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Modline® 5

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1. Modline 5 Rev L4 12 2012 33 Sensor Installation Front Rear Sensor with DWD Dimensions in inches and millimeters Figure 18 Dimensions Sensor with DWD 3 7 3 General Installation Requirements e Sensor should be mounted to provide a minimum of 4 inch 101 6 mm clearance from the housing for connecting the cable e Gently bend the cable into its routing position as shown in the photo below e Minimum cable bend radius is 3 inches 76 2 mm e Rotate the Sensor to avoid cable obstructions e Positioning of any mounting accessory on the Sensor should be as close to the front lens as possible without extending beyond it Some accessories require clamping towards the middle of the body e Never clamp on the Dirty Window Detector hooded mirror or the DWD section Not shown e Never clamp on the rear focusing section of the Sensor A N T DNA a 4 A Figure 19 Interconnecting Cable 3 8 DWD Installation Requirements The Sensor with the Dirty Window Detector option requires the use of an ESA Extension Sleeve Adapter accessory along with other Modline 5 accessories The ESA combined with other accessories serves as protection for the DWD optics The photograph Figure 20 illustrates several of the accessories The ESA is used in the following combinations to provide air purging or to create a dead air space zone in front of the Sensor optics to help keep them clean The combinations also
2. 8 3 Response Time 8 3 1 Description Response Time is the length of time it takes for the displayed temperature the analog current output signal and digital output to reach approximately 95 of a step change in measured temperature The Response Time in the Modline 5 Sensor has an adjustable range from 6 6 or 10 milliseconds minimum depending on Model to 60 seconds Maximum See section 2 Product Description page 13 of this manual for Response Time restrictions by Model The Response time can be set using the HEAD menu RT function and RS 485 Digital Communications If you find that process temperature variations or signal noise is interfering with your measurement or control system increase the Response Time as required Modline 5 Rev L4 12 2012 139 Applications Guide 8 3 2 Determining Response Time to Use The Response Time is factory set for the fastest response time allowed for its Model You may wish to select a slower response time that is more suitable for the process To follow temperature variations as they occur select a fast response time If you prefer to filter out temperature variations select a slower response time In most applications the practical approach is to observe the temperature display or analog current output and adjust the response time for the most meaningful temperature information without distracting variations Observe the temperature indications on a Temperature Display or chart recorder
3. 9 3 Modline 5 Laser Sight Option The Modline 5 Laser Sighting Option can be turned on remotely using the Laser Function in the Engineering parameter section Follow all cautions and instructions shown below and in Section 5 11 Laser Sighting Operation page 110 of this Modline 5 manual CAUTION LASER LIGHT DO NOT STARE INTO BEAM 1 mW at 635 nm CLASS Il LASER PRODUCT other devices using RS 485 Communications insure there are no personnel in the path f Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or of the beam Modline 5 Rev L4 12 2012 165 DPM Installation and Operation 9 4 RS 485 Communication Setup The following Sensor RS 485 Communication parameters must be correctly selected at the Sensor Rear Panel for communications to take place RS 485 Commands for these functions are not provided The parameters cannot be remotely selected by the DPM Instructions are in Section 5 Operation page 90 for the following functions If the Sensor is connected to the DPM these parameters must be set while the DPM is in the DSP Display Mode 9 4 1 CLCK Communications Lock Communications Lock provides for the configuration of the Modline 5 RS 485 Communications Communication can be configured to allow selection and adjustment of functions with Read and Write R W operation Alternately Read Only R O operation does not allow Sensor to execute write commands The Sensor must be
4. F Optical Resolution with Type 2A Lens 5G 1007 250 to 1000 C 482 1832 F D 75 96 1415 300 to 1400 C 572 2552 F D 150 96 2024 350 to 2000 C 662 3632 F D 240 Series 5R Sensor Model Numbers Model Temperature Range in C and F Optical Resolution with Type RA Lens 600 to 1400 C 1112 2552 F D 100 OR 1810 700 to 1800 C 1292 3272 F D 100 OR 3015 1000 to 3000 C 1832 5432 F D 150 Through the Lens Sight Required Selection Visible or Optional Laser Sighting Lens Types Lens selection requires matching the lens to specific models Lens types ending in A are considered standard focusing range lenses Lens types ending in B are considered close focus lenses Lens types ending in C are considered very close focus lenses Complete lens focusing ranges and spot size information are found in Section 3 Sensor Installation page 22 of this manual Dirty Window Detector Option Required Selection The selection is Installed or None The product is covered by Patent Number 5812270 when the Dirty Window Detector Option is installed 2 4 Modline 5 Model Number Summary Modline 5 Model Number as Found on Serial Number Label 16 Rev L4 12 2012 Modline 5 Product Description Sighting DWD None or Transfer Lens Type Visible or Laser Installed Standard Two Characters Four Digits 0 or 1 Dor 1 0 or T Two Characters Example and Explanation 600 to 1400 C Laser
5. Sensor Installation Accessory Illustrations for Groups using WJA Front of Sensor Figure 42 Sensor with DWD WJA Accessory Groups 11 12 13 15 16 17 18 52 Rev L4 12 2012 Modline 5 Sensor Installation 3 11 Installation Drawings and Illustrations 3 11 1 Installation Drawing for the UAA Universal Adapter for Tripod or Custom Mounting Group Mounting Option Required Accessories See Individual Accessory DWD 14 20 Bolt Pattern Mount Descriptions and Dimensions See Notes pp one Large Flange Interface Mount UAA MFL Add ESAS Air Purge with 20 Bolt Pattern Mount UAA APA Add ESA 2 4 AirPurge with Small Flange Mount UAA_ APA i PAPAL MFS Add ESA 2 5 Air Purge with Large Flange Mount APA MEL Add ESA 2 DWD is Dirty Window Detector Option Refer to notes with Grouping table in Section 3 10 Accessory Combinations with Break out Drawings The ESA adds 1 82 46 2 mm to length of the assembled group Table 8 Recommended Accessory Groupings UAA Figure 43 Front mounted Figure 44 UAA with APA the UAA first Place Sensor fully into assembly and rotate Sensor to desired position lil When using the MFL Group 2 or APA Group 3 4 5 assemble these accessories to Tighten clamping screw Sensor front surface will be positioned at the back end of the APA or MFL To determine working distance D for spot size formula d D F measure or calculate fro
6. Symptom Number Three No Analog Output or incorrect Output Accurate temperature displayed on rear panel RS 485 Communications temperature output okay Modline 5 Rev L4 12 2012 Check 24 Vdc Sensor power supply Check AC line voltage supply connections on power supply Check any line fuse switch or circuit breaker for power supply Inspect interconnecting cable and connections for damage Replace Cable if problem found Replace Sensor Sensor warmed up See Section 5 5 Warm up and Initial Setup page 93 Check Sensor sighting and focusing Is target resolved Check for obstruction in sight path Check for background interference reflections causing high temperature readings Check lens and clean if necessary If system includes window or mirror check and clean Check ambient temperature of Sensor If water cooling is used make sure coolant is flowing at recommended rate Check all control settings particularly Emissivity or E Slope for Series Perform Calibration Check M56 Check wiring between the analog output terminals and external devices Device inputs should be differential type and not grounded Make sure device is connected and adjusted correctly and is compatible with Modline 5 specifications Check grounding of external devices Improper grounding could prevent proper signals at external devices Check Analog output Zero and Fu
7. Message Value Range 1 or 2 1 selects single color brightness mode 2 selects two color ratio mode RT Response Time Read Write Sets the Sensor Response Time Scaled Message Value Range 0 to 6000 Scaled value actual value times 100 above Sensor minimum Response Time limit Range for Series 52 or 5G Sensors 0 Minimum to 6000 60 Seconds Zero somewhat less than 006 second Zero not valid for 5R 56 Sensors Range for Series 5R Sensors 10 01 second minimum to 6000 60 Seconds Range for Series 56 Sensors 20 02 second minimum to 6000 60 Seconds ES E Slope Read Write Command is for 5R ratio units only Sets the E Slope for Ratio Sensors operating in the 2 color ratio mode Function is not active for single color mode If the Sensor s remote scaled E Slope input current is active the Sensor returns that setting ignoring any ES Write command or Rear Panel keyboard entry Scaled Message Value Range 800 to 1200 Scaled value actual value times 1000 Actual Range 8 to 1 2 EM Emissivity Read Write Sets Emissivity for single color units or Ratio units in 1 color mode If the Sensor s remote scaled Emissivity input current is active Sensor returns that setting ignoring any EM write command or Rear Panel keyboard entry Scaled Message Value Range 100 to 1000 Scaled value actual value times 1000 Actual Range 01 to 1 0 MT Match Temperature Read Write Alternative method of selecting the val
8. Sensor Output Signal i sasan Reset Below Temperature Time Figure 92 Automatic Peak Picker Reset When the measured temperature is above the selected Reset Below Temperature the displayed temperature will be the measured temperature with the Peak Picker signal conditioning action applied subject to the selected Response Time The Auto Peak Picker Reset can effectively be used to turn ON the Peak Picker function when the target is in view and to turn it OFF when the target is out of view The Reset Below temperature must be properly selected to provide the measurement conditions wanted Too high of a selected temperature may cause the peaking action not il to be activated if the target is cooler than the selected temperature If the Reset Below temperature selected is too low Peak Picker action will continuously take place with higher background temperatures Auto Reset can be affected by long response times The selected Response Time should be fast enough to allow the selected Reset Below Temperature captured and be used to accomplish the reset 8 6 7 Peak Picker Delay The Peak Picker Delay function is used to delay the start of the peaking action for up to 10 seconds following the detection of the leading edge of a new target This function is turned on with the Sensor rear panel PSEL menu DEL function or the RS 485 PD Command It operates independently of the Auto Reset and reset below functions It has limited operation
9. 1 4 16 X Trs Tzs Tzs Expressed as a formula for the 0 20 mA analog output is Tinp I 20 X Trs Tzs Tzs Where l is the current loop output in milliamps Tr s is the corresponding full scale temperature and Tzs is the Zero Scale Temperature Example For a 4 20 mA analog output with a 16 mA span corresponding to the 500 to 2500 degree range and an output current of 8 mA Tino 8 4 16 X 2500 500 500 1000 degrees Example For a 0 20 mA analog output with a 20 mA span corresponding to the 800 to 1800 degree range and an output current of 8 ma Tinp 8 20 X 1800 800 800 1200 degrees 8 2 3 Analog Output Operation Notes 1 The Analog Signal Output is affected by the selected Response Time Value and by any Peak Picker or Track and Hold signal conditioning selections 2 Three Analog Output related alarm functions can be used to set the Analog Current Output to a specified value for certain conditions A LO A HI and FATL alarm functions will force the current output to specific values for Zero Scale Full Scale and two alarm conditions Sensor failure and Dirty Window Detector operation Failure See Section 5 Operation page 90 of this manual for setup instructions 3 A 10 Volt d c full scale signal can be developed by shunting the analog current output with a precision 500 ohm resistor See Section 4 Sensor Wiring page 62 of this manual for more information
10. 3 3 Sighting Methods The Modline 5 Sensor is a precision electro optical instrument that senses infrared radiation This signal is processed by the unit s digital circuits to provide an output proportional to the temperature being measured The Sensor s linear analog current output and RS 485 digital temperature signals are brought out through a connector on the bottom of the Sensor with a shielded cable The output signals are then connected to compatible devices within the process measurement system 3 3 1 Sighting and Focusing The Modline 5 is a variable focus instrument that features visual through the lens sighting by means of a viewing sight at the rear panel of the Sensor An optional internal Laser for through the lens aiming is available Focusing with either the visible or laser sight is accomplished using the rotating rear section of the Sensor 3 3 2 Visual Sight The Modline 5 visible sight is aimed and focused onto the target to be measured as simply as an ordinary camera The rear focus is smooth utilizing almost one turn of the focusing section A circular reticle is contained within the Sensor s optical system and is visible when viewing through the sight During temperature measurement the target image is superimposed on the reticle Focusing is performed by adjusting the rear focusing section while viewing the scene until the target area is clear and well defined Illustrated below is a properly focused Sensor viewing a
11. 6 1 1 Introduction The MODLINE 5 Sensor permits RS 485 digital signal interchange of ASCII coded information with a host computer PLC Programmable Logic Controller or any other RS 485 device The external device can obtain information from the Sensor and modify Sensor settings Be thoroughly familiar with operation of the sensor as explained in Section 5 Operation page 90 of this manual The Yellow and Yellow White twisted wire pair of the standard Sensor interconnecting cable carries the signal See Section 4 Sensor Wiring page 62 of this manual for wiring termination and use of extension cables 6 1 2 Basic Operation The RS 485 Digital Communications interface allows an external device to communicate with the 114 Rev L4 12 2012 Modline 5 Digital Communications Sensor by sending messages it can understand Any messages the Sensor sends back will also be in its own language The messages are based on a list of commands described in this section Any values included in the messages are in decimal and bit mapped values Whenever there is a need to change a Sensor parameter or to obtain information from the Sensor the external device must send a properly coded and formatted message If there is any error the Sensor will ignore the message In turn when the Sensor transmits information back to your external device the response message will be in the same standard message format The external device must be able to inter
12. Any replacement of the Software or hardware accompanying the Software will be warranted for the remainder of the original warranty period or thirty 30 days whichever is longer No Other Warranties Ircon and its suppliers disclaim all other warranties both express and implied including but not limited to implied warranties of merchantability and fitness for a particular purpose with respect to the Software media hardware and the accompanying written materials You expressly acknowledge that no representations other than those contained in this agreement and the accompanying materials have been made regarding the Software media and hardware and you have not relied on any representation not expressly set out in this agreement or in the accompanying materials Disclaimer of Liability In no event shall Ircon and its suppliers be liable for any damages whatsoever including without limitation damages for loss of business profits business interruption loss of business information property damage personal injury and other pecuniary loss arising out of the use of or inability to use this Ircon product even if Ircon has been advised of the possibility of such damages The forgoing limitation shall apply regardless of legal theory and shall include liability based on contract tort and strict products liability principles Warning Ircon is not responsible for 1 User provided information used in connection with the Software and 2 the
13. Before installing and wiring the DPM determine the measurement units to be used and install an F or C overlay behind the DPM Front Window as instructed below Refer to the photographs above and those that follow If an overlay is not used the LED backlights will be visible See Section 9 13 DPM Sensor Diagnostic Functions page 174 to turn backlight off Exposed line voltage exists on the circuit boards Remove all power from the meter AND load circuits before accessing the unit to apply overlays or install relay cards Circuit cards contain static sensitive components Before handling cards discharge static charges from your body by touching a grounded bare metal object Ideally handle cards at a static controlled clean workstation Handle cards by the edges Dirt oil or other contaminants may contact the cards and adversely affect circuit operation Remove the meter base from the case by firmly squeezing and pulling back on the side rear finger tabs This should lower the latch below the case slot which is located is located just in front of the finger tab It is recommended to release the latch on one side and then start the latch on the other side Modline 5 Rev L4 12 2012 163 DPM Installation and Operation Figure 104 Figure 105 Choose an F or C overlay and remove the opaque release paper from its adhesive side Attach the overlay to the front of the white overlay frame insert Align the overlay with the two very s
14. Cold Temperature is Displayed Off Time Less Than 15 minutes warm up time Alarms on for 2 but may not be Accurate starts on return to minutes Accurate after 2 minutes power on Self Calibration is not Initiated Initiate a Manual Cal Check Navigate from TEMP display with J amp A Y to ENGR then use 1 amp AV to CHK DEW Instructions Display and Limits CHK Press ENT to initiate Calibration Check Sensor cycles through Sensor Check and CAL Self Calibration if necessary and then returns to the TEMP display It is not recommended to perform a Manual check more once than every 24 hours If the Check and Self Calibration does not pass the ALARM Indicator on the Sensor rear panel will light Press an Up Down Arrow to view an Error Code on the Display Multiple arrow entries may be required to view all error codes Error Code X102 is an Out of Calibration Alarm See Section 7 Maintenance page 127 for information about alarms and error codes 5 6 7 HOUR Automatic Calibration Check for 56 Models il Refer to the instructions for your Model The HOUR function provides for selection of an automatic System Calibration Check and Self Calibration if needed This function automatically initiates the calibration check described above A Manual or power on Calibration Check will start a new period but not change the value of the HOUR interval Process temperature measurement and control requirements need to be considered when usin
15. Decay Rate in F or C per Second RSET Manual Peak Picker Reset AUTO Auto Peak Picker Reset RBEL Reset Below Temperature DEL Peak Signal Conditioning Delay ENGR Engineering Functions List LOCK Sensor Rear Panel Lockout MODL Model Number Scroll F C F and C Selection RELY Alarm Relay Operation Setup CHK Initiate System Check HOUR Automatic System Check Setup WRNL Optional Dirty Window Detector Setup LASER Energize Laser VER Sensor Firmware Version I ALM Sets Ratio Invalid Measurement Condition as Alarm AOUT Analog Signal Output Current Range Selection and Temperature Scaling SOUT Select Analog Output Current Range ZERO Set Zero Scale Temperature FULL Set Full Scale Temperature Fatl Set Output Current for Sensor or DWD Error A LO Set Alarm Current Output for Temperature Below ZERO A HI Set Alarm Current Output for Temperature Above FULL DIAG Diagnostics List Status Alarms and Measurement Status I Temp Instrument Case Temperature Switch Switch Contact State Emissivity or E Slope Value Monitor 168 Rev L4 12 2012 Modline 5 DPM Installation and Operation 9 8 DPM Quick Programming Mode 9 8 1 Quick Programming Two choices of programming are provided Full and Quick Programming The meter is supplied with a jumper inserted or user switch installed between terminals 7 and 8 This puts the DPM in the Quick Programming mode This mode provides quick access
16. F indication up to 3000 C 5432 F Repeatability at 25 C Within 0 1 of full scale temperature 1 digit Response Time for Display and Outputs Series 5R Adjustable from 0 01 to 60 seconds Series 52 5G Adjustable from 0 0066 to 60 seconds Series 56 Adjustable from 0 020 to 60 seconds Selectable Analog Current Output 0 to 20 mAdc or 4 to 20 mAdc 600 Q maximum load including cable resistance Output is not isolated from power supply common Digital Communications RS 485 Digital Interface Emissivity Range Emissivity is 0 10 to 1 00 Series 52 56 5G and 5R single color mode Emissivity Limitations for Series 5G and 56 Emissivity span is limited to 0 3 to 1 0 for the first 100 F 55 C for all temperature ranges of these models E SLOPE Range Model 5 R Two color Ratio Mode 0 800 to 1 200 Signal Reduction Range Tolerated Sensor Series 5R will tolerate 95 reduction in radiation intensity caused by low emissivity non resolved or obscured 1 All specifications subject to change without notice Modline 5 Rev L4 12 2012 19 Product Description targets or combinations of these conditions above target temperatures of 1500 F 800 C System ALARM Relay Contacts 24 V AC DC at 1 Amp Resistive Peak Picker Rise Time Same as selected Response Time Peak Picker Decay Rate Adjustable 0 00 to 300 degrees F 0 00 to 166 degrees C per second Peak Picker Reset Internal Reset has two Modes Manual and Auto External
17. Figure 89 illustrates the general effects of response times as if plotted by a chart recorder The combination of low target temperature and fast response time will cause unstable temperature indications When measuring low target temperatures adjust the Response Time slowly to obtain stable temperature readings Measurements below 400 F 200 C may require a response time of one second or more A Response Time setting of 30 milliseconds usually provides good starting point for higher process temperatures Fast Response Medium Response Slow Response Dd E E E Temperature Temperature Temperature Temperatur display and output Rapid temperature variations are Sensor tracks slow variations in signals follow temperature filtered out and system follows temperature ans effects of variations as fast as minimum general trends in temperature temperature spikes are response time of instrument with small amounts of ripple eliminated Figure 89 Effects of Response Time 140 Rev L4 12 2012 Modline 5 Applications Guide 8 4 Emissivity Settings An ideal infrared radiator called a blackbody emits the maximum amount of infrared energy possible at a given temperature It has an Emissivity E that equals 1 0 However targets measured in processes are non blackbodies Their emissivity values are less than 1 0 which means they emit a fraction of th
18. J to save and return to TEMP display 5 6 4 CHK Initiate Manual System Check gt for 52 5G 5R models The CHK and Auto Cal Hour functions are different for the Series 56 Models Separate explanations and instructions are provided for Series 56 Models on the pages that follow Modline 5 Rev L4 12 2012 95 Operation lil Refer to the instructions for your Model This function checks the Modline 5 Sensor performance by initiating a System Check When this function is initiated the Sensor s infrared detector output internal gain and offset voltages are checked The check cycle lasts less than ten seconds During the Check the Sensor TEMP display indicates CAL The Alarm Led indicator and Alarm Relay remain at their last condition Target temperature measurement is suspended The Analog Output readings are not derived from real time temperature measurement during Check function The Analog Output is held at its last output value Peak Picker Track and Hold and Response time functions are suspended At the end of the cycle operation returns to normal and temperature measurement resumes If the Check does not pass the ALARM Indicator on the Sensor rear panel will light Press an Up Down Arrow to view an Error Code on the Display See Section 7 Maintenance page 127 for information about alarms and error codes Checks can be made manually or scheduled automatically with the HOUR function that follows Process temperature
19. Proper design of the interface protects against an unwanted interaction between the low level and high level circuits such an interaction can result in a failure of the low voltage circuitry This is potentially dangerous An input and output circuitry incorporating effective isolation techniques which may include limiting impedance or Class 2 supplied circuitry should be selected 3 2 2 Isolation Techniques The most important function of isolation components is to separate high level circuits from low level circuits in order to protect against the transfer of a fault from one level to the other Isolation transformers pulse transformers reed relays or optical couplers are typical means to transmit low level logic signals to power devices in the high level circuit Isolation impedance means also are used to transmit logic signals to power devices 3 3 Special Application Considerations 3 3 1 Converting Ladder Diagrams Converting a ladder diagram originally designed for electromechanical systems to one using solid state control must account for the differences between electromechanical and solid state devices Simply replacing each contact in the ladder diagram with a corresponding solid state contact will not always produce the desired logic functions or fault detection and response For example in electromechanical systems a relay having a mechanically linked normally open NO and normally closed NC contact can be wired to check
20. Shield to clamp gt Violet Pk Hd Switch ve 4 Seine shield Violet White D JZ PKIHA Switch T ei Peak Picker Track amp lo SO sam rey S MAI Hold Reset switch 11 Place Terminal Stripe Plate in metal gt Blake L CD Alam Rey al 4 Grounded shield enclosure for protection from ESD Red o L SY voc re 24VDC electrostatic discharge nn omaan LT Power supply 3 eino a ros tos 77 4 Grounded shield Figure 81 POI Box and Terminal Strip Plate 1 S 2 Ground lead The Sensor mounting surface should be at earth ground potential Provide electrical insulation between the Sensor and mounting surface if the surface is not at ground potential Use non conductive hardware for mounting Mounting surfaces not at ground potential could be hazardous for personnel operating and maintaining the Sensor 2 Terminal Plate as previously instructed in this Section Insure earth ground Dis properly connected to the POI Box enclosure or the Wiring 86 Rev L4 12 2012 Modline 5 Sensor Wirin 4 5 6 For the POI Box Use a clean AC Power line free from noise and transients If a line conditioner or isolation transformer is used connect per manufacturer s instructions These devices must withstand the inrush current specified in Section 4 4 2 AC Power and Earth Ground Connections page 65 Earth ground must be properly connected For the Terminal Strip Plate Connect a regulated power supply The Sensor case i
21. The ideal solution is to power from a separate ac line independent of all interference producing equipment If this is not practical consider using a line conditioner If you use a line conditioner connect per the manufacturer s instructions Improper installation can result in serious injury or death to personnel The Modline 5 Sensor and POI Power Supply were designed to meet EN 61010 1 Safety A Requirements for Electrical Equipment for Measurement The installation should be performed as directed in this manual and following any local electrical codes Compliance with EN61010 1 Safety Requirements for Electrical Equipment for Measurement requires the installation meet the following alternating current supply and earth grounding requirements The installation should be compliant with requirements for a Category II installation A three wire ac supply with a third wire earth ground or a separate earth ground wire is required Power cables and wires should meet recognized European and American standards for Main Voltage Safety with insulation suitable for single fault condition 600V 105 C Strain relief and compression fittings for the power cable must comply with European and American standards as dictated by the power cable selected The wire size for the L and N ac power connections should be no larger than 18 AWG 1 mm These power wires cannot be larger in diameter than the ground wire Ground wire must be the
22. affiliated company YOU MAY NOT USE COPY OR MODIFY THE SOFTWARE IN WHOLE OR IN PART EXCEPT AS EXPRESSLY PROVIDED IN THIS AGREEMENT 3 OWNERSHIP The Software is the sole and exclusive property of IRCON and or its software suppliers By accepting distribution of this Software and accepting this Software agreement license by installing the Software You do not become owner of the Software but are entitled to use the Software according to the terms of this Agreement 4 COPYRIGHT The Software including the related screen displays are copyrighted materials You agree not to copy modify or adapt the Software without the written consent of IRCON in whole or in part except 1 for backup or archival purposes and 2 as an essential step in the utilization of the Software in conjunction with a computer provided that such copy modification or adaptation is strictly for IRCON s intended purpose for the Software as defined in this Agreement and in the accompanying documentation materials Any other copying modification or adaptation is a violation of this license agreement and of applicable copyright laws and shall result in the termination of your rights to use the Software 5 PROTECTION and SECURITY You agree not to deliver or otherwise make available the Software or any part thereof including without limitation the object code of the Software to any party other than IRCON or its employees except for purposes specifically related to your u
23. 4 Sensor Wiring page 62 5 9 7 MTCH E Slope or Emissivity Selection Based on Temperature Match The MTCH function of the Modline 5 Sensor provides for adjusting the E Slope or Emissivity values 106 Rev L4 12 2012 Modline 5 Operation by setting and matching the Sensor s temperature display to the known temperature of a process target The Match temperature should be set with a Sensor Response Time of 100 milliseconds or faster Peak Picker or Track and Hold must be Off The Match function should be set with stable process temperatures After setting the Match temperature the response time Peak Picker and Track and Hold can be set to the values required for process temperature measurement Navigate from TEMP display with 1 amp A Y to Head then use y amp A Y to MICH YEW Instructions Display and Limits MTCH While viewing process target Press ENT to view Match temperature Use Up Temperature in C or F Down Arrows to adjust to the known target temperature XXXX Emissivity or E Slope if within allowed limits will be automatically adjusted for a matching TEMP display During the adjustment the Response Time should be set to 100 milliseconds or faster and Peak Picker or Track and Hold signal conditioning set to Off lf the resulting Emissivity or E Slope is not within allowed limits the Match value cannot be inputted and ERR will be seen on the display after pressing ENT J Return to EMIS or E SLP to view resulting
24. 5 OPERATIO Nica lt A A AAA A AAA AAA TE AA 90 5 Sensor Rear Panels Clu and OPE ISS MS ias 90 LACA CO AS AS A A SA E 90 5 2 Rear Panel Keyboard Displays and Sight and Laser Aiming cooooocccccoaaooooonononanonnnnn no non nono nono non nn non nn nono nn nnnnnos 90 A deneinghieteunentuvan ach ENO T anata cuause ONO T OTOS 90 2 Navia tion and MCU pios idad 91 39L Ener and Ups Down Arrow PushDU ONS AA AA A EAE A 91 SEMI A NS 91 gt Wars and atada 93 DL nes IRo G92 LOWER OM and VIVOS AAA AAA AA E A 93 1002 meres 90 Models Power On and Wm Up AAA AAA AA AAA 93 A NI AA pana neat ic E Ganea nana Saves sabcaa econo due rawor T E 93 roAa Or EUA AAA AAA AAA AAA ASAS 93 5 6 ENGR Setup of Engineering FUNCHONS ooooooooooooooooooooooonnononononononononononononononononononnnononononononnnnnononononononnnos 94 FOT LOCK Panel LOCK OCCUTUY AAA AA 94 9102 MODL Sensor Model NUDI AAA AAA ieutasttancines 94 5 6 3 F C Selection of Fahrenheit or Celsius Indication F or C di neeuteeeitatnes 94 DOs CHR Iuka Mannal System Checker A EEA E AE 95 SOS HOUR Antomake sytem Cheek A T R A N 96 5 6 6 CHK Mandal System Calibration Jor 30 Models iia niea a aai 97 5 6 7 HOUR A tomatic Calibration Check for 56 Models oia en ih 99 5 6 8 WRNL Dirty Window Detector Option Warning Ledel onda tdi 100 0 0 7 VER Sensor Fir MLA Versto AAA A R 100 5 6 10 1ALM Selects Ratio Invalid Measurement Condition as an Alaf M sssessessesseerereereerrrrserreereesees
25. 56 Sensors performance by initiating a System Calibration Check When this function is initiated the Sensor s infrared detector signal internal gain and offset voltages are checked First a flag is closed inside of the unit to block the optical path of the instrument Operation of the Sensor is determined with no target in the field of view of the infrared detector Second a calibration source with a known radiance is activated inside the Sensor and the radiance is seen by the infrared detector The response of the sensor electronics to the radiance is compared to an expected value If the Calibrate Check determines a Model 56 Sensor requires recalibration the sensor firmware performs a Self Calibration adjustment Typically only small changes in calibration will occur During the Calibration Check the Sensor Rear Panel TEMP display indicates CAL The Alarm Led indicator and Alarm Relay remain at their last condition Target temperature measurement is suspended The Analog Output is held at its last output value The Analog Output readings are not derived from real time temperature measurement during Calibration Check function Peak Picker Track and Hold and Response time functions are suspended At the end of the cycle operation returns to normal and real time temperature measurement resumes i Temperature indications may shift slightly upon return to normal operation A Calibrate Check is required for to insure accurate operation
26. Alarm feature you must set the emissivity and also the e slope for the sensor 1 Determine the Emissivity value of your target by referring to the instructions in Section 8 Applications Guide page 137 2 Select the proper Emissivity value from the Tables in Section 8 Applications Guide page 137 for the surface finish 3 The adjustable range of the Emissivity is 0 100 to 1 000 See Section 2 3 Model Configuration and Required Selections page 15 for Emissivity restrictions If the material changes characteristics or you change materials re determine the Emissivity for the new material and adjust the Emissivity value If you are viewing your target through a window consider the effect of window transmission loss as described in Section 8 Applications Guide page 137 Navigate from TEMP display with J amp A Y to Head then use J amp A Y to EMIS NEW Instructions Display and Limits EMIS Press ENT to view Emissivity Value Use Up Down Arrows to adjust 0 100 to 1 000 Press ENT to save and return to TEMP display 5 9 6 Remote Emissivity Current Input You may make remote analog adjustments of the Emissivity value by sending a scaled input of 4 to 20 mAdc This signal is inputted using the Orange and Orange White twisted wire pair of the Sensor s interconnecting cable The Modline 5 senses an input and overrides any rear panel or RS 485 settings of Emissivity or Match Wiring connection and scaling information are in Section
27. Command CodES ococccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninininss 123 00 TANTA UC A a diz 123 6 9 Command Code AI iio 125 TNMAINTENANC E eosa A R ened ec enna aoe 127 TE ROGNE MAMENANG E oarriero n NETE E ETE E T AE R 127 Fe Ma a OL TAO aso AAA ea a a Busilteatiedse ies usocetnaney 127 T2 Sensor Opus EAN da 127 AL CLES OPOS eines 128 P22 ESTOS TRE CASTO OPA A a ias 128 TSENG a a e E E E E E 129 TA Pacto Calibration and EVOCA AS A 129 7 5 Measurement Condition Displays Error Codes and Troubleshooting occcccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 130 TO Status Displays and Error Code Details s cde cc cat actascnca cena dbastaasonsddesdoaneenadessesescbapeasadensednndeastesedeasedwedeaneed 132 FOTA A Sens spite awa medhnad alte an vaed emu neatiitentond ON 135 SoA PPEIC A TIONS GUIDE esse ccscsscezicenscdecacercaviusestonsaccstextawnetsesunessensvoestoascausteresenscczsucusteUicabiteibdcceteseuetsccseces 137 Bole TOC A E naam aslaunatae Meat icaataetnadsaatndenlousatea antec stnanins oaatudoueneneetuees 137 a AAA A E O a O 137 g2 1 AnaS Qutput Range Scali EXA ad 138 3 22 Measured Temperature Calculations Neda 138 BZ S AMAS Output Operation NOLES as 139 S nR E POE LIME neie ct 139 oo O OESP ON On A E 139 0 0 2 Determina Response Jane Osdia 140 NN SCM Os 33 esta E E E E E etl Md eee el E Me oe 141 SE Uso ERAS LADIES AEE T E A E E A is nivnet ume salaaudpiandas 14 9 42 USMO Emis ouy Tiermocouple TOS tddi
28. Do not open the power supply until at least 5 minutes after it has been disconnected from the mains on all poles Modline 5 Rev L4 12 2012 81 Sensor Wiring 4 12 RS 485 Multi Drop Network Power Supply and System Wiring Multiple Modline 5 Sensors communicating via RS 485 with a Host device are installed in a multi drop network configuration The Modline 5 MSI Multiple Sensor Interface a PC a PLC or other Control system are Host devices A block diagram of a multi drop network is shown in the adjacent illustration It is important to wire the network properly to prevent noise pickup and have reliable Operation Sensors should be wired in tandem as shown in the diagram The RS 485 terminals from the Sensor furthest from the host device are wired to the next closest Sensor Then the RS 485 Terminals of that Sensor should be wired back to the next closest sensor Do this until all sensors are wired Do not use any other configuration A 120 ohm termination resistor should be placed across the RS 485 terminals of the Sensor furthest from the Host device as shown in the diagram Consult the manual for the Host device to determine if any termination resistor is required at its terminals The IRCON Model MSI Interface does not require a termination resistor at its input To maintain signal integrity and reduce noise pick up twisted pair shielded cables with overall foil and braid shielding should be used for connecting to all Sensor inputs
29. Factor F 100 CG o aw A Target smaller than Spot Size zo Sensor measures part target and part background Move closer and Refocus Recticle Si Sensor B Target equal to Spot Size Any shift of target or sensor will cause sensor to view part target and part background Move closer and Refocus C Target twice Spot Size Excellent Target is safely resolved Figure 12 Distance and Spot Size Illustration d 1 inches 25 4 mm 0 1 inch 25 4 mm d 0 5 inch 12 7 mm d 0 5 inch 12 7 mm d 0 25 inch 6 35 mm In top example A the rod is 100 in 2540 mm away The spot is 1 inch 25 4 mm in diameter The one half inch diameter rod does not fill the reticle in the viewing sight Middle example B illustrates a viewing distance of 50 inch 1270 mm The spot is 0 5 inch 12 7 mm in diameter the same size as the rod Bottom example C illustrates a viewing distance of 25 inch 635 mm The spot size is 0 25 inch 6 35 mm one half the one half inch target size The view in the eyepiece shows the target completely resolved by the reticle 28 Rev L4 12 2012 Modline 5 Sensor Installation 3 5 Measuring Temperature with Brightness and Ratio Sensors 3 5 1 Resolving Targets with Brightness Sensors When using single color Series 52 56 and 5G brightness Sensors best results are obtained when the resolved portion of the target is two times the diameter of the reticle
30. Important See recommendations in section 5 6 7 HOUR Automatic or 58 Calibration Check page 99 Model 56 only bad FIL Dirty Window Detector OFF Appears if Dirty window option installed OFF turns dirty window detection Setup FORS off Coarse and Sensitive Warning Levels select a greater CORS or SENS lesser SENS amount of Sensor window transmission loss to trigger alarm pp AS Laser Energize Appears if Dirty window option installed OFF turns dirty window detection off Coarse and Sensitive Warning Levels select a greater CORS or lesser SENS amount of Sensor window transmission loss to trigger alarm YEr Software Version 99 99 Reports Sensor firmware version Read Only See Safety Instructions in Sections 9 3 and 5 11 Modline 5 Rev L4 12 2012 171 DPM Installation and Operation 9 11 Sensor Setup Head Menu e Press DSP Display for the Temperature Display at any time e Continually pressing PAR sequences through all the menus and back to ALOR RiMenu entry start point HE Ad menu Use Par to read next Parameter Press PAR again to go next parameter without changing the value To Change a Value or Selection use F1 A F2 Y then Press PAR to enter and saveL Display Parameter Description Selections Information UY 16 Emissivity a gg 888 Sets Emissivity for single color units or ratio sensors in one color mode E 5 E Slope a Bg 200 Sets the E Slope for Ratio Sensors in
31. NFPA 70E 1983 Electrical Safety Requirements for Employee Workplaces 5 2 Preventive Maintenance The following factors should be considered when formulating a maintenance program 1 Maintenance should be performed by qualified personnel familiar with the construction operation and hazards involved with the control 2 Maintenance should be performed with the control out of operation and disconnected from all sources of power If maintenance must be performed while the control is energized the safety related practices of NFPA 70E should be followed 3 Care should be taken when servicing electrostatic sensitive components The manufacturer s recommendations for these components should be followed 4 Ventilation passages should be kept open If the equipment depends upon auxiliary cooling e g air water or oil periodic inspection with filter replacement when necessary should be made of these systems 5 The means employed for grounding or insulating the equipment from ground should be checked to assure its integrity see 4 5 6 Accumulations of dust and dirt on all parts including semiconductor heat sinks should be removed according to the manufacturer s instructions if provided otherwise the manufacturer should be consulted Care must be taken to avoid damaging any delicate components and to avoid displacing dust dirt or debris that permits it to enter or settle into parts of the control equipment 7 Enclosure
32. Output current not correct value detected when output current is greater than 0 mA Caution Inaccurate temperature readings Connected devices should have differential inputs neither input may be displayed or used by external terminal should be grounded as GUIDU Check cables and external devices See symptom number three in Troubleshooting Table below If analog output is not used place a jumper wire across the output terminals to prevent the X108 alarm from occurring Error Code X109 Dirty Window circuit operation malfunction Malfunction of Sensor Dirty Window Detection Replace Sensor 134 Rev L4 12 2012 Modline 5 Maintenance 7 6 1 Troubleshooting If troubles develop in the initial installation or after periods of normal operation these troubleshooting suggestions may help to identify certain trouble symptoms and possibly correct the problem If trouble persists call or contact IRCON Technical Services for help Possible Cause Corrective Action Symptom Symptom Number One Completely inoperative No display of any kind No RS 485 Communications No Analog Output Symptom Number Two Incorrect Temperature Indications No temperature indication or incorrect temperature indication Target temperature known to be within system temperature range Under range LOW or Over range HIGH indication displayed For Sensor Series 5R Ratio series instruments Invalid INV or pINV indication displayed
