ircon Modline 4 Installation And Operation Manual

INSTALLATION and OPERATION MANUAL

Revision S 5

04/20 19

Fluke Process Instruments

Americas

Everett, WA USA
Tel: [phone] (USA and Canada, only)
[phone]

solutions@flukeprocessinstruments.com

EMEA

Berlin, Germany
Tel: [phone]

info@flukeprocessinstruments.de

China

Beijing, China
Tel: [phone]

info@flukeprocessinstruments.cn

Worldwide Service

Fluke Process Instruments offers services, including repair and
calibration. For more information, contact your local office.

www.flukeprocessinstruments.com

© 2019 Fluke Process Instruments
Specifications subject to change without notice.

Interchanging non-CE-approved

components such as older sensing heads,

indicators, PC boards, and cables will not

maintain compliance to the CE Directive.

!

!

CAUTION

For installing, operating, and servicing this instrument, please observe all cautions and
warnings that are located throughout this manual.

CE Compliance Information

Cautions and Warnings

Example of a Caution.

Example of a Warning.

ii

!

CAUTION

!

!

WARNING

!

iv

WARRANTY

Risk of Personal Injury

When this instrument is used on a critical process where failure of this
instrument could cause personal injury or property damage, the user

must provide a redundant device or system that will initiate a safe
process shutdown . The user should also follow NEMA safety guide-

lines in the Appendix of this manual.

CAUTION

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 judgement, 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.

Except as may be expressly provided in an authorized writing by IRCON, IRCON shall not be subject
to any other obligations or liabilities whatsoever with respect to equipment manufactured by IRCON or
services rendered by IRCON. THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF

ALL OTHER EXPRESS AND IMPLIED WARRANTIES EXCEPT WARRANTIES OF TITLE, INCLUDING
BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.

LIMITATION OF LIABILITY

Anything to the contrary herein contained notwithstanding, IRCON, IT’S CONTRACTORS AND

SUPPLIERS OF ANY TIER, SHALL NOT BE LIABLE IN CONTRACT, IN TORT (INCLUDING
NEGLIGENCE OR STRICT LIABILITY) OR OTHERWISE FOR ANY SPECIAL, INDIRECT, INCIDENTAL,
OR CONSEQUENTIAL DAMAGES WHATSOEVER. The remedies of the purchaser set forth herein are

exclusive where so stated and the total cumulative liability of Ircon, it’s contractors and suppliers of any
tier, with respect to this contract or anything done in connection therewith such as the use of any product
covered by or furnished under the contract, whether in contract, in tort (including negligence or strict liabili­ty) or otherwise, shall not exceed the price of the product or part on which such liability is based.

Section 1 – INTRODUCTION

1.1 GENERAL DESCRIPTION

MODLINE 4 is an infrared thermometer with a built-in two
wire transmitter. Power it up with a 16 to 40 volt direct
current source and you get a 4 to 20 mA current (maximum)
that varies linearly with temperature. You can use this
current to operate a 4 to 20 mA indicator, recorder, con­troller or datalogger – or a combination of devices in
the series. Figure 1.1 shows the basic electrical circuit.

This instrument is built for long, trouble-free service in even
the harshest environments. Everything is packaged in
sealed aluminum casting rated NEMA 4. The instrument
can be ordered with a water-cooled casting for operation
in high ambient temperatures.

The lens is recessed and sealed in the front of the casting.
A screw-on back cover with torquing slots gives access to
the adjustments and connections (see figure 1.2). A 1/2
inch NPT conduit hub is provided for wiring. NOTE: The
back cover of the water-cooled enclosure has a pair of
torquing studs.

The MODLINE 4 is easy to install, operate and maintain.
The lens is pre-adjusted and sealed so you don’t have to
make optical adjustments. Just choose a clear sight path
with no obstructions, aim the sensor at the object you want
to measure and read the temperature on your indicator.

The controls on the back panel allow you to adjust for
emissivity of the material you are measuring and for the
most suitable response time for your process. If the instru­ment includes a peak picker (block D of model number
= 1), an additional control is provided for peak picker
decay time. As long as your process stays the same, you
will make these adjustments only once when you set
up the instrument.

The high-level current signal (20 mA maximum) minimizes
noise problems often associated with long cable runs.
Twisted pair cable with an overall shield is all you need
for most applications.

Seven different MODLINE 4 series that differ in spectral
responses, cover a wide variety of processes. Temperature
ranges covering 0 to 2500°F and 0 to 1300°C are available.
Note: General illustrations in this manual that show the
standard MODLINE 4 casting also apply to instruments
with water-cooled castings.

1-1

Fig. 1.1 - BASIC MODLINE 4 ELECTRIC CIRCUIT

Fig. 1.2 - MODLINE 4 REAR VIEW (WITH
COVER REMOVED) and FRONT VIEW
Note: standard enclosure shown.

Section 1 – INTRODUCTION

1.2 HOW IT WORKS

The MODLINE 4 works on a simple principle. A heated
object radiates infrared energy, and the intensity of
radiation depends on the temperature of the object. By
measuring the radiation intensity, it is possible to measure
the temperature without contacting the object.

Fig. 1.3 shows a MODLINE 4 series with a digital meter
across a DC power supply. The current in this circuit is
determined by the MODLINE 4.

Infrared radiation enters the lens of the MODLINE 4
and is focused on an infrared detector. The detector
converts infrared energy to an electrical signal that
varies with the intensity of infrared radiation. This
signal is amplified, linearized, and scaled to the desired
temperature range by the MODLINE 4 electronic circuits.
The resulting output current causes the pointer to deflect
on the meter. If the meter scale is matched to the MOD­LINE 4 range, it’s a simple matter to read temperature
values directly from the scale.

Fig. 1.3 shows how the MODLINE 4 measures a change
in temperature. Assume the MODLINE 4 is scaled for
the 500 to 1500°F range. The circuit current is 4 mA
when the MODLINE 4 is viewing a 500°F target and
20 mA when viewing a 1500°F target. The current
varies linearly between 4 and 20 mA for temperatures
between 500 and 1500°.

In Fig. 1.3a, the target temperature is 500°F. The target
will radiate a certain intensity of infrared energy at
this temperature. When the MODLINE 4 senses this
radiation, it causes 4 mA current in the meter. The
pointer rests at the lowest scale limit (500°).

Figures 1.3b and 1.3c shows what happens when
target temperatures increases. The MODLINE 4 detects
more infrared radiation, and the meter current increases
to display higher temperature readings.

Summarizing the action, the MODLINE 4 provides a DC
current proportional to the infrared energy it senses.
This current can be fed through a variety of current­sensitive devices to indicate temperature or provide a
desired control action.

FIG. 1. 3 - BASIC OPERATING PRINCIPLE OF

MODLINE 4 INSTRUMENT

1-2

TABLE 1.1 – SUMMARY OF MODLINE 4 SERIES

1–3

Section 1 — INTRODUCTION

1.3 OPERATING WAVELENGTHS

It takes a whole family of instruments to cover a
wide range of measurement applications. MOD­LINE 4 features such a family-seven series operat­ing at distinct infrared wavelengths. Each series
includes the temperature spans that are common
for the applications involved.

The wavelength regions selected for the various
MODLINE 4 series are listed in Table 1.1. This
table also summarizes some of the primary appli­cations for these ranges.

120 to 400°F
150 to 500°F
200 to 600°F
300 to 1000°F

50 to 200°C
100 to 400°C
150 to 500°C

43

Measures thin, clear films of C-H
Type plastics such as polyethylene,
polypropylene, polystyrene, vinyls,
and nylon. Also ideal for paints and
organics such as waxes and oils.

3.43 ± 0.07 microns

0 to 200°F
0 to 500°F
0 to 1000°F

0 to 100°C
0 to 250°C
0 to 600°C

500 to 1000°F
500 to 2500°F

300 to 800°C
300 to 1300°C

500 to 1000°F
600 to 1400°F

250 to 600°C
350 to 800°C

44
22

45

46

Ideally suited to all types of very low
temperature applications such as
print drying, food, wood, paper and
textile processing, vacuum forming,
and infrared heating.

Measures subsurface glass tem­perature. Good unit to see though
hot gasses and flame.

All types of medium temperature
applications involving metals.

8 to 14 microns

200 to 1000°F
500 to 1500°F
500 to 2500°F

100 to 600°C
300 to 850°C
300 to 1300°C

47

Measures glass surface tempera­ture in such operations as forming,
bending, tempering annealing, and
sealing. Also suitable for infrared
heating.

4.8 to 5.2 microns

0 to 600°F
500 to 1500°F
500 to 2500°F

0 to 300°C
300 to 800°C
300 to 1300°C

48

Measures refractory brick, painted
surfaces, plastics glass and infrared
heating of these products.
Especially good for thin films of
plastics, oils, paper, wood, and
other organic material.

7.5 to 8.5 microns

3.7 to 4.0 microns

2.0 to 2.6 microns

Series Standard Ranges Wavelength Primary Applications

Section 1 – INTRODUCTION

1.4 OPTICAL RESOLUTION

The MODLINE 4 detector “sees” a certain area
(spot on a target surface. The diameter of the
spot is determined by the design on the
optical system and by the distance to the
ttarget.

Fig. 1.4 is a plot of spot sizes at every incre­ment of distance from the front flange of the
MODLINE 4. The three dimensional “Cone of
Vision” defines the viewing area of the
MODLINE 4 at any given distance. Anything
inside the cone is in the field of view and
anything outside of the field of view is not.

If unobstructed, the cone of vision would expand
to infinity. But in practice, you aim it so it falls
on a target at some finite distance. In Fig. 1.4
below, the cone of vision falls on the target at
the separation distance (D). At this distance,
the diameter of the cone or viewing area on
the target surface will have a spot size (d).

1-4

FIG. 1.4 SPOT SIZE vs. SEPARATION DISTANCE RELATIONSHIP

Note that if you move the MODLINE 4 a little
closer the target will intersect a smaller cross
section of the cone and give you a smaller spot.
Moving it further away will give you a larger spot.

Spot size/separation distance relationships for
the MODLINE 4 are give in the Model Indentifi­cation table (see section 1.5). This relationship
defines the optical resolution or the smallest
target the instrument can measure at any given
distance. If the spot is larger than the target, the
output current will be influenced partly by the
target temperature and partly by the background
temperature, and the instrument will give a false
temperature reading.

The importance of resolving the target will be
emphasized in the installation procedures.

®

Section 1 — INTRODUCTION

Seven standard series are identi­fied by this two-digit block. See
Table 1.1 for characteristics of
each series.

2 2 = 22 Series (8 to 14 µm)
4 3 = 43 Series (3.43 ±0.07 µm)
4 4 = 44 Series (8 to 14 µm)
4 5 = 45 Series (3.7 to 4.0 µm)
4 6 = 46 Series (2.0 to 2.6 µm)
4 7 = 47 Series (4.8 to 5.2 µm)
4 8 = 48 Series (7.5 to 8.5 µm)

22 or 44 SERIES

02F=000 to 0200°F
05F=000 to 0500°F
10F=000 to 1000°F

01C=000 to 0100°C
02C=000 to 0250°C
06C=000 to 0600°C

45 SERIES

1 5 F = 500 to 1500°F
2 5 F = 500 to 2500°F

0 8 C = 300 to 0800°C
1 3 C = 300 to 1300°C

46 SERIES

1 0 F = 500 to 1000°F
1 4 F = 600 to 1400°F

0 6 C = 250 to 0600°C
0 8 C = 350 to 0800°C

47 SERIES

1 0 F = 200 to 1000°F
1 5 F = 500 to 1500°F
2 5 F = 500 to 2500°F

0 6 C = 100 to 0600°C
0 8 C = 300 to 0800°C
1 3 C = 300 to 1300°C

43 SERIES

0 4 F = 120 to 0400°F*
0 6 F = 200 to 0600°F
1 0 F = 300 to 1000°F

02C=050 to 0200°C*
0 4 C = 100 to 0400°C
0 5 C = 150 to 0500°C

*Restrictions:

Case operating temperature range

50 to 113°F (10 to 45°C);

Sudden ambient temperature change

(up or down) of 10°C (18°F) will
cause noticeable errors until the
instrument temperature stabilizes.

Minimum response time setting

10 seconds for target temperatures
from 120 to 300°F (50 to 150°C);

Minimum emissivity setting 0.5.

48 SERIES

06F=000 to 0600°F**
1 5 F = 500 to 1500°F
2 5 F = 500 to 2500°F

03C=000 to 0300°C**
0 8 C = 300 to 0800°C
1 3 C = 300 to 1300°C

**High Resolution versions may require
higher response time settings.

Standard temperature ranges
available in each MODLINE 4
Series are listed below:

BLOCK A Series Designation BLOCK C Optical Resolution

Optical Resolution relates to the
circular area viewed (Spot Size) at
any given distance from the front
of the MODLINE 4. See diagram
and data below.

0 = Standard Resolution
1 = High Resolution
2 = Very High Resolution

BLOCK B Temperature Range

BLOCK B

Temperature Range

(continued)

MODEL NUMBER

A

Series

Temp. Range Opt. Res. Output Enclosure

B C D E

1–5

BLOCK D Output

Standard Modline 4 output is
4-20mA, linear, corresponding
to the temperature range. Peak
Picker is optional (standard with
Series 22).

0 = 4 to 20 mA
1 = 4 to 20 mA with

Peak Picker

BLOCK E Enclosure

Standard Enclosure is an
aluminum casting with NEMA 4
rating (Series 43 through 48).

Water-cooled Enclosure has a
built-in air purge.

0 = Standard Enclosure
1 = Water-cooled Enclosure

Please note: A “9” in any
block means the instrument
has been specially modified.
Refer to Section 1.7 for
details of the modification.

Section 1 – INTRODUCTION

1.5 MODEL IDENTIFICATION

Note the model and serial numbers on the side
plate of the sensor. Unscrew the back cover
to make sure the model and serial numbers on
the identification plate match those on the
packing slip and on the side plate. The model
number digit is explained below.

Example:

This model number designates a series
44 instrument with a temperature range
of 0 to 100°C and high optical resolution.
Output is 4 to 20 mA (peak picker included)
and the instrument has a standard
enclosure.

1-6

Model 44-01C-1-1-0

®

1–7

1.6 SPECIFICATIONS

The following specifications are common to all Series of MODLINE 4:

Operating Wavelength Region: Varies by Series (see Table 1.1)

Emissivity Range: Adjustable from 0.10 to 0.99 in 0.01 increments

Power Supply and Load Requirements: Input voltage: 24V direct current (dc) nominal16V direct

current (dc) minimum to 40V direct current (dc) 20mA
maximum. In order for the MODLINE 4 to meet

European Electromagnetic Compatibility Directive,

a CE version power supply is required.

Load resistance: ≤1 ohm at 16 to 24V direct current;
1200 ohms at 40 V direct current (see Section 2.4 for
additional information)

Fuse Rating: For customer supplied power supplies, the power supply

must be fused such that at 40V direct current the current
(I) level must be less than 4 amps. At 16V direct current
the current (I) cannot exceed 8 amps and the power
supply total output must not exceed 150 VA.

Section 1 — INTRODUCTION

Output Current: 4 to 20 mA direct current

Response Time: Continuously adjustable from approximately

(to 95% of any change in input) 0.15 sec to 10 sec

Peak Picker Decay Range: Continuously adjustable from approximately

(for models with Peak Picker) 15 sec to 30 min for full-scale decay

Humidity Limits: 0 to 90% non-condensing

Enclosure Material: Aluminum

Weight: Standard Enclosure: 2.6 lbs (1.2 kg)

Water-cooled Enclosure: 20 lbs (9.25 kg)

Section 1 — INTRODUCTION

The following specifications differ for Series 22 as compared to Series 43 through 48:

Series 43 through 48 Series 22

Calibration Accuracy: Within 0.75% of full-scale Within 1.0% of full-scale

temperature or 3 °F (1.7 °C), temperature or 5 °F (2.8 °C),
whichever is greater
For the 43-02C and 43-04F:
within 0.75% of full-scale
temperature or 4°F (2.3°C)
whichever is greater

Repeatability: 0.3% of full-scale temperature 0.5% of full-scale temperature

Temperature Coecient: ≤0.015%* of span per °F change ≤0.020% of span per °F change

from nominal value of 77 °F from nominal value of 77 °F
over range of 32 to 150 °F over range of 32 to 130 °F

≤0.027%* of span per °C change ≤0.035% of span per °C change
from nominal value of 25 °C from nominal value of 25 °C
over range of 0 to 66 °C over range of 0 to 54 °C

whichever is greater

Case Operating Standard enclosure: Standard enclosure:

Temperature Range: 32 to 150 °F (0 to 66 °C) 32 to 130 °F (0 to 54 °C)

(see previous page for exceptions)

Water-cooled enclosure: Water-cooled enclosure:
32 to 400 °F (0 to 204 °C) 32 to 400 °F (0 to 204 °C)

Environmental Rating: NEMA 4 NEMA 4

Optical Centering: Optical axis within 1 ° of Optical axis within 2 ° of

mechanical center axis (within mechanical center axis (within

0.2 in. per foot or 17 mm per 0.4 in. per foot or 33 mm per
meter separation distance) meter separation distance)

*For Series 43-04F: ≤ 0.05% per °F

*For Series 43-02C: ≤ 0.09% per °C

1–8

1–9

Section 1 — INTRODUCTION

1.7 PRODUCT MODIFICATIONS

There are no special modifications in this instrument. It is standard in all respects.

Section 2 – INSTALLATION

2.1 INTRODUCTION

MODLINE 4 gives you the capability of building a
custom-made temperature monitoring system for
your process, If you follow the simple guidelines
described in this section, you system will give
accurate, trouble free service.

