User`s Manual
Contents
1. eene eene entren trennen rennen 11 Connecting the Camera ete tete ede UE RERO REPRE SUP erp edes 11 STARTING WANTBES tete eet E E epe eee e c oce der eee pee exe e CA eee ee epe eode Ecc 11 4 WINTES MENUS ssseseuacdsvsetesssuscevcessescessbecevestvevsdeaseesssudcalesusseasbevesesbeasecsiesdse 15 CAMERA CONTROL INTRODUCTION 15 5 MAKING THERMAL IMXAQ ES deae eoe eae eap ape Se ees 21 PREPARING TO TAKE IMAGES eene tette tette tette ttt tette tette tette tette tette tette teste tette a 21 6 OPERATING SUGGESTIONS 52 2 2 e ee et roe orit deese vn feos Pepe ev EEE a Eee ca 23 EOCUSING pier cit acc t eec SARL ce Nem IAM E M D NM EIN USO d i Aen MUI Atlas FRAMING OR DETERMINING WHAT IS BEING VIEWED TEMPERATURE MEASUREMENT teet te tette tette teret rettet EAS EASE tente tette EENS ESEAS ES ES ESEE erener 7 PRINTING AND EXPORTING IMAGES eere eee enne etta eee seen ases seen ee seen nee eate sees 27 8 MAINTENANCE D 29 COATEIBR A TION AAAA AEE S EA 29 GENERA I ARDAO 29 IVETE OR S a A a T E 29 9 INSTALLATION AND OPERATING INSTRUCTIONS FOR THE 100 LENS 31 INTRODUCTION cox acce ierat teen et eet een ised me ttu men 31 SETSUP S INSTAEEXT2. 20 5 MAKING THERMAL IMAGES Once you have completed the set up steps of section 3 the system is ready for operation Definitions The top of the camera is the end with the focusing knob The side with the large opening aperture is the face or front The opposite side with the cable connector is the back Preparing to take images With its face toward the subject position the camera head so it is approximately centered over the area to be scanned The top edge will correspond with the top of the display The face of the camera head should be parallel to the surface of the subject The area scanned by the camera depends on the distance from the camera to the subject As with a box camera the greater the distance the larger the field of view WinTES displays the field of view when the distance from the camera to the object focus is entered in the correction menu Set the camera head at a distance appropriate for the size of the subject It should be no closer than 2 0 inches The focusing knob has a scale showing focal length in inches and mm For an initial focus turn the knob to where the distance indicated by the index mark matches the distance from the camera to the surface of the subject Start WinTES by double clicking on the WinTES icon If the camera has been set up previously the system will configure itself automatically To begin scanning select Single Scan or Continual Scan and click on the Start button The defaul
3. APPENDIX A Efficiency Emissivity Lens Factor and Noise Both emissivity and lens factor work alike to express the efficiency with which radiation from that object reaches the sensor of the camera Use what you already know about emissivity effects to understand the effect of the Lens Factor The overall value for efficiency may be determined by multiplying the emissivity and lens factor In the following examples the first three lines represent mathematically equivalent situations Emissivity Lens Factor Efficiency 49 1 00 49 1 00 49 49 70 70 49 1 00 1 00 1 00 Background noise is exaggerated by non unity lens factor or emissivity settings To fully understand this it may be helpful to view the top two lines of the Apparent Temperature table are reproduced below The first entry of the second row simply indicates that for a 100 emissivity object 30 C would be reported the second entry indicates that a real surface of 0 9 90 emissivity would appear the same as a blackbody of only 29 1 C Another way of looking at the information contained in this table is to realize that if the emissivity were set to 90 then a black body of only 29 1 C would be converted to read out as 30 C Similarly the third entry from the end in the first row indicates that a blackbody of only 22 9 C would be converted to read 30 C if the emissivity setting were 20 Apparent Temperature as a function of Actual Surface Temperature C d
