid emitted radiation from objects in the same field of view (cone of vision) either in
the foreground or behind the target that are at temperatures hotter than the target. Reflected or emitted
radiation from these interferences can cause measurement errors. Significantly cooler objects, well
below the target temperature, will not cause measurable errors.
For best results, brightness sensors that measure radiation intensity at a single wavelength should be
installed so the target area is larger than the instrument spot size. If possible, adhere to the target size is
twice the spot size rule for all types of instruments.
3.6 Sensor Installation Planning
Mechanical Installation of the Modline 5 Sensor requires determining sighting and focusing
requirements, locations for installing Sensors, accessories and cable routing. Planning also includes
evaluating environmental conditions that may cause contamination of the Sensor optics or overheating
of the Sensor or other Modline 5 components. Re-location of the installation or air purging and water
cooling accessories may be required to overcome adverse conditions.
Pre-focusing the Sensor’s optical system may be necessary if the Sensor is to be mounted in a difficult
location and not accessible. Pre-focus by setting up a well-defined target such as a printed page at the
exact distance of the target, and then lock the rear focusing section.
Setup of the Sensor parameters can also be pre-determined and set before installation.
The following guidelines will help you in planning the Sensor installation.
Mechanical Mounting Location Requirements
The Sensor is installed using the mounting brackets and flanges, air purging and water cooling
accessories illustrated in the Section 3.9 Modline 5 Mounting, Cooling and Air Purging Accessories,
page 35.
Sensor Mounted to Earth Ground Potential
If the proposed mounting surface is at Earth Ground potential, you can mount the housing directly
to this surface. If the surface is not at Earth Ground potential, electrical insulating material and nonconducting hardware must be used to isolate the Sensors.
Sensor Interconnecting Cable Length
Maximum cable length between the Sensor and the POI Power Supply/Signal Interface Box or
Terminal Plate is 350 ft. (107 m). Maximum temperature rating of the Sensor Interconnecting cable
is 200 °C (392 °F). Plan the cable route accordingly.
Ambient Temperature Limits for Sensor, POI Box and Terminal Strip Plate
The ambient temperature at the mounting locations for the Sensor, POI Power Supply/Signal
Termination Box and The Terminal Strip Plate must be between 0 and 55°C (32 and 130°F).
If the ambient temperature at the mounting location is beyond these limits, precautions must be
taken to protect the Sensor. A WJA Water and Air Cooling Jacket are available for protection against
excessive temperatures. Use of insulation and reflective shielding for additional protection from
Sensor Installation
32
Rev. L6 Feb 2017 Modline 5
extreme ambient temperatures and radiated heat are described in Section 8 Applications Guide, page
129.
The POI Power Supply/Signal Termination Box and The Terminal Strip Plate must be re-located to a
location that the ambient temperature is between 0 and 55°C (32 and 130°F).
Lens Protection
Be sure the lens is protected from contamination and is accessible for maintenance. If dust, oil,
vapors, etc. collect on the lens, low temperature indications will result. Use an APA – Air Purge
Accessory to maintain a clean lens. Consider use of a Sensor with the Dirty window if errors caused
by lens contamination can seriously affect the process.
Focal Limits
To permit focusing, the target distance must be within the focal range of the objective lens. Ranges
for the Modline 5 objective lenses are given in Section 3.4 Sensor Optical Characteristics, page 26.
Range limitations for close focus lenses may be encountered with the use of certain mechanical
accessories.
Use of Windows
If it is necessary to view the object through a window, as is the case when the object is being heated
in a vacuum or inert atmosphere, correctly select the window material. The material must have
constant transmission characteristics in the operating wavelength range of the Sensor type being
installed. Information on windows is provided in Section 8 Applications Guide, page 129 of this
manual.
Reflections
Reflections from radiating objects represent a potential source of error in temperature measurement.
The total radiation seen by the Sensor will be a combination of intrinsic, emitted, radiation plus
reflected radiation from a nearby hot object off the target surface.
Examples of interfering sources are hot furnace walls and heating elements that are hotter than or
nearly as hot as the target object.
Most reflection problems can be eliminated by changing the viewing angle or shielding the
reflections. Suggestions for anticipating and eliminating common reflection problems are provided
in Section 8 Applications Guide, page 129.
Indirect Viewing
In some situations, it may be necessary to view the target indirectly by means of a mirror. The
characteristics of the mirror and the positioning of both the Sensor and mirror are critical in this type
of arrangement. Refer to Section 8 Applications Guide, page 129 for more information.
Viewing Angle
Viewing angles are limited in some situations. Guidelines are provided in Section 8 Applications
Guide, page 129.
3.7 Sensor Mechanical Installation
3.7.1 Installation Accessories
The Modline 5 Sensor requires the use if one or more installation accessories to mount, align and aim
the Sensor. The installation accessories also provide for cooling the Sensor and air purging the optics to
keep them free from contamination.
Sensor Installation
Modline 5
Rev. L6 Feb 2017 33
Presentation of accessories and sensor installation is organized in the Sections below as follows.
Sensor dimensions and specifications.
General requirements for all installations including cable clearances, access for aiming,
focusing and setup.
Description of each accessory accompanied by dimensions and specifications.
A table of recommended accessory groupings.
Illustrations of the groupings accompanied by overall dimensions.
Other accessories such as pipe mounts, sight tubes, target tubes window assemblies, etc. is referenced
at the end of this section.
3.7.2 Sensor Dimensions
The dimensions of the Standard and Dirty Window Detector Modline 5 Sensors are given below. These
dimensions are without any mounting accessories.
Figure 15: Standard Modline 5 Sensor
Figure 16: Dimensions Standard Sensor
Figure 17: Sensor with Dirty Window Detector (DWD)
Sensor Front
Sensor Installation
34
Rev. L6 Feb 2017 Modline 5
Figure 18: Dimensions Sensor with DWD
3.7.3 General Installation Requirements
Sensor should be mounted to provide a minimum of 4 inch (101.6 mm) clearance from the
housing for connecting the cable.
Gently bend the cable into its routing position as shown in the photo below.
Minimum cable bend radius is 3 inches (76.2 mm).
Rotate the Sensor to avoid cable obstructions.
Positioning of any mounting accessory on the Sensor should be as close to the front lens as
possible without extending beyond it. Some accessories require clamping towards the middle of
the body.
Never clamp on the Dirty Window Detector hooded mirror or the DWD section! (Not shown)
Never clamp on the rear focusing section of the Sensor.
Figure 19: Interconnecting Cable
3.8 DWD Installation Requirements
The Sensor with the Dirty Window Detector option requires the use of an ESA – Extension Sleeve
Adapter accessory along with other Modline 5 accessories. The ESA, combined with other accessories,
serves as protection for the DWD optics. The photograph (Figure 20) illustrates several of the
accessories.
The ESA is used in the following combinations to provide air purging or to create a dead air space zone
in front of the Sensor optics to help keep them clean. The combinations also provide shielding from
stray radiation emanating from high temperature targets and thermal isolation for the Dirty Window
Detector Components. The APA - Air Purge, used in combinations one and two below, provides the
Sensor with DWD
Front
Sensor Installation
Modline 5
Rev. L6 Feb 2017 35
best performance. Groupings of accessories are shown in Section 3.10 Accessory Combinations with
Break-out Drawings page 50. Also see Section 3.9.6.1 WJA Water Cooling Requirements page 45.
When using a WJA – Water Jacket Assembly with air cooling, the use of an APA air
purge is required with Sensors with the DWD. The use of an APA is also required when
viewing large targets over 1000 C (1832 F).
Figure 20: DWD with ESA
1. ESA and APA air purge with clean air provides air purging, and shielding.
2. ESA and APA air purge without air provides a dead air space zone, and shielding.
3. ESA with MFL Flange provides a dead air space zone and shielding.
4. ESA with MFL and AA-3 air purge accessory (not shown) provides air purging and shielding.
See Section 3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling), page 60 for AA-3
references.
3.9 Modline 5 Mounting, Cooling and Air Purging Accessories
3.9.1 UAA – Universal Adapter Accessory Description and Dimensions
The UAA is a circular ring that clamps around the Modline 5 Sensor. A M8 screw tightens the clamp
around the Sensor. Three ¼-20 threaded holes on the bottom flat surface allow fastening the UAA to a
tripod; user designed mounting surface or the RAM – Right Angle Mounting Bracket.
Sensor Installation
36
Rev. L6 Feb 2017 Modline 5
Figure 21: UAA Accessory
Material: Clear Anodized Aluminum
Weight: Approximately 1 Pound (0.5 kg)
Figure 22: UAA Dimensions
Dimensions are in inches and (millimeters). Do not scale.
3 hex Head Screws and
washers supplied
¼ - 20 threaded X.375 (9.5)
deep 3 places
Orientation Holes 2 places
Insert Front of Sensor this Direction
M8 X 30 mm Socket Head Cap Screw
Supplied for clamping Sensor
M6 X 25 mm deep threaded Holes for
IRCON Accessories
3 Places
Flat mounting Surface
Align with other Asccessoiries
Sensor Installation
Modline 5
Rev. L6 Feb 2017 37
Qty
Part No.
Description and use
User Supplied Tools
1
230830C60
M8 X 30 mm socket head caps screw for sensor
clamping
6 mm hex key, long arm L style wrench
recommended
3
202520540
¼-20 x 5/8 inch (15.9 mm) stainless steel hex
head bolt
Adjustable wrench
3
222503200
Stainless steel split ring lock washer
3 260600060
Black oxide flat washer
Table 2: UAA Mounting and Assembly Supplied Parts List
3.9.2 RAM – Right Angle Mount Description and Dimensions
The RAM – Right Angle Mount provides convenience, strength and flexibility in mounting the Modline
5 Sensor. The UAA universal adapter is required to attach the Sensor to the RAM. Two holes and one
slot on the upright side of the mount are for mounting the Sensor and UAA. Use the slot and outer hole
to provide vertical angular adjustment of the Sensor’s optical axis. Use the two holes for fixed axis
mounting. Two holes and one slot for mounting are located in the base of the RAM. Use the slot and
outer hole to provide angular adjustment. Pivoting of the base provides horizontal angular adjustment.
Use just the two holes for fixed axis mounting.
Figure 23 RAM Accessory
Material: Passivated Stainless Steel
Weight: Approximately 1.2 pounds (0.55 Kilogram)
Mounting and Assembly Supplied Parts List:
No hardware is supplied with the RAM. UAA assembly hardware is supplied with the UAA.
Two user supplied M6 or ¼-20 mounting bolts and washers are required to mount the base of
the bracket.
Sensor Installation
38
Rev. L6 Feb 2017 Modline 5
Figure 24: RAM Dimensions
Dimensions are in inches and (millimeters). Do not scale.
All three axis of rotation (including optical axis) intersect at a common point.
This avoids parallax during target alignment
Clearance Holes – 4 Places
Diameter 0.266 (6.8)
Optical Axis when
mounted horizontally
Pivot Axis
Sensor Installation
Modline 5
Rev. L6 Feb 2017 39
3.9.3 APA – Air Purge Accessory Description and Dimensions
IRCON’s specially designed air purge is used to help keep the front optics of the Modline 5 clean. The
purge provides a stream of air away from the Sensor to prevent dust and smoke particles from collecting
on the optics.
The APA is positioned in front of the Sensor with the UAA universal adapter or WJA Water Jacket.
Three through holes in the APA accept mounting hardware to assemble accessories together.
The front of the APA has three threaded holes to attach a MFS or MFL mounting flange. Mounting
hardware is supplied with the flanges.
A ¼ inch NPT threaded air inlet is located on the air purge. A flow rate of 3 SCFM (0.09 m3/min.) clean
air is required for most applications. The flow rate can be increased for difficult environments.
Two drain holes provide an outlet for any condensation accumulation. If necessary, these threaded holes
can be plugged with M3 screws.
Figure 25: APA Accessory
Material: Clear Anodized Aluminum
Weight: Approximately 1.5 pound (0.68 kilograms)
Qty
Part No.
Description and use
User Supplied Tools
1
482202
¼ inch NPT stainless steel fitting for 0.25 inch (6.4 mm)
diameter tubing. Note: Can be replaced with more suitable
fitting if desired.
As needed.
3
230625C60
¼- M6 X 25 mm socket head cap screw for assembling to
the WJA or UAA.
5 mm hex key L style wrench.
3
230670C60
M6 X 70 mm socket head cap screw for assembling to the
WJA or UAA with ESA.
5 mm hex key, long arm L style
Wrench recommended.
Table 3: Mounting and Assembly Supplied Parts List
Sensor Installation
40
Rev. L6 Feb 2017 Modline 5
Figure 26: APA Dimensions
Dimensions are in inches and (millimeters). Do not scale.
3.9.4 MFL – Mounting Flange Large Description and Dimensions
The larger of the two mounting flange accessories, the MFL has the bolt circle pattern that matches many
of IRCON’s other products and accessories. It provides a simple means of replacing older instruments
and using existing accessories. See Section 3.12 for Other Accessories.
The MFL is mated to the Sensor by attaching it to the threaded holes in the front of the UAA, APA and
WJA accessories. Inner and outer groups of three through holes are used for attachment. These holes
are covered by a metal gasket.
Three Counterbore
Holes for M6 Sockethead Cap Screws
For assembling to UAA or WJA
1/4 -20 NPT Air Inlet
Locating PINs 2 Places
Drain Holes
2 Places
Flat surface align with flat
surfaces on other Accessories
Three M6 tapped Holes for
mounting MFS or MFL Flanges
Sensor Installation
Modline 5
Rev. L6 Feb 2017 41
Figure 27: MFL Accessory
Material: Clear Anodized Aluminum
Weight: Approximately 1 pound (0.5 kilograms)
Table 4: MFL Mounting and Assembly Supplied Parts List
Qty
Part No.
