optris PI 160, PI 200, PI 400, PI 230, PI 450G7 Owner's Manual

Operator’s Manual

optris

®

PI

160/ 200/ 230/ 400/ 450/ 450G7/ 640/ 1M

Infrared camera

Optris GmbH

Ferdinand-Buisson-Str. 14
D – 13127 Berlin
Germany

Tel.: [phone]
Fax: [phone]

E-mail: [e-mail]
Internet: www.optris.de

3

Table of contents

Table of contents

1

General Notes ..................................................................................................................................... 7

1.1 Intended use ................................................................................................................................. 7

1.2 Warranty ....................................................................................................................................... 9

1.3 Scope of delivery .......................................................................................................................... 9

1.4 Maintenance ............................................................................................................................... 11

1.4.1 Cleaning .............................................................................................................................. 11

1.5 Model overview ........................................................................................................................... 12

2 Technical Data .................................................................................................................................. 13

2.1 General specifications ................................................................................................................ 13

2.2 Electrical specifications ............................................................................................................... 17

2.3 Measurement specifications ....................................................................................................... 18

2.4 Optical specifications .................................................................................................................. 21

4

3 Mechanical Installation .................................................................................................................... 27

3.1 Dimensions ................................................................................................................................. 27

3.2 Mounting accessories (optional) ................................................................................................. 29

3.3 High temperature accessories .................................................................................................... 30

3.3.1 Cooling Jacket .................................................................................................................... 30

3.3.2 Cooling Jacket Advanced ................................................................................................... 33

4 Electrical Installation ........................................................................................................................ 37

4.1 Process interface ........................................................................................................................ 38

4.1.1 PIN allocation ...................................................................................................................... 40

4.1.2 Industrial Process Interface (optional) ................................................................................ 41

4.2 Example for a Fail-Safe monitoring of the PI with a PLC ........................................................... 45

4.3 USB cable extension .................................................................................................................. 47

5

Table of contents

5 Software PIConnect .......................................................................................................................... 49

5.1 Installation and initial start-up ..................................................................................................... 49

5.2 Software window ......................................................................................................................... 52

5.2.1 Basis features of the software PIConnect .......................................................................... 54

6 Basics of Infrared Thermometry ..................................................................................................... 57

7 Emissivity .......................................................................................................................................... 63

7.1 Definition ..................................................................................................................................... 63

7.2 Determination of unknown emissivity ......................................................................................... 65

7.3 Characteristic emissivity ............................................................................................................. 67

Appendix A – Table of emissivity for metals ......................................................................................... 69

Appendix B – Table of emissivity for non-metals ................................................................................. 71

Appendix C – Quick start for serial communication ............................................................................. 73

Appendix D – Interprocess Communication (IPC) ................................................................................ 75

Appendix E – PI Connect Resource Translator ..................................................................................... 77

6

Appendix F – Wiring diagrams PIF ......................................................................................................... 79

Appendix G – CE Conformity .................................................................................................................. 83

7

General Notes

1 General Notes

1.1 Intended use

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

The PI is a precise instrument and contains a sensitive infrared detector and a high-

quality lens. The alignment of the camera to intensive energy sources (high po we r
laser or reflections of such equipment, e.g.) can have effect on the accuracy of the
measurement or can cause an irreparable defect of the infrared detector.

8

• Avoid abrupt changes of the ambient temperature.

• Avoid static electricity, arc welders, and induction heaters. Keep away from very

strong EMF (electromagnetic fields).

• In case of problems or questions which may arise when you use the infrared
camera, please contact our service department.

► All accessories can be ordered according to the referred part numbers in

brackets [ ].

Read the manual carefully before the initial start-up. The producer reserves the right to

change the herein described specifications in case of technical advance of the product.

9

General Notes

1.2 Warranty

Each single product passes through a quality process. Nevertheless, if failures occur contact the
customer service at once. The warranty period covers 24 months starting on the delivery date. After the
warranty is expired the manufacturer guarantees additional 6 months warranty for all repaired or
substituted product component s. Warranty does not apply to damages, which result from misuse or
neglect. The warranty also expires if you open the product. The manufacturer is not liable for
consequential damage or in case of a non-intended use of the product.

If a failure occurs during the warranty period the product will be replaced, calibrated or repaired without
further charges. The freight costs will be paid by the sender. The manufacturer reserves the right to
exchange components of the product instead of repairing it. If the failure results from misuse or neglect
the user has to pay for the repair. In that case you may ask for a cost estimate beforehand.

