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EXACTUS
http://www.catalysts.basf.com/Main/temperature_sensing
Exactus is a registered trademark for which BASF Catalysts LLC has rights. The data contained in this publication are based on our
current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data
do not relieve processors from carrying out their own investigations and tests; neither do these data imply any guarantee of certain
properties, nor the suitability of the product for a specific purpose. Any descriptions, drawings, photographs, data, proportions,
weights, etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. It
is the responsibility of the recipient of our products to ensure that any proprietary rights and existing laws and legislation are observed
(08/2007). BF-8807
Although all statements and information in this publication are believed to be accurate and reliable, they are presented gratis and for
guidance only, and risks and liability for results obtained by use of the products or application of the suggestions described are
assumed by the user. NO WARRANTIES OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED
OR DESIGNS, DATA OR INFORMATION SET FORTH. Statements or suggestions concerning possible use of the products are
made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe any
patent. The user should not assume that toxicity data and safety measures are indicated or that other measures may not be required.
©2007 BASF Catalysts LLC.
®
OPTICAL THERMOMETER
Manufactured By BASF Corp
USER'S MANUAL
Single or Multi-Channel System
Version 5.04
BASF Corp
Temperature Sensing Group
46820 Fremont Blvd.
Fremont, CA 94538-6540
Phone: (510) 490-2150
Fax: (510) 252-1871
Additional support available:
BASF Temperature Sensing, Portland, Oregon
4011 SE International Way, Suite 604
Portland, OR 97222
Phone: (503) 794-4073
Fax: (503) 794-5591
Copyright© 2001 BASF Catalysts, LLC. All rights reserved.
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Table of Contents
Troubleshooting
Summary of Contents for BASF EXACTUS
- Page 1 Copyright© 2001 BASF Catalysts, LLC. All rights reserved. Exactus is a registered trademark for which BASF Catalysts LLC has rights. The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out their own investigations and tests;...
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Page 3: Table Of Contents
Table of Contents 1. Introduction ......................1-3 Company Profile ......................1 Theory of Operation......................1 ® Overview of the BASF EXACTUS Optical Thermometer ..........2 ® Advantages of the BASF EXACTUS Optical Thermometer ........3 System Description ................... 4-6 Collection Optics......................5 Probe Head........................6 Interface Module, Analog and Digital Output ..............6 Power Supply: ........................6... - Page 4 Table of Figures Figure 1 Probe Head Conceptual Diagram ..............2 Figure 2A Single Channel System ................4 Figure 2B Multi Channel System ................5 ® Figure 3 TemperaSure Graphical User Interface (Main Display Screen)....9 Figure 6 Graph Setup Windows .................12 Figure 7 Probe Setup Window..................13 Figure 10 Auto Calibration Feature................16 Figure 11 Advanced Probe Functions Tab ..............17 Figure 12 Menu for All Probes ...................19...
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Page 5: Introduction
1.1 Company Profile BASF is the worlds leading chemical company with over 100 production sites worldwide. Some facts about BASF: Over 90,000 employees •... -
Page 6: Overview Of The Basf Exactus
2. Wavelength Selective Filters: These select which wavelengths of light are measured. Care must be taken that these filters are kept clean and dry. 3. Photo Detector: Photo detectors convert light (photons) into an electrical signal. BASF uses only high efficiency (D*) solid-state photo detectors of either silicon, InGaAs, or a new patented 900nm narrow band detector. -
Page 7: Advantages Of The Basf Exactus Optical Thermometer
1,000 readings per second. In addition, the instrument performs all the A/D conversions internally, so each instrument provides a digital signal output. BASF also offers an analog output module for applications where a proportional to temperature current or voltage output is desired. -
Page 8: System Description
System Description ® A single channel EXACTUS system is composed of four parts: • Collection optics: either a lightpipe or lens assembly • Probe head: a stainless steel tube (0.998" diameter × 4.5" long / 25.4mm × 114.3mm) • Interface module: for conditioning power and communicating with a PC. -
Page 9: Collection Optics
Lightpipes are more efficient at collecting light than lens systems, therefore they are better suited for low temperature measurements. BASF manufactures custom collection optics for specific user needs and measurement applications. Lightpipes and lenses can be coupled directly to the measurement... -
Page 10: Probe Head
PC or digital data logger. BASF also offers an Analog Output Option, which can be configured to either a voltage or current output. The value of the analog output can be scaled as needed using the TemperaSure software from 0 to 10 volts or 0 to 20 mA to any temperature range. -
Page 11: System Startup
Please read the Warnings in Section 5.0 before you begin. 1. Carefully unpack the parts of the system. 2. Check that you received all the parts of your measurement system. Please contact BASF immediately if you have any questions or if parts have been damaged in shipping. -
Page 12: Software Interface
• Check that the correct COM port(s) on the computer is being used. Consult Section 6 “Troubleshooting” in this manual if cabling and LED are all OK. • • Call BASF Temperature Sensing in Portland, OR (503) 794-4073 or Fremont, CA (510) 490- 2150 for additional help. -
Page 13: Using Temperasure Software Functions
Graph and Y-Axis Quick Data Zoom and Measurement Buttons Track Control Rate Y-Axis Zoom Start and Stop Logging Control Temperature Readings Time Scale Zoom Mouse Annotation Coordinates Status Figure 3: TemperaSure Graphical User Interface - Main Window Using TemperaSure Software Functions The TemperaSure program has 5 menu options: •... - Page 14 Save: Use to save data collected to a “.bin” data file. The .bin file is used for viewing data at a later time with this program. ® © Export (ASCII): Use to export a data file for use in another program, such as Microsoft Excel ©...