Description and use
User Supplied Tools
1
482172
Metal Gasket Cover
2 230312C60
M3 X 12 mm flat head cap screw to secure gasket cover
2 mm hex key wrench
3
230630C60
M6 x 30 mm flat head cap screw to assemble the MFL with the APA
air purge
5 mm hex key, long arm
L style wrench
3
230670C60
M6 x 70 mm socket head cap screw to assemble the MFL to the UAA
and ESA extension sleeve. (Not for use with the WJA. Use last item
below)
5 mm hex key, long arm
L style wrench
3
230620C60
M6 x 20 mm socket head cap screw to assemble the MFL directly to
the WJA water jacket or the UAA adapter.
5 mm hex key, long arm
L style wrench
3
230665C60
M6 x 65 mm socket head cap screw to assemble the MFL to WJA
water jacket with ESA extension sleeve.
5 mm hex key, long arm
L style wrench
Sensor Installation
42
Rev. L6 Feb 2017 Modline 5
Figure 28: MFL Dimensions
Dimensions are in inches and (millimeters). Do not scale.
3.9.5 MFS – Mounting Flange Small Description and Dimensions
The MFS is a scaled down version of the MFL flange with a smaller diameter bolt circle pattern. This
flange provides strength in mounting with a smaller profile. This flange also provides a means of
mounting to accessories of other manufacturers.
The MFS is used by first bolting it to the APA air purge. In the photograph is shown the MFS mounted
to the APA.
Front
Other Accessory
interface side
Mounting Holes 3 Places
Remove Metal Cover Gasket to expose two
Groups of three trough Holes for attaching
Modline 5 Accessories
Back
Modline 5 Accessories
mount to this side
Gasket mount
Hole
Mounting bolt circle
Locating
PINs
2 Places
Sensor Installation
Modline 5
Rev. L6 Feb 2017 43
Figure 29: MFS Accessory
Material: Clear Anodized Aluminum
Weight: Approximately 1 Pound (0.5 kilograms)
Table 5: MFS Mounting and Assembly Supplied Parts List
Figure 30: MFS Dimensions
Dimensions are in inches and (millimeters). Do not scale.
Qty
Part No.
Description and use
User Supplied Tools
3
230630C60
M6 X 30 mm flat head cap screws to assemble the MFS with the
APA air purge
5 mm hex key wrench
Countersink holes for APA Air Purge
3 Places M6 flat head screws
Front Side
Mounting Bolt Circle
Hole
APA Air Purge mounts to Back Side
Sensor Installation
44
Rev. L6 Feb 2017 Modline 5
3.9.6 WJA – Water Jacket Accessory Description and Dimensions
The WJA uses water or air to cool the Modline 5 Sensor in high ambient temperatures. Water cooling
can protect the Sensor in ambient environments up to 200°C (400°F). Air cooling can provide protection
to 105°C (220°F).
To properly mount the WJA, the BMA – Base Mounting Bracket, MFL –Mounting Flange, or the APA
purge with an MFS or MFL flange should be used. The use of an APA – Air Purge Assembly is
recommended with the WJA.
Trunions (pivoting shafts) on the side of the WJA are used to securely mount to the BMA. Threaded
holes in the front of the WJA are used to mount an APA air purge or MFL Flange. The WJA can be
mounted in any position.
The WJA has 1/4” NPT inlet and outlet pipe fitting openings for water or air. See the drawings and
information on the next page for water and cooling air requirements, and installation configurations.
Designed Maximum water or air pressure: 100 PSIG (6.9 BAR)
Figure 31: WJA Accessory
Material: 300 series passivated stainless steel
Empty Weight: Approximately 6 pounds (2.7 Kilograms)
Table 6: Mounting and Assembly Supplied Parts List
Qty
Part No.
Description and use
User Supplied Tools
2
----------
M8 X 16 mm long case hardened steel hex head bolts
Adjustable wrench
2
----------
Extra-large diameter 3/16 “ thick case hardened flat washers
2 482202
¼ inch NPT stainless steel fitting for 0.25 inch (6.4 mm) diameter tubing
As needed
1
142152
Safety Clamp Assembly with captive and permanent mount screws
Blade Screwdriver
Sensor Installation
Modline 5
Rev. L6 Feb 2017 45
Figure 32: WJA Dimensions
Dimensions are in inches and (millimeters). Do not scale.
Tapped Holes on both ends for Ircon, Inc. Accessories.
3.9.6.1 WJA Water Cooling Requirements
Adequate water flow for a 200C (400F) ambient is 15 gallons/hr. (57 liters/hr.). Cooling water
temperature should be 32C (90F) or lower. Use the opening closest to the hottest point on the mounted
Sensor assembly as the water inlet. Typically this is the opening at the front of the assembly. Use only
cooling water compatible with Series 300 stainless steel.
When using water to cool a Sensor with the Dirty Window Detector (DWD), an ESA extension with
either a MFL mounting flange or an APA air purge must be part of the assembly. An APA air purge is
highly recommended for all installations and must be used when viewing large targets over 1000C
(1832 F). A typical water cooling installation for a Sensor is shown below. APA purge air temperature
should be 30C (86F) or lower.
Optical Axis is the same as the Mechanical Axis
Safety Clamp
Sensor Installation
46
Rev. L6 Feb 2017 Modline 5
Figure 33: Water Cooling Standard Sensor
3.9.6.2 WJA Air Cooling Requirements.
Adequate cooling air for a 105C (220F) ambient is 4 SCFM (114 liters/min). Air temperature should be
30C (86F) or lower.
When using air to cool a Sensor with the Dirty Window Detector (DWD), an APA air purge must be
part of the assembly and the installation should reflect the drawing below.
Figure 34: Air Cooling Sensors with DWD
3.9.6.3 Sensor Temperature Alarm
The Modline 5 Sensor provides Alarms when the Sensor’s internal temperature exceeds its allowed
limit. Error Code X105 signifies the outside influences have caused the internal temperature to rise
above its limit. Error Code X103 signifies outside influences have caused the detector to rise above its
limit. If these alarms are triggered, check the installation for proper flow of air or water.
Higher than rated ambient temperature can also be the cause. Other possible causes of overheating
include radiant and conductive transfer of heat. Insulation, shielding and thermal isolation may be
necessary. See Section 8 Applications Guide, page 129 for more information.
Ambient Maximum is 105C (220F)
Air IN at 30C (86F)
Ambient Maximum is 200C (400F)
Water IN
at 32C (90F)
Air IN at 30C (86F)
Add an ESA for Sensor with DWD
Sensor Installation
Modline 5
Rev. L6 Feb 2017 47
3.9.7 BMA – Base Mount Accessory Description and Dimensions
This trunion style U mounting bracket is used as a base mount for the WJA –Water Jacket Accessory. Trunions
(pivoting shafts) on the sides of the WJA are placed into the matching BMA mounting slots. The WJA is held
in a vertical position, with the Sensor side down, and placed into the slots. The BMA and WJA final assembly
can be mounted in any position.
Vertical angular movement of the WJA and Sensor is provided by the pivoting shafts. The BMA mounting
slots (gimbals) are shaped to keep the shaft in place and provide secure mounting. Two bolts and two washers
are supplied with the WJA to lock it in the final position.
The BMA base mount surface has one clearance hole and two radial slots for mounting bolts. Three M8 or
5/16 inch user supplied bolts and washers are required. Approximately plus and minus 10 degrees of
horizontal angular movement is provided to aim the Sensor.
Figure 35: BMA Accessory
Material: Nickel Plated Steel
Weight: Approximately 5.6 pounds (2.5 Kilograms)
Mounting and Assembly Supplied Parts List:
No hardware is supplied with BMA. UAA assembly hardware is supplied with the UAA.
Three user supplied M8 or 5/16 mounting bolts and washers are required to mount the base of
the bracket.
Sensor Installation
48
Rev. L6 Feb 2017 Modline 5
Figure 36: BMA Dimensions
Dimensions are in inches and (millimeters). Do not scale.
Use 5/16 inch or M8 mounting Bolts (3 Places).
3.9.8 ESA – Extension Sleeve Adapter Description and Dimensions
This is a special accessory for Sensors with the Dirty Window Detector (DWD) option. The ESA serves
as protection sleeve over the DWD optics and as the mechanical interface between the Sensor and other
Modline 5 accessories. The ESA is used in the following combinations to provide air purging or create
a dead air space zone in front of the Sensor optics to help keep them clean. The combinations also
provide shielding from stray radiation emanating from high temperature targets. The APA air purge,
shown in combinations one and two, provides the best performance. The use of an APA is required for
large targets over 1000 C.
1. ESA and APA air purge with clean air (air purging and shielding).
2. ESA and APA air purge without air (dead air space zone and shielding).
3. ESA with MFL Flange (dead air space zone and shielding)
4. ESA with MFL and AA-3 air purge accessory (air purging and shielding).
See Section 3.8 DWD Installation Requirements for DWD and Section 3.12 Other Accessories (Sight
Tube, Window, WJ-5 Water Cooling), page 60 for AA-3 references.
Sensor Installation
Modline 5
Rev. L6 Feb 2017 49
Figure 37
The ESA is also used with the MFL Flange when as an interface with the Right Angle Mounting Bracket.
Material: Clear Anodized Aluminum
Weight: Approximately 1 Pound (0.5 kg)
Mounting and Assembly Supplied Parts List:
No hardware is supplied with the ESA.
Assembly screws are supplied with the APA and MFL.
Figure 38: ESA Dimensions
Locating PINs
2 Places.
Flat mounting Surface
Align with other Accessories
Through Holes for M6 Screws
3 Places
Sensor Installation
50
Rev. L6 Feb 2017 Modline 5
Dimensions are in inches and (millimeters). Do not scale.
3.10 Accessory Combinations with Break-out Drawings
3.10.1 Recommended Accessory Groupings
The table below lists the eighteen recommended accessory groupings. Exploded views of the groups
are shown on the following two pages.
The recommended groupings for Sensors with the Dirty Window Detector are identified in the DWD
column. See Section 3.8 DWD Installation Requirements, for more information. Groups are illustrated
with dimensions in Section 3.11 Installation Drawings and Illustrations.
Group
Mounting Option
Required Accessories
DWD
See Notes
1
¼-20 Bolt Pattern Mount
UAA
N. R. (1)
2
Large Flange Interface Mount
UAA MFL
Add ESA (3)
3
Air Purge with ¼-20 Bolt Pattern Mount
UAA APA
Add ESA (2)
4
Air Purge with Small Flange Mount
UAA APA
MFS Add ESA (2)
5
Air Purge with Large Flange Mount
UAA APA MFL
Add ESA (2)
6
Right Angle Base Mount
UAA
RAM N. R. (1)
7
Right Angle Mount with Air Purge
UAA
RAM
APA
Add ESA (2)
8
Right Angle Mount with Large Flange.
This group requires an ESA for clearing the
RAM
UAA
RAM
MFL &
ESA
ESA Included
Note 3
9
Right Angle Mount with Air Purge
UAA
RAM
APA
MFS Add ESA (2)
10
Right Angle Mount with Air Purge
UAA
RAM
APA MFL
Add ESA (2)
11
Water Jacket, Air Purge and Small Flange
APA
WJA MFS Add ESA (2)
12
Water Jacket with Large Flange Mount
WJA
MFL
Add ESA
(3 and 5)
13
Water Jacket, Air Purge and Large Flange
APA
WJA
MFL
Add ESA (2)
14
Water Jacket, Base Mount
WJA
BMA
N. R. (1)
15
Water Jacket, Base Mount, Air Purge
APA
WJA
BMA
Add ESA (2)
16
Water Jacket, Base Mount and Large Flange
WJA
BMA MFL
Add ESA
(3 and 5)
17
Water Jacket, Base Mount, Air Purge
and Small Flange
APA
WJA
BMA
MFS Add ESA (2)
18
Water Jacket, Base Mount, Air Purge
and Large Flange
APA
WJA
BMA MFL
Add ESA (2)
DWD is Dirty Window Detector Option. See ESA on previous page for more information. Also see Sections 3.8 DWD Installation
Requirements and 3.9.6 WJA – Water Jacket Accessory Description and Dimensions.
Notes:
1. N. R. = Group Not Recommended for Sensors with DWD.
2. USE the ESA and APA air purge with clean air for air purging and stray radiation shielding. Use APA without air to
create a dead air space zone and shielding. The use of an APA is required for large targets over 1000 C.
3. The ESA with MFL provides dead air space and stray radiation shielding. Add an AA-3 air purge accessory for air
purging. See Section 3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling), page 60 for AA-3
information. These combinations not recommended for large targets over 1000 C.
Sensor Installation
Modline 5
Rev. L6 Feb 2017 51
4. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
5. Use water for cooling only. Do not use air for cooling with DWD unless the APA air purge accessory is used. See
information in Section 3.9.6 WJA – Water Jacket Accessory Description and Dimensions.
Table 7: 3.10.1 Recommended Accessory Groupings
Sensor Installation
52
Rev. L6 Feb 2017 Modline 5
Accessory Illustrations for Groups using UAA:
Figure 39: Sensor without DWD – UAA Accessory Groups 1 through 10
Figure 40: Sensor with DWD – UAA Accessory Groups 2, 3, 4, 5, 6, 7, 8, 9, 10
Sensor Installation
Modline 5
Rev. L6 Feb 2017 53
Accessory Illustrations for Groups using WJA:
Figure 41: Sensor without DWD – WJA Accessory Groups 11 through 18
Figure 42: Sensor with DWD – WJA Accessory Groups 11, 12, 13, 15, 16, 17, 18
Sensor Installation
54
Rev. L6 Feb 2017 Modline 5
3.11 Installation Drawings and Illustrations
3.11.1 Installation Drawing for the UAA – Universal Adapter for Tripod or Custom
Mounting
Group
Mounting Option
Required Accessories. See Individual Accessory
Descriptions and Dimensions.
