Calex PyroUSB Series Manual

PyroUSB Series
Operator’s Guide

2
PyroUSB Series infrared sensors measure the temperature of surfaces without contact.
They have a linear 2-wire 4 to 20 mA output, which is compatible with almost any indicator,
controller, recorder or data logger without the need for special interfacing or signal
conditioning.
A choice of measurement wavelengths and temperature ranges is available to suit a range of
applications.
General-purpose PUA8 (8-14 μm) models can measure from -40°C to 1000°C. They
are suitable for measuring high-emissivity materials such as paper, thick plastics, food,
pharmaceuticals, rubber, asphalt and painted surfaces.
Short-wavelength PUA2 (2.2 μm) models have a choice of temperature ranges from 45°C to
2000°C. They provide a more accurate reading when measuring low-emissivity materials such
as many reflective metals. They are also capable of measuring through glass viewports.
Glass PUA5 (5 μm) models can measure from 200°C to 1650°C. They are filtered at a
wavelength where glass is least reflective, making them ideal pyrometers for glass surface
temperature measurement.
SPECIFICATIONS
Model PUA2 PUA5 PUA8
Spectral Response 2.0 to 2.6 µm
(2.2 µm nominal)
5 µm 8 to 14 µm
Application Ferrous metals and
high-temperature
targets
Glass General purpose
Temperature range Choice of ranges
from 45°C to
2000°C
Choice of ranges
from 50°C to
1650°C
-40°C to 1000°C
Response time 200 ms
Output 2-wire, 4-20 mA, linear with measured temperature
Communications USB 2.0 (removable USB cable and software included) using the
Modbus protocol
Optics Choice of optics for small or large targets at short or long distances
(see Optics)
Accuracy ± 2°C or 1% of
reading, whichever
is greater
± 1°C or 1% of reading, whichever is greater
Repeatability ± 0.5°C or 0.5% of reading, whichever is greater
Emissivity Setting 0.1 to 1.0
Maximum Span
(4-20 mA output)
Full temperature range
Minimum Span
(4-20 mA output)
100°C
ELECTRICAL
Supply Voltage 24 V DC (28 V DC max)
Sensor Voltage (minimum) 6 V DC
Maximum Loop Impedance 900 Ω @ 24 V DC

3
MECHANICAL
Construction Stainless Steel
Dimensions Ø 27.6 x length 61 mm including cable glands
Thread mounting M20 x 1 mm pitch, length 15 mm
4-20 mA Output Cable Length 1 m (standard), up to 30 m (optional)
Weight with 1 m Output Cable 155 g
USB Cable Length 1.8 m
ENVIRONMENTAL
Environmental Rating IP65
Ambient (Operating)
Temperature
0°C to 70°C (cooled models are available for
higher temperatures)
Relative Humidity 95% max. non-condensing
DIMENSIONS
MINIMUM MEASURABLE TEMPERATURE (PUA2-151-LT ONLY)
160
140
120
100
80
60
40
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Tmin
(°C)
ε
TS = 70°C
TS
= 50°C
TS
= 25°C
Graph showing the
minimum measurable
object temperature (Tmin),
determined by surface
emissivity (ε) and sensor
temperature (TS).

4
MODEL NUMBERS
Short
Wavelength
PUA2 251 MT WJ
Glass
PUA5 251 GHT WJ
Genera
l
Purpose
PUA8 301 WJ
Cooling
(blank) Sensor without coolin
g
WJ
Temperature range
PUA2
LT 45°C to 300°C
(151 models only)
PT 100°C to 400°C
(151 models only)
MT 250°C to 1000°C
HT 450°C to 2000°C
PUA5
GLT
GHT
50°C to 1000°C
200°C to 1650°C
PUA8
(blank) All models:
-40°C to 1000°C
Field of view
PUA2
151 15:1 divergent optics (LT & PT models only)
251 25:1 divergent optics
751 75:1 divergent optics
PUA5
251 25:1 divergent optics
PUA8
301 30:1 divergent optics
CF Close-focus optics (focal spot size
5 mm at 100mm distance)
Spectral response
PUA2 2.2 µm, for measuring reflective metals
and high-temperature objects
PUA5 5 µm, for measuring glass surface temperature
PUA8 8 to 14 µm, general-purpose, for non-reflective
non-metals, painted metal surfaces and most
other applications
Air/water cooled jacket
with air purge collar