1.3 Scope of delivery

Standard version

• PI160, PI200, PI230, PI400, PI450, PI450G7, PI640 or PI1M incl. 1 lens

• USB cable (1 m

1)

)

• Table tripod

• Process interface cable incl. terminal block (1 m)

• Software package PI Connect

10

• Operators manual

• Aluminum case

• PI450/ 640 only: Hard transport case (IP 67)

• PI200/ 230 only: focusing tool for VIS camera

Thermal Analysis Kit

• PI160 or PI200

• 3 lenses (23°, 6° and 41°, incl. calibration certificate)

• USB cable (1 m

1)

and 10 m)

• Tripod (20 - 63 cm)

• Process interface cable incl. terminal block (1 m)

• Software package PI Connect

• Operators manual

• Aluminum case

• PI200/ 230 only: focusing tool for VIS camera

1)

The camera plug of USB cable (1 m) does not feature an IP67 protection class. For industrial applications there are cables with

IP67 available starting at 5 m.

11

General Notes

1.4 Maintenance

1.4.1 Cleaning

Blow off loose particles using clean compressed air. The lens surface can be cleaned with a soft, humid
tissue moistened with water or a water based glass cleaner.

Never use cleaning compounds which contain solvents (neither for the lens nor for the

housing).

12

1.5 Model overview

The cameras of the PI-series are available in the following basic versions:

Modell

Model code

Measurement range

Spectral response

Typical applications

PI 160

IR

-20 to 900 °C

200 to 1500 °C (optional)

7.5-13 µm

Exact measurements of metallic and

non-metallic surfaces

PI 200/ Pi 230

BI-SPEKTRAAL

-20 to 900 °C

200 to 1500 °C (optional)

7.5-13 µm

Synchronous recording of VIS and IR

videos and im ages

PI 400/ PI 450

IR

-20 to 900 °C

200 to 1500 °C
(optional for PI 400)

7.5-13 µm

Real-time thermographic images in high

speed; Detection of smallest
temperature di f fer enc es (PI450)

PI 450 G7

IR

200 to 1500 °C

7.9 µm

Measurement of glass with Line-

Scanning mode

PI 640

IR

-20 to 900 °C

7.5-13 µm

Pin-sharp radiom etric recordings in real

time

PI 1M

IR

450 to 1800 °C

0.92-1.1 µm

Measurement of metallic surfaces,

graphite or ceramics with short
wavelengths

Table 1: Model overview

13

Technical Data

2 Technical Data

2.1 General specifications

Environmental rating:

IP67 (NEMA-4)

Ambient temperature:

0...50 °C (0...70 °C [PI 450/ PI 450 G7])

Storage tem perature:

-40...70 °C (-40...85 °C [PI 450/ PI 450 G7])

Relative humidity:

10...95 %, non-condensing

Material (housing):

Aluminum, anodized

Dimensions:

PI160/ PI20 0/ PI230: 45 x 4 5 x 62 - 65 mm (depending on lens)

PI400/ 450/ 640/1M: 46 x 56 x 86 - 90 mm (depending on lens)

Weight:

PI160: 195 g, P I200/ 230: 215 g, PI400/ PI450/ PI640/PI1M: 320 g

Cable length (USB 2.0):

1 m (standard), 5 m, 10 m, 20 m

Vibration1):

IEC 60068-2-6 (sinus shaped)

IEC 60068-2-64 (broadband noise)

Shock1):

IEC 60068-2-27 (25 g and 50 g)

14

1)

Used standards for vibration and shock:

Figure 1: Used standards

Stress program (camera in operation):

Shock, half sinus 25 g – testing Ea 25 g (acc. IEC 60068-2-27)

Acceleration

245 m/s2

(25 g)

Pulse duration

11 ms

Number of directions

6

(3 axes with 2 directions each)

Duration

600 Shocks

(100 Shocks each direction)

15

Technical Data

Shock, half sinus 50 g – testing Ea 50 g (acc. IEC 60068-2-27)

Acceleration

490 m/s2

(50 g)

Pulse duration

11 ms

Number of directions

6

(3 axes with two directions each)

Duration

18 Shocks

(3 Shocks each direction)

Vibration, sinus shaped – testing Fc (acc. IEC60068-2-6)

Frequency range

10-500 Hz

Acceleration

29.42 m/s2

(3 g)

Frequency change

1 Octave/ min

Number of axes

3

Duration

1:30 h

(3 x 0.30 h)

Vibration, broadba nd nois e – testing Fh (acc. IEC60068-2-64)

Frequency range

10-2000 Hz

16

Acceleration

39.3 m/s2

(4.01 g

RMS

))

Frequency spectrum

10-106 Hz

0.9610 (m/s2)2/Hz

(0.010 g2/Hz)

106-150 Hz

+6 dB/ Octave

150-500 Hz

1.9230 (m/s2)2/Hz

(0.020 g2/Hz)