DWD
See Notes
1
¼-20 Bolt Pattern Mount
UAA
N. R.
2
Large Flange Interface Mount
UAA MFL
Add ESA (3)
3
Air Purge with ¼-20 Bolt Pattern Mount
UAA APA
Add ESA (2)
4
Air Purge with Small Flange Mount
UAA APA
MFS Add ESA (2)
5
Air Purge with Large Flange Mount
UAA APA MFL
Add ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with
Break-out Drawings. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
Table 8: Recommended Accessory Groupings UAA
Figure 43: Front mounted
Figure 44: UAA with APA
Sensor front surface will be positioned at the back end of the APA or MFL. To determine working
distance (D) for spot size formula d=D/F, measure or calculate from that point.
When using the MFL (Group 2) or APA (Group 3, 4, 5), assemble these accessories to
the UAA first. Place Sensor fully into assembly and rotate Sensor to desired position.
Tighten clamping screw.
Sensor Installation
Modline 5
Rev. L6 Feb 2017 55
Figure 45: UAA
3.11.2 Installation Drawing for the RAM – Right Angle Mount
Group
Mounting Option
Required Accessories. See Individual
Accessory Descriptions and Dimensions.
DWD
See Notes
6
Right Angle Base Mount
UAA
RAM
N. R.
7
Right Angle Mount with Air Purge
UAA
RAM
APA
Add ESA (2)
8
Right Angle Mount with Large Flange.
This group requires an ESA for
clearing the RAM
UAA
RAM
ESA
MFL
Note 3
8
Right Angle Mount with Large Flange
UAA
RAM
MFL
Add ESA (3)
9
Right Angle Mount with Air Purge
UAA
RAM
APA
MFS Add ESA (2)
10
Right Angle Mount with Air Purge
UAA
RAM
APA MFL
Add ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with
Break-out Drawings, page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
Table 9: Recommended Accessory Groupings RAM
Dimensions are in inches and (millimeters). Do not scale.
Group 1 shown (UAA and Sensor).
See UAA description and Dimensions.
Sensor Front inserted Level with UAA Front.
¼ hex Head Screws (3)
with flat and lock washers
supplied for mounting.
M8 X 30 mm Socket Head Cup Screw
supplied for clamping Sensor.
Optical Axis
Dia.
Dia.
Sensor Installation
56
Rev. L6 Feb 2017 Modline 5
Figure 46
Figure 47
When using the MFL (Group 8) or APA (Group 7, 9, 10), assemble these accessories
to the UAA and RAM first. Place Sensor fully into assembly and rotate Sensor to
desired position to clear table. Tighten clamping screw.
Sensor front surface will be positioned at the back end of the APA or MFL. To determine working
distance (D) for spot size formula d=D/F, measure or calculate from that point.
Figure 48: Group 7 shown (UAA RAM and APA).
Dimensions are in inches and (millimeters). Do not scale.
See individual Accessory drawings.
Optical Axis Coincident with Axis of Rotation
Axis of Rotation
Sensor Installation
Modline 5
Rev. L6 Feb 2017 57
3.11.3 Installation Drawing using the WJA – Water Jacket Accessory with
Flange Mounts
Group
Mounting Option
Required Accessories. See Individual
Accessory Descriptions and Dimensions.
DWD
See Notes
11
Water Jacket, Air Purge and Small Flange
APA
WJA
MFS Add ESA (2)
12
Water Jacket with Large Flange Mount
WJA MFL
Add ESA (3)
13
Water Jacket, Air Purge and Large Flange
APA
WJA MFL
ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with Break-
out Drawings, page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
Table 10: Recommended Accessory Groupings WJA with Flange Mounts
Figure 49WJA with Flange Mounts
Insert Sensor into the WJA assembly with moderate force until it “snaps” into the
spring catch. Secure the Sensor rear protection and sighting window. Swing safety
clamp into position and tighten.
Sensor Installation
58
Rev. L6 Feb 2017 Modline 5
Figure 50: Group 13 shown WJA, APA and MFL Flange
Dimensions are in inches and (millimeters). Do not scale.
Total Lengths Dimension shown with and without MFL Flange.
Mechanical and optical Centerlines are coincidental.
3.11.4 Installation Drawing using the WJA Water Jacket Accessory with the Base
Mount Adapter
Group
Mounting Option
Required Accessories. See Individual
Accessory Descriptions and Dimensions.
DWD
See Notes
14
Water Jacket, Base Mount
WJA
BMA
N. R. (1)
15
Water Jacket, Base Mount, Air Purge
APA
WJA
BMA
Add ESA (2)
16
Water Jacket, Base Mount and Large Flange
WJA
BMA
MFL
Add ESA (3)
17
Water Jacket, Base Mount, Air Purge and
Small Flange
APA
WJA
BMA
MFS
Add ESA (2)
18
Water Jacket, Base Mount, Air Purge and
Large Flange
APA
WJA
BMA
MFL
Add ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with Break-out Drawings,
page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
Table 11: Recommended Accessory Groupings WJA with BMA
Front of Sensor without DWD with
Reference to WJA
Safety Clamp
Dia.
Dia.
Sensor Installation
Modline 5
Rev. L6 Feb 2017 59
Figure 51
Insert Sensor into the WJA assembly with moderate force until it “snaps” into the
spring catch. Secure the Sensor rear protection and sighting window. Swing safety
clamp into position and tighten.
Figure 52: Group 18 shown (BMA, WJA and MFL).
Dimensions are in inches and (millimeters). Do not scale.
See individual Accessory drawings.
Front of Sensor (without DWD) with Reference to WJA
Through Holes for 5/16 Inch or M6 Bolts (3 Places)
Sensor Axis of
Rotation
(Also Optical Axis)
WJA Mounting Axis
Dia.
Sensor Installation
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Rev. L6 Feb 2017 Modline 5
3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling)
These other accessories are described in Product Bulletin PB-0070. Specification and mounting
configuration changes are required for certain items when used with the Modline 5.
Consult the IRCON factory for information about using these accessories with the Modline 5 Sensor.
Other Accessory Model / Part
Compatibility and main interface
AA-3
Requires MFL Flange to interface.
AP-Q, AP-CF
Requires MFL Flange to interface.
Consult Ircon, Inc. with application details.
MF-1, MF-2 Threaded collars for threaded
1-1/2 inch NPT sight tubes and 2-1/2 inch
NPT sight tube.
Requires the MFL Flange to interface. See note below.
PM-2 Pipe Mounts for use with
STSC and STA Sight and Target Tubes
Requires the MFL Flange to interface. See note below.
STM Sight Tubes with Flange Surface
Requires the MFL Flange to interface. See note below.
WA-3 Water Cooling Accessory
Not compatible with Modline 5 Sensors.
Do not use to provide cooling.
WJ-5 Water Cooling Jacket with Air Purge.
A mounting kit, UAA, and MFL is required to install Modline 5 Standard
Sensor in WJ-5. Maximum ambient temperature limited to 160 C (320
F).
Note: Not compatible with Modline 5 Sensor with Dirty Window Detector
Option (DWD) installed.
See installation details below.
Table 12: Compatibility with other Accessories
Focus Sensor with rear rotating focus section. If looking through a sight tube or sight
hole, position, align and rotate the Sensor and Sight tube to center the reticle or laser
image in the field of view.
3.12.1 M5WJ5 – Mounting Kit
The M5WJ5 Mounting Kit is used with UAA and MFL Mounting Accessories to install a Modline 5
Sensor in an Ircon Model WJ-5 Water Cooling Jacket. The jacket provides cooling through a stainless
steel coiled pipe embedded in the jacket walls. A flow rate of 20 gallons per hour (75 liters per hour) of
water with a temperature of 90F (32C) or less is required.
An air purge is included on the front of the WJ-5. Clean, dry purge air should be provided at a flow rate
6 ft3/min. (0.17m3/min.).
The jacket protects the Modline 5 Sensor in ambient temperatures up to 160C (320F). Complete
specifications, installation and piping instructions are included with the kit. The Modline 5 Sensor cable
is rated to 200C (400F).
Total Lengths Dimension shown with and without MFL Flange.
Sensor Installation
Modline 5
Rev. L6 Feb 2017 61
The Modline 5 Sensor with the Dirty Window Detector Option (DWD) cannot be
installed in a WJ-5 Jacket because of its additional length.
Figure 53: M5WJ5 – Mounting Kit
Accessories and kit required for mounting Modline 5 Sensor in WJ-5 Water Cooling Jacket:
Model WJ-5 Water Cooling Jacket with Air Purge Supplied with its own mounting
hardware (M5WJ5 Kit is not included.)
UAA Universal Adapter Accessory Supplied with its own mounting hardware
MFL Mounting Flange Large Accessory Supplied with its own mounting hardware
M5WJ5 Mounting Parts Kit: Consisting of the following. (Note: These parts are sold only as a
kit.)
Item
Qty.
Part Number
Description
Function
1 1 050501
INST: WJ-5 Rev. C
Complete specifications, cautions and
installation instructions
2 1 482322
Mod 5 WJ5 Spacer Block
Spacer between UAA and Plate
3 1 456862
Mod 5 WJ5 Mounting Plate
Slides assembly into WJ-5
4 2 202524660
¼-20 X ¾ inch long Socket Head Cap Screw
Mount Spacer Block to UAA
5 4 202524540
¼-20 X ¾ inch long Hex Head Screw
Mounting Plate to Spacer (2)
Mounting Plate to WJ-5 (2)
6 4 222503030
1/4 in. Split-ring lock washers
Use with ¼-20 X ¾ inch long Hex Head
Screws (4)
Table 13
Assembly and Sighting Instructions:
Refer to Installation Instructions for WJ-5, Included in M5WJ5 Kit
1. Assemble as indicated in drawing to the right and at top of page.
2. Slide assembly into WJ-5 and tighten rear mounting plate screws.
3. Focus Sensor with rear rotating focus section.
4. If looking through a sight tube or sight hole, position, align and rotate the Sensor and Sight tube
to center the reticle or laser image in the field of view.
Sensor Installation
62
Rev. L6 Feb 2017 Modline 5
5. Route the cable either through the center opening in the mounting plate or along the side walls
of the WJ-5 and out through the insulated opening in the back door.
Figure 54: Mounting Kit
3.13 Sensor Installation Checklist
To ensure accurate, reliable, and trouble-free operation, check the installation for the following:
Sensor is properly mounted and aligned with no obstructions in optical path.
Sensor lens is focused on target. If possible, target size is at least twice diameter of reticle size as seen in
the viewing sight (i.e. twice the calculated spot size at the viewing distance).
Rear Protective window has been securely installed on back of Sensor. After completing the sighting
and focusing routines, screw the protection window back onto the Sensor to maintain the NEMA 4
(IP65) environmental rating.
Sensor lens is protected by air purge and clean purge air if atmosphere is dirty, oily or corrosive. Do not
use purge air with oil or water. Use instrument air or filter adequately.
Sensors with the Dirty Window Detector Option require an APA air purge or other protection as
explained in Section 3.8 DWD Installation Requirements, page 34. If the purging air quality is poor, use
an efficient filter. In worst cases, leave the air purge assembled to the Sensor, but disconnect the air
supply.
Sensor is adequately protected by water or air cooling and/or additional insulation if ambient
temperature exceeds safe limits.
Sensor is not subjected to direct or reflected radiated heat from oven walls, flames, etc. that cause it to
Spacer Block
(Item 2)
Socket Head
Cap Screws (Qty 2)
(Item 4)
Lock washers (Qty 4)
(Item 6)
Hex Head Screws
(Qty 4) (Item 5)
Sensor Installation
Modline 5
Rev. L6 Feb 2017 63
exceed its temperature rating.
The Sensor mounting surface is grounded (Earth Ground). If not, electrically insulate the housing from
the mounting surface. See information in Section 4.11 System Grounding and Shielding, page 79.
Sensor Wiring
64
Rev. L6 Feb 2017 Modline 5
4 Sensor Wiring
4.1 Modline 5 Components
The basic Modline 5 system consists of either a standard Sensor or Sensor with Dirty Window Detector
option, interconnecting cable, a POI Power Supply/Signal Interface Box or Terminal Strip Plate and as
possible option, the DPM Digital Panel Meter Interface.
Figure 55: Modline 5 Components
4.2 Modline 5 Sensor System Interfacing
The following figure shows a block diagram overview for interfacing the Modline 5 into a process
monitoring and control system.
Figure 56: Block diagram
POI
Box
or
Terminal Strip
Plate
Interconnecting Cable
Sensor Alarm Relay Contacts
Peak Picker / Track & Hold Remote
Switch Input
RS-485 Digital Communication to
Modline 5 DPM, PLC, Host
Computer or other Device
24Vdc Sensor Power Supply limited
to 2 Amps
Analog Current Output
Selectable 0 - 20 mA or 4 - 20 mA
Scaled to Sensor temperature span or customized for process
Single or multiple series connected differential input devices,
Digital Indicators, Recorders, Controllers, Control Systems
600 Ohm maximum load resistance, including cable resistance
Sensor
T
A
R
G
E
T
Input 4-20 mAdc for Remote
Emissivity/E-Slope or Laser Switch
100 - 240Vac 50/60Hz (POI)
or 24Vdc (TSP)
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 65
4.3 Modline 5 Sensor Cable
4.3.1 Sensor Interconnecting Cable
The Interconnecting cable carries all inputs, outputs and the 24 VDC power for the Sensor. The cable is
routed from the Sensor to the POI Power Supply/Signal Interface Box or the Terminal Strip Plate
supplied with each cable.
