optris PI 160 User manual

Operators manual
optris®PI
160/ 200/ 230/ 400/ 450/ 450 G7/ 640/ 640 G7/ 1M
Infrared camera

Optris GmbH
Ferdinand-Buisson-Str. 14
13127 Berlin
GERMANY
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.optris.de

-Table of contents 3-
Table of contents
Table of contents..............................................................................................................................................3
1General Notes ...........................................................................................................................................7
1.1 Intended use.......................................................................................................................................7
1.2 Warranty .............................................................................................................................................8
1.3 Scope of delivery ................................................................................................................................9
1.4 Maintenance .......................................................................................................................................9
1.4.1 Cleaning......................................................................................................................................9
1.5 Model overview.................................................................................................................................10
2Technical Data ........................................................................................................................................11
2.1 General specifications ......................................................................................................................11
2.2 Electrical specifications.....................................................................................................................15

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2.3 Measurement specifications.............................................................................................................16
2.4 Optical specifications........................................................................................................................19
3Mechanical Installation ..........................................................................................................................28
3.1 Dimensions.......................................................................................................................................28
3.2 Mounting accessories (optional).......................................................................................................33
3.3 High temperature accessories..........................................................................................................34
3.3.1 CoolingJacket ...........................................................................................................................34
3.3.2 CoolingJacket Advanced ..........................................................................................................36
3.3.3 Outdoor protective housing.......................................................................................................40
4Electrical Installation..............................................................................................................................41
4.1 Process interface..............................................................................................................................42
4.1.1 PIN allocation............................................................................................................................44
4.1.2 Industrial Process Interface (optional)......................................................................................46

-Table of contents 5-
4.2 Example for a Fail-Safe monitoring of the PI with a PLC .................................................................49
4.3 USB cable extension ........................................................................................................................51
5Software PI Connect...............................................................................................................................53
5.1 Installation and initial start-up...........................................................................................................54
5.2 Software window...............................................................................................................................57
5.2.1 Basis features of the software PI Connect ...............................................................................59
6Basics of Infrared Thermometry ...........................................................................................................62
7Emissivity................................................................................................................................................68
7.1 Definition...........................................................................................................................................68
7.2 Determination of unknown emissivity ...............................................................................................70
7.3 Characteristic emissivity...................................................................................................................72
Appendix A –Table of emissivity for metals...............................................................................................73
Appendix B –Table of emissivity for non-metals .......................................................................................75

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Appendix C –Quick start for serial communication...................................................................................76
Appendix D –Interprocess Communication (IPC) ......................................................................................78
Appendix E –PI Connect Resource Translator...........................................................................................79
Appendix F –Wiring diagrams PIF ...............................................................................................................80
Appendix G –Declaration of Conformity.....................................................................................................84

-General Notes 7-
1 General Notes
1.1 Intended use
Thank you for choosing the optris®PI infrared camera.
The optris PI calculates the surface temperature based on the emitted infrared energy of objects
[►6 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 PI
Connect.
The PI is a precise instrument and contains an extremely 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.
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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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.
► All accessories can be ordered according to the referred part numbers in brackets [ ].
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.

-General Notes 9-
1.3 Scope of delivery
PI 160, PI 200, PI 230, PI 400, PI 450, PI 450 G7, PI 640, PI 640 G7 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)
Table tripod
Process interface cable incl. terminal block (1 m)
Software package PI Connect
Operators manual
Aluminum case
PI 450/ 450 G7/ 640/ 640 G7 only: robust hard transport case (IP67)
PI 200/ 230 only: focusing tool for VIS camera
1.4 Maintenance
Never use cleaning compounds which contain solvents (neither for the lens nor for the housing).
1.4.1 Cleaning
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.