33. R effect of momentary interuptions or e um a l l E t interference in the sight path 4 Peak Picker On Slow Decay Peak Picker conditioning shown as a solid line 5 o ca Use this setting to concentrate on peak S 1 a temperature and ignore gaps between a u a p workpieces or interference in the sight 2 a E path but still catch hot spots on a f t s workpiece Time Figure 91 Peak Picker Operation 150 Rev L4 12 2012 Modline 5 Applications Guide 8 6 3 Peak Picker Signal Conditioning Peak Picker signal conditioning takes place with the Peak Picker on Temperature readings may be returned to instantaneous values at any time by setting the SIGL function to OFF The system then follows actual temperature variations as they occur Both Peak Picking signal conditioning and direct instantaneous temperature indication are affected by the selected Response Time 8 6 4 Peak Picker Reset The Peak Picker signal conditioning can be reset by any of the following actions e Manual reset using the Sensor rear panel PSEL menu RSET function e Remote reset with a momentary switch closure across the Sensor s interconnecting cable Violet and Violet White twisted wire pair e Automatic reset using the Auto Peak Picker Reset function with Reset Below Temperature selection e Remote reset with the RS 485 PS Command 8 6 5 Peak Picker Decay Rate The Decay Rate is set to retain peak measured temperature value
34. RELY Alarm Relay Operation The RELY function configures the operation of the Modline 5 Alarm relay for Normally Open or Normally Closed operation The Sensor internal relay contacts are available on the Black and Black White twisted wire pair of the Sensor cable The Alarm Relay contacts are used to report a Sensor alarm condition The sensor self tests its case temperature detector assembly temperature output current flow etc The Check function checks internal circuit and detector operation The optional Dirty Window Detector measures the Sensor s window condition One or more out of limit conditions sensed by these tests triggers an Alarm Set the relay operation to correspond to proper and safe use of the contacts in your overall measurement system Select N C for closed relay operation with Sensor not in Alarm condition open in alarm state Select N O for closed relay operation with Sensor in Alarm condition open when not in alarm condition Contacts are open for both N O and N C operation when the Sensor is not powered and for the 3 to 5 seconds after power is applied during the initiate period Normally Closed N C operation is considered fail safe operation Navigate from TEMP display with J amp A Y to ENGR then use J amp A Y to RELY DEW Instructions Display and Limits RELY Press ENT to view Alarm Relay Operation N O or N C Use Up Down Arrows to select Normally Open N O or Normally Closed N C Press ENT
35. S APA o Uno PAn as ASEOS O KEDUA NENS DRESU Erer NoPE RRENEN A EaP ROS i n An 12 2 FRODUCT DESCRIP TION suiriri anri a E E iio 13 2 1 Modline 5 Sensors Cable and Interface Accessories ooccooccnnnccncnoccnnnccnonocnnnoconnnccnonorononccnonocnonrcnnnrcnonicnnnos 13 ZE PECHO TY LPO TON oa E EA A T T riacpoeneieaneneeaniaserasewriats 13 lA a bdaddaus ta dacdeesau diate tas asatadaddoutedatandetecediateunatee 14 Zed ANSENSOV ANOTA CAL UTES ninia E EE EEE OEE TOE NOE este 14 P22 OPIO SEN SOV FORTU TES A T O R 14 2 5 Model Conticuration and Required Selections arietans ie a e a aia EE Een 15 Lod Monel COnN UTA a 15 24 Modline gt Model Number Summary aisa a a a a a a decd e a aa aes 16 ZSA CCE SONES a a a G a a a a a N badaais 17 200 1 Interconnec Hne Cable RECUA ACCESSU noiae EE EE E 17 26 Power and Interface ACCESSOLE iaa lola EEREN 17 2 nstallat on ACCESSO Baiar o a ias 18 DOSE CIC AMOS NE EE A E E E AE S E TE E A S E E E A E 19 20 CASO PECAR O 19 2 8 2 ACCESOS DEC CAOS aa 20 3 5 ENSORINSTAELA TION a ee ceci 22 SIE Cami al Installation a e ios nadas 22 O E 22 edo Or O O A 23 329 LAO MOS na a A A O A E e 23 SE CAE LOCAS A A E A E E AS 23 De VISUAL O A o 23 RE SC EG E E E E E E E E 24 3 4 Sensor Optical Characteristi S ds 26 DAA OPC RCS ONION Id AA OEO OT NOT AAA AREA AI 26 3 4 2 Lens Focusing Ranges and Optical Resolution Factor sssssssessessersesesrssresrerressrssresrenrenrrssresrenreneeseres 26 3 4 3 Table of Model and Lens Type Com
36. See Section 3 8 DWD Installation Requirements for more information Groups are illustrated with dimensions in Section 3 11 Installation Drawings and Illustrations Modline 5 Rev L4 12 2012 49 Sensor Installation DWD See Notes 1 20BotPatemMout JUAA J 1 hR 2 LargeFlange Interface Mount JuAA MFL AddESA S 3 Air Purge with 4 20 Bolt Patten Mount UAA APA A ESA A AirPurge with Small Flange Mount UAA apa MFS AddESA 5 Air Purge with Large Flange Mount uaa fapa MFL AGG ESA 2 6 RightAngleBase Mount JUAA am 1 NR 7 RightAngle Mount with Air Purge uaa RAM APA AddESA 2 Right Angle Mount with Large Flange This group requires an ESA for clearing the MFL amp ESA Included RAM ma ESA Note 3 9 Right Angle Mount with Air Purge Uaa RAM APA MFS AddESA 2 fo rana Jua fem poa L S ps 14 Water Jacket Air Purge and Small Flange JAPA WA IMFs Add ESA 2 Add ESA Water Jacket with Large Flange Mount WJA MFL 3 and 5 18 Wat Jacket A Purge an ange Fangs Jara Jwa MFL Add ESA 2 14 Water Jacket Base Mount wa BMA NRM 15 Water Jacket Base Mount ArPuge Japa wa fema AddESAQ2 Add ESA Water Jacket Base Mount and Large Flange WJA a and 5 Water Jacket Base Mount Air Purge and Small Flange APA WJA BMA MFS me ESA 2 Water Jacket Base Mount Air Purge and Large Flange APA WJA BMA MFL Add
37. The Sensor measures the average temperature of the target or object seen in the reticle Targets smaller than the reticle will result in low temperature readings if the background object within the cone of vision beyond the target is lower that the target temperature If the background temperature is higher than the target the averaged temperature indication will be higher Low temperature indications can also be caused by other factors An out of focus cool object cutting the cone of vision anywhere between the target and Sensor or a small target may shift position and move partially out of the measurement cone 3 5 2 Obstructions in Cone of Vision Errors can be caused by objects positioned between the Sensor and target Evaluate the Sensor s Cone of Vision and if there is any possibility that an intervening object is within the cone select a different viewing position An object inside the Cone of Vision will be visible to the detector and may cause an error in the temperature measurement Obstructions in the cone of vision whose temperatures are lower than the target temperature will generally cause lower temperature readings when using single color brightness units The obstruction may not be seen clearly in the instrument sight if it is some distance away from the target and out of focus Such an obstruction is illustrated below High temperatures can be caused by an out of focus hot object cutting the cone of vision anywhere betwe
38. Unlocked 1 locked MD Model Number Read Only Returns the Model number of the Sensor Value An eight character Model Number is returned UN Units Select Read Write See Section 5 6 ENGR Setup of Engineering Functions page 94 for important information when changing units Sets the temperature units the Sensor uses for measurement and display Range 0 to 1 0 Fahrenheit 1 Celsius UZ Unit Zero Scale Read Only Returns the Sensor s zero scale temperature as defined its Model Number An F or C is put on the end as appropriate UF Unit Full Scale Read Only Returns the unit s full scale temperature as defined by its Model Number An F or C is put on the end as appropriate AC Auto and Immediate Calibration Initiate Read Write For 52 5G and 5R models See next paragraph for Models begging with 56 See Section 5 5 Warm up and Initial Setup page 93 Sets the number of hours between Systems Checks A manual Check from the Sensor Keyboard or by RS 485 Communication will start a new time period Continuous interval setting should be 8 hours or greater A 168 hour 1 week or greater automatic interval and manually initiated checks are the recommendations that will provide minimal measurement interruption Range 0 to 9999 65535 A zero value disables this function Values between 1 to 9999 sets the time period in hours A value of 65535 FFFF16 causes an immediate Check to occur without changing the previo
39. Zero 0 turns Delay Time to Off E HHA r Color Mode Selects One Color 1 or Two Color 2 operation for a Series 5R ratio Sensor e po E He H MA Yes to Match known target temperature value to be displayed by Sensor Match Sub Menu Sets temperature value to be displayed by Sensor to match The Response Time should known target temperature be set to 100 milliseconds If match requires an out of range E slope or Emissivity Errar or faster and Peak Picker is displayed following the entry or Track and Hold set to Off during adjustment 172 Rev L4 12 2012 Modline 5 DPM Installation and Operation 9 12 Sensor Setup Analog Output Functions e Press DSP Display for the Temperature Display at any time e Continually pressing PAR sequences through all the menus and back to ALOR N Menu entry start point REUE Menu Use Par to read next Parameter Press PAR again to go next parameter without changing the value To Change a Value or Selection use F1 A F2 then Press PAR to enter and save METE Parameter Description Selections Navigation Coe Analog Output Range 7 S Sets Analog Output to 0 to 20 ma or 4 20 ma O ETE Analog Output Zero Scale 4 or 580 1398 Minimum Sensor Temperature to Maximum Sensor Temperature 0 mA equivalent temperature minus 10 F or 10 C Minimum Zero to Full range must be 10 degrees Example Shown for a 600 to 1400 F Range See note below about F and C conversions Analog Output Full
40. across the power supply wire pair will be small and not cause a low voltage condition Whether powering a single Sensor or multiple Sensors there may also be significant voltage drops across the wires connecting the power supply to each TSP Keep the wire lengths between the power 78 Rev L4 12 2012 Modline 5 Sensor Wirin supply and Terminal Strip Plate short The voltage drops developed are dependent upon length and gauge of the wire A qualified electrician or technician should apply power with the all sensors connected and measure 24 VDC 5 at the Red and Red White power supply terminal connections on the left side of each TSP Terminal Strip Plate A 100 Ohm1 Watt fusible resistor is supplied with all TSP plates to connect power supply common to earth ground as shown in the diagrams The 100 Ohm resistor is built into the POI Power Supply Signal Interface Box To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor Power Supply Power Supply Power Supply 24 VDC 24 VDC 24 VDC Figure 73 Sensor Wiring one 24 VDC Supply for each Sensor To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor TSP TSP Tsp O amp 5 ig 24 VDC 24 VDC mu aj ES R em Power Supply 24 VDC Figure 74 Sensor Wiring one 24 VDC Supply and Three Sensors 4 10 1 TSP Terminal Strip Plate DC Power Supply Connections These instructions are for the Terminal Strip P
41. analog outputs can extend beyond the 107 meter limitation See Section 4 Sensor Wiring page 62 for more information TSP Terminal Strip Plate to ensure that the Sensor and cable installation meets RF immunity and emission standards for CE compliance These items are described below i The cable must be terminated into a POI Power Supply Signal Interface Box or a 2 6 Power and Interface Accessories Model POI Power Supply Signal Interface Box This box includes a 24VDC power supply and interconnecting cable termination strip Input power is 100 to 240 VAC 50 60 HZ 15 Watts maximum Model TSP Terminal Strip Plate This plate includes an interconnecting cable termination strip and suppression components Modline 5 Rev L4 12 2012 17 Product Description Model DPM Digital Panel Meter Digital Temperature Indicator and RS 485 Communication Operator Interface 85 to 250 VAC 50 60 HZ 15VA The DPM does not provide power to Sensor 2 7 Installation Accessories Details on the following standard accessories can be found in Section 3 Sensor Installation page 22 An extended family of accessories is available and they are referenced in Section 3 Standard Modline 5 Accessories Model MFS Mounting Flange Small Diameter Pattern Model BMA Base Mount Adapter Model APA Air Purge Accessory Model WJA Water Jacket Accessory Model ESA Dirty Window Detector Extension Sleeve Adapter one included with Dirty Window Dete
42. and ignore momentary decreases in measured temperature caused by process conditions The goal is to eliminate erratic measurements due to gaps in work pieces bursts of smoke or steam etc in the sight path of the Sensor The Decay Rate range is 0 00 to 300 degrees The Decay Rate setting is unit less The units are defined by the selected Sensor measurement units Fahrenheit or Celsius The fastest decay rate is 300 degrees per second The slowest decay rate is O degrees per second This slowest decay for practical purposes can be considered as a Peak Hold with the highest peak measured temperature held until a Reset occurs Select a Decay Rate that will yield the decay needed for meaningful process measurement Refer to Figure 91 8 6 6 Auto Peak Picker Reset with Reset Below An automatic reset is accomplished with the Auto Peak Reset and Reset Below functions These functions are turned on with the Sensor rear panel PSEL menu AUTO and RBEL functions or the RS 485 PS and PK Commands Figure 92 illustrates Auto Peak Picker Reset This reset action is triggered when the measured temperature goes below the selected Reset Below Temperature When the measured temperature is below this temperature the displayed temperature indication will be the measured temperature unaffected by the Peak Picker signal conditioning subject to any Response Time selection Modline 5 Rev L4 12 2012 151 Applications Guide Target Temperature
43. and outputs Belden low capacitance computer cable types 9829 9830 9831 9832 9839 and 9833 or equivalent cables are recommended Each of these cables has a different number of wire pairs varying in quantity from 2 to 7 pairs The cable selected should have a twisted pair nominal impedance of 100 ohms and nominal capacitance between conductors should not exceed 15 5 pF ft 50 9 pF m manual lil Select power supplies and install cables as instructed in previous sections of the To Sensors RS 485 Multi drop Network FUEL Sensors with TSP Terminal Strip Plates APE Power Supply More than one Required see Manual Ground TX A TX B RS 485 Serial Port IRCON Multiple Sensor Interface MSI or PC PLC Control System Figure 76 82 Rev L4 12 2012 Modline 5 Sensor Wiring 4 12 1 Computer Communications Requirements The Host device communicating with The Modline 5 Sensor should have an RS 485 communication port If not an RS 232 Port and a RS 485 to RS 232 converter can be used An RS 485 to USB converter can also be utilized The combined communications port and converters used must have the capability to communicate over a 2 wire half duplex RS 485 network at speeds fast enough to handle command requests with reply turn around times of one millisecond or less The following converters will provide satisfactory performance when used with Modline 5 Sensors CyberResearch Inc Contact www cyberresearch com Su
44. be verified Modline 5 Rev L4 12 2012 89 Operation 5 Operation 5 1 Sensor Rear Panel Setup and Operation 5 1 1 Introduction Become familiar with the displays pushbutton controls menus and the functions required for Sensor setup and operation as described below Modline 5 instruments are thoroughly tested and calibrated to factory specifications before shipment and should require no more than brief function selections and adjustments to meet the requirements for measurement of process temperatures 5 2 Rear Panel Keyboard Displays and Sight and Laser Aiming 5 2 1 Description Located on the rear of the Modline 5 Sensor are a keyboard panel with three setup pushbuttons three red word indicators for Setup Alarm and Window for the Dirty Window Detector optional feature and a four character green alphanumeric Light Emitting Diode dot matrix display with adjacent green F and C indicators The display is identified as the Temperature TEMP display in this manual The TEMP display and F and C indicators are used for temperature indication in Fahrenheit or Celsius LOW or HIGH is displayed when viewing target temperatures below or above the Sensor temperature range INV is presented on the display for Invalid ratio temperature measurement conditions Setup parameters will be shown on the TEMP display during setup and error codes displayed in response to an Alarm inquiry Two of the pushbuttons are Down Up Arrows label
45. cable length 107 meters 350 feet See the first manual pages for CE information for Modline 5 Sensor and POI Box See Red Lion Bulletin PAX P for completing the specifications for DPM Modline 5 Rev L4 12 2012 21 Sensor Installation 3 Sensor Installation 3 1 Mechanical Installation This section provides instructions for installing the Modline 5 Sensor Sighting aiming focusing and resolving targets are explained Mounting and protection of the Sensor in hot and dirty environments using installation air purging and water cooling accessories are presented 3 2 Sensors J eS So aa IRCON Modline 5 S Figure 2 Standard Sensor Figure 3 Sensor with Dirty Window Detector Two Sensors types are available in the Modline 5 Series standard Sensor or Sensor with the Dirty Window Detector option The front of the standard Sensor consists of a front objective lens only The Sensor with the Dirty Window Detector option has internal components and an external protection window located in front of the objective lens A hooded mirror extends out in front of protection window The sensors are illustrated in the photographs above and below The Patented Dirty Window Detector option IRCON inc Patent Number 5812270 checks the Sensors front window for loss of signal caused by a build up of contaminants A Coarse or Sensitive level of signal loss can be selected Visual Alarms and a relay output are provided to indicate
46. determine if any damage occurred in transit If you find such damage promptly inform the freight agent delivering the components Save the carton until you are sure you will have no further use for it Return items for repair in their original packaging Contact Ircon before returning any products for service See Section 7 Maintenance page 127 on how to contact IRCON For Modline 56 sensors occasionally a calibration flag that operates during the Sensor internal Calibrate test may move into the viewing area during shipment If this occurs the viewing area will be dark and appear obstructed This flag will be positioned correctly when power is applied to the Sensor Modline 5 Rev L4 12 2012 13 Product Description 2 2 Modline 5 Description The IRCON Modline 5 is an Infrared Thermometer Sensor State of the art digital circuitry and firmware provide excellent measurement accuracy repeatability and overall performance New diagnostics check the status of the Sensor such as detector temperature sensor failure and some of its external environment such as analog current output open circuit condition and case temperature An internal function check is performed without the need to block the lens The check tests for and internal circuit and detector operation Alarms and Error Codes are outputted when out of limit conditions are sensed The Patented Dirty Window Detector option checks the Sensors front window for loss of signal becaus
47. dirty window detector which will monitor the sensor window for contamination It enables users to monitor any kind of signal attenuation caused by dirty viewports or other external windows Attenuation alarm settings are configurable from 5 to 95 percent from either the back panel of the sensing head or from the Ircon Modview program When an alarm condition is detected relay outputs provide notification to external process control instrumentation When the attenuation adjustment alarming feature is enabled the user can monitor attenuation levels in a graphical format in the Modview program providing a historical view of the levels In addition attenuation levels are available through the Modline 5 RS 485 output fed into an external device 5 7 AOUT Setup of Analog Signal Output Current Range and Temperature Scaling Modline 5 Sensors provide selection of the analog output current range and scaling of the selected range to temperature Scaling establishes a temperature span to correspond to the analog output Modline 5 Rev L4 12 2012 101 Operation current range The span can be equivalent to the Sensor s specified span or narrower See Section 4 Sensor Wiring page 62 for detailed information on analog output signals This signal is available from the Blue and Blue White twisted wire pair of the Sensor cable See Section 4 Sensor Wiring page 62 for wiring details SOUT Analog Output Current Range Selection Modline 5 Sensors pro
48. do not cover reimbursement for transportation removal installation or other expenses which may be incurred in connection with repair or replacement Except as may be expressly provided in an authorized writing by IRCON IRCON shall not be subject to any other obligations or liabilities whatsoever with respect to equipment manufactured by IRCON or services rendered by IRCON THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES EXCEPT WARRANTIES OF TITLE INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY Anything to the contrary herein contained notwithstanding IRCON ITS CONTRACTORS AND SUPPLIERS OF ANY TIER SHALL NOT BE LIABLE IN CONTRACT IN TORT INCLUDING NEGLIGENCE OR STRICT LIABILITY OR OTHERWISE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER The remedies of the purchaser set forth herein are exclusive where so stated and the total cumulative liability of IRCON its contractors and suppliers of any tier with respect to this contract or anything done in connection therewith such as the use of any product covered by or furnished under the contract whether in contract in tort including negligence or strict liability or otherwise shall not exceed the price of the product or part on which such liability is based IRCON Limited Use Software License Agreement and Limited Warranty Modl
49. for mounting bolts Three M8 or 5 16 inch user supplied bolts and washers are required Approximately plus and minus 10 degrees of horizontal angular movement is provided to aim the Sensor 46 Rev L4 12 2012 Modline 5 Sensor Installation Figure 35 BMA Accessory Material Nickel Plated Steel Weight Approximately 5 6 pounds 2 5 Kilograms Mounting and Assembly Supplied Parts List e No hardware is supplied with BMA UAA assembly hardware is supplied with the UAA e Three user supplied M8 or 5 16 mounting bolts and washers are required to mount the base of the bracket Bolt mount ARC 7 450 189 2 7 125 181 0 Figure 36 BMA Dimensions Modline 5 Rev L4 12 2012 47 Sensor Installation Dimensions are in inches and millimeters Do not scale Use 5 16 inch or M8 mounting Bolts 3 Places 3 9 8 ESA Extension Sleeve Adapter Description and Dimensions This is a special accessory for Sensors with the Dirty Window Detector DWD option The ESA serves as protection sleeve over the DWD optics and as the mechanical interface between the Sensor and other Modline 5 accessories The ESA is used in the following combinations to provide air purging or create a dead air space zone in front of the Sensor optics to help keep them clean The combinations also provide shielding from stray radiation emanating from high temperature targets The APA air purge shown in combinations one and two provides the best performanc
50. hr Cooling water temperature should be 32 C 90 F or lower Use the opening closest to the hottest point on the mounted Sensor assembly as the water inlet Typically this is the opening at the front of the assembly Use only cooling water compatible with Series 300 stainless steel When using water to cool a Sensor with the Dirty Window Detector DWD an ESA extension with either a MFL mounting flange or an APA air purge must be part of the assembly An APA air purge is highly recommended for all installations and must be used when viewing large targets over 1000 C 1832 F A typical water cooling installation for a Sensor is shown below APA purge air temperature should be 30 C 86 F or lower Air IN at 30 C 86 F Ambient Maximum is 200 C 400 F Water IN at 32 C 90 F Water OUT Add an ESA for Sensor with DWD Figure 33 Water Cooling Standard Sensor 3 9 6 2 WJA Air Cooling Requirements Adequate cooling air for a 105 C 220 F ambient is 4 SCFM 114 liters min Air temperature should be 30 C 86 F or lower When using air to cool a Sensor with the Dirty Window Detector DWD an APA air purge must be part of the assembly and the installation should reflect the drawing below Modline 5 Rev L4 12 2012 45 Sensor Installation Ambient Maximum is 105 C 220 F Air IN at 30 C 86 F Air OUT p APA Air IN APA Air Exit j ESA with APA Figure 34 Air Cooling Sensors
51. if initiated during warm up If this Alarm occurs repeat the Check 5 5 2 Series 56 Models Power On and Warm up Series 56 Models include a Self Calibration feature which is performed as part of the power on routine 5 5 3 Initial Rear Panel Display After the warm up period is over you should observe one or more of the Modline 5 Sensor responses described below on the TEMP display and at the outputs During initial setup because the Sensor is not adjusted for the process these initial displays are expected 1 Target Within Range If the Sensor is viewing a temperature within its range it will display a temperature value Equivalent analog signals will be supplied to any devices connected to the analog outputs e g recorder or remote indicator If initial setup has not been set to match operation to the process the displayed temperature and analog outputs will not be a true measurement of the target temperature 2 LOW HIGH Indication If the measured temperature is below or above the Sensor temperature range limits LOW or HIGH will be shown on the temperature display The Alarm Indicator does not light because these are normal conditions 3 INVALID An Invalid condition will be indicated any time the sensed infrared radiation is considered to be inadequate for two color Ratio Sensor measurement The word INV is indicated on the TEMP display If the Invalid Alarm ALM is set to On the Alarm Relay will be in alarm condition
52. in forms that are clearly specified Modline 5 Rev L4 12 2012 141 Applications Guide You may wish to read the IRCON publication Spectrum Reprint SR100 Product Temperature Solutions Temperature Errors Caused by Changes in Emissivity 8 4 2 Using Emissivity Thermocouple Test If your material is not listed in the table or if you want to verify the emissivity value being used you can test the emissivity of a target sample in the following lab setup 1 Embed a thermocouple 30 or 36 gauge wire recommended just under the surface to be viewed and heat the target to the desired temperature range Allow the temperature indication from the thermocouple to stabilize 2 Aim the thermometer sensor at the surface of the target sample close to where the thermocouple is installed Observe the temperature indication and adjust the Emissivity value setting so that this temperature indication matches the thermocouple reading The value of the setting is the target emissivity 8 4 3 Setting the Emissivity The Emissivity may be set at the Sensor Rear Panel using the HEAD Menu EMIS function or with the RS 485 EM Command An indirect method of setting the Emissivity is to use the MATCH function or RS 485 MT Command MATCH allows inputting a temperature value known to be the true target temperature The Sensor then automatically adjusts the Emissivity so that the temperature display indicates the same temperature Instructions for setup are
53. lines that will be tapped by the proposed solid state control should be examined for the presence severity and frequency of noise occurrences If found system plans should provide for the control of such noise 3 4 2 Selecting Devices to Provide Noise Immunity Installation planning is not complete without examination of the noise immunity characteristics of the system devices under consideration Results of tests to determine relative immunity to electrical noise may be required from the manufacturer Two such standardized tests are the ANSI C37 90a 1974 Surge Withstand Capability test and the NEMA ICS 1 1983 noise test referred to as The Showering Arc Test These are applied where direct connection of solid state control to other electromechanical control circuits is intended Circuits involving analog regulating systems or high speed logic are generally more sensitive to electrical noise therefore isolation and separation of these circuits is more critical Further information on electrical noise and evaluation of the severity of noise may be found in ANSI IEEE Publication No 518 1982 Where severe power line transients are anticipated or noted appropriate such as commercially available line filter isolation transformers or voltage limiting varistors should be considered All inductive components associated with the system should be examined for the need for noise suppression 3 4 3 Design of Wiring for Maximum Protection Once the ins
54. measurement is interrupted for 5 to 10 seconds during the check period After application of power a warm up time of approximately 5 to 15 minutes is required for the Sensor s infrared detector and or electronics The Sensor Rear Panel Alarm indicator will be lit and Error Code X104 Detector Cold displayed when the A atrow is depressed The instrument Check function should not be initiated until the Alarm indicator has turned off An Out of Alarm X102 may occur if initiated during warm up If a X102 Alarm occurs repeat the Check after warm up operate during Sensor Alarms X107 X106 X105 X104 X103 X101 See Section 5 12 lil On Sensors with firmware Versions 1 08 and higher the Cal Check function will not Out of Range Displays and Error Codes page 112 for error code explanations The Check should not be initiated when a single Alarm or multiple Alarms for Error Codes X103 Detector block too hot X104 Detector block too cold X105 Internal case temperature too high X106 Internal case temperature too low are active Navigate from TEMP display with 4 amp A Y to ENGR then use 1 amp AV to CHK Display Instructions Display and Limits CHK Press ENT to initiate Check Sensor cycles through 10 second check and then CAL returns to the TEMP display 5 6 5 HOUR Automatic System Check gt for 52 5G 5R models lil Refer to the instructions for your Model 96 Rev L4 12 2012 Modline 5 Operation The CHK an
55. protection and sighting window Swing safety clamp into position and tighten 4 94 125 4 5 75 146 1 LD Sensor Axis of Rotation Se eo ae a Also Optical Axis Through Holes for 5 16 Inch or M6 Bolts 3 Places WJA Mounting Axis Figure 52 Group 18 shown BMA WJA and MFL Dimensions are in inches and millimeters Do not scale See individual Accessory drawings Total Lengths Dimension shown with and without MFL Flange 58 Rev L4 12 2012 Modline 5 Sensor Installation 3 12 Other Accessories Sight Tube Window WJ 5 Water Cooling These other accessories are described in Product Bulletin PB 0070 Specification and mounting configuration changes are required for certain items when used with the Modline 5 Consult the IRCON factory for information about using these accessories with the Modline 5 Sensor Other Accessory Model Part Compatibility and main interface Requires MFL Flange to interface Requires MFL Flange to interface AP Q AP CF Consult Ircon Inc with application details MF 1 MF 2 Threaded collars for threaded 1 1 2 inch NPT sight tubes and 2 1 2 inch NPT sight tube Requires the MFL Flange to interface See note below PM 2 Pipe Mounts for use with STSC and STA Sight and Target Tubes Requires the MFL Flange to interface See note below STM Sight Tubes with Flange Surface Requires the MFL Flange to interface See note below Not compatible with Modline 5 Senso
56. ratio temperature measurement When the Invalid Alarm ALM function is set to ON this measurement condition becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear panel If INV is the only Alarm pressing the A pushbuttons will show no other Error Codes The above conditions may relate to improper installation or adjustment of Sensor Functions Avoid reflections from surrounding hot objects unresolved targets and obstructions in the Sensor s optical path True temperature measurement is dependent lil on correct setting of Emissivity or E Slope Use of Pick Picker or Track and Hold signal conditioning may be necessary to capture temperature signals because of process interferences The Rear Panel ALARM indicator signals an error as been detected Press Up Arrow A to view Error Codes Press Up Arrow A multiple times to view all simultaneous Error Codes 130 Rev L4 12 2012 Modline 5 Maintenance Error Codes for Sensor diagnostic information are summarized as follows X101 X102 X103 X104 X105 X106 X107 X108 X109 pINV Li Li Dirty Window Detection or attenuation alarm if using a 5R series with the Attenuation Alarm turned on Out of calibration Detector block too hot Detector block too cold Sensor internal Case temperature too high Sensor internal case temperature too low Sensor failure FAIL may be seen on the Sensor TEMP display Analog Output Current loop malfunction open c
57. return to TEMP display 5 6 9 VER Sensor Firmware Version The VER function reports the Sensors installed firmware version A four digit numerical value is displayed The version information is useful when discussing operation with factory personnel The firmware cannot be updated in the field Navigate from TEMP display with J amp A Wto ENGR then use J amp A Y to VER Display Instructions Display and Limits VER Press ENT to view Sensor Firmware Version Numerical Value Press ENT to return to TEMP display XX XX 5 6 10 iALM Selects Ratio Invalid Measurement Condition as an Alarm Selects the Ratio Unit Invalid Measurement Condition as an Alarm Alarm and Invalid Condition selection sets both the Error Codes and Invalid Measurement Conditions to operate the Alarm rely and ALARM word on the Sensor rear panel Invalid Measurement Conditions do not trigger the Alarm relay or the Alarm word with Error Code Alarms Only selected 100 Rev L4 12 2012 Modline 5 Operation Navigate from TEMP display with amp A Vto ENGR then use 1 amp AV to iALM Display Instructions Display and Limits ALM Press ENT to view Invalid Condition Alarm selection OFF or ON OFF Error Code Alarms only includes the optional Dirty Window Detector alarms ON Error Code Alarms and Invalid Condition INV and pINV activated as Alarms This function also turns on the Attenuation Alarm Use Up Down Arrows to select Press ENT to sav
58. same size or larger than AC power wires 18 AWG 1 mm is recommended A two pole power shutoff or safety switch should be incorporated within the main power line that powers the IRCON equipment This switch should be in close proximity to the operator The switch should be clearly marked as the power shutoff for the equipment A properly sized circuit breaker is required in the ac supply lines connecting power Modline 5 Rev L4 12 2012 65 Sensor Wirin to the Power Supply The two pole switch and all circuit breakers should comply with IEC 947 standard Switches and circuit breakers that carry the markings of TUV VDE or other European Agencies do meet the IEC 947 standard Observe all Local Electrical Codes related to connecting ac power and the grounding of electrical equipment 4 4 3 Connecting the AC Power and Ground Wires Use tinned stranded 18 AWG 1 mm wire for all AC power and ground connections Strip insulation from wires 1 4 inch 8 mm To access the power wiring and ground terminals carefully unscrew start each screw before removing any single screw the four captive screws that attach the aluminum bracket with the terminal strip and wiring label Remove the bracket away from the box Refer to illustration below Leave the Red and Red White wires found in the box disconnected at one end until the aluminum bracket is installed after power wiring is performed Wiring instructions will follow Captive
59. screw to assemble the MFL with the APA 5 mm hex key long arm air purge L style wrench 3 230670C60 M6 x 70 mm socket head cap screw to assemble the MFL to the UAA 5 mm hex key long arm and ESA extension sleeve Not for use with the WJA Use last item L style wrench below 3 230620C60 M6 x 20 mm socket head cap screw to assemble the MFL directly to 5 mm hex key long arm the WJA water jacket or the UAA adapter L style wrench 3 230665C60 M6 x 65 mm socket head cap screw to assemble the MFL to WJA 5 mm hex key long arm water jacket with ESA extension sleeve L style wrench Table 4 MFL Mounting and Assembly Supplied Parts List Remove Metal Cover Gasket to expose two Mounting Holes 3 Places 250 Groups of three trough Holes for attaching Modline 5 Accessories 6 35 7 Outside DIA 5 000 127 Gasket mount DIA 3 000 76 2 A m Hole DIA 1 500 38 1 f Mounting bolt circle Locating DIA 4 377 111 2 PINs 359 Back 2 Places HIPS 9 12 Modline 5 Accessories mount to this side Front 525 eae Other Accessory 15 9 interface side Figure 28 MFL Dimensions Modline 5 Rev L4 12 2012 41 Sensor Installation lil Dimensions are in inches and millimeters Do not scale 3 9 5 MFS Mounting Flange Small Description and Dimensions The MES is a scaled down version of the MFL flange with a smaller diameter bolt circle pattern This flange provides strength in mounting with a smaller profile Thi
60. set to R W operation to use the DPM as a programming interface The Sensor can be set to R O operation to use the DPM as Read Only Device R O operation allows the CHK function to initiate a System Check and RSET to perform a Manual Peak Picker Reset as described in this Section 9 9 4 2 ADDR Sets the Sensor Address The Unit Address is a one digit number or single letter code It ranges from a single numeric 0 to 9 and upper case A to Z The Address factory default setting is 0 zero It is recommended but not necessary that the address be set to 0 The DPM uses the wildcard address that all Sensors recognize 9 4 3 BRAT Baud Rate The Sensor Baud Rate must match that of the other RS 485 device The DPM uses 9600 Baud Four baud rates are supported by the Sensor 9600 19200 38400 and 57600 bits of information per second Set the Sensor Baud Rate to 9600 9 5 DPM Operation Introduction Investigate all alarms indicated by the Flashing ALM indicator Temperature readings on rear panel display at Analog Output or from RS 485 Communications may be lil inaccurate with Error Code X101 through X109 Alarms ALM indicator flashes only in Display Mode 166 Rev L4 12 2012 Modline 5 DPM Installation and Operation Flashing ALM indicates alarm F and C Units Overlay Installed by condition The ALM indicator User Backlight LEDs programmed flashes in Display Mode ON as default MAX and MIN temperatures availab
61. the 2 color ratio mode rk Response Time G og 5g gI Sets the Sensor Response Time Model 52 and 5G Sensors H gt H UG Value 00 0 equals 6 6 milliseconds H ge 62 UG Model 5R Sensors Minimum 01 seconds Model 56 Sensors Minimum 02 seconds 5 H Signal Conditioning Turns Peak Picker or Track and Hold Signal Conditioning on or off E E Sub Menu PSEL and its functions only appear if Peak Picker Signal Conditioning is selected G E A Peak Selector Parameters Yes provides entry into sub menu below Peak Picker Decay Rate in a oo 388 DE Sets the peak picker decay rate in F or C Zero 0 sets the unit degrees C or F F to never decay Press RST Key and F1 or F2 ar Caution Sensors with firmware versions less than 1 02 have simultaneously to quickly O OD 156 66 unit less degrees that range 0 00 to 300 00 for both F and C change value units See Section 5 10 1 D R Decay Rate Function page 108 for more information C SEE Manual Peak Picker Reset no Resets Peak Picker Operation YES FALSE Auto Peak Picker Reset Selects Peak Picker Auto Reset operation YES Peak Picker Reset Below 500 140p Sets the temperature above which Peak Picker action starts Appears if Auto Peak Picker with Auto Peak Picker Reset Function On Reset is On va Da a a D Fr pp dEl Peak Delay g og E 56 Sets the Delay Time in seconds before Peak Picker action starts after a Reset or from zero scale
62. the PAX Bulletin PAXCDS C supplied with the Quad Relay Card for Setpoint operation variations with different setups Refer to the PAXP Bulletin for Module 3 Setup in Section 6 3 Communication Protocol page 116 Module 3 Display and Program Lock out Parameters 3 LOC Do not change tot parameter Set the following seven parameters Hito LEE Then t to LOE Then 5P 1 to Eft Then 5P 2 to Eft Then 5P 3 to Eft Then 5P 4 to Eft Then load to 222 If using MAX or MIN temperature display 4 or 8 may require different setup Module 6 Setpoint Alarm Parameters 6 SPt Do not change parameters SP n HYS n tON n tOF n rST n Stb n Set the following four parameters SPSEL Then Ret to AB H Then aut to ner Then Lf to nar To Program Setpoint 2 SPSEL 2 Then Ret to RB H Then aut to ner Then LIF to nar Repeat setup above for Setpoints 3 and 4 Modline 5 Rev L4 12 2012 175 DPM Installation and Operation Setpoint temperature values are entered in the Quick Programming Mode Par key must be pressed to enter values This setup leaves all other parameters at the factory default values These parameters should be reviewed and changed to match the process requirements using the PAX bulletins Operation Setpoint temperature values are inputted in the Quick Programming Mode using the PAR Key to quickly access and change them Setpoint relay action occurs when displayed temperature is above the Setpoint value Setpoin
63. the left side of the Terminal Strip Plate Insert the 9 5 inches 241 3 mm long Red and Red White twisted pair through the ceramic ferrite core supplied with the plate Keep the exposed wire length between the shielded cable end and the ferrite core as short possible Maintain enough length to allow the core to be inserted into its mounting clip Bring the Red and Red White pair around the outside of the core as tight and as close to the core surface as possible Repeat until 2 wraps have been completed as shown Cut the pair to the required length for connection to the terminal strip Strip wire 3 8 inch 10 mm and tin with solder Route all twisted wire pairs to their corresponding terminals identified by wire color Insert the tinned wire ends of each color coded wire into its terminal and tighten The 100 Ohm 1 watt fusible resistor placed from the ground stud to power supply common is not shown in these illustrations Figure 66 72 Rev L4 12 2012 Modline 5 Sensor Wiring 4 9 Connecting Device Cables to POI Box or Terminal Strip Plate 4 9 1 Recommended Cable Types To maintain signal integrity and reduce noise pick up twisted pair shielded cables with overall foil and braid shielding should be used for connecting to all Sensor inputs and outputs Belden low capacitance computer cable types 9829 9830 9831 9832 9839 and 9833 or equivalent cables are recommended Each of these cables has a different number of wire pairs var
64. through 5 are classified as Authorized Engineering Information 11 15 1984 Solid State and electro mechanical controls can perform similar control functions but there are certain unique characteristics of solid state controls which must be understood In the application installation and maintenance of solid state control special consideration should be given to the characteristics described in 2 1 through 2 7 2 1 Ambient Temperature Care should be taken not to exceed the ambient temperature range specified by the manufacturer 2 2 Electrical Noise Performance of solid state controls can be affected by electrical noise In general complete systems are designed with a degree of noise immunity Noise immunity can be determined with tests such as described in 3 4 2 Manufacturer recommended installation practices for reducing the effect of noise should be followed 2 3 Off State Current Solid state controls generally exhibit a small amount of current flow when in the off state condition Precautions must be exercised to ensure proper circuit performance and personnel safety The value of this current is available from the manufacturer 178 Rev L4 12 2012 Modline 5 Appendix A 2 4 Polarity Incorrect polarity of applied voltages may damage solid state controls The correct polarity of solid state controls should be observed 2 5 Rate of Rise Voltage or Current DV DT or DI DT Solid state controls can be affected by rapid ch
65. to block reflection Cooled Shield ES 7 re Lens Viewing through furnace roof or wall Problem Sensor Lens sees reflections from hot Solution View through sight tube with tip spaced close to of furnace roof surface of workpiece Sensor Lens Sight Tube Sensor Lens Furnace Workpiece Cautions 1 I D of sight tube must be wider than Cone of Vision along entire length See Section 3 2 Sight tube walls may radiate infrared if furnace atmosphere is very hot May require cooled sight tube Consult IRCON for recommendations Figure 97 Solving Common Reflection Problems 8 9 Use of Mirrors In rare situations it may be difficult if not impossible to position the Sensor for a direct view of the desired target surface You may then find it necessary to view the target indirectly by means of a mirror Mirror material surface area and alignment are critical in this application In all cases the mirror must be a first surfaced front surfaced mirror and ideally it should be a perfect reflector at the operating wavelength of the Sensor A first surfaced flat aluminized or gold mirror may be used for all Sensor Series except Series 5R This type of mirror is readily available from optical supply houses For 5R Sensors the mirror must be a front surfaced gold coated mirror Aluminum coated mirrors show a small coloring effect in the Series 5R spectrum causing the instrument to read low This low reading error may be cor