All IRCON Modline 5 interconnecting cables are supplied assembled with the Sensor connector on one
end and the wires stripped, tinned and ready for termination on the opposite end. The cable shield is
also prepared and ready to assemble with the Ircon supplied EMI shielding strain reliefs. All cable wires
are 24 AWG (0.25 mm²), except the 24 V power supply wires that are 22 AWG (0.35 mm²).
Maximum Cable Temperature Cable temperature not to exceed 200C (392F).
Maximum Cable Length 350 feet (107 meters), Minimum Bend Radius 3 inches (76 mm).
Cable Diameter Nominal Diameter 0.310 inch (7.6 mm).
Cable Routing Within conduit or low-level signal plenum or cable tray.
Location Away from high power and high frequency sources and high
temperature sources.
Consider the cable route. The cable should be protected from plant traffic and any hostile environments.
Avoid high temperature zones or areas subject to electrical or high frequency interference.
4.4 TSP Terminal Strip Plate
The TSP is required when the POI Power Supply/Signal Interface Box is not used. This plate mounted
terminal strip with terminal identification label and suppression components allows use of the Modline
5 Sensor and Cable with user-supplied enclosures and power supplies. The TSP ensures Sensor and
cable operation meets RF emission and immunity standards required for CE certification.
The 24Vdc Sensor Power Supply should be limited to 2 Amps.
An earth ground wire is to be connected to the ground stud at the bottom of the Terminal Plate.
Minimum size wire is 18 AWG (1 mm²). A crimp terminal is supplied to mount on the stud.
4.4.1 Dimensions and Installation
The Terminal Plate must be installed in a suitable user-supplied grounded enclosure for protection from
electrostatic discharge (ESD).
Four 0.196 inch (5mm) diameter holes are used to mount the plate. See photo below for mounting
dimensions.
The approximate overall rectangular plate dimensions are 5.39 inches (136.9 mm) long by 3.42 inches
(86.9 mm) wide and 0.8 inches (20.3 mm) high.
Plan access for cables and working space. Minimum Sensor interconnecting cable bend is 3 inches (76
mm).
To prevent possible electrical shock, fire, or personal injury make sure that the sensor
is grounded before use.
Sensor Wiring
66
Rev. L6 Feb 2017 Modline 5
Wiring, grounding and shielding instructions are in the sections that follow.
Figure 57: Dimensions TSP
4.5 Sensor Interconnecting Cable Preparation
4.5.1 Cable Preparation
It is very important that the cable shield be properly prepared and installed. If the Terminal Strip Plate
is used, the shielding must be clamped to the ground shield clamps on the plate.
All cables must be properly dressed for shield grounding. Twisted pair wires must remain twisted and
kept as short as possible. The IRCON Sensor cable is supplied with the connector attached on one end.
The opposite wiring end is prepared and supplied as per the following procedure. If the cable is
shortened, the preparation procedure must be followed. User supplied cables require similar
preparation.
A. Strip off 10 in. (254 mm) of the outer jacket.
B. Partially cut back the outer braided shield. Leave 1 inch (26 mm) of shield exposed to attach a
strain relief or connection to a Terminal Strip Plate shield clamp.
C. Keeping wire pairs twisted, cut wires to lengths shown in the following table. Strip all wire pairs
ends 3/8 inch (10 mm) and tin with solder.
2.32 “(58.9mm)
5.03 “
(127.8 mm)
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 67
Wire Pair
color coded
Wire Length
inches (mm)
YEL & YEL/WHT
3.0 (76)
BLU & BLU/WHT
2.2 (56)
ORG & ORG/WHT
1.4 (36)
VIO & VIO/WHT
2.2 (56)
BLK & BLK/WHT
3.0 (76)
RED & RED/WHT
10.0 (254)
Table: 14
D. Select Next Step. If the preparation is for a POI Box, see the separate POI manual for cable
preparation and installation instructions. If the preparation is for a Terminal Strip Plate, pull back
and comb out the exposed shield. Preparation is now complete. Route and install the
interconnecting cable. Refer to Section 4.6 Terminal Strip Plate – Sensor Interconnecting Cable
Installation, page 68.
4.5.2 Interconnecting Cable Assembly Continuity Check
If desired, a continuity check of the cable can be made. The table below identifies the receptacle pin and
the color coded wire connected to the pin. The illustration below identifies the pin locations on
the cable plug end.
Pin 1 Black/White
Pin 2 Red
Pin 3 Black
Pin 4 Violet
Pin 5 Blue
Pin 6 Yellow/White
Pin 7 Blue/White
Pin 8 Red/White and Violet/White
Pin 9 Orange
Pin 10 Yellow
Pin 11 Orange/White
Figure 58
Cable Shield is connected to the plug shell.
Red Dot Up
Sensor Wiring
68
Rev. L6 Feb 2017 Modline 5
4.6 Terminal Strip Plate – Sensor Interconnecting Cable Installation
Clamp the cable shield to the shield clamp on the left side of the Terminal Strip Plate.
Insert the 9.5 inches (241.3 mm) long Red and Red/White twisted pair through the ceramic ferrite core
supplied with the plate. Keep the exposed wire length between the shielded cable end and the ferrite
core as short possible. Maintain enough length to allow the core to be inserted into its mounting clip.
Bring the Red and Red/White pair around the outside of the core as tight and as close to the core surface
as possible. Repeat until 2 wraps have been completed as shown.
Cut the pair to the required length for connection to the terminal strip. Strip wire 3/8 inch (10 mm) and
tin with solder.
Route all twisted wire pairs to their corresponding terminals identified by wire color. Insert the tinned
wire ends of each color coded wire into its terminal and tighten.
The 100 Ohm 1 watt fusible resistor placed from the ground stud to power supply common is not shown
in these illustrations.
Figure 59
Figure 60
4.7 Connecting Device Cables to Terminal Strip Plate
4.7.1 Recommended Cable Types
To maintain signal integrity and reduce noise pick-up, twisted pair shielded cables with overall foil and
braid shielding should be used for connecting to all Sensor inputs and outputs. Belden low capacitance
computer cable types 9829, 9830, 9831, 9832, 9839 and 9833, or equivalent cables are recommended. Each
of these cables has a different number of wire pairs varying in quantity from 2 to 7 pairs.
The cable selected should have a twisted pair nominal impedance of 100 ohms and nominal capacitance
between conductors should not exceed 15.5 pF/ft. (50.9 pF/m).
Prepare the cables as explained in Section 4.5 Sensor Interconnecting Cable Preparation, page 66.
Ground cable shields on the Terminal Strip Plate by inserting the prepared braid under the shield
clamps.
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 69
4.7.2 Grounding and Shielding
Follow all grounding and shielding instructions provided below. Proper connection of the cable shields
is important to avoid noise and ground loop problems that may cause errors. Do not connect cable
shields at both ends. The illustration below shows the shield not connected at the other end.
Figure 61
Refer to Section 4.11 System Grounding and Shielding, page 79 before beginning wiring. The section
presents an overview on grounding and shielding and contains important information for wiring
system cables.
4.7.3 System Connections
Refer to Manual Sections 5 Operation and 6 RS-485 Digital Communications, page 107, for Operation
Information.
Yellow
RS485 +
RS485 Digital Communications
Yellow/White
RS485 –
Blue Analog Out +
4 – 20 or 0 – 20 mA output
Blue/White
Analog Out –
Orange
mA In +
Remote Emissivity or E-Slope current input
Orange/White
mA In –
Violet
Pk/Hd Switch
Can be used for Peak Picker Reset or Track Mode select or Remote
Laser operation.
Violet/White
Pk/Hd Switch
Black
Alarm Relay
Invalid Condition, Dirty Window and Sensor Error Code Alarm relay
Black/White
Alarm Relay
Red +24VDC
24Vdc Sensor Power Supply
Red/White
Common
Table 15: Sensor Interconnecting Cable / Function
4.7.4 RS-485 Digital Communications
Connections are made on the terminal strip RS485+ (DATA) and RS485 – (DATA*) terminals. The Power
Supply Common (-) terminal is used as the ground reference.
See Section 4.9 for detailed wiring of Sensors in a RS-485 multi-drop network. Section 6 of this manual
details the RS-485 operation.
Maximum cumulative RS-485 cable length, from sensor to the actual process device, is 4000 feet (1220
meters).
4.7.5 Analog Output Temperature Signal
This current loop temperature signal is 4 to 20 mADC or 0 to 20 mADC, user selectable, linear with
Sensor
Input/Output
System
Device
Sensor Wiring
70
Rev. L6 Feb 2017 Modline 5
measured temperature. The corresponding temperature span is adjustable. Temperature signal
connections are made to the Analog Output + and Analog Out – terminals.
Single or multiple series connected indicators, recorders or other instruments can be connected. The
total current loop series DC resistance of all devices and wiring should not exceed 600 ohms.
Figure 62
The minus side of the Analog Output is connected to power supply common (see section 4.11 System
Grounding and Shielding, page 79). Use instruments with ungrounded differential inputs. If
instruments with grounded inputs are connected in the loop, the output may be inoperable or
inaccurate.
If the Analog output is not used, insert a jumper wire or 100 Ohm to 500 Ohm value resistor across the
output terminals. This will prevent an Analog Loop malfunction Alarm (Error X108) from occurring.
4.7.6 Converting the Analog Output from a mA output to a 10 Volt Output
To convert the Analog mA output to 0 to 10 Vdc Output, place a 500 Ohm resistor across the output
terminals. The Sensor Analog output (SOUT) should be set to 0 to 20mA range.
The minus side of the Analog Output is connected to earth ground. Use instruments with ungrounded
differential inputs. If instruments with grounded inputs are connected, the output may be inoperable
or inaccurate.
Figure 63
4.7.7 Current Input for Remote Emissivity, E-Slope or Laser Operation
You may make remote adjustments of the Emissivity or E-Slope by sending a scaled analog input of 4
to 20 mAdc. The Modline 5 senses an input and overrides any Sensor rear panel or RS-485 settings of
Emissivity, E-Slope or Match.
600 Ohm
Maximum
Including Cable
Resistance
Sensor
І OUT = 0 to 20 mA or 4 to 20 mA
500 Ohm @ 0,1%
Sensor
І OUT = 0 to 20 mA
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 71
The input can also be used for remote Laser operation.
Example for Emissivity:
A 4 mAdc signal corresponds to an emissivity setting of 0.100. A 20 mAdc corresponds to an
emissivity of 1.000. The relationship for the values in between is linear.
Example for E-Slope:
For the E-Slope settings, the 4 to 20 mAdc signals correspond to settings of 0.800 to 1.200. The
relationship for the values in between is linear.
Connections are made to Terminals mA In + and mA In –. Input impedance is 120 Ohms. Use Shielded
cable at the TSP Terminal Strip Plate ground terminal.
The (–) terminal of the mA input current input is isolated, but will only tolerate a difference of
approximately 2 Volts between it and Sensor Common.
Remote Laser Operation is selected in COMMS – LASR Menu. See manual Sections 5.8 and 5.11 for
selecting and operating this function. To configure and wire for remote I IN current/switch Laser
operation follow the instructions given below. When selected for remote Laser Operation, Emissivity
and E-Slope are not changed by the input current.
4.7.8 Current Input Terminal Connections for Remote Laser
Use a DC power supply with a maximum output of 24 volts. Maximum input current allowed is 20 mA.
Overloading the input can cause a Sensor Fail alarm.
When calculating a series resistor value to use with a supply voltage, subtract the 120
ohm Sensor internal circuit impedance from the calculated value. See Table below. On
threshold is 15 mA.
DC Voltage Supply
Resistor Value
10 Volts
560 ohms (Plus 120 Internal = 680 ohms total) for 15 mA
24 Volts (Can be Sensor Supply)
1500 Ohms (Plus 120 Internal = 1620 ohms total) for 15 mA
Table 16
Connect the supply circuit as shown in the wiring diagram. The I IN – terminal can be connected to a
floating or earth grounded power supply terminal. In either case, it must be connected directly to the
power supply.
Mount the ½ Watt resistor in a series circuit on the switch or at the external power supply location.
Figure 64
Orange
Orange/White
Remote
Laser Switch
1/2 Watt
Resistor
Sensor Wiring
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Rev. L6 Feb 2017 Modline 5
4.7.9 Peak/Hold Switch for Remote Peak Picker Reset, Track and Hold or Laser
Operation.
An external switch connected to the Pk/Hd Switch terminals will control signal conditioning of the
Modline 5. These terminals can also be used for remote Laser activation.
Switch action for the Peak Picker will provide the following control. Momentary closure of the switch
(>0.08 second) immediately resets the Peak Picker. If the switch is continuously closed, the Temperature
Display will show direct readings without any Peak Picker signal conditioning. The switch may be
manually operated or it may be a contact on a timer, relay, or any other process operated switch.
Switch action for Track and Hold will provide the following control. With the switch open, temperature
tracking continues (Track). With the switch closed, the displayed temperature will be held at the last
reading (Hold). The switch may be manually operated or it may be a contact on a timer, relay, or any
other process-operated switch.
Remote Laser Operation is selected in COMMS – LASR Menu. See manual Sections 5.8 COMM – Setup
of RS-485 Digital Communication Configuration, page 95 and 5.11 Laser Sighting Operation, page 102
for selecting and operating the remote laser function. The PkHd terminals are dedicated to Laser
operation when selected. To wire for remote PkHd switch operation follow the diagram given below.