4. CAUTION To prevent damage to the computer and interface module BE SURE THE PC POWER SWITCH IS TURNED OFF AND THAT THE I F MODULE POWER CORD IS DISCONNECTED BEFORE CONNECTING THE INTERFACE MODULE TO THE COMPUTER Connect the PC2000 e interface cable to an available parallel printer port on your PC Connect the other end of the cable to Centronix 36 pin connector on the interface module Connect the low voltage connector of the PC2000 e power converter to the interface module s mating connector Plug the converter into an available 110 250 50 60 Hz VAC power source You may leave the power module unplugged if you are going to be using the PC for operations not involving the thermal imager but it needs to be plugged in for the following verification 2000 usb Connect the A plug the wider of the two of the USB cable to an available A receptacle on your PC Connect the B plug of the USB cable to the camera to computer interface Connect the low voltage connector of the power converter to the interface module s mating connector Plug the converter into an available 110 250 50 60 Hz VAC power source You may leave the power module unplugged if you are going to be using the PC for operations not involving the thermal imager but it needs to be plugged in for the following verification NOTE WinTES version 1 05 0014 or newer is required for proper functionality of the 2000 usb NOTE for Windows XP users If the host computer operati
5. positioner to get satisfactory access Avoid manually moving the stage against the force of the return springs and especially DO NOT LET THE STAGE RETURN OUT OF CONTROL TO ITS REST POSITION Repeatedly letting the stage slam against its stops under force of the return springs could damage the micrometer mechanisms 4 Finally tighten all four screws uniformly Do not over tighten Tighten them just enough to keep them from vibrating loose or allowing the positioner to wiggle when operating the micrometers Use a torque screwdriver if possible and tighten the screws to 40 in oz Removal Disassembly To remove the lens assembly in order to use the camera for imaging larger objects or for shipment simply reverse the above steps 34 Operation Set up the object to be imaged on a stable surface If the grid of 46 32 threaded holes of the optional X Y positioner are used be careful that the screws never engage beyond 0 2 inches 0 5mm and protrude through the stage Nylon screws are recommended Alternatively a sample can often be installed satisfactorily using masking tape or equivalent Adjust the safety ring so that with the lens cover in place the camera cannot come down any further than to have the lens cover almost touching the sample To raise or lower the camera adjust the tension as needed tight and slowly rotate the height adjustment knob The tension will automatically increase as you lower the camera or decrea
6. WinTES9S Thermal Evaluation Software VERSION 1 0 11 Operator Controls for the Compix PC2000 series Thermal Imaging Cameras Thermal Evaluation Tools for Compix Thermal Images Copyright 1997 Compix Incorporated All Rights Reserved Duplicating this software for use with Compix Thermal Images is permitted For more information on Compix Products contact us at Compix Incorporated PO Box 885 503 639 0496 Tualatin OR 97062 http www telepart com compix Camera Not Installed To use WinTES95 with stored images click Continue Exit Install Camera Fig 3 WinTES Start Screen e Selecting Exit will terminate WinTES and return to the Windows desktop e Selecting Install Camera will launch the diagnostic program WinTESCheck and open the window shown in fig 4 e Selecting Continue will allow the user to run WinTES to view previously saved images If no address was previously saved the Select Camera Address window will contain the message Select A valid address is required for the camera to function e For the PC2000 the addresses will be in hex format e g amp H360 etc You may select any address from 300 hex to 3FC hex however you will need to change the dipswitch settings on the interface card to correspond to the desired address See fig 2 for examples of switch settings e For the PC2000 e the address will either be PRN1 PRN2 or PRN3 e For the 2000 usb the address will be USB WinTESCheck a diagnostic program
7. cable disconnected Carefully reach inside both sides of the bezel and push out as you the bezel away from the camera Avoid touching the mirror It may be easier to cross you arms and slip your thumbs inside so that you can push outward controllably with enough force to remove the bezel easily 3 Remove the internal lens cover from the magnification lens It is not necessary to twist the lens cover to remove or install it but if you do always turn it clockwise so as not to have a tendency to loosen the lens retaining ring Inspect the lens surface and clean it if necessary see section 4 2 Note the value to be used for the Lens Factor as indicated on the label inside the lens bezel assembly Note which end should be up Slide the lens bezel assembly into position Use your fingers to pull the sides apart as the assembly is pushed all the way into place Make sure the protruding setscrews engage the holes in the camera sides 4 Make sure the clamp bolt of the camera support arm is fully loosened Remove the external lens cover After assuring that the lens bezel assembly is properly installed turn the camera over and carefully insert the lens housing into the large hole in the camera support arm The focus knob of the camera may be oriented away from the post or to either side Tighten the arm clamp using the hex wrench just enough to hold the camera securely and prevent it from twisting Do not over tighten 5 Replace the external lens