500-2000 Hz

-6 dB/ Octave

2000 Hz

0.1245 (m/s2)2/Hz

(0.00126 g2/Hz)

Number of axes

3

Duration

3 h

(3 x 1 h)

17

Technical Data

2.2 Electrical specificatio ns

Power Supply:

5 VDC (powered via USB 2.0 interface)

Current draw:

Max 500 mA

Output Proc ess Interface ( P IF

out)

0-10 V (Main area temperature, internal temperature, flag status, alarm)

[►Appendix F – W ir ing di a gr am s PIF]

Input Process Interface (PIF in)

0-10 V (Emissivity, am bient temperature, refere nce temperat ure, flag control, trigger ed

recording, t riggered snapshots, triggered line-scanner, uncommitted value)
[►Appendix F – W ir ing di a gr am s PIF]

Digital Input Process Interface

Flag control, triggered vi deo or triggered snapshots, triggered line-scanner

[►Appendix F – Wiring dia gram s PI F]

Digital interface:

USB 2.0

18

2.3 Measurement specifications

PI 160

PI 2001)

PI 2301)

Temperatur e ranges

20...100 °C; 0...250 °C; 150...900 °C; Option: 200…1500°C

Spectral range

7.5-13 µm

Detector

UFPA,

160 x 120 pixel@120 Hz

UFPA,

160 x 120 pixel @1 28 Hz3)

640 x 480 pixel (visual

Camera)

UFPA,

160 x 120 pixel @1 28 Hz3)

640 x 480 pixel (visual

Camera)

Lenses (FOV)

23° x 17°; 6° x 5° ; 41° x 31°; 72° x 52°

System accuracy2)

±2°C or ±2 %

Temperatur e resolution (NETD):

0.08 K with 23°; 0,3 K with 6°; 0.1 K with 41° and 72°

Warm-up time

10 min

Emissivity

0.100...1.100

Software

PIConnect

1)

For an ideal combination of IR and VIS image we recommend the 41° lens for PI200 and the 23° lens for PI230

2)

At ambient temperature 23±5 °C; whichever is greater

3)

The following options can be set: Option 1 (IR with 96 Hz at 160 x 120 px; VIS with 32 Hz at 640 x 480 px);

Option 2 (IR with 128 Hz at 160 x 120 px; VIS with 32 Hz at 596 x 447 px)

19

Technical Data

PI 400

PI 450

PI 450G7

Temperatur e ranges

20...100 °C; 0...250 °C;

150...900 °C;

Option: 200…1500°C

-20...100 °C; 0...250 °C;

150...900 ° C

200…1500°C

Spectral range

7.5-13 µm

7.5-13 µm

7.9 µm

Detector

UFPA,

382 x 288 pixel@80 Hz

(switchable to 27 Hz)

UFPA,

382 x 288 pixel@80 Hz

(switchable to 27 Hz)

UFPA,

382 x 288 pixel@80 Hz

(switchable to 27 Hz)

Lenses (FOV)

38° x 29°; 62° x 49°;

13° x 10°

38° x 29°; 62° x 49°;

13° x 10°

38° x 29°; 62° x 49°

System accuracy2)

±2°C or ±2 %

Temperatur e resolution

(NETD):

0.08 K1) with 38° and

62°; 0.1 K1) with 13°

0.04 K1) with 38° and

62°; 0.06 K1) with 13°

130 mK

Warm-up time

10 min

Emissivity

0.100...1.100

Software

PI Connect

1)

Value is valid at 40 Hz and 25°C room temperature

2)

At ambient temperature 23±5 °C; whichever is greater

20

PI 640

PI 1ML

PI 1MH

Temperatur e ranges

-20...100 °C; 0...250 °C;

150...900 ° C

450…1400 °C

(500…1400 ° C@1kHz)

700…1800 °C

Spectral range

7.5-13 µm

0.92-1.1 µm

Detector

UFPA,

640 x 480 pixel@32 Hz

UFPA,

382 x 288 pixel@80 Hz

(switchable to 27 Hz)

72x56 pixel@1000 Hz

UFPA,

768 x 480 pixel@32 Hz
382 x 288 pixel@80 Hz

(switchable to 27 Hz)

72x56 pixel@ 10 00 Hz

Lenses (FOV)

33° x 25°

FOV@382x2 88 px:

51°x 39°, 26°x 20°, 20°x

15°, 13°x 10°, 6,2°x

4,7°, 4,0°x 3,0°

FOV@768x4 80 px:

39°x 25°, 20°x 13°, 15°x 9°,

9,6°x 6°, 4,7°x 2,9°,

3,0°x 1,9°

System accuracy2)