- Page 15 Figure 5: Macro Mode setup screen 4.4.3 View Find Data: This feature finds the most up-to-date readings and centers the data in the graph. Find Data is like a beam finder, it auto-scales the graph and places the measurements in view. The Quick-Button at the top of the screen and Right-clicking the mouse also provides access to Find Data.
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Page 16: Probe And Temperasure Software Setup
Therefore, it is very important that the probes be set up correctly. Graph settings will not affect the measurements, only the display of the data. If you are not certain about the correct settings please call BASF for application support. 4.5.1 Logging Rate: The graph rate is the number of readings per second (Rd/Sec) transmitted by the probe. -
Page 17: Figure 7 Probe Setup Window
4.5.2 Probe Setup Options: (The key to good measurements!) Figure 7: Probe Setup Window All instrument settings, with the exception of “graph rate”, can be edited using the Probe Parameters menu for the individual instrument. To access the Probe Parameters for a particular instrument, click on the number box above the instruments measurement display box, or choose Options, Probe. - Page 18 2) Modes: The Exactus instrument can be configure for several different operating modes; please see Sections X.XX for details. Not all probes ship from the factory with these modes activated;...
- Page 19 Figure 8: Modes menu 3) Analog Output: The Analog Output for each probe is also configured from the probe parameters. Users can activate the analog output, select whether the output is to be 0 – 10 VDC or 4 – 20mA, and set the minimum and maximum temperatures. The minimum and maximum temperatures can be any value within the calibrated range of the instrument.
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Page 20: Advanced Probe Features
4.5.3 Advanced Features: The advanced features in the Exactus instrument are designed to allow the user to correct and manage a variety of pyrometric measurement issues, including adjustment of emissivity or slope correction, signal averaging (Averaging Buffer) and heat transfer (Transfer Function). These features can also be entered in table form, with corresponding temperatures for each table entry, so the parameter will automatically adjust the target temperature changes. -
Page 21: Figure 11 Advanced Probe Functions Tab
For more information on emissivity, please see glossary section 7, Emissivity) Figure 11: Advanced functions tab. It is recommended that only small step changes in emissivity be entered. Entering more rows with smaller changes in temperature and emissivity will generally provide better results and less chance of errors. -
Page 22: All Probes
(1.0) is entered. The temperature will increase for values less than one. Low Temperature Signal Averaging: The bottom end of the temperature range for an Exactus instrument is usually the temperature at which the instrument will measure a blackbody with a resolution of 1.0ºC at one reading per second. -
Page 23: Figure 12 Menu For All Probes
Figure 12: All Probes display Figure 13: Analog Output Setup Window -19-... -
Page 24: Graph Setup
BASF recommends maintaining relatively up to date computer systems; any computer manufactured within the previous 5 years should not present a problem. Select a log-rate that is fast enough for your process or needs yet creates files that are manageable in size. - Page 25 Graph Scale Changes: Left-click the mouse on either the vertical or horizontal graph axis to open a Scale Limit Box. Graph Format Changes: Right-click the mouse to edit the graph format, including: zoom, grid lines, and which variable (temperature or diode current) to display. Probe Setup: Left-click the mouse on the probe number above the temperature box to adjust that probe’s setup.