8. checks that the computer has the necessary resources to run the WinTES and that the imaging system is properly connected and functioning The first step in the testing is to select a port address for the computer 12 The Select Camera Address window allows the operator to set the system s I O port address The PC2000 will have hex addresses the PC2000 e will have PRN addresses and the 2000 usb will have an address of USB Click on the Select Camera Address window s down arrow and select a port address WinTESCheck will test the computer for sufficient memory and processor speed and then go on to test the camera interface interface communications detector response mirror motion and finally initialization Select Camera Address Tren Remove Camera Available Memory Processor Speed Camera Interface Interface Communications Detector Response Mirror Motion Is there something in the camera cavity Initalization Fig 4 WinTESCheck Diagnostics Window A green or red light will show up next to each function as it is tested Red will terminate the test and indicate a possible cause of failure If the wrong port is selected the system will fail the camera interface test This doesn t mean the system isn t working just that a wrong port address was selected Try another address until all the lights are green If no address works a problem exists Check for proper seating of the PC2000 board and that all connections are properly m
9. or mini tower configurations The PC2000 is shipped with the dipswitch preset for address 360 hex Any address from 300 hex to 3FC hex in multiples of four is acceptable e g 300 304 340 360 AN CAUTION To prevent damage to the components on the PC2000 interface board WEAR A PROPERLY GROUNDED WRIST STRAP OR TOUCH A GROUNDED METAL OBJECT BEFORE HANDLING THE BOARD A CAUTION To prevent damage to the computer and interface board REMOVE THE COMPUTER COVER ONLY AFTER ASSURING THAT THE COMPUTER IS TURNED OFF To install the interface board remove the rear cover of the expansion slot Insert the PC2000 board in an ISA expansion slot pressing it firmly into place Secure the board to the chassis with the appropriate size screw SWITCHES ARE SHOWN SET VALUE A6 40 A5 20 A4 10 A3 8 A2 4 SWITCHES HAVE HEX VALUES AS ABOVE IN THE OFF POSITION IN THE ON POSITION THEIR VALUE IS ZERO Fig 2 Port Selection DIP Switches The PC2000 comes preset to 360 hex and lists other addresses of 300 304 340 and 360 If all these addresses are in use you will need to select new addresses To find unused addresses click the Start button on the Task Bar Select Settings then click on Control Panel Double click on System choose the Device Manager and double click on Computer Select input output scroll through the list looking for a block of four addresses not in use 7 PC2000 e A
10. to Reference Use For Reference Image Current image is saved as the reference to which others may be compared Display Reference Image Shows the image currently saved as the reference image Revert to Scanned Image Displays the scanned image Compare to Reference Image the current image is compared against the previously saved reference image Each pixel or temperature data point of the reference image is subtracted from the second image compared image current image reference image Compare ALL to reference Image Every scan is immediately compared with the reference image Display Sub Menus Cursor Degree Units Camera Control Window Thermal Image Window and Heat Flow Window Cursor Spot Cursor Profile Cursor Spot Cursor The cursor reads out the temperature of the selected point of the image This is indicated in the TEMP window of the WinTES window Profile Cursor Selecting profile cursor brings up two additional windows at the bottom and side of the image window Temperature ranges are displayed along with a graph of temperature along vertical and horizontal extensions of the cursor The crosshair may be moved using the mouse or the cursor keys The temperature at the intersection of the horizontal and vertical lines is displayed in the temperature window 17 Degree Units Allows for Selecting Celsius or Fahrenheit thermal scale Camera Control Window Thermal Image Window Activates window selecte