±2°C oder ±2 %

Temperatur e resolution (NETD):

0.075 K1) with 33°

< 1K (700 °C), < 2K (1000 °C)

Warm-up time

10 min

Emissivity

0.100...1.100

Software

PI Connect

1)

Value is valid at 40 Hz and 25°C room temperature

2)

At ambient temperature 23±5 °C; whichever is greater

21

Technical Data

2.4 Optical specification s

Figure 2: PI 200 with visual camera

1

IR channel

2

VIS channel

Make sure that the focus of thermal channel and visual channel (PI200/ 230 only) is

adjusted correctly. For focusing the thermal camera turn the lens in right direction for
“close” and to the left for “infinite” (

Figure 2), as well as focusing the visual camera with

the focusing tool supplied in the scope of delivery (Figure 3).

22

Figure 3: Focusing tool for VIS camera

The variety of different lenses offers the possibility to precisely measure objects in different distances. We
offer lenses for close, standard distances and large distances. Different parameters are important if using
infrared cameras. They display the connection between the distance of the measured object and the size
of the pixel (

Table 2).

With the help of BI-SPECTRAL technolo g y at PI200/ 2 30, a visual image (VIS) can be combined with a
thermal image (IR). Both can be finally captured time synchronously:

23

Technical Data

Table 2: Table with examples showing what spot sizes and pixel sizes will be reached in which distance. For
individual configuration there are different lenses available. Wide angle lenses have a radial distortion due to their
large opening angle; the software PIConnec t has an algorithm which corrects this distortion.

* Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.

24

Table 3: Table with examples showing what spot sizes and pixel sizes will be reached in which distance. For
individual configuration there are different lenses available. Wide angle lenses have a radial distortion due to their
large opening angle; the software PIConnec t has an algorithm which corrects this distortion.

* Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.

25

Technical Data

Figure 4: Measurement field of the infrared camera optris PI representing the 23° x 17° lens

26

■

HFOV: Horizontal enlargement of the total measuring at object level

■

VFOV: Vertical enlargement of the total measuring at object level

■

IFOV: Size at the single pixel at object level

■

DFOV: Diagonal dimension of the total measuring field at object level

■

MFOV: Recommended, smallest measured object size of 3 x 3 pixel

27

Mechanical Installation

3 Mechanical Installation

3.1 Dimensions

The PI is equipped with two metric M4 thread holes on the bottom side (6 mm depth) and can be installed
either directly via these threads or with help of the tripod mount (also on bottom side).

Figure 5: PI160, dimensions [mm] Figure 6: PI200/ 230, dimensions [mm]

28

Figure 7: PI400/ PI450/ PI450G7/ PI640/ PI1M, dimensions [mm]

29

Mechanical Installation

3.2 Mounting accessories (optional)

Figure 8: Mounting base, stainless steel, adjustable in 2 axes [Part No.: ACPIMB]

Figure 9: Protective housing, stainless steel, Incl. Mounting base [Part No.: ACPIPH]

30

3.3 High temperature accessories

3.3.1 Cooling Jacket

• The IR camera can be used at ambient temperature up to 50 °C (up to 70 °C with

PI450/ PI450G7). For higher temperatures (up to 240 °C) the Cooling Jacket is
provided.

• For detailed information see installation manual.

31

Mechanical Installation

#

Figure 10: Cooling Jacket - Dimensions

32

Figure 11: Cooling jacket for PI [Part No.: ACPIxxxCJ]

Figure 12: Cooling jacket with mounting bracket

33

Mechanical Installation

3.3.2 Cooling Jacket Advanced

• The Cooling Jacket Advanced is available as Standard Version and Extended

Version.

• The IR camera can be used at ambient temperature up to 50 °C (up to 70 °C with
PI450/ PI450G7). For higher temperatures (up to 300 °C) the Cooling Jacket
Advanced is provided.

• For detailed information see installation manual.

34

Standard Version

Figure 13: Cooling Jacket Advanced [Part No.: ACPIxxxCJAS], Standard Version, 38°/ 62° optics - Dimensions

35

Mechanical Installation

Extended Version

• The Extended Version is provided for applications of the PI series with the PI Netbox

and industrial PIF or the USB Server Gigabit and industrial PIF.

36

Figure 14: Cooling Jacket Advanced [Part No.: ACPIxxxCJAE], Extended Version, 38°/ 62° optics - Dimensions

37

Electrical Installation

4 Electrical Installation

At the back side of the PI there are the two connector plugs. The left plug is for the USB cable. The right
connector plug is only used for the process interface.

