optris PI 400i Operator's Manual

optris PI 400i Operator's Manual

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Operator's Manual
optris
®
PI
400i/ 450i/ 450i G7/ 640/ 640 G7/ 05M/ 08M/ 1M
Infrared camera

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Summary of Contents for optris PI 400i

  • Page 1 Operator’s Manual optris ® 400i/ 450i/ 450i G7/ 640/ 640 G7/ 05M/ 08M/ 1M Infrared 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.global Internet: www.optris.global...
  • Page 3: Table Of Contents

    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 Measurement specifications ......................16 Optical specifications ........................20 Mechanical Installation .......................... 28 Dimensions ............................28 Changing the lens ..........................35 Fixing the focus of the lens (only for PI 05M/ 08M/ 1M) ..............36 Mounting accessories (optional) ....................... 38 High temperature accessories ......................39 3.5.1 CoolingJacket ...........................
  • Page 5 Table of contents Process interface ..........................48 4.1.1 PIN allocation ..........................50 4.1.2 Industrial Process Interface (optional) ..................52 Example for a Fail-Safe monitoring of the PI with a PLC ..............55 USB cable extension ........................57 IRmobile App ............................59 Software PIX Connect ..........................
  • Page 6 Determination of unknown emissivity ....................77 Characteristic emissivity ........................79 Appendix A – Table of emissivity for metals ....................80 Appendix B – Table of emissivity for non-metals ..................82 Appendix C – Quick start for serial communication ................... 83 Appendix D –...
  • Page 7: General Notes

    Thank you for choosing the optris PI infrared camera. The optris PI calculates the surface temperature based on the emitted infrared energy of objects [►7 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. The radiometric processing of the picture data enables the user to do a comfortable detailed analysis with the software PIX Connect.
  • 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  PI 400i, PI 450i, PI 450i G7, PI 640, PI 640 G7, PI 05M, PI 08M or PI 1M incl. 1 lens  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

    Model Model code Temperature range Spectral range Frame rate Typical applications PI 400i/ PI 450i -20 to 900 °C 8 - 14 µm 80 Hz Real-time thermographic images in high speed; 200 to 1500 °C (optional) Detection of smallest temperature differences (PI 450i) PI 450i G7 200 to 1500 °C...
  • Page 11: Technical Data

    Aluminum, anodized Dimensions: PI 400i/ PI 450i (450i G7): 46 x 56 x 68 - 77 mm (depending on lens and focus position) PI 640 (640 G7): 46 x 56 x 76 - 100 mm (depending on lens and focus position) PI 640 microscope optics: 46 x 56 x 119 –...
  • Page 12 Cable length (USB 2.0): 1 m (standard), 3 m, 5 m, 10 m, 20 m Vibration IEC 60068-2-6 (sinus shaped) IEC 60068-2-64 (broadband noise) Shock IEC 60068-2-27 (25 G and 50 G) Used standards for vibration and shock: Figure 1: Used standards Stress program (camera in operation):...
  • Page 13 Technical Data Shock, half sinus 25 G – testing Ea 25 G (acc. IEC 60068-2-27) Acceleration 245 m/s (25 G) Pulse duration 11 ms Number of directions (3 axes with 2 directions each) Duration 600 Shocks (100 Shocks each direction) Shock, half sinus 50 G –...
  • Page 14 Number of axes Duration 1:30 h (3 x 0.30 h) Vibration, broadband noise – testing Fh (acc. IEC60068-2-64) Frequency range 10 - 2000 Hz Acceleration 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...
  • Page 15: Electrical Specifications

    Technical Data 2.2 Electrical specifications Power Supply: 5 VDC (powered via USB 2.0 interface) Current draw: Max 500 mA AO: Output Standard Process Interface recording status, line scan status, 0 - 10 V (Main measure area, measure area, internal temperature, flag status, (PIF out) alarm, frame sync, fail-safe, external communication) [►Appendix F –...
  • Page 16: Measurement Specifications

