optris Bottom-Up GIS 640i G7 User manual

Operators Manual
Bottom-Up GIS
640i G7 and 450i G7
Glass Inspection System

Optris GmbH
Ferdinand-Buisson-Str. 14
13127 Berlin
Germany
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]l
Internet: www.optris.global

-Table of contents 3-
Table of contents
Table of contents...........................................................................................................................................3
1General notes.........................................................................................................................................6
1.1 Intended use....................................................................................................................................6
1.2 Warranty ..........................................................................................................................................7
1.3 Scope of supply ...............................................................................................................................8
2Technical Data .......................................................................................................................................9
2.1 Bottom-Up GIS ................................................................................................................................9
2.2 Factory default...............................................................................................................................14
2.3 Optical specifications.....................................................................................................................15
2.3.1 Camera............................................................................................................................... 15
2.3.2 Pyrometer ........................................................................................................................... 19

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3Installation............................................................................................................................................21
3.1 Hardware installation .....................................................................................................................21
3.1.1 Scan line and FOV.............................................................................................................. 23
3.1.2 Camera positioning............................................................................................................. 26
3.1.3Shutter adjustment.............................................................................................................. 28
3.1.4 Installation control cabinet.................................................................................................. 29
3.2 Software Installation ......................................................................................................................33
3.2.1 Set up of the USB-Server ................................................................................................... 33
3.2.2 Installation PIX Connect ..................................................................................................... 33
3.2.3 Set up of the Software PIX Connect................................................................................... 34
3.2.4 Fine tuning of the Software PIX Connect ........................................................................... 38
3.3 Electrical Installation......................................................................................................................40
4Operation..............................................................................................................................................42

-Table of contents 5-
4.1 Maintenance ..................................................................................................................................45
4.2 Glass breakage sensor CTL 4M....................................................................................................46
5Basics of glass measurement............................................................................................................47
5.1 Reflection and transmission...........................................................................................................47
5.2 Influence of different measuring wavelengths ...............................................................................49
5.3 Hardening of glass sheets.............................................................................................................50
5.4 Angle dependency.........................................................................................................................50
Appendix A –Control cabinet ....................................................................................................................52

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1 General notes
1.1 Intended use
Thank you for choosing the optris®Bottom Up Glass Inspection System (BUGIS).
This compact system is ideal for measuring glass and can be used for process control in glass tempering
machines. This system consists of several components which are already pre-wired and ready for immediate
use. The entire system is supplied with 24 V and is connected to a PC via an Ethernet cable. With the
license free analysis software PIX Connect and a predefined layout the system can be used directly.
Features:
▪Bottom-Up system with additional breakage detection sensor
▪Digital controlled lens protection system (DCLP) avoids additional air purge and protects the camera
lens
▪Automatic calculation of the glass surface
▪Automatic Adjustment of the scan line (Automatic Line Adjustment –ALA)
▪Pre-assembled system for easy installation as retrofit on glass tempering furnaces
Read the manual carefully before the initial start-up. The producer reserves the right to change
the herein described specifications in case of technical advance of the product.

-General notes 7-
1.2 Warranty
Each single product passes through a quality process. Nevertheless, if failures occur please contact the
customer service at once. The warranty period covers 24 months starting on the delivery date. After the
warranty is expired the manufacturer guarantees additional 6 months warranty for all repaired or substituted
product components. Warranty does not apply to damages, which result from misuse or neglect. The
warranty also expires if you open the product. The manufacturer is not liable for consequential damage or in
case of a non-intended use of the product.
If a failure occurs during the warranty period the product will be replaced, calibrated or repaired without
further charges. The freight costs will be paid by the sender. The manufacturer reserves the right to
exchange components of the product instead of repairing it. If the failure results from misuse or neglect the
user has to pay for the repair. In that case you may ask for a cost estimate beforehand.

