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optris PI LightWeight kit Operator's Manual

Miniature lightweight pc with ir camera for flight applications
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Operator's Manual
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optris
PI LightWeight kit
Miniature lightweight PC with IR camera
for flight applications

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Summary of Contents for optris PI LightWeight kit

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

  • Page 3: Table Of Contents

    Table of contents Table of contents General notes ............................7 Intended use ..........................7 Warranty ............................9 Scope of delivery .......................... 9 Maintenance ..........................11 1.4.1 Cleaning ..........................11 Technical Data ..........................13 Data NetBox LW ......................... 13 2.1.1 General specifications ......................13 2.1.2 Electrical specifications .......................
  • Page 4 2.2.1 General specifications ......................15 2.2.2 Electrical specifications ....................... 19 2.2.3 Measurement specifications ....................20 2.2.4 Optical specifications ......................21 Installation ............................25 Mechanical Data PI 400/ PI 450 LW ................... 26 Mechanical Data PI NetBox LW ....................27 Operation ............................31 Operation modes of the NetBox LW ...................
  • Page 5 Table of contents Status-LEDs ..........................38 Switch positions .......................... 39 Remote Access to the NetBox LW ..................... 40 4.7.1 Installation of Ultra VNC ..................... 40 4.7.2 Display the NetBox ......................43 Applications and start options ..................... 44 Watchdog ............................ 50 4.10 Autostart............................
  • Page 6 4.13 USB Driver ..........................71 4.14 System time ..........................71 4.15 Write protection filter ........................73 System Recovery ..........................77 Basics of Infrared Thermometry ..................... 83 Emissivity ............................ 89 CE Conformity ........................... 91...

  • Page 7: General Notes

    1 General notes 1.1 Intended use The optris PI LightWeight Kit consists of a miniaturized lightweight PC (PI NetBox LW) and a weight- optimized optris PI400 LW or PI450 LW infrared camera. The system is ideally suited for radiometric infrared recordings from the air like for maintenance work and quality inspections of solar and wind power systems and for building thermography.
  • Page 8 The optris 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 power 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.

  • Page 9: Warranty

    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 components.
  • Page 10 • optris PI400 LW or PI450 LW (LightWeight) with one lens and fixed mounted USB cable (30 cm) and aluminum case • Software PIConnect • Operators manual For a mobile use you can arrange all components of the system also inside the camera case as shown in .

  • Page 11: Maintenance

    General notes 1.4 Maintenance Never use cleaning compounds which contain solvents (neither for the lens nor for the housing). Take care that no foreign substances penetrate into the venting slots of the NetBox 1.4.1 Cleaning The housing of the NetBox LW can be cleaned with a soft, humid tissue moistened with water or a water based cleaner.

  • Page 13: Technical Data

    Technical Data 2 Technical Data 2.1 Data NetBox LW 2.1.1 General specifications Operating temperature: 0…50 °C Storage temperature: -20...75 °C Relative humidity: 10...95 %, non-condensing Material (housing): aluminum anodized/ plastic Dimensions: 112 mm x 58 mm x 54 mm (L x B x H) Weight: 160 g Vibration:...

  • Page 14: Electrical Specifications

    2.1.2 Electrical specifications Power supply: 8...48 VDC or Power over Ethernet (PoE/ 1000BASE-T) Power consumption: 9.5 W (+ additional 2,5 W for PI camera) Cooling: passive (active via integrated fan for ambient temperatures > 50 °C) Board: COM Express mini embedded board Processor: Intel Atom...

  • Page 15: Data Pi 400/ Pi 450 Lw

    Technical Data 2.2 Data PI 400/ PI 450 LW 2.2.1 General specifications Environmental rating: IP40 Ambient temperature: 0...50 °C [PI 400 LW] / 0...70 °C [PI 450 LW] Storage temperature: -40...70 °C [PI 400 LW] / -40...85 °C [PI 450 LW] Relative humidity: 10...95 %, non-condensing Material (housing):...
  • Page 16 1) Used standards: Figure 2: Used standards...
  • Page 17 Technical Data Stress program (camera in operation): Shock, half sinus 25 g – testing Ea 25 g (acc. IEC 60068-2-27) Acceleration 245 m/s (25 g) Pulse duration 11 ms Number of directions (3 axes with 2 directions each) Duration 600 Shocks (100 Shocks each direction) Shock, half sinus 50 g –...
  • Page 18 Vibration, sinus shaped – testing Fc (acc. IEC60068-2-6) Frequency range 10-500 Hz Acceleration 29.42 m/s (3 g) Frequency change 1 Octave/ min Number of axes Duration 1:30 h (3 x 0.30 h) Vibration, broadband noise – testing Fh (acc. IEC60068-2-64) Frequency range 10-2000 Hz Acceleration...

