Page 1: Operating Instructions
Modline ® Series 52, 56, 5G and 5R Sensors Infrared Thermometer Operating Instructions Rev. L6 Feb 2017 60401...
Page 3 Contacts Fluke Process Instruments  Americas Santa Cruz, CA USA Tel: +1 800 227 8074 (USA and Canada, only) +1 831 458 3900 solutions@flukeprocessinstruments.com EMEA Berlin, Germany Tel: +49 30 478 0080 info@flukeprocessinstruments.de China Beijing, China Tel: +86 10 6438 4691 info@flukeprocessinstruments.cn Worldwide Service Fluke Process Instruments offers services,...
Page 5 This warranty shall not apply (a) to equipment not manufactured by IRCON, (b) to equipment which shall have been repaired or altered by others than IRCON so as, in its judgment, to affect the same adversely, or (c) to equipment which shall have been subject to negligence, accident or damage by circumstances beyond IRCON’s control or to improper operation, maintenance or storage, or to other...
Page 6: Limited Warranty
4. COPYRIGHT. The Software, including the related screen displays, is copyrighted materials. You agree not to copy, modify or adapt the Software without the written consent of IRCON, in whole or in part, except (1) for backup or archival purposes, and (2) as an essential step in the utilization of the...
Page 7 Ircon product, even if Ircon has been advised of the possibility of such damages. The forgoing limitation shall apply regardless of legal theory and shall include liability based on contract, tort, and strict products liability principles.
Page 8: Table Of Contents
3.7.3 General Installation Requirements ..................... 34 3.8 DWD Installation Requirements ......................... 34 3.9 Modline 5 Mounting, Cooling and Air Purging Accessories ..............35 3.9.1 UAA – Universal Adapter Accessory Description and Dimensions ..........35 3.9.2 RAM – Right Angle Mount Description and Dimensions ..............37 3.9.3 APA –...
Page 9 3.13 Sensor Installation Checklist ........................62 4 SENSOR WIRING ............................64 4.1 Modline 5 Components ..........................64 4.2 Modline 5 Sensor System Interfacing ......................64 4.3 Modline 5 Sensor Cable ..........................65 4.3.1 Sensor Interconnecting Cable......................65 4.4 TSP Terminal Strip Plate ..........................65 4.4.1 Dimensions and Installation .......................
Page 10 5 OPERATION ..............................82 5.1 Sensor Rear Panel Setup and Operation ..................... 82 5.1.1 Introduction ............................82 5.2 Rear Panel Keyboard, Displays and Sight and Laser Aiming ..............82 5.2.1 Description ............................82 5.3 Navigation and Menus ..........................83 5.3.1 Enter and Up / Down Arrow Pushbuttons ..................83 5.4 Main Menus ..............................
Page 11 5.11 Laser Sighting Operation ........................102 5.12 Out of Range Displays and Error Codes ....................104 5.12.1 Summary ............................106 6 RS-485 DIGITAL COMMUNICATIONS ....................107 6.1 Introduction ............................... 107 6.2 Basic Operation ............................107 6.3 Sensor Rear Panel Setup for RS-485 Communication ................108 6.3.1 CLCK –...
Page 12 8.6.1 Turning Peak Picker On and Off ...................... 141 8.6.2 External Switch for Remote Peak Picker Operation ................. 142 8.6.3 Peak Picker Signal Conditioning ...................... 143 8.6.4 Peak Picker Reset ..........................143 8.6.5 Peak Picker Decay Rate ........................143 8.6.6 Auto Peak Picker Reset with Reset Below ..................143 8.6.7 Peak Picker Delay ..........................
Page 13: Safety Instructions
The instrument should not be used for medical diagnosis. Replacement Parts and Accessories Use only original parts and accessories approved by the manufacturer. The use of other products can compromise the operation safety and functionality of the instrument. Modline 5 Rev. L6 Feb 2017...
Page 14 Helpful information regarding the optimal use of the instrument. Earth (ground) Protective earth (ground) Chassis ground Switch or relay contact Conforms to European Union directive. Disposal of old instruments should be handled according to professional and environmental regulations as electronic waste. Modline 5 Rev. L6 Feb 2017...
Page 15 Do not use laser viewing glasses as laser protection glasses. Laser viewing glasses are used only for better visibility of the laser in bright light.  Use the product only as specified or hazardous laser radiation exposure can occur. Modline 5 Rev. L6 Feb 2017...
Page 16: Product Description
2 Product Description 2.1 Modline 5 Sensors, Cable and Interface Accessories The basic Modline 5 System consists of either a standard Sensor or Sensor with the Dirty Window Detection option with an interconnecting cable and Terminal Strip Plate. Optional components include the POI Power Supply/Signal Interface Box and the remote DPM Digital Meter operator interface.
Page 17: Modline 5 Description
Product Description 2.2 Modline 5 Description The IRCON Modline 5 is an Infrared Thermometer Sensor. State of the art digital circuitry and firmware provide excellent measurement accuracy, repeatability and overall performance. New diagnostics check the status of the Sensor (such as detector temperature, sensor failure) and some of its external environment (such as analog current output open circuit condition and case temperature).
Page 18: Model Configuration And Required Selections
The product is covered by Patent Number 5812270 when the Dirty Window Option is installed. A Sensor can also be ordered to be used a Transfer Standard to calibrate other Modline 5 Sensors. ModView Calibration Software and an expanded Calibration Certificate are supplied with this Sensor Model.
Page 19: Modline 5 Model Number Summary
The selection is Installed or None. The product is covered by Patent Number 5812270 when the Dirty Window Detector Option is installed. 2.4 Modline 5 Model Number Summary Modline 5 Model Number as Found on Serial Number Label Modline 5 Rev. L6 Feb 2017...
Page 20: Accessories
Standard infinity D/100 The Model Number explanation information provided above defines a Modline 5 Sensor having the following characteristics and features:  Model 5R-1410 is a Series 5R Ratio Type Sensor with the temperature range of 600 to 1400°C (1112 to 2552°F) and D/100 Resolution.