Figure 15: Backside of the camera with connectors

1

Plug for PIF cable

2

Plug for USB cable

38

4.1 Process interface

The PI is equipped with a process interface (cable with integrated electronics and terminal block), which
can be programmed via the software as an Analog Input (AI) and Digital Input (DI) in order to control the
camera or as an Analog Output (AO) in order to control the process. The signal level is always 0-10 V.

The process interface can be activated choosing the following options:

Analog Input (AI):

Emissivity, ambient temperature, reference temperature, flag control, triggered recording, triggered

snapshots, triggered line-scanner, uncommitted value

Analog Output (AO):

Main area temperature, internal temperature, flag status, alarm

Digital Input (DI):

Flag control, triggered recording, triggered snapshots, triggered line-scanner

The process interface (electronics within cable as well as industrial interface) must be

powered separately (5-24 VDC). Before switching on the power the PIF cable must be
connected to the camera.

39

Electrical Installation

Figure 16: Configuration Standard Process Interface (PIF)

The standard process interface provides the following inputs and outputs:

Name

Description

max range1)/ status

AI

Analog input

0-10 V

DI

Digital input

24 V

AO

Analog output

Alarm output

0-10 V

0/ 10 V

1)

Depending on supply voltage; for 0-10 V on the AO the PIF has to be powered with min. 12 V.

40

4.1.1 PIN allocation

Figure 17: Rear side of the camera

USB

PIF

1 VCC

1 INT

2 GND

2 SDA (I²C)

3 SCL (I²C)

4 D -

4 DGND

5 D +

5 3.3 V (Out)

Consider that the input of the PIF is not protected if there is a direct PIF connection!

A voltage > 3 V on the INT pin will destroy the device!

41

Electrical Installation

If the process interface of the camera is directly connected to external hardware1) (without using the
supplied PIF cable) an activation of the field „Support proprietary PIF cable” in the menu
Tools/ Configuration/ Device (PIF) in the PIConnect software is necessary.

Figure 18: Support proprietary PIF cable

1)

We recommend using only a switching contact between INT and DGND as external hardware (button, relay).

4.1.2 Industrial Process Interface (optional)

For use in industrial environment the industrial process interface with 500 VAC

RMS isolation voltage

between PI and process is available (connection box with IP65, 5 m, 10 m or 20 m standard or high
temperature cable for camera connection, terminal for process integration).

[►Appendix F – Wiring

diagrams PIF]

42

Pin assignment PIF cable (industrial process interface)

Figure 19: Connections of the industrial Process Interface

GREY

Interrupt

GREEN

SCL (I²C)

YELLOW

SDA (I²C)

WHITE

3.3 V

BROWN

GND

SHIELD

GND

43

Electrical Installation

The industrial process interface provides the following inputs and outputs:

Name

Description

max range1)/ status

A IN 1 / 2

Analog input 1 and 2

0-10 V

D IN 1

Digital input

24 V

AO1 / 2 / 3

Analog output 1, 2 and 3

Alarm output 1, 2 and 3

0-10 V

0/ 10 V

DO1 / 2/ 3

Relay output 1, 2 and 3 2)

open/ closed (red LED on) / 0...30 V, 400 mA

FS

Fail-safe relay

open/ closed (green LED on)/ 0...30 V, 400 mA

1)

depending on supply voltage; for 0-10 V on the AO the PIF has to be powered with min. 12 V.

2)

active if AO1, 2 or 3 is/ are programmed as alarm output

44

The process interface has an integrated fail-safe mode. This allows to control conditions like interruption
of cables, shut-down of the software etc. and to give out these conditions as an alarm.

Controlled conditions on camera and software

Standard Process interface

ACPIPIF

Industrial Process interface

ACPIPIF500V2CBxx

Interruption USB cable to camera

√

√

Interruption data cable camera - PIF

√

√

Interruption power supply PIF

√

√

Shut-down of PIConnect software

√

√

Crash of PIConnect software

-

√

Fail-Safe-Output

0 V at analog output (AO)

open contact (fail-safe relay)/ green LED off

45

Electrical Installation

4.2 Example for a Fail-Safe monitoring of the PI with a PLC

Figure 20: Fail-Safe monitoring states

Fail-Safe monitoring states

[1]

Breakdown of PIF power supply

[4]

Malfunction of PI

[2]

Cable break of fail-safe cable

[5]

Breakdown of PI power supply/ Interruption of USB cable

[3]

Interruption of cable PI-PIF

[6]

Malfunction of PIConnect software

46

Figure 21: Fail-Safe monitoring states

Fail-Safe monitoring states

[1]

Breakdown of PIF power supply

[5]

Malfunction of PI

[2]

Cable break of fail-safe cable

[6]

Breakdown of PI power supply/ Interruption of USB cable

[3]

Short circuit of fail-safe cable

[7]