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1.5 Model overview
The cameras of the PI-series are available in the following basic versions:
Modell
Model code
Temperature range
Spectral range
Frame rate
Typical applications
PI 160
IR
-20 to 900 °C
200 to 1500 °C
(optional)
7.5 - 13 µm
120 Hz
Surface measurements in industrial application
PI 200/ PI 230
BI-
SPECTRAL
-20 to 900 °C
200 to 1500 °C
(optional)
7.5 - 13 µm
128 Hz
Synchronous recording of VIS and IR videos and
images
PI 400/ PI 450
IR
-20 to 900 °C
200 to 1500 °C
(optional for PI 400)
7.5 - 13 µm
80 Hz
Real-time thermographic images in high speed;
Detection of smallest temperature differences (PI450)
PI 450 G7
IR
200 to 1500 °C
7.9 µm
80 Hz/ 27 Hz
Measurement of glass (with Line-Scanning mode)
PI 640
IR
-20 to 900 °C
7.5 - 13 µm
32 Hz
Pin-sharp radiometric recordings in real time
PI 640 G7
IR
200 to 1500 °C
7.9 µm
32 Hz
Measurement of glass (with Line-Scanning mode)
PI 1M
IR
450 to 1800 °C
0.85 - 1.1 µm
Up to 1 kHz
Measurement of metallic surfaces, graphite or
ceramics with short wavelengths
Table 1: Model overview

-Technical Data 11-
2 Technical Data
2.1 General specifications
Environmental rating:
IP67 (NEMA-4)
Ambient temperature:
0...50 °C [PI 160/ PI 2xx/ PI 400/ PI 640/ PI 640 G7]
5…50 °C [PI 1M]
0...70 °C [PI 450/ PI 450 G7]
Storage temperature:
-40...70 °C (-40...85 °C [PI 450/ PI 450 G7])
Relative humidity:
10...95 %, non-condensing
Material (housing):
Aluminum, anodized
Dimensions:
PI 160/ PI 200/ PI 230: 45 x 45 x 62 - 65 mm (depending on lens)
PI 400/ 450 (450 G7)/ 640 (640 G7)/1M: 46 x 56 x 86 - 90 mm (depending on lens)
Weight:
PI 160: 195 g, PI 200/ 230: 215 g, PI 400/ PI 450 (450 G7)/ PI 640 (640 G7)/PI 1M: 320 g
Cable length (USB 2.0):
1 m (standard), 3 m, 5 m, 10 m, 20 m
Vibration1):
IEC 60068-2-6 (sinus shaped)
IEC 60068-2-64 (broadband noise)

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Shock1):
IEC 60068-2-27 (25 g and 50 g)
1) Used standards for vibration and shock:
Figure 1: Used standards
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

-Technical Data 13-
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)
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)

-14 -
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)
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)

-Technical Data 15-
2.2 Electrical specifications
Power Supply:
5 VDC (powered via USB 2.0 interface)
Current draw:
Max 500 mA
AO: Output Process Interface (PIF out)
0 - 10 V (Main measure area, measure area, internal temperature, flag status, alarm, frame sync, fail-safe, external
communication)
[►Appendix F –Wiring diagrams PIF]
AI: Input Process Interface (PIF in)
0 - 10 V (Emissivity, ambient temperature, reference temperature, flag control, triggered recording, triggered
snapshots, triggered line-scanner, uncommitted value)
[►Appendix F –Wiring diagrams PIF]
DI: Digital Input Process Interface
Flag control, triggered recording, triggered snapshots, triggered line-scanner
[►Appendix F –Wiring diagrams PIF]
Digital interface:
USB 2.0

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2.3 Measurement specifications
PI 160
PI 2001)
PI 2301)
Temperature ranges
-20...100 °C; 0...250 °C; 150...900 °C; Option: 200…1500 °C
Spectral range
7.5 - 13 µm
Detector
UFPA,
160 x 120 pixel @ 120 Hz
UFPA,
160 x 120 pixel @ 128 Hz3)
640 x 480 pixel (visual camera)
UFPA,
160 x 120 pixel @ 128 Hz3)
640 x 480 pixel (visual camera)
Lenses (FOV)
6° x 5°; 23° x 17°; 41° x 31°; 72° x 52°
System accuracy2)
±2°C or ±2 %
Temperature resolution (NETD):
0.08 K with 23°; 0,3 K with 6°; 0.1 K with 41° and 72°
Warm-up time
10 min
Emissivity
0.100...1.100
Software
PIConnect
1) For an ideal combination of IR and VIS image we recommend the 41° lens for PI200 and the 23° lens for PI230
2) At ambient temperature 23
 5 °C; whichever is greater
3) The following options can be set: Option 1 (IR with 96 Hz at 160 x 120 px; VIS with 32 Hz at 640 x 480 px);
Option 2 (IR with 128 Hz at 160 x 120 px; VIS with 32 Hz at 596 x 447 px)