11. values outside the colorbar will show the overrange colors Min Max Auto range reads the minimum and maximum temperatures in the image and sets the min and Max so they encompass the display range The system automatically redraws the image with the new scale Fit ColorMap Auto scale fits the scale so that one cycle of the colormap is used to display the image data Redraw Refreshes the image This is done automatically when Color Scale is changed It is not automatically updated when thermal correction factors are changed 18 Thermal Correction This is an auxiliary window which is opened when Correction is clicked A series of controls are made accessible Ambient Emissivity Lens factor Field of view FOV Focus in Ambient the Emissivity is calculated about this value Set the value to the temperature of the ambient in which the instrument is operating File Edit Compare Display Help Thermal Correction Colomap Max Color A Min Emissivity Fit Colormap pera Lens Factor R f Focus in Temp 83 38 C Correction lt Foy Image Time 11 55 00 AM Image Source DEFAULT CPX Fig 7 WinTES Control Window with Thermal Correction Open Emissivity All materials have characteristic emissivities which are less than 1 0 This means that non black bodies radiate IR at a lower rate than does the ideal source Practically speaking this means that an object w
12. 00 captures this radiation and produces a two dimensional map or thermal image of the object s surface temperatures All configurations of the Compix amp PC2000 family of thermal imagers require a computer for camera control image storage and display WinTES software provides the graphical user interface GUI as well as the interface that permits the computer to communicate with the Compix IR Camera WinTES requires Windows 95 98 2000 NT Me XP and at least a VGA display WinTES lets the operator adjust the display compare images change colormaps compensate for different emissivities read temperatures at specific locations compute area statistics and show thermal profiles An important feature of WinTES is the use of the industry standard TIFF image file format for storing thermal images This makes it easy to use the images with other software programs A second format for image storage is the Compix format cpx This format stores the full 32 bit range of temperature data It is larger than the TIFF file format 192k vs 95k and is readable only with Compix software such as WinTES or Reporter The rest of this manual describes the Compix PC2000 PC2000 e 2000 usb PC2100 PC2100 e 2100 usb and their operation in more detail Note BEFORE ATTEMPTING TO OPERATE THE SYSTEM YOU SHOULD READ SECTIONS 2 SYSTEM DESCRIPTION AND OPERATING REQUIREMENTS 3 INSTALLATION AND SET UP and 5 MAKING THERMAL IMAGES This page was intentionally
13. 5 micron wavelength band These elements are housed in a black anodized aluminum holder mounted in the front panel of the alternate bezel Two lens dust covers are included one for each side of the lens The two lens dust covers are identical A sturdy bench top stand to support the camera with lens attached securely over the object to be imaged and which provides a means for making minute adjustments in the height or Z axis position of the camera A large hex wrench for tightening loosening the clamp arm that holds the camera lens combination Optional Accessories A micrometer style X Y positioner mounted to the base of the bench top stand on which the object to be imaged is mounted 31 Set up amp Installation Assembling the Heavy duty Stand 1 Attach the post to the base plate using the long shaft socket driver 2 Install the safety clamp 3 Install the camera support arm and pinion assembly onto the vertical shaft Make sure the arm support is oriented to the top of the pinion assembly Gradually lower the assembly until the pinion engages the rack Do not force Installing the camera on the bench top stand 1 Position the safety ring four inches 100mm or more above the base Tighten it securely in this position Later you will adjust the height of this ring so that the lens cannot possibly touch or crash into the object being imaged 2 Remove the standard bezel from the camera Lay the camera on its back with camera