5
ACCESSORIES
A range of accessories to suit different applications and industrial environments is available.
These may be ordered at any time and added on-site:
• Fixed and adjustable mounting brackets
• Air purge collar
• Laser sighting tool
• Mounting bracket with continuous laser sighting
OPTIONS
The following options are available. Options are factory installed and must be ordered with
the sensor.
• Air/water cooled housing
• Certificate of calibration
• Longer cable (30 m max.)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 32 48
0.6 1.2 1.9
0 19.7 39.4
0 500 1000
Spot Dia.
(inches)
Spot Dia.
(mm)
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 515
0.6 0.2 0.6
03.9 7.9
0100 200
D:S 30:1
301 CF
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 60 135
0.6 2.4 5.3
059.1 118.1
015003000
Spot Dia.
(inches)
Spot Dia.
(mm)
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 100 215
0.6 3.9 8.5
0 59.1 118.1
59.1 118.1
0 1500 3000
015003000
D:S 25:1D:S 15:1
251
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 75 135
0.6 3.0 5.3
059.1 118.1
015003000
Spot Dia.
(inches)
Spot Dia.
(mm)
D:S 25:1
251
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 20 55
0.6 0.8 2.2
0
Spot Dia.
(inches)
Spot Dia.
(mm)
D:S 75:1
751
151
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15
7.5 30
0.6 0.3 1.2
019.739.4
0500 1000
CF
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 32 48
0.6 1.2 1.9
0 19.7 39.4
0 500 1000
Spot Dia.
(inches)
Spot Dia.
(mm)
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 515
0.6 0.2 0.6
03.9 7.9
0100 200
D:S 30:1
301 CF
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 60 135
0.6 2.4 5.3
059.1 118.1
015003000
Spot Dia.
(inches)
Spot Dia.
(mm)
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 100 215
0.6 3.9 8.5
0 59.1 118.1
59.1 118.1
0 1500 3000
015003000
D:S 25:1D:S 15:1
251
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 75 135
0.6 3.0 5.3
059.1 118.1
015003000
Spot Dia.
(inches)
Spot Dia.
(mm)
D:S 25:1
251
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 20 55
0.6 0.8 2.2
0
Spot Dia.
(inches)
Spot Dia.
(mm)
D:S 75:1
751
151
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15
7.5 30
0.6 0.3 1.2
019.739.4
0500 1000
CF
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 32 48
0.6 1.2 1.9
0 19.7 39.4
0 500 1000
Spot Dia.
(inches)
Spot Dia.
(mm)
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 515
0.6 0.2 0.6
03.9 7.9
0 100 200
D:S 30:1
301 CF
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 60 135
0.6 2.4 5.3
059.1 118.1
015003000
Spot Dia.
(inches)
Spot Dia.
(mm)
Spot Dia.
(inches)
Spot Dia.
(mm)
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 100 215
0.6 3.9 8.5
0 59.1 118.1
59.1 118.1
0 1500 3000
0 1500 3000
D:S 25:1D:S 15:1
251
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 75 135
0.6 3.0 5.3
059.1 118.1
Spot Dia.
(inches)
Spot Dia.
(mm)
D:S 25:1
251
Distance: Sensor to object (inches)
Distance: Sensor to object (mm)
15 20 55
0.6 0.8 2.2
0
Spot Dia.
(inches)
Spot Dia.
(mm)
D:S 75:1
751
151
01500 3000
Optics (PUA2)
Optics (PUA5)
Optics (PUA8)
OPTICS
These diagrams show the nominal target spot
diameter at any given distance from the sensing
head and assumes 90% energy. It is possible to
measure at longer distances than the diagrams
show, with a larger measured spot size. There is
no maximum measurement distance in clear air.