66. to infinity 330 mm to infinity 10 4 to infinity 264 mm to infinity D 240 52 1410 5G 1007 6 to 12 152 mm to 305 mm 3 4 to 9 4 86 to 239 mm D 90 D 67 5G 52 2020 5G 1415 6 to 12 152 mm to 305 mm 3 4 to 9 4 86 to 239 mm D 180 D 135 5G 6 to 12 152 mm to 305 mm 3 4 to 9 4 86 to 239 mm 2 25 to 2 75 57 to 70 mm D 80 D 60 5G D 160 D 120 5G 121 infinity 305 mm to infinity 9 4 to infinity 239 mm to infinity 56 All Models 6B 6to12 152mmto305mm 3 4 to 9 4 86 to 239mm DI135 13 to infinity 330 mm to infinity 10 4 to infinity 264 mm to infinity 13 to infinity 330 mm to infinity 10 4 to infinity 264 mm to infinity 5R 1410 5R 1810 RB 7to14 178 mm to 355 mm 4 4 to 11 4 112 to 289 mm 1 5R 3015 RB 7to14 178mmto 355 mm 4 4 to 11 4 112 to 289 mm 2 25 to 2 75 57 to 70 mm 2 25 to 2 75 57 to 70 mm Table 1 Model and Lens Type Combinations with Focusing Ranges 3 4 4 Spot Size and Viewing Distance Viewing distance and spot size is demonstrated in the Distance and Spot Size illustration A Sensor with a Resolution Factor of F 100 is focused on a 0 5 inch 12 7 mm rod at three distances The drawings at the left for each example illustrate a large circle that represents the total area visible in the Sensor sight The smaller circle represents the reticle Modline 5 Rev L4 12 2012 2 Sensor Installation Resolution
67. to the Ircon parameter menus Setpoint value inputs and ability to access additional meter programming by entering Code 222 Quick Programming is illustrated below Full Programming is discussed in Section 9 13 DPM Sensor Diagnostic Functions page 174 9 8 2 Menu Navigation Programming pushbuttons are provided for programming and navigation Instructions are provided for selecting and adjusting menus and parameters in each of the operating sections that follow e Press DSP Display for the Temperature Display at any time e Continually pressing PAR sequences through all the menus and back to Temperature Display METE Parameter Selections Navigation Description and Information FEDR Entry to IRCON Parameter Signifies choice of Ircon Parameters Menus DPM Setpoint and Entry Code Menus with Menus ng F1A F27 F14 F2 W then PAR for Entry to HEAD OR F14 F2 then PAR for Entry to ENGR Entry to Setpoint Value F1 A F2W then PAR for Entry to AOUT ANALOG OUT settings and DPM Menus F1 A F2 W then PAR for Entry to DIAG DIAGNOSTICS with PAR Key OR Use PAR to select a Setpoint or Code or END Setpoint Values with F1 F2 Arrows Enter Setpoint 1 Value Enter Setpoint 2 Value Enter Setpoint 3 Value Enter Setpoint 4 Value Enter Code 222 to access meter set up programming menus Returns to Temperature Display DSP 9 9 DPM Temperature Display Mode e Press DSP Display for the Temperature Display at any time e Press PAR to go to Quick
68. tripod user designed mounting surface or the RAM Right Angle Mounting Bracket Figure 21 UAA Accessory Modline 5 Rev L4 12 2012 35 Sensor Installation Material Clear Anodized Aluminum Weight Approximately 1 Pound 0 5 kg aes S a 3 hex Head Screws and Flat mounting Surface washers supplied Align with other Asccessoiries K 1 750 44 5 28 6 Ya 20 threaded X 375 9 5 D deep 3 places Orientation Holes 2 places Insert Front of Sensor this Direction lt M8 X 30 mm Socket Head Cap Screw Supplied for clamping Sensor M6 X 25 mm deep threaded Holes for IRCON Accessories 3 Places Figure 22 UAA Dimensions lil Dimensions are in inches and millimeters Do not scale Qty Part No Description and use User Supplied Tools M8 X 30 mm socket head caps screw for sensor 6 mm hex key long arm L style wrench 1 230830060 clamping recommended ls Aaa Ya 20 x 5 8 inch 15 9 mm stainless steel hex 3 202520540 head bolt Adjustable wrench 222503200 Stainless steel split ring lock washer a 260600060 Black oxide flat washer LS Table 2 UAA Mounting and Assembly Supplied Parts List 3 9 2 RAM Right Angle Mount Description and Dimensions The RAM Right Angle Mount provides convenience strength and flexibility in mounting the Modline 5 Sensor The UAA universal adapter is required to attach the Sensor to the RAM Two holes and one slot on the upright side of the m
69. ure is out of causing high readings For Sensor Series 5R This is an Invalid Alarm display The process measurement Temperature Display is INV conditions are invalid The infrared energy reaching the Sensor is too low to provide reliable temperature measurement Note ALM must be set to ON for this Alarm condition to be displayed on Sensor rear panel and for the Alarm Relay to operate For Sensor Series 5R This is an Invalid Alarm with the Peak Picker On It is displayed if Alarm condition is pINV the infrared energy reaching the Sensor is too low to provide reliable temperature measurements Note ALM must be set to ON for this Alarm condition to be displayed on Sensor Displayed temperature readings are peaked values or hold values rear panel and the Alarm Relay operate from Peak Picker or Track and Hold signal conditioning 132 Rev L4 12 2012 Modline 5 Maintenance Status Display Error Code Details Error Code X101 Dirty front Sensor optics detected Clean Sensor front window and Dirty Window Detected mirror This will only be seen on Sensors with the Dirty Window Detector Option Error Code X102 Out of calibration M56 Calibration check has sensed Sensor out of calibration condition Do not Initiate a Calibration Check during Note An out of calibration error may be encountered if the Sensor warm up See Section 5 5 Warm up and temperature is too high or too low Do not calibrate when an Initial Setup page 93 for M
70. value if desired The MATCH function will not operate during Sensor Alarms X107 X106 X105 X104 X103 X101 or a CAL CHK See Section 5 12 Out of Range Displays and Error Codes page 112 for error code explanations 5 9 8 SIGL Signal Conditioning Selection The Modline 5 Sensor can provide Peak Picking or Track and Hold Signal Conditioning The SIGL function sets the signal condition to Peak Picker Track and Hold or Off Peak Picker signal conditioning is used to obtain the peak measured temperature value and ignore momentary decreases in measured temperature This eliminates erratic measurements due to gaps in work pieces bursts of smoke or steam or other intermittent interferences in the sight path of the Sensor Signal conditioning affects all displays and outputs Track and Hold signal conditioning is used to track process temperature when required and then hold the temperature measurement at some point in time as determined by the process requirements This eliminates erratic measurements due to process measurement delays or other undesired measurement periods Peak Picker and the Track and Hold signal conditioning functions are explained in Section 8 Applications Guide page 137 Peak Picker PSEL Functions Peak Picker Signal Conditioning selection activates the PSEL Peak Function menu This menu is used to adjust Peak Picker functions necessary for obtaining the peak measured temperature value These functions must be a
71. view a different Function Functions are displayed for 15 seconds before returning to the TEMP display if no further selection or adjustment is made The main menu functions are shown below Some functions are model specific and only appear for those models ENGR Engineering Functions LOCK Panel Access Security Setup VER Sensor Firmware Version MODL Model Number Scrolling RELY Alarm Relay Operation Setup F C F and C Selection CHK Initiate System Check HOUR Automatic System Check Setup WRNL Optional Dirty Window Detector Setup iALM Sets Ratio Sensor Invalid Condition as Alarm AOUT Analog Signal Output Selection and Scaling SOUT Select Analog Output Current Range ZERO Set Analog Zero Scale Temperature FULL Set Analog Full Scale Temperature Fatl Set Output Current for Sensor or DWD Error A LO Set Alarm Current Output for Temperature Below ZERO A HI Set Alarm Current Output for Temperature Above FULL COMM RS485 Digital Communications CLCK Communications Lock Read Only or Read and Write Setup LASR Select Laser Sight Activation Mode ADDR Set Sensor Address BRAT Set Baud Rate HEAD Sensor Operating Functions EMIS Set Emissivity for Brightness or 1 Color Sensor E SL Set E Slope for 2 Color Ratio Sensor R T Set Response Time SIGL Signal Conditioning Peak Picker or Track Hold PSEL Peak Picker Sub Function Settings COLR Set Ratio Unit for 2 Color or 1 Colo
72. with DWD 3 9 6 3 Sensor Temperature Alarm The Modline 5 Sensor provides Alarms when the Sensor s internal temperature exceeds its allowed limit Error Code X105 signifies the outside influences have caused the internal temperature to rise above its limit Error Code X103 signifies outside influences have caused the detector to rise above its limit If these alarms are triggered check the installation for proper flow of air or water Higher than rated ambient temperature can also be the cause Other possible causes of overheating include radiant and conductive transfer of heat Insulation shielding and thermal isolation may be necessary See Section 8 Applications Guide page 137 for more information 3 9 7 BMA Base Mount Accessory Description and Dimensions This trunion style U mounting bracket is used as a base mount for the WJA Water Jacket Accessory Trunions pivoting shafts on the sides of the WJA are placed into the matching BMA mounting slots The WJA is held in a vertical position with the Sensor side down and placed into the slots The BMA and WJA final assembly can be mounted in any position Vertical angular movement of the WJA and Sensor is provided by the pivoting shafts The BMA mounting slots gimbals are shaped to keep the shaft in place and provide secure mounting Two bolts and two washers are supplied with the WJA to lock it in the final position The BMA base mount surface has one clearance hole and two radial slots
73. with the Sensor Analog current input for remote adjustment of Emissivity or E Slope Sensor diagnostic Alarm relay contacts are brought out on the interconnecting cable 2 2 2 Optional Sensor Features The Dirty Window Detector and Laser Sight are optional features that can be ordered when the Sensor is purchased i These options are not field upgradeable 14 Rev L4 12 2012 Modline 5 Product Description 2 3 Model Configuration and Required Selections 2 3 1 Model Configuration The Modline 5 Model number contains seven alphanumeric characters The first two designate the Sensor Series The Series defines the type of Sensor brightness or ratio and the operating wavelength The next four digits define the Sensor s temperature range and optical resolution with the standard lens installed Selection of sight Visible through the lens or optional Laser aiming is next Permanent factory installation is required Each is exclusive of the other The Dirty Window Detector Option DWD is the next required selection Permanent factory installation is required The product is covered by Patent Number 5812270 when the Dirty Window Option is installed A Sensor can also be ordered to be used a Transfer Standard to calibrate other Modline 5 Sensors ModView Calibration Software and an expanded Calibration Certificate is supplied with this Sensor Model A lens selection is required Lens types for each Sensor must be specified Lenses ar
74. 0 Rev L4 12 2012 Modline 5 Sensor Installation temperature range and the target temperature The signal reduction tolerated is less in the bottom portion of the range The Sensor will indicate invalid when the measurement is not possible 3 5 5 Summary The spot size and target size relationship is not as critical for Series 5R Sensors which use the two color ratio method Avoid emitted radiation from objects in the same field of view cone of vision either in the foreground or behind the target that are at temperatures hotter than the target Reflected or emitted radiation from these interferences can cause measurement errors Significantly cooler objects well below the target temperature will not cause measurable errors For best results brightness sensors that measure radiation intensity at a single wavelength should be installed so the target area is larger than the instrument spot size If possible adhere to the target size is twice the spot size rule for all types of instruments 3 6 Sensor Installation Planning Mechanical Installation of the Modline 5 Sensor requires determining sighting and focusing requirements locations for installing Sensors accessories and cable routing Planning also includes evaluating environmental conditions that may cause contamination of the Sensor optics or overheating of the Sensor or other Modline 5 components Re location of the installation or air purging and water cooling accessories may be requir
75. 012 83 Sensor Wiring 4 12 3 TSP Terminal Strip Plates Multi drop Wiring These illustrations indicate the proper wiring when using TSP Terminal Strip Plates A power supply for each Sensor and TSP pair is shown in the first illustration This is the preferred method A single power supply is shown powering three Sensors in the second illustration A power supply should not power more than 2 or 3 Sensors Use the shielded cable specified in the previous manual sections and install termination resistors as required To Moding 5 Sensor To Modling 5 Sensor TSP TSP a VDC RS 485 RS 485 Power Supply Modline 5 MSI Multi Sensor Interface Ground 24 VDC or PLC PC System TX A TX B 4 Power Supply 24 VDC Figure 78 Multidrop Sensor Wiring with 24 VDC Supply for each Sensor To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor TSP ermination Resistor at furthest Box O Power Supply Modline 5 MSI Multi Sensor Interface 24 VDC or PLC PC other System Figure 79 Three Sensor RS 485 Multi drop with 24 VDC Supply and TSP Terminal Strip Plates 84 Rev L4 12 2012 Modline 5 Sensor Wiring 4 13 Sensor and Cable Connection 4 13 1 Cable Plug and Sensor Receptacle Position the red dot on the interconnecting cable plug on connector to match the red dot on the Sensor housing receptacle Push the connector firmly and completely in to the Sensor receptacle The cable plug and Sensor recepta
76. 0E should be followed Modline 5 Rev L4 12 2012 185 Appendix B 11 Appendix B DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING IRCON MODLINE 5 SERIES PRODUCT AND ACCESSORIES Following are the disassembly instructions for the IRCON Modline 5 Series product including all optional accessories in accordance to guidelines of the European Union Waste Electric and Electronic Equipment WEEE Directive 2002 96 EC This product includes the following materials to be dispensed of properly Aluminum POI box casing WJ 5 water jacket various accessories Steel Sensor and Lens Housings various screws and connectors Plastic Various components within sensor DWD unit and POI box cable coating Printed Circuit Board Circuitry within sensor and DWD unit Silicone Cable coating Rubber Gaskets Fully Assembled View Below is a photograph of a fully assembled Ircon Modline 5 series sensor Disassembly instructions for this product series are shown on the following pages These instructions account for all Modline 5 models and often used accessories as the variation between models affecting recycling is minimal POI Box HE Modline 5 Sensor with DWD Dirty Window Detector Option Modline 5 Sensor with Standard Lense Figure 107 Fully Assembled View 186 Rev L4 12 2012 Modline 5 Appendix B DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING IRCON MODLINE 5 SERIES PRODUCT AND ACCESSORIES SY ae Aluminum Figur
77. 10 specific points on the temperature scale of the instrument A NIST certificate of calibration is furnished with the instrument With the transfer standard you also get the Modview calibration software You aim the transfer standard at the black body and read and record the temperature that is indicated on the transfer standard By using the transfer standard you eliminate any potential errors that may have occurred in the black body such as a defective thermocouple or an inaccurate cavity Next you take the instrument to be calibrated and aim it at the black body and with the software install the corrected calibration temperature Again it is a one point calibration but you can check as many points as you want to insure the best accuracy 7 5 Measurement Condition Displays Error Codes and Troubleshooting The Modline 5 displays word messages on its rear panel display to indicate Sensor diagnostic results Below are explanations of the reported measurement status and error codes Measurement status displays for Out of Range and Invalid measurement conditions are defined as follows LOW Conditions do not allow measurement because the infrared temperature signal is too low The target temperature is too low for the range of the Sensor HIGH Conditions do not allow measurement because the infrared temperature signal is too high The target temperature is too high for the range of the Sensor INV Measurement Conditions are invalid for two color
78. 100 DOLE AL TN Selec Ad enua cion Alarm IPS OLA tii di 101 5 7 AOUT Setup of Analog Signal Output Current Range and Temperature Scalid8 oooonnnnnnnnnononnnnnnnnos 101 5 7 1 Fatl Analog Output Operation for Sensor or Dirty Window Detector Malfunction Alarms 102 91 2 A LO A alos Output Low Temperature AI ii iaa 102 5 7 3 A HI Analog Output High Temperature Alarm id ino 103 5 8 COMM Setup of RS 485 Digital Communication Configuration 0ocococcccononanananononononononononnnnnnnnnnnnnnnnnnnos 103 DIO A CUCK COMU MON ONS LOCK a E EA 103 IL ADDR 9018 TNC SENSOL AAAI CSS ai e i A A O E T 104 EI BRAT DOUG RUO A A E EE AAA OTN ET 104 5 8 4 LASR Laser Operation Sensor Firmware Versions 1 08 and Higher onnoonncnicanicanincananonancnnaraneso 104 5 9 HEAD Setup of Sensor Operating Functions oooooonooooooooooonnnnonnnnnnnononnnnnnnnnnnnnn nono nono nono nn non nro nono nn nnnnnoss 104 E T REPONSE TINE ere O A E A 104 SIZ COLR Rao Unit Operation Se ON EE E E 105 5 9 3 E SL Ratio Unit Two Color Operation E Slope Adjustment aaa 105 Did RENO Es o OPE CUITEML DUE ida 106 5 9 5 EMIS Emissivity Adjustment for Brightness Sensors its 106 TLOREM EIMISGIOILY EUT TAPU onr S da 106 5 9 7 MTCH E Slope or Emissivity Selection Based on Temperature Match oooconoccccnccnananannnanncnnononos 106 IRO SIG ESS OA CONA ONULE SCLC TION Setren A E N E E 107 5 10 PSEL Peak Picker PUNCUONS sinea aaa a tos 108 AO
79. 492 SD RAXOS rendida 163 9 2 9 Quad Relay Card Part Numb PAC S20 abia 164 9 24 Panel TAS TANATORIOS A A A A 164 D2 SCNSON RANC ONC TONS A Must woauabtsana teeta tuuacaeaieuesanenebtacped er estueb A Naaanteviasmeeat 164 LAS PO Wer WITT A A A E 165 D2 dk CHICA PROCESS SALLY CUCA A 165 DS Modine LAS Sight A al 165 ARS AS COMMUNICATOR teca ela iass 166 OA ACC R Communica ONS LOC ai A AA 166 912 ADDR Set Te SCN SOT Add CSS noire ioa al scr E E T E TOO uate chactuch tetsu 166 DAS DIAL DOUG RUO aE E O E E O E ShidiuGe tests 166 2d DEN Operation SANT OGUCHON iia E a 166 9 6 Display and Programming Flow Diagram ccccccccceeesesseseeeeseeseeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 167 2 Sensor setup with tas DP Moni a ia italia 168 9 8 DPM Quick Programming Mode ooooonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 169 DSi d DUCK TOC FAINT adios 169 FiO MENU IN ADICON 169 9 91PM Temperature Display aMSN is 169 OO En me cana MEA ii 171 O Sensor Setup Head MEN ia ads 172 9 12 Sensor Setup Analog Output FUNC IONS nemiri e EEA EE A EAEE EEA 173 9 13 DPM Sensor Diagnostic Functions escremir actuate E OA E E A O E 174 Ola ull Proeraiamina Modus ta 175 FTE LEUE TO OV AIS dto 175 9 14 2 Quad Relay Card Setpoint Baste Setup and OperatiOT rana ltd 175 9 14 3 MAX and MIN Temperature Display Basic Setup and Operation coniccnccnnnnnananonenanonanannnanananinns 176 ALODE BACK OIE AAA AAA T 177 OAS Facto Detali RCS
80. 5 Operation page 90 Protect the Sensor interconnecting cable plug pins from liquids and dirt if disconnected from the Sensor Clean the front surface of the lens or wndow and mirror as often as necessary The frequency of the lens cleaning will depend on the environment at the point of installation Air purging will reduce the necessity of frequent cleaning in dusty dirty areas Modline 5 Rev L4 12 2012 127 Maintenance Treat the Modline 5 Sensor optics with care A Scratches or harmful solvents can destroy the lens or the Dirty Window Detector window and mirror Lenses may be slightly soluble in water and other liquids Do not soak any lens in water or any other liquid for long periods of time Sensor with DWD Mirror and Window Standard Sensor Lens Figure 85 Sensor optics 7 2 1 Cleaning the Optics Clean the front surface of the Standard lens or Sensor with DWD window and mirror as often as necessary Use a soft dry cotton cloth or swab moistened with laboratory grade isopropyl alcohol Wipe gently to remove residue Inspect and re wipe as necessary to remove any film 7 2 2 Restoring the Sensor to Operation Always re install the Sensor in its original position Always verify focusing as instructed in section 3 Sensor Installation page 22 Lock the lens by tightening the lens locking screw on the bottom of the unit with your fingers and thumb Never use a tool Place the rear protection window on the back of t
81. 52 5G and 5R Alarms for error codes X103 X104 X105 X106 exist models Caution Any temperature readings at Analog Output or from RS 485 Communications must be considered inaccurate Check Sensor Calibration on a Blackbody Standard Error Code X103 Detector block too hot Detector Temperature is too high Check ambient temperature 55 C maximum and Sensor internal case temperature using the RS485 RC Command or with a temperature measuring device such as a fine thermocouple If these temperatures are okay and alarm continues Sensor may have a malfunction Caution Any temperature readings on rear panel display at Analog Output or from RS 485 Communications may be inaccurate Error Code X104 Detector block too cold Detector Temperature is too low Note This Error Code is normal during Check ambient temperature 0 C minimum and Sensor internal sensor warm up Warm up typically lasts case temperature using the RS485 RC Command or with a from just a few minutes to 15 minutes temperature measuring device such as a thermocouple lf these temperatures are okay and alarm continue check the 24VDC supply voltage Sensor may have a long warm up time if the voltage not within 5 lf the power supply is remotely installed insure the voltage drop across power supply wires is not causing a low voltage level at the sensor Caution Any temperature readings on rear panel display at Analog Output or from RS 485 Communications may be in
82. 744 840016 Temperature too high above Sensor range TO Temperature Only Read Only Sensor firmware Versions 1 07 and higher Returns the temperature the unit is reading in the current units An F or C is put on the end as appropriate The temperature resolution is 1 F or C Message Value Range This command only reports values that are within the Sensors temperature range Actual reported values are from approximately three degrees below the low end of the Sensor temperature range to approximately three degrees above the high end of the Sensor temperature range Values below zero scale or above full scale are not accurate and should not be used There are no special readings to indicate that the temperature is out of range too high or too low or invalid Use the ST Status command to sense the temperature TO Value is under range below the sensor zero scale temperature or the TO value is over range above the full scale temperature or Invalid for ratio measurements SG Signal Conditioning Usage Read Only Turns Peak Picker or Track and Hold on and off Only one can be turned on at time Range 0 to 2 Message Values 0 Peak picker and track amp hold are both off 1 Peak picker on 2 Track amp Hold on PR Peak Picker Reset Write Only This function is used to reset the Peak Picker It is a write only command and no value is given By sending the PR Command with or without a message value a Peak Picker reset is per
83. ATION GUIDELINES 4 1 Installation Proper installation and field wiring practices are of prime importance to the application of solid state controls Proper wiring practice will minimize the influence of electrical noise which may cause malfunction of equipment Users and installers should be familiar with installation and wiring instructions in addition to requirements of all applicable codes laws and standards The manufacturer of the device or component in question should be consulted whenever conditions arise that are not covered by the manufacturer s instructions Electrical noise is a very important consideration in any installation of solid state control While wiring practices may vary from situation to situation the following are basic to minimizing electrical noise 182 Rev L4 12 2012 Modline 5 Appendix A a Sufficient physical separation should be maintained between electrical noise sources and sensitive equipment to assure that the noise will not cause malfunctioning or un intended actuation of the control b Physical separation should be maintained between sensitive signal wires and electrical power and control conductors This separation can be accomplished by conduits wiring trays or as otherwise recommended by the manufacturer c Twisted pair wiring should be used in critical signal circuits and noise producing circuits to minimize magnetic interference d Shielded wire should be used to reduce the magnitu
84. Box and Terminal Strip Plate The ambient temperature at the mounting locations for the Sensor POI Power Supply Signal Termination Box and The Terminal Strip Plate must be between 0 and 55 C 32 and 130 F If the ambient temperature at the mounting location is beyond these limits precautions must be taken to protect the Sensor A WJA Water and Air Cooling Jacket is available for protection against excessive temperatures Use of insulation and reflective shielding for additional protection from Modline 5 Rev L4 12 2012 31 Sensor Installation extreme ambient temperatures and radiated heat are described in Section 8 Applications Guide page 137 The POI Power Supply Signal Termination Box and The Terminal Strip Plate must be re located to a location that the ambient temperature is between 0 and 55 C 32 and 130 F Lens Protection Be sure the lens is protected from contamination and is accessible for maintenance If dust oil vapors etc collect on the lens low temperature indications will result Use an APA Air Purge Accessory to maintain a clean lens Consider use of a Sensor with the Dirty window if errors caused by lens contamination can seriously affect the process Focal Limits To permit focusing the target distance must be within the focal range of the objective lens Ranges for the Modline 5 objective lenses are given in Section 3 4 Sensor Optical Characteristics page 26 Range limitations for close focus lenses
85. Cone of Vision and Spot Size Formula The diameter of the cone at any point will determine the area of measurement at that point Any part of the target or other intervening object positioned within the cone will be imaged on the detector Anything seen by the detector will become part of the measurement When the Sensor is sighted on an object you are aiming or positioning the cone of vision on the object When you focus you are adjusting the optical system elements so the focal point is at the surface of the object The measurement area as seen by the detector will then be outlined in the reticle The reticle only defines the measured area spot size in the focused condition The formula d D F defines the spot size at the focal point Simply divide the Working Distance D measured from the front of the Sensor to target by the Resolution Factor F to determine the Spot Size d Resolution factors for Sensor Model and Lens combinations are provided in the table on the following page The focusing range for each lens type is also provided in the table The focusing range defines the allowable range for the Working Distance For Sensors with the Dirty Window Detector Option the Working Distance D is calculated by measuring the distance from the front tip of the protruding hood to the target and then adding 2 6 inches 66 mm 3 4 2 Lens Focusing Ranges and Optical Resolution Factor The table below lists Lens Type and Focusing Ra
86. ESA 2 DWD is Dirty Window Detector Option See ESA on previous page for more information Also see Sections 3 8 DWD Installation Requirements and 3 9 6 WJA Water Jacket Accessory Description and Dimensions Group Mounting Option Required Accessories Notes 1 N R Group Not Recommended for Sensors with DWD 2 USE the ESA and APA air purge with clean air for air purging and stray radiation shielding Use APA without air to create a dead air space zone and shielding The use of an APA is required for large targets over 1000 C 3 The ESA with MFL provides dead air space and stray radiation shielding Add an AA 3 air purge accessory for air purging See Section 3 12 Other Accessories Sight Tube Window WJ 5 Water Cooling page 59 for AA 3 information These combinations not recommended for large targets over 1000 C 4 The ESA adds 1 82 46 2 mm to length of the assembled group 5 Use water for cooling only Do not use air for cooling with DWD unless the APA air purge accessory is used See information in Section 3 9 6 WJA Water Jacket Accessory Description and Dimensions Table 7 3 10 1 Recommended Accessory Groupings 50 Rev L4 12 2012 Modline 5 Sensor Installation Accessory Illustrations for Groups using UAA E SA MFL Front of Sensor ES lt MFL E en MFL Front of Sensor Figure 40 Sensor with DWD UAA Accessory Groups 2 3 4 5 6 7 8 9 10 Modline 5 Rev L4 12 2012 51
87. L DIR Deca Rare AAA RE A A a AR 108 5 10 2 RSET Manual Peak Picker NES iii ie 108 5 10 3 External Switch For Remote Peak Picker Reset was xcccsvavetsiosassaaadenioiavesnnssadusnrvenvonuss cheaouiweaneaiaadeuataes 108 LOA AUTO A Lenceria lia 109 00 IR BE b RSet Bele Lempa cock E dealt ates ieyeeices 109 DLO sO DE a Peg Picker DT AA AAA AA AAA AAA AAA 109 Dl ase Si AIN O sealescacrecatccnteis nacaccantantetenmmaecead aneutennen Aaudeuteasouanieeredereibeentunententeeaieecanewtedt 110 5 12 Outor Range Displays and Error C 0G6S ao 112 TEPA o 1d 11411 E RO PEDO O 114 6DIGITAE COMMUNICATION Susanita 114 6 1 RS 485 Digital Communications ss 114 CELIOT ION EE T E E E E 114 IE E O O E bts A T 114 6 2 Sensor Rear Panel Setup for RS 485 Communication occcccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninininss 115 AR ii LOCK ex iets ate erst olik oe sean asian ete eu setiaels boo tes ila eee and ba Sa eetton 115 6 22 ADDR Sets Ie SENSO ADO TESSA A A ccd enigma 115 CL RAT DAA AO sdaadanwecsceactaacestedbeeacwaten sdueturence a 115 6 3 Communication Proloco saaren ito elle tores eli tit 116 OC A MA as stata ea acs N 116 64 Command COS A A dd 116 OAT E A stra dtoctianudad aa a a a cactadanttenttdateantateecusetde lt dactadcettentedstsacGedcntenebansencttdt 116 6 5 Engineering Function Command Codes di 117 6 6 Analog Output Function Command Codes sinaloa 120 6 7 Head Funcion Command Ode aa 121 6 8 Measurement Condition and Alarm
88. M Menu LASR Mode Selection PANL Operation IN Remote Current Input Operation SWIT Remote Pk Hd Switch Operation Sensor Rear Panel LASER Switch Energizes and turns Laser Off Can de energize Laser anytime Can Energize Laser Condition Set One applies Can de energize Laser anytime Can Energize Laser Condition Set Two applies RS 485 LS Command ModView DPM MSI Energizes and turns Laser Off Can de energize Laser anytime Can Energize Laser Condition Set One applies Can de energize Laser anytime Can Energize Laser Condition Set Two applies Peak Hold Switch Remote SPST Switch Required Not Enabled for Laser Operation Not Enabled for Laser Operation in IN mode PkHd Switch operates Laser Condition Set Two applies Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or other devices using RS 485 Communications or a remote switch insure there are no Display and Limits LED above LASER Button Lights IN Current Input Remote SPST Switch Required Not Enabled for Laser Operation 15 mADC input current Switch Closed energizes Laser Current disconnected Switch open de energizes laser Condition Set One applies Not Enabled for Laser Operation in SWIT mode Laser 1 IN Operation When Laser I operational The required SPST switch can be an actual toggle or a press and hold type switch tha
89. Modline 5 Series 52 56 5G and 5R Sensors Infrared Thermometer Operating Instructions IRCON A Fluke Company Rev L4 12 2012 60401 Contacts Worldwide Headquarters Santa Cruz CA USA Tel 1 800 227 8074 USA and Canada only 1 831 458 3900 Fax 1 831 458 1239 info ircon com European Headquarters Berlin Germany Tel 49 30 4 78 00 80 ircon ircon eu Fluke Service Center Beijing China Tel 86 10 6438 691 Tel 86 10 4008103435 Service info ircon com cn Internet http www ircon com A Word About Ircon The IRCON quality system is certified to International Quality Standard ISO 9001 model for quality assurance in design development production installation and servicing IRCON has committed to providing quality products and services that meet customers needs and provide total customer satisfaction Ircon Inc Ircon the Ircon Logo and Modline are registered trademarks of Ircon Inc All rights reserved Specifications subject to change without notice Voltage Directive 2006 95 EC Safety Requirements for Electrical Equipment for Regarding European Electromagnetic Compatibility Directive 2004 108 EC and Low Measurement Control and Laboratory use this device carries the CE mark The Modline 5 Sensor POI Box and TSP terminal strip plate have been tested to and meet the following standards EN 61326 1 2006 Immunity Test Requirements in Industrial Loca
90. Picker mode again after a manual reset 5 10 3 External Switch For Remote Peak Picker Reset The Modline 5 has provisions for a remote process controlled input switch to be wired to the Violet and Violet White twisted wire pair of the Sensor s interconnecting cable If Peak Picker signal conditioning is selected the remote switch can enable or disable the Peaking action With no switch 108 Rev L4 12 2012 Modline 5 Operation or the switch maintained in the open position Peaking action is enabled With the switch closed peaking action is disabled and the Sensor continuously indicates actual temperature variations as they occur A momentary closure of the switch resets the Peak Picker function to the current temperature reading The peaking action begins again when the switch returns to the open position Wiring and switch operation for the Peak Picker are described in Section 4 Sensor Wiring page 62 5 10 4 AUTO Auto Peak Picker Reset With Peak Picker On the Auto Peak Picker Reset function will cause a Reset when the measured temperature matches or is below the selected Reset Below temperature As long as the measured and displayed temperature remains below the selected temperature the Peak Picker remains in reset condition and the Sensor continuously measures and indicates temperature without any peaking picking action This function is affected by the Response Time function It is possible for a long response time to delay
91. Programming Model Modline 5 Rev L4 12 2012 169 DPM Installation and Operation METE Description Selections Navigation and Information Errar No Sensor Communication Insure Sensor Baud Rate BRAT Set to 9600 Note Quad Relays not held Insure Sensor cable attached at both ends and powered LEF P Valid temperature reading Numeric Reading Valid Temp or special displays for Sensor Failure Sensor and Measurement Invalid Reading INV 1 condition Temperature Above Sensor Range Temperature Below Sensor Range Calibration in Progress Quad Relays Held in Last State 170 Rev L4 12 2012 Modline 5 DPM Installation and Operation 9 10 Engineering Menu e Press DSP Display for the Temperature Display at any time e Continually pressing PAR sequences through all the menus and back to ACOA N Menu entry start point EGR Menu Use Par to read next Parameter Press PAR again to go next parameter without changing the value To Change a Value or Selection use F1 A F2 Y then Press PAR to enter and save DEW Parameter Selections Navigation Description Sensor Rear Panel Keyboard Lock Locks Sensor rear panel Keyboard Parameters can be viewed at Sensor but not changed LOCK THE KEYBOARD IF THE DPM IS THE ONLY INTERFACE THAT WILL SETUP SENSOR FINAS Sensor Model Sr 4 0505 Eight Characters Read Only A SR Model example shown F r Measurement Units Selection YES R CJ Fq Selects un
92. Reset Contact closure greater than 08 second Track and Hold Tracking Mode is elected with external contact closure Power Requirements 24 VDC 5 8 Watts Maximum Operating Ambient Temperature Sensor Series 52 56 5R and 5G 0 to 55 C F 32 to 130 With WJA Accessory Air Cooling 0 to 105 C 32 to 220 F With WJA Accessory Water Cooling 0 to 200 C 32 to 400 F Sensor Environmental Sensor Housing NEMA 4 IP65 Sensor Cable Plug and Housing Connector NEMA 4 IP65 Humidity 10 to 90 non condensing Sensor Dimensions See dimensional drawings in Section 3 Sensor Installation page 22 of this manual Weight 4 lbs 1 8 kg approximate Model and option dependent Laser Sight Option Laser Class II Less than 1 mw at 635 nm Shock IEC 68 2 27 Vibration IEC 68 2 6 See the first manual pages for CE information for Modline 5 Sensor and POI Box 2 8 2 Accessory Specifications POI Power Supply Signal Interface Box Ambient Temperature 0 to 55 C 32 to 130 F Environmental NEMA 4 IP65 Power Requirements 100 to 240VAC 50 60 HZ 40 VA DPM Digital Panel Meter Ambient Temperature 0 to 50 C 32 to 122 F Environmental NEMA 4X IP65 Sealed Front Bezel Power Requirements 85 to 250 VAC 50 60 HZ 15VA Terminal Strip Plate Ambient Temperature 0 to 55 C 32 to 130 F Sensor Standard Teflon Interconnecting Cable Maximum temperature 200 C 392 F 20 Rev L4 12 2012 Modline 5 Product Description Maximum
93. Scale 20 6 0 100 Minimum Sensor Temperature 10 F or 10 C to Maximum Sensor mA equivalent temperature Temperature Minimum Zero to Full range must be 10 degrees Example Shown for a 600 to 1400 F Range See note below about F and C conversions FREL Analog Output during Fatal Q 0 24 8 Analog Current Output for Sensor Alarm Condition Alarm R 18 Analog Output Low a 8 48 Analog Current Output for below Zero Temperature Condition Temperature Will not appear for 0 20 mA output range Analog Output High ef D 24 0 Analog Current Output for above Full Scale Temperature Condition Temperature ETE and FULL adjustments are limited to a 10 F or 10 C when using the DPM Sensors with firmware Versions 1 3 can have C units spans less than 10 because the Sensor first calculates in F and then converts to C The equivalent C span is allowed but must be set at the Sensor Spans more than 30 C 60 F may be required to obtain acceptable results Longer response times may be necessary for very narrow spans to smooth magnified temperature variations and noise Modline 5 Rev L4 12 2012 173 DPM Installation and Operation 9 13 DPM Sensor Diagnostic Functions e Press DSP Display for the Temperature Display at any time e Continually pressing PAR sequences through all the menus and back to ALOR NO Menu entry start point d RB Menu Use Par to read next Parameter Press PAR again to go next parameter without changing the v
94. Screws four places AC L AC N FG Grommet Figure 59 AC Power Wiring Detail Connect the LINE and NEUTRAL wires of the AC power line to the Power Supply module inside the POI Box Observe the polarity of these connections LINE to AC L and NEUTRAL to AC N as indicated on the power supply module The Power supply module FG connection is pre wired at the factory Do not remove this wire You must provide an Earth Ground by connecting a ground wire to the threaded grounding stud in the POI Box exactly as shown in the Ground Wire Detail Drawing and Photo illustration shown below in Figure 60 Disassemble the ground stud assembly double crimp the earth ground wire to Item 5 Reassemble the stud assembly exactly as shown below Make sure all hardware is tightly fastened in each step of the reassembly 66 Rev L4 12 2012 Modline 5 Sensor Wiring All parts supplied assembled in box Figure 60 Item 1 Threaded Ground Stud M4 X 0 7 Item 2 Quantity 3 Hex Nut M4 X 0 7 Item 3 Quantity 3 Washer M4 External Star Item 4 Terminal Number 8 Ring 16 22 AWG 0 35 1 5 mm with internal 18 AWG 1 mm stranded Green Yellow wire attached Item 5 Terminal Lug Number 8 Ring LUG 16 22 AWG 0 35 1 5 mm 2 HR om q 2 REF Ground Wire 078 Figure 60 Ground Wire Detail Figure 61 Earth Ground Connection A qualified electrician should inspect the AC wiring and Ground connections The com
95. Sight DWD Installed This unit is not Focusing Range D 100 a Transfer 13 inches to Standard infinity D 100 The Model Number explanation information provided above defines a Modline 5 Sensor having the following characteristics and features e Model 5R 1410 is a Series 5R Ratio Type Sensor with the temperature range of 600 to 1400 C 1112 to 2552 F and D 100 Resolution e The Sensor Sight is Laser through the lens Visible sighting was not selected e The Dirty Window Detector Option DWD is installed e The Sensor is not a Transfer Standard T Transfer Standard e The installed lens is for the 5R Series and provides the standard focusing range of 13 inches to infinity The Sensor Model and lens combination provide a D 100 Optical Resolution 2 5 Accessories 2 5 1 Interconnecting Cable Required Accessory An IRCON supplied interconnecting cable with the Sensor mating connector attached on end one and termination prepared wires on the other end is required Special assembly of the cable is required and the cable is only sold with the Sensor connector attached Maximum cable length is 350 feet 107 meters The cable length limitation is due to the power supply voltage requirements of the Sensor The power supply voltage drop across this length of cable are low enough to provide proper Sensor operation Power supply cable wires are 22 AWG 0 35 mm Input and Output wires are 24 AWG 0 25 mm RS 485 Alarm relay output and
96. X101 through X109 alarms Ratio Temperature measurement conditions are invalid with INV and pINV alarms 5 12 1 Summary The initial setup procedure is complete and the Sensor should provide accurate display of the process temperature Auxiliary equipment connected to outputs will respond to the measured temperature 1 The system should measure process temperatures viewed by the Sensor Response to changes in temperature will depend on the Response Time Peak Picker or Track and Hold Signal Conditioning Functions 2 During start up routines observe measured temperature closely to insure proper measurement If necessary fine tune Sensor operating functions Refer to Section 8 Applications Guide page 137 for applications and measurement information 3 Allow the proper amount of time for the display to settle when making measurements Settling time depends on the Response Time selected Response time also affects the analog outputs and when the sensor is used as input to a closed loop control system consideration should be given to the effects of response time 4 Investigate Alarms and Error Codes to determine if there are installation problems or Sensor malfunctions 5 The Sensor rear screw on protective window must be in place during temperature measurement to maintain the NEMA 4 IP65 Sensor housing rating and protect the keyboard and internal parts from contamination 6 Digital Communications 6 1 RS 485 Digital Communications
97. a Reset triggered by the Reset Below temperature even though the target temperature has decreased 5 10 5 RBEL Reset Below Temperature Automatic Peak Picker Reset must be on for this function to appear in the menu Sets the Reset Below Temperature that causes Automatic Peak Picker Reset with the Peak Picker On and Auto Peak Picker Reset On When the target temperature matches or is below the selected value Automatic Peak Picker Reset will take place and the Sensor indicates temperature without any peaking action 5 10 6 DEL Peak Picker Delay Peak Picker signal conditioning may be delayed The Peak Picker Delay time is selectable in the range of 0 01 to 10 00 seconds Its primary use is with the Auto Peak Picker Reset and Reset Below Temperature functions The Peak Picker Delay function is used to delay the start of the peaking action for up to 10 seconds following the detection of the leading edge of a new target See Section 8 Applications Guide page 137 for a detailed explanation It has limited operation when used with Peak Picker signal conditioning without the Auto Peak Picker Reset function It will provide the selected delay after any Peak Picker Reset The reset can be from the Sensor rear panel a reset from a momentary closure of the Peak Picker Reset external switch or a reset from the RS485 PR command Modline 5 Rev L4 12 2012 109 Operation Navigate from TEMP display with amp A Y to Head then use amp A Y t