The MODLINE 4 is compatible with most 4 to 20
mA devices used in industry today. You can select
a variety of indicators, recorders and other devices
to complete your system. Combine these devices
in series if you like or combine groups of MODLINE
4’s and switch them manually or automatically to
monitor key checkpoints in the process. As long
as your system stays within the MODLINE 4 speci­fications, you will get good results. Most of the
descriptions are based on the use of optional
IRCON components. However, the descriptions
also apply to any other devices that are compatible
with the MODLINE 4 system.

- Model PS4-24 Power Supply

- TV-VIEW-VAAC Digital Indicator
Power Supply

2. 2 BASIC SYSTEM

Fig. 2.1 illustrates a simple system consisting of the
MODLINE 4, a Digital Meter and a Power Supply.
These components form a continuous current loop.

System power is provided by the Power Supply which
provides a DC output typically between 16 and 40 V
direct current. AC line voltage is used to operate
to operate the supply.

Loop current is determined by the MODLINE 4 which
is calibrated to provide a 4 to 20 mA output. this
current flows through all series loop components.
It varies with target temperature over the full
temperature span of the instrument. For example,
an instrument with a temperature span of 500 to
1500°F will have a 4 mA output when viewing a
500°F target. The output increases to 20 mA when
viewing a 1500°F target. The output is a linear
16 mA span, from 4 to 20 mA, over the instrument
temperature range as illustrated in the Fig. 2.1 curve.

®

2-1

Section 2 – INSTALLATION

2.3 SUPPLY AND LOAD REQUIREMENTS

The MODLINE 4 operates at any supply voltage
between 16 and 40 volts direct current. If you
exceed the 40-volt upper i mit, you stand a chance
of damaging the MODLINE 4 sensor. If you go
below the 16-volt lower limit, the MODLINE 4
simply will not work.

If you furnish you own components, make sure
they meet MODLINE 4 requirements. For a
power supply, important specifications to look
for are supply voltage and current capacity. For
indicators, recorders, and other load elements,
pay strict attention to the load resistance and,
of course, the zero scale and full scale currents.

Part of the power supply voltage is dropped
across the load and is not available for the
MODLINE 4. In figure 2.1, for example, suppose
the analog indicator has a resistance of 7 ohms.
At the full scale current of 0.02A, the voltage
drop across the indicator will be:

E = IE = 0.02 x 7 = 0.14 V

If the power supply voltage is 24 V, the MOD­LINE 4 operating voltage at maximum current
will be 24 – 0.14 = 23.86 V, well above the
required minimum of 16 V.

2-2

Table 2.1 shows how load voltage increases with
load resistance. As load resistance increases, you
need more DC supply voltage to cover the load
voltage and still leave enough to operate the
load voltage and still leave enough to operate the
MODLINE 4.

Use Table 2.1 (see following page) as a guide in
selecting your power supply. Be sure to total up all
load resistance in your lood and add cable
resistance if it will have a noticeable effect on loop
resistance. If you plan to operate several indicators
or other devices in the series, be sure to use toe
TOTAL series resistance in your calculations (see
figure 2.2 for an example).

NOTE: Connecting cable wires contribute a certain
amount of resistance which adds to the load
resistance. However, cable resistance per foot is
usually small, and a cable run of 1500 feet will add
no more than a few ohms to the circuit.

®

Section 2 - INSTALLATION

2.4 MULTIPLE LOAD SYSTEM

In Fig. 2.2, a recorder, analog indicator and controller are
connected in a series in the loop. The 4 to 20 mA current
determined by the MODLINE 4 flows through all of these
load elements, producing voltage drops proportional to the
resistance of each load element. The total load voltage is
the sum of these voltage drops plus the drop across the
connecting wires.

Assume the resistances are as indicated in Fig. 2.2:

With 8 V dropped across the load elements and cables,
a supply voltage of at least 24 V is needed to ensure the
required 16 V minimum for the MODLINE 4 (see table 2.1 –
Minimum DC Supply Requirements).

IMPORTANT

exceed 40 volts!

2-3

®

FIG. 2.2 MODLINE 4 MULTIPLE LOAD ELECTRICAL CIRCUIT

TABLE 2.1

MINIMUM DC SUPPLY REQUIREMENTS

FOR MULTIPLE LOADS

Total Load Total Load Minimum DC
Resistance Load Supply
(ohms) (volts) (volts)

≥ 50 1 17
100 2 18
200 4 20
300 6 22
400 8 24
500 10 26
600 12 28
700 14 30
800 16 32
900 18 34
1000 20 36
1100 22 38
1200 24 40

: DC supply voltage must never

Section 2 - INSTALLATION

2.5 MULTIPLE LOOP SYSTEMS

Fig. 2.3 is an example of a multiple loop system. Two
MODLINE 4 loops are operated from a single power
supply. An arrangement of this type is suitable for measuring
temperatures at two or more stations with an independent
readout for each station. The advantage is the economy of a
single power supply for all loops.

An important consideration in this system is the current capacity
of the power supply. For example, if loops A and B in Fig. 2.3
are both measuring full scale temperature, currents 1
will be 20 mA for a total supply current of 40 mA.

The IRCON model PS4-24 power supply has a current
capacity of 200 mA giving it the capability of powering up to
ten MODLINE 4 loops.

2. 6 SWITCHED MODLINE 4 SYSTEM

Sometimes you can gain economy or efficiency by switching
between circuit components. Fig 2.4 shows how this idea might
be used to switch a single indicator and power supply to either of
two MODLINE 4 units. This time-sharing system permits
measuring the temperature at either of two stations on a single
indicator.

The switching system shows consists of a double pole, double
throw switch which allows simultaneous switching of both
MODLINE 4 output leads. The switch can be a manual or
an automatically controlled switch or a set of appropriate
relay contacts.

NOTE: These illustrations give you an idea of how
versatile MODLINE 4 can be in system design. Our systems
give you just about any results you’re looking for. If you need
qualified help in choosing components or planning your
system, contact IRCON Applications Engineering.
.

2-4

®

A and 1B

FIG. 2.3 MULTIPLE LOOPS OPERATED
FROM SINGLE SUPPLY

FIG. 2.4 SWITCHED MODLINE 4 UNITS

2–5

Section 2 — INSTALLATION

2.7 PRE-INSTALLATION NOTES

2.7a. General

The MODLINE 4 is a fixed focus instrument. The
optical components are factory aligned to provide
a fixed optical pattern which determines the size of
measuring area, or what is called the "spot size" at
any given distance from the front flange of the unit.
This is the area the detector in the MODLINE 4 will
"see" on the target surface.

Every step has been taken to ensure accurate
measurements with excellent repeatability. the
optical and electronic systems are factory calibrat­ed against precision laboratory standards to ini­tially set their accuracy specification.

If the MODLINE 4 is installed with reasonable
care, it will provide accurate temperature measure­ments and a long, trouble-free operating life.

Modline 4 instruments are available in standard of
water-cooled castings as shown in Fig. 2.5. The
optical and electrical systems are essentially the
same in both versions. Any differences that affect
installation or operation will be pointed out in the
following instructions.

WATER

FITTINGS

MOUNTING

FLANGE

MOUNTING

FLANGE

CONDUIT

HUB

CONDUIT

HUB

AIR FITTING

LENS

LENS

FIG. 2.5 – MODLINE 4 STANDARD AND WATER-COOLED CASTINGS

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 a

redundant device or system that will initiate a
safe process shutdown in the event that this

instrument should fail. The user should follow

NEMA safety guidelines in the appendix.

!

CAUTION

!

All MODLINE 4 Series instruments use multilayer
coatings on their lenses to define their spectral prop­erties and to increase optical transmission. Although
these coatings satisfy military specifications for durabili­ty, all coated lenses are susceptible to damage from
harsh environments.

Whenever moisture, oils, or active chemicals con­dense on a coated lens, the optics become stained.

The stains are difficult to clean and tend to break
down the coating. Use of an air purge will help prevent
condensation and damage in harsh environments, but
only the purge is supplied with clean air.

If necessary, install air filters in the air path.

NOTICE

2–6

Section 2 — INSTALLATION

2. 7b. Mechanical Mounting

The MODLINE 4 may be mounted either by the
front flange or by the mounting pad at the bottom
of the casting. Mounting accessories are available
as described in Section 5.

Procedures for aligning the unit on target are pro­vided in Section 2.10.

If the proposed mounting surface is at earth
ground potential, you can mount the Sensor direct­ly to this surface with the bolts supplied. If the sur­face is not at earth ground potential, insulate the
Sensor casting from the surface by inserting an
insulating gasket and using insulating mounting
hardware. See Section 2.15 for grounding details.

NOTE: Maximum Signal Cable length is 3000 ft
(1000 m). Plan your mounting location and cable
route accordingly.

2.7c. Ambient Temperature

STANDARD CASTING
The MODLINE 4 with a standard casting has an

operating case temperature range of 32 to 150°F
(0 to 66°C).* If you allow the temperature to go
beyond these limits, incorrect temperature indica­tions or damage to the instrument may result.

If you think the case temperature will approach the
upper temperature limit due to ambient conditions,
consider some type of auxiliary cooling. An IRCON
Model WA-3 Water Cooling Accessory is one solu­tion. (See Section 5 for details on this and other
accessories.)

A heat shield between instrument and target as
shown in Fig. 2.7 is another possible solution to
excessive ambient temperatures. Air cooling by
means of a blower fan or IRCON AA-3 Air Purge is
another option. Call IRCON for other suggestions.

If the MODLINE 4 is to be located in the cold envi­ronments where its temperature may go below the
lower temperature limit, consider some form of
heating. For example, install the instrument in a
temperature controlled enclosure or wrap it with
electrical heater tape.

*Operating case temperature range for Series 43­04F and 43-02C are 50 to 113°F and 10 to 45°C,
respectively.

Operating case temperature range for all Series 22
is 30 to 130°F (0 to 54°C).

2.7e. Spot Size and Resolution

Observe the guidelines in Section 2.9 regarding
spot size and resolution. Above all, make sure the
target surface is at least twice the spot size (or the
spot size is less than half the target size) at the
viewing distance.

WATER-COOLED CASTING
A MODLINE 4 with a water-cooled casting can

operate in ambient temperatures up to 400°F
(200°C) with a minimum water flow rate of 20
gal./hr (75 liter/hr) of tap water at less than 75°F
(24°C).

CABLE TEMPERATURE LIMITS
Maximum temperature rating of the Signal Cable is

220° F (100°C) for standard PVC-covered cable or
400°F (200°C) for IRCON-supplied silicone rubber­covered cable. Plan the cable routing accordingly.

2.7d. Air Purge

If dust, oil, vapors, etc. collect on the lens, low tem­perature indications will result. For instruments with
standard castings, use an IRCON Model AA-3.

Air Purge to avoid the problem; a MODLINE 4 with
water-cooled casting has an integral air purge.

NOTE: For Series 43-04F or 43-02C do not use a
Model AA-3 Air Purge with a Model WA-3 Water
Cooling accessory. With these two accessories
combined, the front edge of the AA-3 will obstruct
the Cone of Vision and cause errors in the temper­ature readings.

A supply of clean, dry instrument air or filtered dry
plant air at a flow rate of 6 ft 3/min (0.17 m 3/min) is
recommended.

Section 2 — INSTALLATION

2.7f. Intervening Objects

Errors can be caused by objects between the
MODLINE 4 and target. Any such object that hap­pens to be inside the Cone of Vision will be visible
to the detector, and will cause an error in the tem­perature reading.

Before selecting the mounting location, consider
the sight path just as you do when you aim a cam­era to take a photograph. Try to picture the Cone
of Vision, is within the cone, select a different view­ing angle.

2.7g. Reections

Reflections from other radiating objects represent
a potential source of error in your temperature
readings. The total radiation seen by the MOD­LINE 4 will be a combination of intrinsic radiation
plus reflected radiation.

Examples of interfering sources are hot furnace
walls and heating elements that are hotter than the
target object.

Most reflection problems can be eliminated by
changing the viewing angle or shielding the reflec­tions. Suggestions for anticipating and eliminating
common ref lect ion problems are provided in
Section 6. However, if you are faced with unusual
reflection problems, call IRCON Technical Service
for recommendations.

2,7h. 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, be careful in
selecting the window material. The material must
have good transmission characteristics in the
wavelength band of the MODLINE 4 series.

A guide to appropriate windows for all MODLINE 4
Series is provided in Section 3.4.

WA-3

WATER COOLING

ACCESSORY

AA-3

AIR PURGE

ACCESSORY

FIG. 2.6 – MODLINE 4 (STANDARD ENCLOSURE)

WITH AIR PURGE and WATER

COOLING SYSTEM

HEAT

ECRAN

SHIELD

TROU DE

SIGHT HOLE

MODLINE 4

NOTE: Sight hole must be large enough so heat shield

VISEE

MODLINE 4

does not obstruct sight path. (See Sections 2.9
and 2.10). Also, MODLINE 4 must not contact
heat shield.

THERMIQUE

PRODUIT CHAUD

HOT TARGET

FIG. 2.7 – MODLINE 4 (STANDARD ENCLOSURE)

PROTECTED BY HEAT SHIELD

2–7

2–8

Section 2 — INSTALLATION

2.8 OPTICAL CHARACTERISTICS

The detector responds to infrared radiation in a
area indicated by the CONE OF VISION in Fig.

2.8. It will measure temperature of objects inside
this cone. It will not measure objects outside the
cone.

The spot size (d) is the diameter of the cone at a
particular separation distance (D). Separation dis­tance is the distance between the front of the sen­sor and the target object whose temperature is
being measured. In Fig. 2.8, d1and d2represent
the spot size at two different distances D1and D

2.

Correct temperature measurement requires that
the field of view be filled entirely by the target. Fig.

2.9 illustrates this ideal condition. Good practice is
to make sure that the target surface is at least
twice the spot size at the spacing used. This gives
you a "cushion" for shifts in MODLINE 4 or target
position, and for the small tolerances in true vs.

design diameter of the Cone of Vision that are
inherent in all optical pyrometers.

If the target is not larger than the spot size, the
detector will see infrared radiation from other
objects in its field of view as well as the target.
This causes incorrect temperature indications.

d2

D2

d2

D1

NOTE: See Table 2.2 for details on finding Spot Size at any given SEPARATION Distance.

AXE OPTIQUE

ALIGNE SUR LE CENTRE

DE LA CIBLE

TAILLE DU SPOT

INFERIEURE A LA TAILLE

DE LA CIBLE

FIG. 2.8 – SPOT SIZE VS. SEPARATION DISTANCE

FIG. 2.9 – IDEAL RESOLUTION AND AIMING PROVIDE MAXIMUM MEASUREMENT ACCURACY

TARGET SIZE

MORE THAN TWICE

SPOT SIZE

OPTICAL AXIS

AIMED AT

CENTER OF TARGET

2–9

Section 2 — INSTALLATION

TABLE 2.2 – SPOT SIZE VS. SEPARATION DISTANCE

Spot Size/Separation Distance relationships are
given in Table 2.2. As shown in the table, MOD­LINE 4 models are available with Standard
Resolution, High Resolution and Very High
Resolution.

NOTE: Series 22 instruments are not available
with Very High Resolution; Series 43 instruments
are available only with Standard Resolution.

The Resolution is designated by model number
Block C labeled on the back of the identification
plate on the side of a standard casting.

A 0 designates Standard Resolution; a 1 desig­nates High Resolution; and a 2 designates Very
High Resolution.

Determine the Resolution rating (Standard, High or
Very High Resolution) of your instrument, then
refer to Table 2.2 for details on the optical charac­teristics.

0 1.00
15 1.25
30 1.5
60 2.0
70 2.5

100 4.0
150 6.5
200 9
300 14
500 24
700 34

1000 49

025
300 30
700 37

1000 42
1500 50
2000 75
3000 125
5000 225

7000 325
10000 475
15000 725
20000 975

Formula

If D > 8 inches or 203 mm
d

inches

= 0.1 (D – 8) + 0.3

dmm= 0.1 (D – 203) + 8

For Sensors with water-cooled castings, multiply
spot size (d) from table or formula by 1.1
Example: If d is 8.2 inches per table or diagram,
then d for water-cooled casting is:

d = 8.2 x 1.1 = 9.02 inches

Dd

mm mm

8 0.3
15 1
25 2
35 3
45 4

203 7.6
381 25.4
635 50.8
889 76.2

1143 101.6

VERY HIGH RESOLUTION

Dd

inches inches

Dd

mm mm

Notes: 1. Series 22 not available

with very high resolution.

2. Series 43 available only
with standard resolution.

D

d

0 to 15 1.0

20 1.7
30 3.0
50 5.6

70 8.2
100 12
150 13
200 25
300 38
500 64
700 90

1000 123

0 to 380 25

500 41

700 67
1000 106
1500 171
2000 236
3000 366
5000 626
7000 886

10000 1280
15000 1930
20000 2580

Reference Diagram
(not to scale)

d = Spot Size
D = Separation Distance

Formula

If D > 15 inches or 380 mm
d

inches

= 0.13 (D

inches

– 15) + 1.0

dmm= 0.13 (Dmm– 380) + 25

Example:

If D = 45 inches,

d = 0.13 (45 – 15) + 1.0

= 0.13 (30) + 1.0 = 3.9 + 1.0
= 4.9 inches
= 5 inches

For Models 43-04F and 43-02C only:

d

inches

= 0.17 (D

inches

) + 1.0

d

inches

= 0.17 (Dmm) + 25

STANDARD RESOLUTION

HIGH RESOLUTION

Dd

inches inches

Dd

mm mm

Formula

If D > 60 inches or 1500 mm
d

inches

= 0.05 (D

inches

– 60) + 2.0

dmm= 0.05 (Dmm– 1500) + 50

If D < 60 inches or 1500 mm
d

inches

= 0.017 (D

inches

) + 1.0

dmm= 0.017 (Dmm) + 25

Example:

If D = 90 inches,

d = 0.05 (90 – 60) + 2.0

= 0.05 (30) + 2.0 = 1.5 + 2.0
= 3.5 inches

Dd

inches inches

2–10

Section 2 — INSTALLATION

2.9 ALIGNING THE MOUNTING AXIS

A MODLINE 4 is "sighted" on the target object by
aligning its mechanical axis so that its mechanical
centerline intersects the target at the center of the
desired viewing area. The optical axis is aligned
very closely with the mechanical axis. Thus, by
aligning the mechanical axis you are also aligning
the Cone of Vision so it is centered on the desired
viewing area.