Figure 65
4.7.10 Sensor Alarm Relay Contacts
The sensor tests its case temperature, detector assembly temperature, output current flow, etc. The
Check function checks internal circuit and detector operation. The optional Dirty Window Detector
measures the Sensor’s window condition. One or more out of limit conditions sensed by these tests
triggers an Alarm and operates the Alarm relay within the Modline 5. The relay contacts may be used
in the process control system to indicate measurement conditions do not allow process temperature
measurements or Sensor operation may be impaired. Appropriate action for the various conditions can
then be initiated.
Alarm Relay contact connections are made to the Alarm Relay Terminals. The relay contact is rated for
24 Volts AC or DC, 1 AMP resistive loads only.
The Alarm relay can be configured for Normally Open or Normally Closed operation. The configuration
can be performed at the Sensor Rear panel with the Engineering RELY function, or with RS-485 digital
communications.
Set the relay operation to correspond to proper and safe use of the contacts in your overall measurement
system.
Select N C. for closed relay operation with Sensor not in Alarm condition (open in alarm state).
Violet
Violet/White
Remote
Laser Switch
Pk/Hd Switch
Pk/Hd Switch
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 73
Select N.O. for closed relay operation with Sensor in Alarm condition (open when not in alarm
condition).
Contacts are held open for both N.O. and N.C. operation when the Sensor is not powered, and, for 3 to
5 seconds after power is applied to the Sensor during the initiate period. Normally Closed N.C,
operation is considered fail-safe operation.
The table below details the alarms and measurement conditions that trigger the Alarm Relay. Details
about these Alarms are found in Section 7 Maintenance, page 119.
Sensor Error Code Alarms
X101
Dirty Window Detection
X102
Out of calibration
X103
Detector block too hot
X104
Detector block too cold
X105
Case temperature too high
X106
Case temperature too low
X107
Sensor failure FAIL may be seen on the Sensor TEMP display
X108
Analog Output Current loop malfunction (open circuit)
X109
Dirty Window Detection malfunction
Measurement Condition Alarms
INV
Measurement Conditions are invalid for two color ratio temperature measurement.
When the Invalid Alarm (iALM) function is set to ON, this measurement condition becomes an alarm
and triggers the Alarm relay and the ALARM word on the Sensor rear panel
pINV
pINV is only displayed when the Invalid Alarm (iALM) function is set to ON and Peak Picker or Track
and Hold is On, this condition becomes an alarm and triggers the Alarm relay and the ALARM word
on the Sensor rear panel.
Temperature displayed is Peak Picked or Hold Mode Temperature values from prior valid
measurement conditions.
4.8 Selection of a Power Supply for Sensors used with TSP Terminal
Strip Plates
When using a Modline 5 Sensor with the TSP Terminal Strip Plate, select a switching type power supply
that will provide reliable startup. The power supply output should remain at rated voltage during the
Sensor current loading that occurs at startup. Sensor displays and alarms will not properly start with
low voltage.
A dedicated Power supply for each Sensor is the simplest and best configuration. Section 4.9 RS-485
Multi-Drop Network Power Supply and System Wiring, page 75, provides instructions for using a
chassis mount 15 watt, 24 Volt DC Switching Power Supply supplied by IRCON. The part number for
this power supply is 551632.
Multiple Sensor installations may require more than one power supply. A single supply will not be able
to properly provide startup power to a large number of sensors. Limit the number of Sensors supplied
from a single power supply to no more than 2 or possibly 3. Dividing the Sensors into groups can
Sensor Wiring
74
Rev. L6 Feb 2017 Modline 5
eliminate long cable runs when sensors are installed at distant locations. This is especially the case when
AC power is available locally.
The standard Modline 5 cable that is routed between the Sensor and TSP Plate is limited to 350 Feet (107
meters). The power supply wires in this cable are 22 gauges. This maximum cable distance and wire
gauge assures enough voltage will be available at the sensor. The voltage drop developed across the
power supply wire pair will be small and not cause a low voltage condition.
Whether powering a single Sensor or multiple Sensors, there may also be significant voltage drops
across the wires connecting the power supply to each TSP. Keep the wire lengths between the power
supply and Terminal Strip Plate short. The voltage drops developed are dependent upon length and
gauge of the wire.
A qualified electrician or technician should apply power with the all sensors connected and measure 24
VDC, +/– 5%, at the Red and Red/White power supply terminal connections on the left side of each TSP
Terminal Strip Plate.
A 100 Ohm1 Watt fusible resistor is supplied with all TSP plates to connect power supply common to
earth ground as shown in the diagrams.
Figure 66: Sensor Wiring one 24 VDC Supply for each Sensor
To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor
Power Supply Power Supply Power Supply
24 VDC 24 VDC 24 VDC
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 75
Figure 67: Sensor Wiring one 24 VDC Supply and Three Sensors
4.8.1 TSP Terminal Strip Plate DC Power Supply Connections
These instructions are for the Terminal Strip Plate only. For the POI Box, see the separate POI manual
for mounting instructions, wiring requirements, and specifications.
See Section 4.4 to review Terminal Strip Plate enclosure, power supply and ground connection
requirements.
The external 24 VDC power is wired to the right side of the Terminal Strip. Use 22 AWG (0.35 mm²)
wire. Total power supply cable run using 22 AWG (0.35 mm²) wire is 107 meters (350 feet). Shielded
cable is recommended. Paralleling two pairs of 24 AWG (0.25 mm²) cabling is equivalent to using
22 AWG (0.35 mm²) cable.
Connect the positive side of the 24 VDC power source to the +24VDC Terminals.
Connect the common or negative side of the source to the Common Terminal.
4.8.2 Power Supply Common Ground Connection
The Common side of the power source must be connected to earth Ground. If the dc power source
common is not already connected to ground at some point in the system, make the connection at the
Terminal Strip Plate.
The recommended and preferred method of making the ground connection to is to connect the power
supply Common Terminal to Ground through a 100 Ohm 1 Watt fusible resistor. The resistor is inserted
between the Ground Stud and the Common Terminal.
4.9 RS-485 Multi-Drop Network Power Supply and System Wiring
Multiple Modline 5 Sensors communicating via RS-485 with a Host device are installed in a multi-drop
network configuration. The Modline 5 MSI Multiple Sensor Interface, a PC, a PLC or other Control
system are Host devices. A block diagram of a multi-drop network is shown in the adjacent illustration.
It is important to wire the network properly to prevent noise pickup and have reliable operation.
To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor
Power Supply
24 VDC
Sensor Wiring
76
Rev. L6 Feb 2017 Modline 5
Sensors should be wired in tandem as shown in the diagram. The RS-485 terminals from the Sensor
furthest from the host device are wired to the next closest Sensor. Then the RS-485 Terminals of that
Sensor should be wired back to the next closest sensor. Do this until all sensors are wired. Do not use
any other configuration.
A 120 ohm termination resistor should be placed across the RS-485 terminals of the Sensor furthest from
the Host device as shown in the diagram. Consult the manual for the Host device to determine if any
termination resistor is required at its terminals. The IRCON Model MSI Interface does not require a
termination resistor at its input.
To maintain signal integrity and reduce noise pick-up, twisted pair shielded cables with overall foil and
braid shielding should be used for connecting to all Sensor inputs and outputs. Belden low capacitance
computer cable types 9829, 9830, 9831, 9832, 9839 and 9833, or equivalent cables are recommended. Each
of these cables has a different number of wire pairs varying in quantity from 2 to 7 pairs.
The cable selected should have a twisted pair nominal impedance of 100 ohms and nominal capacitance
between conductors should not exceed 15.5 pF/ft. (50.9 pF/m).
Select power supplies and install cables as instructed in previous sections of the
manual.
Figure 68
4.9.1 Computer Communications Requirements
The Host device communicating with The Modline 5 Sensor should have an RS-485 communication
port. If not, an RS-232 Port and a RS-485 to RS-232 converter can be used. An RS-485 to USB converter
can also be utilized. The combined communications port and converters used must have the capability
to communicate over a 2 wire, half duplex RS-485 network at speeds fast enough to handle command
requests with reply turnaround times of one-millisecond or less.
The following converters will provide satisfactory performance when used with Modline 5 Sensors.
To Sensors RS-485 Multi-drop Network
Ground TX-A TX-B
RS-485 Serial Port
IRCON Multiple Sensor Interface (MSI)
or PC, PLC, Control System
Sensors with TSP Terminal Strip Plates
Power Supply
More than one
Required,
see Manual
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 77
CyberResearch Inc.
Contact: www.cyberresearch.com
SuperverterTM Model 285 R-422/RS-485 to RS-232 Converter.
CyMODTM Model CM 4530 USB to RS-232/422/485 Converter with isolation.
(Superverter and CyMOD are trademarks of CyberResearch Inc.)
DGH Corporation
Contact: www.dghcorp.com
A1000 and 2000 Series (The A1000 will also provide 24 Volt DC power for 3 Sensors)
RS-232/RS-485 Converters and RS-485 Repeaters
Black Box Corporation
Contact: www.blackbox.com
RS-422/485 PCMCIA Serial I/O Adapters, Single-Port
Product Code IC114A-R2 (for laptop computers)
See section 6 RS-485 Digital Communications, page 107, for Modline 5 Sensor communications details
and commands.
4.9.2 TSP Terminal Strip Plates Multi-drop Wiring
These illustrations indicate the proper wiring when using TSP Terminal Strip Plates. A power supply
for each Sensor and TSP pair is shown in the first illustration. This is the preferred method.
A single power supply is shown powering three Sensors in the second illustration. A power supply
should not power more than 2 or 3 Sensors.
Use the shielded cable specified in the previous manual sections and install termination resistors as
required.
Figure 69: Multidrop Sensor Wiring with 24 VDC Supply for each Sensor
To Modline 5 Sensor To Modline 5 Sensor
Modline 5 MSI Multi-Sensor Interface
or PLC, PC, System
RS-485
Ground
TX-A
Termination Resistor
at furthest Box
Power Supply
24 VDC
Power Supply
24 VDC
Sensor Wiring
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Rev. L6 Feb 2017 Modline 5
Figure 70: Three Sensor RS-485 Multi-drop with 24 VDC Supply and TSP Terminal Strip Plates
4.10 Sensor and Cable Connection
4.10.1 Cable Plug and Sensor Receptacle
Position the red dot on the interconnecting cable plug on connector to match the red dot on the Sensor
housing receptacle. Push the connector firmly and completely in to the Sensor receptacle.
The cable plug and Sensor receptacle combination are NEMA 4 (IP65) rated. However, provide
protection for the plug and receptacle if they are disconnected and the contacts and pins are exposed to
harsh environments.
Make sure the 24Vdc power to the Modline 5 Sensor is turned off whenever connecting and
disconnecting the cable.
Make sure the rear protection window is in place after making adjustments to maintain the Sensor’s
NEMA 4 (IP65) environmental rating.
Figure 71
To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor
Modline 5 MSI Multi-Sensor Interface
or PLC, PC, other System
RS-485
Ground
TX-A
TX-B
Termination Resistor
at furthest Box
Power Supply
24 VDC
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 79
4.11 System Grounding and Shielding
4.11.1 Terminal Strip Plate Diagram
Figure 72: Terminal Strip Plate
1) The Sensor mounting surface should be at earth ground potential . Provide electrical
insulation between the Sensor and mounting surface if the surface is not at ground
potential. Use non-conductive hardware for mounting. Mounting surfaces not at
ground potential could be hazardous for personnel operating and maintaining the
Sensor.
2) Insure earth ground is properly connected to the Terminal Strip Plate as previously
instructed in this Section.
3) For the Terminal Strip Plate: Connect a regulated power supply.
4) If the Terminal Strip Plate is used, the interconnecting cable shield is connected to
ground with the shield clamp on the plate.
Twisted pair shielded computer cable is required for all connections.
If the Terminal Strip Plate is used, cable shields are connected to ground with ground
clamps on the plate.
This manual specifies the shields of cables connecting between the Terminal Strip
Plate and system devices be connected to ground only at the plate. The recommended
shield connections are shown in the drawing below. This recommendation is to
prevent ground loops due to the difference in ground potential between locations of
components and provide adequate shielding of cables.
Some devices call for connecting the shield to ground at the device input. If ground
loops develop with this connection, it may be necessary to experiment with shield
Mounting surface not
at ground potential
Insulation
1) Ground
Cable clamp (3 Places)
Interconnecting cable
4) Shield to clamp
2) Ground lead
Terminal Strip Plate
11) Place Terminal Stripe Plate in metal enclosure
for protection from ESD (electrostatic discharge)
4) Grounded shield
4) Grounded shield
4) Grounded shield
4) Grounded shield
Analog
output
mA IN
EMIS/E-SLOPE
Peak Picker/Track &
Hold Reset switch
24 VDC
Power supply 3)
Mounting surface at
ground potential
1) Ground
Sensor Wiring
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Rev. L6 Feb 2017 Modline 5
connections. The ground connection at the Terminal Strip Plate and the
interconnecting cable shield should always be connected!
Figure 73: Sensor shield
5) Several Sensor circuits are connected to an internal common. The minus (–) or common
terminals for the 24 VDC Power Supply, Peak Picker/Track and Hold Switch, and
Analog Output are connected internally.
A.) Connect the Analog Output to devices with differential inputs that have not been
grounded.
B.) The ( – ) terminal of the mA input for remote Emissivity and E-Slope current input
is isolated but will only tolerate a difference of approximately 2 Volts between it and
Sensor Common. Input impedance is 120 Ohms.
See Note 8 for connecting Common to ground
6) The RS485 Data connection is not isolated. Use an external isolator if isolation is
required.
7) Alarm Relay contacts are isolated from ground and Sensor internal common.
8) For the Terminal Strip Plate: Depending on the installation, the internal common will
be connected to ground through a 100 Ohm 1 Watt fusible resistor.
See Section 4.8 for details.