14. COMPIX PC2000 Series Thermal Imaging Systems Installation and Operating Instructions PC2000 PC2000 e 2000 usb PC2100 PC2100 e 2100 usb Version 1 6 04 23 02 INCORPORATED COMPIX PC2000 Series Thermal Imaging Systems Installation and Operating Instructions PC2000 PC2000 e 2000 usb PC2100 PC2100 e 2100 usb Version 1 6 04 23 02 This page was intentionally left blank NOTICE This manual is intended solely to provide instructions for operation of the Compix PC2000 PC2000 e 2000 usb PC2100 PC2100 e and 2100 usb Thermal Imaging Systems and their accompanying Thermal Evaluation Software WinTES Compix reserves the right to change the information contained in this manual without notice No warranty expressed or implied is made regarding the accuracy of the information in this manual at any time following its release or for any purpose other than as a guide to operation of Compix Systems WinTES the Thermal Evaluation Software for Windows95 98 2000 NT Me XP may be distributed to others provided the following requirements are met 1 No fee charge or compensation may be accepted or requested 2 The WinTES distribution disk must be copied in unmodified form complete with this copyright notice and other files listed in the FILES TXT 3 The sole purpose of such distribution is to operate demonstrate analyze or distribute images produced with equipment manufactured by Compix O
15. ION REG RR ERE ERA ERFURT DT 32 OPERATION eS 35 MAINTENANCGE RR RR RR RR E DR RR NE 36 M 36 Cleaning uon Ia tie deett ge Gee yate radice pe te tse veter e qe e 36 Preventative Maihtenah6e 3 dee 36 Repackaping for Shipment I eqq S IR 37 LO USER SUPPORT SS 39 APPENDIX A EFFICIENCY EMISSIVITY LENS FACTOR AND NOISE 41 This page was intentionally left blank vi 1 INTRODUCTION The Compix amp PC2000 family of thermal imagers work with any Windows 95 98 2000 NT Me XP based computer They are designed for non contact mapping and measuring of surface temperatures The heart of the systems is a sophisticated camera that is sensitive to infrared IR radiation These cameras are reliable cost effective tools that provide fast comprehensive evaluations of thermal performance Since elevated temperatures are often cited as a cause of failure in electronic products thermal phenomena are of particular interest to design and reliability engineers An example of their application is the study of temperature distribution and heat flow on electronic circuit boards In an energized electronic circuit power is dissipated as heat that produces radiant infrared IR energy The PC20
16. When reasonably good focus is achieved further refinement may be made adjusting either the height or the focus knob Overall performance will be best if the camera focus setting is kept between 12 and 18 inches between 300 and 450mm 35 Maintenance Storage Use the lens cover to protect the exposed lens whenever the 100 is not in use If for any reason the magnification lens is removed from the camera be sure to protect both internal and external lenses with the lens covers Cleaning Small amounts of dust or lint on the lens surface will have little or no effect on the performance or calibration of the lens It is possible to degrade the lens surface by improper or excessive cleaning techniques Use the following cleaning techniques carefully and not too frequently To remove loose dust or debris use a gentle stream of dry air Aerosol type cans of clean dry air available at camera and electronic stores are suitable for this purpose For more persistent loose dust or debris you may use a camelhair brush or soft cotton swab Q tip Do not use lens tissues Lens tissues intended for eye glasses contain chemical additives and lens tissues available in camera stores are often not soft enough Avoid touching the lens surface with your fingers If you do need to clean off fingerprints or other more resistant material use clean alcohol or acetone to dampen a soft cotton swab gently dab and swipe the spot or fingerprint If you loo
17. a well focused image Operating hint Look for obvious reference points Typical hot spots are power resistors power transistors and power IC s Cold or low emissivity components would normally include mounting brackets metal capacitors or crystal cans and bare copper runs Surface mount devices hybrids etc are often framed by the contrasting colors of surrounding heat sinks or substrates Packaged IC s may be identified by the rows of legs or leads on the sides Edges of circuit boards are usually easy to find In an energized board conduction through the substrate and ground plane normally creates some visible differential heating to the edge of the board Providing a good background can make the edges easier to see A dark matte finish material such as cardboard or black paper behind the board can improve contrast Simple markers can be used as pointers Any small non conductive for safety reasons object at room temperature will work Plastic tools non metallic rulers are also useful Put the marker on the target as a pointer or an edge indicator and then take an image The marker should show up as a distinct dark area against the warmer background of the board and its components Objects you take out of your pocket will already be warm and may not show up in the image Some users have reported good success with active hot markers The wire will appear as a distinct hot pattern in the thermal image The focusing technique described ab