Where very large target surfaces are involved (tar­get size many times larger than spot size), align­ment can be as simple as sighting along the top or
side of the casting and aiming it so it points rough­ly at the center of the target. For more accurate
alignment, refer to the following instructions.

BASE MOUNTING

If you plan to mount the MODLINE 4 by its base
pad, project a straight line from the bottom surface
of the base pad to a point below the center of the
desired point of measurement on the target as
shown in Fig. 2.10. For a standard casting this
point should be 2.1 in. (53 mm) below the center of
the measurement point. For a water-cooled casting
it will be 3.3 in. (84 mm) below the center of the
measurement point. This establishes your vertical
alignment.

Align the mounting hole positions on the mounting
support 50 they form a straight line aimed at the
center of the desired measuring point on the target
surface. This establishes your horizontal align­ment.

Note that these alignment axes and prepare the
mounting support. When the base pad is bolted to
the mounting support, the optical axis will be cen­tered on the desired viewing area.

FRONT FLANGE MOUNTING

The second mounting method is to use the front
flange of the MODLINE 4 as the mounting surface.
The instrument's optical axis, which is coincident
with the mechanical centerline of its casting, is per­pendicular to the front flange mounting surface.
The instrument should be mounted such that the
optical axis projects to intersect the target surface
at the center of the desired viewing area.

This method requires that you visualize a straight
line from the center of the lens to the desired cen­ter point on the target. This line is the optical axis.
Erect a mounting support with surfaces perpendic­ular to this axis. When the front flange is placed
against this mounting support, its line of sight will
be properly aligned with the target.

NOTE: The diagram shows the MODLINE 4 front
flange parallel to the target surface, and the optical
axis exactly perpendicular to the surface. However,
you can mount the MODLINE 4 so the optical axis
is at some other angle to the target. In this case
the "spot" will be elliptical rather than circular, but
as long as the target surface is large enough to
accommodate the widest axis of the spot, this will
not present a problem.

2–11

Section 2 — INSTALLATION

90° 90°

VUE DE COTE

VUE DE COTE

CIBLE

BOITIER REFROIDI

A. MONTAGE PAR LA BASE

B. MONTAGE PAR LA FACE AVANT

BOITIER STANDARD

VUE DE FACE

VUE DE DESSOUS

VUE DE DESSUS

C

L

C

L

C

L

C

L

C

L

C

L

BASE DE MONTAGE

désigne l'axe mécanique

NOTE:

L'axe potique est en coincidence aves
l'axe mecanique a 1° maximum (17 mm
par metre de distance).

84 mm

53 mm

FIG. 2.10 – DETERMINING ALIGNMENT OF MOUNTING AXIS

TARGET

BASE PAD

designates mechanical centerline

TOP VIEW

SIDE VIEW

STANDARD CASTING

WATER COOLED CASTING

SIDE VIEW

A. BASE MOUNTING ALIGNMENT

B. FLANGE MOUNTING ALIGNMENT

BOTTOM VIEW

FRONT VIEW

3.3” (84 mm)

Optical axis for Series 43 through 48 within 1°
of mechanical axis (within 0.2” per foot sepa­ration distance). For Series 22, optical axis is
within 2° of mechanical axis (within 0.4” per
foot separation distance, or 33 mm per meter
separation distance.

2–12

Section 2 — INSTALLATION

2.10 MOUNTING PROCEDURE

(Standard Casting)

These instructions apply to instruments with stan­dard castings. Instructions for mounting water­cooled castings are provided in Section 2.12.

The MODLINE 4 is ordinarily mounted by the front
circular flange or base mounting pad to a support
which has been previously installed to provide the
correct line of sight. Mounting dimensions are
given in Fig. 2.11.

The instrument may be mounted in any orientation
that will afford a clear, unobstructed line of sight
and a reliable support.

BASE MOUNTING

If you are mounting the MODLINE 4 with no acces­sories, attach it to the fixture of your choice using
three 1/4–20 NC bolts. Observe grounding precau­tions in Section 2.15.

In some cases freedom of final adjustment in sight­ing may be desirable. In these cases the Swivel
Mounting Base, Model SB-1, is recommended as
an optional accessory. See Section 5 for a descrip­tion of this accessory.

If you are using accessories such as the Model
WA-3 Water Cooling Accessory and/or Model AA-3
Air Purge, you can assemble the MODLINE 4 and
accessories, then mount the complete assembly
by means of the MODLINE 4 base pad. See Fig.

2.12 for an example of this arrangement.

FLANGE MOUNTING

The MODLINE 4 can be flange mounted to mount­ing supports or accessories by means of three 5/1
6–18NC bolts supplied. The flange cutouts and
special bolts provide a 'quick disconnect" feature
that makes it easy to remove the MODLINE 4 for
lens cleaning and other service routines. The
mounting procedure is illustrated in Fig. 2.13.
Observe the grounding precautions in Section

2.15.

2–13

Section 2 — INSTALLATION

96.5

139

0.5"
NPT

135.4

101.6

53.3

58.4

0.25 - 20 UNC
(3 PLACES)

29.2

28.7

22.4

75.7

NOTE:

désigne l'axe mécanique

A. Place flange cutouts
over 5/16–18 NC bolts
installed in mount or
accessory.

B. Rotate MODLINE 4 so
bolts capture flange,
and tighten bolts.

WA-3

WATER COOLING

ACCESSORY

AA-3

AIR PURGE

ACCESSORY

FIG. 2.11 – DIMENSIONS AND CLEARANCES OF STANDARD CASTING

FIG 2.12 – MODLINE 4 (STANDARD CASTING)

WITH AIR PURGE AND WATER

COOLING ACCESSORIES

FIG. 2.13 – FLANGE MOUNTING PROCEDURE

designates mechanical centerline

5.33”

135.4 MM)

2.99”

(75.9 mm)

2.10”

(53.3 mm)

2.30 “
(58.4 mm)

0.88”

(22.4 mm)

5.08”

(139.0 mm)

4.00”

(101.6 mm)

1.15”

(29.2 mm)

0.25 - 20 UNC
(3 PLACES)

1.13”

(28.7 mm)

0.5”
NPT

3.80”

(96.5 mm)

2–14

Section 2 — INSTALLATION

2.11 MOUNTING PROCEDURE

(Water-Cooled Casting)

These instructions apply to instruments with water
cooled castings. Instructions for mounting standard
castings are provided in Section 2.11.

The MODLINE 4 is ordinarily mounted by the front
circular flange or base mounting pad to fixed
brackets which have been previously installed to
provide the correct line of sight. Mounting dimen­sions are given in Fig. 2.14.

The instrument may be mounted in any orientation
that will afford a clear, unobstructed line of sight
and a reliable support, and also allow access to
the water, air and cable fittings.

BASE MOUNTING

If you are mounting the MODLINE 4 with no acces­sories, attach it to the fixture of your choice using
three 1/4–20 NC bolts. Observe grounding precau­tions in Section 2.15.

For freedom of final adjustment in sighting, the
Swivel Mounting Base, Model SB-3, is recom­mended as an optional accessory. See Section 5
for a description of this accessory.

FLANGE MOUNTING

The MODLINE 4 can be flange mounted to mount­ing supports or accessories by means of three
5/16–18 NC bolts supplied. The flange cutouts and
special bolts provide a "quick disconnect' feature
that makes it easy to remove the MODLINE 4 for
lens cleaning and other service routines. The
mounting procedure is illustrated in Fig. 2.15.
Observe the grounding precautions in Section

2.15.

FIG. 2.14 – DIMENSIONS AND CLEARANCES OF WATER-COOLED CASTING

7.40

(187.96 mm)

7.15

(181.61 mm)

2.98”

(75.7 mm)

6.66”

(169.16 mm)

6.81”

(172.97 mm)

4.00”

(101.60 mm)

3.50”

(88.90 mm)

3.68”

93.47 mm)

3.31”

(84.07 mm)

3-0.19” (4.8333 mm) DIA.
Bleed Holes. Spaced 120°

2.75”

(69.85 mm)

1/2” NPT

Air Inlet Connection

1/2” NPT
Water Inlet/Outlet
Connection

1/4” – 20 UNC

(3 Mtg. Holes)

1.125”

(28.57 mm)

1.125”

(28.57 mm)

4.06

(103.12

mm)

0.9”

(22.86

mm)

5.96”

(151.38 mm)

1/2” NPT
Electrical
Connection

2–15

Section 2 — INSTALLATION

A. Place flange
cutouts over
5/16–18 NC
bolts installed
in mount or
accessory.

B. Rotate MODLINE 4 so
bolts capture flange, and
tighten bolts.

FIG. 2.15 – FLANGE MOUNTING PROCEDURE

PRECAUTIONS

1. DO NOT loosen or remove screws holding
front or rear bell to main casting. This would
destroy factory seal, degrading performance
and creating possible leakage problems.

2. In closed loop water systems, install relief
valve with maximum pressure rating not to
exceed 75 psi (5.1 bar) to prevent possible
damage to MODLINE 4.

FIG. 2.16 – TYPICAL WATER AND AIR FLOW CONFIGURATIONS

WATER AND AIR REQUIREMENTS

Route water and air lines before installing the
MODLINE 4. Coolant water must flow to protect
the Sensor from high ambient temperature
whether the system is operating or not.

NOTICE

The chemical content of the coolant water must
be compatible with Sil Brass (CDA 87500) of the
casting to ensure normal operating life.

Fittings are provided for standard pipe threads or
hose fittings as indicated in Fig. 2.16. Direction of
water flow is not critical. However, if the MODLINE
4 is oriented so the water fittings are not level,
attach the inlet line to the lower of the two fittings.

COOLING WATER

Supply . . . . . . . . . . . . . . .Tap water (see Notice)

Flow rate . . . . . . . . . . . . .20 gal./hr (75 liters/hr)

Flow direction . . . . . . . . .Either

Temperature at inlet . . . .75°F (24°C) maximum*

Pressure inside

enclosure . . . . . . . . . . . . .Must not exceed 75 psi

(5.1 bar)

*Permits operation at ambient up to 400°F (200°C)

PURGING AIR

Supply . . . . . . . . . . . . . . .Clean, dry instrument air

or filtered dry plant air

Flow rate . . . . . . . . . . . . .6 ft

3

/min (0.17 m3/min)

Flow direction . . . . . . . . .Either

Temperature at inlet . . . .50 to 100°F (16 to 31°C)

OPEN LOOP WATER SYSTEM

CLOSED LOOP WATER SYSTEM

WATER
SUPPLY

AIR
SUPPLY

MODLINE 4

WATER COOLED

CASTING

(FRONT VIEW)

MODLINE 4

WATER COOLED

CASTING

(FRONT VIEW)

NOTE: Observe drain stream.
Typical stream should be
about the diameter of an
ordinaray lead pencil.

SUMP

SUMP

WATER
SUPPLY

AIR
SUPPLY

RELIEF VALVE:
Maximum pressure
rating not to
exceed
75 psi (5.1 bar)

2–16

Section 2 — INSTALLATION

CIBLE

CONE DE

VISEE

TROU DE

VISEE

MODLINE 4

HUBLOT

90°

e

e

MAX = 45°

CIBLE

2.12 SPECIAL MOUNTING SITUATIONS

Sometimes it is necessary to view a target through
a sight hole, or through an aperture sealed by a
window. There are also times when the physical
restraints of the process environment make it diffi­cult, if not impossible, to mount the MODLINE 4 for
a convenient, head-on view of the target. These
and other 'special situations" call for special
mounting procedures.

Fig. 2.17 is an example of a MODLINE 4 sighted
on a target through a sight hole cut for the pur­pose. A sight window is shown mounted on the
sight hole.

Two special considerations immediately present
themselves in this situation:

1. The sight hole diameter must be large enough
to allow the instrument to view the target. Never
obstruct any part of the Cone of Vision.

2. The window must be able to transmit the
infrared energy. Consult Table 3.1 of Section 3
to determine the proper material for your MOD­LINE 4. If a window is used, it must be kept
clean or low temperature indications will result.

Acute viewing angles can present problems of
reduced emissivity values, particularly if you are
dealing with smooth target surfaces.

Figure 2.18 shows the permissible angles when
viewing smooth surfaced objects such as metals,
glass or plastics. Angles of up to 45° from the per­pendicular will not appreciably affect the measure­ment. Angles greater than 45° should be avoided.
An increase in reflectance occurs when smooth
surfaces are viewed at large angles, and conse­quently the target emissivity decreases.

These are just a couple of special situations and
the things to watch for in dealing with them. If you
run into these or other situations that may cause
problems, consult IRCON Applications
Engineering. Our many years of experience in fac­ing and solving temperature measurement prob­lems can be of great benefit!

NOTE: Section 6 offers some application guides
that may be helpful.

FIG. 2.17 – VIEWING TARGET THROUGH

SIGHT HOLE AND WINDOW

FIG. 2.18 – VIEWING ANGLE LIMITATIONS

FOR SMOOTH TARGET SURFACES

SIGHT

HOLE

WINDOW

TARGET

TARGET

MODLINE 4

CONE OF

VISION

Section 2 — INSTALLATION

2.13 CABLE SELECTION and MODLINE 4 WIRE TERMINATIONS

SPECIAL INSTRUCTIONS FOR EEC
COMPLIANCE

In order for the MODLINE 4 to be immune to RF
susceptibility, either all wiring to the sensing head
must be run in conduit or a single overall shielded
cable must be used. The shield must be 360°, ter­minated at the sensing head using the special
cable shield grip adapter provided. To maintain
electromagnetic immunity, only Indicators and
Power Supplies that meet EMC Directive
and carry the CE Mark can be used
with the MODLINE 4.

SELECTING AND PLANNING CABLING

After you have mounted all system components,
proceed with the electrical wiring. We recommend
a three-conductor twisted cable with overall shield.
The most practical wire sizes to use for the signal
loop are 14- to 18-gauge.

If the instrument you have ordered has a peak
picker and you plan to wire an external peak picker
control switch, select a five-conductor twisted
cable with overall shield to feed through the cord
grip. A 18-gauge wire size is required to support
an external peak picker.

The longest run of wiring will usually be from the
MODLINE 4 to the Power Supply and Indicator.
Cable lengths up to 3000 ft (1000 m) are accept­able for most installations. (This limit on cable
length also applies to the peak picker wiring.)

However, make sure the cable resistance at the
length you plan to use between the MODLINE 4
and the power supply will not cause an excessive
voltage drop. As an example, a 3000-foot length of
18-gauge cable may develop a voltage drop of

0.65 V when carrying 20 mA full-scale current. The
power supply voltage must be sufficient to accom­modate this voltage drop and still supply normal
operating voltage for the MODLINE 4.

Keep the MODLINE 4 system wiring away from
high power or r-f wiring and avoid hot areas that
can damage the cable. If needed, high-tempera­ture cables are available that can withstand 400°F
(200°C).

INSTRUMENT AND WIRING ENCLOSURE

Cabling enters the MODLINE 4 through a conduit
hub threaded for 0.5-inch conduit. The cord grip
has a bushing (grommet) that accepts cable diam­eters from 0.225 to 0.350 in. (5.72 to 8.89 mm).

IMPORTANT: The cord grip assembly must be
tightened sufficiently following wiring installation to
provide the NEMA 4 rating of the MODLINE 4.

If you ordered your MODLINE 4 with the peak
picker option and are installing an external switch,
select a five-conductor twisted cable with overall
shield to feed through the cord grip.

NOTE: If plant practices or electrical codes require
the use of conduit, use the appropriate conduit fit­ting in place of the cord grip.

CAUTION

!

In order for the MODLINE 4 to meet EMC

Directive,the Indicators and Power

Supplies must also meet the Directive and carry

the CE Mark.

CAUTION

Risk of Personal Injury

!

2–17

2–18

Section 2 — INSTALLATION

FIG. 2.20 – CONNECT THE SERIES LOOP WIRES
TO THE MODLINE 4 TERMINAL STRIP: plus (+) and
minus (-), and EARTH GROUND TERMINAL SCREWS.

CONNECT

FIG. 2.19 – CORD GRIP WITH CABLING

GROMMET

CAP

COMPRESSION

SPRING

CONDUIT HUB

CABLE ROUTING FOR THE INSTRUMENT

Remove the back cover of the enclosure. Unscrew
by hand, or if the cover is sealed tightly, use a rod
or bar in the torquing slots (standard enclosure) or
against the torquing studs (water-cooled enclo­sure).