98. ables oils meats bakery goods etc Gallium Arsenide solid polished 0 5 mm thick water Glass commercial sodalime 2222 YO _ Oil animal or vegetable 0 040 _ _____ _ ____ Ol mineral 0040 22 o Paints oil or water base on metal on plastic or wood 1 Highly variable Values for low emissivity entries can be significantly greater than shown if even small amounts of impurities are present Paints with metallic pigments may have much lower emissivities Table 19 Emissivity Values of miscellaneous Materials 146 Rev L4 12 2012 Modline 5 Applications Guide Material Emissivity Range by Sensor Series 52 5R 5G 56 One Color Mode Plastics all 1 8 thick 0 90 1 00 Ca polyester film mylar 0 0002 thi __ _ _____ 0 0 polyethylene film 0 0002 thiet 0 10 Rubber po E 0 95 1 00 Silicon solid polished 0 5 mm thick wafer Silicon moten f o ow S Textiles Fabrics o o T e Carpet cotton wool synthetic PP Fabrics close weave cotton wool MO eae synthetic leather o Water 0 0002 fim Ao o Wood O O 3 Emissivity values may be significantly lower than shown for very sheer materials 4 Note that objects with even a very thin coating of water have very high emissivities Table 20 Emissivity Values of miscellaneous Materials Continued Modline 5 Rev L4 12 2012 147 Applications Guide 8 5 Ratio Sensors Modline 5 Series 5R Sensors utilize a
99. accurate Error Code X105 Case temperature too high sensor case temperature is below is above specification Check ambient temperature 55 C maximum and Sensor internal case temperature using the RS485 RC Command or with a temperature measuring device such as a thermocouple If these temperatures are okay and alarm continues Sensor may have a malfunction Caution Any temperature readings on rear panel display at Analog Output or from RS 485 Communications may be inaccurate Modline 5 Rev L4 12 2012 133 Maintenance Status Display Error Code Details Error Code X106 Case temperature too low Sensor case temperature is below is below specification Check ambient temperature and Sensor internal case temperature using the RS485 RC Command or with a temperature measuring device such as a thermocouple If these temperatures are okay and alarm continues Sensor may have a malfunction Caution Any temperature readings on rear panel display at Analog Output or from RS 485 Communications may be inaccurate Error Code X107 Serious problem with Sensor operation exists Sensor failure Caution Any temperature readings at Analog Output or from RS FAIL may be seen on the Sensor TEMP 485 Communications must be considered inaccurate Ennio Replace Sensor Error Code X108 Sensor has sensed external analog output current flow is not Analog Output Current loop malfunction accurate Note this Error Code only will be seen for errors Analog
100. alog Output is connected to earth ground Use instruments with ungrounded differential inputs If instruments with grounded inputs are connected the output may be inoperable or inaccurate I OUT 0 to 20 mA 500 Ohm 0 1 Figure 70 4 9 7 Current Input for Remote Emissivity E Slope or Laser Operation You may make remote adjustments of the Emissivity or E Slope by sending a scaled analog input of 4 to 20 mAdc The Modline 5 senses an input and overrides any Sensor rear panel or RS 485 settings of Emissivity E Slope or Match The input can also be used for remote Laser operation Example for Emissivity A 4 mAdc signal corresponds to an emissivity setting of 0 100 A 20 mAdc corresponds to an emissivity of 1 000 The relationship for the values in between is linear Example for E Slope For the E Slope settings the 4 to 20 mAdc signals correspond to settings of 0 800 to 1 200 The relationship for the values in between is linear Connections are made to Terminals mA In and mA In Input impedance is 120 Ohms Use Shielded cable and ground shields at POI BOX with grounding strain relief supplied or at the TSP Terminal Strip Plate ground terminal The terminal of the mA input current input is isolated but will only tolerate a difference of approximately 2 Volts between it and Sensor Common Remote Laser Operation is selected in COMMS LASR Menu See manual Sections 5 8 and 5 11 for selecting and operating this f
101. alog Outputs All Modline 5 Sensors provide an analog current signal output of 0 to 20 mAdc or 4 to 20 mAdc The output range is selected using the Sensors rear panel AOUT and SOUT function menus or RS 485 Digital Communications command codes This current output will drive remote current meters recorders and other devices calibrated to read dc milliamps and scaled to convert the analog signals to temperature Multiple devices Loads can be connected in a series current loop configuration The maximum series resistance that can be connected in the loop is 600 Ohms This maximum includes the resistance of all devices and cables See Figure 87 The minus side of the Analog Output is connected to power supply common See Section 4 12 RS 485 Multi Drop Network Power Supply and System Wiring page 82 of this manual about Sensor Grounding Use instruments with ungrounded differential inputs If instruments with grounded inputs are connected in the loop the output may be inoperable or inaccurate If the Analog output is not used insert a jumper wire across the output terminals This will prevent an Analog Loop malfunction open circuit Alarm Error X108 from occurring The current signal varies linearly with the measured temperature There are several schemes for temperature scaling these outputs current The standard scaling is when the output zero scale current and full scale current is scaled to equal the Sensor s zero scale and full temperatures Al
102. alue To Change a Value or Selection use F1 A F2 then Press PAR to enter and save Display SERE EMT iS or E Si PAP Stuff h 174 Parameter Description Status lil The Measurement Status and Alarms are multiplexed on the display one at a time ina repeating loop The display update is set at a faster rate to speed up the viewing of all alarms In the Display Mode When an Alarm condition occurs the ALM indictor on the DPM Meter Flashes Remote Emissivity or E Slope input monitor Instrument Internal Case Temperature Peak Picker Reset or Track and Hold Switch Status Readings Rev L4 12 2012 Navigation and Information Alarms and equivalent Sensor Display Error Codes Out of Calibration Error Same as Error Code X102 Signal Invalid 1 Same as Error Code INV Case Temp Low Same as Error Code X106 Case Temp High Same as Error Code X105 Detector Cold Same as Error Code X104 Detector Hot Same as Error Code X103 Current Loop Failure Same as Error Code X108 Dirty Window Detected Same as Error Code X101 Sensor Failure Same as Error Code X107 DWD Failure Same as Error Code X109 Signal Invalid 2 Same as Error Code pINV Measurement Condition Status No Alarm RS485 Lock Sensor in Read Only Mode Under range Same as LOW on Sensor rear panel display Over range Same as HIGH on Sensor rear panel display Laser Pointer On Same as LED lit on Sensor rear panel Calibration in Pr
103. an 200 milliseconds 6 3 1 Command Message Format All command messages have the same format lt Start Bit gt lt Sensor Address gt lt Channel Number gt lt Command Code gt lt Value gt lt Carriage Return gt Example AOCCXXXXX lt CR gt Where Start Bit Always the pound sign character Sensor Address A A single alphanumeric character address of the Sensor 0 to 9 A to Z O zero is the factory default setting The wild card address of is accepted by the MODLINE 5 regardless of its set address Do not use the address if more than one Sensor is connected Channel Number 0 Is always the 0 zero character This one digit entry value is not used in the MODLINE 5 SET to 0 zero for future use Command Code CC Is one of the two alpha character command codes from the list below All the commands are detailed below Value XXXXX Is the value included with a Write message and reported in the Sensor reply The range of acceptable input value is given for each command code If the value is omitted execution of the instruction will return the present value of the parameter involved If a value 1s included execution of the instruction will store the specified value to in the Sensor s non volatile memory Carriage return lt CR gt All messages are concluded with ASCII code CR Enter on computer keyboard 6 4 Command Codes 6 4 1 Introduction The Command Codes allow operation and setup of the Modli
104. and the word Alarm lit on the Sensor rear panel 5 5 4 Initial Sensor Setup Initial Sensor setup should follow the menu orders indicated in the following instructions Menu navigation is shown using the amp AV symbols for Enter and Up Down arrows The menus and functions available and the sequence in which they appear depends on the Sensor Model and the purchased options A function variable is expressed as a word or as a number A function variable may be changed from State A to State B or from a higher or lower numerical value by using the Up Down arrows Modline 5 Rev L4 12 2012 93 Operation Momentarily depress the Up or Down Arrow pushbutton to make single digit changes starting with the least significant digit Keep the pushbutton depressed to quickly change values All values are retained in non volatile memory and are automatically reloaded in the event of a power loss Temperature measurement continues during menu operations and changing of function values The Analog Output and RS 485 temperature indications continue to reflect changes in target temperatures When a changed function value that affects the measured and displayed temperature is entered with the ENT J pushbutton the temperature reading at the outputs updates in about 150 milliseconds 5 6 ENGR Setup of Engineering Functions 5 6 1 LOCK Panel Lock Security In the Panel Lock Off state viewing and adjustment access to all menus and functions is a
105. anel ALARM indicator signals an error as been detected Press Up Arrow A to view Error Codes Press Up Arrow A multiple times to view all simultaneous Error Codes Error Codes for Sensor diagnostic information are summarized as follows X101 Dirty Window Detection X102 Out of calibration X103 Detector block too hot X104 Detector block too cold X105 Internal Case temperature too high X106 Internal Case temperature too low X107 Sensor failure FAIL may be seen on the Sensor TEMP display X108 Analog Output Current loop malfunction X109 Dirty Window Detection malfunction pINV pINV is only displayed when the Invalid Alarm ALM function is set to ON and Peak Picker or Track and Hold is On This condition becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear panel Temperature displayed is Peak Picked or Hold Mode Temperature values from prior valid measurement conditions Environmental conditions can cause Sensor errors High or low ambient temperatures can cause Sensor case temperature too high or too low errors Dirty lens conditions can be avoided using air purging Modline 5 Rev L4 12 2012 113 Digital Communications See Section 7 Maintenance page 127 for possible causes of problems and troubleshooting Investigate all alarms indicated by the ALARM word indicator Temperature readings on rear panel display at Analog Output or from RS 485 Communications may be inaccurate with Error Codes
106. anges of voltage or current if the rate of rise DV DT and or DI DT is greater than the maximum permissible value specified by the manufacturer 2 6 Surge Current Current of a value greater than that specified by the manufacturer can affect the solid state control Current limiting means may be required 2 7 Transient Over voltage Solid state controls may be affected by transient over voltages that are in excess of those specified by the manufacturer Voltage limiting means should be considered and may be required SECTION 3 APPLICATION GUIDELINES 3 1 General Application Precautions 3 1 1 Circuit Considerations The consequences of some malfunctions such as those caused by shorted output devices alteration loss of memory or failure of isolation within components or logic devices require that the user be concerned with the safety of personnel and the protection of the electronics It is recommended that circuits which the user considers to be critical to personnel safety such as end of travel circuits and emergency stop circuits should directly control their appropriate functions through an electromechanical device independent of the solid state logic Such circuits should initiate the stop function through de energization rather than energization of the control device This provides a means of circuit control that is independent of system failure 3 1 2 Power Up Power Down Considerations Consideration should be given t
107. ation provided in this Modline 5 Manual e Install and wire the Modline 5 Sensor per the Instructions in Section 3 Sensor Installation page 22 and Section 4 Sensor Wiring page 62 of this Modline 5 Manual e Prepare the Sensor to communicate with the DPM per the instructions provided Section 9 3 Modline 5 Laser Sight Option page 165 e Program the DPM Quad Relay Setpoints and MAX and MIN features of the DPM if those features are being used See the information provided under Full Programming in Section 9 14 Full Programming Mode on page 175 e Doacomplete initial Sensor setup with the DPM 9 2 DPM Installation PAR Fi amp A F2 RST Figure 102 DPM Meter Front 162 Rev L4 12 2012 Modline 5 DPM Installation and Operation Finger tabs both sides ST RES RESALTA Latches are just in front of tabs NS Figure 103 Rear Wiring Terminals 9 2 1 DPM Pre installation The DPM is delivered in a separate carton Remove the DPM meter its mounting clip and gasket an F and C overlay with insert frame kit and Red Lion Controls Bulletin No PAX B or later release from the carton All items are needed keep them all The Red Lion Bulletin No PAX B contains installation and wiring information for the DPM Refer to Sections 2 and 4 for Panel Installation and AC wiring instructions The bulletin also contains safety information and lists CE and safety compliances 9 2 2 F and C Units Overlay Part Number 478432 SBPAX03
108. autions below and operating instructions in Section 5 11 Laser Sighting Operation page 110 of this Modline 5 Manual A CAUTION LASER LIGHT DO NOT STARE INTO BEAM 1 mW at 635 nm CLASS Il LASER PRODUCT other devices using RS 485 Communications insure there are no personnel in the path f Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or of the beam FT Features Matrix Read Only Returns the features that this unit supports Note When bits 1 and 2 are not set Sensor is 52 Series Brightness Unit Range N A Bit Values Two color detector R series LASER pointer Dirty window detector G series 0x0008 l8 Transfer Standard 0x0010 Unit is chopped 0x0020 Unit has TEC 0x0040 Ignoring LASER DWD and Transfer Standard 5R series 1 52 series 0 5G series 8 56 series 96 60Hex 57 series 32 20Hex SN Sensor Unit Serial Number Read Only Range N A Message Value Returns the serial number string of the unit RR Alarm Operation Read Write Command is only available with Series 5R ratio units When this is turned on it also enables the Attenuation alarm AT Attenuation Alarm Threshold Read Write Set the percent attenuation alarm threshold Any attenuation greater than this value will turn on the alarm and also turn on the dirty window LED on the back panel Setting this to 95 will turn this Modline 5 Rev L4 12 2012 119 Digital Communica
109. binations with Focusing RANGES sssessessessersersseereererrerrsrrrreseeseen Lh DA POP SIZE ana V EONS STA A AAA A AA AA 27 3 5 Measuring Temperature with Brightness and Ratio Sensors cccccccccccceececeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 29 Sd Ll IRCSOL UU AT OCIS or DITO IeSS SENSO A A AS 29 Sopiru On tit CONGO VIS ASA ASA A AAA 29 D0 RESOLVING Lar eects On Twr COLO RAO SCS VS A A RA 29 DIAO TIAL RCAC O AAA ASA AAA E E A AAA AA AS 30 EOE A E E E E N E E A E E E E E E e ae oa cence et 31 36 Sensor Installation Panne A A aS 31 3 1 Sensor Mechanical latas di 32 DL INSTA ON AA CE COSMOS A A E 32 2 SIE DCN SIONS AAA A nee mesial yenctaie 33 0 0 General Tastallation ReguIrementS AA 34 sS DWD Installation Req E tie Cia 34 3 9 Modline 5 Mounting Cooling and Air Purging ACCESSOTIES seeeeeeereererserererirsrrtrereerrrererersrresererereese 35 3 9 1 UAA Universal Adapter Accessory Description and DimensionS essesseesersrsrrsrerrerrrrrrrrrrrrerrees 35 3 9 2 RAM Right Angle Mount Description and Dimensions omoconoccnonnconnnannnnanonancnnn conocieran econ con nonnecnns 36 IISAFA Alr Puree Accessory Description and DIMENSIONS esisiini dia 39 3 9 4 MFL Mounting Flange Large Description and Dimensi0nS coocinnorormenmicincriarnanoncncornarranracncarncones 40 3 9 5 MFS Mounting Flange Small Description and Dimensions cscssssscsrecsesssersessecstasssnsessseseaseenees 42 3 9 6 WJA Water Jacket Accesso
110. cable seal darker gray is for cable diameters from 0 20 inch 5 1 mm to 0 39 inch 9 9 mm One is supplied Select the fittings that match the user cable diameters to be installed 1 The Strain Relief Figure 64 drawing illustrates how a braided wire shielded cable is grounded when using either the Grounding Strain Relief fittings 2 Slip the Compression Nut Item A and the Compression Assembly Item B onto the cable as in Figure 64 Pay attention to their order position and direction of each part shown 3 Unbraid and comb out the shield wires Flare all the combed shield wires evenly all around down and over the Compression Fitting Item B If an inner foil is used in the cable check that no inner foil drapes over the shield wires trim it if necessary 4 Itis very important that the compression assembly rest on the un stripped portion of the outer cable jacket to make a proper environmental seal 5 Push the Compression Body Item C all the way into the Compression Fitting Item B Carefully rotate until it seats properly 70 Rev L4 12 2012 Modline 5 Sensor Wiring 6 Trim the shield wires to a spot just past the o ring on the compression fitting as shown in Figure 64 7 Hold the cable firmly so that the cable does not twist in the fitting as you screw the Compression Nut Item A onto the Compression Fitting to make a watertight seal Tighten all parts firmly 8 The Locking Nut Item D is used to fasten the
111. cable to the POI BOX Assembly Checklist e Check insulation resistance between all wires Resistance should be 50 megohms or greater e Check closely for any wire strands that could cause shorting Trim Unstranded Shield Wires Here Enclosure Wall Compression Nut O Ring on the Compression Item A Assembly Item B O Ring on the Fitting Body Item C Locking Nut Item D Figure 64 Grounding Strain Relief Fitting Assembly 4 7 POI Box Sensor Interconnecting Cable Installation cover is removed Use the power switch installed previously to disconnect power during wiring of the unit For safety of personnel AC power should not be applied to the POI box when its Remove the protective seal from the cable entry hole on the left side of the enclosure The left side has a single entry hole in the center position Insert the IRCON supplied interconnecting cable using the Grounded Strain Relief fitting into that hole attach the locking nut to the fitting and tighten Reference Figure 64 drawing in previous section Route all twisted wire pairs to their corresponding terminals identified by wire color Insert the tinned wire ends of each color coded wire into its terminal and tighten Modline 5 Rev L4 12 2012 71 Sensor Wiring Violet whites Black Black White Figure 65 POI Box 4 8 Terminal Strip Plate Sensor Interconnecting Cable Installation Clamp the cable shield to the shield clamp on
112. ce 2 43 61 7 mm 0 82 20 8 mm Y 0 83 Dia gt 21 1 mm 0 17 4 3 mm Dia Mounting Holes 4 Places under Cover T 5 39 136 9 mm 5 90 149 9 mm 395 100 3 mm 2 95 74 9 mm nes 5 0 73 1 95 oe 18 5 mm 9p ai Dia 2 Es Dia 1 47 i 3 43 a 37 3 mm 87 1 mm LD 37 3 mm 3 1 a 3 94 78 7 mm 100 1 mm Figure 58 POI Box Dimensions 64 Rev L4 12 2012 Modline 5 Sensor Wiring 4 4 2 AC Power and Earth Ground Connections The POI Box does not include a power switch You must supply a two pole switch for 100VAC to 240 VAC at 50 to 60 Hz The power consumption of the unit is 40 VA maximum The switch should be clearly marked as the power shutoff for the equipment visible and accessible to the operator The AC Power Requirement for the Model POI Power Supply Signal Interface Box is shown below AC Power Input Requirements Nominal Continuous 100 to 240 V 0 3 A 50 60 Hz Typical Inrush Current 20 A at 100 VAC 40 A at 200 VAC The typical inrush current occurs over a few cycles when power is first applied to the box The AC supply should be from a separate branch circuit with appropriate circuit breakers Consideration should be given to the wire size used the continuous nominal current rating and typical inrush current A clean power line such as instrument power line is essential Avoid power lines serving noisy electrical equipment
113. cing 0 2 4c s00c00necnnensnnenncnonacnnsnrnnnnngecnacnhennanenncannaanssnaneetacennaannennns 62 T Modine Sy Sensor Cable scrierii e here ici odi cn 63 0 Sensor Miterconteciiio CADIE A AAA AAA AAA 63 4 4 Model POL Power Supply Signal Interface BOX etica delve nbsetarmedelcenosstmonsdetdeusetiaewsdetdetuosetbeenes 63 LAT Moun mE tre TPO BON AA AA AS 64 442 AC Lower ana Carth Ground ORMECHOMS a ii Ad O 65 44o CONNECIING NE AS POWEF and Gronnad Wire lit AA 66 424 Connect ie 24 VDC PODWer Supply WITE Sii id at 67 a a e dare nate arsdanaesd ones oto taatodad eae A eat onaemce eee 67 4o dL Dimensions AME Intal ATION tai its 68 4 6 Sensor Interconnectine Cable Preparation os 69 OLEA rea it d tii 69 4 0 2 Interconnectiine Cable Assembly Continuity Cesa ia 70 40 Ground mE Stran Relief FUNAI ASS MO ssl aE ds 70 4 7 POI Box Sensor Interconnecting Cable Installati0N oooonnnnnnonononononononononononn nono nononnnnnnnnnnononnnnnnonononnnos 71 4 8 Terminal Strip Plate Sensor Interconnecting Cable Installati0D ooonnnnnnnnininininnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnos 12 4 9 Connecting Device Cables to POI Box or Terminal Strip Plate ooonnnnccnnnnccioncccnonancnonnnonancnonanaconanaconannnos 73 49 L Recommended Cable TY VCS rl li a a 73 L9 2 GOUNIT ANE MICA il dc 73 SYSTEM CONE ON llos 74 4 94 RS ASO Digital Communications siue tosh h a RS nicled ted dinetanAbs dren ques E 74 9 7D AMOS OUTIL I eM pe
114. cle combination are NEMA 4 IP65 rated However provide protection for the plug and receptacle if they are disconnected and the contacts and pins are exposed to harsh environments Make sure the 24Vdc power to the Modline 5 Sensor is turned off whenever connecting and disconnecting the cable Make sure the rear protection window is in place after making adjustments to maintain the Sensor s NEMA 4 IP65 environmental rating O Figure 80 Modline 5 Rev L4 12 2012 85 Sensor Wiring 4 14 System Grounding and Shielding 4 14 1 POI Box and Terminal Strip Plate Diagram AC Supply Input 3 Line conditioner or isolation transformer S sie AC Supply 2 Ground lead P 2 Ground lead O EN POI Power Supply Signal Interface Box a Analog J 4 Output 4 Grounded shield Interconnecting cable E mA IN 9 F m a EMIS E SLOPE Mounting surface at 4 Shield to enclosure 74 Grounded shield a Peak Picker Track 8 hold u 7 Reset switch 4 Grounded shield 24 VDC T Power suppl 1 Ground O Al es A a S 74 Grounded shield Mounting surface not at ground potential Insulation Terminal Stripe Plate Yelow D BRs Analog Yelowwhite 2 D rsaes _ _ i _ output 1 Ground Cable clamp 3 Places 3 S magos a 4 Srna shield T Blue White K D Analog Out I Pi A Interconnecting cable y 0 O mn S i a EMISE SLOPE OrangeWhite A a es pd eee 4
115. ct its reflectance R and transmittance T These factors in turn reduce the emissivity E value as shown in the following general equation relating the three characteristics Er 1 Ri Tr Figure 90 shows how a target s surface characteristics affect its reflective properties hence its emissivity It is assumed in the figure that each sample of Material A is thick enough to be completely opaque T 0 Notice that a cavity in an opaque object comes very close to having blackbody characteristics E 1 when both R 0 and T 0 From Figure 90 you can see why the lower value of a given range represents a flat highly polished sample of the material The upper value represents a sample of the material that has a flat surface that is as rough as might be expected when in its crude or unfinished form Some entries in Table 19 and Table 20 are marked with asterisks to signify that the range of values results from more than just the target s reflective characteristics These materials in their specified forms are partially transparent to infrared radiation In spectral regions where the materials transmit energy the emissivity typically increases with target thickness Follow the guidelines in the tables to estimate the emissivity of your target Even a rough estimation can significantly improve the accuracy of your measurements over only using averaged values Note that table entries having a single value represent targets
116. ctable range is 20 0 mA to 24 0 mA Analog Output Settings Navigate from TEMP with J amp A Wto AOUT then use J amp A Y to SOUT or ZERO or FULL or Fatl or A LO or A HI Press ENT J to save and return to TEMP display after each function Display Instructions Display and Limits SOUT Press ENT to view the SOUT output current range 0 to 20 mA or 4 to 20 mA 0 20 or 4 20 Use Up Down Arrows to select output current range ZERO Press ENT to view temperature corresponding to the selected Analog Output Temperature Value Current Range minimum value 0 or 4 mA Maximum is 10 F below the Use Up Down Arrows to set Temperature within the Sensor temperature selected FULL temperature range and high limit shown see below See note above for C operation FULL Press ENT to view Temperature Corresponding to the Analog Output Temperature Value Maximum value 20 mA Minimum is 10 F above the Use Up Down Arrows to set Temperature within the Sensor temperature selected ZERO temperature range and low limit shown see above See note above for C operation Fatl Press ENT to view the Analog Output selected mA current value 00 0 to 24 0 Use Up Down Arrows to set the current value A LO This function does not appear if the SOUT selected range is 0 to 20 mA 00 0 to 4 00 Press ENT to view the Analog Output selected mA current value Use Up Down Arrows to set the current value A HI Press ENT to view the Analog Output selected mA curre
117. ctor Option Model UAA Universal Accessory Adapter Model MFL Mounting Flange Large Model RAM Right Angle Mount Model M5WJ5 Mounting Kit to mount Sensor in WJ 5 Water Cooling Jacket Protective Window Sight Accessory The EP 5 with a dimming filter is available for viewing very high temperatures This window replaces the standard rear protection sight window supplied with the Sensor This filtered window is for viewing high temperature targets from 1200 C 2192 F to 2300 C 4172 F Spare part standard protection windows are identified as the RPW rear protection window assembly with clear sight window One of these is supplied with every Sensor 18 Rev L4 12 2012 Modline 5 Product Description 2 8 Specifications 2 8 1 Sensor Specifications Spectral Response Series 52 0 85 to 1 1 microns Series 56 2 0 to 2 8 microns Model 56 to 0315 only 2 3 to 2 6 microns All other models Series 5G 1 6 microns Series 5R Ratio Mode 0 75 to 1 05 1 0 to 1 1 microns Single Color Brightness Mode 1 0 to 1 1 All specifications subject to change without notice Calibration Blackbody Accuracy at 25 C Sensor Series 52 Within 0 3 of reading plus 1 C up to 2800 C 5072 F indication up to 3000 C 5432 F Sensor Series 5G Within 0 3 of reading plus 1 C Sensor Series 56 Within 0 3 of reading plus 1 C or 2C whichever is greater Sensor Series 5R Within 0 5 of reading plus 2 C up to 2800 C 5072
118. d Bb The meter will display reset and return the display to 58 This will overwrite all user settings to the factory settings If removed replace the jumper between terminals 7 and 8 Test the meter to make sure it is back in the correct mode of operation Setpoint and MIN MAX parameters need to be programmed again Modline 5 Rev L4 12 2012 177 Appendix A 10 Appendix A NEMA SAFETY GUIDELINES for the Application Installation and Maintenance of Solid State Control SECTION 1 DEFINITIONS This section is classified as NEMA Standard 11 15 1984 Electrical Noise Unwanted electrical energy which has the possibility of producing undesirable effects in the control its circuits and system Electrical Noise Immunity The extent to which the control is protected from a stated electrical noise Off State Current The current that flows in a solid state device in the off state condition Off State Condition The conditions of a solid state device where no control signal is applied On State Condition The condition of a solid state device when conducting Surge Current A current exceeding the steady state current for a short time duration normally described by its peak amplitude and time duration Transient Over voltage The peak voltage in excess of steady state voltage for a short time during the transient conditions e g resulting from the operations of a switching device SECTION 2 GENERAL Sections 2
119. d Auto Cal Hour functions are different for the Series 56 Models Separate explanations and instructions are provided for Series 56 Models on the pages that follow The HOUR function provides for selection of an automatic System Check This function automatically initiates the check described above A selection of OFF or a time interval in hours between checks is offered A manual Check from the Sensor Keyboard as explained above or by RS 485 Communication will start a new period but not change the value of the interval This will start a new interval Process temperature measurement and control requirements need to be considered when using this automatic function Real time process temperature measurement and signal conditioning is suspended for up to ten seconds Continuous interval setting should be 8 hours or greater A 168 hour 1 week or greater automatic interval and manually initiated checks are the recommendations that will provide minimal measurement interruption Navigate from TEMP display with J amp A Wto ENGR then use J amp A Y to Hour Display Instructions Display and Limits HOUR Press ENT to view Automatic Check selection OFF or numerical value OFF or representing hours between Checks Value 1 to 9999 Use Up Down Arrows to change selection and setting See above recommendations Press ENT J to save and return to TEMP display 5 6 6 CHK Manual System Calibration for 56 Models This function checks a Model
120. de of the noise coupled into the low level signal circuit by electrostatic or magnetic coupling e Provisions of the 1984 National Electrical Code with respect to grounding should be followed Additional grounding precautions may be required to minimize electrical noise These precautions generally deal with ground loop current arising from multiple ground paths The manufacturer s recommendations should be followed 4 2 Enclosures cooling and ventilating Suitable enclosures and control of the maximum operating temperature both of which are environmental variables may be needed to prevent malfunction of solid state control Follow the manufacturer s recommendations for the selection of enclosures ventilation air filtering if required and ambient temperature These recommendations may vary from installation to installation even within the same facility 4 3 Special Handling of Electrostatic Sensitive Devices Some devices may be damaged by electrostatic charges These devices are identified and should be handled in the special manner specified by the manufacturer Plastic wrapping materials used to ship these devices may be conductive and should not be used as insulating material 4 4 Compatibility of Devices with Applied Voltages and Frequencies Users and installers should verify that the applied voltage and frequency agree with the rated voltage and frequency specified by the manufacturer Incorrect voltage or frequenc
121. djusted to match the process for proper operation External Switch Control of Track and Hold Operation The Modline 5 has provisions for a remote process controlled input switch be wired to the Violet and Violet White twisted wire pair of the Sensor s interconnecting cable If Track and Hold signal conditioning is selected the switch input is required to change from Track temperature operation switch open to Hold mode switch closed as required in the process system Modline 5 Rev L4 12 2012 107 Operation Wiring and switch operation for the Track and Hold feature are described in Section 4 Sensor Wiring page 62 Navigate from TEMP display with amp A Y to Head then use JA Y to SIGL Display Instructions Display and Limits SIGL Use Up Down Arrows to select OFF PEAK TRAK OFF No Signal Conditioning Note TRAK Track and Hold Use external control switch to operate Track and Hold modes PEAK EEA IKE Adjust PSEL Parameters if Peak Picker selected Use external control switch for remote Peak Picker reset and operation Press ENT to save and return to TEMP display 5 10 PSEL Peak Picker Functions The PSEL Functions are for Peak Picker Operation Refer to Section 8 Applications Guide page 137 for a description of Peak Picker signal conditioning operation including these functions 5 10 1 D R Decay Rate Function The Decay Rate range is 0 00 to 300 00 F or 0 00 to 166 66 C per seco
122. dual detector assembly that measures temperature by comparing infrared radiation levels in two wavelength bands 0 85 to 1 05 microns and a narrow band centered at 1 0 to 1 10 microns They have the capability to measure temperature by comparing the relative infrared radiance at two different wavelengths and computing the ratio of the two Temperature readings are based on the ratio of the two signals in these bands See Section 3 Sensor Installation page 22 of this manual for more information about signal reduction resolving targets and other factors about using ratio sensors 8 5 1 E Slope Settings When using a Series 5R Sensor as a two color ratio Sensor you must properly select the E slope value An E Slope adjustment is provided to allow you to calibrate the Sensor to measure the temperature of the target material accurately Series 5R Sensors are commonly used for applications involving materials in one of two main classifications 1 Greybody materials have an Emissivity that is the same at both detected wavelengths 2 Materials with emissivities that are not the same at both detected wavelengths a slope or variance in the emissivity at the two wavelengths exists The first of these the class of greybody materials contains those materials that have emissivities that are the same at both detected wavelengths The most common greybody materials are described below When your target is made from any of these materials and are oxidiz
123. e The use of an APA is required for large targets over 1000 C 1 ESA and APA air purge with clean air air purging and shielding 2 ESA and APA air purge without air dead air space zone and shielding 3 ESA with MFL Flange dead air space zone and shielding 4 ESA with MFL and AA 3 air purge accessory air purging and shielding See Section 3 8 DWD Installation Requirements for DWD and Section 3 12 Other Accessories Sight Tube Window WJ 5 Water Cooling page 59 for AA 3 references V 3 A Figure 37 The ESA is also used with the MFL Flange when as an interface with the Right Angle Mounting Bracket Material Clear Anodized Aluminum Weight Approximately 1 Pound 0 5 kg Mounting and Assembly Supplied Parts List e No hardware is supplied with the ESA e Assembly screws are supplied with the APA and MFL 48 Rev L4 12 2012 Modline 5 Sensor Installation Locating PINs 2 Places 1 820 46 23 Flat mounting Surface Align with other Accessories Through Holes for M6 Screws 3 Places Figure 38 ESA Dimensions lil Dimensions are in inches and millimeters Do not scale 3 10 Accessory Combinations with Break out Drawings 3 10 1 Recommended Accessory Groupings The table below lists the eighteen recommended accessory groupings Exploded views of the groups are shown on the following two pages The recommended groupings for Sensors with the Dirty Window Detector are identified in the DWD column
124. e installed in a WJ 5 Jacket because of its additional length Modline 5 Rev L4 12 2012 59 Sensor Installation Figure 53 M5WJ5 Mounting Kit Accessories and kit required for mounting Modline 5 Sensor in WJ 5 Water Cooling Jacket e Model WJ 5 Water Cooling Jacket with Air Purge Supplied with its own mounting hardware M5WJ5 Kit is not included e UAA Universal Adapter Accessory Supplied with its own mounting hardware e MFL Mounting Flange Large Accessory Supplied with its own mounting hardware e M5WJ5 Mounting Parts Kit Consisting of the following Note These parts are sold only as a kit Qty PartNumber Description Function Item a de Torero ro 1 1 050501 INST WJ 5 Rev C installation instructions 3 Slides assembly into WJ 5 4 20 X inch long Socket Head Cap Screw le aaa 5 4 202524540 4 20 X 3 4 inch long Hex Head Screw Mounting Plate to WJ 5 2 a le lemom an anamannan sears 4 222503030 1 4 in Split ring lock washers Screws 4 Table 13 Assembly and Sighting Instructions Refer to Installation Instructions for WJ 5 Included in M5WJ5 Kit Assemble as indicated in drawing to the right and at top of page Slide assembly into WJ 5 and tighten rear mounting plate screws Focus Sensor with rear rotating focus section TE E be ee If looking through a sight tube or sight hole position align and rotate the Sensor and Sight tube t
125. e 108 Modline 5 Sensor with WJ5 Cooling Jacket Accessory Y yy i te Steel g Aluminum Figure 109 Modline 5 Sensors with WJA Cooling Jacket Left and other Accessories Right Modline 5 Rev L4 12 2012 187 Appendix B DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING IRCON MODLINE 5 SERIES PRODUCT AND ACCESSORIES KM Power Supply Signal Interface Box POD Disassembly Instructions e E Aluminum Y fae Plastic gt 7 Eg oy Aluminum fae Steel Plastic 2A Eg Y Aluminum e Aluminum 188 Rev L4 12 2012 Modline 5 Appendix B DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING IRCON MODLINE 5 SERIES PRODUCT AND ACCESSORIES 2 Removal of Modline 5 Sensor Standard Lens Removal of Modline 5 Sensor Lens with DWD Dirty Window Detector Option Modline 5 Rev L4 12 2012 189 Appendix B DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING IRCON MODLINE 5 SERIES PRODUCT AND ACCESSORIES EN Disassembly of Sensor Body 190 Rev L4 12 2012 Modline 5 Appendix B DISASSEMBLY INSTRUCTIONS FOR DISPOSAL AND RECYCLING IRCON MODLINE 5 SERIES PRODUCT AND ACCESSORIES 5 Fully Disassembled Sensor s Y Y E e Aluminum Glass Rubber oy Y Y te Steel Glass Lens Aluminum Rubber Rubber Gasket Modline 5 Rev L4 12 2012 191
126. e Chassis Mount 24 Volt DC Switching Power Supply The part number for this power supply is 551632 This is the same chassis mount 15 watt 24 VDC switching power supply used in the POI Power Supply Signal Interface Box The supply powers one Modline 5 Sensor and must be used with the TSP Terminal Strip Plate supplied separately The power supply module operates with 100 to 240 VAC power 50 60 HZ Nominal continuous input current is 0 3 A The power supply module and TSP are shown in Figure 75 These component parts must be installed in a grounded metal enclosure for safety and electrostatic protection Select enclosures designed for electrical use with the NEMA and IP environmental ratings required at the point of installation The rectangular mounting hole layout dimensions for the module are 3 39 inches 86 mm by 1 81 inches 46 mm Module height is 1 04 inches 26 5 mm Design and implementation of the installation must be performed by qualified personnel Installation instructions and important warnings are included in the carton with the power supply Further instructions are provided on the power supply manufacturer s website It will be useful to review Section 4 4 Model POI Power Supply Signal Interface Box page 63 Wiring and installation of the TSP Terminal Strip Plate is covered in Sections 4 5 4 6 4 8 4 9 4 10 and 4 14 80 Rev L4 12 2012 Modline 5 Sensor Wiring Figure 75 Compliance with relevant national r
127. e a build up of contaminants An easy to read bright LED alphanumeric temperature display and three pushbuttons on a keyboard is located at the rear of the Sensor Each Sensor has a full complement of easy to navigate rear panel setup and operating functions Operation as a stand alone Sensor is accomplished simply by using its rear panel keyboard to access and setup operating parameters The Sensor can display and output temperature signals and operates with an external de power source The Sensor optics and electronics are contained in a small rugged stainless steel NEMA 4 IP65 rated housing Modline 5 accessories for mounting air purging and cooling the Sensor have been designed to maintain a small installation footprint 2 2 1 Sensor Standard Features Through the lens visible rear focusing and sighting with standard or close focus lenses Field selected F or C measuring units Field selectable analog current outputs 0 to 20 mA or 4 to 20 mA Temperatures within the span of the Sensor can be assigned to the Analog output Zero and Full scale current values to customize the corresponding output temperature range Peak Picker and Track and Hold Signal Conditioning with remote switch input for Peak Picker Reset or Track and Hold operation RS 485 Digital Communications allows interfacing with any RS 485 capable device to setup and operate the Sensor remotely This allows use of a Host computer Programmable Logic Controller PLC etc
128. e actual process device is 4000 feet 1220 meters 4 9 5 Analog Output Temperature Signal This current loop temperature signal is 4 to 20 mADC or 0 to 20 mADC user selectable linear with measured temperature The corresponding temperature span is adjustable Temperature signal connections are made to the Analog Output and Analog Out terminals Single or multiple series connected indicators recorders or other instruments can be connected The total current loop series DC resistance of all devices and wiring should not exceed 600 ohms I OUT 0 to 20 mA or 4 to 20 mA 600 Ohm Maximum Including Cable Resistance Figure 69 The minus side of the Analog Output is connected to power supply common see section 4 14 System Grounding and Shielding page 86 Use instruments with ungrounded differential inputs If 74 Rev L4 12 2012 Modline 5 Sensor Wiring instruments with grounded inputs are connected in the loop the output may be inoperable or inaccurate If the Analog output is not used insert a jumper wire or 100 Ohm to 500 Ohm value resistor across the output terminals This will prevent an Analog Loop malfunction Alarm Error X108 from occurring 4 9 6 Converting the Analog Output from a mA output to a 10 Volt Output To convert the Analog mA output to 0 to 10 Vdc Output place a 500 Ohm resistor across the output terminals The Sensor Analog output SOUT should be set to 0 to 20mA range The minus side of the An
129. e actual target but not necessary Preset of the function selections is possible and may be required if the access to the Sensor is not possible or safe conditions to perform adjustments do not exist 5 9 1 R T Response Time The Modline 5 Sensor Response Time function provides signal filtering for meaningful temperature information while eliminating unwanted temperature variations Refer to Section 8 Applications Guide page 137 for Response Time Application Information See section 2 Product Description page 104 Rev L4 12 2012 Modline 5 Operation 13 for Model specific response time information If you determine that your Response Time must be greater than 30 seconds it is recommend that you trial your process Long Response Time settings are close approximations and may vary from the selected value The Response Time selected affects the temperature signal input to Temperature Display Analog Output RS 485 Communications and the Peak Picker and Track and Hold signal conditioning functions The Response Time setting for a Ratio Sensor in the two color ratio mode takes effect under valid measurement conditions Under Invalid measurement conditions the Sensor response time is preset for a fast response regardless of the Response Time function setting Navigate from TEMP display with 1 amp A Y to Head then use 1 amp A Y to R T Display Instructions Display and Limits R T Press ENT to view Response Time in Seconds 0 01