Page 21: Power And Interface Accessories
Details on the following standard accessories can be found in Section 3 Sensor Installation, page 22. An extended family of accessories is available and they are referenced in Section 3. Standard Modline 5 Accessories Model – MFS Mounting Flange (Small Diameter Pattern) Model – BMA Base Mount Adapter Model –...
Page 22: Specifications
Model 5 R (Two color Ratio Mode) 0.800 to 1.200. Signal Reduction Range Tolerated Sensor Series 5R will tolerate 95% reduction in radiation intensity caused by low emissivity, non-resolved or obscured All specifications subject to change without notice. Modline 5 Rev. L6 Feb 2017...
Page 23: Accessory Specifications
Ambient Temperature: 0 to 50°C (32 to 122°F) Environmental: NEMA 4X (IP65) Sealed Front Bezel Power Requirements: 85 to 250 VAC 50/60 HZ, 15VA. Terminal Strip Plate Ambient Temperature: 0 to 55°C (32 to 130°F) Modline 5 Rev. L6 Feb 2017...
Page 24: Sensor Installation
Figure 3: Sensor with Dirty Window Detector Two Sensors types are available in the Modline 5 Series, standard Sensor or Sensor with the Dirty Window Detector option. The front of the standard Sensor consists of a front objective lens only. The Sensor with the Dirty Window Detector option has internal components and an external protection window located in front of the objective lens.
Page 25: Sensor Parts
Sensor. 3.3.2 Visual Sight The Modline 5 visible sight is aimed and focused onto the target to be measured as simply as an ordinary camera. The rear focus is smooth, utilizing almost one turn of the focusing section.
Page 26: Laser Sight
For difficult conditions, pre-focus the Sensor optics while aiming the laser at a white reflective target. Then use the Laser to aim the pre-focused Sensor on to the target. Modline 5 Rev. L6 Feb 2017...
Page 27 Laser is energized remotely or at the Sensor Rear Panel. Warning Label Figure 9: Sensor Laser Label The sensor label is shown in detail in Figure 10. Figure 10: Sensor Laser Label in Detail Modline 5 Rev. L6 Feb 2017...
Page 28: Sensor Optical Characteristics
3.4.2 Lens Focusing Ranges and Optical Resolution Factor The table below lists Lens Type and Focusing Ranges for the Modline 5 Series 52, 56, 5G and 5R. Two ranges are shown. The first range is for a Sensor without the Dirty Window Detector Option (DWD) option.
Page 29: Table Of Model And Lens Type Combinations With Focusing Ranges
Resolution Factor of F = 100 is focused on a 0.5 inch (12.7 mm) rod at three distances. The drawings at the left for each example illustrate a large circle that represents the total area visible in the Sensor sight. The smaller circle represents the reticle. Modline 5 Rev. L6 Feb 2017...
Page 30 Bottom example C illustrates a viewing distance of 25 inch (635 mm). The spot size is 0.25 inch (6.35 mm) one half the one half inch target size. The view in the eyepiece shows the target completely resolved by the reticle. Modline 5 Rev. L6 Feb 2017...
Page 31: Measuring Temperature With Brightness And Ratio Sensors
Figure 13: Cone of Vision Obstruction 3.5.3 Resolving Targets with Two Color Ratio Sensors Modline 5 Series 5R Ratio Sensors utilize a dual detector assembly that measures temperature by comparing infrared radiation levels in two wavelength bands (0.85 to 1.05 microns and 1.0 to 1.1 microns).
Page 32: Signal Reduction
The Series 5R Sensors have a limit as to how much the signal from a hot target can be reduced. The reduction in the signal can be as high as 95% with target temperatures above 800C (1500F). The Modline 5 Rev. L6 Feb 2017...
Page 33: Summary
Sensors, accessories and cable routing. Planning also includes evaluating environmental conditions that may cause contamination of the Sensor optics or overheating of the Sensor or other Modline 5 components. Re-location of the installation or air purging and water cooling accessories may be required to overcome adverse conditions.
Page 34: Sensor Mechanical Installation
3.7 Sensor Mechanical Installation 3.7.1 Installation Accessories The Modline 5 Sensor requires the use if one or more installation accessories to mount, align and aim the Sensor. The installation accessories also provide for cooling the Sensor and air purging the optics to keep them free from contamination.
Page 35: Sensor Dimensions
Other accessories such as pipe mounts, sight tubes, target tubes window assemblies, etc. is referenced at the end of this section. 3.7.2 Sensor Dimensions The dimensions of the Standard and Dirty Window Detector Modline 5 Sensors are given below. These dimensions are without any mounting accessories. Figure 15: Standard Modline 5 Sensor...
Page 36: General Installation Requirements
The Sensor with the Dirty Window Detector option requires the use of an ESA – Extension Sleeve Adapter accessory along with other Modline 5 accessories. The ESA, combined with other accessories, serves as protection for the DWD optics. The photograph...
Page 37: Modline 5 Mounting, Cooling And Air Purging Accessories
3.9.1 UAA – Universal Adapter Accessory Description and Dimensions The UAA is a circular ring that clamps around the Modline 5 Sensor. A M8 screw tightens the clamp around the Sensor. Three ¼-20 threaded holes on the bottom flat surface allow fastening the UAA to a tripod;...
Page 38 M8 X 30 mm Socket Head Cap Screw Supplied for clamping Sensor M6 X 25 mm deep threaded Holes for IRCON Accessories 3 Places Figure 22: UAA Dimensions Dimensions are in inches and (millimeters). Do not scale. Modline 5 Rev. L6 Feb 2017...
Page 39: Ram - Right Angle Mount Description And Dimensions
No hardware is supplied with the RAM. UAA assembly hardware is supplied with the UAA.  Two user supplied M6 or ¼-20 mounting bolts and washers are required to mount the base of the bracket. Modline 5 Rev. L6 Feb 2017...