Thread the cables through the cord grip grommet
into the MODLINE 4 case. Figure 2.19 illustrates
proper assembly of the cord grip, grommet, and
cable. When assembling the parts of the cord grip,
you will thread components onto the cabling in
their specified order, which is as follows:

1. Hub cap and grommet

2. Compression spring

3. Connection housing

4. Conduit hub

Insert Wires

Prepare the series loop cable by stripping the two
wires. Leave enough of the braided shield exposed
so that the compression spring can make ade­quate contact. Attach the signal cable shield to
earth ground at the power supply end. Insert the
wires under the compression clamps on the termi­nal strip as shown in Fig. 2.20.

NOTE: For proper termination of your system
(including systems with multiple device loads),
refer to Section 2.15.

If you ordered your MODLINE 4 with a peak picker
option, refer to Section 2.16.

Section 2 – INSTALLATION

2-21

®

Section 2 – INSTALLATION

2-22

®

2–23

Section 2 — INSTALLATION

FIG. 2.23 – PEAK PICKER CABLE AND SWITCH WRING

+

–

EXTERNAL

SPST SWITCH

MODLINE 4

BACK PANEL

®

MOD.

S.N. SP.

+ +

––

99

ε

CRIMP

AND

SOLDER

SOLDER

PLUG COVER

CUT SHIELD HERE;

DO NOT TERMINATE

PEAK PICKER

PLUG WIRING DETAIL

1

2

+

–

1

2

SHIELD

2.15 PEAK PICKER WIRING

If you ordered the peak picker option and you are
planning to reset the peaked signal remotely, you
will need to wire to the peak picker plug and a
remote switch as it is shown in Fig. 2.25.

Customer-Supplied Items

Customer-supplied items needed to install the
peak picker are listed below.

• Wire: 5-conductor cable with overall shield (con­ductor should be at 18–22-gauge)

• Switch (for remote reset): SPST

• Wire clipper and soldering iron

To Install

To wire the peak picker plug and remote switch,
follow these steps:

1. Strip the two peak picker remote reset wires.

2. Thread the two wires through the plug cover.

3. Solder Wire 1 (see Fig. 2.25) to the center sol­der cup of the plug.

4. Solder Wire 2 (see Fig. 2.25) to the solder/
crimp lug and crimp.

5. Screw down the plug cover over wires.

6. Connect the cable shield to an external Earth
Ground at the switch end.

2–25

Section 2 — INSTALLATION

2.16 INSTALLATION CHECKLIST

To ensure accurate, reliable, and trouble-free operation, check your installation for the following:

❑ Ensure proper dc supply voltage is used.
❑ Check wiring polarity of system component connections.
❑ Ensure all loop components are calibrated for 4 to 20 mA and scaled for temperature range of the

MODLINE 4.

❑ Ensure that the loop for the load devices is grounded at only one point.
❑ Ensure temperature of MODLINE 4 case will not go beyond rated limits.
❑ Ensure MODLINE 4 has been properly grounded.
❑ Ensure proper window material has been selected for process sight window (if used).
❑ Ensure that the target fills the field of view of the MODLINE 4.
❑ Ensure that no obstructions are in the Cone of Vision.

Section 3– OPERATION

3.1 INTRODUCTION

The following instructions explain how to place the
MODLINE 4 system in operation. Most of these
instructions are related directly to IRCON components.
If you are using other components be sure to follow
any special instructions provided by the manufacturer.

For information and suggestions on various
measurement situations, refer to the Applications
Guide (Section 6) for your instrument series.

If you run into any problems, review the installation
procedures. Make sure you have completed all
wiring and observed all precautions. Refer to the
trouble shooting instructions in Section 4 if trouble
persists.

3.2 INITIAL ADJUSTMENT

Before turning on power, observe the control
settings on the back panel of the MODLINE 4 and
any indicators, controllers or other instruments in
the system. Fig 3.1 shows the location and brief
descriptions of the MODLINE 4 controls.

If the MODLINE 4 has a Peak Picker (Block D of
Model No. = 1), it must be in the Direct Mode for
the initial observations. The Peak Picker Plug
(Fig. 3.1, bottom) must be in its jack. If you have
wired an external switch to this plug as in Section

2.1 3, the external switch must be open.

3.3 EMISSIVITY SETTING

The emissivity (ε) control setting of the MODLINE
4 must match the emissivity of the material being
measured to obtain accurate temperature readings.

If you know the emissivity value of the target
material, set the ε control to the known value. You
are ready to proceed to the next section.

If you do not know the target emissivity, you can
determine it in several ways.

®

3-1

a. Refer to the tables in the Applications Guide
(Section 6). Set the emissivity control as
recommended for the material you plan to
measure.

b, In a test setup, imbed an accurate thermocouple
just below the front surface of a sample of the
material to be measured and heat the sample.
Simultaneously reading the temperature shown
by the thermocouple (in a stabilized temperature
condition) and observing the surface of the
MODLINE 4, adjust the emissivity control until
the meter reading obtained corresponds to the
thermocouple temperature.

c. In a test setup, apply a uniform coating of a material
with known emissivity to a part of the surface of
a sample of the material to be measured.

With the emissivity control set to the known
emissivity of the coating, heat the sample and
observe the temperature (in a stabilized tem­ perature condition) of the coated area, Now view
the uncoated surface and adjust the emissivity
control until you read the same temperature. The
new setting is the true emissivity of the uncoated
surface.

d. If you are unable to arrive at a suitable value,
contact IRCON Applications Engineering. We can
advise you of the correct emissivity setting from
either laboratory tests on the sample you submit
or from previous experience.

While all MODLINE 4 instruments are capable of
emissivity settings of 0.10 to 0.99, it is not always
adviseable to use the lower emissivity settings.

Section 3 — OPERATION

3–2

TABLE 3.1 – WINDOWS FOR MODLINE 4

SPECTRUM RECOMMENDED WINDOW

SERIES (µm) MATERIAL

1

TRANSMITTANCE

43 3.43 ±0.07 Synthetic Sapphire 0.88

44 or 22 8 to 14 Germanium

2,3

≥0.90
45 3.7 to 4.0 Synthetic Sapphire 0.88
46 2.0 to 2.6 Fused Quartz

3,4

0.94
47 4.8 to 5.2 Calcium Fluoride 0.94
48 7.5 to 8.5 Calcium Fluoride 0.92

NOTES: 1. Optical grade, 1/8-inch thick, polished to “plate glass” finish.

2. Requires anti-reflection coatings, optimized for 8 to 14 µm, applied to both surfaces. This window is very
expensive and requires careful handling.

3. Do not exceed 1/8-inch thickness or the transmittance will be degraded.

4. Water-free quality. General Electric Type 124 or equivalent.

RECOMMENDED SOURCES:

Bond Optics, P.O. Box 422, Etna Road, Lebanon, New Hampshire 03766
Adolph Meller Optics, P.O. Box 6001, Providence, Rhode Island 02940
Janos Technology Inc., HCR#33, Box 25, Route 35, Townshend, Vermont 05353-7702
Karl Lambrecht Corp., 4204 Lincoln Avenue, Chicago, Illinois 60618

Potential interference and temperature measure­ment errors in any given measurement situation
are aggravated by a combination of decreasing
target emissivity and decreasing target tempera­ture compared to surrounding temperatures. At
target temperatures below 400˚F (200˚C), the gen­eral trend of temperature /emissivity combinations
to be avoided is as follows:

Temperature Avoid Emissivity

Settings Below

350°F/175°C 0.10
300°F/150°C 0.30
250°F/120°C 0.50
200°F/90°C 0.70
150°F/65°C 0.90

IMPORTANT! For Series 43 instruments,
emissivity must be greater than 0.9 for
measurements in which temperature will be less
than 300°F (150°C).

Measurements may be made under these condi­tions, but special precautions will undoubtedly be
necessary and measurement problems may be

3.4 EFFECT OF WINDOWS ON
EMISSIVITY SETTING

If you view your target through a window, a certain
percentage of the target radiation will be reflected
or absorbed by the window material and will not
reach the MODLINE 4. To compensate for the
window loss,multiply the target emissivity, εT, by
the transmittance of the window, τW, and set the ε
control to this value, ε

SET.

Example: A target with an emissivity of 0.80 is
viewed through a window with 90% transmittance.

ε

SET

= εTX τ

W

= 0.80 X 0.90
= 0.72

Transmittance factors for some commercially avail­able window materials are given in Table 3.1.

anticipated. If you are operating under these condi­tions and encounter measurement problems,
contact IRCON Technical Service for advice.

EMISSIVITY (ε)

Range .10 to .99

Two-digit “press to change” digital switch used to adjust the
electronic circuits to match the emissivity to the material being
measured.

Response Time

Range 0.15 to 10 seconds

Potentiometer used to adjust the electronics circuits for the
most suitable response to temperature changes. Use low
setting to "track" rapid changes. Use higher setting to get a
smooth, average temperature display.

EMISSIVITY (ε)

Range .10 to .99

Two-digit “press to change” digital switch used to adjust the
electronics circuits to match the emissivity to the material
being measured.

PEAK PICKER PLUG (See Text)

PEAK PICKER DECAY TIME

Range 15 seconds to 30 minutes for Full Scale

Decay

Potentiometer used to adjust the time it takes for a full scale
signal to decay to zero scale value. Rotate in direction of
arrow (clockwise) to increase decay time. Rotate in opposite
direction (counterclockwise) to decrease decay time.

RESPONSE TIME

Range 0.15 to 10 seconds

Potentiometer used to adjust the electronic circuits for the
most suitable response to temperature changes. Use low
setting to "track" rapid changes. Use higher setting to get a
smooth, average temperature display. Rotate in direction of
arrow (clockwise) to increase response time. Rotate in
opposite direction (counterclockwise) to decrease response
time.

Section 3 — OPERATION

3–3

BASIC MODLINE 4

(Model No. Block D = 0)

FIG. 3.1 – QUICK GUIDE TO CONTROLS

MODLINE 4 WITH

PEAK PICKER OPTION

(Model No. Block D = 1)

Section 3 – OPERATION

3.5 INITIAL OBSERVATION

NOTE: For Series 43 Models 43-04F and 43-02C,
allow a 15-minute warm-up time before proceeding
with any observation or adjustment.

With all initial adjustments complete, you are ready
to apply power to the MODLINE 4 and any related
equipment. As heated object moves into the field
of view, the MODLINE 4 will respond to temperatures
within its temperature range. If you have the IRCON
Model AI-4 Analog Indicator or equivalent, the
pointer will move upscale as the lower inscribed
temperature is reached. If you have a digital readout
such as the IRCON Model IDP-4 Digital Indicator, the
temperature will be displayed on the readout.

If you are using a recorder with a fast response
time, you may note that it is not plotting a straight
line. This doesn’t necessarily mean the instrument
is faulty. You may be reading surface temperature
variations especially if the target material is moving.

3.6 RESPONSE TIME ADJUSTMENT

The temperature signal outputs have a full scale
step response time from 0.15 sec to 10 sec as
adjusted by the Response Time control on the panel
of the MODLINE 4.

Fig. 3.2 illustrates the effect of response time as it
might be displayed by a strip chart recorder. Notice
that longer response times tend to average out
signal fluctuations and produce more constant
signal outputs. On an analog or digital indicator,
this would give a more stable pointer action or less
digital “bounce.”

As you observe the temperature readings on your
indicator, adjust the Response Time control to
provide the most useful temperature information
without any distracting “jitter.” For instruments
with Peak Pickers, insert a small screwdriver in
the slot on the potentiometer and turn to the
desired setting.

3-4

FIG. 3.2 – EFFECT OF RESPONSE
TIME ON TEMPERATURE
SIGNAL

®

Section 3 — OPERATION

3–5

TEMPS

TEMPERATURE

TEMPS

TEMPS

TEMPERATURETEMPERATURE

Interferences

dans le chemin

de visee

Espaces
entre les
produits

Points chauds

sur le produit

MODE DIRECT

(Sans Action Detecteur de Cretes)

La température indiquée suit les variations
de la température du produit et est sensible
aux interférences dans le chemin de visée.
Elle est seulement affectée par le Temps
de Réponse du MODLINE 4.

MODE DETECTEUR DE CRETES

TEMPS DE DESCENTE RAPIDE

(Potentiometre sens inverse des

aiguilles d'une montre)

Utilisez ce réglage pour suivre les tendances
de la température et pour réduire l'effet des
interruptions momentanées ou des inter-
ferences dans le chemin de visée.

MODE DETECTEUR DE CRETES

TEMPS DE DESCENTE LENT

(Potentiometre sens des aiguilles

d'un montre)

Utilisez ce réglage pour lire la température de
crete et pour ignorer les espaces entre les
produits ou les interferences dans le champ
de visée. Permet également de détecter les
points chauds sur un produit.

FIG. 3.3 – EFFECT OF PEAK PICKER ON TEMPERATURE INDICATION

3.7 PEAK PICKER OPERATION

If your MODLINE 4 includes the Peak Picker
option (Block D of the Model Number = 1), you
may want to use it in certain measurement
situations:

a. If the workpiece you are measuring is moving

and is in the field of view for only a brief period
of time;

b. If a succession of small parts is to be viewed

with variable spacing between them;

c. If the temperature of a moving workpiece varies

because of slag, oxides, etc., but you wish to
know the highest temperatures;

d. If the line of sight between the instrument and

the workpiece is momentarily or periodically
interrupted, as by a moving piece of machinery
or bursts of steam or smoke.

Fig. 3.3 illustrates the Peak Picker action. The
Peak Picker circuitry responds to the highest
instantaneous value of temperature and holds this
value even if the temperature source is interrupted
by one of the conditions listed above.

Interference

in sight path

Gap in

workpiece

Hot spot on

workpiece

DIRECT MODE

(No Peak Picker action)

Indicated temperature tracks changes in ac­tual temperature, including interferences in
sight path. Limited only by Response Time of
MODLINE 4.

PEAKING MODE

FAST DECAY TIME

Use this setting to concentrate on temper­ature trends, and to reduce the effect of
momentary interruptions or interference in
the sight path.

(DECAY control fully counterclockwise)

PEAKING MODE

SLOW DECAY TIME

(DECAY control fully clockwise)

Use this setting to concentrate on peak
temperature and ignore gaps between work­pieces or interference in the sight path. Also,
to catch “hot spots” on a workpiece.

Section 3 — OPERATION

3–6

The indicated temperature (solid line) rises almost
instantly, depending on the response time of the
MODLINE 4, to follow the peaks in actual temper­ature (dashed line) in the field of view. This
indicated temperature decays at a rate determined
by the setting of the Peak Picker Decay Time
control on the back panel. Fig. 3.3 shows the effect
of changing the decay time

To operate the Peak Picker, first place the Peak
Picker plug in its jack on the back panel, and if you
have wired an external switch to this plug, open
the switch for at least 15 seconds. This "dumps"
the peaking circuits and updates the circuitry to the
temperature being observed at the time. Close the
switch (or remove the plug from its jack) to place
the circuits in the Peaking mode

Adjust the Peak Picker Decay Time control to set
the desired decay time At the extreme
counterclockwise position is the fastest decay,
approximately 15 seconds for a full scale indicated
value to decay to zero scale if the source is
interrupted completely.

At the extreme clockwise position you will observe
the slowest decay rate, approximately 30 minutes
for full scale decay. Adjustment somewhere in
between these extremes will yield the decay you
need for your particular measurement situation.

This peak signal reading may be returned to the in­stantaneous value at any time by opening the
external switch. This switch may be controlled
manually, or it may be operated by a microswitch
installed in the process or by a timer at desired
intervals. In the Direct mode the circuit follows
actual temperature variations as they occur.

NOTE: If you have not wired an external switch,
you can remove the Peak Picker Plug from its jack
to switch to the Peaking mode, and insert it in the
jack to switch to the Direct mode.

3.8 CLOSING THE ENCLOSURE

When all connections have been made, and when
you have adjusted all controls, place the cap on
the back panel of the enclosure to shield the con­nections and protect the controls from tampering.

Align the thread of the cap with those on the back
panel of the enclosure. Then, tighten the cap by
hand. Use a bar or rod in the torquing slots (stan­dard enclosure) or against the torquing studs
(water-cooled enclosure) to ensure a firm seal.

Section 4 — MAINTENANCE & SERVICE

4–1

4.1 ROUTINE MAINTENANCE

Routine Maintenance is essential for reliable, trouble-free operation. It consists of a thorough inspection and
“tune-up” at regular intervals to keep the instrument working efficiently and head off problems before they occur.

Most service problems are caused by control misadjustment, improper instrument positioning, dirty optics, and
other conditions that will be caught and corrected by an orderly maintenance program.

The checklist below will help you develop a maintenance routine suitable for your installation.

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 a

redundant device or system that will initiate a safe process

shutdown in the event that this instrument should fail. The user

should follow NEMA safety guidelines in the appendix of this manual.

!

!

CAUTION

CAUTION

■■ Check control settings on the MODLINE 4, and on

any other instruments in the system. Make sure
controls are set correctly for the process being
measured.

IMPORTANT! Do not vary control settings
indiscriminately to compensate for conditions
such as dirty optics.

■■ Check for proper alignment. Make sure there are

no obstructions in the optical path between
the MODLINE 4 and the target.

■■ Check lens and clean if necessary. Refer to lens

cleaning instructions in Section 4.2.

■■ Make sure the MODLINE 4 is not overheated.

(Refer to Section 1.6 for operating temperature
limits for your MODLINE 4 model.) If water cooling
and/or air purge accessories are used, make sure
there is adequate flow of cooling water and/or
clean, dry air.

■■ Make sure all connections are secure.

■■ Check signal cables for any signs of mechanical

damage or overheating.

4.2 LENS CLEANING

The MODLINE 4 uses an anti-reflection coated lens
made from either silicon or germanium, depending on
the model. The lens is accessible for cleaning from
the front end of the casting and does not require
removal.

