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optris Xi 80 Operator's Manual

Spot finder ir camera
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optris
Xi
80/ 400
Spot finder IR camera

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  • Page 1 Operator’s Manual ® optris 80/ 400 Spot finder IR camera...
  • Page 2 Optris GmbH Ferdinand-Buisson-Str. 14 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 .............................. 3 General Notes ............................7 Intended use ............................7 Warranty ............................. 8 Scope of delivery ..........................9 Maintenance ............................9 1.4.1 Cleaning ............................9 Model overview ..........................10 Technical Data ............................11 General specifications ........................
  • Page 4 4.1.4 PIN allocation Xi 400 ........................ 32 4.1.5 Industrial Process Interface for Xi 80 (optional) ................ 34 4.1.6 Industrial Process Interface for Xi 400 (optional) ..............37 Example for a Fail-Safe monitoring of the Xi with a PLC ..............40...
  • Page 5 Table of contents USB cable extension for Xi 400 ......................42 Software PIX Connect ..........................43 Installation and initial start-up ......................44 Software window ..........................46 Basis features of the software PIX Connect ..................48 Basics of Infrared Thermometry ......................51 Emissivity ..............................
  • Page 6 Appendix D – Interprocess Communication (IPC) ..................66 Appendix E – PIX Connect Resource Translator ..................67 Appendix F – Wiring diagrams PIF for Xi 400 ....................68 Appendix G – Declaration of Conformity ..................... 72...

  • Page 7: General Notes

    Thank you for choosing the optris Xi spot finder infrared camera. The optris Xi calculates the surface temperature based on the emitted infrared energy of objects [►6 Basics of Infrared Thermometry]. The two-dimensional detector (FPA - focal plane array) allows a measurement of an area and will be shown as thermal image using standardized palettes.

  • Page 8: Warranty

     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.

  • Page 9: Scope Of Delivery

    General Notes 1.3 Scope of delivery  Xi 80 or Xi 400  USB cable: 1 m (standard scope of supply, no IP67 protection class) 1 m, 3 m, 5 m, 10 m, 20 m (optional, for industrial applications, with IP67) ...

  • Page 10: Model Overview

    The cameras of the PI-series are available in the following basic versions: Modell Model code Temperature range Spectral range Frame rate Typical applications Xi 80 -20 to 900 °C 7.5 - 13 µm 50 Hz Surface measurements in industrial application, autonomous operation with automatic spot finder Xi 400 -20 to 900 °C...

  • Page 11: Technical Data

    -40...70 °C Relative humidity: 10...95 %, non-condensing Material (housing): Stainless steel Dimensions: Xi 80: 36 x 90 mm / M30 Xi 400: 36 x 100 mm / M30 Weight: Xi 80: 185 g Xi 400: 200 g Cable length: USB: 1 m (standard), 3 m, 5 m, 10 m, 20 m...
  • Page 12 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/s (25 G) Pulse duration 11 ms Number of directions (3 axes with 2 directions each) Duration 600 Shocks (100 Shocks each direction)
  • Page 13 Technical Data Shock, half sinus 50 G – testing Ea 50 G (acc. IEC 60068-2-27) Acceleration 490 m/s (50 G) Pulse duration 11 ms Number of directions (3 axes with two directions each) Duration 18 Shocks (3 Shocks each direction) Vibration, sinus shaped –...
  • Page 14 Acceleration 39.3 m/s (4.01 G Frequency spectrum 10 - 106 Hz 0.9610 (m/s (0.010 G /Hz) 106 - 150 Hz +6 dB/ Octave 150 - 500 Hz 1.9230 (m/s (0.020 G /Hz) 500 - 2000 Hz -6 dB/ Octave 2000 Hz 0.1245 (m/s (0.00126 G /Hz)

  • Page 15: Electrical Specifications

    AO: Output Process Interface (PIF out) 0 - 10 V (Main measure area, measure area, internal temperature, flag status, alarm, frame sync, fail-safe, external communication), 0/4 – 20 mA (Xi 80) [►Appendix F – Wiring diagrams PIF] AI: Input Process Interface (PIF in)

  • Page 16: Measurement Specifications

    2.3 Measurement specifications Xi 80 Xi 400 Temperature ranges -20...100 °C; 0...250 °C; (20) 150...900 °C Spectral range 7.5 - 13 µm Detector UFPA, UFPA, 80 x 80 pixel @ 50 Hz 382 x 288 pixel @ 80 Hz/ 27 Hz Lenses (FOV) 12°...