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Page 26: Warnings
• Probe heads should never be exposed to temperatures over 60°C (158°F) or they will be damaged. If the application requires the probe to be exposed to temperatures above 60°C, please contact BASF Temperature Sensing customer support. BASF manufactures air- cooling assembles which protect the probes in high-temperature environments. The operating specification is 10°C to 60°C and up to 250ºC for the lens and fiber optic cable... -
Page 27: Troubleshooting
9. Dirty viewport or incorrect transmission factor entered under probe setup. 10. Cracked or Broken lightpipes. Every application has its own set of measurement challenges and problems so the order may vary depending on the application. BASF’s technical support staff is available to help with these issues. -23-... -
Page 28: Glossary Of Terms
(See also Freeze Point Furnaces). BASF offers an analog output module. The module takes the high speed digital Analog probe signal and converts it to an analog signal which is linear with respect to Output measured temperature. - Page 29 Errors can also occur at the connection ends of the cables. BASF’s compact probe is small enough to be placed directly behind the collection optics in most applications, thus eliminating the need for these cables.
- Page 30 A rod typically made from sapphire or quartz which acts as a guide to “pipe” light from a hot object back to a fiber optic cable or, in BASF’s case, directly to the photo detector. BASF offers lightpipes in standard diameters of 2 mm, 3 mm, and 4 mm.
- Page 31 12 volts DC use by the interface box and probe. A generic term that is used to describe many types of temperature sensors. Probe BASF defines the optics, in combination with the stainless steel tube containing the electronics, as the probe or probe head. -27-...
- Page 32 The most common term used to describe temperature measurements based on Pyrometry the Planck Equation. The extent of the instrument’s ability to measure temperature. BASF has a Range number of temperature range options associated with different measurement wavelengths and optical sensor designs. Some of the basic ranges are: •...
- Page 33 Sheaths lightpipes. BASF recommends using a sheath to protect the lightpipes from breakage and deposition. BASF offers a wide range of standard and custom sheaths, including gas-purged sheaths for deposition processes. The response time of the electronics (versus bandwidth, which is the “cutoff”...
- Page 34 Seebeck emf. Seebeck’s work directly lead George Ohm to the formulation of Ohm’s law a few years later. BASF is the world leader in Platinum and other precious metal thermocouples. Found in the Probe Setup dialog box (Setup, Probe…) as an option under...
- Page 35 The distance between two crests (peaks) of an electromagnetic light wave. Wavelength BASF works with customers to select the best wavelength(s) for the specific measurement (See also Micron). Recommended References: The most comprehensive coverage of the basic physics can be found in Theory and Practice of Radiation Thermometry, by David DeWitt and Gene Nutter, 1988 John Wiley &...
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Page 36: Specifications
650°C Lightpipe 3mm 210°C 1250°C 18°C 630°C Lightpipe 4mm * Instrument temperature must be below target temperature. This document contains specifications and information about a patent-pending product-line. BASF Catalysts, LLC reserves the right to change product specifications without notice. -32-... -
Page 37: Figure 14 Drawing Of Probe With Lens Collection Optics (Pyrometer)
Figure 14: Lens Collection Optics – Pyrometer -33-... -
Page 38: Figure 15 Drawing Of Probe With Lightpipe
Figure 15: Probe with Lightpipe -34-... -
Page 39: Figure 16 Lightpipe Detail
Figure 16: Lightpipe and Sleeve Detail FERRULE LIGHTPIPE, SAPPHIRE DIAMETER: 2mm, 3mm, 4mm O-RING LENGTH: 1" TO 18" LOCK NUT SLEEVE - WIDE RANGE OF OPTIONS SHEATH, SAPPHIRE 4.5mm OD, 5.5mm OD, 6.5mm OD OPEN AND CLOSED ENDS LIGHTPIPE FERRULE Fremont, CA Phone: (510) 490-2150 Portland, OR Phone: (503) 794-4073 -35-... -
Page 40: Appendix 1: Multi-Channel Interface Box Installation Guide
The Exactus® Industrial Mux is designed to provide data packaging, instrument monitoring, and (optionally) analog output for up to eight Exactus pyrometers. In most situations, the Industrial Mux can be connected and operate without any setup or configuration changes. Some of the features that can be programmed to the Industrial Mux include: •... -
Page 41: Figure A-15 Analog Output/ Digital Interface Module Connections
Right-click on My Network Places and choose ‘Properties’ from the pop-up menu. See Figure A-1. Figure A-1: Selecting Properties of My Network Places b. Double-click on the connection. If there is more than one connection, you can determine which connection to use by unplugging the LAN cable from the Mux, and the Status will change to “Network Cable Unplugged”. -
Page 42: Figure A-16 External Power Jumper
c. The following screen (Figure A-3) will appear, click the ‘ Properties’ button. Figure A-3: d. Double-click the ;Internet Protocol (TCP/IP); line (Figure A-4), this will bring up the screen shown in Figure A-5: Figure A-4: -38-... -
Page 43: Figure A-17 External Power Wiring
Figure A-5: e. Click on the radio button ‘Use the following IP address’ and then set the IP address using the following rules: i. The first 3 numbers of both the IP address and the Default Gateway must agree with the first three numbers of the Mux’s address (Default Address = 192.168.1.80). -
Page 44: Figure A-18 Analog Output Scaling
Figure A-6: b. Choose a name (such as i-MUX) and an icon as shown in Figure A-7 and click Figure A-7: c. Select the ‘TCP/IP (Winsock)’ option from the “Connect using:” drop-down box, then enter the Mux’s IP address and click “OK” (See Figure A-8): -40-... - Page 45 Figure A-8: d. When you hit the OK buttons, you should get the menu shown in Figure A-9: Figure A-9: e. After you make changes to the Industrial Mux configuration, be sure the select ‘9. . As noted, this will reboot the Industrial Mux. Save Changes’...