To clean the lens, use clean, laboratory-grade
isopropyl alcohol and a clean, soft, lint-free cloth or
cotton swab. Dampen the cloth with alcohol and very
gently swab the surface of the lens. Be sure to clean
the entire exposed surface of the lens.

Dry the lens with a clean, dry, soft cloth. Repeat the
procedure if necessary.

After repeated cleanings, some minor scratches may
appear on the lens. These minor scratches are purely
cosmetic and will not affect the instrument. However,
improper cleaning or other abuse may damage the
anti-reflection coating to the point where the lens
must be replaced. The unit should then be returned to
the nearest service center for repair or calibration.

The frequency of lens cleaning will depend on the
environment at the point of installation. Air purging
will reduce the necessity of frequent cleaning in
dusty, dirty areas.

Section 4 — MAINTENANCE & SERVICE

4–2

(Continued)

TABLE 4.1 – MODLINE 4 SYSTEM TROUBLESHOOTING

No temperature indication

(Target known to be at a
temperature within the
MODLINE 4 range)

Incorrect temperature indications

(Compared to readings of some
reliable standard of known accuracy)

SYMPTOM POSSIBLE CAUSE/RECOMMENDED ACTION

1. Check for proper dc power supply voltage to system.

2. Ensure loop wiring is correct
a) Check for proper polarity of system component connections.
b) Ensure no opens or shorts exist in wiring.
c) Make sure loop is grounded at one point only.

3. Ensure MODLINE 4 has unobstructed view of target and correct
window materials are used.

4. Check that the MODLINE 4 is not being operated at temperatures
beyond its case operating temperature range (above maximum or
below minimum):

minimum limit: 32°F (0°C) for all models*
maximum limit: 150°F (66°C) for Series 43* through 48, or 130°F

(54°C) for Series 22, in standard enclosure; 400°F
(204°C) for all series in water cooled enclosure.

1. Ensure components in system loop are calibrated for 4 to 20 mA
and scaled to temperature range of the MODLINE 4.

2. Ensure dc power supply voltage is correct.

3. Ensure MODLINE 4 has unobstructed view of the object being
measured. Target must be large enough to fill the MODLINE 4
field of view.

4. Check that the instrument’s lens and process sight window (if
used) are clean.

5. Ensure

ε setting is correct.

6. Ensure that the MODLINE 4 is not receiving reflected infrared
energy from objects surrounding the target. This occurs when
viewing low emissivity targets which act as reflectors or partial
mirrors. (See Section 6.)

7. Ensure that the MODLINE 4 is not receiving transmitted energy
from objects behind the target. (See Section 6.)

8. Check that the MODLINE 4 is not being operated at temperatures
beyond its case operating temperature range (above maximum or
below minimum):

minimum limit: 32°F (0°C) for all models*
maximum limit: 150°F (66°C) for Series 43* through 48, or 130°F

(54°C) for Series 22, in standard enclosure; 400°F
(204°C) for all series in water cooled enclosure.

Section 4 — MAINTENANCE & SERVICE

TABLE 4.1 – MODLINE 4 SYSTEM TROUBLESHOOTING (CONTINUED)

SYMPTOM POSSIBLE CAUSE/RECOMMENDED ACTION

Erratic operation

(Target known to be at stable
temperature)

*Exception: for Series 43, Models 04F, 05F, 02C, and 03C, case operating temperature range is 50 to 113°F (10 to 45°C).

4.3 SYSTEM TROUBLESHOOTING

If trouble is encountered in obtaining temperature
readings after installation of the system, consult
Table 4.1. If necessary, call or write for further
assistance. For instrument services, contact
IRCON Technical Services. For applications
assistance, contact IRCON Sales Applications
Engineering.

1. Check for loose, intermittent connections.

2. Ensure MODLlNE 4 case is properly grounded.

3. Ensure loop is grounded at one point.

4. Use shielded cable that has shield returned to earth ground.

5. Separate system wiring from power or r-f wiring.

6. Use a “clean” instrumentation power line.

7. Check that the MODLINE 4 is not being operated at temperatures
beyond its case operating temperature range (above maximum or
below minimum):

minimum limit: 32°F (0°C) for all models*
maximum limit: 150°F (66°C) for Series 43* through 48, or 130°F

(54°C) for Series 22, in standard enclosure; 400°F
(204°C) for all series in water cooled enclosure.

8. Determine if large amounts of smoke or steam are “interfering”

with measurement. If MODLINE 4 has a Peak Picker (Block D of
Model No. = 1), operation in Peaking mode may overcome this
problem.

4.4 CALIBRATION SERVICE

The MODLINE 4 is calibrated against precision
laboratory standards and “burned in” for a full
week before shipment to ensure accurate
temperature measurements throughout the
operating range.

To preserve this accuracy, each MODLINE 4
should be recalibrated periodically on a Blackbody
standard. We recommend recalibration of this type
on a yearly basis.

You can have your MODLINE 4 calibrated in our
Pyrometer Service Center. Calibration traceable to
the National Institute of Standards and Technology
(National Bureau of Standards) is an available
option. If you prefer, IRCON can provide a Model
BCH, BCL or BCN Blackbody Calibration System
that lets you perform your own calibration.
Complete instructions are supplied with the unit.
You can also arrange for an IRCON Field Service
Engineer to train your technicians in calibration
procedures. Call IRCON Technical Services for
details.

4–3

Section 4 — MAINTENANCE & SERVICE

4–4

NOTES:

Section 5 — OPTIONAL ACCESSORIES

5–1

5.1 GENERAL

This section contains information about the basic MODLINE 4 accessories. These include Analog and
Digital Indicators, Power Supplies, and Accessories to facilitate mounting and provide environmental pro­tection for the MODLINE 4. The more commonly used accessories are described in this section. More
specialized accessories, such as sight tubes, are described in Product Bulletin PB0070, available on
request.

Section 5 — OPTIONAL ACCESSORIES

5–2

5.2 MODEL AA-3 AIR PURGE
ACCESSORY

(Used only with MODLINE 4 with standard
enclosure. For Series 43-04F or 43-02C
only. DO NOT combine with Model WA-3
Water Cooling Accessory.)

A Model AA-3 Air Purge Accessory provides a
stream of clean air to prevent smoke, particles,
steam, etc., from collecting on the lens. This
accessory bolts to the front flange of a MODLINE 4
and can be used in combination with other
accessories such as a Model WA-3 Water Cooling
Accessory.

A 1/2-inch NPT tapped hole is provided for air
intake. Air flow of about 5 ft3/min. is suitable for
most applications.

ASSEMBLY NOTES:

Two gaskets and three 5/16–18 NC flanged, hex head bolts are supplied. Insert bolts through unthreaded
holes on front flange of AA-3 and bolt to mounting support (or additional accessory, if used). Insert
gasket(s)* in recess at rear, and bolt MODLINE 4 flange (or WA-3 Water Cooling Accessory, if used) to rear
flange of AA-3. Use bolts supplied with MODLINE 4 (or WA-3).

* Use one or two gaskets, as needed, to form good seal and still allow flange surfaces to touch.
NOTE: Refer to Section 2 for MODLINE 4 grounding information. If necessary, use appropriate insulation

between flanges of MODLINE 4 and AA-3, and attach with insulating hardware.

5 in. DIA

(127 mm)

2.984 in.

(75.4 mm)

TAPPED

1/2 in. NPT

(13 mm)

3.875 in.
(98 mm)

4.125 in.

(105 mm)

FRONT FACE

0.375 in. DIA.
(10 mm)

3 HOLES

REAR FACE

5/16–18

(3 PLACES)

30°

THIS SURFACE
MOUNTS AGAINST
SENSOR FLANGE
(OR TO WA-3
WATER COOLING
ACCESSORY,
IF USED)

1 in.
(25 mm)

4.375 in. (111 mm)

DIA. BOLT CIRCLE

PHYSICAL DIMENSIONS

Section 5 – OPTIONAL ACCESSORIES

5.3 MODEL TV-VIEW DIGITAL
INDICATOR / POWER SUPPLY

The Model TV-VIEW digital meter is a power supply
and a digital indicator. It can be scaled for any
MODLINE 4 range, both °C or F. It provides 24 Vdc
power to the sensor and accepts the 4-20 mA output.

SPECIFICATIONS

Temperature Ranges: All Modline 4 ranges °C or F
Accuracy: ± 12% of reading

Loop Current Supply: 50 mA Max
Output Voltage: ± 24 Vdc, ± 5%
Ambient Range: 0 to 50°C
Digits: 5 digit Red LED

19,999 to 99,999
Conversion Rate: 20 readings/second
Input Power: TV-VIEW-VAAC, 85–250 VAC,
50/60 Hz, 15 Va
TV-VIEW-VADC, 11-36 Vdc,
11 W
Options: Alarms
RS232, RS485
Output 0-10 Vdc / 4-20 mAdc

PHYSICAL DIMENSIONS

5-3

®

Section 5 – OPTIONAL ACCESSORIES

5.4 MODEL PS4-24 POWER SUPPLY

The PS4-24 power supply delivers isolated dc power and provides short circuit and overload protection.

Technical Data

Protection class: class I
Operating temperature range: -25°C to 60°C (-13 to 140°F)

AC input: 100 to 240 VAC

- external fuse (required): 1.5 A slow blow type (recommendation)
DC output: 24 VDC / 840 mA
derate 3%/°C above 50°C (122°F)
Wire cross sections input/output: 1.5 mm² max.

± 10% 47 - 440 Hz

To prevent electrical shocks,

the power supply must be used in

protected environments (cabinets)!

27. 6 (1.09)

(2.15)

54. 6

(0.20)

5.5

4.0

46. 0 (1.81)

5.0

(0.22)

(0.16)

4 x ø3.5

(4 x ø0.14)

1

2

3

Top view

86. 0

96.0

4

5

6

7

8

(3.38)

(3.78)

®

5-4

SB-1 swivel base bottom view

Section 5 – OPTIONAL ACCESSORIES

5.5 MODEL SB-1 SWIVEL MOUNTING BASE

The swivel mounting base may be used for installations
that require good line of sight adjustment capability.
device permits tilting and panning motions and may be
locked securely in place when optical alignment is
completed. Note: Don’t use the SB-1 or the EE-2

accessories since they are too heavy to hold the
swivel base securely.

There are three 1/4 x 20 NC hex head bolts and 1/4 inch
split ring lock washers that are supplied with each swivel
base. Insert two bolts with lock washers through mounting
plate holes into corresponding threaded holes on the
sensor base and tighten the bolts.

Attach the base to the desired mounting surface using
customer-supplied mounting hardware. Refer to
grounding information in the manual when planning
the mounting procedure.

SB-1 swivel base side view

®

5-5

SB-1 swivel base bottom view

Section 5 – OPTIONAL ACCESSORIES

5.6 MODEL WA-3 WATER COOLING ACCESSORY

Used only with Modline 4 and standard enclosure. For Series

43-04F or Series 43-02C only (do not combine with Model
WA-3 Water Cooling accessory). Model WA-3 water cooling
accessory is recommended where ambient temperatures are
expected to exceed the maximum rating of the Modline 4.
Nominal water flow of 10 to 20 gallons per hour at water
temperatures below 90°F (32°C) is suitable for most
applications. The cooling effect must be sufficient to keep
the case temperature of the instrument below its maximum
rating.

Two 1/2 inch NPT tapped holes accept water intake and outlet
pipes. A matched flange permits bolting to the Modline 4 and
other standard accessories. Where high ambients and moist
atmospheres are encountered, the use of an AA-3 Air Purge
accessory with a WA-3 water cooling accessory prevents
moisture condensation on the lens of the Modline 4.

PHYSICAL DIMENSIONS

ASSEMBLY NOTES

Two gaskets and three 5/16-18 NC flanged hex head bolts are supplied. Insert bolts through
unthreaded holes on front flange of WA-3 and bolt to mounting support (or additional accessory if
used). Use one or two gaskets as needed, to form a good seal and still allow flange surfaces to touch.
Insert the gasket(s) in recess at rear and bolt the sensor flange to the WA-3 rear flange. Note: use bolts

supplied with instrument. Refer to Section 2 for grounding information. If necessary, use appropriate
insulation between flanges of Modline 4 and WA-3 and attach with insulating hardware.

5-8

®

Section 6 — APPLICATIONS GUIDE

6–1

6.1 INTRODUCTION

MODLINE 4 is a precision measuring instrument
built for rugged service and ease of operation.
When installed and maintained with reasonable
care, it will give you reliable, trouble-free service in
a wide variety of applications.

In this section we offer some guidelines to further
ensure accuracy and reliability. We urge you to
review this information to make sure your
instrument gives you the results it is capable of.

BACKGROUND

Make sure the infrared energy being measured is
emitted by the target only. Energy picked up from
some other source is called background. It com­bines with the true target energy to cause
measurement errors.

Causes of background error are as follows:

• unresolved targets

• energy transmitted through the target

• energy reflected off the surface of the target

Unresolved Targets

An unresolved target can mean any of three
things: (1) the spot size is larger than the target
size, (2) the optical axis of the MODLINE 4 is not
centered on the target, or (3) there is an interfering
object in the sight path. Any of these conditions will
cause the detector to "see" something besides
target radiation and to produce measurement
errors.

To avoid problems: (1) make sure the spot size is
smaller than the target size, (2) aim the MODLINE
4 so its optical axis is centered on the target, and
(3) make sure there are no obstructions in the
sight path. Review Section 2.9 for details.

Emissivity, Reflectance, and Transmittance

An ideal infrared radiator, called a blackbody,
emits the maximum possible amount of infrared
energy when heated to any given temperature. It

has an Emissivity (ε) of 1.0. It does not reflect or
transmit background energy (its Reflectance and

Transmittance values are zero).

The MODLINE 4 is factory calibrated using
blackbody standards. However, the targets you
deal with in practice are non-blackbodies. Their
Emissivity values are less than 1.0, which means
they emit some traction of the infrared energy a
blackbody would emit at a given temperature. You
must compensate for this difference by adjusting
the Emissivity (ε) control for a setting of less than

1.0.
Non-blackbodies exhibit two potential causes of

background error: Reflectance (r) and Transmit­tance (τ).

Reflectance causes the target to act as a mirror,
and it will reflect infrared energy generated by
some other source (e.g., a furnace wall or heater
element). If the MODLINE 4 picks up the reflection,
measurement errors will result.

Reflectance depends on the target material and
the condition of its surface. Flat, smooth surfaces
tend to have larger reflectance values than
roughened surfaces of the same material.

Reflectance problems may be reduced by
changing the viewing angle so that the reflection is
not picked up by the MODLINE 4 or by the use of
sight tubes or some other form of shielding. (See
Fig. 6.1.) Contact IRCON Applications Engineering
for further recommendations.

Transmittance means the target is not completely
opaque at the operating wavelength of the
MODLINE 4, so it may act as a window for infrared
emission from objects behind it (e.g., an oven wall
or heater element).

Transmittance depends on target material and
thickness. For a given material at a given
wavelength, transmittance is inversely related to
thickness.

Transmittance problems are sometimes corrected
by changing the viewing angle so that the
background source is not directly behind the
target, by selecting a different measurement point
away from the background source, or by inserting
a shield behind the workpiece. (See Fig. 6.2 for
examples.) If you are faced with a persistent
transmittance problem, contact IRCON
Applications Engineering for suggestions.

Section 6 — APPLICATIONS GUIDE

6–2

Emissivity (ε), Reflectance (r), and Transmittance
(τ) are related as follows:

ε = 1 - τ - r

Maximum accuracy is possible when ε = 1.0
(blackbody condition). In this condition there is no

reflection and no transmission of background
energy to cause measurement errors.

As Emissivity decreases it is harder to get
accurate readings because Reflectance and
Transmittance become more pronounced. Use
caution when attempting to measure materials with
Emissivity known to be 0.80 or less. Take any
appropriate steps to shield the MODLINE 4 from
background radiation. Contact IRCON Applications
Engineering if problems persist.

;;;

;;;

;;;

FIG. 6.1 – SOLVING COMMON REFLECTANCE PROBLEMS

VIEWING AT FURNACE EXIT

VIEWING THROUGH FURNACE

ROOF OR WALL

FURNACE

WORKPIECE

Problem: MODLINE 4 “sees” reflections of

furnace aroof or wall.

Solution: View through sight tube with tip

spaced close to surface of workpiece.

Cautions: 1. I.D. of sight tube must be wider

than Cone of Vision along entire
length (See Section 2).

2. Sight tube walls may radiate
infrared if furnace atmosphere is

very hot. May require cooled sight
tube. Consult IRCON for recommendations.

Solution 2: Install shield to

block reflection.

Solution 1: Change viewing angle.

Problem: MODLINE 4 “sees” reflections

of hot furnace roof.

WORKPIECE

FURNACE ROOF

Section 6 — APPLICATIONS GUIDE

6–3

6.2 EMISSIVITY TABLES

For accurate temperature measurements, you
must set the Emissivity (E) control of the
MODLINE 4 to the emissivity value of the material
you intend to measure. As explained in Section

3.3, one way to determine the correct control
setting is to refer to a set of Emissivity Tables. The
tables in this section of the manual are provided
for this purpose. They are based on actual tests on
samples of the materials listed. Tables are
provided for each MODLINE 4 instrument series.
The materials in each table are grouped according
to the classes of materials usually measured by
that series (e.g., Plastics; Glass; Building
Materials; etc. for Series 44).

To use the Emissivity Tables, go to the appropriate
table for your instrument series, and locate the
material of interest in that table. Note the value in
the Emissivity column and set the ε control to this
value.

Be sure to observe any notes or descriptions
included in the tables. If your material is not listed,
or if you are in doubt about any of the values,
contact IRCON Applications Engineering.