-Technical Data 17-
PI 400
PI 450
PI 450 G7
Temperature ranges
-20...100 °C; 0...250 °C;
150...900 °C;
Option: 200…1500 °C
-20...100 °C; 0...250 °C;
150...900 °C
200…1500 °C
Spectral range
7.5 - 13 µm
7.9 µm
Detector
UFPA,
382 x 288 pixel @ 80 Hz
(switchable to 27 Hz)
UFPA,
382 x 288 pixel @ 80 Hz
(switchable to 27 Hz)
UFPA,
382 x 288 pixel @ 80 Hz
(switchable to 27 Hz)
Lenses (FOV)
13° x 10°, 29° x 22°, 38° x 29°;
53° x 40°; 62° x 49°; 80° x 56°
13° x 10°, 29° x 22°, 38° x 29°;
53° x 40°; 62° x 49°; 80° x 56°
13° x 10°, 29° x 22°; 53° x 40°;
80° x 56°
System accuracy2)
±2°C or ±2 %
Temperature resolution (NETD):
0.08 K1) with 29°, 38°, 53°, 62°
and 80°; 0.1 K1) with 13°
0.04 K1) with 29°, 38°, 53°, 62°
and 80°; 0.06 K1) with 13°
130 mK (Tobj = 650 °C)
Warm-up time
10 min
Emissivity
0.100...1.100
Software
PI Connect
1) Value is valid at 40 Hz and 25°C room temperature
2) At ambient temperature 23
 5 °C; whichever is greater

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PI 640
PI 640 G7
PI 1M
Temperature ranges
-20...100 °C; 0...250 °C;
150...900 °C
200…1500 °C
4503)…1800 °C (27 Hz mode)
5003)…1800 °C (80 Hz and 32 Hz mode)
6003)…1800 °C (1 kHz mode)
Spectral range
7.5 - 13 µm
7,9 µm
0,85 - 1,1 µm
Detector
UFPA,
640 x 480 Pixel @ 32 Hz
640 x 120 Pixel @ 125Hz
UFPA,
640 x 480 Pixel @ 32 Hz
640 x 120 Pixel @ 125Hz
CMOS,
764 x 480 pixel @ 32 Hz
382 x 288 pixel @ 80 Hz/ (switchable to 27 Hz)
72x56 pixel @ 1 kHz
764 x 8 Pixel @ 1 kHz (fast linescanning-mode)
Lenses (FOV)
15° x 11°; 33° x 25°;
60° x 45°; 90° x 64°
15° x 11°; 33° x 25°;
60° x 45°; 90° x 64°
FOV@382x288 px: 20°x 15°, 13°x 10°, 7°x 5°, 4°x 3°
FOV@764x480 px: 39°x 25°, 26°x 16°, 13°x 8°, 9°x 5°
System accuracy
±2°C or ±2 %2)
±1 % of reading (object temperature <1400 °C)
Temperature resolution (NETD):
0.075 K1) with 33°
130 mK (Tobj = 650 °C)
< 1K (700 °C), < 2K (1000 °C)
Warm-up time
10 min
Emissivity
0.100...1.100
Software
PI Connect
1) Value is valid at 32 Hz and 25°C room temperature
2) At ambient temperature 23
 5 °C; whichever is greater
3) +75 °C start temperature for optics with focal length f= 50 mm, f= 75 mm

-Technical Data 19-
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". The visual camera (PI 200/230
only) is adjusted with the supplied focusing tool (Figure 3). For this purpose, the focusing tool
with the two pins is placed on the visual camera and is focused to "near" by a left turn and
focused to "infinity" by a right rotation.
Figure 2: PI 200/ 230 with visual camera
Figure 3: Focusing tool for VIS camera
1
IR channel
2
VIS channel

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The variety of different lenses offers the possibility to precisely measure objects in different distances. We
offer lenses for close, standard distances and large distances. 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).
With the help of BI-SPECTRAL technology at PI 200/ 230, a visual image (VIS) can be combined with a
thermal image (IR). Both can be finally captured time synchronously.