optris PI 160 User manual

Operator’s Manual
optris®PI
160/ 200/ 230/ 400/ 450/ 450G7/ 640/ 1M
Infrared camera

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

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Table of contents
Table of contents
1General Notes ..................................................................................................................................... 7
1.1 Intended use................................................................................................................................. 7
1.2 Warranty ....................................................................................................................................... 9
1.3 Scope of delivery .......................................................................................................................... 9
1.4 Maintenance ............................................................................................................................... 11
1.4.1 Cleaning.............................................................................................................................. 11
1.5 Model overview........................................................................................................................... 12
2Technical Data .................................................................................................................................. 13
2.1 General specifications ................................................................................................................ 13
2.2 Electrical specifications............................................................................................................... 17
2.3 Measurement specifications....................................................................................................... 18
2.4 Optical specifications.................................................................................................................. 21

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3Mechanical Installation .................................................................................................................... 27
3.1 Dimensions................................................................................................................................. 27
3.2 Mounting accessories (optional)................................................................................................. 29
3.3 High temperature accessories.................................................................................................... 30
3.3.1 Cooling Jacket .................................................................................................................... 30
3.3.2 Cooling Jacket Advanced ................................................................................................... 33
4Electrical Installation........................................................................................................................ 37
4.1 Process interface........................................................................................................................ 38
4.1.1 PIN allocation...................................................................................................................... 40
4.1.2 Industrial Process Interface (optional)................................................................................ 41
4.2 Example for a Fail-Safe monitoring of the PI with a PLC........................................................... 45
4.3 USB cable extension .................................................................................................................. 47

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Table of contents
5Software PIConnect.......................................................................................................................... 49
5.1 Installation and initial start-up..................................................................................................... 49
5.2 Software window......................................................................................................................... 52
5.2.1 Basis features of the software PIConnect .......................................................................... 54
6Basics of Infrared Thermometry ..................................................................................................... 57
7Emissivity.......................................................................................................................................... 63
7.1 Definition..................................................................................................................................... 63
7.2 Determination of unknown emissivity ......................................................................................... 65
7.3 Characteristic emissivity............................................................................................................. 67
Appendix A – Table of emissivity for metals......................................................................................... 69
Appendix B – Table of emissivity for non-metals ................................................................................. 71
Appendix C – Quick start for serial communication............................................................................. 73
Appendix D – Interprocess Communication (IPC) ................................................................................ 75
Appendix E – PI Connect Resource Translator..................................................................................... 77

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Appendix F – Wiring diagrams PIF ......................................................................................................... 79
Appendix G – CE Conformity .................................................................................................................. 83

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General Notes
1 General Notes
1.1 Intended use
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 plain 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 a sensitive infrared detector and a high-
quality lens. The alignment of the camera to intensive energy sources (high power
laser or reflections of such equipment, e.g.) can have effect on the accuracy of the
measurement or can cause an irreparable defect of the infrared detector.

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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 [ ].
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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General Notes
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.
1.3 Scope of delivery
Standard version
•PI160, PI200, PI230, PI400, PI450, PI450G7, PI640 or PI1M incl. 1 lens
•USB cable (1 m1))
•Table tripod
•Process interface cable incl. terminal block (1 m)
•Software package PI Connect

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•Operators manual
•Aluminum case
•PI450/ 640 only: Hard transport case (IP 67)
•PI200/ 230 only: focusing tool for VIS camera
Thermal Analysis Kit
•PI160 or PI200
•3 lenses (23°, 6° and 41°, incl. calibration certificate)
•USB cable (1 m1) and 10 m)
•Tripod (20 - 63 cm)
•Process interface cable incl. terminal block (1 m)
•Software package PI Connect
•Operators manual
•Aluminum case
•PI200/ 230 only: focusing tool for VIS camera
1) The camera plug of USB cable (1 m) does not feature an IP67 protection class. For industrial applications there are cables with
IP67 available starting at 5 m.

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General Notes
1.4 Maintenance
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.
Never use cleaning compounds which contain solvents (neither for the lens nor for the
housing).