PRODUIT

ELEMENT
CHAUFFANT

Modifier l'angle de visée ou changer
le point de mesure pour que l'élément
chauffant ne soit pas dans le champ

Solution:

PRODUIT

MUR DU
FOUR

Les MODLINE 4 "voit" l'énergie
emise par le mur chaud du four
et transmise à travers le produit

Problème: Le MODLINE 4 "voit" l'énergie

émise par l'élement chauffant et
transmise à travers le produit

Problème:

Installer un écran thermique
entre le produit et le mur du four

Solution:

ECRAN

FIG. 6.2 – SOLVING COMMON TRANSMITTANCE PROBLEMS

WORKPIECE

FURNACE
WALL

Problem: MODLINE 4 “sees” radiation from hot

furnace wall transmitted
through workpiece.

WORKPIECE

HEATING
ELEMENT

Problem: MODLINE 4 “sees” radiation from hot

furnace wall transmitted
through workpiece.

SHIELD

Solution: Change viewling angle, or measuring

location, so heating element is
not in field of view of MODLINE 4.

Solution: Install heat insulating shield

between workpiece and
furnace wall.

Section 6 — APPLICATIONS GUIDE

6–4

TABLE 6.1

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN IDEALIZED FORM

ARRANGED BY CLASSES OF MATERIALS

INSTRUMENT SERIES: MODLINE 4, Series 44 and 22 SPECTRUM: 8 to 14 microns

All specimens in this table are in the following form:

1. Thick enough to reduce Transmittance

τ

to less than 0.01.

2. Viewed surface clean, flat, and optically smooth.

(Continued)

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

PLASTICS

ABS, “CYCOLAC” 0.020 0.04 0.96
ACETAL, “DELRIN” .010 .05 .95
ACRYLIC, “PLEXIGLAS”, “LUCITE” .010 .05 .95

ALKYDS,"PLENCO" .010 .05 .95
CELLULOSICS .010 .05 .95
CELLOPHANE .010 .05 .95

EPOXY .006 .05 .95
FLUOROPOLYMERS, "TEFLON" .015 .06 .94
PHENOLICS, "PLENCO" .010 .05 .94

POLYAMIDE, “NYLON” .015 .04 .96
POLYAMIDE, "KAPTON" .010 .08 .92
POLYCARBONATE, “LEXAN” .010 .06 .94

POLYESTER, P.E.T., “MYLAR”, “DACRON” .010 .08 .92
POLYETHYLENE .15 .04 .96
POLYPROPYLENE .10 .04 .96

POLYSTYRENE .040 .04 .96
POLYURETHANE .010 .05 .95
POLYVINYL CHLORIDE (PVC), “GEON” .015 .04 .96

LIQUIDS

WATER 0.002 0.02 0.98
OIL, MINERAL .080 .03 .97
OIL, ANIMAL OR VEGETABLE .020 .05 .95

GLASSES

SODA-LIME (WINDOWS, BOTTLES) 0.001 0.10 0.90
CHEMICAL “PYREX” .001 .15 .85
FUSED QUARTZ .001 .20 .80

Section 6 — APPLICATIONS GUIDE

6–5

FOR ADDITIONAL EMISSIVITY VALUES FOR SERIES 44 AND 22, SEE TABLE 6.2.

TABLE 6.1 (Continued)

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

METALS, BARE Unoxidized (For oxidized samples of metals, refer to “Composites and Miscellaneous” of Table 6.12.)

ALUMINUM Materials in this class are 0.98 0.02
CHROMIUM opaque (zero transmittance) .92 .08
COPPER at any thickness .98 .02

GOLD .98 .02
IRON, CARBON STEEL .95 .05
LEAD .95 .05

NICKEL .96 .04
SILVER .98 .02
STAINLESS STEEL .89 .11

TIN .84 .16
ZINC .98 .02
(GRAPHITE) .40 .60

Section 6 — APPLICATIONS GUIDE

6–6

(Continued)

TABLE 6.2

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN THEIR “USUAL” FORM

ARRANGED BY CLASSES OF MATERIAL

INSTRUMENT SERIES: MODLINE 4, Series 44 AND 22 SPECTRUM: 8 to 14 microns

All specimens in this table are in their common physical form — e.g. raw materials like coal, gravel, sand, etc. in
their normal granular form; construction products like lumber, paneling, tiles, roofing, etc. in their normal delivered
forms.

Unless otherwise noted, these materials have negligible Transmittance

τ

in their common form. Any difference

between the listed Emissivity

ε

and a “perfect” Emissivity of 1.0 is due to Reflectance r.

TARGET MATERIAL EMISSIVITY

ε

TEXTILES, FABRICS

CARPET (COTTON, WOOL, SYNTHETIC) 0.98
FABRICS, CLOSE WEAVE (COTTON,
WOOL, SYNTHETIC) .80 - .95

FUR .96
LEATHER .96
PLASTICS .95

FOODS, FOOD PROCESSING

BAKERY GOODS 0.98
BATTERS .98
CANDY .98

CONFECTIONS .98
DAIRY PRODUCTS .98
FATS .98

FRUITS .98
FLOUR .98
GRAIN .98

GRAVIES .98
JELLIES, JAMS .98
LIQUIDS .98

MEATS .98
OILS .98
SAUCES .98

SUGAR .98
VEGETABLES .98

TARGET MATERIAL EMISSIVITY

ε

WOOD PRODUCTS

PAPER, WOOD PULP (0.003" THICK) ~0.80
PAPER, BOND STATIONERY (0.003" THICK) ~.80*
PAPER, CLAY FILLED (0.012" THICK) .85

CARDBOARD .88
WOOD, SOFT OR HARD .90
HARDBOARD .92

BUILDING MATERIALS

ASPHALT, MACADAM 0.98
CLAY, DRY .90
CLAY , WET .98

CONCRETE, DRY .91
CONCRETE, WET .98
CORK .98

FIBERGLASS BATTS .98
FORMICA .94
GLASS .90

GRAVEL .95
LINOLEUM .96
PAINTED METAL .75 - .95

PAINTED WOOD, PLASTIC .96
PLASTIC PANELS .96
PLYWOOD .90

ROCK, CRUSHED .95
ROOFING, COMPOSITION .95
RUBBER CLOTH .96

SAND .92
TILES, CERAMICS ~.80
TILES, RUBBER, PLASTIC .95

Section 6 — APPLICATIONS GUIDE

6–7

TABLE 6.2 (Continued)

TARGET MATERIAL EMISSIVITY

ε

INDUSTRIAL MATERIALS, INORGANIC

CERAMICS ~0.80
CLAY .90
CHEMICALS, LIQUID .95

CHEMICALS, SOLID .80 - .95
COAL .98
COKE .98

FIREBRICK .85
GLASS .90
GRAVEL .95

MINERALS, ORES .95
SAND .95
SLAG .95

STEEL BILLET, OXIDIZED .82
SLURRIES .98
WATER, AQUEOUS SOLUTIONS .98

INDUSTRIAL MATERIALS, ORGANIC

CARBON BLACK 0.98
CHEMICALS, LIQUID .96
CHEMICALS, SOLID .96

COAL, COKE .98
OILS, FATS, GREASE .96
PETROLEUM PRODUCTS .96

PLASTICS .96
SOLVENTS .96
WAXES .96

TARGET MATERIAL EMISSIVITY

ε

COMPOSITES AND MISCELLANEOUS

CARBON STEEL, OXIDIZED 0.82
DRUGS, PHARMACEUTICALS .95
FIBERGLASS—EPOXY FORMS .95

GLASS COATED METAL .90
NICKEL, OXIDIZED .85
PAINTED METAL .75 - .95

PAINTED WOOD .95
PLASTIC LAMINATED WOOD .95
PRINTED CIRCUIT BOARDS .95

RECORDING TAPE .85
SALT BATH .95
SANDPAPER .90

STAINLESS STEEL, OXIDIZED .85
TOBACCO .96

Section 6 — APPLICATIONS GUIDE

6–8

TABLE 6.3

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN IDEALIZED FORM

ARRANGED BY CLASSES OF MATERIALS

INSTRUMENT SERIES: MODLINE 4, Series 45 SPECTRUM: 3.7 to 4.0 microns

All specimens in this table are in the following form:

1. Thick enough to reduce Transmittance

τ

to less than 0.01.

2. Viewed surface clean, flat, and optically smooth.

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

GLASSES

SODA-LIME (WINDOWS, BOTTLES) 0.40 0.02 0.98
CHEMICAL “PYREX” 0.10 .02 .98
FUSED QUARTZ 1.4 .02 .98

METALS, BARE Unoxidized (For oxidized samples of metals, refer to Table 6.4.)

ALUMINUM Materials in this class are 0.97 0.03
CHROMIUM opaque (zero transmittance) .75 .25
COPPER at any thickness .98 .02

GOLD .98 .02
IRON, CARBON STEEL .88 .12
NICKEL .92 .08

SILVER .97 .03
STAINLESS STEEL .83 .17
TIN .73 .27

ZINC .93 .07
(GRAPHITE) .48 .52

Section 6 — APPLICATIONS GUIDE

6–9

TABLE 6.4

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN THEIR “USUAL” FORM

ARRANGED BY CLASSES OF MATERIAL

INSTRUMENT SERIES: MODLINE 4, Series 45 SPECTRUM: 3.7 to 4.0 microns

All specimens in this table are in their common physical form. These materials have negligible transmittance

τ

in their common form. Any difference between the listed Emissivity εand a “perfect” Emissivity of 1.0 is due
to Reflectance

r.

TARGET MATERIAL EMISSIVITY

ε

METALS, Oxidized

NICKEL, OXIDIZED 0.85
STAINLESS STEEL, OXIDIZED .85
STEEL OXIDIZED .82

TARGET MATERIAL EMISSIVITY

ε

MISCELLANEOUS MATERIALS

COKE 0.98
FIREBRICK .5 -.9
SLAG .85

Section 6 — APPLICATIONS GUIDE

6–10

TABLE 6.5

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN IDEALIZED FORM

ARRANGED BY CLASSES OF MATERIALS

INSTRUMENT SERIES: MODLINE 4, Series 46 SPECTRUM: 2.0 to 2.6 microns

All specimens in this table are in the following form:

1. Thick enough to reduce Transmittance

τ

to less than 0.01.

2. Viewed surface clean, flat, and optically smooth.

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

GLASSES

SODA-LIME (WINDOWS, BOTTLES) ~ 5. 0.03 0.97

METALS, BARE Unoxidized (For oxidized samples of metals, refer to Table 6.4.)

ALUMINUM Materials in this class are 0.97 0.03
CHROMIUM opaque (zero transmittance) .66 .34
COPPER at any thickness .98 .02

GOLD .98 .02
IRON, CARBON STEEL .89 .21
NICKEL .91 .09

SILVER .97 .03
STAINLESS STEEL .78 .22
TIN .62 .38

TITANIUM .70 .30
ZINC .91 .09
(GRAPHITE) .37 .63

Section 6 — APPLICATIONS GUIDE

6–11

TABLE 6.6

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN THEIR “USUAL” FORM

ARRANGED BY CLASSES OF MATERIAL

INSTRUMENT SERIES: MODLINE 4, Series 46 SPECTRUM: 2.0 to 2.6 microns

All specimens in this table are in their common physical form . These materials have negligible transmittance

τ

in their common form. Any difference between the listed Emissivity εand a “perfect” Emissivity of 1.0 is due
to Reflectance

r.

TARGET MATERIAL EMISSIVITY

ε

METALS, Oxidized

NICKEL, OXIDIZED 0.85
STAINLESS STEEL, OXIDIZED .85
STEEL OXIDIZED .82

TARGET MATERIAL EMISSIVITY

ε

MISCELLANEOUS MATERIALS

CERAMICS 0.3 - 0.9
COKE .98
FIREBRICK .5 - .9

SALT BATH .96
SILICON CARBIDE .85
SLAG .85

Section 6 — APPLICATIONS GUIDE

6–12

TABLE 6.7

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN IDEALIZED FORM

ARRANGED BY CLASSES OF MATERIALS

INSTRUMENT SERIES: MODLINE 4, Series 47 SPECTRUM: 4.8 to 5.2 microns

All specimens in this table are in the following form:

1. Thick enough to reduce Transmittance

τ

to 0.00

2. Viewed surface clean, flat, and optically smooth.

(Continued)

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

PLASTICS

ABS, “CYCOLAC” 0.050 0.03 0.97
ACETAL, “DELRIN” .050 .03 .97
ACRYLIC, “PLEXIGLAS”, “LUCITE” .050 .03 .97

ALKYDS,"PLENCO" .040 .03 .97
CELLULOSICS .040 .03 .97
CELLOPHANE .040 .03 .97

EPOXY .025 .03 .97
FLUOROPOLYMERS, "TEFLON" .25 .02 .98
PHENOLICS, "PLENCO" .040 .03 .97

POLYAMIDE, “NYLON” .060 .02 .98
POLYAMIDE, "KAPTON" .040 .06 .94
POLYCARBONATE, “LEXAN” .040 .06 .94

POLYESTER, P.E.T., “MYLAR”, “DACRON” .040 .03 .92
POLYETHYLENE .30 .04 .96
POLYPROPYLENE .30 .04 .96

POLYSTYRENE .25 .03 .97
POLYURETHANE .040 .03 .97
POLYVINYL CHLORIDE (PVC), “GEON” .12 .04 .96

LIQUIDS

WATER 0.005 0.02 0.98
OIL, MINERAL 1.0 .03 .97
OIL, ANIMAL OR VEGETABLE 0.15 .03 .97

GLASSES

SODA-LIME (WINDOWS, BOTTLES) 0.040 0.02 0.98
CHEMICAL “PYREX” .025 .02 .98
FUSED QUARTZ .040 .02 .98

Section 6 — APPLICATIONS GUIDE

6–13

FOR ADDITIONAL EMISSIVITY VALUES FOR SERIES 47, SEE TABLE 6.8.

TABLE 6.7 (Continued)

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE

EMISSIVITY

(inches) r

ε

METALS, BARE Unoxidized (For oxidized samples of metals, refer to “Composites and Miscellaneous” of Table 6.8.)

ALUMINUM Materials in this class are 0.97 0.03
CHROMIUM opaque (zero transmittance) .81 .19
COPPER at any thickness .98 .02

GOLD .97 .03
IRON, CARBON STEEL .91 .09
LEAD .92 .08

NICKEL .94 .06
SILVER .97 .03
STAINLESS STEEL .85 .15

TIN .76 .24
ZINC .97 .03
(GRAPHITE) .28 .72

Section 6 — APPLICATIONS GUIDE

6–14

TABLE 6.8

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN THEIR “USUAL” FORM

ARRANGED BY CLASSES OF MATERIAL

INSTRUMENT SERIES: MODLINE 4, Series 47 SPECTRUM: 4.8 to 5.2 microns

Materials in this table are in their common physical form — e.g. raw materials like coal, gravel, sand, etc. in their
normal granular form; construction products like lumber, paneling, tiles, roofing, etc. in their normal delivered
forms.

Target materials with Emissivity values less than 1 will reflect and/or transmit to the extent of 1-e . Low values of e
(e.g., e<0.8) suggest precautions are in order to prevent background interference from other hot objects in the
area.