18. ade In the case of the PC2000 e or 2000 usb check that the module has been turned on If these steps don t allow the system to initialize then it is necessary to call Compix Customer Support 13 This page was intentionally left blank 14 4 WinTES MENUS When the Compix amp PC2000 takes a thermal image or when a TIFF TIF or Compix CPX image file is opened the user is relieved from having to deal with many details associated with handling tens of thousands of temperature measurements This section explains how the control and display functions may be used in combinations that get the most out of the thermal images Please read this section before attempting to use the system Take time to familiarize yourself with the functions and controls of WinTES and the PC2000 PC2000 e or 2000 usb system WinTES menus are largely self explanatory and the system permits risk free exploration Once an image has been saved no combination of menu functions will change the saved temperature data The exception to this is when another image is saved under the same file name Therefore if you try something and don t get the desired result you can always reload the saved image and try again Camera Control Introduction When opened WinTES will display three windows Camera Control WinTES Thermal Image Clicking the cursor on any of these windows will make it the active window Camera Control Window This window fig 5 controls the camera sc
19. an It also provides for auto scaling of images and or automatic saving of images Auto Min Max Fast Scan Auto Save Line Sean Continual Scart Period Single Scan SCAN Fig 5 WinTES Camera Control Window Two modes of scanning are available with WinTES These are Continual Scan and Single Scan Continual Scan causes the camera to scan reset and scan until told to STOP or until Single Scan is selected Single Scan causes the camera to take one scan and then stop The Scan button initiates a scan With Continual Scan the operator can control the time from the start of one scan to the start of the next by using the Period feature This is accomplished by typing the desired time in seconds in the period window A normal scan takes approximately 14 seconds thus a period of 20 default setting would have a scan starting every 20 15 seconds Switching from Continual Scan to Single Scan will cause the camera to complete the current scan then wait for the next scan command The Stop button causes the camera to immediately stop scanning Auto Min Max provides automatic scaling The minimum and maximum temperatures for the displayed image are updated after each scan Auto Save automatically saves each image to a file after each scan Fast Scan causes the PC2000 PC2000 e or 2000 usb to scan in approximately 8 seconds In this mode the image resolution is half that achieved at the normal scan rate Lin
20. cover until you are ready to actually start imaging The external lens cover may be twisted if desired in either direction Store the internal lens cover in a safe place where you can find it later if you want to remove the lens 32 and use the camera for imaging larger objects The lens covers are interchangeable 6 Re position the safety ring so that the camera cannot come down too close to the object being imaged Tighten the safety ring Always keep the safety ring positioned and tightened to insure that the lens cannot fall onto or come in contact with the object being imaged 33 Mounting the positioner if applicable The optional positioner if ordered is shipped separately to prevent damage to the micrometer adjustment mechanisms It is to be installed on the base of the bench top stand using the four threaded holes 1 Remove the four 6 32 socket head cap screws from their holes in the base plate 2 Position the X Y positioner over these four holes The positioner may be mounted in any of four orientations The most common is to have one adjustment in front and the other to the right However on a crowded bench better protection against damage and accidental change may be worth the inconvenience of mounting one adjustment to the back and the other to either side as dictated by the environment or by the preference of the operator 3 Install all four cap screws finger tight It may be necessary to move the stage of the