  • Page 17: Optical Specifications

    Technical Data 2.4 Optical specifications Make sure that the focus of thermal channel is adjusted correctly. The cameras have a motorized focus, which can be adjusted in the PIX Connect software (Menu View/ Windows/ Distance or over the icon Figure 2: Motorized focus settings in PIX Connect The variety of different lenses offers the possibility to precisely measure objects in different distances.
  • Page 18 For individual configuration there are different lenses available. Wide angle lenses have a radial distortion due to their large opening angle; the software PIX Connect has an algorithm which corrects this distortion. As an alternative to the tables below, the optics calculator can also be used on the optris website (http://www.optris.com/optics-calculator).
  • Page 19 Technical Data Table 2: * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 20 * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.

  • Page 21: Mechanical Installation

    Mechanical Installation 3 Mechanical Installation 3.1 Dimensions The Xi is equipped with a metric M30x1 thread and can be installed either directly via the sensor thread or with help of the supplied mounting nut (standard) and adjustable mounting bracket (standard) to a mounting device available.
  • Page 22 Figure 5: Xi 80, dimensions [mm]...
  • Page 23 Mechanical Installation Figure 6 : Xi 400, dimensions [mm]...

  • Page 24: Electrical Installation

    4 Electrical Installation At the back side of the Xi there are the two connector plugs (see Figure 7 and Figure 8). Figure 7: Backside of the Xi 80 with connectors Figure 8: Backside of the Xi 400 with connectors...

  • Page 25: Process Interface

    Process interface Xi 80 The Xi 80 is equipped with an integrated process interface (cable with terminal block included in scope of supply), which can be programmed via the software as an direct analog input (AI) / digital input, as an direct analog output (AO) in order to control the process or as an RS485 interface .
  • Page 26 Figure 9: Configuration terminal block Xi 80 Shield Black Ground Brown 5-28 V Power White Analog/Digital Input or RS485 (A) Green Analog Output or RS485 (B) Yellow Isolated Ground for IN and OUT Gray Power supply only necessary when using the Ethernet connection (without PoE) or self-sufficient operation...
  • Page 27 The AI is designed for max. 24 V, the voltage level above 10 V is not interpreted In addition to the above direct in- and outputs, the Xi 80 has an RS485 interface. This interface can be used to control the external industrial PIF.

  • Page 28: Process Interface Xi 400

    4.1.2 Process interface Xi 400 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. The Xi 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.
  • Page 29 Electrical Installation Figure 10: Configuration Standard Process Interface (PIF) Xi 400 Shield Black Ground Brown Digital Input Gray Power supply, 5…24 V DC White Analog Input Green Analog Output Yellow...
  • Page 30 The standard process interface provides the following inputs and outputs: Name Description max range / status Analog input 0-10 V Digital input 24 V (active-low = 0…0,6 V) Analog output 0-10 V Alarm output 0/ 10 V Depending on supply voltage; for 0-10 V on the AO the PIF has to be powered with min. 12 V. The AI is designed for max.

  • Page 31: Pin Allocation Xi 80

    Ethernet 1 VCC 1 VCC 2 D + 2 RS485 or AO 3 D - 3 RS485 or AI Tx + 4 GND Tx - 5 GND-ISO Rx + Rx - 8 GND Figure 11: Rear side of Xi 80...

  • Page 32: Pin Allocation Xi 400

    4.1.4 PIN allocation Xi 400 1 VCC 1 INT 2 GND 2 SDA (I²C) 3 SCL (I²C) 4 D - 4 DGND 5 D + 5 3,3 V (Out) Figure 12: Rear side of Xi 400...
  • Page 33 Electrical Installation If the process interface of the camera is directly connected to external hardware (without using the supplied PIF cable) an activation of the field „Support proprietary PIF cable” in the menu Tools/ Configuration/ Device (PIF) in the PIX Connect software is necessary. Figure 13: Support proprietary PIF cable Consider that the input of the PIF is not protected if there is a direct PIF connection! A voltage >...