(Continued)

TARGET MATERIAL EMISSIVITY

ε

TEXTILES, FABRICS

CARPET (COTTON, WOOL, SYNTHETIC) 0.88
FABRICS, CLOSE WEAVE (COTTON,
WOOL, SYNTHETIC) .60 - .90

FUR .93
LEATHER .90
PLASTICS (See Table 6.7 on Plastics")

FOODS, FOOD PROCESSING

BAKERY GOODS 0.96
BATTERS .96
CANDY AND CONFECTIONS .96

DAIRY PRODUCTS .96
FRUITS .96
FLOUR .94

GRAIN .94
GRAVIES .96
JELLIES, JAMS .98

LIQUIDS .98
MEATS .98
OILS (See Table 6.7 on "Liquids")

SAUCES .98
SUGAR .96
VEGETABLES .98

TARGET MATERIAL EMISSIVITY

ε

WOOD PRODUCTS

PAPER, WOOD PULP (0.003" THICK) ~0.50
PAPER, BOND STATIONERY (0.003" THICK) ~.50*
PAPER, CLAY FILLED (0.012" THICK) .75

CARDBOARD .80
WOOD, SOFT OR HARD .75
HARDBOARD .75

BUILDING MATERIALS

ASPHALT, MACADAM 0.98
CLAY, DRY .90
CLAY , WET .98

CONCRETE, DRY .93
CONCRETE, WET .98
CORK .98

FIBERGLASS BATTS .98
FORMICA .95
GLASS .98

GRAVEL .93
LINOLEUM .96
PAINTED METAL 0.20 - 0.40

PAINTED WOOD, PLASTIC .80
PLASTIC PANELS (See Table 6.7 on
"Plastics")

PLYWOOD .75
ROCK, CRUSHED .93
ROOFING, COMPOSITION .95

RUBBER CLOTH .96
SAND .97
TILES, CERAMICS .97

TILES, RUBBER, PLASTIC .95
WOOD .75

Section 6 — APPLICATIONS GUIDE

6–15

TABLE 6.8 (Continued)

TARGET MATERIAL EMISSIVITY

ε

INDUSTRIAL MATERIALS, INORGANIC

CERAMICS 0.98
CLAY .92
CHEMICALS, LIQUID .96

CHEMICALS, SOLID .80 - .95
COAL .98
COKE .98

FIREBRICK .96
GLASS .98
GRAVEL .95

MINERALS, ORES .95
SAND .98
SLAG .98

STEEL BILLET, OXIDIZED .82
SLURRIES .98
WATER, AQUEOUS SOLUTIONS .98

INDUSTRIAL MATERIALS, ORGANIC

CARBON BLACK 0.98
CHEMICALS, LIQUID .96
CHEMICALS, SOLID .96

COAL, COKE .98
OILS, FATS, GREASE (See Table 6.7 on
"Liquids")

PLASTICS (See Table 6.7 on "Plastics") .96
SOLVENTS (See Table 6.7 on "Liquids") .96

TARGET MATERIAL EMISSIVITY

ε

COMPOSITES AND MISCELLANEOUS

CARBON STEEL, OXIDIZED 0.82
DRUGS, PHARMACEUTICALS .96
FIBERGLASS—EPOXY FORMS .96

GLASS COATED METAL .98
NICKEL, OXIDIZED .85
PAINTED METAL .20 - .40

PAINTED WOOD .80
PLASTIC LAMINATED WOOD .85
PRINTED CIRCUIT BOARDS .85

RECORDING TAPE .50 - .80
SALT BATH .95
SANDPAPER .85

STAINLESS STEEL, OXIDIZED .85
TOBACCO .85

Section 6 — APPLICATIONS GUIDE

6–16

TABLE 6.9

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN IDEALIZED FORM

ARRANGED BY CLASSES OF MATERIALS

INSTRUMENT SERIES: MODLINE 4, Series 48 SPECTRUM: 7.5 to 8.5 microns

All specimens in this table are in the following form:

1. Thick enough to reduce Transmittance

τ

to less than 0.01

2. Viewed surface clean, flat, and optically smooth.

(Continued)

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

PLASTICS

ABS, “CYCOLAC” 0.010 0.04 0.96
ACETAL, “DELRIN” .005 .05 .95
ACRYLIC, “PLEXIGLAS”, “LUCITE” .002 .03 .97

ALKYDS,"PLENCO" .005 .05 .95
CELLULOSICS .002 .05 .95
CELLOPHANE .003 .05 .95

EPOXY .004 .04 .96
FLUOROPOLYMERS, "TEFLON" .010 .03 .97
PHENOLICS, "PLENCO" .005 .05 .95

POLYAMIDE, “NYLON” .010 .04 .96
POLYAMIDE, "KAPTON" .002 .07 .93
POLYCARBONATE, “LEXAN” .005 .07 .93

POLYESTER, P.E.T., “MYLAR”, “DACRON” .004 .09 .91
POLYETHYLENE .10 .04 .96
POLYPROPYLENE .050 .04 .96

POLYSTYRENE .030 .04 .96
POLYURETHANE .003 .05 .95
POLYVINYL CHLORIDE (PVC), “GEON” .005 .04 .96

LIQUIDS

WATER 0.003 0.02 0.98
OIL, MINERAL .040 .03 .97
OIL, ANIMAL OR VEGETABLE .006 .05 .95

GLASSES

SODA-LIME (WINDOWS, BOTTLES) 0.006 0.02 0.98
CHEMICAL “PYREX” .001 .06 .94
FUSED QUARTZ .006 .15 .85

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

METALS, BARE Unoxidized (For oxidized samples of metals, refer to “Composites and Miscellaneous” of Table 6.12.)

ALUMINUM Materials in this class are 0.98 0.02
CHROMIUM opaque (zero transmittance) .91 .09
COPPER at any thickness .98 .02

GOLD .98 .02
IRON, CARBON STEEL .95 .05
LEAD .95 .05

NICKEL .96 .04
SILVER .98 .02
STAINLESS STEEL .87 .13

TIN .82 .18
ZINC .98 .02
(GRAPHITE) .35 .65

Section 6 — APPLICATIONS GUIDE

6–17

FOR ADDITIONAL EMISSIVITY VALUES FOR SERIES 48, SEE TABLE 6.10.

TABLE 6.9 (Continued)

Section 6 — APPLICATIONS GUIDE

6–18

TABLE 6.10

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN THEIR “USUAL” FORM

ARRANGED BY CLASSES OF MATERIAL

INSTRUMENT SERIES: MODLINE 4, Series 48 SPECTRUM: 7.5 to 8.5 microns

All specimens in this table are in their common physical form — e.g. raw materials like coal, gravel, sand, etc. in
their normal granular form; construction products like lumber, paneling, tiles, roofing, etc. in their normal delivered
forms.

Unless otherwise noted, these materials have negligible Transmittance

τ

in their common form. Any difference

between the listed Emissivity

ε

and a “perfect” Emissivity of 1.0 is due to Reflectance r.

Materials designated by a "†" symbol have negligible transmittance in bulk form, but thin films of these same
materials may be transparent. Emissivity will decrease in proportion to the increase in Transmittance.

TARGET MATERIAL EMISSIVITY

ε

TEXTILES, FABRICS

CARPET (COTTON, WOOL, SYNTHETIC) 0.98
FABRICS, CLOSE WEAVE (COTTON,
WOOL, SYNTHETIC) .90 - .95

FUR .96
LEATHER .96
PLASTICS .95

FOODS, FOOD PROCESSING

BAKERY GOODS 0.98
BATTERS .98
CANDY .98

CONFECTIONS .98
DAIRY PRODUCTS .98
FATS .98

FRUITS .98
FLOUR .98
GRAIN .98

GRAVIES .98
JELLIES, JAMS .98
LIQUIDS .98

MEATS .98
OILS .98
SAUCES .98

SUGAR .98
VEGETABLES .98

(Continued)

TARGET MATERIAL EMISSIVITY

ε

WOOD PRODUCTS

PAPER, WOOD PULP (0.003" THICK) 0.90
PAPER, BOND STATIONERY (0.003" THICK) .92*
PAPER, CLAY FILLED (0.012" THICK) .96

CARDBOARD .96
WOOD, SOFT OR HARD .95
HARDBOARD .95

BUILDING MATERIALS

ASPHALT, MACADAM 0.98
CLAY, DRY OR WET .98
CONCRETE, DRY .94

CONCRETE, WET .98
CORK .98
FIBERGLASS BATTS .98

FORMICA .92
GLASS .98
GRAVEL .98

LINOLEUM .96
PAINTED METAL .95
PAINTED WOOD, PLASTIC .96

PLASTIC PANELS .96
PLYWOOD .96
ROCK, CRUSHED .98

ROOFING, COMPOSITION .95
RUBBER CLOTH .96
SAND .96

TILES, CERAMICS .98
TILES, RUBBER, PLASTIC .95
WOOD .96

Section 6 — APPLICATIONS GUIDE

6–19

TABLE 6.10 (Continued)

TARGET MATERIAL EMISSIVITY

ε

COMPOSITES AND MISCELLANEOUS

CARBON STEEL, OXIDIZED 0.82
DRUGS, PHARMACEUTICALS .96
FIBERGLASS—EPOXY FORMS .96

GLASS COATED METAL .98
NICKEL, OXIDIZED .85
PAINTED METAL .90 - .97

PAINTED WOOD .97
PLASTIC LAMINATED WOOD .96
PRINTED CIRCUIT BOARDS .96

RECORDING TAPE .90
SALT BATH .96
SANDPAPER .96

STAINLESS STEEL, OXIDIZED .85
TOBACCO .96

TARGET MATERIAL EMISSIVITY

ε

INDUSTRIAL MATERIALS, INORGANIC

CERAMICS 0.98
CLAY .98
CHEMICALS, LIQUID OR SOLID .95

COAL .98
COKE .98
FIREBRICK .98

GLASS .98
GRAVEL .98
MINERALS, ORES .98

SAND .96
SLAG .98
STEEL BILLET, OXIDIZED .82

SLURRIES .98
WATER, .98
AQUEOUS SOLUTIONS .98

INDUSTRIAL MATERIALS, ORGANIC

CARBON BLACK 0.98
CHEMICALS, LIQUID .96
CHEMICALS, SOLID .96

COAL, COKE .98
OILS, FATS, GREASE † .96
PETROLEUM PRODUCTS † .96

PLASTICS † .96
SOLVENTS † .96

† Bulk form. Thin films of these materials may be transparent.

Section 6 — APPLICATIONS GUIDE

6–20

TABLE 6.11

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN IDEALIZED FORM

ARRANGED BY CLASSES OF MATERIALS

INSTRUMENT SERIES: MODLINE 4, Series 43 SPECTRUM: 3.36 to 3.50 microns

All specimens in this table are in the following form:

1. Thick enough to reduce Transmittance

τ

to less than 0.01.

2. Viewed surface clean, flat, and optically smooth.

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

PLASTICS

ABS, “CYCOLAC” 0.015 0.03 0.97
ACETAL, “DELRIN” 0.008 0.03 0.97
ACRYLIC, “PLEXIGLAS”, “LUCITE” 0.008 0.03 0.97

CELLULOSICS 0.003 0.03 0.97
CELLOPHANE 0.003 0.03 0.97
EPOXY 0.002 0.03 0.97

POLYAMIDE, “NYLON” 0.005 0.03 0.97
POLYCARBONATE, “LEXAN” 0.015 0.03 0.97
POLYESTER, PET, “MYLAR”, “DACRON” 0.020 0.03 0.97

POLYETHYLENE 0.005 0.03 0.97
POLYPROPYLENE 0.005 0.03 0.97
POLYSTYRENE 0.010 0.03 0.97

POLYVINYL CHLORIDE (PVC), “GEON” 0.010 0.03 0.97

LIQUIDS

WATER 0.003 0.02 0.98
OIL, MINERAL 0.003 0.03 0.97
OIL, ANIMAL OR VEGETABLE 0.003 0.03 0.97

GLASSES

SODA-LIME (WINDOWS, BOTTLES) 0.30 0.03 0.97
CHEMICAL “PYREX” 0.12 0.03 0.97

Section 6 — APPLICATIONS GUIDE

6–21

TABLE 6.11 (Continued)

TARGET MATERIAL MINIMUM THICKNESS REFLECTANCE EMISSIVITY

(inches) r

ε

METALS, BARE Unoxidized (For oxidized samples of metals, refer to “Composites and Miscellaneous” of Table 6.12.)

ALUMINUM Materials in this class are 0.98 0.02
COPPER opaque (zero transmittance) 0.98 0.02
GOLD at any thickness. 0.98 0.02

IRON, CARBON STEEL 0.85 0.15
NICKEL 0.93 0.07
SILVER 0.98 0.02

STAINLESS STEEL 0.85 0.15
TIN 0.69 0.31
ZINC 0.93 0.07

(GRAPHITE) 0.38 0.62

FOR ADDITIONAL EMISSIVITY VALUES FOR SERIES 43, SEE TABLE 6.12.

Section 6 — APPLICATIONS GUIDE

6–22

TABLE 6.12

GUIDE TO EMISSIVITY VALUES FOR TARGET MATERIALS IN THEIR “USUAL” FORM

ARRANGED BY CLASSES OF MATERIAL

INSTRUMENT SERIES: MODLINE 4, Series 43 SPECTRUM: 3.36 to 3.50 microns

All specimens in this table are in their common physical form—e.g. raw materials like coal, gravel, sand, etc. in
their normal granular form; construction products like lumber, paneling, tiles, roofing, etc. in their normal delivered
forms.

Unless otherwise noted, these materials have negligible Transmittance

τ

in their common form. Any difference

between the listed Emissivity

ε

and a “perfect” Emissivity of 1.0 is due to Reflectance r.

TARGET MATERIAL EMISSIVITY

ε

WOOD PRODUCTS

PAPER, WOOD PULP (0.003" THICK) ~0.85
PAPER, BOND STATIONERY (0.003" THICK) ~0.85
PAPER, CLAY FILLED (0.012" THICK) 0.75

CARDBOARD 0.92
WOOD, SOFT OR HARD 0.95
HARDBOARD 0.95

BUILDING MATERIALS

ASPHALT, MACADAM 0.98
CORK 0.98
FIBERGLASS BATTS 0.90

FORMICA 0.95
LINOLEUM 0.96
PAINTED METAL 0.75–0.95

PAINTED WOOD, PLASTIC 0.97
PLASTIC PANELS 0.97
PLYWOOD 0.90

ROOFING, COMPOSITION 0.95
RUBBER CLOTH 0.96
TILES, RUBBER, PLASTIC 0.95

TARGET MATERIAL EMISSIVITY

ε

TEXTILES, FABRICS

CARPET (COTTON, WOOL, SYNTHETIC) 0.97
FABRICS, CLOSE WEAVE (COTTON,
WOOL, SYNTHETIC) 0.80–0.95

FUR 0.96
LEATHER 0.96
PLASTICS 0.97

FOODS, FOOD PROCESSING

BAKERY GOODS 0.98
BATTERS 0.98
CANDY 0.98

CONFECTIONS 0.98
DAIRY PRODUCTS 0.98
FATS 0.98

FRUITS 0.98
FLOUR 0.98
GRAIN 0.98

GRAVIES 0.98
JELLIES, JAMS 0.98
LIQUIDS 0.97

MEATS 0.98
OILS 0.97
SAUCES 0.98

SUGAR 0.98
VEGETABLES 0.98

(Continued)

Section 6 — APPLICATIONS GUIDE

6–23

TABLE 6.12 (Continued)

TARGET MATERIAL EMISSIVITY

ε

INDUSTRIAL MATERIALS, INORGANIC

CERAMICS 0.96
CLAY 0.90
CHEMICALS, LIQUID 0.97

CHEMICALS, SOLID 0.80 - 0.95
COAL 0.98
COKE 0.98

FIREBRICK 0.85
GLASS 0.97
GRAVEL 0.95

MINERALS, ORES 0.80 - 0.96
SAND 0.97
SLAG 0.95

STEEL BILLET, OXIDIZED 0.82
SLURRIES 0.98
WATER, AQUEOUS SOLUTIONS 0.98

INDUSTRIAL MATERIALS, ORGANIC

CARBON BLACK 0.98
CHEMICALS, LIQUID 0.97
CHEMICALS, SOLID 0.80 - 0.96

COAL, COKE 0.98
OILS, FATS, GREASE 0.97
PETROLEUM PRODUCTS 0.97

PLASTICS 0.97
SOLVENTS 0.97
WAXES 0.97

TARGET MATERIAL EMISSIVITY

ε

COMPOSITES AND MISCELLANEOUS

CARBON STEEL, OXIDIZED 0.82
DRUGS, PHARMACEUTICALS 0.97
FIBERGLASS—EPOXY FORMS 0.97

GLASS COATED METAL 0.97
NICKEL, OXIDIZED 0.85
PAINTED METAL 0.90 - 0.97

PAINTED WOOD 0.97
PLASTIC LAMINATED WOOD 0.97
PRINTED CIRCUIT BOARDS 0.97

RECORDING TAPE 0.85
SALT BATH 0.97
SANDPAPER 0.90

STAINLESS STEEL, OXIDIZED 0.85
TOBACCO 0.97

Section 6 — APPLICATIONS GUIDE

6–24

Appendix

A–1

NEMA SAFETY GUIDELINES FOR THE APPLICATION, INSTALLATION, AND
MAINTENANCE OF SOLID STATE CONTROL

Section 1: DEFINITIONS

(This section is classified as NEMA Standard 11­15-1984.)

Electrical Noise—Unwanted electrical energy
which has the possibility of producing undesirable
effects in the control, its circuits, and system.

Electrical Noise Immunity—The extent to which
the control is protected from a stated electrical
noise.

Off-State Current—The current that flows in a
solid state device in the off-state condition.

Off-State Condition—The conditions of a solid
state device where no control signal is applied.

On-State Condition—The condition of a solid
state device when conducting.

Surge Current—A current exceeding the steady
state current for a short time duration, normally
described by its peak amplitude and time duration.

Transient Overvoltage—The peak voltage in
excess of steady state voltage for a short time dur­ing the transient conditions (e.g., resulting from the
operations of a switching device).

Section 2: GENERAL

(Sections 2 through 5 are classified as Authorized

Engineering Information 11-15-1984.)

Solid State and electro-mechanical controls can
perform similar control functions, but there are cer­tain unique characteristics of solid state controls
which must be understood.

In the application, installation and maintenance of
solid state control, special consideration should be
given to the characteristics described in 2.1
through 2.7.

2.1 AMBIENT TEMPERATURE

Care should be taken not to exceed the ambient
temperature range specified by the manufacturer.

2.2 ELECTRICAL NOISE

Performance of solid state controls can be affected
by electrical noise. In general, complete systems
are designed with a degree of noise immunity.
Noise immunity can be determined with tests such
as described in 3.4.2. Manufacturer recommended
installation practices for reducing the effect of
noise should be followed.

2.3 OFF-STATE CURRENT

Solid state controls generally exhibit a small
amount of current flow when in the off-state condi­tion. Precautions must be exercised to ensure
proper circuit performance and personnel safety.
The value of this current is available from the man­ufacturer.

2.4 POLARITY

Incorrect polarity of applied voltages may damage
solid state controls. The correct polarity of solid
state controls should be observed.

2.5 RATE OF RISE–VOLTAGE OR CURRENT
DV/DT or DI/DT

Solid state controls can be affected by rapid
changes of voltage or current if the rate of rise
(DV/DT and/or DI/DT) is greater than the maximum
permissible value specified by the manufacturer.

2.6 SURGE CURRENT

Current of a value greater than that specified by
the manufacturer can affect the solid state control.
Current limiting means may be required.

2.7 TRANSIENT OVERVOLTAGE

Solid state controls may be affected by transient
over-voltages which are in excess of those speci­fied by the manufacturer. Voltage limiting means
should be considered and may be required.