Malfunction of PIConnect software

[4]

Interruption of cable PI-PIF

47

Electrical Installation

4.3 USB cable extension

The maximum USB cable length is 20 m. For greater distances between PI and computer or for stand­alone solutions the optional PI NetBox or the USB Server Gigabit is provided:

Figure 22: Ethernet direct communication with PI Netbox

Figure 23: Ethernet network communication with PI Netbox

48

Figure 24: Stand-Alone operation with PI Netbox

Figure 25: USB Server Gigabit

49

Software PIConnect

5 Software PIConnect

5.1 Installation and initial start-up

Uninstall previous versions of the PI Connect before installing the new software. To

uninstall the software from your system use the Uninstall icon in the start menu.

A detailed description is provided in the software manual on the software CD.

Minimum system requirements:

• Windows Vista, Windows 7, Windows 8

• USB interface

• Hard disc with at least 30 MByte of free space

• At least 128 MByte RAM

• CD-ROM drive

50

1. Insert the installation CD into the according drive on your computer. If the autorun option is
activated the installation wizard will start automatically.

2. Otherwise start setup.exe from the CD-ROM. Follow the instructions of the wizard until the
installation is finished.

The installation wizard places a launch icon on the desktop and in the start menu:
Start\Programs\PIConnect

To uninstall the software from your system use the uninstall icon in the start menu.

1. To connect the camera to the PC, plug the USB cable to the camera first. Afterwards connect it
with the PC.

2. To disconnect the camera and the computer remove the USB cable from the computer first and
then disconnect it from the camera.

After the software has been started the live image from the camera is shown inside a window on your
PC screen.

3. Install the calibration data at first start of the software (supplied on the CD) .

51

Software PIConnect

Figure 26: Calibration data transfer

4. If necessary adjust the sharpness of the image by turning the exterior lens ring at the camera.

52

5.2 Software window

Figure 27: Software window

53

Software PIConnect

1

IR image from the camera

2

Icon for quick access to Image subtraction functio n

3

Icon enabling switching between color palettes

4

Temperature of measure area: Analyses the temperature according to the selected shape, e.g. average

temperature of the rectangle. The value is shown inside the IR image and the control displays

5

Alarm settings: Bar showing the defined temperature thresholds for low alarm value (blue arrow) and high

alarm value (red arrow). The color of numbers within control displays changes to red (when temperature above
the high alarm value) and to blue (when temperature below the low alarm value)

6

Control displays: Displays all temperature values in the defined measure areas like Cold Spots, Hot Spots,

temperature at cursor, internal temperature and chip temperature

7

Reference bar: Shows the scaling of temperature within the color palette

8

Histogram: Shows the statistic distribution of single tem perature values

9

Automatic/ manual scaling of the palette (displayed temperature range): Man., </> (min, max),

1σ : 1 Sigma, 3σ : 3 Sigma

10

Temperature profile: Shows the temperatures along max. 2 lines at any size and position in the image

54

5.2.1 Basis features of the software PIConnect

Extensive infrared camera software

• No restrictions in licensing

• Modern software with int uit i ve user interf ac e

• Remote control of camera via software

• Display of multiple camera images in different windows

• Compatible with Windows Vista, 7 and 8

High level of individualization for customer specific display

• Various language option including a translat ion too l

• Temperature display in °C or °F

• Different layout options for an individual setup (arrangement of

windows, toolbar)

• Range of individual measurement parameter fitting for each application

• Adaption of thermal image (mirror, rotate)

• Individual start options (full screen, hidden, etc.)

55

Software PIConnect

Video recording and snapshot function (IR o r BI-SPECTRAL)

• Recording of video sequences and detailed frames for further analysis
or documentation

• BI-SPECTRAL video analysis (IR and VIS) in order to highlight critical
temperatures

• Adjustment of recording frequency to reduce data volume

• Display of snapshot history for immediate analysis

Extensive online and offline data a nalysis

• Analysis supported by measurement fields, hot and cold spot
searching, image subtraction

• Real time temperature information within main window as digital or
graphic display (line profile, temperature time diagram)

• Slow motion repeat of radiometric files and analysis without camera
being connected

• Editing of sequences such as cutting and saving of individual images

• Various color palettes to highlight thermal contrasts

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Automatic process control

• Individual setup of alarm levels depending on the process

• BI-SPECTRAL process monitoring (IR and VIS) for easy orientation at

point of measurement

• Definition of visual or acoustic alarms and analog data output

• Analog and digital signal input (process parameter)

• External communication of software via Comports and DLL

• Adjustment of thermal image via reference values

Temperature data analysis and documentation

• Triggered data collection

• Radiometric video sequences (*.ravi) radiometric snapshots (*.tiff)

• Text files including temp. information for analysis in Excel (*.csv, *.dat)

• Data with color information for standard programmes such as

Photoshop or Windows Media Player (*.avi, *.tiff)

• Data transfer in real time to other software programs DLL or Comport
interfaces

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Basics of Infrared Thermometry

6 Basics of Infrared Thermometry

Depending on the temperature each object emits a certain amount of infrared radiation. A change in the
temperature of the object is accompanied by a change in the intensity of the radiation.