  • Page 19: Electrical Specifications

    Technical Data 500-2000 Hz -6 dB/ Octave 2000 Hz 0,1245 (m/s (0,00126 g /Hz) Number of axes Duration (3 x 1 h) 2.2.2 Electrical specifications Power Supply: 5 VDC (powered via USB 2.0 interface) Current draw: Max 500 mA Digital interface: USB 2.0...

  • Page 20: Measurement Specifications

    2.2.3 Measurement specifications Temperature ranges: -20...100 °C; 0...250 °C; 150...900 °C Detector: UFPA, 382 x 288 pixel Spectral range: 7.5...13 µm Lenses (FOV): 38° x 29°; 62° x 49° System accuracy ±2°C or ±2 % Temperature resolution (NETD): PI 400 LW : 0.08 K with 38°...

  • Page 21: Optical Specifications

    Technical Data 2.2.4 Optical specifications • Make sure that the focus of the infrared camera is adjusted correctly. For focusing turn the lens ( Figure 3 • For the PI 400 LW and PI 450 LW two different lenses are available: 38° x 29° and 62°...
  • Page 22 Table 1: 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 PIConnect an algorithm which corrects this distortion. * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 23 Technical Data Figure 4: Measurement field of the infrared camera optris PI representing the 23° x 17° lens...
  • Page 24 ■ HFOV: Horizontal enlargement of the total measuring at object level ■ VFOV: Vertical enlargement of the total measuring at object level ■ IFOV: Size at the single pixel at object level ■ DFOV: Diagonal dimension of the total measuring field at object level ■...

  • Page 25: Installation

    Installation 3 Installation The PI 400 LW/ 450 LW are equipped with two metric M4 thread holes on the bottom side (6 mm depth) and can be installed either directly via these threads or with help of the tripod mount (also on bottom side).

  • Page 26: Mechanical Data Pi 400/ Pi 450 Lw

    3.1 Mechanical Data PI 400/ PI 450 LW Figure 6: Dimensions PI 400/ PI 450 LW...

  • Page 27: Mechanical Data Pi Netbox Lw

    Installation 3.2 Mechanical Data PI NetBox LW Figure 7: Dimensions PI NetBox LW...
  • Page 28 Figure 8: Controls and connections PI NetBox LW...
  • Page 29 Installation Cooling fan USB 2.0 socket Video socket Ethernet socket USB 2.0 socket Mode switch (S1/ S2) Power supply socket Mini USB socket (slave mode) Status-LEDs (L1-L6) microSDHC card slot...

  • Page 31: Operation

    Operation 4 Operation 4.1 Operation modes of the NetBox LW • Use the recommended PoE injector (Order No.: ACPIPOE) only. • Damages which are caused by usage of another PoE injector are excluded from warranty The NetBox LW can be used in three different operation modes: •...

  • Page 32: Stand-Alone Operation

    4.2 Stand-Alone operation • For a self-contained power supply we recommend a lithium-polymer battery with a voltage between 8 and 14 VDC. • To switch between the analog video output signal of the PI 400 LW / LW 450 and a visual camera we recommend the use of an electronic universal switch from Co.
  • Page 33 Operation Figure 9: Recommended video system integration of the PI LightWeight...
  • Page 34 • Before switching on the NetBox LW and monitor must be connected via cable to ensure a correct initialization of the video output. • A change of the preset PAL mode to NTSC e.g. can be done in the BIOS. [Keyboard and monitor necessary] After powering the NetBox LW the system will boot and is ready after 2-3 minutes.

  • Page 35: Start A Recording

    Operation 4.3 Start a recording 1. To start the recording remotely use the supplied video cable (Order No.: ACPILKVCB2), see left: Figure 11 bk (thick) bk (thin) Recording trigger Video signal The recording starts if the trigger is connected with GND and stops if you interrupt this connection. Figure 11: Video cable (Order No.: ACPILKVCB2) left and video cable...
  • Page 36 Alternatively you can start the recording by using the red sliding switch at the backside of the IR camera. 1. To start a recording move the switch into the right position. To stop a recording remove the switch back into the left position. Figure 12: Start and stop a recording...

  • Page 37: Sd Card

    Operation 4.4 SD card • The NetBox LW will be delivered with an 8 GB SDHC card which is already installed on the unit. If required you can exchange this card. The NetBox is supporting SD cards up to 32 GB capacity. •...

