optris Top-down GIS User manual

Operators Manual
Top-down GIS
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 Top-down GIS................................................................................................................................9
2.2 Factory default............................................................................................................................ 13
2.3 Optical specifications^ ................................................................................................................ 15
2.3.1 Camera............................................................................................................................... 15
2.3.2 Pyrometer ........................................................................................................................... 18

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3Installation......................................................................................................................................... 20
3.1 Hardware installation .................................................................................................................. 20
3.2 Software Installation ................................................................................................................... 24
3.3 Electrical Installation................................................................................................................... 30
4Operation........................................................................................................................................... 32
4.1 Maintenance ............................................................................................................................... 35
4.2 Low-E measurement................................................................................................................... 36
5Basics of glass measurement......................................................................................................... 37
5.1 Reflection and transmission........................................................................................................ 37
5.2 Influence of different measuring wavelengths ............................................................................ 39
5.3 Hardening of glass sheets.......................................................................................................... 40
5.4 Referencing from below.............................................................................................................. 40
5.5 Angle dependency...................................................................................................................... 41

-Table of contents 5-
Appendix A –Control cabinet ................................................................................................................. 43

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1 General notes
1.1 Intended use
Thank you for choosing the optris®Top-down Glass Inspection System (TDGIS).
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 analysis
software PIX Connect and a predefined layout the system can be used directly.
Features:
▪Top-down system with additional reference pyrometer from below for automatic emissivity correction
on low-E glasses
▪Digital controlled lens protection system (DCLP) avoids additional air purge
▪Automatic calculation of the glass surface
▪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
▪PI 640i with 60° or 90° FOV
▪CT G5 reference pyrometer with USB interface
▪2x Shutter systems with mounting bracket
▪USB-Server Gigabit 2.0
▪Control cabinet (pre-assembled and pre-wired)
▪Industrial Process Interface (PIF)
▪Power supply 24 V
▪Cable set (10 m)
▪Control unit with 2 buttons (for triggger signal of shutter and Low-E)
▪USB stick with Software and Layout
▪Operators manual
▪Calibration certificate for CT G5

-Technical Data 9-
2 Technical Data
2.1 Top-down GIS
Temperature range
-20…900 °C
Spectral range
Reference sensor: 5 µm
Imager: 8-14 µm
Optical resolution
640x480 Pixel VGA
Up to 800 points/line
Accuracy
± 2°C or ± 2%
Frame rate / Scan speed
Up to 125 Hz
NETD / Temperature resolution
40 mK
Ambient temperature (complete system)
0 - 50 °C
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

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Dimensions:
Shutter: 116 x 57 x 121 mm
Switch cabinet: 400 x 200 x 155 mm
Weight
Imager with shutter: 1.1 kg
Sensor with shutter: 1 kg
Control cabinet: 10 kg
13 kg (complete system)
Material
Stainless steal
Warm-up time
10 min
Table 1: Technical Data of Top-down GIS

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

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Figure 2: Dimensions [mm], switch cabinet

-Technical Data 13-
2.2 Factory default
The CT G5L pyrometer is delivered with the following factory settings:
Signal output object temperature
0-10 V
Emissivity
0,920
Transmissivity
1,000
Averaging (AVG)
0,2 s
Smart Averaging
inactive
Peak hold
active (Hold time: 15 s)
Valley hold
Inactive
Lower limit temperature range [°C]
100
Upper limit temperature range [°C]
900
Lower alarm limit [°C] (normally closed)
200
Upper alarm limit [°C] (normally open)
500
Lower limit temperature range [°C]
0 V
Upper limit temperature range [°C]
10 V
Temperature unit
°C
Ambient temperature compensation
internal head temperature probe

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(Output at OUT-AMB as 0-5 V signal on LT, G5 and P7)
Baud rate [kBaud]
115
You can change the settings either directly with the CompactConnect 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 3). 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 3: 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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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.

-Technical Data 19-
CT G5L (SF optics)

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3 Installation
3.1 Hardware installation
Basically the whole system consists of three main components:
▪Temperature measuring system 1: Camera with shutter (measurement from above)
▪Temperature measuring system 2: Reference pyrometer with shutter (measurement from below)
▪Switch cabinet with complete electronic unit and control unit
Hardware and software recommendations:
▪Computer with OS Windows 10 or higher
Note:
•The camera must be focused.
•Consider the minimum distance of the selected optics.
•For installation, the components must be detached from the profiles.
All components must be correctly positioned for the first commissioning of the entire system. Since all
components are already pre-wired, they only have to be brought into the correct position. A suitable position
for glass measurement is between the furnace and the immediately following annealing furnace. In most cases,