Page 40 Figure 24: RAM Dimensions Dimensions are in inches and (millimeters). Do not scale. All three axis of rotation (including optical axis) intersect at a common point. This avoids parallax during target alignment Modline 5 Rev. L6 Feb 2017...
Page 41: Apa - Air Purge Accessory Description And Dimensions
3.9.3 APA – Air Purge Accessory Description and Dimensions IRCON’s specially designed air purge is used to help keep the front optics of the Modline 5 clean. The purge provides a stream of air away from the Sensor to prevent dust and smoke particles from collecting on the optics.
Page 42: Mfl - Mounting Flange Large Description And Dimensions
The larger of the two mounting flange accessories, the MFL has the bolt circle pattern that matches many of IRCON’s other products and accessories. It provides a simple means of replacing older instruments and using existing accessories. See Section 3.12 for Other Accessories.
Page 43 M6 x 65 mm socket head cap screw to assemble the MFL to WJA 5 mm hex key, long arm water jacket with ESA extension sleeve. L style wrench Table 4: MFL Mounting and Assembly Supplied Parts List Modline 5 Rev. L6 Feb 2017...
Page 44: Mfs - Mounting Flange Small Description And Dimensions
Sensor Installation Remove Metal Cover Gasket to expose two Groups of three trough Holes for attaching Mounting Holes 3 Places Modline 5 Accessories Outside Gasket mount Hole Mounting bolt circle Locating PINs 2 Places Back Modline 5 Accessories mount to this side...
Page 45 Mounting Bolt Circle Countersink holes for APA Air Purge 3 Places M6 flat head screws APA Air Purge mounts to Back Side Figure 30: MFS Dimensions Dimensions are in inches and (millimeters). Do not scale. Modline 5 Rev. L6 Feb 2017...
Page 46: Wja - Water Jacket Accessory Description And Dimensions
3.9.6 WJA – Water Jacket Accessory Description and Dimensions The WJA uses water or air to cool the Modline 5 Sensor in high ambient temperatures. Water cooling can protect the Sensor in ambient environments up to 200°C (400°F). Air cooling can provide protection to 105°C (220°F).
Page 47: Wja Water Cooling Requirements
Figure 32: WJA Dimensions Dimensions are in inches and (millimeters). Do not scale. Tapped Holes on both ends for Ircon, Inc. Accessories. 3.9.6.1 WJA Water Cooling Requirements Adequate water flow for a 200C (400F) ambient is 15 gallons/hr. (57 liters/hr.). Cooling water temperature should be 32C (90F) or lower.
Page 48: Wja Air Cooling Requirements
Figure 34: Air Cooling Sensors with DWD 3.9.6.3 Sensor Temperature Alarm The Modline 5 Sensor provides Alarms when the Sensor’s internal temperature exceeds its allowed limit. Error Code X105 signifies the outside influences have caused the internal temperature to rise above its limit.
Page 49: Bma - Base Mount Accessory Description And Dimensions
 No hardware is supplied with BMA. UAA assembly hardware is supplied with the UAA.  Three user supplied M8 or 5/16 mounting bolts and washers are required to mount the base of the bracket. Modline 5 Rev. L6 Feb 2017...
Page 50: Esa - Extension Sleeve Adapter Description And Dimensions
DWD optics and as the mechanical interface between the Sensor and other Modline 5 accessories. The ESA is used in the following combinations to provide air purging or create a dead air space zone in front of the Sensor optics to help keep them clean. The combinations also provide shielding from stray radiation emanating from high temperature targets.
Page 51  No hardware is supplied with the ESA.  Assembly screws are supplied with the APA and MFL. Locating PINs DIA. 2 Places. Flat mounting Surface Align with other Accessories Through Holes for M6 Screws 3 Places Figure 38: ESA Dimensions Modline 5 Rev. L6 Feb 2017...
Page 52: Accessory Combinations With Break-Out Drawings
3. The ESA with MFL provides dead air space and stray radiation shielding. Add an AA-3 air purge accessory for air purging. See Section 3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling), page 60 for AA-3 information. These combinations not recommended for large targets over 1000 C. Modline 5 Rev. L6 Feb 2017...
Page 53 5. Use water for cooling only. Do not use air for cooling with DWD unless the APA air purge accessory is used. See information in Section 3.9.6 WJA – Water Jacket Accessory Description and Dimensions. Table 7: 3.10.1 Recommended Accessory Groupings Modline 5 Rev. L6 Feb 2017...
Page 54 Front of Sensor Figure 39: Sensor without DWD – UAA Accessory Groups 1 through 10 Front of Sensor Figure 40: Sensor with DWD – UAA Accessory Groups 2, 3, 4, 5, 6, 7, 8, 9, 10 Modline 5 Rev. L6 Feb 2017...
Page 55 Front of Sensor Figure 41: Sensor without DWD – WJA Accessory Groups 11 through 18 Front of Sensor Figure 42: Sensor with DWD – WJA Accessory Groups 11, 12, 13, 15, 16, 17, 18 Modline 5 Rev. L6 Feb 2017...
Page 56: Installation Drawings And Illustrations
Tighten clamping screw. Sensor front surface will be positioned at the back end of the APA or MFL. To determine working distance (D) for spot size formula d=D/F, measure or calculate from that point. Modline 5 Rev. L6 Feb 2017...
Page 57: Installation Drawing For The Ram - Right Angle Mount
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with Drawings, page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group. Break-out Table 9: Recommended Accessory Groupings RAM Modline 5 Rev. L6 Feb 2017...
Page 58 (D) for spot size formula d=D/F, measure or calculate from that point. Axis of Rotation Optical Axis Coincident with Axis of Rotation Figure 48: Group 7 shown (UAA RAM and APA). Dimensions are in inches and (millimeters). Do not scale. See individual Accessory drawings. Modline 5 Rev. L6 Feb 2017...
Page 59: Installation Drawing Using The Wja - Water Jacket Accessory With Flange Mounts
Figure 49WJA with Flange Mounts Insert Sensor into the WJA assembly with moderate force until it “snaps” into the spring catch. Secure the Sensor rear protection and sighting window. Swing safety clamp into position and tighten. Modline 5 Rev. L6 Feb 2017...