130. e and return to TEMP display 5 6 11 ATTN Selects Attenuation Alarm Threshold Set the percent attenuation alarm threshold Any attenuation greater than this value will turn on the alarm and also turn on the Dirty Window LED on the back panel Setting this to 95 will turn this alarm off since that is the invalid threshold The iALM must be set on in order to enable this alarm Navigate from TEMP display with J amp A Y to ENGR then use 1 amp AV to ATTN Display Instructions Display and Limits ATIN Press ENT to view Attenuation Threshold 10 95 Use Up Down Arrows to select Press ENT to save and return to TEMP display Background With most two color infrared thermometers an invalid indication is reached when the reduction in signal from the target is greater than 95 percent When the signal reduction is too great an invalid condition occurs This variation can be caused by emission characteristics of the target or the target being too small to completely resolve as well as obstructions in the sight path i e certain types of smoke When an invalid condition occurs an alarm output is provided to indicate the signal variation is too great between the two detectors While this type of detection method is suitable for many applications there are some instances where the user wants to adjust the sensitivity level of attenuation The Modline 5 attenuation adjustment alarming feature operates independent from the optional
131. e factory installed and are not field changeable Series designation temperature range optical resolution optional Laser and DWD information is provided in the tables sections below Lens focusing ranges are found in Section 3 4 Sensor Optical Characteristics page 26 Ordering information and Model Number examples follow the tables Two Digit Sensor Series Designation Sensor Type Spectral Response in u microns Brightness 0 85 to 1 1 Brightness Lowest Temperature Range 2 0 to 2 8 Other A 2 3 to 2 6 selectable Modes Ratio Ratio Mode 0 75 to CO 1 0 to 1 1 or Brightness 1 Color Mode Brightness Mode 1 0 to 1 1 Series 52 Sensor Model Numbers Model Temperature Range in C and F Optical Resolution with Type 2A Lens 900 to 1400 C 932 to 2552 F D 100 02 2020 600 to 2000 C 1112 to 3632 F D 200 92 3024 750 to 3000 C 1382 to 5434 F D 240 Modline 5 Rev L4 12 2012 15 Product Description Series 56 Sensor Model Numbers Emissivity span is limited to 0 3 to 1 0 for the first 55 C 100 F for all temperature ranges Model Temperature Range in C and F Optical Resolution with Type 6A Lens 56 0315 50 to 300 C 122 to 572 F D 150 56 0415 100 to 400 C 212 to 752 F D 150 56 0815 200 to 800 C 392 to 1472 F D 150 Series 5G Sensor Model Numbers Emissivity span is limited to 0 3 to 1 0 for the first 55 C 100 F for all temperature ranges Model Temperature Range in C and
132. e for Terminal Strip Plate 10 inches 241 3 mm D Select Next Step If the preparation is for a POI Box go to sub section Grounding Strain Relief Fitting Assembly on next page If the preparation is for a Terminal Strip Plate pull back and comb out the exposed shield Preparation is now complete Route and install the interconnecting cable Refer to Section 4 8 Terminal Strip Plate Sensor Interconnecting Cable Installation page 72 Modline 5 Rev L4 12 2012 69 Sensor Wirin 4 6 2 Interconnecting Cable Assembly Continuity Check If desired a continuity check of the cable can be made The table below identifies the receptacle pin and the color coded wire connected to the pin The illustration below identifies the pin locations on the cable plug end lil Cable Shield is connected to the plug shell Pin1 Black White Pin2 Red Pin3 Black 1 0 Pin4 Violet 11 RedDotUp 9 Pin5 Blue Pin6 Yellow White Pin7 Blue White Pin8 Red White and Violet White Pin9 Orange Pin 10 Yellow Pin 11 Orange White Figure 63 4 6 3 Grounding Strain Relief Fitting Assembly Inspect the three metal grounding cable strain reliefs supplied with the POI Box Identify the cable seal The cable seal is seen from the compression nut side of the fitting assembly The smaller diameter seal light gray is for cable diameters from 0 11 inch 2 8 mm to 0 28 inch 7 1 mm Two are supplied Use one for the IRCON Sensor interconnecting cable The larger
133. e infrared energy a blackbody would emit at a given temperature All Modline 5 Sensors are factory calibrated using blackbody standards For accurate measurements you must compensate for the difference between the emissivity of your target and that of a blackbody radiator Modline 5 Series Sensors except the Series 5R are single color brightness thermometers Brightness thermometers depend upon the intensity of the infrared radiation Since most process targets have an emissivity of less than 1 0 setting the Emissivity value to match the emissivity of the target material is necessary Series 5R Sensor use the two color ratio measurement described in Section 8 5 Ratio Sensors page 148 Methods of determining emissivity are described below 8 4 1 Using Emissivity Tables One way to determine an approximate Emissivity setting is to refer to a set of emissivity tables Table 17 Table 18 Table 19 and Table 20 are provided for this purpose Emissivity values in the tables are based on actual tests on samples of the materials Because the emissivity of most materials changes with wavelength a separate column of emissivity values is provided for each Sensor series To use the tables locate your target material and obtain a value from the column for the Sensor series you are using Adjust the Emissivity value setting to this value Most table values are in the form of ranges This is because the details of an object s form and characteristics affe
134. e limited in some situations Guidelines are provided in Section 8 Applications Guide page 137 3 7 Sensor Mechanical Installation 3 7 1 Installation Accessories The Modline 5 Sensor requires the use if one or more installation accessories to mount align and aim the Sensor The installation accessories also provide for cooling the Sensor and air purging the optics to keep them free from contamination Presentation of accessories and sensor installation is organized in the Sections below as follows 32 Rev L4 12 2012 Modline 5 Sensor Installation e Sensor dimensions and specifications e General requirements for all installations including cable clearances access for aiming focusing and setup e Description of each accessory accompanied by dimensions and specifications e A table of recommended accessory groupings e Illustrations of the groupings accompanied by overall dimensions Other accessories such as pipe mounts sight tubes target tubes window assemblies etc are referenced at the end of this section 3 7 2 Sensor Dimensions The dimensions of the Standard and Dirty Window Detector Modline 5 Sensors are given below These dimensions are without any mounting accessories Figure 15 Standard Modline 5 Sensor 8 28 Sensor Front 210 4 Rear Size of Cone of Vision at the Lens is 0 95inch 24 mm Figure 16 Dimensions Standard Sensor Figure 17 Sensor with Dirty Window Detector DWD
135. ed set the E Slope Control of the Sensor to a value of 1 00 Materials which require an E Slope setting of 1 0 e Blackbody calibration standard e Cavities in any opaque isothermal body e The following metals when worked in air are subject to oxidizing Iron Cobalt Steel Nickel Stainless Steel The second main classification is a family of metals with emissivity that exhibit a non linearity or slope of approximately 1 06 Materials which require an E Slope setting of 1 6 e Clean smooth unoxidized surfaces of the following metals Iron Molybdenum Molten Grey Iron Platinum Cobalt Rhodium Nickel Steel Tungsten Stainless Steel Tantalum If the materials in your process do not fall into either of these categories you will have to test your product to find the appropriate E Slope setting To do this sight the instrument on a sample target having a temperature that you have accurately determined by some other means such as a reliable thermocouple For best accuracy select a temperature near the center of the instrument s range or better still carry out the test at several points throughout its range Adjust the E Slope Setting until the indicated temperature matches the value you have previously determined Set the E Slope control to this value whenever measuring this type of target If you use several tests average the results and use the averaged value as your E Slope setting 148 Rev L4 12 2012 Modline 5 A
136. ed Y and A The third is an Enter pushbutton labeled ENT with the keyboard enter symbol J These buttons are identified as WA and in this manual A sight for visually aiming the Sensor is located in the center of the keyboard The process target and Sensor circular reticle can be seen when viewing through the sight Sensors with the Laser aiming option have a pushbutton to energize a laser in place of the sight Access to the keypad requires removal of a screw on protective window with O ring gasket The protective window must be in place during temperature measurement to maintain the NEMA 4 IP65 Sensor housing rating Temperature in C or F LOW Below zero scale temperature HIGH Above full scale temperature INV Invalid Condition for Ratio Temperature Measurement Figure 83 Sensor with Visual Through the Lens Sight 90 Rev L4 12 2012 Modline 5 Operation Figure 84 Sensor with Laser Through the Lens Aiming Option Laser pushbutton is located on the edge of rear panel Visual sight is not available with this option installed LED above pushbutton is on when laser is energized See Section 5 11 Laser Sighting Operation page 110 for complete Laser operation and safety instructions 5 3 Navigation and Menus 5 3 1 Enter and Up Down Arrow Pushbuttons Up and Down Arrows WA are inoperative during valid temperature measurement Arrows are operable when an Alarm Condition has been sensed and the ALARM indicator is
137. ed to overcome adverse conditions Pre focusing the Sensor s optical system may be necessary if the Sensor is to be mounted in a difficult location and not accessible Pre focus by setting up a well defined target such as a printed page at the exact distance of the target then lock the rear focusing section Setup of the Sensor parameters can also be pre determined and set before installation The following guidelines will help you in planning the Sensor installation Mechanical Mounting Location Requirements The Sensor is installed using the mounting brackets and flanges air purging and water cooling accessories illustrated in the Section 3 9 Modline 5 Mounting Cooling and Air Purging Accessories page 35 Sensor Mounted to Earth Ground Potential If the proposed mounting surface is at Earth Ground potential you can mount the housing directly to this surface If the surface is not at Earth Ground potential electrical insulating material and non conducting hardware must be used to isolate the Sensors See Section 4 11 Installing and Wiring the Chassis Mount 24 Volt DC Switching Power Supply page 80 for more information Sensor Interconnecting Cable Length Maximum cable length between the Sensor and the POI Power Supply Signal Interface Box or Terminal Plate is 350 ft 107 m Maximum temperature rating of the Sensor Interconnecting cable is 200 C 392 F Plan the cable route accordingly Ambient Temperature Limits for Sensor POI
138. egulations in the USA Europe and the other countries must be ensured Adhere to all safety and local electrical codes Before operation is started the following conditions must be ensured Connection to mains supply in compliance with national and local regulations Mains cables must be sufficiently fused Supply a two pole switch for 100 VAC to 240 VAC at 50 to 60 Hz The switch should be clearly marked as the power shutotf for the equipment visible and accessible to the operator Install in environments where the power supply enclosure will not exceed 55 C 131 Keep away from fire and water Tinned stranded 18 AWG 1 mm wire for AC power and ground connections is recommended terminals accept 16 AWG wire maximum Strip insulation from wires 1 4 inch 8 mm Connect the LINE and NEUTRAL wires of the AC power line to the power supply module as indicated on the module LINE to AC L and NEUTRAL to AC N The non fused protective earth ground connection must be connected to the FG terminal of the module Protection Class 1 Ground wire must be the same size or larger than AC power wires Use tinned stranded 22 AWG 0 35 mm wire for the 24 VDC plus and minus connections to the TSP Observe polarity Improper installation or operation can result in serious injury or death to personnel The installation should be performed following all national and local electrical A codes Never work on the power supply if mains power is supplied
139. elay the start of peaking action Example Before a moving work piece enters the target viewing area the System may be sensing a measured temperature below the selected Reset Below temperature As the target comes into view the hotter temperature is sensed and the Peak Picker Delay time out begins When the delay is completed the system will begin peaking action on the measured temperature until the work piece passes the Sensor Peak Picker with Delay Time Sensor Output Signal Delay Time Figure 93 Peak Picker Delay The Delay Time can be used with the Auto Reset turned off In this case the Delay will only begin after a reset occurs See sub section Peak Picker Reset above for how to initiate a reset 8 7 Track and Hold The Modline 5 includes a Track and Hold function that allows continuous temperature measurement in the Track mode and suspended measurement in the Hold mode with the last temperature reading held Selection of the Track and Hold function is made with the Sensor rear panel SIGL menu and TRAK function or the RS 485 TS Command 8 7 1 External Switch Control of Track and Hold The Modline 5 has provisions for a remote process controlled input switch be wired to the Violet and Violet White twisted wire pair of the Sensor s interconnecting cable If Track and Hold signal operation is selected the switch input is required to change from Track temperature operation to Hold temperature mode as required in the proce
140. en the target and Sensor Two color ratio units are usually not affected by obstructions that are significantly lower in temperature than the target Ratio units are affected by hot objects in the cone of vision that are much higher in temperature than the target If too high the hot targets can dominate the measurement If the object temperature is the same the measured temperature is not affected Target Obstruction Cone of Vision Sensor Figure 13 Cone of Vision Obstruction 3 5 3 Resolving Targets with Two Color Ratio Sensors Modline 5 Series 5R Ratio Sensors utilize a dual detector assembly that measures temperature by comparing infrared radiation levels in two wavelength bands 0 85 to 1 05 microns and 1 0 to 1 1 microns Temperature readings are based on the ratio of the two signals in these bands Modline 5 Rev L4 12 2012 29 Sensor Installation Because Series 5R Sensors measure the ratio of radiation intensities at two wavelengths rather than the absolute intensity of radiation at a single wavelength they are almost immune to error caused by loss of signal Small targets that do not fill the field of view and partial obstructions from bursts of steam dust and solid objects in their sight path can be tolerated 3 5 4 Signal Reduction Three causes contribute to the loss of signal e Low target emissivity e The measured object is too small to fill the reticle as seen in the Sensor sight and is not complete
141. ench recommended Table 3 Mounting and Assembly Supplied Parts List Modline 5 Rev L4 12 2012 39 Sensor Installation 3 00 76 2 mm Locating PINs 2 Places Drain Holes 2 Places Flat surface align with flat Three Counterbore surfaces on other Accessories Holes for M6 Sockethead Cap Screws For assembling to UAA or WJA Three M6 tapped Holes for DIA 3 500 88 9 mounting MFS or MFL Flanges Figure 26 APA Dimensions i Dimensions are in inches and millimeters Do not scale 3 9 4 MFL Mounting Flange Large Description and Dimensions The larger of the two mounting flange accessories the MFL has the bolt circle pattern that matches many of IRCON s other products and accessories It provides a simple means of replacing older instruments and using existing accessories See Section 3 12 for Other Accessories The MFL is mated to the Sensor by attaching it to the threaded holes in the front of the UAA APA and WJA accessories Inner and outer groups of three through holes are used for attachment These holes are covered by a metal gasket Figure 27 MFL Accessory 40 Rev L4 12 2012 Modline 5 Sensor Installation Material Clear Anodized Aluminum Weight Approximately 1 pound 0 5 kilograms Qty Part No Description and use User Supplied Tools 482172 Metal Gasket Cover 230312060 M3 X 12 mm flat head cap screw to secure gasket cover 2 mm hex key wrench 3 230630C60 M6 x 30 mm flat head cap
142. ept the 24 V power supply wires that are 22 AWG 0 35 mm Maximum Cable Temperature Cable temperature not to exceed 200 C 392 F Maximum Cable Length 350 feet 107 meters Minimum Bend Radius 3 inches 76 mm Cable Diameter Nominal Diameter 0 310 inch 7 6 mm Cable Routing Within conduit or low level signal plenum or cable tray Location Away from high power and high frequency sources and high temperature sources Consider the cable route The cable should be protected from plant traffic and any hostile environments Avoid high temperature zones or areas subject to electrical or high frequency inter ference 4 4 Model POI Power Supply Signal Interface Box A POI Power Supply Signal Interface Box with cover removed and with full a set of Grounding Strain Relief fittings installed is shown below The box is sent with protective NEMA 4 seals inserted in all cable and conduit entry holes The strain relief fittings are used to ground the cable shield and are supplied with the box Figure 57 POI Power Supply Signal Interface Box Modline 5 Rev L4 12 2012 63 Sensor Wiring The POI Box contains a DC power supply that develops 24V for the Sensor Power The POI accessory also contains a terminal strip for connecting the Sensor cable to user supplied interface cables Sensor inputs and outputs are interfaced to the user s system at this point POI Box Specifications Maximum Ambient Temperature Ambient temperature should not
143. erature below which the peak picker signal conditioning is in reset or direct reading mode Sensor is measuring temperature without peaking action in this mode Function is used with Auto Peak Picker Reset Message Value Range Unit s Zero Scale Temperature to Unit s Full Scale Temperature F or C PD Peak Delay Read Write Sets the delay time before Peak Picker action starts Message Value Range 0 to 1000 Zero 0 turns off any delay Above 0 this is a scaled value Scaled input above 0 actual value times 100 Actual Delay Range in Seconds 0 010 to 10 seconds 6 8 Measurement Condition and Alarm Command Codes 6 8 1 Introduction This section identifies measurement and alarm status commands and defines the reported errors and measurement conditions TI TS Temperature Status and Attenuation Read Only Returns the temperature the unit is reading followed by a comma then the current status see the ST command for details another comma and then the current attenuation percent expressed as a number from 0 to 100 Range N A TS TS Temperature and Status Read Only Returns the temperature the unit is reading followed by a comma and then either a 0 no alarm conditions or a number with the same format as the ST Command Range measured temperature in degrees C or F and 32768 to 32767 ST System Alarm and Measurement Condition Status Read Only The Sensor returns a message indicating the curre
144. erfacing the Modline 5 into a process monitoring and control system POI Power Supply Signal Interface Box AC Power Input 100 240Vac 50 60Hz T Interconnecting Cable Sensor Alarm Relay Contacts A A Peak Picker Track amp Hold Remote E 7 Switch Input T Terminal Strip Input 4 20 mAdc for Remote Plate 24Vdc Sensor Power Supply limited to 2 Amps RS 485 Digital Communication to Modline 5 DPM PLC Host Analog Current Output Computer or other Device Selectable 0 20 mA or 4 20 mA Scaled to Sensor temperature span or customized for process Single or multiple series connected differential input devices Digital Indicators Recorders Controllers Control Systems 600 Ohm maximum load resistance including cable resistance Figure 56 Block diagram 62 Rev L4 12 2012 Modline 5 Sensor Wiring 4 3 Modline 5 Sensor Cable 4 3 1 Sensor Interconnecting Cable The Interconnecting cable carries all inputs outputs and the 24 VDC power for the Sensor The cable is routed from the Sensor to the Model POI Power Supply Signal Interface Box or the Terminal Strip Plate supplied with each cable All IRCON Modline 5 interconnecting cables are supplied assembled with the Sensor connector on one end and the wires stripped tinned and ready for termination on the opposite end The cable shield is also prepared and ready to assemble with the Ircon supplied EMI shielding strain reliefs All cable wires are 24 AWG 0 25 mm exc
145. et s true temperature For Series 5R Sensors background interference that is slightly cooler than the target results in temperature indications that are too low When the background temperature is much lower than that of the target however the indicated temperature is unaffected If the interfering background sources are hotter than the target the indicated temperature is too high There is no error in the indicated temperature with a Series 5R Sensor when the background temperature matches the target temperature Sensor Lens F Max 45 Target Figure 95 Viewing Angle When the environment includes unfiltered background light or heat sources select a viewing arrangement that minimizes these problems In general the higher the target s Emissivity the less susceptible the measurement is to errors Emissivity E Reflectance R and Transmission T are related as follows E 1 T Ry Maximum accuracy is possible when E 1 0 blackbody condition In this condition there is no reflection and no transmission of background energy to cause measurement errors As emissivity decreases it is harder to get accurate readings because reflectance and or transmittance become more pronounced Use caution when attempting to measure materials with emissivity values known to be 0 2 or less 8 8 3 Transmission Effects If the target has some transmission at the operating wavelength it can act as a window for infrared emission from object
146. formed Message Value Range Not Applicable Actual value Always returns AOPR lt CR gt where A the sensor DR Peak Picker Read Write Sets the peak picker decay rate Zero 0 sets the unit to never decay Otherwise decay is in selected measurement units F or C See Section 5 10 1 D R Decay Rate Function page 108 for more information For Sensors with firmware versions 1 02 and higher Scaled Message Value Range 0 to 30000 F per second times 100 Scaled Message Value Range 0 to 16666 C per second times 100 Actual Value 01 to 300 00 F per second except 0 which Off Actual Value 01 to 166 66 C per second except 0 which Off Sensor Firmware Version Operation Summary Original Sensors with firmware versions less than 1 02 have unit less degree units lil that range 0 00 to 300 00 for both F and C units selection For those Sensors the following operation applies Sets the peak picker decay rate Zero 0 sets the unit to never decay Otherwise decay is in F or C per second 122 Rev L4 12 2012 Modline 5 Digital Communications Scaled Message Value Range 0 to 30000 F or C per second times 100 PS Peak Picker Auto Reset Read Write Selects Peak Picker Auto Reset operation Scaled Message Value Range 0 to 2 Actual Value 0 to 2 Zero 0 Sets Auto Reset to Off 1sets it to On 2 is reserved for future use PK Peak Picker Reset Below Temperature Read Write Sets the temp
147. found in Section 5 Operation page 90 of this manual A third way to adjust the Emissivity is to send a scaled input of 4 to 20 mAdc via the Orange and Orange White twisted wire pair of the Sensor s interconnecting cable The Modline 5 senses an input and overrides any other setting of Emissivity or Match Wiring and scaling information is in Section 4 Sensor Wiring page 62 of this manual 8 4 4 Using Relative Readings True temperature readings are not always necessary Relative temperature readings may suffice in applications where temperature variations rather than precise temperature values are of interest It is not necessary to know the target s emissivity for relative temperatures Meaningful relative temperatures can be obtained if a the Emissivity value setting is kept constant and b the target objects to be viewed are of similar form and composition For relative readings we suggest an Emissivity setting of 1 000 8 4 5 Practical Limits on Emissivity While all MODLINE 5 instruments are capable of emissivity settings of 0 100 to 1 000 it is not always advisable to use the lower emissivity settings Potential temperature measurement errors due to background reflections are aggravated by a combination of decreasing target emissivity and decreasing target temperature Temperature indications may become noisy due to the higher amplification at low emissivty settings For Series 56 and 5G Sensors it is recommended that the Emissiv
148. g this Modline 5 Rev L4 12 2012 99 Operation automatic function Real time process temperature measurement and signal conditioning are suspended for 15 seconds RS485 and Current Loop Outputs are held at the last reading during the Self Calibration Navigate from TEMP display with J amp A Vto ENGR then use J amp A Y to Hour METE Instructions Display and Limits HOUR Press ENT to view Automatic Calibration Check Selection is a numerical value Value in hours representing hours between a Check with Self Calibration 168 168 hours only or OFF Factory setting Press ENT to save and return to TEMP display or OFF If OFF is selected user must perform Manual Cal every 168 hours or less 5 6 8 WRNL Dirty Window Detector Option Warning Level The Dirty Window Detector Option is specified at the time the Sensor is ordered and must be factory installed The WRNL function is only viewed on Sensors with the option Select OFF CORS or SENS OFF turns the dirty window detection off Coarse and sensitive Warning Levels select a greater CORS or lesser SENS amount of Sensor window transmission loss required to trigger an alarm Navigate from TEMP display with J amp A Vto ENGR then use J amp AV to WRNL Display Instructions Display and Limits WRNL Press ENT to view Dirty Window Detector Warning Level selection OFF CORS SENS OFF SENS Sensitive or CORS Coarse Use Up Down Arrows to select Press ENT to save and
149. h mirror quality finish to dull mill finish e Values for low emissivity entries can be significantly greater than shown if surfaces are even slightly contaminated Material Emissivity Range by Sensor Series 52 5R 5G 56 One Color Mode Table 17 Emissivity Values of Metals and Alloys 144 Rev L4 12 2012 Modline 5 Applications Guide Emissivity Values of oxidized Metals and Alloys Flat Surfaces e Emissivity ranges shown represent differences in surface finish smooth finish to rough grainy finish e Oxide film assumed to be sufficiently thick to avoid thin film interference effects Material Emissivity Range by Sensor Series 52 5R 5G 56 One Color Mode Aluminium anodized S Table 18 Emissivity Values of oxidized Metals and Alloys Modline 5 Rev L4 12 2012 145 Applications Guide Emissivity Values of miscellaneous Materials Bulk Normal Form e Unless otherwise noted these materials have no transmittance in their normal form e Emissivity ranges shown for opaque materials represent differences in surface finish smooth polished finish to rough uneven finish e Emissivities of partially transparent materials will also increase with sample thickness Material Emissivity Range by Sensor Series 52 5R 5G One Color Mode Asphalt Tar Pitch Po 0 95 100 Carbon Graphite 0 65 0 80 Cinders Slag Cinkers 0 85 0 95 0 95 1 00 Firebrick 2 thick O Foods bulk fruits veget
150. h the Laser Sight option installed see section 5 11 Laser Sighting Operation page 110 of this manual for safe and full operating instructions Install Sensor and setup Laser operating procedures so that personnel are not exposed to the laser beam at any time whether the Laser is energized remotely or at the Sensor Rear Panel Certification and Identification Label Warning Label Figure 9 Sensor Laser Labels These two Sensor Laser labels are shown in detail in Figure 10 CAUTION LASER LIGHT Ircon Inc DO NOT STARE 7300 N Natchez Ave Niles IL 60714 USA INTO BEAM Model No ___ Serial No 1 mW at 635 nm Date Manufactured CLASS Il ipa a Complies with 21 CFR 1040 10 and 1040 11 LASER PRODUCT Certification and except for deviations pursuant to Warning Label Identification Label cies tadashi leotard dei Figure 10 Sensor Laser Labels in Detail Modline 5 Rev L4 12 2012 25 Sensor Installation 3 4 Sensor Optical Characteristics 3 4 1 Optical Resolution The Sensing Head is sensitive to infrared radiation in the area indicated by the Cone of Vision in the illustration below Focal Point l d D F l I l i where 4 d diameter of cone at focal point d D distance from front of Sensor to focal point For Sensors with DWD Option add 2 6 inches 66 mm for distances measured from tip of front hood Cone of Vision F Resolution Factor of Sensor Model and Lens combination Sensor Figure 11
151. he Sensor and perform any operational checks that may be necessary to make sure the instrument is functioning properly Rear Focusing Section Lens Lock Thumb Screw Do Not Use Tools Cable Connection Match Red Dots Rear Protection Window Figure 86 128 Rev L4 12 2012 Modline 5 Maintenance For Modline 56 sensors occasionally a calibration flag that operates during the Sensor internal Calibrate test may move into the viewing area during shipment If this occurs the viewing area will be dark and appear obstructed This flag will be positioned correctly when power is applied to the Sensor The Modline 5 Sensor with Laser sighting option is a Class II Laser product When restoring a Sensor with this option back to service follow the Cautions outlined below and the operating instructions in Section 5 11 Laser Sighting Operation page 110 of this manual A CAUTION LASER LIGHT DO NOT STARE INTO BEAM 1 mW at 635 nm CLASS Il LASER PRODUCT other devices using RS 485 Communications insure there are no personnel in the lil Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or path of the beam 7 3 Servicing There are no user adjustable controls or serviceable parts within the Sensor Housing Units must be returned to the factory for calibration and adjustments Do not disassemble the unit 7 4 Factory Calibration and Service Instruments are calibrated against precision labo
152. he shielding must be clamped to the ground shield clamps on the plate All cables must be properly dressed for shield grounding Twisted pair wires must remain twisted and kept as short as possible The IRCON Sensor cable is supplied with the connector attached on one end The opposite wiring end is prepared and supplied as per the following procedure If the cable is shortened the preparation procedure must be followed User supplied cables require similar preparation A Strip off 9 inches 229 mm of the outer jacket B Partially cut back the outer braided shield Leave 1 inch 26 mm of shield exposed to attach a strain relief or connection to a Terminal Strip Plate shield clamp C Cut wires to lengths shown in table below Note different Red and Red White wire lengths for POI Box and Terminal Strip Plate Strip all wire pairs ends 3 8 inch 10 mm and tin with solder 3 5 inches 3 25inches 3 00 inches 2 50 inches 2 25inches 1 75 inches Pair 89 mm 83 mm 77 mm 64 mm 57 mm 45 mm 0 50 eee D O E Yellow White Yellow Yellow White al S T Sanm _ Blue White Blue Blue White omava AO E PA omenie Orange White Orange Orange White Violet White Violet White Violet Black White Black White Black Table 14 Red and Red White wire lengths for POI Box and Terminal Strip Plate Red for POI Box 3 25 inches 83 mm Red White for POI Box 3 5 inches 89 mm Red for Terminal Strip Plate 10 inches 241 3 mm Red Whit
153. iamps can be set to equal the Sensor s 2500 degree full scale temperature or to an alternate value such as the 1800 degrees illustrated in the figure When scaled to equal the Sensor s complete range the analog current output corresponds to a 500 to 2500 degree range and a temperature span of 2000 degrees With the alternate temperature scaling the analog current output corresponds to a 1000 to 1800 degree range and a temperature span of 1000 degrees A minimum 10 degree F 6 degree C span between zero scale and full scale is required 500 2500 Sensor temperature span 2000 Scaled analog Scaled analog output zero scale output full scale Figure 88 Analog Output Scaling 8 2 2 Measured Temperature Calculations An analog current signal output of 0 to 20 mA provides a full 20 mA current span The 4 to 20 mA output provides a 16 mA current span To convert the output current to temperature you must know the current output span and corresponding temperature span to calculate the resultant temperature 138 Rev L4 12 2012 Modline 5 Applications Guide Zero current output 0 or 4 mA as selected equals the corresponding zero scale temperature A 20 mA reading corresponds to the full scale temperature Since the output current varies linearly with temperature equal increments in current will provide equal increments in temperature between these range limits Expressed as a formula for the 4 20 mA analog output is Tinp
154. in Alarm condition open when not in alarm condition Contacts are held open for both N O and N C operation when the Sensor is not powered and for 3 to 5 seconds after power is applied to the Sensor during the initiate period Normally Closed N C operation is considered fail safe operation The table below details the alarms and measurement conditions that trigger the Alarm Relay Details about these Alarms are found in Section 7 Maintenance page 127 Modline 5 Rev L4 12 2012 7 Sensor Wiring Sensor Error Code Alarms X101 Dirty Window Detection X102 Out of calibration X103 Detector block too hot X104 Detector block too cold X105 Case temperature too high X106 Case temperature too low X107 Sensor failure FAIL may be seen on the Sensor TEMP display X108 Analog Output Current loop malfunction open circuit X109 Dirty Window Detection malfunction Measurement Condition Alarms INV Measurement Conditions are invalid for two color ratio temperature measurement When the Invalid Alarm ALM function is set to ON this measurement condition becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear panel pINV pINV is only displayed when the Invalid Alarm ALM function is set to ON and Peak Picker or Track and Hold is On this condition becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear panel Temperature displayed is Peak Picked or Hold Mode Temperature val
155. inals for the 24 VDC Power Supply Peak Picker Track and Hold Switch and Analog Output are connected internally A Connect the Analog Output to devices with differential inputs that have not been grounded B The terminal of the mA input for remote Emissivity and E Slope current input is isolated but will only tolerate a difference of approximately 2 Volts between it and Sensor Common Input impedance is 120 Ohms See Note 8 for connecting Common to ground The RS485 Data connection is not isolated Use an external isolator if isolation is required Modline 5 Rev L4 12 2012 87 Sensor Wirin lil 7 Alarm Relay contacts are isolated from ground and Sensor internal common 8 For the POI Box A 100 ohm 5 watt resistor is connected between the Sensor internal common to earth ground For practical purposes the minus terminals connected to the internal common should be considered grounded For the Terminal Strip Plate Depending on the installation the internal common will be connected to ground through a 100 Ohm 1 Watt fusible resistor See Section 4 10 for details 9 The Terminal Strip Plate is supplied with a transient suppressor across the Red and Red White power supply wires on the left side of the terminal strip 10 The Terminal Plate is supplied with a ceramic ferrite bead for the Red and Red White power supply wires 11 The Terminal Strip Plate must be placed in a metal enclosure for protection from electros
156. indow materials for various Modline 5 Sensor Series are listed in the Window Selection Guide Table 21 Available Windows Specifications Optical Grade 1 8 inch thick Polished to Plate Glass Finish Series Pyrex 7740 Fused Quartz Synthetic Calcium Fluoride Cleartran ZnS G E 124 or eqiv Sapphire 52 5G Suitable T 0 92 Recommended T 0 94 Suitable T 0 85 Suitable T 0 94 Suitable T 0 94 Recommended T 0 94 Suitable T 0 85 Suitable T 0 94 Suitable T 0 94 Recommended T 0 94 Suitable T 0 85 Suitable T 0 94 Suitable T 0 94 Table 21 Window Suitability and Transmission Factor T The window material must be highly transparent in the Sensor s infrared spectral region Yet there is always some signal loss due to reflection or absorption when using a window To compensate for this 158 Rev L4 12 2012 Modline 5 Applications Guide loss first multiply the emissivity of the target object by the window s transmission factor T shown in the Window Selection Guide Then adjust the emissivity setting to this value Example Emissivity of object 0 8 Transmission factor of window 0 92 Emissivity setting 0 8 X 0 92 0 74 The window specifications given at the top of the chart are suitable for most applications However high pressure or vacuum chamber applications may require windows that are thicker than 1 8 3 mm Be aware that transmission of thicker windows may be significantly degraded Itis good practice to
157. ine 5 ModView Configuration Software Distributed with Ircon Modline 5 Sensors IMPORTANT THE ENCLOSED SOFTWARE IS LICENSED ONLY ON THE CONDITION THAT THE LICENSEE REFERRED TO IN THIS AGREEMENT AS YOU AGREES WITH IRCON INC REFERRED TO IN THIS AGREEMENT AS IRCON TO THE TERMS AND CONDITIONS SET FORTH IN THE FOLLOWING LEGAL AGREEMENT READ THIS SOFTWARE LICENSE AGREEMENT CAREFULLY AT THE END YOU WILL BE ASKED TO ACCEPT THIS AGREEMENT AND CONTINUE TO INSTALL THE SOFTWARE OR IF YOU DO NOT WISH TO ACCEPT THIS AGREEMENT TO NOT ACCEPT THIS AGREEMENT IN WHICH CASE YOU WILL NOT BE ABLE TO INSTALL AND USE THIS SOFTWARE LIMITED USE LICENSE AGREEMENT IRCON will grant You a nonexclusive nontransferable license to use the enclosed computer program and accompanying documentation including software updates if any if you agree to the following terms and conditions 1 TERM This Agreement is effective from the date on which You install the Software This Agreement may be terminated by You at any time by uninstalling the Software on any and all computers on which You have installed the Software together with all copies modifications and adaptations in any form It will also terminate if You fail to comply with any material term or condition of this Agreement 2 LICENSE The license granted to You by IRCON when You install the Software authorizes You to use the Software on any computer that may be owned or operated by You or Your subsidiary or
158. ing held an Note 1 Factory default setting 168 DPM MSI OFF User must perform Manual Cal every 168 hours or less X104 X103 X101 A Detector Hot or Cold alarm must be off for at least 15 minutes before a Cal Check can be initiated See Section 5 12 Out of Range Displays and Error Codes page 112 for error code explanations lil The Calibrate Check function will not operate with Sensor Alarms X107 X106 X105 98 Rev L4 12 2012 Modline 5 Operation Series 56 Self Calibration at Power On or After Power Interruption of 15 minutes or longer Calibration Check Initiation Alarm Temperature RS485 and 20mA Condition Display Temperature Outputs sensor is within Operating Temperature 15 minute warm Detector Hot Cold Temperature is Displayed Range 0 to 55 C 32 to 131 F at Power On up and Self Cal Alarms on and provided at outputs but cycle time is not accurate until alarms are off and after Self Cal cycle At Power On Warm up and Self Detector Hot Cold Temperature is Displayed sensor is outside Operating Temperature Cal requires Alarms on and provided at outputs but Range 0 to 55 C 32 to 131 F but in warm up within is not accurate until alarms Storage Temperature range Operating are off and after Self Cal 20 C to 0 C or 55 C to 65 C 4 to 32 F or Temperature f cycle 131 to 149 F Power Interruption of less than 15 minutes Operation Power Interrupt ON OFF On Fifteen minute Detector Hot
159. ion Installation and Maintenance of Solid State Control The thrust of this document is personal safety The guidelines contained in this document should be followed for critical processes that depend upon the operation of this instrument The user should provide a redundant system or device that will initiate a safe process shutdown in the event that this instrument or associated system should fail The control of a process should not 88 Rev L4 12 2012 Modline 5 Sensor Wiring be solely dependent upon this instrument and its peripheral components Other measuring and controlling safe guards should be included in a redundant system designed to provide warning of conditions that may cause personal injury or property damage These safeguards should be in place at all times including startup and shutdown as well as normal operation Procedures should be in place that verify proper instrument and system operation after service maintenance or replacement to insure the instrument and peripheral components are returned to service properly All alignments settings and connections required for proper operation must be performed or verified A computer with specialized software may be used as an operator interface for setup and operation of the system Digital and analog communication with alarms and controllers may be part of the system making it a more complex system Changing software configurations and settings requires that process performance
160. ions The following symbols are used to highlight essential safety information in the operation instructions Helpful information regarding the optimal use of the instrument Warnings concerning operation to avoid instrument damage and personal injury Incorrect use of 110 230 V electrical systems can result in electrical hazards and personal injury All instrument parts supplied with electricity must be covered to prevent physical contact and other hazards at all times 2 Rev L4 12 2012 Modline 5 j Product Description 2 Product Description 2 1 Modline 5 Sensors Cable and Interface Accessories The basic Modline 5 System consists of either a standard Sensor or Sensor with the Dirty Window Detection option with an interconnecting cable and Terminal Strip Plate Optional components include the POI Power Supply Signal Interface Box and the remote DPM Digital Meter operator interface 2 1 1 Preliminary Inspection The Modline 5 is delivered in plastic wrappings cradled in foam inside rugged cartons The Sensor and any accessories you have ordered are shown on the packing list The photograph above identifies Modline 5 system components See Section 3 Sensor Installation page 22 to identify mounting air purging water cooling and other mechanical accessories Figure 1 Sensors Cable and Interface Accessories Place all items on a workbench or desk before removing the plastic covers Inspect each item carefully to
161. ircuit Dirty Window Detection malfunction pINV is only displayed when the Invalid Alarm ALM function is set to ON and Peak Picker or Track and Hold is On This condition becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear panel Temperature displayed is Peak Picked or Hold Mode Temperature values from prior valid measurement conditions Environmental conditions can cause Sensor errors High or low ambient temperatures can cause Sensor case temperature too high or too low errors Dirty lens conditions can be avoided using air purging Investigate all alarms indicated by the ALARM word indicator Temperature readings on rear panel display at Analog Output or from RS 485 Communications may be inaccurate with Error Codes X101 through X109 alarms Ratio Temperature measurement conditions are invalid with INV and pINV alarms Modline 5 Rev L4 12 2012 131 Maintenance 7 6 Status Displays and Error Code Details Status Display Error Code Details The temperature display is The display shows LOW when the measured temperature is below LOW or HIGH the Sensor Zero Scale Temperature by a few degrees Is the Emissivity or E Slope setting correct The display shows HIGH when the measured temperature is Is the field of view blocked above the Sensor Full Scale value by a few degrees The display remains LOW or HGH as long as the measured Are reflections or background energy temperature is out of range
162. its to be used for display Use matching units display overlay provided See Figure 102 in this Section See Section 5 6 ENGR Setup of Engineering Functions page 94 of manual for further instructions rELY Relay Polarity Set the relay operation to correspond to proper and safe use of the contacts in the process system Select N C for closed relay operation with Sensor not in Alarm condition open in alarm state Select N O for closed relay operation with Sensor in Alarm condition open when not in alarm condition Normally closed operation is considered fail safe operation AL FW Invalid Measurement DFF Condition Alarm HH System Check YES Checking Cal Hour ON selects Invalid Condition as ALARM to activate Alarm relay and rear panel ALARM display OFF Invalid is not alarm condition Initiates Sensor internal circuit and detector check Do not initiate Check with active Alarm s for Error Codes X103 X104 X105 and X106 See Section 5 6 ENGR Setup of Engineering Functions page 94 ra Displayed during check Read Only May be displayed after check Read Only May be displayed after Cal check Read Only Check DPM Diagnostics Section for Alarm Status and Section 7 Maintenance page 127 sowana a E o 9999 Time before next Auto CHK in Hours 0 OFF no timed Automatic Check Other Numerical value sets interval Models 52 5G between Automatic Calibration checks and 5R