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1.5 Model overview
The cameras of the PI-series are available in the following basic versions:
Modell
Model code
Measurement range
Spectral response
Typical applications
PI 160
IR
-20 to900 °C
200 to 1500 °C (optional)
7.5-13 µm
Exact measurementsof metallicand
non-metallic surfaces
PI 200/ Pi 230
BI-SPEKTRAAL
-20 to900 °C
200 to 1500 °C (optional)
7.5-13 µm
Synchronousrecording of VIS and IR
videosand images
PI 400/ PI 450
IR
-20 to 900 °C
200 to 1500 °C
(optional forPI 400)
7.5-13 µm
Real-time thermographic images inhigh
speed; Detection of smallest
temperature differences(PI450)
PI 450 G7
IR
200 to 1500 °C
7.9 µm
Measurement of glass with Line-
Scanning mode
PI 640
IR
-20 to 900 °C
7.5-13 µm
Pin-sharp radiometricrecordingsin real
time
PI 1M
IR
450 to 1800 °C
0.92-1.1 µm
Measurement of metallic surfaces,
graphite or ceramicswith short
wavelengths
Table 1: Model overview

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Technical Data
2 Technical Data
2.1 General specifications
Environmental rating:
IP67 (NEMA-4)
Ambient temperature:
0...50 °C (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:
PI160/ PI200/ PI230: 45 x 45 x 62 - 65 mm (depending on lens)
PI400/ 450/ 640/1M: 46 x56 x86 - 90 mm (depending on lens)
Weight:
PI160: 195 g, PI200/ 230: 215 g, PI400/PI450/ PI640/PI1M: 320 g
Cable length (USB 2.0):
1 m (standard),5 m, 10 m, 20 m
Vibration1):
IEC 60068-2-6 (sinus shaped)
IEC 60068-2-64 (broadbandnoise)
Shock1):
IEC 60068-2-27 (25 g and 50 g)

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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
Number of directions
6
(3 axes with 2 directions each)
Duration
600 Shocks
(100 Shocks each direction)

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Technical Data
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)
Vibration, broadband noise – testing Fh (acc. IEC60068-2-64)
Frequency range
10-2000 Hz

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Acceleration
39.3 m/s2
(4.01 g
RMS
))
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)

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Technical Data
2.2 Electrical specifications
Power Supply:
5 VDC (powered via USB 2.0 interface)
Current draw:
Max500mA
Output Process Interface (PIF
out)
0-10 V (Main area temperature, internal temperature, flag status, alarm)
[►Appendix F – Wiring diagrams PIF]
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]
Digital InputProcess Interface
Flag control,triggered video or 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@128Hz3)
640 x 480 pixel (visual
Camera)
UFPA,
160 x 120 pixel@128Hz3)
640 x 480 pixel (visual
Camera)
Lenses(FOV)
23° x 17°;6° x5°; 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)

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Technical Data
PI 400
PI 450
PI 450G7
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
7.5-13 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)
38° x 29°;62° x49°;
13° x 10°
38° x 29°;62° x49°;
13° x 10°
38° x 29°;62° x49°
System accuracy2)
±2°C or ±2 %
Temperature resolution
(NETD):
0.08 K1) with38° and
62°; 0.1 K1) with 13°
0.04 K1) with 38° and
62°; 0.06 K1) with13°
130 mK
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 1ML
PI 1MH
Temperature ranges
-20...100 °C; 0...250 °C;
150...900 °C
450…1400°C
(500…1400 °C@1kHz)
700…1800°C
Spectral range
7.5-13 µm
0.92-1.1 µm
Detector
UFPA,
640 x 480 pixel@32 Hz
UFPA,
382 x 288 pixel@80 Hz
(switchable to 27 Hz)
72x56 pixel@1000 Hz
UFPA,
768 x 480 pixel@32 Hz
382 x 288 pixel@80 Hz
(switchable to 27 Hz)
72x56 pixel@1000 Hz
Lenses(FOV)
33° x 25°
FOV@382x288 px:
51°x 39°, 26°x 20°, 20°x
15°, 13°x 10°, 6,2°x
4,7°,4,0°x3,0°
FOV@768x480 px:
39°x 25°, 20°x 13°, 15°x 9°,
9,6°x6°, 4,7°x 2,9°,
3,0°x1,9°
System accuracy2)
±2°C oder ±2 %
Temperature resolution (NETD):
0.075K1) with 33°
< 1K (700 °C), < 2K (1000 °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