Page 60: Installation Drawing Using The Wja Water Jacket Accessory With The Base Mount Adapter
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with Break-out Drawings, page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group. Table 11: Recommended Accessory Groupings WJA with BMA Modline 5 Rev. L6 Feb 2017...
Page 61 Through Holes for 5/16 Inch or M6 Bolts (3 Places) WJA Mounting Axis Figure 52: Group 18 shown (BMA, WJA and MFL). Dimensions are in inches and (millimeters). Do not scale. See individual Accessory drawings. Modline 5 Rev. L6 Feb 2017...
Page 62: Other Accessories (Sight Tube, Window, Wj-5 Water Cooling)
3.12.1 M5WJ5 – Mounting Kit The M5WJ5 Mounting Kit is used with UAA and MFL Mounting Accessories to install a Modline 5 Sensor in an Ircon Model WJ-5 Water Cooling Jacket. The jacket provides cooling through a stainless steel coiled pipe embedded in the jacket walls.
Page 63 The Modline 5 Sensor with the Dirty Window Detector Option (DWD) cannot be installed in a WJ-5 Jacket because of its additional length. Figure 53: M5WJ5 – Mounting Kit Accessories and kit required for mounting Modline 5 Sensor in WJ-5 Water Cooling Jacket:  Model WJ-5 Water Cooling Jacket with Air Purge Supplied with its own mounting hardware (M5WJ5 Kit is not included.)
Page 64: Sensor Installation Checklist
Route the cable either through the center opening in the mounting plate or along the side walls of the WJ-5 and out through the insulated opening in the back door. MFL Mounting Flange Large Accessory UAA Universal Adapter Accessory Modline 5 Sensor (without DWD option) Spacer Block (Item 2) Socket Head...
Page 65 Sensor Installation exceed its temperature rating. The Sensor mounting surface is grounded (Earth Ground). If not, electrically insulate the housing from the mounting surface. See information in Section 4.11 System Grounding and Shielding, page 79. Modline 5 Rev. L6 Feb 2017...
Page 66: Sensor Wiring
4 Sensor Wiring 4.1 Modline 5 Components The basic Modline 5 system consists of either a standard Sensor or Sensor with Dirty Window Detector option, interconnecting cable, a POI Power Supply/Signal Interface Box or Terminal Strip Plate and as possible option, the DPM Digital Panel Meter Interface.
Page 67: Modline 5 Sensor Cable
The cable shield is also prepared and ready to assemble with the Ircon supplied EMI shielding strain reliefs. All cable wires are 24 AWG (0.25 mm²), except the 24 V power supply wires that are 22 AWG (0.35 mm²).
Page 68: Sensor Interconnecting Cable Preparation
All cables must be properly dressed for shield grounding. Twisted pair wires must remain twisted and kept as short as possible. The IRCON Sensor cable is supplied with the connector attached on one end. The opposite wiring end is prepared and supplied as per the following procedure. If the cable is shortened, the preparation procedure must be followed.
Page 69: Interconnecting Cable Assembly Continuity Check
Pin 3 Black Pin 4 Violet Red Dot Up Pin 5 Blue Pin 6 Yellow/White Pin 7 Blue/White Pin 8 Red/White and Violet/White Pin 9 Orange Pin 10 Yellow Pin 11 Orange/White Figure 58 Modline 5 Rev. L6 Feb 2017...
Page 70: Terminal Strip Plate - Sensor Interconnecting Cable Installation
15.5 pF/ft. (50.9 pF/m). Prepare the cables as explained in Section 4.5 Sensor Interconnecting Cable Preparation, page 66. Ground cable shields on the Terminal Strip Plate by inserting the prepared braid under the shield clamps. Modline 5 Rev. L6 Feb 2017...
Page 71: Grounding And Shielding
Maximum cumulative RS-485 cable length, from sensor to the actual process device, is 4000 feet (1220 meters). 4.7.5 Analog Output Temperature Signal This current loop temperature signal is 4 to 20 mADC or 0 to 20 mADC, user selectable, linear with Modline 5 Rev. L6 Feb 2017...
Page 72: Converting The Analog Output From A Ma Output To A 10 Volt Output
You may make remote adjustments of the Emissivity or E-Slope by sending a scaled analog input of 4 to 20 mAdc. The Modline 5 senses an input and overrides any Sensor rear panel or RS-485 settings of Emissivity, E-Slope or Match.
Page 73: Current Input Terminal Connections For Remote Laser
In either case, it must be connected directly to the power supply. Mount the ½ Watt resistor in a series circuit on the switch or at the external power supply location. 1/2 Watt Resistor Orange Remote Laser Switch Orange/White Figure 64 Modline 5 Rev. L6 Feb 2017...
Page 74: Peak/Hold Switch For Remote Peak Picker Reset, Track And Hold Or Laser Operation
Sensor’s window condition. One or more out of limit conditions sensed by these tests triggers an Alarm and operates the Alarm relay within the Modline 5. The relay contacts may be used in the process control system to indicate measurement conditions do not allow process temperature measurements or Sensor operation may be impaired.
Page 75: Selection Of A Power Supply For Sensors Used With Tsp Terminal Strip Plates
4.8 Selection of a Power Supply for Sensors used with TSP Terminal Strip Plates When using a Modline 5 Sensor with the TSP Terminal Strip Plate, select a switching type power supply that will provide reliable startup. The power supply output should remain at rated voltage during the Sensor current loading that occurs at startup.
Page 76 AC power is available locally. The standard Modline 5 cable that is routed between the Sensor and TSP Plate is limited to 350 Feet (107 meters). The power supply wires in this cable are 22 gauges. This maximum cable distance and wire gauge assures enough voltage will be available at the sensor.
Page 77: Tsp Terminal Strip Plate Dc Power Supply Connections
4.9 RS-485 Multi-Drop Network Power Supply and System Wiring Multiple Modline 5 Sensors communicating via RS-485 with a Host device are installed in a multi-drop network configuration. The Modline 5 MSI Multiple Sensor Interface, a PC, a PLC or other Control system are Host devices.