    2.3 Measurement specifications PI 400i PI 450i PI 450i G7 Temperature ranges -20...100 °C; 0...250 °C; (20) 150...900 °C ; Option: 200…1500 °C 200…1500 °C 150…900 °C Sighting range / low energy range 0…250 °C Spectral range 8 - 14 µm 7.9 µm...
  • Page 17 Technical Data PI 640 PI 640 G7 Temperature ranges -20...100 °C; 0...250 °C; (20) 150...900 °C 200…1500 °C Option: 200…1500 °C 150…900 °C Sighting range / low energy range 0…250 °C Spectral range 8 - 14 µm 7,9 µm Detector UFPA, 640 x 480 Pixel @ 32 Hz 640 x 120 Pixel @ 125Hz...
  • Page 18 PI 05M PI 08M PI 1M Temperature ranges 900 … 2450 °C (27 Hz mode) 575 …1900 °C (27 Hz mode) …1800 °C (27 Hz mode) …1800 °C (80 Hz and 32 Hz mode) 950 … 2450 °C (80 Hz and 32 Hz mode) 625 …...
  • Page 19 Technical Data Emissivity 0.100...1.100 Software PIX Connect +75 °C start temperature for optics with focal length f= 50 mm, f= 75 mm An additionally purchased lens for the PI 05M/ 08M/ 1M camera comes with the corresponding protective tube At an ambient temperature of 25 ° C Specified NETD value applies to all frequencies...
  • Page 20: Optical Specifications

    2.4 Optical specifications Make sure that the focus of thermal channel is adjusted correctly. If necessary, focus the thermal imaging camera with the optics (Figure 2). The turning out of the optics leads to the focus setting "near" and the turning in of the lens to the focus setting "infinity". Figure 2: Focusing by turning the exterior Figure 3: PI 05M/ PI 08M / PI 1M lens ring of camera...
  • Page 21 Different parameters are important if using infrared cameras. They display the connection between the distance of the measured object and the size of the pixel (Table 2). ® Figure 4: Measurement field of the infrared camera optris PI representing the 23° x 17° lens...
  • Page 22 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 (https://www.optris.global/optics-calculator) or via the optris calculator app. The...
  • Page 23 Technical Data Table 2: * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 24 * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 25 Technical Data * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 26 * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance. PI 05M is only available with OF25 optics and PI 08M is only available with OF16 and OF25 optics...
  • Page 27 Technical Data * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance. PI 05M is only available with OF25 optics and PI 08M is only available with OF16 and OF25 optics...
  • Page 28: Mechanical Installation

    3 Mechanical Installation 3.1 Dimensions The PI is equipped with two metric M4 thread holes on the bottom side (6 mm depth) and can be installed either directly via these threads or with help of the tripod mount (also on bottom side). The tightening torque of the M4 screws for mounting the PI camera should be between 1 ...
  • Page 29 Mechanical Installation Figure 5: PI 400i/ PI 450i/ PI 450i G7, dimensions [mm]...
  • Page 30 Figure 6: PI 640/ PI 640 G7, optics 29°/33° & 53°/60°, dimensions [mm]...
  • Page 31 Mechanical Installation Figure 7: PI 640/ PI 640 G7, optics 13°/15°, dimensions [mm]...
  • Page 32 Figure 8: PI 640/ PI 640 G7, optics 80°/90°, dimensions [mm]...
  • Page 33 Mechanical Installation Figure 9: PI 640, microscope optics 10°/12°, dimensions [mm]...
  • Page 34 Figure 10: PI 05M/ PI 08M/ PI 1M, dimensions [mm]...
  • Page 35: Changing The Lens

    Mechanical Installation 3.2 Changing the lens The PI camera is offered with several different lenses (lenses depending on the camera variant). To change a lens, rotate it as shown below. For the PI 05M, PI 08M and PI 1M, the protective tube must first be turned off (see Figure 3).
  • Page 36: Fixing The Focus Of The Lens (Only For Pi 05M/ 08M/ 1M)

    3.3 Fixing the focus of the lens (only for PI 05M/ 08M/ 1M) With the PI 05M, PI 08M and PI 1M, it is possible to fix the focus of the lens. To do this, unscrew the protective tube of the camera (see Figure 3). There are three small holes on the lens. Take the three screws that are included and attach them to the three holes.
  • Page 37 Mechanical Installation Figure 16: Focusing screws for focus ring...
  • Page 38: Mounting Accessories (Optional)

    3.4 Mounting accessories (optional) Figure 17: Mounting base, stainless steel, adjustable in 2 axes [Part No.: ACPIMB] Figure 18: Protective housing, stainless steel, Incl. Mounting base [Part No.: ACPIPH]...
  • Page 39: High Temperature Accessories

    Mechanical Installation 3.5 High temperature accessories 3.5.1 CoolingJacket  The IR camera can be used at ambient temperature up to 50 °C (up to 70 °C with PI 450i/ PI 450i G7). For higher temperatures (up to 180 °C) the CoolingJacket is provided. ...
  • Page 40 Figure 19: CoolingJacket – Dimensions...
  • Page 41: Coolingjacket Advanced