Searching for new optical material William Herschel by chance found the infrared radiation in 1800.

Figure 28: William Herschel (1738-1822)

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He blackened the peak of a sensitive mercury thermometer. This thermometer, a glass prism that led sun
rays onto a table made his measuring arrangement. With this, he tested the heating of different colors of
the spectrum. Slowly moving the peak of the blackened thermometer through the colors of the spectrum,
he noticed the increasing temperature from violet to red. The temperature rose even more in the area
behind the red end of the spectrum. Finally he found the maximum temperature far behind the red area.

Nowadays this area is called “infrared wavelength area”.

Figure 29: The electromagnetic spectrum and the area used f or tempera t ure mea sur eme nt

For the measurement of “thermal radiation” infrared thermometry uses a wave-length ranging between
1 µ and 20 µm. The intensity of the emitted radiation depends on the material. This material contingent
constant is described with the help of the emissivity which is a known value for most materials
(see enclosed table emissivity).

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Basics of Infrared Thermometry

Infrared thermometers are optoelectronic sensors. They calculate the surface temperature on the basis of
the emitted infrared radiation from an object. The most important feature of infrared thermometers is that
they enable the user to measure objects contactless. Consequently, these products help to measure the
temperature of inaccessible or moving objects without difficulties.

Figure 30: Main principle of noncontact thermometry

Infrared thermometers basically consist of the following components:

• Lens

• Spectral filter

• Detector

• Electronics(amplifier/ linearization/ signal processing)

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The specifications of the lens decisively determine the optical path of the infrared thermometer, which is
characterized by the ratio Distance to Spot size. The spectral filter selects the wavelength range, which is
relevant for the temperature measurement. The detector in cooperation with the processing electronics
transforms the emitted infrared radiation into electrical signals.

The advantages of noncontact thermometry are clear - it supports:

• temperature measurements of moving or overheated
objects and of objects in hazardous surroundings

• very fast response and exposure times

• measurement without inter-reaction, no influence on the

• measuring object

• non-destructive measurement

• long lasting measurement, no mechanical wear

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Basics of Infrared Thermometry

Figure 31: Non-contact thermometry

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Application field:

Monitoring of electronic

cabinets

R&D of electroni cs

R&D of electroni c parts

Process control extruding

plastic parts

Process control

manufacturing s olar
modules

Process control at

calendering

R&D of mechanical parts

Monitoring of cables

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Emissivity

7 Emissivity

7.1 Definition

The intensity of infrared radiation, which is emitted by each body, depends on the temperature as well as
on the radiation features of the surface material of the measuring object. The emissivity (ε – Epsilon) is
used as a material constant factor to describe the ability of the body to emit infrared energy. It can range
between 0 and 100 %. A “blackbody” is the ideal radiation source with an emissivity of 1.0 whereas a
mirror shows an emissivity of 0.1.

Figure 32: Capability of an object to em it radiation

I

Passed radiation

ε

Reflection

ρ

Transmission

τ

Emissivity=Absorption

ε + ρ+ τ = 1

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Figure 33: Spectral emissivity of several materials: 1 Enamel, 2 Plaster, 3 Concrete, 4 Chamotte

If the emissivity chosen is too high, the infrared thermometer may display a temperature value which is
much lower than the real temperature – assuming the measuring object is warmer than its surroundings.
A low emissivity (reflective surfaces) carries the risk of inaccurate measuring results by interfering infrared
radiation emitted by background objects (flames, heating systems, chamottes). To minimize measuring
errors in such cases, the handling should be performed very carefully and the unit should be protected
against reflecting radiation sources.

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Emissivity

7.2 Determination of unknown emissivity

► First determine the actual temperature of the measuring object with a thermocouple or contact sensor.

Second, measure the temperature with the infrared thermometer and modify the emissivity until the
displayed result corresponds to the actual temperature.

► If you monitor temperatures of up to 380 °C you may place a special plastic sticker (emissivity dots –

Part No.: ACLSED) onto the measuring object, which covers it completely.

Figure 34: Plastic sticker at metal surface

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1. Set the emissivity to 0.95 and take the temperature of the sticker.

2. Afterwards, determine the temperature of the adjacent area on the measuring object and adjust
the emissivity according to the value of the temperature of the sticker.