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Page 46: Figure A-19 Analog Output Calibration
(circled in blue in Figure A-10 below) and then select the radio button for “Echo typed characters locally”: Check the “Echo typed characters locally” check box and close the dialog windows. Figures A-10 and A-11 User Interface Menu: The User Interface Menu is shown in Figure A-9 above. Below is a description of each menu item: -42-... - Page 47 Analog Output Enabled (Factory Default) is displayed, than the outputs are currently Enabled. • Pyrometer Supply Voltage (mV): This is the voltage that supplies power to each Exactus pyrometer. Please consult with the factory before adjusting this value; otherwise it should be left at the default value of 6000mV (suitable for pyrometer power/communications cables up to 15 meters long).
- Page 48 Depending on the operating speed of the pyrometer, and other environmental factors, the measured temperature of the electronics can be 5 to 12ºC above the actual ambient air temperature. The submenu for each pyrometer configuration is self-explanatory. Figure A-13: Alarm configuration menu Figure A-14: Instrument Ambient Configuration Menu Pyrometer Analog Watchdog: If the Pyrometer Analog Watchdog is activated, the Industrial Mux will watch for missed readings from the pyrometer, an indication that the pyrometer has...
- Page 49 Analog Output Wiring: The analog outputs for the Exactus Industrial Mux do not generate a voltage to drive the analog output and must receive the voltage externally. Many data logging systems are configured to supply this voltage; if yours is not, you can use the same power supply driving the Industrial Mux to provide the power.
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Page 50: Appendix 2: Probe Transmit Data Protocol
Technical information and data regarding performance or use of the optical thermometer product described herein is believed to be reliable. However, BASF Catalysts, LLC cannot assume responsibility for the misuse of this product or any warranty other than that made at the time of sale in writing. The information contained in this document is subject to change without notice. - Page 51 At this time, the host system can proceed to communicate with the pyrometer in Modbus Protocol mode, or a Modbus command can be sent to switch the pyrometer into the Exactus Protocol mode. NOTE: For an example Modbus message to switch the pyrometer into the Exactus Protocol mode, see Example 2 below.
- Page 52 Coil Address Hi 00 Coil Address Lo 13 Force Data Hi Force Data Lo CRC Hi CRC Lo Note: After issuing this command, there will be no response because the pyrometer will enter Exactus Mode immediately. Duplex Full Parity None...
- Page 53 Message Formats Header Packet Type Value 1 Value 2 (Hex) 0x81 Temperature Target Temperature None 0x82 Current Photodiode Current None 0x83 Dual Target Temperature Photodiode Current 0x84 Ambient Electronics Temperature Chassis Temperature 0x85 Reserved for Future Use Data Message Escape Sequence In order to remain synchronized with the host in the case of buffer overflows or other communications errors, the pyrometer uses an escape character for Header byte values that occur in the binary data being sent.
- Page 54 Ambient Temperature Message Header Byte: 0x84 Message Format: 0x84 <AmbE 32 bit IEEE> <AmbC 32 bit IEEE> Description: Pyrometer ambient temperatures. AmbE = Electronics Temperature. AmbC = Chassis Temperature. Example: Electronics temperature of 28.4C and photodiode temperature of 31.5C. Message: 84 41 E3 33 33 41 FC 00 00 Host to Pyrometer Commands Commands to the pyrometer always start with the Start of Command (STX).