21. d Heat Flow Window Selecting this item opens a window with a movable slide bar This feature allows the operator to move the scale up and down over the displayed image The minimum and maximum temperatures of the scale define the range of temperatures displayed The movable window allows subtle temperature differences to be accentuated Sub Window Color Edit contains image display controls ColorMap The color scale has six built in display palettes Default Rainbow Blue to Red Blue Green Red Grayscale and Medical Image files may be displayed in any of these six colormaps or palettes Each is useful for displaying images and personal preferences may dictate the operator s choice The palettes contain 234 shades of color or grayscale Changing color palettes doesn t affect temperatures in the image The Max Color value is the highest temperature displayed in the color palette The Min Color value is the lowest value displayed in the color palette The values above and below the MIN and MAX are useful for setting and displaying over range and under range values To set upper or lower control or over range values double click on the color bar A secondary window will appear and the operator can select a color to signify over and under range values Select the color and tell the program to apply the chosen colors The top and bottom portions of the colorbar will now display those colors Subsequent display of images having
22. duce a high ratio of reflected undesirable to radiate desirable infrared thus yielding less accurate temperature readings The solution is to reduce the reflectivity of these objects Fortunately surfaces that are reflective to infrared are usually reflective to visible light So look for bright shiny or metallic surfaces as they will be the problem There are several easy ways to reduce reflectivity while minimally effecting the component s thermal performance A strip of electrical or masking tape on the top surface is one Anything with a matte surface is a good choice Or a quick light buffing with fine emery paper just enough to break the surface sheen will also help Most conformal coatings and solder masks provide a low reflectivity surface for thermal images Adjust the Emissivity setting The default Emissivity setting of the PC2000 system is 1 00 This is appropriate for the highly emissive low reflectivity materials that are most common on circuit boards For components with lower emissivity temperature accuracy will be improved if the PC2000 system s Emissivity setting is adjusted to match the component s emissivity Emissivity tables are available for many of the materials commonly used on printed circuit boards 26 7 PRINTING AND EXPORTING IMAGES WinTES produces TIFF Tag Image File Format images that adhere strictly to the TIFF standard Revision 5 0 for Class P Palette Color Images Some software applicat
23. e Scan allows the operator to park the scanner over a point or line on a sample The pan motion is disabled and the camera is allowed to line scan over a two pixel wide area The display is converted from a x y thermal map to a display of temperature Vs time Fast changes can be detected using this mode WinTES Window File Edi Compare Display Help Colormap Max Color Grevscale 120C amp Min Max i Fit Colormap EE Min Color Jum Temp Correction gt Image Time 11 56 00 DEFAULT CPX Image Source Fig 6 WinTES Control Window Menus File Edit Compare Display and Help File Sub menu items Open File Save File Exit Open File Allows operator to open a previously saved image configuration or colormap Save File Allows operator to save an image as a TIFF orasa Compix Image File that retains the full resolution temperature data Exit terminates the program 16 Edit Sub menu Copy ColorMap Copy Copies the displayed image to the Windows clipboard where it can be accessed by other programs ColorMap Provides a ColorMap Editor for setting under and overrange colors Compare Permits the operator to compare images with a reference or previously stored images Differences between an unknown and golden board can quickly be determined Compare Sub Menus Use for Reference Image Display Reference Image Revert to Scanned Image Compare to Reference Image Compare ALL