Page 78: Computer Communications Requirements
Host device as shown in the diagram. Consult the manual for the Host device to determine if any termination resistor is required at its terminals. The IRCON Model MSI Interface does not require a termination resistor at its input.
Page 79: Tsp Terminal Strip Plates Multi-Drop Wiring
Product Code IC114A-R2 (for laptop computers) See section 6 RS-485 Digital Communications, page 107, for Modline 5 Sensor communications details and commands. 4.9.2 TSP Terminal Strip Plates Multi-drop Wiring These illustrations indicate the proper wiring when using TSP Terminal Strip Plates. A power supply for each Sensor and TSP pair is shown in the first illustration.
Page 80: Sensor And Cable Connection
Make sure the 24Vdc power to the Modline 5 Sensor is turned off whenever connecting and disconnecting the cable. Make sure the rear protection window is in place after making adjustments to maintain the Sensor’s NEMA 4 (IP65) environmental rating.
Page 81: System Grounding And Shielding
Some devices call for connecting the shield to ground at the device input. If ground loops develop with this connection, it may be necessary to experiment with shield Modline 5 Rev. L6 Feb 2017...
Page 82: Summary Caution And Warning
Sensor Wiring, page 64, should also be complete. The Modline 5 Sensor can now be powered and the initial setup for operation performed as described in Section 5 Operation. Look for any signs of overheating or smoking when applying power. Investigate any signs of improper installation Please read the following important Caution and Warning.
Page 83 A computer with specialized software may be used as an operator interface for setup and operation of the system. Digital and analog communication with alarms and controllers may be part of the system making it a more complex system. Changing software configurations and settings requires that process performance be verified. Modline 5 Rev. L6 Feb 2017...
Page 84: Operation
5.2 Rear Panel Keyboard, Displays and Sight and Laser Aiming 5.2.1 Description Located on the rear of the Modline 5 Sensor are: a keyboard panel with three setup pushbuttons, three red word indicators for Setup, Alarm and Window (for the Dirty Window Detector optional feature), and a four character green alphanumeric Light Emitting Diode dot matrix display with adjacent green °F and °C indicators.
Page 85: Navigation And Menus
At a Main Menu, Press ENT  once to enter the Menu. One of the Function selections will be displayed. USE the UP / Down Arrows ▲▼ to view a different function. Functions are displayed for 15 seconds Modline 5 Rev. L6 Feb 2017...
Page 86 SUB FUNCTION PSEL (Peak Picker Function Settings) D.R. (Decay Rate in ºF or ºC per Second) AUTO (Auto Peak Picker Reset) RSET (Manual Peak Picker Reset) RBEL (Reset Below Temperature) DEL (Peak Signal Conditioning Delay) Modline 5 Rev. L6 Feb 2017...
Page 87: Warm-Up And Initial Setup
5.5.3 Initial Rear Panel Display After the warm-up period is over, you should observe one or more of the Modline 5 Sensor responses described below on the TEMP display and at the outputs. During initial setup, because the Sensor is not adjusted for the process, these initial displays are expected.
Page 88: Engr - Setup Of Engineering Functions
Press ENT to enter and save selection and return to TEMP display. 5.6.2 MODL – Sensor Model Number The MODL function reports the Modline 5 Sensor Model Number as an eight character alphanumeric display. Product Description The Sensor Model number is explained in Section 2 , page 14.
Page 89: Chk - Initiate Manual System Check
Press ENT  to save and return to TEMP display. RELY – Alarm Relay Operation The RELY function configures the operation of the Modline 5 Alarm relay for Normally Open or Normally Closed operation. The Sensor internal relay contacts are available on the Black and Black/White twisted wire pair of the Sensor cable.
Page 90: Hour- Automatic System Check
Operation Refer to the instructions for your Model! This function checks the Modline 5 Sensor performance by initiating a System Check. When this function is initiated, the Sensor’s infrared detector output, internal gain and offset voltages are checked. The check cycle lasts less than ten seconds. During the Check, the Sensor TEMP display indicates CAL.
Page 91: Chk - Manual System Calibration For 56 Models
A Calibrate Check is required for to insure accurate operation of the Series 56 Sensors and should be performed routinely, every 168 hours or less. The check can be initiated by any of the three methods Modline 5 Rev. L6 Feb 2017...
Page 92 OFF setting is also available. If the OFF is selected, Manual Calibrate Checks must be initiated every at least every 168 hours. Manually Initiate a Manual Calibrate Check using the Sensor Rear Panel Keypad or Modline 5 accessory. Accessories include the Model DPM Panel Meter, Model MSI multiple sensor interface, ModView software or an RS-485 communication command.
Page 93: Hour- Automatic Calibration Check For 56 Models
The HOUR function provides for selection of an automatic System Calibration Check and Self Calibration if needed. This function automatically initiates the calibration check described above. A Manual or power on Calibration Check will start a new period, but not change the value of the HOUR interval. Modline 5 Rev. L6 Feb 2017...
Page 94: Wrnl - Dirty Window Detector Option Warning Level
Alarm and Invalid Condition selection sets both the Error Codes and Invalid Measurement Conditions to operate the Alarm rely and ALARM word on the Sensor rear panel. Invalid Measurement Conditions do not trigger the Alarm relay or the Alarm word with Error Code Alarms Only selected. Modline 5 Rev. L6 Feb 2017...
Page 95: Attn - Selects Attenuation Alarm Threshold
5.7 AOUT – Setup of Analog Signal Output Current Range and Temperature Scaling Modline 5 Sensors provide selection of the analog output current range and scaling of the selected range to temperature. Scaling establishes a temperature span to correspond to the analog output current Modline 5 Rev.
Page 96: Fatl - Analog Output Operation For Sensor Or Dirty Window Detector Malfunction Alarms
Wiring, page 64 for wiring details. SOUT – Analog Output Current Range Selection Modline 5 Sensors provide a selection of one of two analog output direct current ranges, 0 to 20 mA or 4 to 20 mA. This function selects the desired range.