9) The Terminal Strip Plate is supplied with a transient suppressor across the Red and
Red/White power supply wires on the left side of the terminal strip.
10) The Terminal Plate is supplied with a ceramic ferrite bead for the Red and Red/White
power supply wires.
11) The Terminal Strip Plate must be placed in a metal enclosure for protection from
electrostatic discharge (ESD).
4.12 Summary Caution and Warning
Inspect the installation for proper wiring, possible loose connections or potential shorts.
The installation of the Sensor described in Section 3 Sensor Installation, page 22 should be complete.
The wiring of the Sensor and system devices described in this Section 4 Sensor Wiring, page 64, should
also be complete. The Modline 5 Sensor can now be powered and the initial setup for operation
performed as described in Section 5 Operation.
Look for any signs of overheating or smoking when applying power. Investigate any signs of improper
installation
Please read the following important Caution and Warning.
Sensor
Input/Output
System
Device
Sensor Wiring
Modline 5
Rev. L6 Feb 2017 81
If you observe any signs of malfunctions smoke or overheating; complete lack of any
indication; etc. - turn off power immediately. Recheck all wiring, and refer to
Section 7.6.1 for troubleshooting.
Critical Process Safety Guideline
Risk of Personal Injury
When this instrument is being used in a critical process that could cause property
damage and personal injury, the user should provide redundant device or system that
will initiate a safe process shutdown in the event that this instrument should fail.
The user should provide a redundant system or device that will initiate a safe process shutdown in
the event that this instrument or associated system should fail. The control of a process should not
be solely dependent upon this instrument and its peripheral components. Other measuring and
controlling safe-guards should be included in a redundant system designed to provide warning of
conditions that may cause personal injury or property damage. These safeguards should be in place
at all times, including startup and shutdown, as well as normal operation.
Procedures should be in place that verifies proper instrument and system operation after service,
maintenance or replacement to insure the instrument and peripheral components are returned to service
properly. All alignments, settings and connections required for proper operation must be performed or
verified.
A computer with specialized software may be used as an operator interface for setup and operation of
the system. Digital and analog communication with alarms and controllers may be part of the system
making it a more complex system. Changing software configurations and settings requires that process
performance be verified.
Operation
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5 Operation
5.1 Sensor Rear Panel Setup and Operation
5.1.1 Introduction
Become familiar with the displays, pushbutton controls, menus and the functions required for Sensor
setup and operation as described below. Modline® 5 instruments are thoroughly tested and calibrated
to factory specifications before shipment and should require no more than brief function selections and
adjustments to meet the requirements for measurement of process temperatures.
5.2 Rear Panel Keyboard, Displays and Sight and Laser Aiming
5.2.1 Description
Located on the rear of the Modline 5 Sensor are: a keyboard panel with three setup pushbuttons, three
red word indicators for Setup, Alarm and Window (for the Dirty Window Detector optional feature),
and a four character green alphanumeric Light Emitting Diode dot matrix display with adjacent green
°F and °C indicators.
The display is identified as the Temperature (TEMP) display in this manual. The TEMP display and °F
and °C indicators are used for temperature indication in Fahrenheit or Celsius. LOW or HIGH is
displayed when viewing target temperatures below or above the Sensor temperature range. INV is
presented on the display for Invalid ratio temperature measurement conditions. Setup parameters will
be shown on the TEMP display during setup and error codes displayed in response to an Alarm inquiry.
Two of the pushbuttons are Down / Up Arrows labeled ▼ and ▲. The third is an Enter pushbutton
labeled ENT with the keyboard enter symbol . These buttons are identified as ▼▲ and in this
manual.
A sight for visually aiming the Sensor is located in the center of the keyboard. The process target and
Sensor circular reticle can be seen when viewing through the sight. Sensors with the Laser aiming option
have a pushbutton to energize a laser in place of the sight.
Access to the keypad requires removal of a screw on protective window with O-ring gasket. The
protective window must be in place during temperature measurement to maintain the NEMA 4 (IP65)
Sensor housing rating.
Figure 74: Sensor with Visual Through the Lens Sight
Temperature in °C or °F
LOW = Below zero scale temperature
HIGH = Above full scale temperature
INV = Invalid Condition for Ratio
Temperature Measurement
Operation
Modline 5
Rev. L6 Feb 2017 83
Figure 75: Sensor with Laser Through the Lens Aiming Option
Laser pushbutton is located on the edge of rear panel. Visual sight is not available with this option
installed. LED above pushbutton is on when laser is energized.
See Section 5.11 Laser Sighting Operation, page 102 for complete Laser operation and safety instructions.
5.3 Navigation and Menus
5.3.1 Enter and Up / Down Arrow Pushbuttons
Up and Down Arrows ▼▲ are inoperative during valid temperature measurement. Arrows are
operable when an Alarm Condition has been sensed and the ALARM indicator is lit. Depressing the UP
Arrow ▲ will display an error code. The Up Arrow should be depressed multiple times to view
simultaneous multiple Error Codes that might occur. If multiple errors have been displayed, the
Down Arrow ▼ will scroll backwards through the errors. To return to the TEMP display while
viewing an Error Code, press Enter . If no button is pressed after 15 seconds, the display returns to the
temperature display.
The ENT () pushbutton is also used to navigate from the TEMP display to the Main Setup Menus. Up
and Down Arrows ▼▲ and the ENT pushbutton are used to View, Select and Adjust Sensor Functions.
ENT () must be momentarily depressed (less than 5 seconds) when changing function
values and making selections. If ENT () is held depressed for 5 seconds, all
adjustments made in the current menu are canceled and the unit returns to the TEMP
Display.
5.4 Main Menus
Navigate from TEMP display, by pressing ENT once. The last selected Main Menu will be displayed.
USE the UP / Down Arrows ▲▼ to step through and view the following four Main Menus. Menus are
displayed for 15 seconds before returning to the TEMP display if no further selection is made.
ENGR (Engineering)
AOUT (Analog Output)
COMM (RS-485 Communications)
HEAD (Operation Functions)
At a Main Menu, Press ENT once to enter the Menu. One of the Function selections will be displayed.
USE the UP / Down Arrows ▲▼ to view a different function. Functions are displayed for 15 seconds
Operation
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Rev. L6 Feb 2017 Modline 5
before returning to the TEMP display if no further selection or adjustment is made. The main menu
functions are shown below. Some functions are model specific and only appear for those models.
ENGR (Engineering Functions)
LOCK (Panel Access Security Setup)
VER (Sensor Firmware Version)
MODL (Model Number Scrolling)
RELY (Alarm Relay Operation Setup)
F/C (°F and °C Selection)
CHK (Initiate System Check)
HOUR (Automatic System Check Setup)
WRNL (Optional Dirty Window Detector Setup)
iALM (Sets Ratio Sensor Invalid Condition as Alarm)
AOUT (Analog Signal Output Selection and Scaling)
SOUT (Select Analog Output Current Range)
ZERO (Set Analog Zero Scale Temperature)
FULL (Set Analog Full Scale Temperature)
Fatl (Set Output Current for Sensor or DWD Error)
A–LO (Set Alarm Current Output for Temperature Below ZERO)
A–HI (Set Alarm Current Output for Temperature Above FULL)
COMM (RS485 Digital Communications)
CLCK (Communications Lock, Read Only or Read and Write Setup)
LASR (Select Laser Sight Activation Mode)
ADDR (Set Sensor Address)
BRAT (Set Baud Rate)
HEAD (Sensor Operating Functions)
EMIS (Set Emissivity for Brightness or 1 Color Sensor)
E-SL (Set E-Slope for 2 Color Ratio Sensor)
R.T. (Set Response Time)
SIGL (Signal Conditioning Peak Picker or Track/Hold)
PSEL (Peak Picker Sub Function Settings)
COLR (Set Ratio Unit for 2 Color or 1 Color Operation)
MTCH (Match Known Temperature)
SUB FUNCTION PSEL (Peak Picker Function Settings)
D.R. (Decay Rate in ºF or ºC per Second)
AUTO (Auto Peak Picker Reset)
RSET (Manual Peak Picker Reset)
RBEL (Reset Below Temperature)
DEL (Peak Signal Conditioning Delay)
Operation
Modline 5
Rev. L6 Feb 2017 85
5.5 Warm-up and Initial Setup
5.5.1 Series 5R, 5G, 52 Power On and Warm-up
When power is applied to the Sensor, a three to five second initiate condition occurs. All segments of
the dot matrix TEMP display and all word and symbol indicators are lit. The alarm relay is always held
open during this short period.
After application of power, a warm-up time of approximately 5 to 15 minutes is required for the Sensor’s
infrared detector and/or electronics. The Sensor Rear Panel Alarm indicator will be lit and Error Code X104
(Detector Cold) displayed when the ▲ arrow is depressed. During the warm-up time, temperature
measurements can be made and outputs are operational. However, the Alarm signifies that the
temperature indication may not be accurate. Temperature indications will be accurate after the Alarm
indicator has turned off when warm-up is completed. If there is a brief power outage, Sensors may restart
and go into the initiate and warm-up conditions described above.
The Sensor Check function should not be initiated until the Sensor has warmed up and the Alarm indicator
has turned off. An Out of Calibration Alarm (X102) may occur if initiated during warm-up. If this Alarm
occurs, repeat the Check.
5.5.2 Series 56 Models Power On and Warm-up
Series 56 Models include a Self-Calibration feature which is performed as part of the power on routine.
5.5.3 Initial Rear Panel Display
After the warm-up period is over, you should observe one or more of the Modline 5 Sensor responses
described below on the TEMP display and at the outputs. During initial setup, because the Sensor is not
adjusted for the process, these initial displays are expected.
1.Target Within Range — If the Sensor is viewing a temperature within its range, it will display a
temperature value. Equivalent analog signals will be supplied to any devices connected to the analog
outputs (e.g., recorder or remote indicator). If initial setup has not been set to match operation to the
process, the displayed temperature and analog outputs will not be a true measurement of the target
temperature.
2. LOW / HIGH Indication — If the measured temperature is below or above the Sensor temperature
range limits LOW or HIGH will be shown on the temperature display. The Alarm Indicator does not
light because these are normal conditions.
3. INVALID — An Invalid condition will be indicated any time the sensed infrared radiation is
considered to be inadequate for two color Ratio Sensor measurement. The word INV is indicated on the
TEMP display. If the Invalid Alarm (iALM) is set to On, the Alarm Relay will be in alarm condition and
the word Alarm lit on the Sensor rear panel.
5.5.4 Initial Sensor Setup
Initial Sensor setup should follow the menu orders indicated in the following instructions. Menu
navigation is shown using the &▲▼ symbols for Enter and Up / Down arrows. The menus and
functions available and the sequence in which they appear depends on the Sensor Model and the
purchased options.
A function variable is expressed as a word or as a number. A function variable may be changed from
State A to State B or from a higher or lower numerical value by using the Up / Down arrows.
Operation
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Rev. L6 Feb 2017 Modline 5
Momentarily depress the Up or Down Arrow pushbutton to make single digit changes starting with the
least significant digit. Keep the pushbutton depressed to quickly change values.
All values are retained in non-volatile memory and are automatically reloaded, in the event of a power loss.
Temperature measurement continues during menu operations and changing of function values. The Analog
Output and RS-485 temperature indications continue to reflect changes in target temperatures. When a
changed function value that affects the measured and displayed temperature is entered with the ENT
pushbutton, the temperature reading at the outputs updates in about 150 milliseconds.
5.6 ENGR – Setup of Engineering Functions
5.6.1 LOCK – Panel Lock Security
In the Panel Lock “Off” state viewing and adjustment access to all menus and functions is allowed. In
the “ON” state, viewing all menus and functions is allowed, but changes are not allowed. This prevents
unauthorized changes. Panel lock does not interfere with temperature measurement.
Panel Lock can be controlled with an external RS485 device using the KL Command. Changes can be
made using the RS 485 Interface or the Auxiliary Current Input (for Emissivity or E-Slope adjustment)
when LOCK ON has been selected. The Password is fixed and cannot be changed.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to LOCK
Display
Instructions
Display and Limits
LOCK
Press ENT to view Panel Lock state, OFF or ON.
Use Up / Down Arrows to enter numerical Password 751. Press ENT.
Use Up / Down Arrows to turn Panel Lock OFF or ON.
Press ENT to enter and save selection and return to TEMP display.
OFF, ON, 0 to 999
5.6.2 MODL – Sensor Model Number
The MODL function reports the Modline 5 Sensor Model Number as an eight character alphanumeric display.
The Sensor Model number is explained in Section 2 Product Description, page 14. The Sensor series,
temperature range, optical resolution, and Dirty Widow Detector and Laser Sight options are defined in the
Model Number. This information is used during the selection and setup of various functions.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to MODL
Display
Instructions
Display and Limits
MODL
Press ENT to view Model. Use Up / Down Arrows to scroll forward and
backward through model number shown in the display.
Press ENT to return to TEMP display.
Eight Alphanumeric
Character Scroll
XX-XXXXXX
5.6.3 F/C – Selection of Fahrenheit or Celsius Indication (°F or °C)
Modline 5 Sensors are specified and delivered in Celsius temperature ranges. The F/C function allows
changing the temperature display to indicate in either Celsius or Fahrenheit. The conversion of the Sensor
temperature span from Celsius to Fahrenheit follows the formula: F= (1.8 x Celsius) + 32. Example, a 600°C
to 1400°C span converts to 1112°F to 2552°F. All outputs and function settings will be in the same units and
correspond to the temperature range selected for display. The appropriate °F or °C indicator will be lit for
temperature display and setup adjustments when applicable.