6
INSTALLATION
The installation process consists of the following stages:
1 Preparation
2 Mechanical installation
3 Electrical installation
Please read the following sections thoroughly before proceeding with the installation.
PREPARATION
Ensure that the sensor is positioned so that it is focused on the target only.
DISTANCE AND SPOT SIZE
The size of the area (spot size) to be measured determines the distance between the sensor
and the target. The spot size must not be larger than the target. The sensor should be
mounted so that the measured spot size is smaller than the target.
REFLECTIONS
The sensor must be installed in a location where energy from lamps, heaters and sunlight
cannot be reflected from the target into the lens. The use of shields may help in this respect.
For further information and assistance contact Calex.
AMBIENT TEMPERATURE
The sensor is designed to operate in ambient temperatures from 0°C to 70°C. For ambient
temperatures above 70°C, an air/water-cooled housing will be required. Avoid thermal shock.
Allow 20 minutes for the unit to adjust to large changes in ambient temperature.
ATMOSPHERIC QUALITY
Smoke, fumes or dust can contaminate the lens and cause errors in temperature
measurement. In these types of environment the air purge collar should be used to help keep
the lens clean.
ELECTRICAL INTERFERENCE
To minimise electromagnetic interference or ‘noise’, the sensor should be mounted away from
motors, generators and such like.

7
WIRING
Check the distance between the sensor and the indicating/controlling device. If necessary, the
sensor can be ordered with a longer cable attached.
POWER SUPPLY
Be sure to use a 24 V DC (22 mA) power supply.
MECHANICAL INSTALLATION
All sensors come with a 1m cable and a mounting nut. The sensor can be mounted on
brackets or cut outs of your own design, or you can use the fixed and adjustable mounting
bracket accessories which are shown below.
AIR/WATER COOLED HOUSING
The air/water cooled housing shown below allows the sensor to withstand high ambient
temperatures. It is equipped with two 1/8” BSP fittings. Water temperature should be
10°C to 27°C for efficient cooling. Chilled water below 10°C is not recommended. To avoid
condensation, the air purge collar should be used with the water-cooled housing. Water flow
rate should be 0.5 to 1.5 litres/min. Adjust the flow rate and temperature of the cooling fluid
to keep the sensor body between 0°C and 70°C.

8
AIR PURGE COLLAR
The air purge collar below is used to keep dust, fumes, moisture, and other contaminants
away from the lens. It must be screwed in fully. Air flows into the 1/8” BSP fitting and out of
the front aperture. Air flow should be 5 to 15 litres/min.
Clean or ‘instrument’ air is recommended.
27
58.5 47
34
26
Air out
Air connection
1/8 BSPT
Screw thread fitting
for sensor
M20 x 1
ELECTRICAL INSTALLATION
The 4-20 mA output cable is 1 m long as standard. The outer jacket is PVC. One end is
attached, at the factory, to the sensor head. The other end has a pair of wires and a shield
(ground) wire.
WIRING
The sensor can be used in 3 different ways as shown below. To use the 4-20 mA output,
connect the sensor to the controller/indicator with the 24 V DC power supply in the loop
using the following table and connection diagram as a guide. The maximum loop impedance
is 900 ohms.
Note: The sensor must be grounded at only one point, either the cable shield or the
sensor housing.
Output Wire No. Wire Colour Function
4 to 20 mA 1 Red Power supply + / signal +
2 Black Power supply - / signal -
– 3 Bare Shield ground
Alternatively, to use the USB output, connect the sensor to a PC using the cable provided. No
external power supply is required when using the USB output. The sensor can also be used
with both the 4-20 mA loop and USB connected, provided that the negative terminal of the 24
V DC power supply being used is not grounded.
IMPORTANT: The sensor will work only with the supplied USB cable. Connecting any
other type of USB cable may damage the sensor and invalidate the warranty.
Note: The software must be installed before connecting the sensor to a PC.