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1.3 Scope of supply
▪2x PI 640i G7 with 90° FOV or 2x PI 450i G7 with 80° FOV
▪CTLaser 4M pyrometer for the breakage detection with electronic box
▪2x Shutter systems with mounting bracket and electronic box
▪2x USB-Server Gigabit 2.0 and 1x Ethernet switch
▪Control cabinet (pre-assembled and pre-wired) with 10m cable set and 24V Power supply
▪2x Industrial Process Interface (PIF)
▪Remote control (for trigger signal of shutter)
▪USB stick with Software, Layout and calibration files
▪Operators manual

-Technical Data 9-
2 Technical Data
2.1 Bottom-Up GIS
System
640i G7
450i G7
Temperature range
150-900°C or 200-1500°C
Spectral range
breakage sensor: 2,2-6 µm
Imager: 7,9 µm
Optical resolution
640x480 Pixel VGA
Up to 1600 points/line
382x288 Pixel
Up to 955 points/line
Accuracy
± 2°C or ± 2%
Frame rate / Scan speed
32Hz / 125 Hz @ 640x120
Pixel
80 Hz / switchable to 27 Hz
NETD / Temperature resolution
80 mK
150 mK
Ambient temperature camera
0 - 50 °C
0 - 70 °C
Ambient temperature pyrometer
0 - 70 °C
Ambient temperature control cabinet
0 - 50 °C

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In- and Outputs
0-10 V Inputs, digital input, 3x 0/4-20 mA output or alarm-
/Relais outputs
Interface
Integrated TCP/IP Ethernet interface via USB Server
Environmental rating
IP67
Dimensions:
Shutter: 116 x 57 x 121 mm
control cabinet: 400 x 200 x 155 mm
CTlaser 4M Pyrometer: L=100mm, Ø=55mm
Weight (complete system)
16,5 kg
Material
Stainless steal
Warm-up time
10 min
Table 1: Technical Data of Bottom Up GIS

-Technical Data 11-
Figure 1: Dimensions [mm], shutter system

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Figure 2: Dimensions [mm], control cabinet

-Technical Data 13-
Figure 3: Dimensions [mm], CTL 4M

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2.2 Factory default
The CTL 4M pyrometer is delivered with the following factory settings:
Emissivity
1,00
Exposure time (90%) [µs]
90
Averaging (AVG)
inactive
Lower limit temperature range [°C]
0
Upper limit temperature range [°C]
500
alarm limit (AL2) [°C]
300
Alarm source and alarm mode
Tproc - normally open
Temperature unit
°C
Baud rate [kBaud]
921,6
You can change the settings either directly with the CompactPlusConnect software or via the
programming keys on the electronics box

-Technical Data 15-
2.3 Optical specifications
2.3.1 Camera
Make sure that the focus of thermal channel is adjusted correctly. If necessary, focus the thermal
imaging camera with the optics (Figure 4). The turning out of the optics leads to the focus setting
"near" and the turning in of the lens to the focus setting "infinity".
Note: The focus of the optics is set at the factory to an object distance of 90 cm (camera lens to
measurement object - Ain Figure 7). The optics only must be focused if the distance is not
equal to 90 cm. When refocusing the optics, the shutter must also be adjusted (see chapter
3.1.3 on page 28).
Figure 4: Focusing by turning the exterior lens ring of camera

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The following table with examples shows what spot sizes and
pixel sizes will be reached in which distance. For individual
configuration there are different lenses available. Wide angle
lenses have a radial distortion due to their large opening angle;
the software PIX Connect has an algorithm which corrects this
distortion. As an alternative to the tables below, the optics
calculator can also be used on the optris website or via the
optris calculator app. The app can be downloaded for free from
the Google Play Store (see QR code).

-Technical Data 17-
* Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.

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* Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.

-Technical Data 19-
2.3.2 Pyrometer
The following optical chart show the diameter of the measuring spot in dependence on the distance between
measuring object and sensing head. The spot size refers to 90 % of the radiation energy.
The distance is always measured from the front edge of the sensing head.
As an alternative to the optical diagrams, the spot size calculator can also be used on the
Optris website or via the Optris calculator app. The app can be downloaded for free from the
Google Play store (see QR code).
D = Distance from front of the sensing
head to the object
S = Spot size
The size of the measuring object and the optical resolution of the infrared thermometer determine the
maximum distance between sensing head and measuring object.
In order to prevent measuring errors the object should fill out the field of view of the optics completely.
Consequently, the spot should at all times have at least the same size like the object or should be smaller
than that.

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CTL 4M (FF optics)
Figure 5: spot size diagram