Operation
Modline 5
Rev. L6 Feb 2017 87
After changing the Sensor operation from F to C, or C to F, fine-tuning of the
parameters that are related to the F and C measuring units is required. These include:
Analog output ZERO and FULL functions in the AOUT Menu; the DR peak picker
decay rate and the RBEL reset below temperature functions in the Head Menu.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to F/C
Display
Instructions
Display and Limits
F/C
Press ENT to view ºF or ºC selection.
Use Up / Down Arrows to change the setup.
Press ENT to save and return to TEMP display.
ºF or ºC
RELY – Alarm Relay Operation
The RELY function configures the operation of the Modline 5 Alarm relay for Normally Open or
Normally Closed operation. The Sensor internal relay contacts are available on the Black and
Black/White twisted wire pair of the Sensor cable. The Alarm Relay contacts are used to report a Sensor
alarm condition.
The sensor self-tests its case temperature, detector assembly temperature, output current flow, etc. The
Check function checks internal circuit and detector operation. The optional Dirty Window Detector
measures the Sensor’s window condition. One or more out of limit conditions sensed by these tests
triggers an Alarm.
Set the relay operation to correspond to proper and safe use of the contacts in your overall measurement
system. Select N C. for closed relay operation with Sensor not in Alarm condition (open in alarm state).
Select N.O. for closed relay operation with Sensor in Alarm condition (open when not in alarm
condition).
Contacts are open for both N.O. and N.C. operation when the Sensor is not powered, and, for the 3 to 5
seconds after power is applied during the initiate period.
Normally Closed N.C, operation is considered fail-safe operation.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to RELY
Display
Instructions
Display and Limits
RELY
Press ENT to view Alarm Relay Operation.
Use Up / Down Arrows to select Normally Open, N.O., or Normally Closed, N.C.
Press ENT to save and return to TEMP display.
N.O. or N.C.
5.6.4 CHK – Initiate Manual System Check
for 52, 5G, 5R models
The CHK and Auto Cal Hour functions are different for the Series 56 Models. Separate explanations
and instructions are provided for Series 56 Models on the pages that follow.
Operation
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Rev. L6 Feb 2017 Modline 5
Refer to the instructions for your Model!
This function checks the Modline 5 Sensor performance by initiating a System Check. When this
function is initiated, the Sensor’s infrared detector output, internal gain and offset voltages are checked.
The check cycle lasts less than ten seconds. During the Check, the Sensor TEMP display indicates CAL.
The Alarm Led indicator and Alarm Relay remain at their last condition. Target temperature
measurement is suspended. The Analog Output readings are not derived from real time temperature
measurement during Check function. The Analog Output is held at its last output value. Peak Picker,
Track and Hold and Response time functions are suspended. At the end of the cycle, operation returns
to normal and temperature measurement resumes.
If the Check does not pass, the ALARM Indicator on the Sensor rear panel will light. Press an Up/Down
Arrow to view an Error Code on the Display. See Section 7 Maintenance, page 119, for information about
alarms and error codes.
Checks can be made manually or scheduled automatically with the HOUR function that follows. Process
temperature measurement is interrupted for 5 to 10 seconds during the check period.
After application of power, a warm-up time of approximately 5 to 15 minutes is
required for the Sensor’s infrared detector and/or electronics. The Sensor Rear Panel
Alarm indicator will be lit and Error Code X104 (Detector Cold) displayed when the
▲ arrow is depressed.
The instrument Check function should not be initiated until the Alarm indicator has turned off. An Out
of Alarm (X102) may occur if initiated during warm-up. If an X102 Alarm occurs, repeat the Check after
warm-up.
On Sensors with firmware Versions 1.08 and higher, the Cal Check function will not
operate during Sensor Alarms X107, X106, X105, X104, X103, X101. See Section 5.12
Out of Range Displays and Error Codes, page 104, for error code explanations.
The Check should not be initiated when a single Alarm or multiple Alarms for Error Codes X103
(Detector block too hot), X104 (Detector block too cold), X105 (Internal case temperature too high), X106
(Internal case temperature too low) are active.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to CHK
Display
Instructions
Display and Limits
CHK
Press ENT to initiate Check. Sensor cycles through 10 second check and then
returns to the TEMP display.
CAL
5.6.5 HOUR– Automatic System Check
for 52, 5G, 5R models
Refer to the instructions for your Model!
Operation
Modline 5
Rev. L6 Feb 2017 89
The CHK and Auto Cal Hour functions are different for the Series 56 Models. Separate explanations
and instructions are provided for Series 56 Models on the pages that follow.
The HOUR function provides for selection of an automatic System Check. This function automatically
initiates the check described above. A selection of OFF or a time interval in hours between checks is
offered.
A manual Check from the Sensor Keyboard, as explained above, or by RS-485 Communication will start
a new period, but not change the value of the interval. This will start a new interval.
Process temperature measurement and control requirements need to be considered when using this
automatic function. Real time process temperature measurement and signal conditioning is suspended
for up to ten seconds.
Continuous interval setting should be 8 hours or greater. A 168 hour, 1 week, (or greater) automatic
interval and manually initiated checks are the recommendations that will provide minimal
measurement interruption.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to Hour
Display
Instructions
Display and Limits
HOUR
Press ENT to view Automatic Check selection, OFF or numerical value
representing hours between Checks.
Use Up / Down Arrows to change selection and setting.
See above recommendations.
Press ENT to save and return to TEMP display.
OFF or
Value 1 to 9999
5.6.6 CHK – Manual System Calibration for 56 Models
This function checks a Model 56 Sensors performance by initiating a System Calibration Check. When
this function is initiated, the Sensor’s infrared detector signal, internal gain and offset voltages are
checked. First, a flag is closed inside of the unit to block the optical path of the instrument. Operation of
the Sensor is determined with no target in the field of view of the infrared detector. Second, a calibration
source with a known radiance is activated inside the Sensor and the radiance is “seen” by the infrared
detector. The response of the sensor electronics to the radiance is compared to an expected value.
If the Calibrate Check determines a Model 56 Sensor requires recalibration, the sensor firmware
performs a Self-Calibration adjustment. Typically, only small changes in calibration will occur.
During the Calibration Check, the Sensor Rear Panel TEMP display indicates CAL. The Alarm Led
indicator and Alarm Relay remain at their last condition. Target temperature measurement is
suspended. The Analog Output is held at its last output value. The Analog Output readings are not
derived from real time temperature measurement during Calibration Check function. Peak Picker,
Track and Hold and Response time functions are suspended. At the end of the cycle, operation returns
to normal and real time temperature measurement resumes.
Temperature indications may shift slightly upon return to normal operation.
A Calibrate Check is required for to insure accurate operation of the Series 56 Sensors and should be
performed routinely, every 168 hours or less. The check can be initiated by any of the three methods
Operation
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described below.
Upon Sensor Turn On
If the Sensor has not been powered for 15 minutes or more, a Calibration Check will be performed after
the unit is powered and warmed up and stabilized, approximately 15 to 20 minutes after powering on.
Automatically
A Calibrate Check can be initiated every 168 hours using the Sensor Auto Calibrate HOUR function. An
OFF setting is also available. If the OFF is selected, Manual Calibrate Checks must be initiated every at
least every 168 hours.
Manually
Initiate a Manual Calibrate Check using the Sensor Rear Panel Keypad or Modline 5 accessory.
Accessories include the Model DPM Panel Meter, Model MSI multiple sensor interface, ModView
software or an RS-485 communication command.
Series 56 Manual and Automatic (HOUR Function) Initiated Calibration Check Summary
Calibration Check Initiation
Alarm
Condition
Display
RS485 and 20mA
Temperature Outputs
Manually Initiated Calibration Check
with Self Calibration, if required.
It is not recommended to perform a Manual
check more once than every 24 hours.
Alarms Off
Note 1
CAL
(Sensor, ModView,
DPM, MSI)
Last Temperature
reading held
HOUR Parameter (168 Hours or OFF)
User Selected Time Interval 168 hours only.
(Factory default setting = 168)
OFF
User must perform Manual Cal every 168
hours or less.
Alarms Off
Note 1
CAL
(Sensor, ModView,
DPM, MSI)
Last Temperature
reading held
The Calibrate Check function will not operate with Sensor Alarms X107, X106, X105,
X104, X103, X101. A Detector Hot or Cold alarm must be off for at least 15 minutes
before a Cal Check can be initiated. See Section 5.12 Out of Range Displays and Error
Codes, page 104 for error code explanations.
Operation
Modline 5
Rev. L6 Feb 2017 91
Series 56 Self Calibration at Power On or After Power Interruption of 15 minutes or longer
Calibration Check Initiation
Alarm
Condition
Temperature
Display
RS485 and 20mA
Temperature Outputs
Sensor is within Operating Temperature
Range (0 to 55°C /32 to 131°F)) at Power On
15 minute warmup and Self Cal
cycle time
Detector Hot / Cold
Alarms on
Temperature is Displayed
and provided at outputs but
is not accurate until alarms
are off and after Self Cal
cycle
At Power On:
Sensor is outside Operating Temperature
Range (0 to 55°C /32 to 131°F)) but in
Storage Temperature range
(-20°C to 0°C or 55°C to 65°C / -4 to 32°F or
131 to 149 °F).
Warm-up and Self
Cal requires
warm-up within
Operating
Temperature f
Detector Hot / Cold
Alarms on
Temperature is Displayed
and provided at outputs but
is not accurate until alarms
are off and after Self Cal
cycle
Power Interruption of less than 15 minutes Operation
Power Interrupt (ON-OFF-On)
Off Time Less Than 15 minutes
Fifteen minute
warm-up time
starts on return to
power on.
Self-Calibration is
not Initiated
Detector Hot / Cold
Alarms on for 2
minutes
Temperature is Displayed
but may not be Accurate
Accurate after 2 minutes
Initiate a Manual Cal Check
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to CHK
Display
Instructions
Display and Limits
CHK
Press ENT to initiate Calibration Check. Sensor cycles through Sensor Check and
Self Calibration, if necessary, and then returns to the TEMP display.
It is not recommended to perform a Manual check more once than every 24 hours
CAL
If the Check and Self Calibration does not pass, the ALARM Indicator on the Sensor rear panel will light.
Press an Up/Down Arrow to view an Error Code on the Display. Multiple arrow entries may be required
to view all error codes. Error Code X102 is an Out of Calibration Alarm. See Section 7 Maintenance,
page 119 for information about alarms and error codes.
5.6.7 HOUR– Automatic Calibration Check for 56 Models
Refer to the instructions for your Model!
The HOUR function provides for selection of an automatic System Calibration Check and Self
Calibration if needed. This function automatically initiates the calibration check described above.
A Manual or power on Calibration Check will start a new period, but not change the value of the HOUR
interval.
Operation
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Process temperature measurement and control requirements need to be considered when using this
automatic function. Real time process temperature measurement and signal conditioning are suspended
for 15 seconds.
RS485 and Current Loop Outputs are held at the last reading during the Self Calibration.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to Hour
Display
Instructions
Display and Limits
HOUR
Press ENT to view Automatic Calibration Check. Selection is a numerical value
representing hours between a Check with Self Calibration.
168 hours only or OFF
Press ENT to save and return to TEMP display.
If OFF is selected, user must perform Manual Cal every 168 hours or less.
Value in hours =
168
(Factory setting)
or OFF
5.6.8 WRNL – Dirty Window Detector Option Warning Level
The Dirty Window Detector Option is specified at the time the Sensor is ordered and must be factory
installed. The WRNL function is only viewed on Sensors with the option. Select OFF, CORS or SENS.
OFF turns the dirty window detection off. Coarse and sensitive Warning Levels select a greater (CORS)
or lesser (SENS) amount of Sensor window transmission loss required to trigger an alarm.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to WRNL
Display
Instructions
Display and Limits
WRNL
Press ENT to view Dirty Window Detector Warning Level selection,
OFF, SENS (Sensitive) or CORS (Coarse)
Use Up / Down Arrows to select.
Press ENT to save and return to TEMP display.
OFF, CORS, SENS.
5.6.9 VER – Sensor Firmware Version
The VER function reports the Sensors installed firmware version. A four-digit numerical value is
displayed. The version information is useful when discussing operation with factory personnel. The
firmware cannot be updated in the field.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to VER
Display
Instructions
Display and Limits
VER
Press ENT to view Sensor Firmware Version.
Press ENT to return to TEMP display.
Numerical Value
XX.XX
5.6.10 iALM – Selects Ratio Invalid Measurement Condition as an Alarm
Selects the Ratio Unit Invalid Measurement Condition as an Alarm.
Alarm and Invalid Condition selection sets both the Error Codes and Invalid Measurement Conditions
to operate the Alarm rely and ALARM word on the Sensor rear panel. Invalid Measurement Conditions
do not trigger the Alarm relay or the Alarm word with Error Code Alarms Only selected.
Operation
Modline 5
Rev. L6 Feb 2017 93
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to iALM
Display
Instructions
Display and Limits
iALM
Press ENT to view Invalid Condition Alarm selection.
OFF = Error Code Alarms only (includes the optional Dirty Window Detector
alarms)
ON = Error Code Alarms and Invalid Condition (INV and pINV) activated as
Alarms. This function also turns on the Attenuation Alarm.
Use Up / Down Arrows to select.
Press ENT to save and return to TEMP display.
OFF or ON
5.6.11 ATTN – Selects Attenuation Alarm Threshold
Set the percent attenuation alarm threshold. Any attenuation greater than this value will turn on the
alarm and also turn on the Dirty Window LED on the back panel. Setting this to 95 will turn this alarm
off since that is the invalid threshold. The iALM must be set on in order to enable this alarm.
Navigate from TEMP display with &▲▼to ENGR then use & ▲▼ to ATTN
Display
Instructions
Display and Limits
ATTN
Press ENT to view Attenuation Threshold.