9
CONNECTIONS
The sensor will operate with either the 4 to 20 mA cable connected, the USB cable connected,
or both.
+- -
+
Display/
Controller
Red
kcalB
Power Supply
+- -
+
Display/
Controller
Red
Black
Power Supply
PC
PC
Not Connected
USB
USB
SOFTWARE
The sensor may be used with a choice of software: CalexConfig (for one sensor), CalexSoft 2
(for multiple sensors), or third-party Modbus software.
System Requirements
• Windows 7 or newer
• USB 2.0 port, Internet access (for software download)
Installation
1 Download and run the software installer at www.calex.co.uk/software
2 Follow the on-screen instructions
NOTE: Do not use any other USB cable than the one supplied with the sensor. Do not
connect the sensor to the PC before the software is installed.
CONNECTING THE SENSOR TO A PC
1 Connect the circular connector on the USB cable provided to the sensor
2 Connect the USB A connector on the USB cable provided to an available USB 2.0 port
3 Double click on the software desktop icon

10
CONFIGURATION (VIA CALEXCONFIG SOFTWARE)
Configuration settings are password protected. To access the Settings menu, go to the Unlock
screen and enter the password. The default password is 1234.
Temperature Units
On the temperature display screen, click °C or °F to switch between temperature units.
Output Processing
Go to the Settings screen, then Output Processing.
4 to 20 mA output scale
Set the temperature range limits for the 4 to 20 mA output. The temperature limits
depend on the sensor model (see Model Numbers). Ensure the temperature range on the
measurement instrument matches the 4-20 mA output scale.
Default setting: Full temperature range (depending on model).
The difference between the temperatures at 4 mA and at 20 mA must be at least 100°C.
The temperature at 20 mA must be greater than the temperature at 4 mA.
Averaging period
Set the time, in seconds, over which the measured temperature is averaged. Note:
averaging prevents the sensor from following rapid temperature changes.
Default setting: 0.
Peak/valley hold processing
If required, hold processing can be applied by setting Hold Mode to “Peak” or “Valley” and
setting the hold period. This is useful if the temperature reading is interrupted by gaps
between moving objects, or by an obstruction.
Default settings: Hold Mode: Off
Hold Period: 0
Emissivity and Compensation
From the Settings menu, go to Emissivity and Compensation.
Emissivity Setting
Enter the emissivity of the target. Target emissivity can be determined experimentally, or
estimated using an emissivity table. For more information, contact Calex.
Default setting: 0.95
Window Transmissivity
When aiming the sensor through an IR-transmissive window, this setting should be
adjusted to compensate for the presence of the window. Enter the transmissivity of the
window (Enter “1” if no window is present.
Default Setting: 1
Reflected Energy Compensation On/Off
If enabled, compensates for errors caused by reflected energy from hotter or colder
objects.
Default setting: Off
Reflected Temperature
Enter the temperature of the surroundings of the target for Reflected Energy
Compensation.
Changing this setting has no effect when Reflected Energy Compensation is Off.

11
MODBUS OVER SERIAL LINE
Interface
Baud rate 9600
Format (bits) 8 data, No parity, 1 stop
Reply delay 20 ms
Supported Functions
Read register 0x03, 0x04
Write single register 0x06
Write multiple register 0x10
List of Modbus Addresses
The list below includes all available addresses:
R = Read, W = Write
Address Length (words) Description R/W
0x00 1 Sensor Type
21 = PUA8, 22 = PUA2, 23 = PUA5
R
0x01 1 Field of view:
PUA8: 0 = 30:1, 1 = CF
PUA2: 0 = 15:1, 1=25:1, 2 = 75:1
PUA5: 0 = 25:1
R
0x02 2 Serial number R
0x04 1Temperature range (PUA2 only):0 = LT, 1 = PT,
2 = MT, 3 = HT
R
0x05 1 Modbus slave address R/W
0x06 1Reflected Energy Compensation
0 = Off, 1 = On
R/W
0x07 1 Reflected Temperature R/W
0x08 1Emissivity (1 LSB = 0.0001)
Minimum 0.1000, Maximum 1.0000
R/W
0x09 1Window Transmissivity (1 LSB = 0.0001)
Minimum 0.2000, Maximum 1.0000
For when using the sensor with an IR window
R/W
0x0A 1 Output Scale: Temperature at 4 mA R/W
0x0B 1 Output Scale: Temperature at 20 mA R/W
0x0C 1 Hold Mode
0 = Off, 1 = Peak, 2 = Valley
R/W
0x0D 1Hold Period (1 LSB = 0.1 seconds)
Minimum 0, maximum 1200.0 s
R/W
0x0E 1Average Period (1 LSB = 0.1 seconds)
Minimum 0, maximum 60.0 s
R/W
0x0F 1 Average Temperature R
0x10 1 Minimum Temperature R