3. Cove a part of the surface of the measuring object with a black, flat paint with an emissivity of

0.98. Adjust the emissivity of your infrared thermometer to 0.98 and take the temperature of the
colored surface.

Figure 35: Shiny metal surface left and blackened metal surface right

4. Afterwards, determine the temperature of a directly adjacent area and modify the emissivity until
the measured value corresponds to the temperature of the colored surface.

CAUTION: On all three methods the object temperature must be different from ambient temperature.

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Emissivity

7.3 Characteristic emissi vity

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

• temperature

• measuring angle

• geometry of the surface

• thickness of the material

• constitution of the surface (polished, oxidized, rough, sandblast)

• spectral range of the measurement

• transmissivity (e.g. with thin films)

Figure 36: Adjustment of the emissivity in the software PI Connect (menu Configuration/ Device)

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69

Emissivity metals

Appendix A – Table of emissivity for metals

70

71

Emissivit y non-metals

Appendix B – Table of emissivity for non-metals

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73

Serial communication

Appendix C – Quick start for serial communication

Introduction

One special feature of the PI Connect software contains the possibility to communicate via a serial
comport interface. This can be a physical comport or a Virtual Comport (VCP). It must be available on the
computer where the PI connect software is installed.

Setup of the interface

1. Open the Options dialog and enter the tab “Extended Communication” to enable the
software for the serial communication.

2. Select the mode “Comport” and choose the appropriate port.

3. Select the baud rate that matches the baud rate of the other communication device. The other
interface parameters are 8 data bits, no parity and one stop bit (8N1).

These parameters are used in many other communication devices too. The other station must support 8
bit data.

4. Connect the computer with the communication device. If this is a computer too, use a null modem
cable.

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Command list

The command list is provided on the software CD. Every command must expire with

CR/LF (0x0D, 0x0A).

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Interprocess communication (ICP)

Appendix D – Interprocess Communication (IPC)

The communication to the process imager device is handled by the PI Connect software (Imager.exe)
only. A dynamic link library (ImagerIPC2.dll) provides the interprocess communication (IPC) for other
attached processes. The DLL can be dynamically linked into the secondary application. Or it can be done
static by a lib file too. Both Imager.exe and ImagerIPC.dll are designed for Windows Vista/ 7/ 8
only. The application must support call-back functions.

The ImagerIPC.dll will export a bunch of functions that are responsible for initiating the
communication, retrieving data and setting some control parameters.

The description of the initialization procedure as well as the necessary command list is

provided on the CD.

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77

Resource Translator

Appendix E – PI Connect Resource Translator

PI Connect is a .Net Application. Therefore it is ready for localization. Localization as a Microsoft
idiom means a complete adaption of resources to a given culture. Learn more about the
internationalization topics consult Microsoft’s developer documentation on

http://msdn.microsoft.com/en-us/goglobal/bb688096.aspx

.

If desired the localization process can be illustrated in detail. Also the resizing of buttons or other visible
resources and the support of right-to-left-languages are supported. Ex perts who have the appropriate
tools should handle it. Nevertheless we have developed the small tool “Resource Translator” to
make the translation of the resources of the PI Connect application possible for everybody.

This tool helps to translate any visible text within the PI Connect application.

A detailed tutorial is provided on the CD.

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79

Wiring diagrams PIF

Appendix F – Wiring diagrams PIF

Analog Output:

Figure 37: Analog output

For voltage measurements the minimum load impedance must be 10KOhm.
The analog output can be used as a digital output too. The voltage for “no alarm” and “alarm on” is

set within the software. The analog output (0 … 10 V) has a 100 Ohm resistor in series. With a maximum
current of 10 mA the voltage drop is 1 V.

To use an alarm LED with a forward voltage of 2 V the analog output value for “alarm on” must be 3 V
as maximum.

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Digital Input:

Figure 38: Digital input

The digital input can be activated with a button to the PI GND-Pin or with a low level CMOS/TTL signal:
Low level 0…0.6 V; High level 2…24 V

Example Button:

Figure 39: Button

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Wiring diagrams PIF

Analog input (usable voltage range: 0 … 10 V):

Figure 40: Analog input

Relay output at industrial PIF [Part No.: ACPIPIF500V2CBxx]

The analog output must be set to “Alarm”. The voltage level for AO1-AO3 can be set in the software
(no alarm: 0 V/ alarm: 2-10 V)

REL1-3 (DO1-DO3): U

max

= 30 VDC

I

max

= 400 mA

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Figure 41: Relay output at industrial PIF

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CE Conformity

Appendix G – CE Conformity

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optris PI-MA-E2014-12-A