163. itself Solid state components do not have a mutually exclusive NO NC arrangement However external circuitry can be employed to sample the input and contact state and compare to determine if the system is functioning properly 3 3 2 Polarity and Phase Sequence Input power and control signals should be applied with polarity and phase sequence as specified by the manufacturer Solid state devices can be by the application of reverse polarity or incorrect phase sequence 3 4 Planning Electrical Noise Rejection The low energy levels of solid state controls may cause them to be vulnerable to electrical noise This should be considered in the planning stages 3 4 1 Assessing Electrical Environment Sources of noise are those pieces of equipment that have large fast changing voltages or currents when they are energized or de energized such as motor starters welding equipment SCR type adjustable speed devices and other inductive devices These devices as well as the more common control relays and their associated wiring all have the capability of inducing serious current and voltage transients on their respective power lines It is these transients which nearby solid state controls must withstand and for which noise immunity should be provided 180 Rev L4 12 2012 Modline 5 Appendix A An examination of the proposed installation site of the solid state control should identify equipment that could contaminate power lines All power
164. ity setting be limited to 0 3 to 1 0 for the first 55 C 100 F for all temperature ranges 142 Rev L4 12 2012 Modline 5 Applications Guide The more times reflected radiation bounces on a surface the less reflective the target This is because the surface absorbs more of the radiation at each bounce leaving less and less radiation to be reflected away from the surface Since targets that are less reflective have higher Emissivity the rough surface and the cavity illustrated in Figure 90 represent increasingly higher emissivity values even though they are made from the same material as the polished surface It is best to measure targets with high emissivity values High reflectance off or transmittance through the target introduces the possibility of measurement error due to background interference Avoid reflections when measuring targets with Emissivity less than about 0 8 Highly Reflective Low Emissivity 1 Polished surface of material Highly Reflective Good Emissivity gt 2 Rough surface of material A Very poor Reflector Approaching blackbody condition Best Emissivity 3 gt gt 1 00 3 Cavity surface of material Figure 90 Surface Finish affects Emissivity Modline 5 Rev L4 12 2012 143 Applications Guide Emissivity Values of Metals and Alloys Flat Unoxidized Surfaces e Emissivity ranges shown represent differences in surface finis
165. k function in Engineering Menu Sensor rear panel RS 485 Communications problems Check Communications Lock setting in COMMS Menu Selections are Read Only and Read Write 2 Check Baud Rate setting in COMMS Menu 3 Check Address setting in COMMS Menu Laser will not energize 1 Laser will not energize when CAL function is operating or initiated Peak Picker signal conditioning not 1 Check if the Auto Peak Picker Reset is On If ON evaluate the functioning Reset Below Temperature settings Peak Picker may be Auto reset with Reset Below temperature too low Peak Picker Delay not operating 1 Peak Picker Delay only operates after a Peak Picker Reset or after the first temperature indication displayed after an Invalid INV condition or below Sensor temperature range LOW condition 2 Delay timing starts immediately after the reset or the Invalid or LOW condition Can not adjust AOUT ZERO or FULL Scale 1 Check both ZERO and FULL settings Minimum 10 F span is required or equivalent C span values 136 Rev L4 12 2012 Modline 5 Applications Guide 8 Applications Guide 8 1 Introduction This section offers guidelines to assure measurement accuracy and reliability Although it is impossible to cover every application in detail the general information provided can be adapted to most situations If you run into other situations that may cause problems consult the IRCON Applications Engineering Department 8 2 An
166. las 142 9 o Seo THE EMISOR E E E E E O 142 SAA UNER TOE RELH GS sernir eie i a E A E E A 142 Sit LTN TNO ONESTO U seror A EEN E T 142 S RAO DENSOS a aaa 148 Di nl ee OPC SCI OS E A E E emacs 148 D2 DELI OIE Ta LOVE cies eco Sata ach O E 0 tesuvau E E 149 8 0 Peak Picker Signal OMCIMOMING a hoses sansa sok A a a a 149 9 01 Tarne Peak Picker OVARIO a RARA AAA AAA 149 8 6 2 External Switch jor Remote Peak Picker Oper OD A A AAA 150 E Picker Y A native tata AR I AA AEA 151 BO FP CAG PICK ICSE Laci teasep sas A da atmeeaeee 151 PORC PICKED Decat AENA AA AS 151 SOC AUTO Ben Picker Keser ita Reset BCO A AAA ASA 151 O A A nics beeches wien E A E E E uate E A uct es Susana 152 Sacando diarias pri aii dd 153 Ga IE XI erial Uli COn OF TIC ARA TIONG ia AA AA AA AAA ANA AA 153 8 8 Avoiding Common Measurement Problerms oooooonononooooononnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnono non non ono nnnnnnnnnnnnss 154 AT A NS irre E te T outs tas N E E V E 154 002 BAKO TOUNO INLET N TCE EAE EE E A ORE 154 SiO E E COS aa 155 GOA LIUASTUSSION PAN ES AS ARA AAA 156 0 00 RCAC EL TOS ii li idad pitt 156 97 US OLMOS illa tlildonianliba nl 157 SIOE Or WM OS A A ea nee A saat tetune 158 8 101 Special Considerations Jor Ratio IAS si A A AAN ASA 159 SALE Preventing Sensor OVA cin 160 IDEMINSTALLA TON AND OPERA TION olaa a deca 162 A O E 162 ka Uso tie OLIN ii A ideal 162 22 OF WATS talado lara 162 ADS AA O 163 922 F and C Units Overlay Part Number 41
167. late only The POI Box has its own internal Power Supply that is connected to the right side of the Terminal Strip in Section 4 4 Modline 5 Rev L4 12 2012 79 Sensor Wiring See Section 4 5 to review Terminal Strip Plate enclosure power supply and ground connection requirements Section 4 11 provides instructions for using a chassis mount 15 watt 24 Volt DC Switching Power Supply supplied by IRCON The part number for this power supply is 551632 The external 24 VDC power is wired to the right side of the Terminal Strip Use 22 AWG 0 35 mm wire Total power supply cable run using 22 AWG 0 35 mm wire is 107 meters 350 feet Shielded cable is recommended Paralleling two pairs of 24 AWG 0 25 mm cabling is equivalent to using 22 AWG 0 35 mm cable Connect the positive side of the 24 VDC power source to the 24VDC Terminals Connect the common or negative side of the source to the Common Terminal 4 10 2 Power Supply Common Ground Connection The Common side of the power source must be connected to earth Ground If the de power source common is not already connected to ground at some point in the system make the connection at the Terminal Strip Plate The recommended and preferred method of making the ground connection to is to connect the power supply Common Terminal to Ground through a 100 Ohm 1 Watt fusible resistor The resistor is inserted between the Ground Stud and the Common Terminal 4 11 Installing and Wiring th
168. le by programming Module 3 of DPM in Full Programming Mode Setpoint Annunciators with Optional Quad Relay Card Function Keys A ma av Setpoint values programmed in Quick Menu Additional features available by programming Module 3 of DPM in Full Programming Mode Figure 106 Temperature Display and Function Keys 9 6 Display and Programming Flow Diagram G25 C Quad Relay Setpoint Temperature Alarms are only operational in the Display Mode Temperature Display ig Key Navigates from Temperature Display through Quick Programming Menus back to Display GP J 5P Y Cad Setpoint 1 Setpoint2 Setpoint Setpoint ENTER 3 Value 4 Value eee CGR Rg Access to Ircon Menus With F1 and F2 Keys F1 A F2 Y Provides access to IRCON Menus Head Functions Engineering Functions Analog Output Functions Diagnostic Functions Back to Start of Access to IRCON Menus Setpoints and Code Modline 5 Rev L4 12 2012 167 DPM Installation and Operation 9 7 Sensor Setup with the DPM HEAD Sensor Operating Functions List EMIS Set Emissivity for Brightness or 1 Color Sensor E SLP Set E Slope for 2 Color Ratio Sensor R T Set Response Time SIGL Signal Conditioning Peak Picker or Track Hold PSEL Peak Picker Sub Function Settings COLR Set Ratio Unit for 2 Color or 1 Color Operation MTCH Match Known Temperature SUB FUNCTION PSEL Peak Picker Function Settings D R
169. le the Peak Picking signal conditioning 8 6 2 External Switch for Remote Peak Picker Operation The Modline 5 has a provision for a remote process controlled input switch to be wired to the Violet and Violet White twisted wire pair of the Sensor s interconnecting cable If Peak Picker signal conditioning is selected the remote switch can enable or disable the Peaking action With no switch or the switch in maintained in the open position Peaking action is enabled With the switch closed peaking action is disabled and the Sensor continuously indicates actual temperature variations as they occur This can be called the Direct operating mode A momentary closure of the switch greater than 0 08 seconds resets the Peak Picker function to the current temperature reading The peaking action begins again when the switch returns to the open position Wiring and switch operation for the Peak Plcker are described in Section 4 Sensor Wiring page 62 of this manual Peak Picker Off Interference Gap in Hot spot in l in sight path workpiece workpiece Actual temperature shown as a solid D se line T Indicated temperature tracks changes in S actual temperature including S interferences in sight path Limited only by Response Time of Modline 5 Time Peak Picker On Fast Decay Peak Picker conditioning shown as a Y solid line gt a i E oe l r a Use this setting to concentrate on 2 e e 5 temperature trends and to reduce the D TE l
170. lit Depressing the UP Arrow A will display an error code The Up Arrow should be depressed multiple times to view simultaneous multiple Error Codes that might occur If multiple errors have been displayed the Down Arrow Y will scroll backwards through the errors To return to the TEMP display while viewing an Error Code press Enter J If no button is pressed after 15 seconds the display returns to the temperature display The ENT 4 pushbutton is also used to navigate from the TEMP display to the Main Setup Menus Up and Down Arrows WA and the ENT pushbutton are used to View Select and Adjust Sensor Functions ENT 1 must be momentarily depressed less than 5 seconds when changing function values and making selections If ENT 4 is held depressed for 5 seconds all adjustments made in the current menu are canceled and the unit returns to the TEMP Display 5 4 Main Menus Navigate from TEMP display by pressing ENT 4 once The last selected Main Menu will be displayed USE the UP Down Arrows A Y to step through and view the following four Main Menus Menus are displayed for 15 seconds before returning to the TEMP display if no further selection is made ENGR Engineering AOUT Analog Output COMM RS 485 Communications HEAD Operation Functions Modline 5 Rev L4 12 2012 91 Operation At a Main Menu Press ENT J once to enter the Menu One of the Function selections will be displayed USE the UP Down Arrows A Y to
171. ll Scale Adjustment Check F C measurement units selection of Sensor and external device to make sure they are compatible Series resistance of all devices and cable pairs on Analog Output should not exceed 600 Ohms 135 Maintenance Symptom Possible Cause Corrective Action Symptom Number Four 1 Check for recurrent interruptions in sight path e g bursts of smoke Erratic temperature display and outputs or steam moving equipment 2 Use air purge to clear some obstructions If using air purge check air flow and operation e Target and measurement conditions unknown Actual temperature variations may sensed Vary the Response Time to see if the symptom changes Use Peak Picker signal conditioning with suitable decay rate Use Track and Hold signal conditioning Symptom Number Five Check Sensor cable connections Also check the signal cable Erratic display and outputs shield connection at the Grounded Strain Relief Fitting Check f ing of all s nad Check for proper grounding of all system components conditions known to be stable Check cable routing Signal cables must not run in the same conduit as noisy power lines or power lines with transients Check ambient temperature of Sensor Add water cooling and or heat shielding to Sensor if necessary No Invalid Measurement Condition Alarm 1 Check iALM function under Engineering Menu Cannot adjust or select functions at the Check Panel Loc
172. ll forward and Eight Alphanumeric backward through model number shown in the display Character Scroll XX XXXXXX Press ENT J to return to TEMP display 5 6 3 F C Selection of Fahrenheit or Celsius Indication F or C Modline 5 Sensors are specified and delivered in Celsius temperature ranges The F C function allows changing the temperature display to indicate in either Celsius or Fahrenheit The conversion of the Sensor temperature span from Celsius to Fahrenheit follows the formula F 1 8 x Celsius 32 Example a 600 C to 1400 C span converts to 1112 F to 2552 F All outputs and function settings will be in the same units and correspond to the temperature range selected for display The appropriate F or C indicator will be lit for temperature display and setup adjustments when applicable 94 Rev L4 12 2012 Modline 5 Operation After changing the Sensor operation from F to C or C to F fine tuning of the parameters that are related to the F and C measuring units is required These i include Analog output ZERO and FULL functions in the AOUT Menu the DR peak picker decay rate and the RBEL reset below temperature functions in the Head Menu Navigate from TEMP display with J amp A Vto ENGR then use y amp A Y to F C Display Instructions Display and Limits Press ENT to view F or C selection F or C Use Up Down Arrows to change the setup Press ENT to save and return to TEMP display
173. llowed In the ON state viewing all menus and functions is allowed but changes are not allowed This prevents unauthorized changes Panel lock does not interfere with temperature measurement Panel Lock can be controlled with an external RS485 device using the KL Command Changes can be made using the RS 485 Interface or the Auxiliary Current Input for Emissivity or E Slope adjustment when LOCK ON has been selected The Password is fixed and cannot be changed Navigate from TEMP display with J amp A Y to ENGR then use J amp A Y to LOCK Display Instructions Display and Limits LOCK Press ENT to view Panel Lock state OFF or ON OFF ON 0 to 999 Use Up Down Arrows to enter numerical Password 751 Press ENT Use Up Down Arrows to turn Panel Lock OFF or ON Press ENT to enter and save selection and return to TEMP display 5 6 2 MODL Sensor Model Number The MODL function reports the Modline 5 Sensor Model Number as an eight character alphanumeric display The Sensor Model number is explained in Section 2 Product Description page 13 The Sensor series temperature range optical resolution and Dirty Widow Detector and Laser Sight options are defined in the Model Number This information is used during the selection and setup of various functions Navigate from TEMP display with 1 amp A Y to ENGR then use J amp A Y to MODL Display Instructions Display and Limits MODL Press ENT to view Model Use Up Down Arrows to scro
174. ly resolve e Partial obstruction of the optical path caused by smoke steam dust dirty window or a solid object The total reduction in signal is the sum of the losses from all three causes Example Assume the target emissivity is 0 45 The reduction in signal due to low emissivity is 55 If the instrument can operate with a 95 signal reduction another 40 can be lost due to an unresolved target and or obstructions in the cone of vision such as smoke steam dust a dirty window or partial blockage by solid objects Target Emissivity 0 45 Target Valid Measurement Conditions y Cone of Vision smoke in Sight Path Target Target Sensor Invalid Measurement Conditions Total Signal Loss Greater than 95 Sensor 1 Intense Smoke in Sight Path 2 Target too small for Spot Size Sensor 3 Low Emissivity Figure 14 Invalid Measurement Conditions When you reach the maximum allowed reduction the Sensor will indicate Invalid An Invalid measurement condition also occurs without any obstructions if the target temperature signal is below a level that can be accurately measured by the instrument Signal Reduction Tolerated The Series 5R Sensors have a limit as to how much the signal from a hot target can be reduced The reduction in the signal can be as high as 95 with target temperatures above 800 C 1500 F The amount of signal reduction that the Series 5R Sensors will tolerate depends upon the Sensor 3
175. m that point Modline 5 Rev L4 12 2012 53 Sensor Installation Ya hex Head Screws 3 with flat and lock washers i supplied for mounting 2 24 n 56 9 en Dia Dia M8 X 30 mm Socket Head Cup Screw supplied for clamping Sensor 8 283 210 4 1 750 44 5 Figure 45 UAA Dimensions are in inches and millimeters Do not scale Group 1 shown UAA and Sensor i See UAA description and Dimensions Sensor Front inserted Level with UAA Front 3 11 2 Installation Drawing for the RAM Right Angle Mount Required Accessories See Individual DWD Group Mounting Option Accessory Descriptions and Dimensions See Notes 6 Right Angle Base Mount po nro APA Add ESA 2 ESA MFL Add ESA 3 MFL Add ESA 3 Right Angle Mount with Large Flange U Right Angle Mount with Air Purge CAPA MFS Add ESA 2 Right Angle Mount with Air Purge UAA RAM APA MEL Add ESA 2 DWD is Dirty Window Detector Option Refer to notes with Grouping table in Section 3 10 Accessory Combinations with Break out Drawings page 49 The ESA adds 1 82 46 2 mm to length of the assembled group Right Angle Mount with Large Flange This group requires an ESA for clearing the RAM Table 9 Recommended Accessory Groupings RAM 54 Rev L4 12 2012 Modline 5 Sensor Installation Figure 46 Figure 47 the UAA and RAM first Place Sensor fully into assembly and rotate Sen
176. mall pins on the front of the frame Remove clear protective film from overlay Insert the long pins on the frame into the matching holes on DPM display board Before returning meter to its case install optional Quad Relay Card if supplied See instructions below Slide the assembly back into its case Be sure the rear cover fully latches into the case 9 2 3 Quad Relay Card Part Number PAXCDS20 If an optional Quad Relay Card has been purchased the card is delivered as an accessory item in a separate carton The relay card a label for the meter case and Red Lion Bulletin PAXCDS C or later release are in the carton Read and follow all warnings installation and operation instructions in the Red Lion Bulletin Adhere the wiring label supplied with card to DPM case in the space provided beneath main label A simplified initial Setpoint setup is found in Section 9 13 DPM Sensor Diagnostic Functions page 174 The quad relays are intended for use as temperature alarms not closed loop process control Determine if use of the relays are adequate for the process requirements 9 2 4 Panel Installation and Wiring Install the DPM as per all installation instructions in Red Lion Controls Bulletin No PAX B supplied A cutout template and instruction are supplied in bulletin Section 1 0 9 2 5 Sensor RS485 Connections See Section 4 Sensor Wiring page 62 for recommended computer cable type and shielding information 164 Rev L4 12 2012 M
177. may be encountered with the use of certain mechanical accessorles Use of Windows If it is necessary to view the object through a window as is the case when the object is being heated in a vacuum or inert atmosphere correctly select the window material The material must have constant transmission characteristics in the operating wavelength range of the Sensor type being installed Information on windows is provided in Section 8 Applications Guide page 137 of this manual Reflections Reflections from radiating objects represent a potential source of error in temperature measurement The total radiation seen by the Sensor will be a combination of intrinsic emitted radiation plus reflected radiation from a nearby hot object off the target surface Examples of interfering sources are hot furnace walls and heating elements that are hotter than or nearly as hot as the target object Most reflection problems can be eliminated by changing the viewing angle or shielding the reflections Suggestions for anticipating and eliminating common reflection problems are provided in Section 8 Applications Guide page 137 Indirect Viewing In some situations it may be necessary to view the target indirectly by means of a mirror The Characteristics of the mirror and the positioning of both the Sensor and mirror are critical in this type of arrangement Refer to Section 8 Applications Guide page 137 for more information Viewing Angle Viewing angles ar
178. n induction heated rod The visible sight rear panel is shown below Modline 5 Rev L4 12 2012 23 Sensor Installation Figure 6 Visible Sight Figure 7 Reticle When properly focused the area of the target within the reticle will be measured The Sensor infrared detector will see the same image seen defined by the reticle Approximately 97 of the measured energy will come from the area defined by the reticle To check or adjust focus slowly move your head slightly from side to side or up and down Note whether the target appears to move with respect to the reticle If it does adjust the lens focusing section until there is no perceived motion between the reticle and target hence eliminating parallax between the two The instrument is then in sharp focus Lock the lens rear focusing section in place using the locking thumbscrew on the bottom of the Sensor If looking through a sight tube or sight hole position align and rotate the Sensor and Sight tube to center the reticle in the field of view Calibrate test may move into the viewing area during shipment If this occurs the viewing area will be dark and appear obstructed This flag will be positioned correctly when power is applied to the Sensor G For Modline 56 sensors occasionally a calibration flag that operates during the Sensor 3 3 3 Laser Sight With the optional Laser sight a laser light spot is projected onto the target and used to aim the Sensor The
179. nd Dimensions IRCON s specially designed air purge is used to help keep the front optics of the Modline 5 clean The purge provides a stream of air away from the Sensor to prevent dust and smoke particles from collecting on the optics The APA is positioned in front of the Sensor with the UAA universal adapter or WJA Water Jacket Three through holes in the APA accept mounting hardware to assemble accessories together The front of the APA has three threaded holes to attach a MFS or MFL mounting flange Mounting hardware is supplied with the flanges A inch NPT threaded air inlet is located on the air purge A flow rate of 3 SCFM 0 09 m3 min clean air is required for most applications The flow rate can be increased for difficult environments Two drain holes provide an outlet for any condensation accumulation If necessary these threaded holes can be plugged with M3 screws 4 Figure 25 APA Accessory Material Clear Anodized Aluminum Weight Approximately 1 5 pound 0 68 kilograms Qty Part No Description and use User Supplied Tools 1 482202 Ya inch NPT stainless steel fitting for 0 25 inch 6 4 mm As needed diameter tubing Note Can be replaced with more suitable fitting if desired 3 230625C60 Ya M6 X 25 mm socket head cap screw for assembling to 5 mm hex key L style wrench the WJA or UAA 3 230670C60 M6 X 70 mm socket head cap screw for assembling to the 5 mm hex key long arm L style WJA or UAA with ESA wr
180. nd depending on Fahrenheit or Celsius units selection The Decay Rate must be set to retain peak measured temperature value and ignore momentary decreases in measured temperature caused by process conditions The goal is to eliminate erratic measurements due to gaps in work pieces bursts of smoke or steam etc in the sight path of the Sensor while allowing the peaked value to decay down to lower process temperature values as they occur Sensor Firmware Version Operation Summary Original Sensors with firmware versions less than 1 02 have unit less degree units that range 0 00 to 300 00 for both F and C units selection The instructions provided on the next page are for Sensors with firmware versions 1 02 and higher DPM Digital Panel Meter Interface firmware version operation For DPM Interfaces with firmware versions 1 2 used with Sensor firmware version less than 1 02 Sensor set for C DPM will read but not enter values higher than 166 Sensor can be set to 300 Sensor set for F DPM and Sensor are compatible For DPM Interfaces with firmware versions 1 1 used with Sensor firmware 1 02 and higher Sensor set for C DPM will read or enter values to 300 Sensor can be set to 166 66 maximum Sensor set for F DPM and Sensor are compatible 5 10 2 RSET Manual Peak Picker Reset Performs a manual Peak Picker reset The Peak Picker Reset clears the stored peak information The Sensor begins to measure temperature in the Peak
181. ne 5 Sensor similar to the Rear Panel pushbuttons Refer to the manual section referenced for configuration and operation information as directed for each code The Command Codes have been separated into four categories as follows e Engineering Functions e Analog Output Functions e Head Functions e Measurement Conditions and Alarms If the command is fully recognized the command will be echoed back as AQCCXXXXX lt CR gt where XXXXX will be the value sent if the command sent parameters that changed something or the 116 Rev L4 12 2012 Modline 5 Digital Communications current setting if no parameters were sent If the parameters sent are out of range or otherwise not allowed the current setting will be returned The message format must be correct for the sensor to reply If the A0 is followed by any number of characters and a carriage return character is not received the unit will not respond at all If at least a fragment of the command is received but the command code is not recognized a response of a0cc HUH will be returned 6 5 Engineering Function Command Codes KL Keyboard Lock Read Write Locks or unlocks the Sensor s rear panel keyboard When the keyboard is locked all functions work and can be viewed but not changed at the Sensor The keyboard can also be locked and unlocked from the Sensor rear panel RS 485 Write commands are not locked out with this command Range 0 or 1 0
182. nges for the Modline 5 Series 52 56 5G and 5R Two ranges are shown The first range is for a Sensor without the Dirty Window Detector Option DWD option The distance is measured from the front metal surface of the standard Sensor 26 Rev L4 12 2012 Modline 5 Sensor Installation The second range is for a Sensor with the DWD option This distance is measured from the tip of the front mirror hood Very close lens types that include alpha character C are not useable with the DWD option Some installation cooling and air purging accessories will limit some of the usable close focus range accessory The Model number and installed lens type is found on the Sensor Model number tag Range tolerance of is 10 3 4 3 Table of Model and Lens Type Combinations with Focusing Ranges The Optical Resolution Factor for each Model and Lens combination is given in the table Use the formula d D F to calculate the spot size at any working distance within the specified range The smallest spot size can be determined using the closest distance within the range Model Number Lens Focusing Range in inches and millimeters mm Resolution Type Factor Standard Sensor Sensor with DWD Option 52 1410 5G 1007 13 to infinity 330 mm to infinity 10 4 to infinity 264 mm to infinity D 100 D 75 5G 52 2020 5G 1415 13 to infinity 330 mm to infinity 10 4 to infinity 264 mm to infinity D 200 D 150 5G 52 3024 5G 2024 13
183. nsor Series a poor transmission path causes the indicated temperature to be lower than the target s true temperature These problems may be minimized by keeping the System s optical components clean and by selecting a sight path for which the entire optical cone between the target and the instrument is free of solid objects dust smoke and evaporates Sight tubes shown in Figure 97 can be used for this purpose For information on the use of windows refer to Section 8 10 Use of Windows page 158 8 8 5 Reflectance Effects If the target has some reflectance it acts as a mirror and reflects infrared energy generated by other sources e g a furnace wall or heating element If the Sensor picks up the reflection measurement errors will result Reflectance depends on the target material and the condition of its surface Flat smooth surfaces tend to have larger reflectance values than roughened surfaces of the same material Reflectance problems may be reduced by changing the viewing angle so that the reflection is not picked up by the Sensor or by the use of sight tubes or some other form of shielding See Figure 97 examples These considerations apply to all Sensor Series 156 Rev L4 12 2012 Modline 5 Applications Guide Viewing at furnace exit Problem Sensor Lens sees reflections of furnace aes roof or wall Solution 1 Change viewing angle je Lens A Furnace Roof Sensor Lens Workpiece Solution 2 Install shield
184. nsor window transmission loss required to trigger a dirty window alarm Range 0 to 2 Message Value 0 Dirty Window Detection Alarm Off 1 Sensitive SENS 2 Coarse CORS SW Switch Input Status Read Only Command Returns the Sensor s external switch status Peak Picker reset and Hold mode select Range 0 or 1 0 closed 1 open BT Report Isoblock Temperature Read Only Returns the infrared detector isoblock temperature in C Typical Value Range 0 to 65 RC Instrument Temperature Read Only Returns the unit s internal case temperature in F or C Range N A Expected value is within the Range 0 to 65 C VR Firmware Version Read Only The VR command returns the Sensor s firmware version number in the format VV RR VV is the major version number RR is the revision number Range N A TP Controller Type Read Only Reserved for future use Always returns zero Range Not Applicable LS Laser Control Command is available with Laser sighting option only Turns the sighting laser on or off Note that the laser has an automatic timeout of twenty minutes Range 0 or 1 Values Turns on the laser 1 or turns off the laser 0 The Laser will not energize during the System Check Also if the Laser is energized and a manual CHK function or automatic HOUR function system check is initiated the Laser will turn off 118 Rev L4 12 2012 Modline 5 Digital Communications Observe and follow c
185. nt measurement condition status and the status of alarms Range Not Applicable Values Bit mapped values for alarm and measurement status Value Condition Equivalent Display or Error Code None to Report None EN Out of calibration Same as Error Code X102 2 signal invalid may not be set in Peak Picker mode Invalid 1 Same as INV on rear panel Case temperature too low Same as Error Code X106 Case temperature too high Same as Error Code X105 Modline 5 Rev L4 12 2012 123 Digital Communications Same as Error Code X104 sensor failure Same as Error Code X107 or FAIL on rear panel display DWD failure Same as Error Code X109 1024 Signal invalid Always set regardless of Peak Invalid 2 Same as Error Code pINV on rear panel Picker mode Measured Signal too low for ratio display when Alarm button pushed measurement Displayed Temperature is Peak Picked or Hold mode Temperature 124 Rev L4 12 2012 Modline 5 Digital Communications 6 9 Command Code Summary Code Command Type Group Notes Description Sets the Analog Output to a specified value when unit Is in any of Out two alarm conditions Error Codes X107 X109 in hours immediate check Out that will produce the Analog Output full scale current temperature alarm Out temperature is above the value for Analog Full Scale Output e ess temperature alarm Out temperature is below the value for Analog Zero Scale Output Qut 20 mA Alarm threshold Out Ze
186. nt value 20 0 to 24 0 Use Up Down Arrows to set the current value 5 8 COMM Setup of RS 485 Digital Communication Configuration The Modline 5 RS 485 Digital Communication interface permits interchange of ASCII coded information between the Modline 5 Sensor and a host computer PLC Programmable Logic Controller or any other RS 485 device The RS 485 data signal is transmitted on the Yellow and Yellow White twisted wire pair of the Sensor s interconnecting cable All communication is via half duplex two wires Refer to Section 6 Digital Communications page 114 for the complete explanation of the RS 485 Digital Communications operation and commands 5 8 1 CLCK Communications Lock Communications Lock provides for the configuration of the Modline 5 RS 485 Communications Communication can be configured to allow selection and adjustment of functions in Read and Write Modline 5 Rev L4 12 2012 103 Operation R W operation or in Read Only R O operation Read Only operation does not allow external RS 485 devices to change settings in the Sensor Command to initiate a check CHK and the PR Peak Picker Reset Command to perform a lil R O operation still allows the unit to respond to the RS485 AC Automatic Calibrate reset 5 8 2 ADDR Sets the Sensor Address The Unit Address is a one digit number or single letter code It ranges from a single numeric 0 to 9 to an upper case A to Z The Address factory defa
187. o PSEL then use J amp A Y to D R or RSET or AUTO or RBEL or DEL Press ENT J to save and return to TEMP display after each function Display Instructions Display and Limits PSEL Use Up Down Arrows to select D R or RSET or AUTO or RBEL or D R or RSET or AUTO or RBEL or DEL DEL Then press ENT to view select and adjust Function Instructions for Sensors with firmware versions 1 02 and higher 0 00 to 166 66 C Sensor Or Press ENT to view and then use UP Down Arrows to adjust 0 00 to 300 00 F Sensor Decay Rate will is in degrees per second depending on the measuring units selected RSET Press ENT to trigger Manual Peak Picker Reset Display will automatically return to TEMP AUTO Press ENT to view Use Up Down Arrows to select Auto Peak ON OFF Picker Reset operation ON or OFF RBEL Press ENT to view Use Up Down Arrows to set Reset Below Numerical Value XXXX Temperature within Sensor s specified temperature Range Temperature in C or F DEL Press ENT to view Use Up Down Arrows to Select Off or set OFF or Peak Picker Signal Conditioning Delay in seconds 0 01 to 10 00 5 11 Laser Sighting Operation The Laser Sighting Option is specified at the time the Sensor is ordered and must be factory installed A pushbutton labeled LASER is supplied on the rear panel to energize the laser The pushbutton is located in the center of the rear panel in place of the visible sight Press the LASER pushbutton once to ene
188. o center the reticle or laser image in the field of view 5 Route the cable either through the center opening in the mounting plate or along the side walls of the WJ 5 and out through the insulated opening in the back door 60 Rev L4 12 2012 Modline 5 Sensor Installation MFL Mountina Flanae Larae Accessorv UAA Universal Adapter Accessorv Modline 5 Sensor without DWD option Spacer Block Socket Head Item 2 Cap Screws Qty 2 Item 4 Mountina Plate Item 3 Lock washers Qty 4 Item 6 i Y g Hex Head Screws Qty 4 Item 5 Figure 54 Mounting Kit 3 13 Sensor Installation Checklist To ensure accurate reliable and trouble free operation check the installation for the following Sensor is properly mounted and aligned with no obstructions in optical path Sensor lens is focused on target If possible target size 1s at least twice diameter of reticle size as seen in the viewing sight i e twice the calculated spot size at the viewing distance Rear Protective window has been securely installed on back of Sensor After completing the sighting and focusing routines screw the protection window back onto the Sensor to maintain the NEMA 4 IP65 environmental rating Sensor lens is protected by air purge and clean purge air if atmosphere is dirty oily or corrosive Do not use purge air with oil or water Use instrument air or filter adequately Sensors with the Dirty Window Detector Option
189. o system design so that unsafe operation does not occur under these conditions since solid state outputs may operate erratically for a short period of time after applying or removing power 3 1 3 Redundancy and Monitoring When solid state devices are being used to control operations which the user determines to be critical it is strongly recommended that redundancy and some form of checking be included in the system Monitoring circuits should check that actual machine or process operation is identical to controller commands and in the event of failure in the machine process or the monitoring system the monitoring circuits should initiate a safe shutdown sequence 3 1 4 Over current Protection To protect triacs and transistors from shorted loads a closely matched short circuit protective device SCPD is often incorporated These SCPD s should be replaced only with devices recommended by the manufacturer Modline 5 Rev L4 12 2012 179 Appendix A 3 1 5 Over voltage Protection To protect triacs SCR s and transistors from over voltages it may be advisable to consider incorporating peak voltage clamping devices such as arrestors zener diodes or snubber networks in circuits incorporating these devices 3 2 Circuit Isolation Requirements 3 2 1 Separating Voltages Solid state logic uses low level voltage e g less than 32 volts dc circuits In contrast the inputs and outputs are often high level e g 120 volts ac voltages
190. odline 5 DPM Installation and Operation DPM Terminal 12 to Modline 5 Sensor Cable Yellow wire DPM Terminal 13 to Sensor Cable Yellow White DPM Terminal 14 to Sensor Cable Red White power supply common direct wire connection to TSP Plate or POI Box Do not use shortcut wiring route to any other point s User 1 Input Jumper The DPM is supplied with a jumper installed between the User 1 input terminals 7 and 8 Jumper can be replaced with a SPST switch if it is anticipated that full programming access is going to be required often Ircon recommends that the simple jumper be used unless you intend to become thoroughly familiar with the DPM and use other features 9 2 6 AC Power Wiring Reference Red Lion Bulletin No PAXP Section 3 0 for AC power wiring Follow all warnings and instructions Quad Relay Connections If optional Quad Relay Card is installed wire relays per Red Lion Controls Bulletin PAXCDS C supplied with the Quad Relay Card Follow all warnings and instructions 9 2 7 Critical Process Safety Guideline When this instrument is being used in a critical process that could cause property damage and personal injury the user should provide redundant device or system that A will initiate a safe process shutdown in the event that this instrument should fail The user should follow NEMA Safety Guidelines for the Application Installation and Maintenance of Solid State Control A copy of the standard is reprinted in Appendix A
191. of the Series 56 Sensors and should be Modline 5 Rev L4 12 2012 97 Operation performed routinely every 168 hours or less The check can be initiated by any of the three methods described below Upon Sensor Turn On If the Sensor has not been powered for 15 minutes or more a Calibration Check will be performed after the unit is powered and warmed up and stabilized approximately 15 to 20 minutes after powering on Automatically A Calibrate Check can be initiated every 168 hours using the Sensor Auto Calibrate HOUR function An OFF setting is also available If the OFF is selected Manual Calibrate Checks must be initiated every at least every 168 hours Manually Initiate a Manual Calibrate Check using the Sensor Rear Panel Keypad or Modline 5 accessory Accessories include the Model DPM Panel Meter Model MSI multiple sensor interface ModView software or an RS 485 communication command Series 56 Manual and Automatic HOUR Function Initiated Calibration Check Summary Calibration Check Initiation Alarm Display RS485 and 20mA Condition Temperature Outputs Manually Initiated Calibration Check Alarms Off CAL Last Temperature Sensor ModView reading held DPM MSI with Self Calibration if required It is not recommended to perform a Manual check more once than every 24 hours Note 1 HOUR Parameter 168 Hours or OFF Alarms Off CAL Last Temperature User Selected Time Interval 168 hours only Sensor ModView read
192. of the peak picker and the Track and Hold function are not operational The SPST switch can be an actual toggle or a press and hold type switch which would de energize the laser when released The Peak Picker can be reset at the Sensor Rear or with a RS 485 command Condition Set Two 2 A If Sensor is powered up with the PkHd switch closed the Laser will not operate until the switch is opened and then closed again Laser will only operate with PkHd switch closed 2 B When the Laser is energized with a PkHd switch closure the laser can be de energized with the Rear Panel Laser Switch a RS 485 Command or by opening the PkHd switch If none of these occur the Laser de energizes after the 20 minute time out period 2 C If the Laser has been de energized by a RS485 Command the Rear Panel Laser Switch or the 20 minute timeout period the PkHd switch must be opened then closed to energize the Laser with the PkHd switch However the laser can be activated with the Rear Panel or RS485 command without opening and closing the switch 2 D The Laser can be energized by the Rear Panel Laser Switch or a RS485 command only when the PkHd switch is closed and condition 2 A has been met PkHd Switch wiring The switch is wired directly across the PkHd Switch terminals on the POI Power Supply Signal Interface Box or the TSP Terminal Strip Plate See Section 4 9 Connecting Device Cables to POI Box or Terminal Strip Plate page 73 for switch wiring 5 12 Ou
193. ogress Same as Cal on Sensor display Instrument Temperature in selected units C F Indicates the remote input switch condition open or closed Modline 5 DPM Installation and Operation 9 14 Full Programming Mode Setpoints MAX and MIN Displays Overlay Backlight Reference the Red Lion Inc PAX P Bulletin supplied with the meter for complete programming instructions for the DPM 9 14 1 Full Programming Using the PAR Key select Code and Enter 222 then Press PAR The DPM meter is now in Full Programming Mode Depressing PAR displays the meter menus indicated below Only the modules and the parameters appearing in the modules are available to users The DPM is a custom meter and several parameters are for dedicated use Module 1 IRCON No IRCON Programming also accessed in Quick Programming replaces Signal Input Module Module 2 User Input and Front Panel Function Key Parameters Module 3 Display and Program Lock out Parameters Module 4 Secondary Function Parameters Module 5 Totalizer Integrator Parameters Not available on the Ircon DPM Module 6 Setpoint Alarm Parameters Module 7 Serial Communications Parameters Baud must be set 9600 Data 8 Module 8 Analog Output Parameters Not available on the Ircon DPM Module 9 Factory Service Operations 9 14 2 Quad Relay Card Setpoint Basic Setup and Operation The operation described is with the DPM in the Quick Programming Mode Refer to
194. on Modline 5 Rev L4 12 2012 67 Sensor Wiring 24Vdc Power Requirements Regulated DC Voltage 24V 5 Power Rating 8 Watts Maximum Required Current Per Sensor 380 mA The 24Vdc Sensor Power Supply should be limited to 2 Amps An earth ground wire is to be connected to the ground stud at the bottom of the Terminal Plate Minimum size wire is 18 AWG 1 mm A crimp terminal is supplied to mount on the stud 4 5 1 Dimensions and Installation The Terminal Plate must be installed in a suitable user supplied grounded enclosure for protection from electrostatic discharge ESD Four 0 196 inch 5mm diameter holes are used to mount the plate See photo below for mounting dimensions The approximate overall rectangular plate dimensions are 5 39 inches 136 9 mm long by 3 42 inches 86 9 mm wide and 0 8 inches 20 3 mm high Plan access for cables and working space Minimum Sensor interconnecting cable bend is 3 inches 76 mm Wiring grounding and shielding instructions are in the sections that follow 2 32 58 9mm 5 03 127 8 mm Figure 62 Dimensions TSP 68 Rev L4 12 2012 Modline 5 Sensor Wiring 4 6 Sensor Interconnecting Cable Preparation 4 6 1 Cable Preparation It is very important that the cable shield be properly prepared and installed All signal cable shielding must be grounded to the POI Box enclosure with the IRCON supplied Grounding Strain Reliefs If the Terminal Strip Plate is used t