  • Page 38: Status-Leds

    4.5 Status-LEDs The NetBox LW is equipped with 6 status LEDs (L1-L6): Function LED is lightning, if Power NetBox is powered via PoE or a power supply (via power connector) Power out NetBox is powered via PoE and (in this case) supplies 12 V at the power connector Net data video frames are transmitted through the network connection continuously (flashing) USB Data...

  • Page 39: Switch Positions

    Operation 4.6 Switch positions The mode switch is set default to S1. At position S2 the IR camera which is connected to the USB-A socket will be linked directly with the Mini-USB socket. With this you get a direct access to the IR camera from a PC which is connected to the Mini USB socket without changing cables on the NetBox LW.

  • Page 40: Remote Access To The Netbox Lw

    4.7 Remote Access to the NetBox LW For settings on the NetBox LW you can connect a keyboard and a mouse to the available USB sockets adapter cable). ► 4.1 Stand-alone as well as a monitor to the VGA socket (or a TV monitor via the TV Operation Another very simple way is remote control software, for example remote desktop (RDP) which is available on each Windows system or Ultra VNC which you will find on your software CD.
  • Page 41 Operation Figure 15: Short cuts 3. Use the short cut SyncViewer for access to a NetBox which is directly connected to your PC over an Ethernet cable. This short cut is synchronizing the time automatically on the NetBox and is starting then the UltraVNC viewer which is showing the screen of the NetBox.
  • Page 42 Figure 16: NetBox lister With the UltraVNC Viewer a simultaneous access to one NetBox from different PCs inside a network is possible.

  • Page 43: Display The Netbox

    Operation For access to a NetBox inside your network start the program UltraVNC Viewer which is located in the program folder NetBox – UltraVNC. After starting the viewer the following screen appears: Figure 17: UltraVNC Viewer setup 4.7.2 Display the NetBox 1.

  • Page 44: Applications And Start Options

    Figure 18: VNC Identification 4.8 Applications and start options On the desktop of the NetBox LW the following short cuts are available: Figure 19: Application Start Config short cut and Application Start Manager short cut Application Start Config: Starts the configuration dialog (Config Server) Application Start Manager: Starts the program selected in the configuration dialog...
  • Page 45 Operation After booting the system the PIConnect software starts in full screen mode with a special flight layout (factory-provided). • Option: User defined in Application Start Config In the configuration dialog you can select programs which start automatically after booting the NetBox: Figure 20: Config Server window...
  • Page 46 No automatic start of the program Imager Net Server Automatic start of the server application PI Connect Automatic start of the PI Connect software User defined User defined start of one of the upper two programs The Imager Net Server application is needed for the operation modes: •...
  • Page 47 Operation Figure 21: Configuration to start PIConnect in full screen mode Figure 22: Screen of the NetBox LW – Imager Net Server left and of the NetBox – PI Connect right...
  • Page 48 If the IR camera is connected to the NetBox two applications are shown: Monitor Imager Net Server and Imager Net Server or PI Connect. Counter for the application monitoring function Appl. Watchdog: Device: Frequency of the device Processing: Frequency of the processing Net connection: Frequency of the network Monitor:...
  • Page 49 Operation Menu File Exit of the program Devices Shows the connected imager Flag Manual operation of the camera flag USB video device Serial number of the connected imager device Device temperatures (°C): T (C, F, B): C: FPA-Chip F: Flag temperature B: Housing temperature PIFin (A, D): Status of the PIF input:...

  • Page 50: Watchdog

    N: Network Time: Time per single frame Queue: Number of frames in network queue FOV, TR: Field of view (horizontal) of the imager lens, Temperature range Table 4: Imager Net Server – Application window 4.9 Watchdog If the main application (Imager Net Server respectively PIConnect) for any reason does not work properly (in case of a software crash) or is closed, the monitor application restarts the program automatically.
  • Page 51 Operation Consider that all restarts will be counted even those which were not initialized by the Watchdog application. If the Watchdog application identifies a system error the NetBox restarts automatically. The Watchdog window opens by clicking the right mouse button on the symbol in the task bar. It shows the following information.

  • Page 52: Autostart

    • Last elapsed time • Number of restarts (can be reset with the right mouse button on WD symbol – Reset counter) 4.10 Autostart In the Windows Autostart folder of the NetBox LW the following short cuts are set by factory default: Figure 26: Startup window...