Page 97: A-Hi - Analog Output High Temperature Alarm
5.8 COMM – Setup of RS-485 Digital Communication Configuration The Modline 5 RS-485 Digital Communication interface permits interchange of ASCII coded information between the Modline 5 Sensor and a host computer, PLC (Programmable Logic Controller), or any other RS-485 device.
Page 98: Clck - Communications Lock
5.9 HEAD – Setup of Sensor Operating Functions The HEAD menus and functions set up the Modline 5 Sensor for process temperature measurement. The initial setup should follow the order given below. It is useful to perform the setup while the Sensor is sighted on the actual target, but not necessary.
Page 99: Response Time
0.02 to 60.0 seconds Model 56 Sensors* 5.9.2 COLR – Ratio Unit Operation Selection The COLR function sets the Modline 5 Ratio Sensor operation in the two color mode for ratio temperature measurement or in the single color mode for brightness temperature measurement.
Page 100: Remote E-Slope Current Input
This signal is inputted using the Orange and Orange/White twisted wire pair of the Sensor’s interconnecting cable. The Modline 5 senses an input and the overrides any rear panel or RS-485 settings of E-Slope or Match. Wiring connection and scaling information are in Section 4 Sensor Wiring , page 64.
Page 101: Remote Emissivity Current Input
This signal is inputted using the Orange and Orange/White twisted wire pair of the Sensor’s interconnecting cable. The Modline 5 senses an input and overrides any rear panel or RS-485 settings of Emissivity or Match. Wiring connection and scaling information are in Section 4...
Page 102: Psel - Peak Picker Functions
External Switch Control of Track and Hold Operation The Modline 5 has provisions for a remote process controlled input switch be wired to the Violet and Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Track and Hold signal conditioning is selected, the switch input is required to change from Track temperature operation (switch open) to Hold mode (switch closed) as required in the process system.
Page 103: Rset - Manual Peak Picker Reset
5.10.3 External Switch for Remote Peak Picker Reset The Modline 5 has provisions for a remote process controlled input switch to be wired to the Violet and Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Peak Picker signal conditioning is selected, the remote switch can enable or disable the Peaking action.
Page 104: Laser Sighting Operation
(CHK function) or automatic (HOUR function) system check or MATCH Function is initiated, the Laser will turn off. Refer to Section 3.3.3 Laser Sight, page 24, for information on using the Laser to aim and focus the Sensor. Modline 5 Rev. L6 Feb 2017...
Page 105 PkHd Switch operates Not Enabled for Laser anytime. anytime. Laser. Operation in SWIT mode Remote Pk/Hd Can Energize Laser. Can Energize Laser. Condition Set Two Switch Condition Set Two Condition Set Two applies. Operation applies. applies. Modline 5 Rev. L6 Feb 2017...
Page 106: Out Of Range Displays And Error Codes
POI Power Supply/Signal Interface Box. 5.12 Out of Range Displays and Error Codes The Modline 5 displays word messages on its rear panel display to indicate Sensor diagnostic results. Below are explanations of the reported measurement status and error codes.
Page 107 Temperature displayed is Peak Picked or Hold Mode Temperature values from prior valid measurement conditions. Environmental conditions can cause Sensor errors. High or low ambient temperatures can cause Sensor case temperature too high or too low errors. Dirty lens conditions can be avoided using air purging. Modline 5 Rev. L6 Feb 2017...
Page 108: Summary
5. The Sensor rear screw on protective window must be in place during temperature measurement to maintain the NEMA 4 (IP65) Sensor housing rating and protect the keyboard and internal parts from contamination. Modline 5 Rev. L6 Feb 2017...
Page 109: Digital Communications
6 RS-485 Digital Communications 6.1 Introduction The MODLINE 5 Sensor permits RS-485 digital signal interchange of ASCII coded information with a host computer, PLC (Programmable Logic Controller), or any other RS-485 device. The external device can obtain information from the Sensor and modify Sensor settings.
Page 110: Sensor Rear Panel Setup For Rs-485 Communication
Sensor is connected. Channel Number = 0 Is always the 0 (zero) character. This one-digit entry value is not used in the MODLINE 5. SET to 0 (zero) for future use. Modline 5 Rev. L6 Feb 2017...
Page 111: Command Codes
6.5 Command Codes 6.5.1 Introduction The Command Codes allow operation and setup of the Modline 5 Sensor similar to the Rear Panel pushbuttons. Refer to the manual section referenced for configuration and operation information as directed for each code.
Page 112 2 = Coarse (CORS) SW – Switch Input Status (Read Only) Command Returns the Sensor’s external switch status (Peak Picker reset and Hold mode select). Range: 0 or 1 (0 = closed; 1 = open) Modline 5 Rev. L6 Feb 2017...
Page 113 Observe and follow cautions below and operating instructions in Section 5.11 Laser Sighting Operation, page 102 of this Modline 5 Manual. Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or other devices using RS– 485 Communications, insure there are no personnel in the path of the beam.
Page 114: Analog Output Function Command Codes
Message Value Range: Sensor’s zero scale temperature + 10 to its full scale temperature. The Sensor selected measurement units, “F” or “C”, are ignored in the Write command. Sensor Reply Returns with an “F” or “C” to indicate which units are selected. Modline 5 Rev. L6 Feb 2017...
Page 115: Head Function Command Codes
If the Sensor’s remote scaled E-Slope input current is active, the Sensor returns that setting ignoring any ES Write command or Rear Panel keyboard entry. Scaled Message Value Range: 800 to 1200 (Scaled value = actual value times 1000) Actual Range: .8 to 1.2 Modline 5 Rev. L6 Feb 2017...
Page 116 Turns Peak Picker or Track and Hold on and off. Only one can be turned on at time. Range: 0 to 2 Message Values: 0 – Peak picker and track & hold are both off. 1 – Peak picker on. 2 – Track & Hold on. Modline 5 Rev. L6 Feb 2017...