195. ons 6 2 1 CLCK Communications Lock Communications Lock provides for the configuration of the Modline 5 RS 485 Communications Communication can be configured to allow selection and adjustment of functions for Read and Write R W operation or Read Only R O operation Read Only operation causes write commands sent to the Sensor to be turned into Read Commands R O operation does allow the RS485 AC Automatic Calibrate Command to initiate a CHK and the PR Peak Picker Reset Command to perform a reset 6 2 2 ADDR Sets the Sensor Address The Unit Address is a one digit number or single letter code It ranges from a single numeric 0 to 9 to and upper case A to Z The Address factory default setting is 0 zero 6 2 3 BRAT Baud Rate The Sensor Baud Rate must match that of the other RS 485 device Four baud rates are supported 9600 19200 38400 and 57600 bits of information per second Modline 5 Rev L4 12 2012 115 Digital Communications 6 3 Communication Protocol Communication is half duplex two wire The Sensor does not support simultaneous transmit and receive Four baud rates are supported 9600 19200 38400 and 57600 bits of information per second All characters are ASCII 7 bits even parity 1 stop Commands have a response Another command should not be sent until a response has been completely received There is a 1 millisecond minimum delay between receipt of command and response The maximum delay is less th
196. ooth surfaced objects such as metals glass or plastics Angles up to 45 from the perpendicular usually will not appreciably affect the measurement although the smaller the angle from the perpendicular the better In general angles greater than 45 should be avoided An increase in reflectance occurs when smooth surfaces are viewed at large angles and consequently the target emissivity decreases 8 8 2 Background Interference Under ideal circumstances the radiant energy being measured should be from the target only This is why you must center the Cone of Vision on the target and make sure that its cross section spot size is smaller than the target That way the sensor can t see past the target into the background Although the Sensor Models 5R have somewhat looser restrictions on filling the field of view it is still affected by background interference if significant sources of background radiation are present 154 Rev L4 12 2012 Modline 5 Applications Guide Significant background radiation comes from comparable temperature or hotter objects in the target s surroundings This background radiation may be reflected off or transmitted through the target adding to the radiant energy detected by the instrument related to the target temperature This results in measured temperature error For all Modline 5 Sensor Series except the Series 5R this extra radiation if detected causes a temperature indication that is higher than the targ
197. ount are for mounting the Sensor and UAA Use the slot and outer hole to provide vertical angular adjustment of the Sensor s optical axis Use the two holes for fixed axis mounting Two holes and one slot for mounting are located in the base of the RAM Use the slot and outer hole to provide angular adjustment Pivoting of the base provides horizontal angular adjustment Use just the two holes for fixed axis mounting 36 Rev L4 12 2012 Modline 5 Sensor Installation Figure 23 RAM Accessory Material Passivated Stainless Steel Weight Approximately 1 2 pounds 0 55 Kilogram Mounting and Assembly Supplied Parts List e No hardware is supplied with the RAM UAA assembly hardware is supplied with the UAA e Two user supplied M6 or 4 20 mounting bolts and washers are required to mount the base of the bracket Modline 5 Rev L4 12 2012 37 Sensor Installation 4 000 101 6 1 50 38 1 4 5 Bolt Arc Radius 7 1 94 LES L E i Clearance Holes 4 Places Diameter 0 266 6 8 0 562 14 3 Optical Axis when mounted horizontally S EL AS 6 SLL COST Y lt e gt lt D Figure 24 RAM Dimensions Dimensions are in inches and millimeters Do not scale All three axis of rotation including optical axis intersect at a common point This avoids parallax during target alignment 38 Rev L4 12 2012 Modline 5 Sensor Installation 3 9 3 APA Air Purge Accessory Description a
198. perverter Model 285 R 422 RS 485 to RS 232 Converter CyMOD Model CM 4530 USB to RS 232 422 485 Converter with isolation Superverter and CyMOD are trademarks of CyberResearch Inc DGH Corporation Contact www dghcorp com A1000 and 2000 Series The A1000 will also provide 24 Volt DC power for 3 Sensors RS 232 RS 485 Converters and RS 485 Repeaters Black Box Corporation Contact www blackbox com RS 422 485 PCMCIA Serial I O Adapters Single Port Product Code IC114A R2 for laptop computers See Section 6 of this manual for Modline 5 Sensor communications details and commands 4 12 2 POI Power Supply Operator Interface Box Multi drop Wiring A block diagram of a multi drop network using POI Box interfaces is included on below The 100 Ohm resistor is installed inside each POI Box do not install one externally Use the shielded cable specified in the previous manual sections To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor AC Power AC Power AC Power AC Power POI Box POI Box POI Box POI Box ermination Resistor at furthest Box 24VDC RS 485 24VDC RS 485 24vbc RS 485 24vDC RS 485 E FIL gt t f Te iI i 5 Modline 5 MSI Multi Sensor Interface Ground Or PC PLC other System TX A TX B Figure 77 Four Sensor RS 485 Multi drop with POI Power Supply Operator Interface Box Modline 5 Rev L4 12 2
199. piece of machinery or by bursts of steam or smoke Figure 91 illustrates the Peak Picker action The Peak Picker circuitry responds to the highest instantaneous value of temperature and holds this value even if the temperature source is interrupted by one of the conditions listed above The indicated temperature solid line rises almost instantly depending on the selected Response Time to follow the peaks in actual temperature dashed line The indicated temperature decays at a rate determined by the setting of the Peak Picker Decay Rate Figure 91 shows the effect of changing the decay rate The Peak Picker action affects the Temperature Display Analog Current Output and RS 485 responses to commands 8 6 1 Turning Peak Picker On and Off The Peak Picker can be turned on and off by using the following 1 The Sensor Rear Panel HEAD menu with the SIGL function When the Peak Picker is selected the PSEL function menu appears for setting of all the Peak Picker operating parameters Operation of the SIGL Peak Picker PSEL Decay Rate Automatic Reset Below Reset Below and Delay functions are explained in Section 5 Operation page 90 of this manual 2 Remotely using the RS 485 PK and related Commands See Section 6 Digital Communications page 114 of this manual Modline 5 Rev L4 12 2012 149 Applications Guide When the Peak Picker function is turned on by using 1 or 2 above a remote switch as explained below can enable or disab
200. plete installation should be reviewed to insure that all switches circuit breakers and other components have been properly selected and installed 4 4 4 Connect the 24 VDC Power Supply Wires Bring the Red and Red White power wires through the grommet at the bottom of the terminal strip aluminum bracket Dress the wires so they will not be pinched by the bracket Re install the bracket by carefully attaching and securely tightening the four retaining screws Be sure not to cross thread or otherwise damage any screws Start each screw before tightening any single screw Connect the Red wire to the 24VDC terminal and Red White wire to the Common terminal on the right side of the terminal strip A qualified electrician technician should apply power to the box and measure 24 VDC 5 at the Red and Red White power supply connections on the left side of the terminal strip Disconnect AC power at the installed power switch and prepare for connecting the Sensor interconnecting cable and system device cables as explained later in this section 4 5 TSP Terminal Strip Plate The TSP is required when the POI Power Supply Signal Interface Box is not used This plate mounted terminal strip with terminal identification label and suppression components allows use of the Modline 5 Sensor and Cable with user supplied enclosures and power supplies The TSP ensures Sensor and cable operation meets RF emission and immunity standards required for CE certificati
201. pplications Guide 8 5 2 Setting the E Slope The E Slope may be set at the Sensor Rear Panel using the HEAD Menu E SL function or remotely with the RS 485 ES Command An indirect method of setting the Emissivity is to use the MATCH function or RS 485 MT Command MATCH allows inputting a temperature value known to be the true target temperature The Sensor then automatically adjusts the Emissivity so that the temperature display indicates the same temperature Instructions for setup are found in Section 5 Operation page 90 of this manual A third way to adjust the Emissivity is to send a scaled input of 4 to 20 mAdc via the Orange and Orange White twisted wire pair of the Sensor s interconnecting cable The Modline 5 senses an input and overrides any other setting of Emissivity or Match Wiring and scaling information is in Section 4 Sensor Wiring page 62 of this manual 8 6 Peak Picker Signal Conditioning Peak Picker signal conditioning is advisable for certain measurement situations e Ifthe workpiece you are measuring is moving and is in the field of view for only a brief period of time e f a succession of small parts is to be viewed with variable spacing between them e If the temperature of a moving work piece varies because of slag oxides etc Using the Peak Picker allows measuring the highest temperature e If the line of sight between the instrument and the workpiece is momentarily or periodically interrupted as by a moving
202. pret the response message Command Codes are the part of the message that request work change values etc to be done by the Sensor Commands that request work are Write commands The same codes used Read commands request the Sensor to report the status of the work Command Codes are listed later in this section All except one of the command codes can be used as Read commands to obtain the current status of functions and readings Many commands are Write compatible and are used to change settings Read request command messages sent from the external RS 485 device cause the Sensor to automatically send back a status message For example if the external device host PLC sends a read command to the Sensor to report the Emissivity value the Sensor sends a response message containing the current Emissivity setting Write command messages sent by an external device include value or other information These messages will cause a change of Sensor parameters The Sensor replies with a status message Note Writing new values into the unit will cause it to stop updating the temperature the temperature for up to 200 milliseconds 6 2 Sensor Rear Panel Setup for RS 485 Communication The following Sensor RS 485 Communication attributes must be correctly selected at the Sensor Rear Panel for communications to take place RS 485 Commands for these functions are not provided The instructions are in manual Section 5 Operation page 90 for these functi
203. provide shielding from stray radiation emanating from high temperature targets and thermal isolation for the Dirty Window Detector Components The APA Air Purge used in combinations one and two below provides the best performance Groupings of accessories are shown in Section 3 10 Accessory 34 Rev L4 12 2012 Modline 5 Sensor Installation Combinations with Break out Drawings page 49 Also see Section 3 9 6 1 WJA Water Cooling Requirements page 45 purge is required with Sensors with the DWD The use of an APA is also required i When using a WJA Water Jacket Assembly with air cooling the use of an APA air when viewing large targets over 1000 C 1832 F Figure 20 DWD with ESA 1 ESA and APA air purge with clean air provides air purging and shielding 2 ESA and APA air purge without air provides a dead air space zone and shielding 3 ESA with MFL Flange provides a dead air space zone and shielding 4 ESA with MFL and AA 3 air purge accessory not shown provides air purging and shielding See Section 3 12 Other Accessories Sight Tube Window WJ 5 Water Cooling page 59 for AA 3 references 3 9 Modline 5 Mounting Cooling and Air Purging Accessories 3 9 1 UAA Universal Adapter Accessory Description and Dimensions The UAA is a circular ring that clamps around the Modline 5 Sensor A M8 screw tightens the clamp around the Sensor Three 20 threaded holes on the bottom flat surface allow fastening the UAA to a
204. r Operation MTCH Match Known Temperature SUB FUNCTION PSEL Peak Picker Function Settings 92 D R Decay Rate in F or C per Second AUTO Auto Peak Picker Reset RSET Manual Peak Picker Reset RBEL Reset Below Temperature DEL Peak Signal Conditioning Delay Rev L4 12 2012 Modline 5 Operation 5 5 Warm up and Initial Setup 5 5 1 Series 5R 5G 52 Power On and Warm up When power is applied to the Sensor a three to five second initiate condition occurs All segments of the dot matrix TEMP display and all word and symbol indicators are lit The alarm relay is always held open during this short period After application of power a warm up time of approximately 5 to 15 minutes is required for the Sensor s infrared detector and or electronics The Sensor Rear Panel Alarm indicator will be lit and Error Code X104 Detector Cold displayed when the A arrow is depressed During the warm up time temperature measurements can be made and outputs are operational However the Alarm signifies that the temperature indication may not be accurate Temperature indications will be accurate after the Alarm indicator has turned off when warm up is completed If there is a brief power outage Sensors may restart and go into the initiate and warm up conditions described above The Sensor Check function should not be initiated until the Sensor has warmed up and the Alarm indicator has turned off An Out of Calibration Alarm X102 may occur
205. rat are MAL cas 74 4 9 6 Converting the Analog Output from a mA output to a 10 Volt Output ooconiccninccannanananancnnnnonanonanens 75 4 9 7 Current Input for Remote Emissivity E Slope or Laser Operation siseinisiasicsactsasvassneoitesauewssvecaceiiavves 75 4 9 8 POI BOX or Terminal Strip Plate Current Input Terminal Connections for Remote Laser Operation E A E I E E AT E T noo 76 4 9 9 Peak Hold Switch for Remote Peak Picker Reset Track and Hold or Laser Operation 76 4910 Sensor Alarni Relay COMAS ai II 4 10 Selection of a Power Supply for Sensors used with TSP Terminal Strip Plates ooooccccccccncnnnnnnnann ns 78 410 1 TSP Terminal Strip Plate DC Power Supply Connections incio 79 4 10 2 Power Sup ply Common Ground COMME a a 80 4 11 Installing and Wiring the Chassis Mount 24 Volt DC Switching Power Supply coccnnnnnnnnnnnnninnnnnnnno 80 4 12 RS 485 Multi Drop Network Power Supply and System WiIring ccccccccceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 82 417 1 Compuler Communica IONS ASCO SA 83 4 12 2 POI Power Supply Operator Interface Box Multi drop Wiring ocnnconiccnnnnnnananananenanonananannanaranananenas 83 4 123 Lol Termunal Stip Plates MUIE ATO WTO slats 54 4 3 Sensor and Cable COnme ctl OM Si a Satataataauasant 85 ATL Cable Ple and Sensor RECP E dida 85 A VA System Gro ndne and MIO ae 86 ANAT POLE Bow and Terminal Strip Flate Datat dopra N a NE 86 4 15 Summary ao and Warning A S A AA 88
206. ratory standards and are burned in for before shipment to ensure accurate temperature measurements throughout the operating range To preserve this accuracy each instrument should be recalibrated periodically on a Blackbody standard We recommend recalibration of this type on a yearly basis There are the following methods of calibrating IRCON Modline 5 units e You can have your instruments calibrated at our Service Center An available option is calibration traceable to the National Institute of Standards and Technology NIST e Field Service Agreements geared to your requirements are also available Options include periodic maintenance with provisions for guaranteed emergency service rates and field maintenance with emergency service and parts replacement e Using the Modview Calibration software not available for M56 This software is for sale and allows you to calibrate the Modline 52 5G and 5R as long as the calibration does not require a change of more than 30 of the range You basically need a black body and while the instrument is aimed at the black body you allow the software to set the calibration of the Modline 5 Rev L4 12 2012 129 Maintenance instrument You only do one set point with the software but you can make as many checks as you want e The fourth method is to use a sensor that is titled a transfer standard This is a Modline 5 usually the same model as the customers equipment and it is specially calibrated at
207. reading No alarm or special values are Fs a a ES for over range and under range conditions TP Controller type Reserved for future use Reserved for future use Always retums 0 sell a Status alarm Returns the temperature the unit is reading in the current units F or CA repo Ta Special bit mapping messages for measurement status E Returns unit s full scale temperature as defined Returns units full scale temperature as defined by Model No Model No Returns Sensor s zero scale temperature as defined Model No Returns the Sensor s firmware version number 126 Rev L4 12 2012 Modline 5 Maintenance 7 Maintenance 7 1 Routine Maintenance 7 1 1 Maintenance Checklist The Modline 5 Sensor is a precision temperature measuring instrument built for rugged service and ease of operation When installed and maintained with reasonable care it will give you reliable service in a wide variety of applications Routine Maintenance is essential for reliable trouble free operation It consists of a thorough inspection at regular intervals to keep the instrument working efficiently and to head off problems before they occur Most service problems are caused by incorrect function setup improper Sensor sighting and focusing dirty optics and over heating of the sensor and other conditions that can be found and corrected by a maintenance program The following checklist will help you develop a maintenance routine suitable for yo
208. rected by the E Slope adjustment but a gold mirror is preferred Modline 5 Rev L4 12 2012 157 Applications Guide As indicated in Figure 98 the Cone of Vision extends from Sensor to mirror to target The mirror effectively bends the cone but does not change its shape There are two spot sizes to consider in Figure 98 spot size d1 at the mirror surface distance D1 and spot size d2 at the target surface distance D2 Mirror and target areas must be at least twice the cone diameter at their respective distances The mirror must be positioned and angled so that the axis of the reflected target image coincides with the optical axis of the Sensor You should be able to accomplish the alignment without difficulty by sighting through the viewing telescope Be sure to lock the mirror firmly in position and check the alignment on a regular basis Also inspect and clean the mirror in manner recommended by the manufacturer as part of your regular maintenance routine If you have any trouble in obtaining an appropriate mirror or in erecting your system please contact IRCON for recommendations d2 aie Target d1 Mirror Da Sensor Lens E o Figure 98 Effect of Using a Mirror on Optical Cone 8 10 Use of Windows To view an object in an inert atmosphere or vacuum chamber you must use an infrared transmitting window Selection of an appropriate window material will depend on the Sensor s spectral response Some suggested w
209. rely mount to the BMA Threaded holes in the front of the WJA are used to mount an APA air purge or MFL Flange The WJA can be mounted in any position The WJA has 1 4 NPT inlet and outlet pipe fitting openings for water or air See the drawings and information on the next page for water and cooling air requirements and installation configurations Designed Maximum water or air pressure 100 PSIG 6 9 BAR Modline 5 Rev L4 12 2012 43 Sensor Installation Figure 31 WJA Accessory Material 300 series passivated stainless steel Empty Weight Approximately 6 pounds 2 7 Kilograms Qty Part No Description and use User Supplied Tools ENEE M8 X 16 mm long case hardened steel hex head bolts Adjustable wrench Extra large diameter 3 16 thick case hardened flat washers 482202 4 inch NPT stainless steel fitting for 0 25 inch 6 4 mm diameter tubing 142152 Safety Clamp Assembly with captive and permanent mount screws Blade Screwdriver Table 6 Mounting and Assembly Supplied Parts List 9 27 235 5 8 25 209 5 1 faa 1 13 28 6 Optical Axis is the same as the Mechanical Axis Figure 32 WJA Dimensions 44 Rev L4 12 2012 Modline 5 Sensor Installation Dimensions are in inches and millimeters Do not scale Tapped Holes on both ends for Ircon Inc Accessories 3 9 6 1 WJA Water Cooling Requirements Adequate water flow for a 200 C 400 F ambient is 15 gallons hr 57 liters
210. require an APA air purge or other protection as explained in Section 3 8 DWD Installation Requirements page 34 If the purging air quality is poor use an efficient filter In worst cases leave the air purge assembled to the Sensor but disconnect the air supply Sensor is adequately protected by water or air cooling and or additional insulation if ambient temperature exceeds safe limits Sensor is not subjected to direct or reflected radiated heat from oven walls flames etc that cause it to exceed its temperature rating The Sensor mounting surface is grounded Earth Ground If not electrically insulate the housing from the mounting surface See information in Section 4 14 System Grounding and Shielding page 86 Modline 5 Rev L4 12 2012 61 Sensor Wiring 4 Sensor Wiring 4 1 Modline 5 Components The basic Modline 5 system consists of either a standard Sensor or Sensor with Dirty Window Detector option interconnecting cable a POI Power Supply Signal Interface Box or Terminal Strip Plate and as possible option the DPM Digital Panel Meter Interface This section provides instructions for connecting these components except the DPM to a process system Section 9 of this manual describes the installation wiring and operation of the Model DPM Meter with the Sensor s RS 485 Communications Figure 55 Modline 5 Components 4 2 Modline 5 Sensor System Interfacing The following figure shows a block diagram overview for int
211. rgize the laser press the pushbutton once again to de energize the laser A red LED located above the pushbutton is illuminated when the laser is energized The Laser also can be operated remotely using a switch See Section 5 8 COMM Setup of RS 485 Digital Communication Configuration page 103 for selecting remote switch operation See next page for operating instructions The Laser will not energize during the CHK or the MATCH function In addition if the Laser is energized and a manual CHK function or automatic HOUR function system check or MATCH Function is initiated the Laser will turn off Refer to Section 3 3 3 Laser Sight page 24 for information on using the Laser to aim and focus the Sensor 110 Rev L4 12 2012 Modline 5 Operation AS CAUTION LASER LIGHT DO NOT STARE INTO BEAM 1 mW at 635 nm A Display Manual Pushbutton Instructions CLASS Il LASER PRODUCT personnel in the path of the beam Normal Rear Panel Operation See next page for Remote Switch Operation Under safe operating conditions Momentarily depress LASER pushbutton to energize the Class 2 Laser Press pushbutton again to de energize Laser will automatically turn off after 20 minutes if not de energized Remote Laser Operation Sensor Firmware Versions 1 08 and Higher Remote operation is selected from the COMMS LASR Menu The operation for PANL I IN and SWIT modes of operation are explained below COM
212. ro Scale Parren temperature G CE e o mode Sensor Peak picker decay rate RW Head Sets the peak picker decay rate in F or C Zero 0 sets the unit to never decay Keyboard lock Turns the sighting laser on or off MT Match Temp Display R W Head Writes temperature value to be displayed to match target Read replies Emissivity or E Slope value PD Peak delay Sets the delay time before Peak Picker action starts peak picker reset R W Head Sets the temperature at which Peak Picker action starts with Auto TO POAR Picker Reset Function ER Head Re Reay polaty RW_ Eng ets porty ofthe atm ey RR_ Alarm Operation RW Eng When this is turned on it also enables the attenuation alarm RT Responsetime RW Head Sets tne Sensor Response Time lt SG Signal Conditioning RW_ Head _ Turns Peak Picker or Track and Hold on or off a R10 Eng Retuns te seal number sing ofthe unt ST System alarm status Alarm Sensor returns bit mapped values for lame and the current measurement condition status Modline 5 Rev L4 12 2012 125 Digital Communications Code Command Type Group Notes Description SW Switch input status R O Head Returns the Sensor s external Peak Picker reset and Hold mode select switch status TI Temperature status R O Head Returns the temperature current status and the current attenuation and attenuation percentage TO Temperature Only R O Head Returns the temperature the unit is
213. rrower equivalent C span is allowed Spans more than 30 C 60 F may be required to obtain acceptable results Longer response times may be necessary for very narrow spans to smooth magnified temperature variations and noise 5 7 1 Fatl Analog Output Operation for Sensor or Dirty Window Detector Malfunction Alarms Sets the Analog Output current to a specified value when unit is in one of two alarm conditions A Sensor failure Error Code X107 or Dirty Window Detector operation failure Error Code X109 will trigger this alarm Selectable range is from 0 mA to 24 mA 5 7 2 A LO Analog Output Low Temperature Alarm Sets the Analog Output current value if the measured temperature is below the temperature that produces Analog Zero Scale Output as determined by the Analog Output Zero Scale Temperature Scaling explained above Selectable range is 0 mA to 4 mA for the 4 to 20 mA current output range menu item The analog output always goes to 0 mA if the measured temperature is below lil If the current loop is set for 0 to 20 mA operation the A LO function will not appear as a the Analog Output Zero Sale temperature 102 Rev L4 12 2012 Modline 5 Operation 5 7 3 A HI Analog Output High Temperature Alarm Sets the Analog Output current value if the measured temperature is above the temperature that produces Analog Full Scale Output as determined by the Analog Output Full Scale Temperature Scaling explained above Sele
214. rs WA 3 Water Cooling Accessory Do not use to provide cooling A mounting kit UAA and MFL is required to install Modline 5 Standard sensor in WJ 5 Maximum ambient temperature limited to 160 C 320 F Note Not compatible with Modline 5 Sensor with Dirty Window Detector Option DWD installed WJ 5 Water Cooling Jacket with Air Purge See installation details below Table 12 Compatibility with other Accessories Focus Sensor with rear rotating focus section If looking through a sight tube or sight hole position align and rotate the Sensor and Sight tube to center the reticle or laser image in the field of view 3 12 1 M5WJ5 Mounting Kit The M5WJ5 Mounting Kit is used with UAA and MFL Mounting Accessories to install a Modline 5 Sensor in an Ircon Model WJ 5 Water Cooling Jacket The jacket provides cooling through a stainless steel coiled pipe embedded in the jacket walls A flow rate of 20 gallons per hour 75 liters per hour of water with a temperature of 90 F 32 C or less is required An air purge is included on the front of the WJ 5 Clean dry purge air should be provided at a flow rate 6 ft min 0 73m min The jacket protects the Modline 5 Sensor in ambient temperatures up to 160 C 320F Complete specifications installation and piping instructions are included with the kit The Modline 5 Sensor cable is rated to 200 C 400F The Modline 5 Sensor with the Dirty Window Detector Option DWD cannot b
215. rtex coolers heat exchanges and air conditioned rooms Over temperature sensors are recommended for systems where special cooling is employed Use of air conditioning should include means for prevention of condensing moisture 3 6 2 Contaminants Moisture corrosive gases and liquids and conductive dust can all have adverse effects on a system that is not adequately protected against atmospheric contaminants If these contaminants collect on printed circuit boards bridging between the conductors may result in malfunction of the circuit This could lead to noisy erratic control operation or at worst a permanent malfunction A thick coating of dust could also prevent adequate cooling on the board or heat sink causing malfunction A dust coating on heat sink reduces their thermal efficiency Preventive measures include a specially conditioned room or a properly specified enclosure for the system 3 6 3 Shock and Vibration Excessive shock or vibration may cause damage to solid state equipment Special mounting provisions may be required to minimize damage 3 7 Safety Knowledge Leads to Safety Planning for an effective solid state circuit requires enough knowledge to make basic decisions that will render the system safe as well as effective Everyone who works with a solid state control should be educated in its capabilities and limitations This includes in plant installers operators service personnel and system designers SECTION 4 APPLIC
216. ry Description and DIMCNSIONS setoaisiorida delia iia 43 SOLITA Waer Coone Regue meni Sorner aa R EA TEA E TE 45 3962 WJA Air GOONS ReguiremMeNtS isinin n aA ii 45 970 0 Censor Temperature late E E E OAE O RENE 46 3 9 7 BMA Base Mount Accessory Description and Dimensions cid a di 46 3 9 8 ESA Extension Sleeve Adapter Description and Dimensions ic 48 3 10 Accessory Combinations with Break out Drawings occccccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnanoss 49 p10 L Recommended ACCESSOTY GrOU PS Saian AA A 49 3 11 Installation Drawings and Illustrati0DS oooocccccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninoss 53 3 11 1 Installation Drawing for the UAA Universal Adapter for Tripod or Custom Mounting 53 3 11 2 Installation Drawing for the RAM Right Angle Mount oonnccnoncconccnanonaninanccnnnonanonanccnnnonanaranccnncons 54 3 11 3 Installation Drawing using the WJA Water Jacket Accessory with Flange MountS ooonconiiconc 56 3 11 4 Installation Drawing using the WJA Water Jacket Accessory with the Base Mount Adapter 57 3 12 Other Accessories Sight Tube Window WJ 5 Water CooliMg occcccccccccncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonininoss 59 IZ LIM O QUA AAA AAA AA 99 13 Sensor Installation COCK arios id A iaa 61 ASENSOR WIRTN GA E EEEE a Eee 62 AT Modhine 5 Componcats srasni E SE EE SA 62 4 2 Modline 5 Sensor System Interfa
217. s behind it e g an oven wall or heating element Such problems can sometimes be corrected by changing the viewing angle so that the background source is not directly behind the target by selecting a different measurement point away from the background source or by inserting a Modline 5 Rev L4 12 2012 155 Applications Guide cooled shield behind the workpiece See Figure 96 for examples These considerations apply to all Sensor series Problem Sensor Lens sees radiation from Solution Change viewing angle or measuring location so heating element transmitted through workpiece heating element is not in field of view of sensor Sensor Lens SY Workpiece AAA DN l Heating Element M oT Problem Sensor Lens sees radiation from hot Solution Install heat insulating shield between workpiece furnace wall transmitted through workpiece and furnace wall Sensor Lens l Workpiece Qe _ o Po FA FA as FA ARA A A a ak ion A ae 4 Sa a at a s Sa a AAA a LA ae at Vettes eb bees eh ee SAMs a a ae AAA Furnace Wall Figure 96 Solving Common Transmission Problems 8 8 4 Transmission Path Effects Materials in the transmission path may absorb infrared radiation reducing the amount of radiant energy an instrument receives This is less of a problem for Series 5R Ratio Sensors as long as the radiance at both detected wavelengths is reduced equally For any other Se
218. s connected to the shield of the interconnecting cable The cable shield connects to the grounded POI Box enclosure with the Grounding Strain Reliefs If the Wiring Terminal Plate is used the interconnecting cable shield is connected to ground with the shield clamp on the plate Twisted pair shielded computer cable is required for all connections Ground the cable shields at the POI Box with the supplied Grounding Strain Reliefs If the Wiring Terminal Plate is used cable shields are connected to ground with ground clamps on the plate This manual specifies the shields of cables connecting between the POI Box or Terminal Strip Plate and system devices be connected to ground only at the Box or Plate The recommended shield connections are shown in the drawing below This recommendation is to prevent ground loops due to the difference in ground potential between locations of components and provide adequate shielding of cables Some devices call for connecting the shield to ground at the device input If ground loops develop with this connection it may be necessary to experiment with shield connections The ground connection at the Terminal Strip Plate or POI Box and the interconnecting cable shield should always be connected p eee e e r Input Output Y Device l Eg l Sensor System i I Figure 82 Sensor shield Several Sensor circuits are connected to an internal common The minus or common term
219. s flange also provides a means of mounting to accessories of other manufacturers The MFS is used by first bolting it to the APA air purge In the photograph is shown the MFS mounted to the APA Figure 29 MFS Accessory Material Clear Anodized Aluminum Weight Approximately 1 Pound 0 5 kilograms Qty Part No Description and use User Supplied Tools 3 230630C60 M6 X 30 mm flat head cap screws to assemble the MFS with the 9 mm hex key wrench APA air purge Table 5 MFS Mounting and Assembly Supplied Parts List 42 Rev L4 12 2012 Modline 5 Sensor Installation e 375 3 850 l 9 50 Front Side Hole DIA 1 500 38 1 Mounting Bolt Circle DIA 3 00 76 2 Countersink holes for APA Air Purge 3 Places M6 flat head screws APA Air Purge mounts to Back Side Figure 30 MFS Dimensions lil Dimensions are in inches and millimeters Do not scale 3 9 6 WJA Water Jacket Accessory Description and Dimensions The WJA uses water or air to cool the Modline 5 Sensor in high ambient temperatures Water cooling can protect the Sensor in ambient environments up to 200 C 400 F Air cooling can provide protection to 105 C 220 F To properly mount the WJA the BMA Base Mounting Bracket MEL Mounting Flange or the APA purge with an MFS or MFL flange should be used The use of an APA Air Purge Assembly is recommended with the WJA Trunions pivoting shafts on the side of the WJA are used to secu
220. s should be inspected for evidence of deterioration Accumulated dust and dirt should be removed from the top of the enclosures before opening doors or removing covers 8 Certain hazardous materials removed as part of maintenance or repair procedure e g polychlorinated biphenyls PCB found in some liquid filled capacitors must be disposed of as described in federal regulations 184 Rev L4 12 2012 Modline 5 Appendix A 5 3 Repair If equipment condition indicates repair or replacement the manufacturer s instruction manual should be followed carefully Diagnostic information within such a manual should be used to identify the probable source of the problem and to formulate a repair plan When solid state equipment is repaired it is important that any replacement part be in accordance with the recommendations of the equipment manufacturer Care should be taken to avoid the use of parts which are no longer compatible with other changes in the equipment Replacement parts should be inspected for deterioration due to shelf life and for signs of rework or wear that may involve factors critical to safety After repair follow proper start up procedures Take special precautions to protect personnel from hazards during start up 5 4 Safety Recommendations for Maintenance Personnel Qualified personnel familiar with the construction operation and hazards involved should do all maintenance work The appropriate work practices of NEPA 7
221. same rear focusing method applies and is to be used to adjust for the smallest laser light spot The projected focused laser image will be approximately the same diameter spot as measured by the detector See Section 3 4 Sensor Optical Characteristics page 26 for determining spot size The Laser image is reflected from the target surface The image can easily be seen on most targets at distances of 10 feet and further The visibility of the reflected image is dependent on the reflection characteristics of the target material as well as the intensity of the ambient lighting When viewing hot glowing targets the visibility of the image also depends upon its temperature The color and intensity of a hot glowing object may override the reflected Laser image Use of the laser on distant targets or poorly reflecting targets may require some white paint on the target or a white substitute target such as a sheet of paper to accomplish focusing Ambient light dimming may be required for targets that reflect poorly For difficult conditions pre focus the Sensor optics while aiming the laser at a white reflective target Then use the Laser to aim the pre focused Sensor on to the target 24 Rev L4 12 2012 Modline 5 Sensor Installation Figure 8 Laser Sight If looking through a sight tube or sight hole position align and rotate the Sensor and Sight tube to center the laser image in the field of view The Sensor is a Class II Laser Product wit
222. se of the Software on Your computers without the prior written consent of IRCON You agree to use reasonable efforts and take all reasonable steps to safeguard the Software to ensure that no unauthorized copy publication disclosure or distribution in whole or in part in any form shall be made You acknowledge IRCON s claim that the Software contains valuable confidential information and trade secrets that are the property of IRCON and or its suppliers and that unauthorized use and or copying are harmful to IRCON and or its software suppliers LIMITED WARRANTY Limited Warranty Ircon warrants that 1 the Software will perform substantially in accordance with the accompanying written materials and 2 any media and or hardware accompanying the Software will be free from defects in materials and workmanship under normal use and service Your Limited Warranty commences upon receipt of the Software and continues for a period of ninety 90 days Customer Remedies Ircon s entire liability and Your exclusive remedy shall be at Ircon s option either 1 return of the license fee paid if any or 2 repair or replacement of the Software and or media and or hardware that does not satisfy Ircon s Limited Warranty and which is returned to Ircon with a copy of Your receipt or purchase order This Limited Warranty is void if failure of the Software has resulted from accident abuse or use that is not in accordance with the accompanying written materials
223. sor to desired i When using the MFL Group 8 or APA Group 7 9 10 assemble these accessories to position to clear table Tighten clamping screw Sensor front surface will be positioned at the back end of the APA or MFL To determine working distance D for spot size formula d D F measure or calculate from that point Axis of Rotation Optical Axis Coincident with Axis of Rotation Figure 48 Group 7 shown UAA RAM and APA Dimensions are in inches and millimeters Do not scale See individual Accessory drawings Modline 5 Rev L4 12 2012 55 Sensor Installation 3 11 3 Installation Drawing using the WJA Water Jacket Accessory with Flange Mounts Group Mounting Option Required Accessories See Individual DWD Accessory Descriptions and Dimensions See Notes 3 11 Water Jacket Air Purge and Small Flange APA WA MFS 12 Water Jacket with Large Flange Mount WJA MFL Add ESA Water Jacket Air Purge and Large Flange ESA 2 DWD is Dirty Window Detector Option Refer to notes with grouping table in Section 3 10 Accessory Combinations with Break out Drawings page 49 The ESA adds 1 82 46 2 mm to length of the assembled group Table 10 Recommended Accessory Groupings WJA with Flange Mounts Jo Figure 49WJA with Flange Mounts spring catch Secure the Sensor rear protection and sighting window Swing safety lil Insert Sensor into the WJA assembly with moderate force until i
224. ss system Figure 94 illustrates Track and Hold operation The Sensor will be in the Track Mode with the switch open and in the Hold mode with the switch closed e The remote switch may be manually operated or it may be a contact on a timer relay or movement of a target or its timing in the process to close the remote switch Modline 5 Rev L4 12 2012 153 Applications Guide e Track and Hold temperature readings are affected by the Response Time setting a Target Temperature Signal j Sensor Output Hold Track Figure 94 Track and Hold Example you may want to scan the surface of a moving workpiece and hold the temperature reading at middle point on the workpiece while ignoring the readings at the beginning and the end of the workpiece Another Example the temperature tracking can be made to hold a temperature even after the temperature in the sighted area has dropped It will hold the value without any decay until the switch is opened Peak Picker and Track and Hold Signal conditioning cannot be simultaneously selected Use of Peak Picker with zero or very low Decay rates and an external reset can accomplish similar results 8 8 Avoiding Common Measurement Problems 8 8 1 Viewing Angle Limitations Acute viewing angles can present the problem of reduced emissivity values particularly if you are dealing with smooth target surfaces Figure 95 shows the permissible angles for all Sensor Series when viewing sm
225. t IN operation is selected remote current input of Emissivity and E Slope is not Modline 5 111 Rev L4 12 2012 Operation would de energize the laser when released See Section 4 9 Connecting Device Cables to POI Box or Terminal Strip Plate page 73 for resistor DC Voltage selection and circuit wiring I IN Operation Condition Set One 1 A If Sensor is powered up with I IN current applied remote switch closed the Laser will not operate until the remote switch is opened and then closed again The Laser will only operate with switch closed 1 B When the Laser is energized by closing the remote switch the laser can be de energized with a RS 485 Command the Rear Panel Laser Switch or by disconnecting I IN current remote switch open If none of these occur the Laser de energizes after the 20 minute time out period 1 C If Laser has been de energized by a RS485 Command the Rear Panel Laser Switch or the 20 minute timeout period the I In current must be disconnected switch open and re applied switch closed to energize the Laser with the remote switch However the laser can be activated with the Sensor Rear Panel Laser switch or RS485 command without opening and closing the switch 1 D The Laser can be energized by the Rear Panel Laser Switch or a RS485 command only when the remote switch is closed and condition 1A has been satisfied PkHd Switch Operation When Laser PkHd switch operation is selected remote switch Reset
226. t snaps into the clamp into position and tighten 56 Rev L4 12 2012 Modline 5 Sensor Installation 897 Front of Sensor without DWD with gt 22 8 Reference to WJA Safety Clamp Figure 50 Group 13 shown WJA APA and MFL Flange Dimensions are in inches and millimeters Do not scale Total Lengths Dimension shown with and without MFL Flange Mechanical and optical Centerlines are coincidental 3 11 4 Installation Drawing using the WJA Water Jacket Accessory with the Base Mount Adapter Group Mounting Option Required Accessories See Individual DWD Accessory Descriptions and Dimensions See Notes 14 Water Jacket Base Mount wa BMA NRO 15 Water Jacket Base Mount Air Purge APA WJA BMA AddESA 2 Water Jacket Base Mount and Large Flange WA BMA IML Add ESA 3 Water Jacket Base Mount Air Purge and 1 Small Flange Add ESA 2 T APA WJA BMA MFS Water Jacket Base Mount Air Purge and 18 Large Flange APA WJA BMA MFL Add ESA 2 DWD is Dirty Window Detector Option Refer to notes with Grouping table in Section 3 10 Accessory Combinations with Break out Drawings page 49 The ESA adds 1 82 46 2 mm to length of the assembled group Table 11 Recommended Accessory Groupings WJA with BMA Modline 5 Rev L4 12 2012 57 Sensor Installation Figure 51 Insert Sensor into the WJA assembly with moderate force until it snaps into the spring catch Secure the Sensor rear