  • Page 53: File Transfer Between Netbox Lw And Pc

    Operation ewfMonitor Write protection filter MouseHider Hides the mouse pointer after 10 s of inactivity Watchdog Starts the Watchdog application Application Start Manager Starts the program selected in the Application Start Config 4.11 File transfer between NetBox LW and PC 1.
  • Page 54 The window shows the local PC (LOCAL MACHINE) on the left side and the NetBox (REMOTE MACHINE) on the right side. Files can be copied between both computers via the network link by selecting them and by confirming with the Send button respectively Receive button. Figure 28: File transfer window...

  • Page 55: Communication

    Operation 4.12 Communication 4.12.1 Ethernet direct communication The applied Ethernet cable must be complied at least with category 5 (Cat-5 according ISO/IEC 11801). 1. Connect the IR camera and the NetBox with the supplied USB connection cable. 2. Connect the PC and the NetBox with an Ethernet cable. 3.
  • Page 56 Figure 29: Ethernet direct connection (point-to-point connection)/ NetBox LW powered via power supply 4. Using a PoE injector the power supply for the NetBox is not needed. In this case the PoE injector must be connected as shown in . With orderly function L1, L2 and L5 are illuminating. Figure 30...
  • Page 57 Operation Figure 30: Ethernet direct connection (point-to-point connection)/ NetBox LW via PoE injector Connection to the NetBox LW The NetBox is already set to a fixed IP address (192.168.0.100) by factory default. The communication with the NetBox is occurring via the TCP/ IP protocol (Transmission Control Protocol/ Internet Protocol).
  • Page 58 With a direct connection to a PC both the NetBox as well as the PC must use a fixed IP address. A DHCP server is not available. Once the following settings must be done on your PC (the procedure is depending on the operating system and can differ from the following description –...
  • Page 59 Operation If there is no network connection click Network- and Sharing Center, then Change Adapter Settings. After it Local Area Connection, right mouse button: Properties [-> continue with item 3]. 2. Enter Local Area Connection – status screen ( [1]) is shown and subsequently Figure 32 Properties.
  • Page 60 Figure 32: Windows – Local Area Connection Status [1], Local Area Connection Properties [2] und Internet protocol version 4 (TCP/IPv4) properties [3]...
  • Page 61 Operation Figure 33: Alternate Configuration After connecting your PC with the NetBox via an Ethernet cable a point-to-point connection is established. This may take several minutes. Your network is shown as non-identified network in the Network and Sharing Center. 1. Start the PIConnect software on your local PC and open with the menu Tools/ Extended/ remote devices...
  • Page 62 2. Set the Enable checkbox and enter the address range of your local network in Detect devices (range 0 to 255). 3. Enable the Filter checkbox and enter NetBox. Press the Ping button to detect devices within the range and with NetBox in their name. 4.
  • Page 63 Operation In the menu Devices the imager which is connected to the NetBox is shown as remote device. Select the following functions: Figure 35: Remote device Connect Connect with the remote device manually Restart Restart of the Imager Net Server Application on the NetBox Reboot Reboot of the NetBox Remove...
  • Page 64 6. If the applied imager is connected to the NetBox for the first time a warning message appears. Confirm with Yes. Figure 36: Warning Figure 37: Sending calibration data files...

  • Page 65: Ethernet Network Communication

    Operation The calibration files are transferred from your PC to the NetBox automatically and stored there. Alternatively a manual copy of the calibration files is possible via USB stick to the NetBox folder D:\Imager\Cali. The live image of the IR camera is displayed on your PC. 4.12.2 Ethernet network communication Consider that the NetBox must be converted to DHCP using a network connection.
  • Page 66 Figure 38: Ethernet network connection/ NetBox LW powered via power supply Using a PoE injector the power supply for the NetBox is not needed. In this case the PoE injector must be connected as shown in . With orderly function L1, L2 and L5 are illuminating. Figure 39...
  • Page 67 Operation Figure 39: Ethernet network connection/ NetBox LW powered via PoE injector If the NetBox is used in a network it gets its IP address from a DHCP server. In order to find the PIConnect on your local PC the address range of the local network must be known. For this start the program IP Address Finder (►...
  • Page 68 3. Enable the Filter checkbox and enter NetBox. Press the Ping button to detect devices within the range and with NetBox in their name. 4. Select the desired frame rate in Remote framerate which should be transmitted via network. 5. In the Hosts area your NetBox is listed. Assign it and confirm with OK. Figure 40: Remote device window In the menu Devices the imager which is connected to the NetBox is shown as remote device.
  • Page 69 Operation Figure 41: Remote device Connect Connect with the remote device manually Restart Restart of the Imager Net Server Application on the NetBox Reboot Reboot of the NetBox Remove Remove of the device entry in this menu 6. If the applied imager is connected to the NetBox for the first time a warning message appears. Confirm with Yes.
  • Page 70 Figure 42: Warning Figure 43: Sending calibration data files The calibration files are transferred from your PC to the NetBox automatically and stored there. Alternatively a manual copy of the calibration files is possible via USB stick to the NetBox folder D:\Imager\Cali.