    Mechanical Installation Figure 21: CoolingJacket with mounting bracket Figure 20: CoolingJacket for PI [Part No.: ACPIxxxCJ] 3.5.2 CoolingJacket Advanced  The CoolingJacket Advanced is available as Standard Version and Extended Version.  The IR camera can be used at ambient temperature up to 50 °C (up to 70 °C with PI 450i/ PI 450i G7).
  • Page 42 Standard Version Figure 22: CoolingJacket Advanced [Part No.: ACPIxxxCJAS], Standard Version - Dimensions...
  • Page 43 Mechanical Installation Extended Version The Extended Version is provided for applications of the PI series with the PI Netbox and industrial PIF or the USB Server Gigabit and industrial PIF. Both PI Netbox and industrial PIF or USB Server Gigabit and industrial PIF can be integrated in the CoolingJacket. Figure 23: Cooling Jacket Advanced (Extended Figure 24:Cooling Jacket Advanced (Extended Version) Version) with PI Netbox and industrial PIF...
  • Page 44 Figure 25: CoolingJacket Advanced [Part No.: ACPIxxxCJAE], Extended Version – Dimensions...
  • Page 45: Laminar Air Purge For Coolingjacket

    Mechanical Installation 3.5.3 Laminar air purge for CoolingJacket Laminar air purge for front mounting of the CoolingJacket Advanced (Standard and Extended). Two different versions are available: One for standard camera applications [Part-No.: ACCJAAPLS] and the other for line scanning applications [Part-No.: ACCJAAPLL]. Those two versions are fitting to all focusing units with production date ≥01/2018.
  • Page 46: Outdoor Protective Housing

    3.5.4 Outdoor protective housing  The infrared camera PI and the USB server can also be used for outdoor applications by using the outdoor protective housing.  The outdoor protective housing can be used for any PI camera (lenses up to 90° FOV) ...
  • Page 47: Electrical Installation

    Electrical Installation 4 Electrical Installation At the back side of the PI there are the two connector plugs. The left plug is for the USB cable. The right connector plug is only used for the process interface. Figure 27: Backside of the camera with connectors Plug for USB cable Plug for PIF cable...
  • Page 48: Process Interface

    4.1 Process interface 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 PI is equipped with a process interface (cable with integrated electronics and terminal block), which can be programmed via the software as an Analog Input (AI) and Digital Input (DI) in order to control the camera or as an Analog Output (AO) in order to control...
  • Page 49 Electrical Installation Figure 28: Configuration Standard Process Interface (PIF) 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;...
  • Page 50: Pin Allocation

    4.1.1 PIN allocation 1 VCC 1 INT 2 GND 2 SDA (I²C) 3 SCL (I²C) 4 D - 4 DGND 5 D + 5 3.3 V (Out) Figure 29: Rear side of the camera...
  • Page 51 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 30: Support proprietary PIF cable Consider that the input of the PIF is not protected if there is a direct PIF connection! A voltage >...
  • Page 52: Industrial Process Interface (Optional)

    4.1.2 Industrial Process Interface (optional) For use in industrial environment the industrial process interface with 500 V AC isolation voltage between PI and process is available (connection box with IP65, 5 m, 10 m or 20 m standard or high temperature cable Appendix F –...
  • Page 53 Electrical Installation 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 D IN 1 Digital input 24 V (active-low = 0…0,6 V) AO1 / 2 / 3 Analog output 1, 2 and 3 0/4-20 mA...
  • Page 54 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. The time constant of the fail-safe is 1.5 seconds. Controlled conditions on camera and software Standard Process interface Industrial Process interface...
  • Page 55: Example For A Fail-Safe Monitoring Of The Pi With A Plc

    Electrical Installation 4.2 Example for a Fail-Safe monitoring of the PI with a PLC Figure 32: Fail-Safe monitoring states Fail-Safe monitoring states Breakdown of PIF power supply Malfunction of PI Cable break of fail-safe cable Breakdown of PI power supply/ Interruption of USB cable Interruption of cable PI-PIF Malfunction of PIX Connect software...
  • Page 56 Figure 33: Fail-Safe monitoring states Fail-Safe monitoring states Breakdown of PIF power supply Malfunction of PI Cable break of fail-safe cable Breakdown of PI power supply/ Interruption of USB cable Short circuit of fail-safe cable Malfunction of PIX Connect software Interruption of cable PI-PIF...
  • Page 57: Usb Cable Extension