227. t alarm annunciators on the DPM display also light Output logic is normally open Setpoints are only operational when the DPM is in the Display mode The Setpoint any programming or diagnostic mode Relays also held in their last state during Sensor relay outputs are held in their last state before leaving the display mode and entering lil CAL Calibration in progress Relay states will be in an unknown condition with a Sensor error 9 14 3 MAX and MIN Temperature Display Basic Setup and Operation The operation described is with the DPM in the Quick Programming Mode Refer to the PAX Bulletin supplied with the meter for MAX and MIN operation variations with different setups This Setup displays captured MAX and MIN in the Quick Programming mode by pressing Display function key to choose MAX MIN or Current Temperature Setup Module 2 User Input and Front Panel Function Key Parameters 2 FNC Do not change User 1 parameter leave at PLOC Do not change ScF1 or ScF2 leave at NO Set USPr 2 to d La Then USPr 3to d H Then Fito r H Then F to r la Then r 5 to r Ht Module 3 Display and Program Lock out Parameters 3 LOC Set Hito rld Then LE to rEd All other parameters remain at the factory default settings Operation Press Display DSP function key to choose MAX MIN or current Temperature The MAX and MIN temperatures have been captured since the last reset of these functions The Front Panel F1 Key resets the MIN
228. t and the unit to allow air to circulate between them Figure 100 Sensor Water or Air Cooling with Added Insulation Wrap 160 Rev L4 12 2012 Modline 5 Applications Guide Figure 101 Protection Using Reflective Heat Shield Modline 5 Rev L4 12 2012 161 DPM Installation and Operation 9 DPM Installation and Operation 9 1 Introduction The IRCON Model DPM is an accessory to the Modline 5 Series of Infrared Thermometers As a remote operator interface the DPM provides complete setup of the Modline 5 It connects to the Sensor s RS 485 Digital Communications to interface with the Sensor Read and Write commands are used to obtain and display temperature measurement values and Sensor status including diagnostic Alarms The DPM can also be used as a read only device by configuring the Sensor to accept read commands only The DPM can be programmed to display stored Maximum and Minimum temperatures as well as the current temperature With the optional Quad Relay Card four setpoints can be used as temperature alarms The DPM is an OEM product supplied by Red Lion Controls 9 1 1 Using the DPM The following steps are necessary to use the DPM e Prepare and install the DPM as instructed in Section 9 2 DPM Installation page 162 e Be thoroughly familiar with the operation of Sensor as explained in Section 5 Operation page 90 of this Modline 5 Manual e Follow the safety warnings cautions and Instructions for safe Laser oper
229. t of Range Displays and Error Codes The Modline 5 displays word messages on its rear panel display to indicate Sensor diagnostic results Below are explanations of the reported measurement status and error codes 112 Rev L4 12 2012 Modline 5 Operation Measurement status displays for Out of Range and Invalid measurement conditions are defined as follows LOW Conditions do not allow measurement because the infrared temperature signal is too low The target temperature is too low for the range of the Sensor HIGH Conditions do not allow measurement because the infrared temperature signal is too high The target temperature is too high for the range of the Sensor INV Measurement Conditions are invalid for two color ratio temperature measurement When the Invalid Alarm ALM function is set to ON this measurement condition becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear panel If INV is the only Alarm pressing the A pushbuttons will show no other Error Codes The above conditions may relate to improper installation or adjustment of Sensor Functions Avoid reflections from surrounding hot objects unresolved targets and obstructions in the Sensor s optical path True temperature measurement is dependent on correct setting of Emissivity or E Slope Use of Pick Picker or Track and Hold signal conditioning may be necessary to capture temperature signals because of process interferences The Rear P
230. tO e 1 510 OPA OPA E PO Mace zebin a a inven Sonata Mecarrels 177 TAPREENDE A a 178 IM APRENDE Diana aereo rio 186 Safety Instructions 1 Safety Instructions This document contains important information which should be kept at all times with the instrument during its operational life Other users of this instrument should be given these instructions with the instrument Eventual updates to this information must be added to the original document The instrument can only be operated by trained personnel in accordance with these instructions and local safety regulations Acceptable Operation This instrument is intended only for the measurement of temperature The instrument is appropriate for continuous use The instrument operates reliably in demanding conditions such as in high environmental temperatures as long as the documented technical specifications for all instrument components are adhered to Compliance with the operating instructions is necessary to ensure the expected results Unacceptable Operation The instrument should not be used for medical diagnosis Replacement Parts and Accessories Use only original parts and accessories approved by the manufacturer The use of other products can compromise the operation safety and functionality of the instrument Instrument Disposal Disposal of old instruments should be handled according to professional and environmental regulations as electronic waste x Operating Instruct
231. tallation site and power conductors have been examined the system wiring plans that will provide noise suppression should be considered Conducted noise enters solid state control at the points where the control is connected to input lines output lines and power supply wires Input circuits are the circuits most vulnerable to noise Noise may be introduced capacitatively through wire to wire proximity or magnetically from nearby lines carrying large currents In most installations signal lines and power lines should be separate Further signal lines should be appropriately routed and shielded according to the manufacturer s recommendations When planning a system layout care must be given to appropriate grounding practice Because design differences may call for different grounding the control manufacturer s recommendations should be followed 3 5 Countering the Effects of Off State Current 3 5 1 Off State Current Solid state components such as triacs transistors and thyristors inherently have in the off state a small current flow called off state current Off state current may also be contributed by devices used to protect these components such as RC snubbers 3 5 2 Off State Current Precautions Off state currents in a device in the off state may present a hazard of electrical shock and the device should be disconnected from the power source before working on the circuit or load Precautions should be taken to prevent the off sta
232. tatic discharge ESD 4 15 Summary Caution and Warning Inspect the installation for proper wiring possible loose connections or potential shorts The installation of the Sensor described in Section 3 Sensor Installation page 22 should be complete The wiring of the Sensor and system devices described in this Section 4 Sensor Wiring page 62 should also be complete The Modline 5 Sensor can now be powered and the initial setup for operation performed as described in Section 5 Operation Look for any signs of over heating or smoking when applying power Investigate any signs of improper installation Please read the following important Caution and Warning If you observe any signs of malfunctions smoke or overheating complete lack of any indication etc turn off power immediately Recheck all wiring and refer to Section 7 6 1 for troubleshooting Critical Process Safety Guideline Risk of Personal Injury When this instrument is being used in a critical process that could cause property damage and personal injury the user should provide redundant device or system A that will initiate a safe process shutdown in the event that this instrument should fail The user should follow NEMA Safety Guidelines For the Application Installation and Maintenance of Solid State Control A copy of the guidelines is reprinted in Appendix A The National Electrical Manufacturers Association NEMA has published safety guidelines for the Applicat
233. tch for Remote Peak Picker Reset Track and Hold or Laser Operation An external switch connected to the Pk Hd Switch terminals will control signal conditioning of the Modline 5 These terminals can also be used for remote Laser activation Switch action for the Peak Picker will provide the following control Momentary closure of the switch gt 0 08 second immediately resets the Peak Picker If the switch is continuously closed the Temperature Display will show direct readings without any Peak Picker signal conditioning The switch may be manually operated or it may be a contact on a timer relay or any other process operated switch Switch action for Track and Hold will provide the following control With the switch open temperature tracking continues Track With the switch closed the displayed temperature will be held at the last reading Hold The switch may be manually operated or it may be a contact on a timer relay or any other process operated switch 76 Rev L4 12 2012 Modline 5 Sensor Wiring Remote Laser Operation is selected in COMMS LASR Menu See manual Sections 5 8 COMM Setup of RS 485 Digital Communication Configuration page 103 and 5 11 Laser Sighting Operation page 110 for selecting and operating the remote laser function The PkHd terminals are dedicated to Laser operation when selected To wire for remote PkHd switch operation follow the diagram given below Use Shielded cable and ground shields at POI BOX
234. te current of an output device which is in the off state from energizing an input device 3 6 Avoiding Adverse Environmental Conditions 3 6 1 Temperature Solid state devices should only be operated within the temperature ranges specified by the manufacturer Because such devices generate heat care should be taken to see that the ambient temperature at the device does not exceed the temperature range specified by the manufacturer Modline 5 Rev L4 12 2012 181 Appendix A The main source of heat in a solid state system is the energy dissipated in the power devices Since the life of the equipment can be increase by reducing operating temperature it is important to observe the manufacturer s maximum minimum ambient temperature guidelines where ambient refers to the temperature of the air providing the cooling The solid state equipment must be allowed to stabilize to within the manufacturers recommended operating temperature range before energizing control functions When evaluating a system design other sources of heat in the enclosure which might raise the ambient temperature should not be overlooked For example power supplies transformers radiated heat sunlight furnaces incandescent lamps etc should be evaluated In instances where a system will have to exist in a very hot ambient environment special cooling methods may have to be employed Techniques that are employed include cooling fans with adequate filtering vo
235. terial and readjust the E SL function if necessary If you are viewing your target through a window consider the effect of window transmission as described in Section 8 Applications Guide page 137 Modline 5 Rev L4 12 2012 105 Operation Navigate from TEMP display with J amp A Y to Head then use J amp A Y to E SL Display Instructions Display and Limits E SL Press ENT to view E Slope Use Up Down Arrows to adjust 0 800 to 1 200 Press ENT to save and return to TEMP display 5 9 4 Remote E Slope Current Input You may make remote analog adjustments of the E Slope value by sending a scaled input of 4 to 20 mAdc This signal is inputted using the Orange and Orange White twisted wire pair of the Sensor s interconnecting cable The Modline 5 senses an input and the overrides any rear panel or RS 485 settings of E Slope or Match Wiring connection and scaling information are in Section 4 Sensor Wiring page 62 5 9 5 EMIS Emissivity Adjustment for Brightness Sensors Modline 5 brightness sensors and one color operation of ratio sensors require Emissivity adjustment for accurate temperature measurement The Emissivity value is set to the characteristics of the material being measured using the EMIS function Ratio sensors that are using the Attenuation Alarm feature will need to set the sensor to a single color mode set the correct emissivity for the target then set the sensor back to 2 color mode When using the Attenuation
236. ternate temperature scaling can be accomplished using the Sensor s AOUT Main Menu the ZERO and FULL functions See Section 5 Operation page 90 of this manual for instructions The paragraphs and diagram below provide further explanation The ZERO function sets a temperature to correspond to the selected Analog Output Current Range minimum value 0 or 4 mA This temperature must be within the Sensor s specified temperature range and is limited to a maximum value 10 below the Sensor s specified full scale temperature Minimum setting is the Sensors specified zero scale temperature The FULL Sets a temperature to correspond to the Analog Output Current Range maximum value 20 mA Temperature must be within the Sensor specified temperature range and is limited to a minimum value 10 above the Sensors specified zero scale temperature Maximum setting is the Sensor s specified full scale temperature Modline 5 Rev L4 12 2012 137 Applications Guide 0to 20 mA or 4to 20 mA LOAD S 600 Ohm Maximum Current Loop Resistance Figure 87 Analog Output Configuration 8 2 1 Analog Output Range Scaling Example The Sensor temperature range example shown in Figure 88 is 500 degrees to 2500 degrees The minimum analog output at 0 or 4 milliamps as selected can be set to equal the Sensor s 500 degree zero scale temperature or to an alternate value such as the 1000 degrees illustrated in the figure The maximum analog output 20 mill
237. tions alarm off since that is the invalid threshold The relay response see command RR must be set on in order to enable this alarm 6 6 Analog Output Function Command Codes AO Analog Output Current Range Read Write Sets the Analog Output Current loop range to either 0 to 20 mA or 4 20 mA Range 0 or 1 0 4 to 20 mA 1 0 to 20 mA AZ Analog Zero Scale Read Write Analog Zero Scale command specifies the measured temperature that will produce the Analog Output Zero Scale current See Section 5 7 AOUT Setup of Analog Signal Output Current Range and Temperature Scaling page 101 about minimum spans and F C operation Message Value Range Sensor s zero scale temperature to 10 F below its full scale temperature The Sensor s selected measurement units F or C are ignored in the Write command Sensor Reply Returns with an F or C to show which units are selected AF Analog Full Scale Read Write Analog Full Scale command specifies the measured temperature that will produce the Analog Output full scale current See Section 5 7 AOUT Setup of Analog Signal Output Current Range and Temperature Scaling page 101 about minimum spans and F C operation Message Value Range Sensor s zero scale temperature 10 to its full scale temperature The Sensor selected measurement units F or C are ignored in the Write command Sensor Reply Returns with an F or C to indicate
238. tions EMC EN 60825 1 2001 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Covered by Patent No 5812270 when Dirty Window Detector Option installed A Use the product only as specified or hazardous laser radiation exposure can occur Warranty IRCON Inc warrants equipment manufactured by it to be free from defects in materials and workmanship for a period of one year from the date of shipment by IRCON Customer paid repairs are warranted for 90 days from date of shipment If within such period any such equipment shall be proved to IRCON s satisfaction to be so defective such equipment shall be repaired or replaced at IRCON s option provided the defective equipment is returned to IRCON transportation charges prepaid by purchaser This warranty shall not apply a to equipment not manufactured by IRCON b to equipment which shall have been repaired or altered by others than IRCON so as in its judgement to affect the same adversely or c to equipment which shall have been subject to negligence accident or damage by circumstances beyond IRCON s control or to improper operation maintenance or storage or to other than normal use or service With respect to equipment purchased by IRCON but not manufactured by IRCON the warranty obligations of IRCON shall in all respects conform and be limited to the warranty actually extended to IRCON by its supplier the manufacturer The foregoing warranties
239. to 60 0 Seconds for 5R Ratio Sensors Use Up Down Arrows to adjust Response Time 0 006 to 60 0 Seconds for Series 52 and 5G Press ENT to save and return to TEMP display 006 6 6 milliseconds 0 02 to 60 0 seconds Model 56 Sensors 5 9 2 COLR Ratio Unit Operation Selection The COLR function sets the Modline 5 Ratio Sensor operation in the two color mode for ratio temperature measurement or in the single color mode for brightness temperature measurement Navigate from TEMP display with J amp A Y to Head then use J amp A Y to COLR Display Instructions Display and Limits COLR Press ENT to view Color Selection 1or2 Use Up Down Arrows to select 1 for single color brightness operation or 2 for two color ratio operation 5 9 3 E SL Ratio Unit Two Color Operation E Slope Adjustment Ratio Sensors require the correct E Slope value selection for measuring temperatures of both non greybody and greybody blackbody targets To get a true measure of the temperature you must select the E Slope values to match the material being measured The value can be set in real time while viewing the process The adjustable range for this function is 0 800 to 1 200 e Determine the E Slope value by referring to Section 8 Applications Guide page 137 or other reliable source e Enter the proper E Slope value in the E SL function If you change materials or if the material characteristics change re determine the E Slope for the ma
240. to exceed 55 C 131 F Environmental rating NEMA 4 IP65 A three wire AC power cable or individual discrete wires may be used A 0 83 inch 21 1 mm conduit entrance is provided for AC power wiring entry Conduit or a suitable strain relief is required Four cable grip strain reliefs are supplied One is for the Sensor interconnecting cable entry and two are for user supplied cables that connect to process system devices These three NEMA 4 IP65 compliant devices provide electromagnetic interference EMI shielding The fourth is a plastic strain relief for a power cable To maintain the NEMA 4 IP65 rating the four cable grip strain reliefs supplied and properly sized cables must be installed in the box entrance holes Do not leave a hole empty Use a properly sized hole seal that is NEMA 4 IP65 rated The hole covers shipped with the box are for shipping purposes only and are not rated 4 4 1 Mounting the POI Box Figure 58 includes the mounting dimensions and cable entry locations of the POI Box Locate to allow clearance for cable entry and cable fittings Mounting is by means of four user supplied 6 or metric equivalent pan head sheet metal or machine screws at the four corners of the main part of the box When you have selected your mounting location remove the cover Mark the hole positions for the mounting screws on the panel or mounting surface you have selected Drill the mounting holes and attach the box to the mounting surfa
241. ue for Emissivity or E Slope The Write Message Value is the known temperature of the target the Sensor is measuring The unit will change Emissivity single color units or E Slope two color ratio units to a value to that produces a displayed temperature equivalent to the target temperature The Sensor returns the required Emissivity or E Slope value if the result is in range If the unit is unable to match the temperature then the return value is ERR The Match temperature should be set with a Sensor Response Time of 100 milliseconds or faster Peak Picker or Track and Hold must be Off The Match function should be set with stable process temperatures After setting the Match temperature the Response Time Peak Picker and Track and Hold can be set to the values required for process temperature measurement Write Message Range Unit s zero scale to full scale temperature Reply Message Value Emissivity or E Slope value or ERR TT Temperature Read Only Returns the temperature the unit is reading in the current units An F or C is put on the end as appropriate The temperature resolution is 1 F or C Message Value Range From the low end to the high end of the Sensor temperature range Some special readings are Modline 5 Rev L4 12 2012 121 Digital Communications 32768 800016 Sensor Failure 32512 810016 Unit not warmed up 32256 820016 Invalid 32000 830016 Temperature too low below Sensors range 31
242. ues from prior valid measurement conditions 4 10 Selection of a Power Supply for Sensors used with TSP Terminal Strip Plates When using a Modline 5 Sensor with the TSP Terminal Strip Plate select a switching type power supply that will provide reliable startup The power supply output should remain at rated voltage during the Sensor current loading that occurs at startup Sensor displays and alarms will not properly start with low voltage A dedicated Power supply for each Sensor is the simplest and best configuration IRCON offers a chassis mount single sensor supply The IRCON part number for this power supply is 551632 See Section 4 11 Installing and Wiring the Chassis Mount 24 Volt DC Switching Power Supply for all details Multiple Sensor installations may require more than one power supply A single supply will not be able to properly provide startup power to a large number of sensors Limit the number of Sensors supplied from a single power supply to no more than 2 or possibly 3 Dividing the Sensors into eroups can eliminate long cable runs when sensors are installed at distant locations This is especially the case when AC power is available locally The standard Modline 5 cable that is routed between the Sensor and TSP Plate is limited to 350 Feet 107 meters The power supply wires in this cable are 22 gauge This maximum cable distance and wire gauge assures enough voltage will be available at the sensor The voltage drop developed
243. ult setting is O zero 5 8 3 BRAT Baud Rate The Sensor Baud Rate must match that of the other RS 485 device Four baud rates are supported 9600 19200 38400 and 57600 bits of information per second Baud The factory setting is 57 6K Baud 5 8 4 LASR Laser Operation Sensor Firmware Versions 1 08 and Higher Selects Sensor Rear Panel or RS485 operation only or remote switch operation using the I IN or PkHd functions See Section 5 11 Laser Sighting Operation page 110 RS485 Communication Navigate from TEMP with J amp A Vto COMM then use 1 amp A Y to ADDR or BRAT or CLCK Press ENT J to save and return to TEMP display after each function MENE Instructions Display and Limits CLCK Press ENT to view Communications LOCK R OorR W Use Up Down Arrows to select R O Read Only or R W Read and Write operation ADDR Press ENT to view Sensor Address 0 to 9 and A to Z Use Up Down Arrows to set to one of thirty six addresses BRAT Press ENT to view baud rate 9600 or 19 2K or 38 4K or 57 6K Use Up Down Arrows to select 9600 19 2K 38 4K or 57 6K Baud LASR Press ENT to view Laser operation Selection PANL or IN or SWIT Use Up Down Arrows to select 5 9 HEAD Setup of Sensor Operating Functions The HEAD menus and functions set up the Modline 5 Sensor for process temperature measurement The initial setup should follow the order given below It is useful to perform the setup while the Sensor is sighted on th
244. unction To configure and wire for remote I IN current switch Laser operation follow the instructions given below When selected for remote Laser Operation Emissivity and E Slope are not changed by the input current Modline 5 Rev L4 12 2012 75 Sensor Wirin 4 9 8 POI BOX or Terminal Strip Plate Current Input Terminal Connections for Remote Laser Operation Use a DC power supply with a maximum output of 24 volts Maximum input current allowed is 20 mA Overloading the input can cause a Sensor Fail alarm ohm Sensor internal circuit impedance from the calculated value See Table below lil When calculating a series resistor value to use with a supply voltage subtract the 120 On threshold is 15 mA DC Voltage Supply Resistor Value 10 Volts 960 ohms Plus 120 Internal 680 ohms total for 15 mA 24 Volts Can be Sensor Supply 1500 Ohms Plus 120 Internal 1620 ohms total for 15 mA Table 16 Connect the supply circuit as shown in the wiring diagram The I IN terminal can be connected to a floating or earth grounded power supply terminal In either case it must be connected directly to the power supply If using the POI BOX internal 24 VDC power supply common must be directly connected to the mA terminal Mount the Y Watt resistor in a series circuit on the switch or at the external power supply location 1 2 Watt Resistor Remote Laser Switch Orange Orange White Figure 71 4 9 9 Peak Hold Swi
245. ur installation e Perform Sensor Check CHK as instructed under Engineering functions menu for Sensor setup in Section 5 Operation page 90 e Check Sensor function settings A record of the correct settings for process being measured should be made e Check Sensor for proper alignment and focus Make sure there are no obstructions in the optical path between Sensor and target Process viewing windows should be clean e Check Sensor lens and clean if necessary Refer to cleaning instructions below e Make sure Sensor is not overheated If water cooling and or air purge accessories are used make sure there is adequate flow of cooling water and clean dry air e Check Sensor interconnecting cable for any signs of mechanical damage or overheating Make sure all connections are secure 7 2 Sensor Optics Cleaning Inspect the standard Sensor lens or the front window and mirror on the Sensor with the Dirty Window Detector option on a routine schedule Clean these optics of any dust or residue that may have accumulated If this requires removing the Sensor from its mounting make sure you note the mounting alignment and lens focus position so you will be able to restore the Sensor to its correct operating position Always verify focusing as instructed in Section 3 Sensor Installation page 22 If the Sensor includes the Laser aiming option see the Laser option cautions on Section 2 3 Model Configuration and Required Selections page 15 and Section
246. use a window at least twice the diameter of the Cone of Vision at the point where the window is to be installed Note that the dimensions of the Cone of Vision can be changed by focusing the optics It is essential for all Sensor Series except Series 5R that you never allow any part of the Cone of Vision to be obstructed Figure 99 illustrates the correct use of windows Keep the window clean to prevent low temperature indications Sight Hole mn H A ice Target Sensor Lens ____ L _ _ Cone of Vision g Window Y Figure 99 Viewing a Target through a Sight Hole and Window 8 10 1 Special Considerations for Ratio Units Because Modline Series 5R ratio Sensors compare the radiation detected at two separate wavelengths the best windows for these units have the same transmission value at both wavelengths All acceptable Series 5R windows specified in the Guide have this characteristic No additional E Slope adjustment is required when these windows are used Note that certain materials which are transparent to the human eye can cause serious measurement errors when with a 5R Ratio Sensor For instance it almost always causes problems if any of soda lime plate glass PLEXIGLASTM water or PYREXTM glass lies between the Sensor and the target during a measurement Similarly if you need to reflect your target s radiation in order to measure it with a 5R Ratio Sensor use a front surface gold mirror not a mirror
247. use of the Software except as described in the accompanying written materials In order to minimize the likelihood of property damage and personal injury the user should follow guidelines provided in the appendix of the user manual and establish independent safety procedures and systems U S GOVERNMENT RESTRICTED RIGHTS The Software is provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of The Rights in Technical Data and Computer Software clause at 52 227 7013 Contractor manufacturer is IRCON Inc 1201 Shaffer Road Building 2 Santa Cruz CA 95060 5731 If any provision or portion of a provision of this Agreement is determined to be invalid under any applicable law it shall be deemed omitted and the remaining provisions and partial provisions of this Agreement shall continue in full force and effect This Agreement is to be governed by and construed in accordance with the laws of the State of Illinois This Agreement constitutes the entire agreement between the parties with respect to the subject matter hereof and all prior agreements representations statements and under takings are hereby expressly cancelled Should you have any questions concerning this Agreement or if you wish to contact Ircon for any reason please write Ircon Inc Customer Service 1201 Shaffer Road Building 2 Santa Cruz CA 95060 5731 Content EA INS FRO CTION
248. usly set time period value AC Auto and Immediate Calibration Initiate Read Write For Models begging with 56 Series 56 Models include a Self Calibration feature performed as part of the power on routine Explanation of this feature is provided in Section 5 5 Warm up and Initial Setup page 93 under the explanations for sensor parameters CHK Models Beginning with 56 and HOUR Models Beginning with 56 Range 0 or 168 65535 Modline 5 Rev L4 12 2012 117 Digital Communications A zero value disables this function a Manual Initiation must be performed at least every 168 hours A value of 168 sets the time period between calibration checks to 168 hours Factory setting A value of 65535 FFFFis causes an immediate Calibration to occur without changing the previously set time period value This is equivalent to a Manual Calibration at the Sensor Rear Panel RP Relay Polarity Read Write Sets the polarity of the alarm relay Set to 1 for fail safe operation Contacts are held open with power off or power on and in the brief warm up state for either polarity Range 0 or 1 0 N O to 1 N C DT Dirty Window Detector Warning Level Read Write This command is available only with the Dirty Window Detector option This command is the same as the Sensor Rear Panel WRNL OFF turns the dirty window detection function off Course and Sensitive Warning Levels select a greater CORS or lesser SENS amount of Se
249. value to the current temperature reading on the display The MIN temperature function continues from that point The Front Panel F2 Key resets the MAX value to the current temperature reading on the display The MAX temperature function continues from that point The Front Panel RST Key resets both MAX and MIN values to the current temperature reading on the display 176 Rev L4 12 2012 Modline 5 DPM Installation and Operation 9 14 4 Overlay Backlight The DPM is factory set for using an F or C units display overlay If an overlay is not used the backlight can be turned off in the Full Programming as follows Module 4 Secondary Functions 4 SEC Only change the 6 L E parameter Change to Qf 9 15 Factory Default Restoration If for some reason the DPM settings have been changed and set to values that are now unknown restoration to factory settings can be made Access to Module 9 Factory Service Operations is required Refer to the Red Lion PAX B Bulletin for complete instructions To access Factory Service from the Quick Programming Mode display the fed parameter and enter eee Alternately with the User 1 jumper between Terminals 7 and 8 removed the unit is in Full Programming mode and access to all meter programming modules is immediately available Remove the jumper only as an alternate to the Code 222 entry in the Quick Programming Mode Select Module 9 Factory Service Operations Go to Code Enter fa
250. vide a selection of one of two analog output direct current ranges 0 to 20 mA or 4 to 20 mA This function selects the desired range ZERO Analog Output Zero Scale Temperature Scaling This function sets a temperature to correspond to the selected Analog Output Current Range minimum value 0 or 4 mA This temperature must be within the Sensor s specified temperature range and is limited to a maximum value equivalent to 10 F 12 2 C below the Sensor full scale temperature or 10 F 12 2 C below the adjusted Analog Output Full Scale temperature value explained below Minimum setting is the Sensor specified zero scale temperature See notes after FULL explanation for ZERO FULL C operation and span setting information FULL Analog Output Full Scale Temperature Scaling Sets a temperature to correspond to the Analog Output Current Range maximum value 20 mA Temperature must be within the Sensor specified temperature range and is limited to a minimum value 10 F 12 2 C above the Sensor s specified zero scale temperature or 10F 12 2 C above the adjusted Analog Output Zero Scale temperature value explained above Maximum setting is the Sensor specified full scale temperature For ZERO FULL span setting F and C operation The minimum 10 span is calculated by the Sensor in F When using C units the span will be less than 10 because the Sensor first calculates in lil F and then converts to C The na
251. when used with Peak Picker signal conditioning without the Auto Peak Picker Reset function It will provide the selected delay for the first hot target seen after any Peak Picker Reset The reset can be from the Sensor rear panel a reset from a momentary closure of the Peak Picker Reset external switch or a reset from the RS485 PR command The primary use of Peak Picker Delay is with the Auto Peak Picker Reset and Reset Below Temperature functions as explained below The Peak Picker Delay time out will be not begin until a target whose temperature is above the selected Reset Below Temperature comes into view and remains in view Figure 93 shows the delay time in relation to the target temperature and the reset below temperature level The Peak Picker action will begin after the selected delay time and will continue until the actual measured temperature 152 Rev L4 12 2012 Modline 5 Applications Guide goes below the selected Reset Below temperature The system will then return to direct temperature indication until a new target comes into view The Decay Cycle will repeat as describe above Delaying the start of the peaking action allows peaked temperature measurement of targets with hot leading edges and cooler middle temperatures without peaking on the hotter leading edge The delay time selected determines at what position or point on the target peaking action begins This function may be affected by a slow Response Time which could further d
252. which units are selected AA Analog Output Alarm Read Write Sets the Analog Output current to a specified value when unit is in any of two alarm conditions A Sensor failure Error Code X107 or Dirty Window Detector circuit failure Error Code X109 will trigger this alarm Scaled Message Value Range 0 to 240 Actual Range 0 0 mA to 24 0 mA AL Analog Output Low Temperature Read Write This command is used to set the value of the current loop output as an alarm if the measured temperature is below the scaled or default temperature that produces Analog Zero Scale Output current Scaled Message Value Range 0 to 40 Actual Range is 0 0 mA to 4 0 mA for the 4 to 20 mA current output range If the current loop is set for 0 to 20 mA operation the AL command setting is overridden and the analog output always goes to 0 mA if below zero scale temperature AH Analog Output High Temperature Read Write This command is used to set the value of the current loop output as an alarm if the measured temperature is above the scaled or default temperature that produces Analog Full Scale Output current Scaled Message Value Range 200 240 Actual Range 20 0 mA to 24 0 mA 120 Rev L4 12 2012 Modline 5 Digital Communications 6 7 Head Function Command Codes CL Select Mode of Ratio Sensor Operation Read Write Command is for 5R ratio units only The CL command selects One Color or Two Color operation for a Series 5R ratio Sensor
253. window contamination Dimensions for the Sensor with the DWD is slightly different because of the additional components Measurement of the optical working distance on the standard Sensor is made from the front surface of the unit The working distance determination on the Sensor with DWD requires a simple calculation Measurement is made from the front tip of the hooded mirror and 66 mm 2 6 inches is added to the distance to compensate for the extended optics fi d J Sensor with DWD Mirror Standard Sensor Lens Window Figure 4 Standard Sensor Lens and Lens with DWD 22 Rev L4 12 2012 Modline 5 Sensor Installation 3 2 1 Sensor Parts The photograph below illustrates the Sensor parts called out in this manual Rear Rotating Focusing Section Focuses the Sensor optical system on the target UAA Universal Adapter Accessory for mounting Lens Lock Thumb Screw Locks the focusing section in place after focusing Cable Connection Match Do Not Use Tools Red Dots to connect NEMA 4 IP65 environmental rating Rear Protection Visual Sight Window Threads on focusing section to cover rear panel display and keypad Provides NEMA 4 IP65 environmental rating See note below about EP 5 window Figure 5 Sensor Parts The EP 5 Protective Visual Sight Window with a dimming filter is available for viewing very high temperatures This replaces the standard rear protection and sight window shown above
254. with an aluminum reflecting surface The materials listed in the Guide are not all common optical materials and you may have some difficulty locating a source for windows If you do here are some suggestions Modline 5 Rev L4 12 2012 159 Applications Guide Adolph Meller Optics Karl Lambrecht Corp Janos Technology Inc P O Box 6001 4204 Lincoln Ave Route 35 Townshend Providence Rhode Island Chicago Illinois 60618 Vermont 05353 802 365 7714 02940 401 331 3717 773 472 5442 www janostech com www klccgo com 8 11 Preventing Sensor Overheating The Modline 5 Sensor can be cooled with the WJA accessory presented in Section 3 Sensor Installation page 22 Do not use a WA 3 accessory for cooling Under extreme conditions it may be necessary to provide insulation and reflective shielding for additional protection from high ambient temperatures and radiated heat using materials available at the installation site Figure 100 shows one means of providing insulation protection In this example a Sensor is mounted at a sight hole cut into a furnace wall The Sensor is protected from the atmosphere by a water cooling accessory and is insulated from the atmosphere near the wall by aluminum backed insulation A radiant heat shield can be any reflective metal shield in the path between the heat source and the Sensor as in Figure 101 It should be close enough to the Sensor to block random reflected radiation but with a space between i
255. with grounding strain relief supplied or at the TSP Terminal Strip Plate ground terminal Violet Pk Hd Switch Remote Laser Switch Violet White Pk Hd Switch Figure 72 4 9 10 Sensor Alarm Relay Contacts The sensor self tests its case temperature detector assembly temperature output current flow etc The Check function checks internal circuit and detector operation The optional Dirty Window Detector measures the Sensor s window condition One or more out of limit conditions sensed by these tests triggers an Alarm and operates the Alarm relay within the Modline 5 The relay contacts may be used in the process control system to indicate measurement conditions do not allow process temperature measurements or Sensor operation may be impaired Appropriate action for the various conditions can then be initiated Alarm Relay contact connections are made to the Alarm Relay Terminals The relay contact is rated for 24 Volts AC or DC 1 AMP resistive loads only The Alarm relay can be configured for Normally Open or Normally Closed operation The configuration can be performed at the Sensor Rear panel with the Engineering RELY function or with RS 485 digital communications Set the relay operation to correspond to proper and safe use of the contacts in your overall measurement system Select N C for closed relay operation with Sensor not in Alarm condition open in alarm state Select N O for closed relay operation with Sensor
256. y may cause a malfunction or damage to the control 4 5 Testing Precautions When testing solid state control the procedures and recommendations set forth by the manufacturer When applicable instrumentation and test equipment should be electrically equivalent to that recommended by the manufacturer for the test procedure Do not use a low impedance voltage tester High voltage insulation tests and dielectric tests should never be used to test solid state devices If high voltage insulation of field wiring is required solid state devices should be disconnected Ohm Modline 5 Rev L4 12 2012 183 Appendix A meters should only be used when recommended by the manufacturer Testing equipment should be grounded if it is not special precautions should be taken 4 6 Start up Procedures Checks and tests prior to start up and start up procedures recommended by the manufacturer should be followed SECTION 5 PREVENTIVE MAINTENANCE and REPAIR GUIDELINES 5 1 General A well planned and executed maintenance program is essential to the satisfactory operation of solid state electrical equipment The kind and frequency of the maintenance operation will vary with the complexity of the equipment as well as with the nature of the operating conditions The manufacturer s maintenance recommendations should be followed Useful reference publications for setting up a maintenance program are NFPA 70B 1983 Maintenance of Electrical Equipment and
257. ying in quantity from 2 to 7 pairs The cable selected should have a twisted pair nominal impedance of 100 ohms and nominal capacitance between conductors should not exceed 15 5 pF ft 50 9 pF m All user supplied cables should be grounded to the POI Box with one of the supplied Grounding Strain reliefs Two different size cable entry Grounded Strain Reliefs are supplied with the POI Box The relief with the smaller diameter seal light gray is for cable diameters from 0 11 inch 2 8 mm to 0 28 inch 7 1 mm The larger diameter cable seal darker gray is for cable diameters from to 0 20 inch 5 1 mm to 0 39 inch 9 9 mm Select the fittings that match the cable diameters to be used Prepare the cables as explained in Section 4 6 Sensor Interconnecting Cable Preparation page 69 Ground cable shields on the Terminal Strip Plate by inserting the prepared braid under the shield clamps 4 9 2 Grounding and Shielding Follow all grounding and shielding instructions provided below Proper connection of the cable shields is important to avoid noise and ground loop problems that may cause errors Do not connect cable shields at both ends The use of the Grounding Strain Reliefs and cable shield clamps connect the shield to ground at the POI Box and Terminal Strip Plate side of the connection The illustration below shows the shield not connected at the other end l Sensor Input Output i l Figure 68 Refer to Section 4 14 S
258. ystem Grounding and Shielding page 86 before beginning wiring The section presents an overview on grounding and shielding and contains important information for wiring system cables Modline 5 Rev L4 12 2012 73 Sensor Wiring 4 9 3 System Connections Refer to Manual Sections 5 Operation and 6 Digital Communications for Operation Information Yelow O RS485 RS485 Digital Communications Yelowwnite e Rs485 o O Bue AnaogOut 4 200r0 20mAoutput o BueWnite Anaogout 3 3 3 3 3 3 3 3 O Orange mAIn Remote Emissivity or E Slope currentinput OrangeMWhite mamn S OSO Vidt 90 lo Pk Hd Switch Can be used for Peak Picker Reset or Track Mode select or Remote Vioetwnite Pura switch 2507 Operation Black AlarmRelay Invalid Condition Dirty Window and Sensor Error Code Alarm relay _ BiackWhite O AtamRelay Rea 24vDc 24vdc Sensor Power Supply o Z Reawnite OS e commn fo Table 15 Sensor Interconnecting Cable Function 4 9 4 RS 485 Digital Communications Connections are made on the terminal strip RS485 DATA and RS485 DATA terminals The Power Supply Common terminal is used as the ground reference See Section 4 12 for detailed wiring of Sensors in a RS 485 multi drop network Section 6 of this manual details the RS 485 operation Maximum cumulative RS 485 cable length from sensor to th

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