optris PI LightWeight kit User manual

Operator’s Manual
optris®PI LightWeight kit
IR camera with Recording box for
flight applications

Optris GmbH
Ferdinand-Buisson-Str. 14
D –13127 Berlin
Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.optris.com

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Table of contents
1 General notes ............................................................................................................................... 8
1.1 Intended use................................................................................................................................. 8
1.2 Warranty ..................................................................................................................................... 10
1.3 Scope of delivery ........................................................................................................................ 11
1.4 Maintenance ............................................................................................................................... 12
1.4.1 Cleaning...................................................................................................................................... 12
2 Technical Data............................................................................................................................ 13
2.1 Recording box............................................................................................................................. 13
2.1.1 General specifications ................................................................................................................ 13
2.1.2 Electrical specifications............................................................................................................... 14
2.2 Camera PI 400 / PI 450 / PI640 LW ........................................................................................... 15
2.2.1 General specifications ................................................................................................................ 15

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2.2.2 Electrical specifications............................................................................................................... 19
2.2.3 Measurement specifications....................................................................................................... 19
2.2.4 Optical specifications.................................................................................................................. 21
3Installation................................................................................................................................... 26
3.1 Physical installation .................................................................................................................... 26
3.2Mechanical Data PI 400/ PI 450 / PI 640 LW............................................................................. 27
3.3 Dimensions Recording box......................................................................................................... 28
3.4 Functional interfaces Recording box .......................................................................................... 29
3.5 Recording box operating modes................................................................................................. 32
3.5.1 Configuration for PI on HDMI output .......................................................................................... 33
3.5.2 Configuration for PI on analog TV output ................................................................................... 33
3.5.3 Configuration for PI + GoPro on TV output ................................................................................ 33

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3.5.4 Configuration for PI on HDMI output + GoPro on TV output ...................................................... 34
4Operation.................................................................................................................................... 35
4.1 Startup of the Recording box...................................................................................................... 35
4.2 Stand-Alone operation................................................................................................................ 36
4.3 Multifunction button..................................................................................................................... 37
4.4 Start a recording ......................................................................................................................... 38
4.4.1 Recording control with an electrical switch................................................................................. 38
4.4.2 Recording control with the Recording box multifunction button ................................................. 39
4.4.3 Recording control with a servo control ....................................................................................... 40
4.4.4 Recording control via screw terminal block ................................................................................ 40
4.4.5 Recording time duration.............................................................................................................. 41
4.4.6 Record Storage........................................................................................................................... 41

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4.5 Operation Display....................................................................................................................... 44
4.6 Analyzing of radiometric videos on a PC.................................................................................... 46
4.7 Recording box configuration....................................................................................................... 49
4.8 GoPro Camera............................................................................................................................ 52
4.9 Using a GPS............................................................................................................................... 54
4.10 Micro SD card............................................................................................................................. 57
4.11 LED indicators ............................................................................................................................ 58
4.12 Using servo control..................................................................................................................... 59
4.12.1 Servo connector wiring............................................................................................................... 59
4.13 Screw connectors interface ........................................................................................................ 60
5System Update and Recovery.................................................................................................... 62
5.1 System updates.......................................................................................................................... 62

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5.2 Recorder Software Update......................................................................................................... 63
5.3 System Recovery........................................................................................................................ 64
6Calibration files and Time settings.............................................................................................. 65
6.1 Installing the calibration files through Internet ............................................................................ 65
6.2 Installing the calibration files with an USB flash memory........................................................... 65
6.3 Time settings .............................................................................................................................. 67
7Backup battery replacement....................................................................................................... 68
8Basics of Infrared Thermometry ................................................................................................. 69
9CE Conformity ............................................................................................................................ 77

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1 General notes
1.1 Intended use
The optris PI LightWeight kit consists of a miniaturized lightweight Linux computer (Recording box) and
a weight-optimized PI400 LW, PI450 LW or PI640 LW infrared camera. The system is ideally suited for
UAV based radiometric infrared recordings. It can be used for applications like maintenance work and
quality inspections of solar and wind power systems and for building thermography.
The Recording box works with a Linux operating system that allows on-flight recording of infrared videos
with the maximum speed of the camera.
The optris PI 400 LW, 450 LW or 640 LW measures the surface temperature based on the emitted
infrared energy of objects [►Basics of Infrared Thermometry]. The two-dimensional detector (FPA -
focal plane array) allows a measurement of an area which will be shown as thermal image using
standardized color palettes. The radiometric processing of the picture data enables the user to do a
comfortable detailed analysis with the software PI Connect retrospectively.

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The PI is a precise instrument and contains a sensitive infrared detector and a high-
quality lens.
The alignment of the camera to intensive energy sources (e.g. devices which emit
laser radiation or reflections of such equipment) can cause an irreparable defect of the
infrared detector. This is also valid if the camera is switched off.
Such kinds of damages are excluded from warranty.
Avoid static electricity, arc welders, and induction heaters. Keep away from very
strong EMF (electromagnetic fields).
Avoid abrupt changes of the ambient temperature.
In case of problems or questions which may arise when you use the infrared
camera contact our service department.
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.