Appendix

A–2

Section 3: APPLICATION GUIDELINES

3.1 GENERAL APPLICATION PRECAUTIONS

3.1.1 Circuit Considerations

The consequences of some malfunctions such as
those caused by shorted output devices, alteration,
loss of memory, or failure of isolation within compo­nents or logic devices require that the user be con­cerned with the safety of personnel and the protec­tion of the electronics.

It is recommended that circuits which the user con­siders to be critical to personnel safety, such as
“end of travel” circuits and “emergency stop” cir­cuits, should directly control their appropriate func­tions through an electromechanical device indepen­dent of the solid state logic. Such circuits should ini­tiate the stop function through deenergization rather
than energization of the control device. This pro­vides a means of circuit control that is independent
of system failure.

3.1.2 Power Up/Power Down Considerations

Consideration should be given to system design so
that unsafe operation does not occur under these
conditions since solid state outputs may operate
erratically for a short period of time after applying or
removing power.

3.1.3 Redundancy and Monitoring

When solid state devices are being used to control
operations, which the user determines to be critical,
it is strongly recommended that redundancy and
some form of checking be included in the system.
Monitoring circuits should check that actual
machine or process operation is identical to con­troller commands; and in the event of failure in the
machine, process, or the monitoring system, the
monitoring circuits should initiate a safe shutdown
sequence.

3.1.4 Overcurrent Protection

To protect triacs and transistors from shorted loads,
a closely matched short circuit protective device
(SCPD) is often incorporated. These SCPD’s
should be replaced only with devices recommend­ed by the manufacturer.

3.1.5 Overvoltage Protection

To protect triacs, SCR’s and transistors from over­voltages, it may be advisable to consider incorpo­rating peak voltage clamping devices such as varis-

tors, zener diodes, or snubber networks in circuits
incorporating these devices.

3.2 CIRCUIT ISOLATION REQUIREMENTS

3.2.1 Separating Voltages

Solid state logic uses low level voltage (e.g., less
than 32 volts dc) circuits. In contrast, the inputs and
outputs are often high level (e.g., 120 volts ac) volt­ages. Proper design of the interface protects
against an unwanted interaction between the low
level and high level circuits; such an interaction can
result in a failure of the low voltage circuitry. This is
potentially dangerous. An input and output circuitry
incorporating effective isolation techniques (which
may include limiting impedance or Class 2 supplied
circuitry) should be selected.

3.2.2 Isolation Techniques

The most important function of isolation compo­nents is to separate high level circuits from low
level circuits in order to protect against the transfer
of a fault from one level to the other.

Isolation transformers, pulse transformers, reed
relays, or optical couplers are typical means to
transmit low level logic signals to power devices in
the high level circuit. Isolation impedance means
also are used to transmit logic signals to power
devices.

3.3 SPECIAL APPLICATION CONSIDERATIONS

3.3.1 Converting Ladder Diagrams

Converting a ladder diagram originally designed for
electromechanical systems to one using solid state
control must account for the differences between
electromechanical and solid state devices. Simply
replacing each contact in the ladder diagram with a
corresponding solid state “contact” will not always
produce the desired logic functions or fault detec­tion and response. For example, in electromechani­cal systems, a relay having a mechanically linked
normally open (NO) and normally closed (NC) con­tact can be wired to check itself. Solid state compo­nents do not have a mutually exclusive NO-NC
arrangement. However, external circuitry can be
employed to sample the input and “contact” state
and compare to determine if the system is function­ing properly.

Appendix

A–3

3.3.2 Polarity and Phase Sequence

Input power and control signals should be applied
with polarity and phase sequence as specified by
the manufacturer. Solid state devices can be dam­aged by the application of reverse polarity or incor­rect phase sequence.

3.4 PLANNING ELECTRICAL NOISE -

REJECTION

The low energy levels of solid state controls may
cause them to be vulnerable to electrical noise.
This should be considered in the planning stages.

3.4.1 Assessing Electrical Environment

Sources of noise are those pieces of equipment
that have large, fast changing voltages or currents
when they are energized or de-energized, such as
motor starters, welding equipment, SCR type,
adjustable speed devices, and other inductive
devices. These devices, as well as the more com­mon control relays and their associated wiring, all
have the capability of inducing serious current and
voltage transients on their respective power lines. It
is these transients which nearby solid state controls
must withstand and for which noise immunity
should be provided.

An examination of the proposed installation site of
the solid state control should identify equipment
that could contaminate power lines. All power lines
that will be tapped by the proposed solid state con­trol should be examined for the presence, severity,
and frequency of noise occurrences. If found, sys­tem plans should provide for the control of such
noise.

3.4.2 Selecting Devices to Provide Noise
Immunity

Installation planning is not complete without exami­nation of the noise immunity characteristics of the
system devices under consideration. Results of
tests to determine relative immunity to electrical
noise may be required from the manufacturer. Two
such standardized tests are the ANSI (C37.90a-

1974) Surge Withstand Capability Test and the

NEMA (ICS 1-1983) noise test referred to as The
Showering Arc Test. These are applied where
direct connection of solid state control to other elec­tromechanical control circuits is intended. Circuits
involving analog regulating systems or high speed
logic are generally more sensitive to electrical
noise; therefore, isolation and separation of these
circuits is more critical.

Further information on electrical noise and evalua­tion of the severity of noise may be found in
ANSI/IEEE Publication No. 518-1982.

Where severe power line transients are anticipated
or noted, appropriate filters such as commercially
available line filter, isolation transformers, or volt­age limiting varistors, should be considered.

All inductive components associated with the sys­tem should be examined for the need for noise sup­pression.

3.4.3 Design of Wiring for Maximum Protection

Once the installation site and power conductors
have been examined, the system wiring plans that
will provide noise suppression should be consid­ered.

Conducted noise enters solid state control at the
points where the control is connected to input lines,
output lines, and power supply wires.

Input circuits are the circuits most vulnerable to
noise. Noise may be introduced capacitatively
through wire to wire proximity or magnetically from
nearby lines carrying large currents. In most instal­lations, signal lines and power lines should be sep­arate. Further, signal lines should be appropriately
routed and shielded according to the manufactur­er’s recommendations.

When planning system layout, care must be given
to appropriate grounding practice. Because design
differences may call for different grounding, the
control manufacturer’s recommendations should be
followed.

3.5 COUNTERING THE EFFECTS OF OFF-
STATE CURRENT

3.5.1 Off-State Current

Solid state components, such as triacs, transistors,
and thyristors, inherently have in the off-state a
small current flow called “off-state current”.

Off-state current may also be contributed by
devices used to protect these components, such
as RC snubbers.

3.5.2 Off-State Current Precautions

Off-state currents in a device in the off-state may
present a hazard of electrical shock and the device
should be disconnected from the power source
before working on the circuit or load.

Appendix

A–4

Precautions should be taken to prevent the off­state current of an output device which is in the off­state from energizing an input device.

3.6 AVOIDING ADVERSE ENVIRONMENTAL
CONDITIONS

3.6.1 Temperature

Solid state devices should only be operated within
the temperature ranges specified by the manufac­turer. Because such devices generate heat, care
should be taken to see that the ambient tempera­ture at the device does not exceed the tempera­ture range specified by the manufacturer.

The main source of heat in a solid state system is
the energy dissipated in the power devices. Since
the life of the equipment can be increased by
reducing operating temperature, it is important to
observe the manufacturer’s “maximum/minimum
ambient temperature” guidelines, where ambient
refers to the temperature of the air providing the
cooling. The solid state equipment must be
allowed to stabilize to within the manufacturer’s
recommended operating temperature range before
energizing control functions.

When evaluating a system design, other sources
of heat in the enclosure which might raise the
ambient temperature should not be overlooked.
For example, power supplies, transformers, radiat­ed heat, sunlight, furnaces, incandescent lamps,
and so forth should be evaluated.

In instances where a system will have to exist in a
very hot ambient environment, special cooling
methods may have to be employed. Techniques
that are employed include cooling fans (with ade­quate filtering), vortex coolers, heat exchanges,
and air conditioned rooms.

Over-temperature sensors are recommended for
systems where special cooling is employed. Use of
air conditioning should include means for preven­tion of condensing moisture.

3.6.2 Contaminants

Moisture, corrosive gases and liquids, and conduc­tive dust can all have adverse effects on a system
that is not adequately protected against atmo­spheric contaminants.

If these contaminants are allowed to collect on
printed circuit boards, bridging between the con­ductors may result in malfunction of the circuit.
This could lead to noisy, erratic control operation
or, at worst, a permanent malfunction. A thick coat­ing of dust could also prevent adequate cooling on
the board or heat sink, causing malfunction. A dust
coating on heat sinks reduces their thermal effi­ciency.

Preventive measures include a specially condi­tioned room or a properly specified enclosure for
the system.

3.6.3 Shock and Vibration

Excessive shock or vibration may cause damage
to solid state equipment. Special mounting provi­sions may be required to minimize damage.

3.7 THE NEED FOR SAFETY–KNOWLEDGE
LEADS TO SAFETY

Planning for an effective solid state circuit requires
enough knowledge to make basic decisions that will
render the system safe as well as effective.

Everyone who works with a solid state control
should be educated in its capabilities and limita­tions. This includes in-plant installers, operators,
service personnel, and system designers.

Section 4: APPLICATION GUIDELINES

4.1 INSTALLATION AND WIRING PRACTICE

4.1.1 Proper installation and field wiring practices

are of prime importance to the application of solid
state controls. Proper wiring practice will minimize
the influence of electrical noise, which may cause
malfunction of equipment.

Users and installers should familiarize themselves
with and follow installation and wiring instructions
in addition to requirements of all applicable codes,
laws, and standards. The manufacturer of the
device or component in question should be con­sulted whenever conditions arise that are not cov­ered by the manufacturer’s instructions.

Appendix

A–5

4.3 SPECIAL HANDLING OF ELECTROSTATIC
SENSITIVE DEVICES

Some devices may be damaged by electrostatic
charges. These devices are identified and should
be handled in the special manner specified by the
manufacturer.

NOTE: Plastic wrapping materials used to ship
these devices may be conductive and should not
be used as insulating material.

4.4 COMPATIBILITY OF DEVICES WITH
APPLIED VOLTAGES AND FREQUENCIES

Prior to energization, users and installers should
verify that the applied voltage and frequency agree
with the rated voltage and frequency specified by
the manufacturer.

NOTE: Incorrect voltage or frequency may cause a
malfunction of, or damage to, the control.

4.5 TESTING PRECAUTIONS

When testing solid state control, the procedures
and recommendations set forth by the manufactur­er should be followed.

When applicable, instrumentation and test equip­ment should be electrically equivalent to that rec­ommended by the manufacturer for the test proce­dure. A low impedance voltage tester should not
be used.

High voltage insulation tests and dielectric tests
should never be used to test solid state devices. If
high voltage insulation of field wiring is required,
solid state devices should be disconnected.
Ohmmeters should only be used when and as rec­ommended by the equipment manufacturer.

Testing equipment should be grounded; if it is not,
special precautions should be taken.

4.6 STARTUP PROCEDURES

Checks and tests prior to startup and startup pro­cedures recommended by the manufacturer
should be followed.

4.1.2 Electrical noise is a very important considera-
tion in any installation of solid state control. While
wiring practices may vary from situation to situa­tion, the following are basic to minimizing electrical
noise:

1. Sufficient physical separation should be main­tained between electrical noise sources and
sensitive equipment to assure that the noise
will not cause malfunctioning or unintended
actuation of the control.

2. Physical separation should be maintained
between sensitive signal wires and electrical
power and control conductors. This separation
can be accomplished by conduits, wiring trays,
or as otherwise recommended by the manu­facturer.

3. Twisted-pair wiring should be used in critical
signal circuits and noise producing circuits to
minimize magnetic interference.

4. Shielded wire should be used to reduce the
magnitude of the noise coupled into the low
level signal circuit by electrostatic or magnetic
coupling.

5. Provisions of the 1984 National Electrical Code
with respect to grounding should be followed.
Additional grounding precautions may be
required to minimize electrical noise. These
precautions generally deal with ground loop
currents arising from multiple ground paths.
The manufacturer’s recommendations should
be followed.

4.2 ENCLOSURES (COOLING AND

VENTILATING)

Suitable enclosures and control of the maximum
operating temperature, both of which are environ­mental variables, may be needed to prevent mal­function of solid state control.

The manufacturer’s recommendations should be
followed for the selection of enclosures, ventilation,
air filtering (if required), and ambient temperature.
These recommendations may vary from installation
to installation, even within the same facility.

Appendix

A–6

Section 5: PREVENTIVE MAINTENANCE
AND REPAIR GUIDELINES

5.1 GENERAL

A well-planned and -executed maintenance pro­gram is essential to the satisfactory operation of
solid state electrical equipment. The kind and fre­quency of the maintenance operation will vary with
the kind and complexity of the equipment as well
as with the nature of the operating conditions.
Maintenance recommendations of the manufactur­er or appropriate product standards should be fol­lowed.

Useful reference publications for setting up a main­tenance program are NFPA 70B-1983,
Maintenance of Electrical Equipment, and NFPA
70E-1983, Electrical Safety Requirements for

Employee Workplaces.

5.2 PREVENTIVE MAINTENANCE

The following factors should be considered when
formulating a maintenance program:

1. Maintenance must be performed by qualified
personnel familiar with the construction, opera­tion, and hazards involved with the control.

2. Maintenance should be performed with the
control out of operation and disconnected from
all sources of power. If maintenance must be
performed while the control is energized, the
safety related practices of NFPA 70E should
be followed.

3. Care should be taken when servicing electro­static sensitive components. The manufactur­er’s recommendations for these components
should be followed.

4. Ventilation passages should be kept open. If
the equipment depends upon auxiliary cooling,
e.g., air, water, or oil, periodic inspection (with
filter replacement when necessary) should be
made of these systems.

5. The means employed for grounding or insulat­ing the equipment from ground should be
checked to assure its integrity (see 4.5).

6. Accumulations of dust and dirt on all parts,
including on semiconductor heat sinks, should
be removed according to the manufacturer’s

instructions, if provided; otherwise, the manu­facturer should be consulted. Care must be
taken to avoid damaging any delicate compo­nents and to avoid displacing dust, dirt, or
debris in a way that permits it to enter or settle
into parts of the control equipment.

7. Enclosures should be inspected for evidence
of deterioration. Accumulated dust and dirt
should be removed from the top of the enclo­sures before opening doors or removing
covers.

8. Certain hazardous materials removed as part
of maintenance or repair procedure (e.g., poly­chlorinated biphenyls (PCB) found in some liq­uid filled capacitors) must be disposed of as
described in Federal regulations.

5.3 REPAIR

If equipment condition indicates repair or replace­ment, the manufacturer’s instruction manual should
be followed carefully. Diagnostic information within
such a manual should be used to identify the prob­able source of the problem, and to formulate a
repair plan. The level of field repair recommended
by the manufacturer should be followed.

When solid state equipment is repaired, it is impor­tant that any replacement part be in accordance
with the recommendations of the equipment manu­facturer. Care should be taken to avoid the use of
parts which are no longer compatible with other
changes in the equipment. Also, replacement parts
should be inspected for deterioration due to “shelf
life” and for signs of rework or wear which may
involve factors critical to safety.

After repair, proper start-up procedures should be
followed. Special precautions should be taken to
protect personnel from hazards during start-up.

5.4 SAFETY RECOMMENDATIONS FOR
MAINTENANCE PERSONNEL

All maintenance work should be done by qualified
personnel familiar with the construction, operation,
and hazards involved with the equipment. The
appropriate work practices of NFPA 70E should be
followed.

DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING:

IRCON MODLINE 4 PRODUCT AND ACCESSORIES

Following are the disassembly instructions for the Ircon Modline 4 product, including all optional
accessories, in accordance to guidelines of the European Union Waste Electric and Electronic
Equipment (WEEE) Directive 2002/96/EC.

This product includes the following materials to be dispensed of properly:

Aluminum Standard Sensor Casing Body and Lid, Spacers

Brass Cooling Jacket Body and Lid

Plastic Lens Housing
Steel Screws, Brackets within Lens Housing
Printed Circuit Board Within Modline 4 Sensor Assembly

Rubber Gaskets

Fully Assembled View:

At right is a photograph of a fully-assembled Ircon
Modline 4 sensor with standard casing.
Disassembly instructions for the Modline 4 sensor
with Standard casing, and with the Cooling Jacket
accessory is shown on the following pages. These
instructions account for all Modline 4 models, as
the variation between models affecting recycling is
minimal.

1

2

Modline 4 – with Cooling Jacket

Modline 4 – with Standard Casing

Standard

Casing

Lid

Modline 4

Sensor

Assembly

Standard

Casing

Body

Cooling

Jacket

Lid

Modline 4

Sensor

Assembly

Cooling

Jacket

Body

3 3

Page 1 of 3

DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING:

IRCON MODLINE 4 PRODUCT AND ACCESSORIES

Modline 4 – with Standard Casing

1

2

Modline 4 – with Cooling Jacket

Rubber

(Gasket)

Aluminum

Aluminum

Steel

Aluminum

3

Brass

Rubber

(Gasket)

Steel

Brass

Rubber

(Gasket)

Brass

3

Page 2 of 3

Brass

DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING:

IRCON MODLINE 4 PRODUCT AND ACCESSORIES

3

Steel

Rubber

Plastic Steel

Remove
Switch
Assembly

Remove
Wiring
Bracket
Assembly

Remove
Knob and
Switch
Assembly

Plastic

(Switch Assembly)

Aluminum

Steel

(Wiring Bracket Assembly,

Knob and Switch Assembly)

Aluminum

Page 3 of 3

Steel

(Backing Plate

and Screws)