  • Page 34: Industrial Process Interface For Xi 80 (Optional)

    4.1.5 Industrial Process Interface for Xi 80 (optional) For use in industrial environment the industrial process interface with 500 V AC isolation voltage between Xi and process is available (connection box with IP65, 5 m, 10 m or 20 m standard or high temperature cable Appendix F –...
  • Page 35 Electrical Installation The industrial process interface provides the following inputs and outputs: Name Description max range / status INPUT 1 / 2 / 3 Analog or digital input 0-10 V Analog output 1, 2 and 3 0-10 V AO1 / 2 / 3 Alarm output 1, 2 and 3 0/4-20 mA DO1 / 2 / 3...
  • Page 36 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 Industrial Process interface ACXIIOCB1 ACXIPIFCBxx...

  • Page 37: Industrial Process Interface For Xi 400 (Optional)

    Electrical Installation 4.1.6 Industrial Process Interface for Xi 400 (optional) For use in industrial environment the industrial process interface with 500 V AC isolation voltage between Xi and process is available (connection box with IP65, 5 m, 10 m or 20 m standard or high temperature cable Appendix F –...
  • Page 38 The industrial process interface provides the following inputs and outputs: Name Description max range / status A IN 1 / 2 Analog input 1 and 2 0-10 V Digital input D IN 1 24 V (active-low = 0…0,6 V) AO1 / 2 / 3 Analog output 1, 2 and 3 0-10 V Alarm output 1, 2 and 3...
  • Page 39 Electrical Installation 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 Industrial Process interface ACPIPIF ACPIPIF500V2CBxx...

  • Page 40: Example For A Fail-Safe Monitoring Of The Xi With A Plc

    4.2 Example for a Fail-Safe monitoring of the Xi with a PLC Figure 16: Fail-Safe monitoring states Fail-Safe monitoring states Breakdown of PIF power supply Malfunction of Xi Cable break of fail-safe cable Breakdown of Xi power supply/ Interruption of USB cable Interruption of cable Xi-PIF Malfunction of PIX Connect software...
  • Page 41 Electrical Installation Figure 17: Fail-Safe monitoring states Fail-Safe monitoring states Breakdown of PIF power supply Malfunction of Xi Cable break of fail-safe cable Breakdown of Xi power supply/ Interruption of USB cable Short circuit of fail-safe cable Malfunction of PIX Connect software Interruption of cable Xi-PIF...

  • Page 42: Usb Cable Extension For Xi 400

    4.3 USB cable extension for Xi 400 The maximum USB cable length is 20 m. For greater distances between Xi 400 and computer or for stand- alone solutions the optional USB Server Gigabit is provided: Figure 18: USB Server Gigabit...

  • Page 43: Software Pix Connect

    Software PIX Connect 5 Software PIX Connect Minimum system requirements:  Windows Vista, Windows 7, Windows 8, Windows 10  USB interface  Hard disc with at least 30 MByte of free space  At least 128 MByte RAM  CD-ROM drive A detailed description is provided in the software manual on the software CD.

  • Page 44: Installation And Initial Start-Up

    4. Start the software. At the initial start the software asks for the calibrations files which are available via internet or on the CD (only for Xi 400). With the Xi 80, the calibration files are already included in the device.
  • Page 45 Software PIX Connect 5. Install the calibration files at first start of the software (only necessary for Xi 400). After the calibration files have been installed the live image from the camera is shown inside a window on your PC screen. 6.

  • Page 46: Software Window

    5.2 Software window Figure 19: Software window...
  • Page 47 Software PIX Connect IR image from the camera Temperature profile: Shows the temperatures along max. 2 lines at any size and position in the image. Control displays: Displays all temperature values in the defined measure areas like Cold Spots, Hot Spots, temperature at cursor, internal temperature and chip temperature.