Page 117: Measurement Condition And Alarm Command Codes
6.9 Measurement Condition and Alarm Command Codes 6.9.1 Introduction This section identifies measurement and alarm status commands and defines the reported errors and measurement conditions. TI – TS – Temperature, Status, and Attenuation (Read Only) Modline 5 Rev. L6 Feb 2017...
Page 118 Same as HIGH on rear panel TEMP display 16384 Laser pointer is on Same as Laser LED on Sensor rear panel –32768 Unit under Cal test Same as CAL on rear panel TEMP display Modline 5 Rev. L6 Feb 2017...
Page 119: Command Code Summary
Turns Peak Picker or Track and Hold on or off. Serial Number Eng. Returns the serial number string of the unit. System alarm status Alarm Sensor returns bit mapped values for alarms and the current measurement condition status. Modline 5 Rev. L6 Feb 2017...
Page 120 Eng. Sets the units the Sensor uses for measurement (F or C). Unit zero scale Eng. Returns Sensor’s zero scale temperature as defined Model No. Firmware version Eng. Returns the Sensor’s firmware version number Modline 5 Rev. L6 Feb 2017...
Page 121: Maintenance
7.1 Routine Maintenance 7.1.1 Maintenance Checklist The Modline 5 Sensor is a precision temperature measuring instrument built for rugged service and ease of operation. When installed and maintained with reasonable care, it will give you reliable service in a wide variety of applications.
Page 122: Cleaning The Optics
Maintenance Treat the Modline 5 Sensor optics with care. Scratches or harmful solvents can destroy the lens or the Dirty Window Detector window and mirror. Lenses may be slightly soluble in water and other liquids. Do not soak any lens in water or any other liquid for long periods of time.
Page 123: Servicing
Sensor. The Modline 5 Sensor with Laser sighting option is a Class II Laser product. When restoring a Sensor with this option back to service, follow the Cautions outlined below and the operating instructions in Section 5.11...
Page 124: Measurement Condition Displays, Error Codes And Troubleshooting
 The fourth method is to use a sensor that is titled a transfer standard. This is a Modline 5, usually the same model as the customers equipment and it is specially calibrated at 10 specific points on the temperature scale of the instrument.
Page 125 Investigate all alarms indicated by the ALARM word indicator. Temperature readings on rear panel display, at Analog Output or from RS-485 Communications may be inaccurate with Error Codes X101 through X109 alarms. Ratio Temperature measurement conditions are invalid with INV and pINV alarms. Modline 5 Rev. L6 Feb 2017...
Page 126: Status Displays And Error Code Details
Note: iALM must be set to ON for this  Displayed temperature readings are peaked values or hold values Alarm condition to be displayed on Sensor from Peak Picker or Track and Hold signal conditioning. rear panel and the Alarm Relay operates. Modline 5 Rev. L6 Feb 2017...
Page 127 If these temperatures are okay and alarm continues Sensor may have a malfunction.  Caution: Any temperature readings on rear panel display, at Analog Output or from RS-485 Communications may be inaccurate Modline 5 Rev. L6 Feb 2017...
Page 128  If analog output is not used, place a jumper wire across the output terminals to prevent the X108 alarm from occurring.  Dirty Window circuit operation malfunction. Error Code X109 Malfunction of Sensor Dirty Window  Replace Sensor Detection. Modline 5 Rev. L6 Feb 2017...
Page 129: Troubleshooting
If troubles develop in the initial installation or after periods of normal operation, these troubleshooting suggestions may help to identify certain trouble symptoms and possibly correct the problem. If trouble persists, call or contact IRCON Technical Services for help. Symptom...
Page 130 2. Delay timing starts immediately after the reset or the Invalid or LOW condition. Cannot adjust AOUT ZERO or FULL Scale 1. Check both ZERO and FULL settings. Minimum 10°F span is required (or equivalent °C span values) Modline 5 Rev. L6 Feb 2017...
Page 131: Applications Guide
8.2 Analog Outputs All Modline 5 Sensors provide an analog current signal output of 0 to 20 mAdc or 4 to 20 mAdc. The output range is selected using the Sensors rear panel AOUT and SOUT function menus or RS-485 Digital Communications command codes.
Page 132: Analog Output Range Scaling Example
An analog current signal output of 0 to 20 mA provides a full 20 mA current span. The 4 to 20 mA output provides a 16 mA current span. To convert the output current to temperature, you must know the current output span and corresponding temperature span to calculate the resultant temperature. Modline 5 Rev. L6 Feb 2017...
Page 133: Analog Output Operation Notes
95% of a step change in measured temperature. The Response Time in the Modline 5 Sensor has an adjustable range from 6.6 or 10 milliseconds minimum, depending on Model, to 60 seconds Maximum. See section 2...
Page 134: Determining Response Time To Use
“filtered out“ and system follows temperature ans effects of variations as fast as minimum general trends in temperature, temperature spikes are response time of instrument. with small amounts of “ripple“. eliminated. Figure 80: Effects of Response Time Modline 5 Rev. L6 Feb 2017...
Page 135: Emissivity Settings
All Modline 5 Sensors are factory calibrated using blackbody standards. For accurate measurements, you must compensate for the difference between the emissivity of your target and that of a blackbody radiator.
Page 136: Using Emissivity Thermocouple Test
1.000. 8.4.5 Practical Limits on Emissivity While all MODLINE 5 instruments are capable of emissivity settings of 0.100 to 1.000 it is not always advisable to use the lower emissivity settings. Potential temperature measurement errors due to background reflections are aggravated by a combination of decreasing target emissivity and decreasing target temperature.
Page 137 1. Polished surface of material Highly Reflective Good Emissivity: 2. Rough surface of material A Very poor Reflector Approaching blackbody condition Best Emissivity: 3. Cavity surface of material Figure 81: Surface Finish affects Emissivity Modline 5 Rev. L6 Feb 2017...