12
Address Length (words) Description R/W
0x11 1Maximum Temperature R
0x12 1 Filtered Temperature R
0x13 1 Unfiltered Temperature R
0x14 1 Sensor Temperature R
0x15 1Status (bits active high):
Bit 0: Measurement error
Bit 1: Sensor temperature low
Bit 2: Sensor temperature high
Bit 3: Object temperature low
Bit 4: Object temperature high
R
0x17 1 Reflected Temperature
Not saved to non-volatile memory
Use this register when writing frequently
R/W
0x18 1Emissivity (1 LSB = 0.0001)
Minimum 0.1000, Maximum 1.0000
Not saved to non-volatile memory
Use this register when writing frequently
R/W
Notes:
1 All temperature are in tenths of degrees C
2 With the exception of addresses 0x17 and 0x18, all write operations are saved to non-
volatile memory
3 For further information please refer to http://www.modbus.org/specs.php
4 The default Modbus slave address of the sensor is 1; it is also possible to use slave
address 255 to communicate. 1 sensor may be connected per COM port.

13
DEFAULT SETTINGS
Modbus Slave Address 1
Emissivity Setting 0.95
Reflected Energy Compensation Off
Window Transmissivity 1
4-20 mA Output Scale Full temperature range, depending on model
Hold Mode Off
Hold Period 0
Average Period 0
OPERATION
Once the sensor is in position and the appropriate power, air, water, and cable connections
are secure, the system is ready for continuous operation by completing the following simple
steps:
1 Turn on the power supply (not required if connected by USB only)
2 Turn on the instrument or PC
3 Read / monitor the temperature
IMPORTANT
Be aware of the following when using the sensor:
• If the sensor is exposed to significant changes in ambient temperature (hot to cold,
or cold to hot), allow 20 minutes for the temperature to stabilise before taking or
recording measurements.
• Do not operate the sensor near large electromagnetic fields (e.g. around arc welders
or induction heaters).
• Electromagnetic interference can cause measurement errors.
• Wire must be connected only to the appropriate terminals.
• Do not open the sensor housing. This will damage the sensor and invalidate the
warranty.
MAINTENANCE
Our customer service representatives are available for application assistance, calibration,
repair, and solutions to specific problems. Contact our Service Department before returning
any equipment. In many cases, problems can be solved over the telephone.
If the sensor is not performing as it should, see TROUBLESHOOTING and try to match the
symptom to the problem. If the table does not help, call Calex for further advice.
LENS CLEANING
Keep the lens clean at all times. Any foreign matter on the lens would affect measurement
accuracy. Blow off loose particles (if not using the air purge accessory) with an air ‘puffer’.

14
TROUBLESHOOTING
Symptom Probable Cause Solution
No output No power to sensor Check power supply and wiring
Inaccurate
measured
temperature
Target too small for
sensor’s field of view
Ensure the sensor’s view is completely filled
by the target. Position the sensor closer to
the target to measure a smaller area.
Ensure the target is at least twice the size of
the given measured spot
Target is a reflective
metal surface
All models: Measure a non-reflective area,
or paint or coat a measurable area of the
target to make it non-reflective.
2.2 µm models: When measuring reflective
metals, try changing the emissivity setting
Field of view
obstruction
Remove obstruction; ensure sensor has a
clear view of target
Dust or condensation
on lens
Ensure lens is clean and dry. Clean gently
with a soft lens cloth and water. If problem
recurs, consider using an air purge collar
Incorrect wire
connections
Check wire colour codes and tags - see
WIRING
Output temperature
scale mismatch
Re-scale input temperature range on
measurement instrument to match sensor.
Use software to check output temperature
range.
GUARANTEE
Calex guarantees each instrument it manufactures to be free from defect in material and
workmanship under normal use and service for the period of two years from the date of
purchase. This guarantee extends only to the original buyer according to Calex Terms and
Conditions of Sale.

15

16
Calex Electronics Limited
PO Box 2, Leighton Buzzard, Bedfordshire, England LU7 4AZ
Tel: [phone] | [email protected] | www.calex.co.uk
Issue K - Dec 19