- Page 55 Note that the LRC for single byte commands is simply the command byte repeated. All values used in the protocol description are represented in hexadecimal format. Summary of Commands Switch to Modbus Mode Description: Commands the Pyrometer to switch to Modbus Mode Command Byte: 0x4D Format: STX 0x4D 0x4D ETX Response: None (pyrometer switches to Modbus Mode immediately)
- Page 56 32 bit IEEE Floating Point Format The IEEE 754-1990 standard for binary floating point arithmetic defines the format for representing single precision (32 bit) floating point numbers. The 32 bits in the number are divided into the sign, exponent and fraction portion as follows: Sign Exponent Fraction...
- Page 57 MODBUS Communication Introduction The following appendix describes the Modbus RTU communication protocol interface for the BASF optical pyrometer. The protocol provides the means for a host computer or PLC to read the pyrometer temperature and photodiode current values. The pyrometer’s configuration and calibration settings are also made accessible through the Modbus protocol.
- Page 58 Temperature = 252.55 C -> IEEE-754 Reverse Representation = 437C8CCC Temperature Reading at register locations 0000h-0001h: Address Data 0000h 437Ch 0001h 8CCCh The pyrometer temperature and current values are available at multiple register addresses. For example, the temperature reading is mapped at both 0x0000-0x0001 and 0x0006-0x0007. These redundant mappings provide the ability to read more than one reading using a single Modbus message.
- Page 59 Configuration Register Bit Descriptions GenConfigReg1 (1000h) Bit(s) Description Send Temperature (Legacy Mode) Send Current (Legacy Mode) Send Ambient Temperature (Legacy Mode) Enable Averaging / Bandwidth Table Enable Fit Function Table Enable Emissivity Table 0=Emiss. Extrap., 1=Emiss. Hold 0=Fit Extrap, 1=Fit Hold Set Temp=99999.99 when pyrometer max.temp.
- Page 60 0016-0017 RESERVED 0018-00ff RESERVED 0800-0801 Chassis Ambient Temperature Configuration Registers 1000 Configuration Register 1 1001 Configuration Register 2 1002-1006 RESERVED 1007 Modbus Device Address 1008 Modbus Baud Rate 1009-1010 RESERVED 1011 Pyrometer Sample Rate This setting is called the “Graph Rate” in TemperaSure.
- Page 61 3106-3107 Voltage Mode Max. Temp. Voltage Mode Maximum Temperature 3110-3111 Current Mode Min. Current Analog current output at minimum temperature. 3112-3113 Current Mode Max. Current Analog current output at maximum temperature. 3114-3115 Current Mode Min. Temp. Current Mode Minimum Temperature 3114-3117 Current mode Max.
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Page 62: Appendix 3: Analog Output Guide
There are four wires that must be connected between the Analog Output Module and the Digital Interface Module. The two modules are designed to stack one above the other. BASF provides a pre-made connector designed for use when the two modules are stacked. When the two modules are stacked vertically the power input and digital communications connections are, pin for pin, directly above one another. - Page 63 If the modules are not to be stacked, the connections are wired the same as described above in Figure A-15. The Analog Output Module and the Digital Interface Module can be wired up to 50 meters from each other. Shielded wiring is recommended for distances greater than a few meters or if the electronics are mounted in an area of high electromagnetic interference.
- Page 64 Configuration section below. If you initially purchased your BASF probe without an analog output, a single line needs to be written into the probe initialization file.
- Page 65 2. Click the Use Analog Output button. 3. Click on either Voltage or Current button. 4. Go to the corresponding section and type in the minimum temperature and the maximum temperature and the corresponding voltage or current values. Voltages between 0 and 10 volts and currents between 0 and 20mA may be entered.
- Page 66 reduced proportionally. The resolution of the module in current mode is 20,000 different current levels spread over the 0 – 20mA current range; when the current output range is reduced (e.g. 4 – 20mA) the number of different current levels will be reduced proportionally. Reverse Scaling: The output can be set up as reverse acting if desired.
- Page 67 10. Measure the voltage or current from the Analog Output Module. For a voltage output there should be a potential of 10 volts across the +V out and –V out terminals. For a current output there should be a 20mA current flowing between the +I out and –I out terminals (ExtPWR and –V out if External Power is utilized –...