Page 138 0.40-0.60 0.35-0.50 0.20-0.35 Tantalum 0.20-0.60 0.15-0.30 0.10-0.30 Titanium 0.40-0.60 0.30-0.50 0.20-0.35 Tungsten 0.35-0.50 0.25-0.40 0.10-0.25 Vanadium 0.35-0.50 0.30-0.40 0.25-0.35 Zinc, molten 0.20-0.40 0.15-0.30 0.10-0.25 Code 1 Table 17: Emissivity Values of Metals and Alloys Modline 5 Rev. L6 Feb 2017...
Page 139 0.80-0.95 Steel, Carbon, oxidized 0.80-0.95 0.80-0.95 0.80-0.95 Steel, Stainless, oxidized 0.80-0.95 0.80-0.95 0.80-0.95 Tantalum, oxidized 0.40-0.80 0.40-0.80 0.40-0.80 Titanium, oxidized 0.50-0.80 0.50-0.80 0.50-0.80 Code 2 Table 18: Emissivity Values of oxidized Metals and Alloys Modline 5 Rev. L6 Feb 2017...
Page 140 ¹ Highly variable. Values for low emissivity entries can be significantly greater than shown if even small amounts of impurities are present. ² Paints with metallic pigments may have much lower emissivities. Table 19: Emissivity Values of miscellaneous Materials Modline 5 Rev. L6 Feb 2017...
Page 141 ³ Emissivity values may be significantly lower than shown for very sheer materials. Note that objects with even a very thin coating of water have very high emissivities. Table 20: Emissivity Values of miscellaneous Materials (Continued) Modline 5 Rev. L6 Feb 2017...
Page 142: Ratio Sensors
Applications Guide 8.5 Ratio Sensors Modline 5 Series 5R Sensors utilize a dual detector assembly that measures temperature by comparing infrared radiation levels in two wavelength bands (0.85 to 1.05 microns and a narrow band centered at 1.0 to 1.10 microns). They have the capability to measure temperature by comparing the relative infrared radiance at two different wavelengths and computing the ratio of the two.
Page 143: Setting The E-Slope
A third way to adjust the Emissivity is to send a scaled input of 4 to 20 mAdc via the Orange and Orange/White twisted wire pair of the Sensor’s interconnecting cable. The Modline 5 senses an input and overrides any other setting of Emissivity or Match. Wiring and scaling information is in Section 4 Sensor Wiring, page 64.
Page 144: External Switch For Remote Peak Picker Operation
8.6.2 External Switch for Remote Peak Picker Operation The Modline 5 has a provision for a remote process controlled input switch to be wired to the Violet and Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Peak Picker signal conditioning is selected, the remote switch can enable or disable the Peaking action.
Page 145: Peak Picker Signal Conditioning
This reset action is triggered when the measured temperature goes below the selected Reset Below Temperature. When the measured temperature is below this temperature, the displayed temperature indication will be the measured temperature unaffected by the Peak Picker signal conditioning, subject to any Response Time selection. Modline 5 Rev. L6 Feb 2017...
Page 146: Peak Picker Delay
The Peak Picker action will begin after the selected delay time and will continue until the actual measured temperature goes below Modline 5 Rev. L6 Feb 2017...
Page 147: Track And Hold
8.7.1 External Switch Control of Track and Hold The Modline 5 has provisions for a remote process controlled input switch be wired to the Violet and Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Track and Hold signal operation is selected, the switch input is required to change from Track temperature operation to Hold temperature mode as required in the process system.
Page 148: Avoiding Common Measurement Problems
Cone of Vision on the target and make sure that its cross-section (spot size) is smaller than the target. That way the sensor can't "see" past the target into the background. Although Modline 5 Rev. L6 Feb 2017...
Page 149: Transmission Effects
This results in measured temperature error. For all Modline 5 Sensor Series, except the Series 5R, this extra radiation, if detected, causes a temperature indication that is higher than the target's true temperature.
Page 150: Transmission Path Effects
Reflectance problems may be reduced by changing the viewing angle so that the reflection is not picked up by the Sensor, or by the use of sight tubes or some other form of shielding. (See Figure 88 examples.) These considerations apply to all Sensor Series. Modline 5 Rev. L6 Feb 2017...
Page 151: Use Of Mirrors
Cautions: 1. I.D. of sight tube must be wider than Cone of Vision along entire length. (See Section 2. Sight tube walls may radiate infrared if furnace atmosphere is very hot. May require cooled sight tube. Consult IRCON for recommendations. Figure 88: Solving Common Reflection Problems 8.9 Use of Mirrors...
Page 152: Use Of Windows
To view an object in an inert atmosphere or vacuum chamber, you must use an infrared transmitting window. Selection of an appropriate window material will depend on the Sensor's spectral response. Some suggested window materials for various Modline 5 Sensor Series are listed in the Window Selection Guide Table 21.
Page 153: Special Considerations For Ratio Units
Ratio Sensor, use a front surface gold mirror, not a mirror with an aluminum reflecting surface. The materials listed in the Guide are not all common optical materials and you may have some difficulty locating a source for windows. If you do, here are some suggestions. Modline 5 Rev. L6 Feb 2017...
Page 154: Preventing Sensor Overheating
8.11 Preventing Sensor Overheating The Modline 5 Sensor can be cooled with the WJA accessory presented in Section 3 Sensor Installation, page 22. Do not use a WA-3 accessory for cooling. Under extreme conditions, it may be necessary to provide insulation and reflective shielding for additional protection from high ambient temperatures and radiated heat using materials available at the installation site.
Page 155 Applications Guide Heat Shield Sight Hole Hot Target Figure 92: Protection Using Reflective Heat Shield Modline 5 Rev. L6 Feb 2017...
Page 156: Notices
Notices 9 Notices Modline 5 Rev. L6 Feb 2017...

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ircon Modline 5 Operating Instructions Manual

1 Safety Instructions

2 Product Description

3 Sensor Installation

4 Sensor Wiring

5 Operation

6 Digital Communications

7 Maintenance

8 Applications Guide

9 Notices

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Operating Instructions

Troubleshooting

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