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1.2 Warranty
Each single product passes through a quality process. Nevertheless, if failures occur 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 delivery
IR camera PI400 LW or PI450 LW or PI640 LW (LightWeight) with one lens and fixed mounted
USB cable (40 cm)
Recording box (Linux computer)
Power supply (100-240 VAC / 24 VDC)
Power cable (with open ends)
Video cable bridge (HDMI to micro-HDMI, 16 cm)
USB 2.0 cable bridge (USB to mini-USB, 15 cm)
Special USB+video cable for GoPro camera (mini-USB to mini-USB, 30 cm)
Video cable (stereo mini jack-open ends) including external recording pin
128 GB high speed USB 3.0 memory stick
16 GB micro SDHC memory card
CD-ROM including PIConnect software, camera calibration files, documentation
Rugged outdoor case, IP67
Operators manual

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1.4 Maintenance
1.4.1 Cleaning
The housing of the Recording box can be cleaned with a soft, humid tissue moistened with water or a
water based cleaner.
Blow off loose particles using clean compressed air. The lens surface can be cleaned with a soft, humid
tissue moistened with water or a water based glass cleaner.
Never use cleaning compounds which contain solvents (neither for the lens nor for the
housing).
Take care that no foreign substances penetrate into the venting slots of the Recording
box.

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2 Technical Data
2.1 Recording box
2.1.1 General specifications
Operating temperature:
0…50 °C
Storage temperature:
-20...75 °C
Relative humidity:
10...95 %, non-condensing
Material (housing):
aluminum
Dimensions:
96 mm x 67 mm x 47 mm (L x W x H)
Weight:
172 g (without the four mounting bricks)
Vibration:
IEC 60068-2-6 (sinus shaped), IEC 60068-2-64 (broad band noise)
Shock:
IEC 60068-2-27 (25 g and 50 g)
Operating system
Linux Ubuntu 14.04 LTS

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2.1.2 Electrical specifications
Power supply:
10 to 48 VDC
Power consumption:
12 W
Cooling:
active via integrated temperature controlled fan
Module:
ODROID-XU4
Processor:
Samsung Exynos5422 (Cortex™ A15 2GHz and Cortex™ A7) Octa core
Memory:
8 GB eMMC flash storage/ 16 GB Micro-SDHC card (not intended to be exchanged by user)
RAM:
2 GB LPDDR3 RAM
Ports:
2 x USB 3.0; 1 x USB 2.0; 1 x Mini-USB for a GoPro Hero 3+ and higher; RJ45 Ethernet (Gigabit Ethernet)
HDMI 1.4a or Mini jack 2.5 mm Video composite (CVBS) NTSC TVout; 2 x Servo-connector (Uni, Graupner /JR);
2 x 4-screw terminal
Additional functions
5 x Status-LED; Function button

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2.2 Camera PI 400 / PI 450 / PI640 LW
2.2.1 General specifications
Environmental rating:
IP40
Ambient temperature:
0...50 °C [PI 400 LW & PI640 LW] / 0...70 °C [PI 450 LW]
Storage temperature:
-40...70 °C [PI 400 LW& PI640 LW]] / -40...85 °C [PI 450 LW]
Relative humidity:
10...95 %, non-condensing
Material (housing):
aluminum, anodized/ plastic
Dimensions:
46 x 56 x 84 - 88 mm (depending on lens)
Weight (incl. lens):
207 g
Cable length (USB 2.0):
40 cm
Vibration1):
IEC 60068-2-6 (sinus shaped)
IEC 60068-2-64 (broad band noise)
Shock1):
IEC 60068-2-27 (25 g and 50 g)
1) Used standards:

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Figure 1: Used standards

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Stress program (camera in operation):
Shock, half sinus 25 g –testing Ea 25 g (acc. IEC 60068-2-27)
Acceleration
245 m/s2
(25 g)
Pulse duration
11 ms
Number of directions
6
(3 axes with 2 directions each)
Duration
600 Shocks
(100 Shocks each direction)
Shock, half sinus 50 g –testing Ea 50 g (acc. IEC 60068-2-27)
Acceleration
490 m/s2
(50 g)
Pulse duration
11 ms
Number of directions
6
(3 axes with two directions each)
Duration
18 Shocks
(3 Shocks each direction)

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Vibration, sinus shaped –testing Fc (acc. IEC60068-2-6)
Frequency range
10-500 Hz
Acceleration
29.42 m/s2
(3 g)
Frequency change
1 Octave/ min
Number of axes
3
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/s2
(4,01 gRMS))
Frequency spectrum
10-106 Hz
0,9610 (m/s2)2/Hz
(0,010 g2/Hz)
106-150 Hz
+6 dB/ Octave
150-500 Hz
1,9230 (m/s2)2/Hz
(0,020 g2/Hz)

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500-2000 Hz
-6 dB/ Octave
2000 Hz
0,1245 (m/s2)2/Hz
(0,00126 g2/Hz)
Number of axes
3
Duration
3 h
(3 x 1 h)
2.2.2 Electrical specifications
Power Supply:
5 VDC (powered via USB 2.0 interface)
Current draw:
Max 500 mA
Digital interface:
USB 2.0
2.2.3 Measurement specifications
Temperature ranges:
-20...100 °C; 0...250 °C; 150...900 °C

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Detector:
UFPA, 382 x 288 pixels (PI4xx) / 640 x 480 pixels (PI640)
Spectral range:
7.5...13 µm
Lenses (FOV):
13° x 10°; 29° x 22°, 38° x 29°; 53° x 40°, 62° x 49°; 80° x 58° [PI4xx]
15° x 11°; 33° x 25°; 60°x 45°; 90° x 66° [PI640]
System accuracy 1):
±2°C or ±2 %
Temperature resolution (NETD):
PI 400 LW 2): 0.08 K
P I450 LW 2): 0.04 K
PI640 LW 3): 0.075 K
Frame rate:
27 & 80 Hz (PI4xx) / 32 Hz (PI640) / 125 Hz (PI640 in VGA sub-frame mode)
1) At ambient temperature 23
 5 °C; whichever is greater; 2) Value is valid at 40 Hz and 25°C object temperature, 2) Value is valid at 32 Hz and 25°C object
temperature