  • Page 48: Basis Features Of The Software Pix Connect

    5.3 Basis features of the software PIX Connect Extensive infrared camera software  No restrictions in licensing  Modern software with intuitive user interface  Remote control of camera via software  Display of multiple camera images in different windows ...
  • Page 49 Software PIX Connect Video recording and snapshot function (IR)  Recording of video sequences and detailed frames for further analysis or documentation  Adjustment of recording frequency to reduce data volume  Display of snapshot history for immediate analysis Extensive online and offline data analysis ...
  • Page 50 Automatic process control  Individual setup of alarm levels depending on the process  Definition of visual or acoustic alarms and analog data output  Analog and digital signal input (process parameter)  External communication of software via COM-Ports and DLL ...

  • Page 51: 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 52 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 21: The electromagnetic spectrum and the area used for temperature measurement For the measurement of “thermal radiation”...
  • Page 53 Basics of Infrared Thermometry Figure 22: Main principle of non-contact thermometry Infrared thermometers basically consist of the following components:  Lens  Spectral filter  Detector  Electronics (amplifier/ linearization/ signal processing) The specifications of the lens decisively determine the optical path of the infrared thermometer, which is characterized by the ratio Distance to Spot size.
  • Page 54 The advantages of non-contact 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 ...
  • Page 55 Basics of Infrared Thermometry Application field: Monitoring of electronic R&D of electronics R&D of electronic parts Process control extruding cabinets plastic parts Process control Process control at R&D of mechanical parts Monitoring of cables manufacturing solar calendering modules...

  • Page 56: 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.
  • Page 57 Emissivity Figure 25: 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).

  • Page 58: Determination Of Unknown 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. ►...
  • Page 59 Emissivity ► 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. 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.

  • Page 60: Characteristic Emissivity

    7.3 Characteristic emissivity 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: ...

  • Page 61: Appendix A – Table Of Emissivity For Metals

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

  • Page 63: Appendix B – Table Of Emissivity For Non-Metals

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

  • Page 64: Appendix C – Quick Start For Serial Communication

    Appendix C – Quick start for serial communication Introduction One special feature of the PIX Connect software contains the possibility to communicate via a serial COM- Port interface. This can be a physical COM-Port or a virtual COM-Port (VCP). It must be available on the computer where the PIX connect software is installed.
  • Page 65 Appendix C – Quick start for serial communication Command list The command list is provided on the software CD and in the PIX Connect software (Help → SDK). Every command must expire with CR/LF (0x0D, 0x0A).

  • Page 66: Appendix D – Interprocess Communication (Ipc)

    The ImagerIPC2.dll will export a bunch of functions that are responsible for initiating the communication, retrieving data and setting some control parameters. The main difference to the former Version 1 (ImagerIPC.dll) is the support of more than one Optris Xi via multiple instances of Optris PIX Connect.

  • Page 67: Appendix E – Pix Connect Resource Translator

    Appendix E – PIX Connect Resource Translator Appendix E – PIX Connect Resource Translator A detailed tutorial is provided on the CD. PIX 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.

  • Page 68: Appendix F – Wiring Diagrams Pif For Xi 400

    Appendix F – Wiring diagrams PIF for Xi 400 Analog Output: Figure 29: Analog output For voltage measurements the minimum load impedance must be 10 kOhm. The analog output can be used as a digital output too. The voltage for “no alarm” and “alarm on” is set within the software.
  • Page 69 Appendix F – Wiring diagrams PIF for Xi 400 Digital Input: Figure 30: Digital input The digital input can be activated with a button to the Xi GND-Pin or with a low level CMOS/TTL signal: Low level 0…0.6 V; High level 2…24 V Example Button: Figure 31: Button...
  • Page 70 Analog input (usable voltage range: 0 … 10 V): Figure 32: 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): = 30 VDC...
  • Page 71 Appendix F – Wiring diagrams PIF for Xi 400 Figure 33: Relay output at industrial PIF...

  • Page 72: Appendix G – Declaration Of Conformity

    Appendix G – Declaration of Conformity...

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