    Electrical Installation 4.3 USB cable extension The maximum USB cable length is 20 m. For greater distances between PI and computer or for stand-alone solutions the optional PI NetBox or the USB Server Gigabit is provided: Figure 34: Ethernet direct communication with PI Netbox Figure 35: Ethernet network communication with PI Netbox...
  • Page 58 Figure 36: Stand-Alone operation with PI Netbox Figure 37: USB Server Gigabit...
  • Page 59: Irmobile App

    With IRmobile you can monitor and analyze your infrared temperature measurement directly on a connected smartphone or tablet. All you need is an Optris infrared camera. This app runs on most Android (5 or higher) devices with a micro USB port or USB-C port that supports USB OTG (On The Go). The app is easy to use:...
  • Page 60  Integrated simulator IRmobile supported for:  Optris IR cameras: PI and Xi series  Optris pyrometers: Compact series, high performance series and video thermometers  For Android 5 (or higher) devices with a micro USB port or USB C port...
  • Page 61: Software Pix Connect

    A detailed description is provided in the software manual on the USB stick. See also Help menu in the PIX Connect software (Help → Documentation). Alternatively, the software can also be downloaded via the Optris website under the following link:...
  • Page 62: Installation And Initial Start-Up

    Start\Programs\Optris GmbH\PIX Connect 3. To connect the camera to the PC, plug the USB cable to the camera first. Afterwards connect it with the PC (to disconnect the camera and the computer remove the USB cable from the computer first and then disconnect it from the camera).
  • Page 63 Software PIX Connect Figure 38: Calibration data transfer After the calibration files have been installed the live image from the camera is shown inside a window on your PC screen. 6. Choose the desired language in the menu Tools → Language. 7.
  • Page 64: Software Window

    6.2 Software window Figure 39: Software window...
  • Page 65 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. Reference bar: Shows the scaling of temperature within the color palette. Temperature of measure area: Analyses the temperature according to the selected shape, e.g. average temperature of the rectangle.
  • Page 66: Basis Features Of The Software Pix Connect

    6.2.1 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 67 Software PIX Connect Video recording and snapshot function  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 68 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 69: Basics Of Infrared Thermometry

    Basics of Infrared Thermometry 7 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 70 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 41: The electromagnetic spectrum and the area used for temperature measurement For the measurement of “thermal radiation”...
  • Page 71 Basics of Infrared Thermometry Figure 42: 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 72 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 73 Basics of Infrared Thermometry Figure 43: Non-contact thermometry...
  • Page 74 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 75: Emissivity

    Emissivity 8 Emissivity 8.1 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 76 Figure 45: 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 77: Determination Of Unknown Emissivity

    Emissivity 8.2 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 78 ► 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 79: Characteristic Emissivity

    Emissivity 8.3 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 80: Appendix A - Table Of Emissivity For Metals

    Appendix A – Table of emissivity for metals...
  • Page 81 Appendix A – Table of emissivity for metals...
  • Page 82: Appendix B - Table Of Emissivity For Non-Metals

    Appendix B – Table of emissivity for non-metals...
  • Page 83: Appendix C - Quick Start For Serial Communication

    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 84 3. Select the baud rate that matches the baud rate of the other communication device. The other interface parameters are 8 data bits, no parity and one stop bit (8N1). These parameters are used in many other communication devices too. The other station must support 8 bit data.
  • Page 85: 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 PI via multiple instances of Optris PIX Connect.
  • Page 86: Appendix E - Pix Connect Resource Translator

    Appendix E – PIX Connect Resource Translator A detailed tutorial is provided on the USB stick. 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 87: Appendix F - Wiring Diagrams Pif

    Appendix F – Wiring diagrams PIF Appendix F – Wiring diagrams PIF Analog Output: The maximum load impedance is 500 Ohm. The analog output can be used as a digital output too. The current value for “no alarm” and “alarm on” is set within the software.
  • Page 88 Digital Input: Figure 49: Digital input The digital input can be activated with a button to the PI GND-Pin or with a low level CMOS/TTL signal: Low level 0…0.6 V; High level 2…24 V Example Button: Figure 50: Button...
  • Page 89 Appendix F – Wiring diagrams PIF Analog input (usable voltage range: 0 … 10 V): Figure 51: Analog input Relay output at industrial PIF [Part No.: ACPIPIFMACBxx] The analog output must be set to “Alarm”. The range for AO1-AO3 can be set in the software (no alarm: 0-4 mA/ alarm: 10-20 mA).
  • Page 90 Figure 52: Relay output at industrial PIF...
  • Page 91: Appendix G - Declaration Of Conformity

    Appendix G – Declaration of Conformity Appendix G – Declaration of Conformity...

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