Use Up / Down Arrows to select.
Press ENT to save and return to TEMP display.
10% - 95%
Background:
With most two-color infrared thermometers, an invalid indication is reached when the reduction in
signal from the target is greater than 95 percent. When the signal reduction is too great, an invalid
condition occurs. This variation can be caused by emission characteristics of the target or the target
being too small to completely resolve, as well as obstructions in the sight path (i.e., certain types of
smoke). When an invalid condition occurs, an alarm output is provided to indicate the signal variation
is too great between the two detectors. While this type of detection method is suitable for many
applications, there are some instances where the user wants to adjust the sensitivity level of attenuation.
The Modline 5 attenuation adjustment alarming feature operates independent from the optional dirty
window detector, which will monitor the sensor window for contamination. It enables users to monitor
any kind of signal attenuation caused by dirty viewports or other external windows. Attenuation alarm
settings are configurable from 5 to 95 percent, from either the back panel of the sensing head or from
the Ircon ModView program. When an alarm condition is detected, relay outputs provide notification
to external process control instrumentation.
When the attenuation adjustment alarming feature is enabled, the user can monitor attenuation levels
in a graphical format in the ModView program providing a historical view of the levels. In addition,
attenuation levels are available through the Modline 5 RS-485 output fed into an external device.
5.7 AOUT – Setup of Analog Signal Output Current Range and Temperature Scaling
Modline 5 Sensors provide selection of the analog output current range and scaling of the selected range
to temperature. Scaling establishes a temperature span to correspond to the analog output current
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range. The span can be equivalent to the Sensor’s specified span or narrower. See Section 4 Sensor
Wiring, page 64 for detailed information on analog output signals.
This signal is available from the Blue and Blue/White twisted wire pair of the Sensor cable. See Section
4 Sensor Wiring, page 64 for wiring details.
SOUT – Analog Output Current Range Selection
Modline 5 Sensors provide a selection of one of two analog output direct current ranges, 0 to 20 mA or
4 to 20 mA. This function selects the desired range.
ZERO – Analog Output Zero Scale Temperature Scaling
This function sets a temperature to correspond to the selected Analog Output Current Range minimum
value (0 or 4 mA). This temperature must be within the Sensor’s specified temperature range and is
limited to a maximum value equivalent to 10°F (-12.2°C) below the Sensor full scale temperature, or,
10°F (-12.2°C) below the adjusted Analog Output Full Scale temperature value (explained below).
Minimum setting is the Sensor specified zero scale temperature. See notes after FULL explanation for
ZERO – FULL °C operation and span setting information.
FULL – Analog Output Full Scale Temperature Scaling
Sets a temperature to correspond to the Analog Output Current Range maximum value (20 mA).
Temperature must be within the Sensor specified temperature range and is limited to a minimum value
10°F (-12.2°C) above the Sensor’s specified zero scale temperature, or, 10F° (-12.2°C) above the adjusted
Analog Output Zero Scale temperature value (explained above). Maximum setting is the Sensor
specified full scale temperature.
For ZERO – FULL span setting.
°F and °C operation: The minimum 10° span is calculated by the Sensor in °F.
When using °C units, the span will be less than 10° because the Sensor first calculates in °F
and then converts to °C. The narrower equivalent °C span is allowed.
Spans more than 30°C (60°F) may be required to obtain acceptable results. Longer response
times may be necessary for very narrow spans to smooth magnified temperature variations
and noise.
5.7.1 Fatl – Analog Output Operation for Sensor or Dirty Window Detector
Malfunction Alarms
Sets the Analog Output current to a specified value when unit is in one of two alarm conditions. A
Sensor failure (Error Code X107) or Dirty Window Detector operation failure (Error Code X109) will
trigger this alarm.
Selectable range is from 0 mA to 24 mA
5.7.2 A–LO – Analog Output Low Temperature Alarm
Sets the Analog Output current value if the measured temperature is below the temperature that
produces Analog Zero Scale Output as determined by the Analog Output Zero Scale Temperature
Scaling explained above. Selectable range is 0 mA to 4 mA for the 4 to 20 mA current output range.
Operation
Modline 5
Rev. L6 Feb 2017 95
If the current loop is set for 0 to 20 mA operation, the A–LO function will not appear as a
menu item. The analog output always goes to 0 mA if the measured temperature is below
the Analog Output Zero Sale temperature.
5.7.3 A–HI – Analog Output High Temperature Alarm
Sets the Analog Output current value if the measured temperature is above the temperature that
produces Analog Full Scale Output as determined by the Analog Output Full Scale Temperature Scaling
explained above. Selectable range is 20.0 mA to 24.0 mA.
Analog Output Settings
Navigate from TEMP with &▲▼to AOUT then use &▲▼ to SOUT or ZERO or FULL or Fatl or
A-LO or A-HI
Press ENT to save and return to TEMP display after each function.
Display
Instructions
Display and Limits
SOUT
Press ENT to view the SOUT output current range, 0 to 20 mA or 4 to 20 mA
Use Up / Down Arrows to select output current range.
0-20 or 4-20
ZERO
Press ENT to view temperature corresponding to the selected Analog Output
Current Range minimum value (0 or 4 mA)
Use Up / Down Arrows to set Temperature within the Sensor temperature
range and high limit shown.
Temperature Value
Maximum is 10 F below the
selected FULL temperature
(see below)
See note above for °C
operation.
FULL
Press ENT to view Temperature Corresponding to the Analog Output
Maximum value (20 mA)
Use Up / Down Arrows to set Temperature within the Sensor temperature
range and low limit shown.
Temperature Value
Minimum is 10 F above the
selected ZERO temperature
(see above)
See note above for °C
operation.
Fatl
Press ENT to view the Analog Output selected mA current value.
Use Up / Down Arrows to set the current value.
00.0 to 24.0
A–LO
This function does not appear if the SOUT selected range is 0 to 20 mA.
Press ENT to view the Analog Output selected mA current value.
Use Up / Down Arrows to set the current value.
00.0 to 4.00
A–HI
Press ENT to view the Analog Output selected mA current value.
Use Up / Down Arrows to set the current value.
20.0 to 24.0
5.8 COMM – Setup of RS-485 Digital Communication Configuration
The Modline 5 RS-485 Digital Communication interface permits interchange of ASCII coded
information between the Modline 5 Sensor and a host computer, PLC (Programmable Logic Controller),
or any other RS-485 device.
The RS-485 data signal is transmitted on the Yellow and Yellow/White twisted wire pair of the Sensor’s
interconnecting cable. All communication is via half-duplex two wires.
Refer to section 6 RS-485 Digital Communications, page 107, for the complete explanation of the RS-485
Operation
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Digital Communications operation and commands.
5.8.1 CLCK – Communications Lock
Communications Lock provides for the configuration of the Modline 5 RS-485 Communications.
Communication can be configured to allow selection and adjustment of functions in Read and Write (R
/ W) operation, or in Read Only (R / O) operation. Read Only operation does not allow external RS-485
devices to change settings in the Sensor.
R / O operation still allows the unit to respond to the RS485 AC Automatic Calibrate
Command to initiate a check (CHK) and the PR Peak Picker Reset Command to perform a
reset.
5.8.2 ADDR – Sets the Sensor Address
The Unit Address is a one digit number or single letter code. It ranges from a single numeric 0 to 9 to an
upper case A to Z. The Address factory-default setting is 0 (zero).
5.8.3 BRAT – Baud Rate
The Sensor Baud Rate must match that of the other RS-485 device. Four baud rates are supported: 9600,
19200, 38400, and 57600 bits of information per second (Baud). The factory setting is 57.6K Baud.
5.8.4 LASR –Laser Operation (Sensor Firmware Versions 1.08 and Higher)
Selects Sensor Rear Panel or RS485 operation only or remote switch operation using the I IN or PkHd
functions. See Section 5.11 Laser Sighting Operation, page 102.
RS485 Communication
Navigate from TEMP with &▲▼to COMM then use &▲▼ to ADDR or BRAT or CLCK
Press ENT to save and return to TEMP display after each function.
Display
Instructions
Display and Limits
CLCK
Press ENT to view Communications LOCK.
Use Up / Down Arrows to select R / O (Read Only)
or R / W (Read and Write) operation.
R / O or R / W
ADDR
Press ENT to view Sensor Address.
Use Up / Down Arrows to set to one of thirty-six addresses.
0 to 9 and A to Z
BRAT
Press ENT to view baud rate.
Use Up / Down Arrows to select 9600, 19.2K, 38.4K or 57.6K Baud.
9600 or 19.2K or 38.4K or 57.6K
LASR
Press ENT to view Laser operation Selection.
Use Up / Down Arrows to select
PANL or I IN or SWIT
5.9 HEAD – Setup of Sensor Operating Functions
The HEAD menus and functions set up the Modline 5 Sensor for process temperature measurement.
The initial setup should follow the order given below. It is useful to perform the setup while the Sensor
is sighted on the actual target, but not necessary. Preset of the function selections is possible and may
Operation
Modline 5
Rev. L6 Feb 2017 97
be required if the access to the Sensor is not possible or safe conditions to perform adjustments do not
exist.
5.9.1 R.T. – Response Time
The Modline 5 Sensor Response Time function provides signal filtering for meaningful temperature
information while eliminating unwanted temperature variations. Refer to Section 8 Applications Guide,
page 129 for Response Time Application Information. See section 2 Product Description, page 14 for
Model specific response time information.
If you determine that your Response Time must be greater than 30 seconds, it is recommend that you
trial your process. Long Response Time settings are close approximations and may vary from the
selected value.
The Response Time selected affects the temperature signal input to Temperature Display, Analog
Output, RS-485 Communications and the Peak Picker and Track and Hold signal conditioning
functions.
The Response Time setting for a Ratio Sensor in the two-color ratio mode takes effect under valid
measurement conditions. Under Invalid measurement conditions, the Sensor response time is preset for
a fast response regardless of the Response Time function setting.
Navigate from TEMP display with &▲▼to Head then use &▲▼ to R.T.
Display
Instructions
Display and Limits
R. T.
Press ENT to view Response Time in Seconds.
Use Up / Down Arrows to adjust Response Time.
Press ENT to save and return to TEMP display.
0.01 to 60.0 Seconds for * 5R Ratio Sensors
0.006 to 60.0 Seconds for Series 52 and 5G
.006 = 6.6 milliseconds
0.02 to 60.0 seconds Model 56 Sensors*
5.9.2 COLR – Ratio Unit Operation Selection
The COLR function sets the Modline 5 Ratio Sensor operation in the two color mode for ratio
temperature measurement or in the single color mode for brightness temperature measurement.
Navigate from TEMP display with &▲▼to Head then use &▲▼ to COLR.
Display
Instructions
Display and Limits
COLR
Press ENT to view Color Selection.
Use Up / Down Arrows to select: 1 for single color
brightness operation or 2 for two color ratio operation
1 or 2
5.9.3 E-SL – Ratio Unit Two Color Operation E-Slope Adjustment
Ratio Sensors require the correct E-Slope value selection for measuring temperatures of both non-graybody
and graybody/blackbody targets. To get a true measure of the temperature you must select the E-Slope values
to match the material being measured. The value can be set in “real time” while viewing the process. The
adjustable range for this function is 0.800 to 1.200.
• Determine the E-Slope value by referring to Section 8 Applications Guide, page 129 or other
reliable source.
Operation
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• Enter the proper E-Slope value in the E-SL function.
If you change materials or if the material characteristics change, re-determine the E-Slope for the
material and readjust the E-SL function if necessary.
If you are viewing your target through a window, consider the effect of window
transmission as described in Section 8 Applications Guide, page 129.
Navigate from TEMP display with &▲▼to Head then use &▲▼ to E-SL.
Display
Instructions
Display and Limits
E-SL
Press ENT to view E-Slope. Use Up / Down Arrows to adjust.
Press ENT to save and return to TEMP display.
0.800 to 1.200
5.9.4 Remote E-Slope Current Input
You may make remote analog adjustments of the E-Slope value by sending a scaled input of 4 to 20 mAdc.
This signal is inputted using the Orange and Orange/White twisted wire pair of the Sensor’s interconnecting
cable. The Modline 5 senses an input and the overrides any rear panel or RS-485 settings of E-Slope or Match.
Wiring connection and scaling information are in Section 4 Sensor Wiring, page 64.
5.9.5 EMIS – Emissivity Adjustment for Brightness Sensors
Modline 5 brightness sensors and one color operation of ratio sensors require Emissivity adjustment for
accurate temperature measurement. The Emissivity value is set to the characteristics of the material
being measured using the EMIS function. Ratio sensors that are using the Attenuation Alarm feature
will need to set the sensor to a single color mode, set the correct emissivity for the target, then set the
sensor back to 2 color mode (When using the Attenuation Alarm feature, you must set the emissivity
and also the e-slope for the sensor)
1. Determine the Emissivity value of your target by referring to the instructions in Section 8
Applications Guide, page 129.
2. Select the proper Emissivity value, from the Tables in Section 8 Applications Guide, page 129 for
the surface finish.
3. The adjustable range of the Emissivity is 0.100 to 1.000. See Section 2.3 Model Configuration and
Required Selections, page 16 for Emissivity restrictions.
If the material changes characteristics or you change materials, re-determine the Emissivity for the new
material and adjust the Emissivity value.
If you are viewing your target through a window, consider the effect of window transmission loss as
described in Section 8 Applications Guide, page 129.
Navigate from TEMP display with &▲▼to Head then use &▲▼ to EMIS.
Display
Instructions
Display and Limits
EMIS
Press ENT to view Emissivity Value. Use Up / Down Arrows to adjust.
Press ENT to save and return to TEMP display.
0.100 to 1.000
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