  • Page 71: Usb Driver

    Operation 4.13 USB Driver The USB-IR camera as well as the USB sticks, the USB keyboards or the USB mouses do not need a special device driver. To ensure a convenient use of the NetBox LW and its recommended standard components, system messages to new installed USB devices are suppressed therefore.
  • Page 72 Figure 44: Date and time properties The NetBox LW does not contain a CMOS battery which is typically used to keep the system time if the computer is switched off. That is why during operation the time is saved continuously. In case of a restart the system time is proceeding automatically beginning at the last saved value.

  • Page 73: Write Protection Filter

    Operation 4.15 Write protection filter Use the NetBox with an enabled write protection filter only! [Red dot: Saved mode enabled; green dot: writing mode enabled]. The NetBox LW is equipped with a write protection filter (factory-provided). It reliably protects the operation system and the complete C drive.
  • Page 74 (ewfMonitor) Figure 45: Short cut - Write protection filter in Autostart folder To save changed settings or to install additional software the write protection must be deactivated temporarily. 1. Move the cursor to the red dot in the task bar and click the right mouse button. Select between four different actions: Save and reboot Changes will be saved + restart...
  • Page 75 Operation Standard write Switch to writing mode (green dot) mode Reboot Restart without saving changes The SSD drive of the NetBox LW has two partitions by factory default. The write protection refers to partition C only. In partition D application data can be saved. The calibration data of the imager is stored there too.

  • Page 77: System Recovery

    System recovery 5 System Recovery • In case a recovery of the Windows operating system of the NetBox LW is necessary you should use the supplied USB recovery stick. Follow the steps described hereafter. Do not disconnect power from the NetBox during the recovery procedure.
  • Page 78 2. Select USB Device and press Enter. Then the connected USB stick is shown. Confirm with Enter as well. Figure 47: Selecting the USB-Stick...
  • Page 79 System recovery Figure 48: Several displays during recovery After complete system recovery the NetBox shuts down automatically and switches off (all LEDs are off). 3. Disconnect the power supply shortly (pulling off the power supply unit). Afterwards reconnect the power and boot the system up.
  • Page 80 4. Click the Next button and select Random SID. Confirm with Next. Figure 49: SID selection With the rename option you can give the NetBox a different name. 5. Rename the NetBox (optional). It must not be more than 15 characters. Then confirm with Next for two times.
  • Page 81 System recovery Figure 50: Rename option...
  • Page 82 After this the system shuts down. The NetBox is ready for use again. Figure 51: System update...

  • Page 83: Basics Of Infrared Thermometry

    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.
  • Page 84 He blackened the peak of a sensitive mercury thermometer. This thermometer, a glass prism that led sun rays onto a table made his measuring arrangement. With this, he tested the heating of different colors of the spectrum. Slowly moving the peak of the blackened thermometer through the colors of the spectrum, he noticed the increasing temperature from violet to red.
  • Page 85 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.
  • Page 86 The specifications of the lens decisively determine the optical path of the infrared thermometer, which is characterized by the ratio Distance to Spot size. The spectral filter selects the wavelength range, which is relevant for the temperature measurement. The detector in cooperation with the processing electronics transforms the emitted infrared radiation into electrical signals.
  • Page 87 Basics of Infrared Thermometry Figure 55: Noncontact thermometry...
  • Page 88 Application field: Monitoring of electronic Process control extruding R&D of electronics R&D of electronic parts cabinets plastic parts Process control Process control at R&D of mechanical parts Monitoring of cables manufacturing solar calendering modules...

  • Page 89: Emissivity

    Basics of Infrared Thermometry 6.1 Emissivity Definition: The intensity of infrared radiation, which is emitted by each body, depends on the temperature as well as on the radiation features of the surface material of the measuring object. The emissivity (ε – Epsilon) is used as a material constant factor to describe the ability of the body to emit infrared energy.
  • Page 90 Figure 57: Spectral emissivity of several materials: 1 Enamel, 2 Plaster, 3 Concrete, 4 Chamotte...

  • Page 91: Ce Conformity

    CE Conformity 7 CE Conformity...

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