24. e cable of this length is provided Cable extensions are not recommended The e interface module is connected to the computer s parallel interface via a standard printer cable This second cable is included with the PC2000 e The 2000 usb interface module is connected to the Universal Serial Bus USB via a standard USB Type A B M M cable The camera should be treated with the same care given a good visible light camera or other optical instrument Minor vibration can reduce image quality major vibration or shock may result in damage And while the longer wavelength IR energy makes it less sensitive to dirt care should be taken to keep the mirrors and detector window clean See Section 8 Maintenance NOTE There are no components on the PC circuit board interface in the PC2000 e or 2000 usb interface module or inside the camera head designed for user service Removing the cover of the camera or interface unit may void the warranty UNDER NO CIRCUMSTANCES SHOULD THE SYSTEM BE OPERATED WITHOUT THE COVERS IN PLACE WinTES for Windows 95 98 2000 NT Me XP Computers The WinTES software is distributed on a CD ROM The software has been designed to work with personal computers running Windows 95 98 2000 NT Me XP The display system must be capable of supporting at least the VGA standard 3 INSTALLATION AND SET UP Unpack the system Lift off the aperture cover on the camera and carefully remove the foam strip from behind the mirror Inspect
25. e natural A technique which gives excellent results involves indirectly shining a 40 to 60 W incandescent light on the unpowered target To the PC2000 this is the functional equivalent of an infrared flashbulb The lamp illuminates the target and the camera displays the reflected IR energy The resulting image will look much like a visible light picture Edges will be sharply defined components will stand out in sharp relief and fine focusing will be easier To use this technique place the lamp about two feet above and at an angle of about 45 to an unpowered target Don t shine the light directly into the aperture of the camera Use Grayscale colormap and take an image You may have to experiment with the position of the lamp to get the best result When finished focusing turn off the lamp as high levels of reflected infrared will distort the temperature readings Framing or Determining What is Being Viewed 23 Framing involves two things first the aiming of the camera so the target is centered in the image second being able to relate specific points in the thermal image to the corresponding locations on the target The same factors that make it more difficult to focus a thermal image can also make it harder to frame properly Many users find their first thermal images are ambiguous and confusing But image interpretation is quickly learned if the user has a working knowledge of the object being scanned Remember it is important to have
26. eadings between boards will be more accurate if both circuits are at approximately the same point in their warm up cycles Use the same scan rate in both cases Minimize external sources of infrared energy The Compix PC2000 measures temperature using emitted infrared energy i e the infrared energy generated by the target Objects also reflect infrared energy from their surroundings The PC2000 system or any other infrared system can t tell the difference between reflected and emitted energy Therefore reflected energy is a potential source of error Some reflected infrared IR energy is unavoidable and the PC2000 will automatically compensate for typical levels of external IR energy which are uniformly distributed over the target Nevertheless it will be helpful to minimize significant sources of external IR particularly those that may not be uniformly distributed Other sources to avoid are direct sunlight coming through a window and shining on the target or heat from nearby electronic devices A general rule of thumb is that if you can feel heat from a source near the target then it will affect the accuracy of the image 25 Minimize the reflectivity of the target Another aspect of the problem described above is that some objects naturally reflect more infrared energy than others do Unfortunately due to the laws of physics good reflectors are poor emitters of infrared emissivity 1 00 As a result these objects pro
27. er Range colors will open another window entitled Color The operator can select the color to represent these extremes Clicking OK will bring back the ColorMap editor window Clicking Apply will change the value to that color Repeat the process for the other range Thermal Image Window Stats Statistics Stats provides the ability for the operator to define an area of the image and have the system report out the temperature min max avg and standard deviation for the area To define a measurement area hold down the left mouse button and move the cursor across the image A box will open within the displayed image Releasing the mouse button will cause a window labeled Stats to appear Max 121 95 C Ave 70 46 C Min 45 54 C Std Dev 39 24 Fig 8 Statistics Window Within the window are displayed the maximum minimum average and standard deviation of the temperatures Repeating the process anywhere on the image will yield the data for the newly defined The box can be moved across the image by using the Shift key and Arrow keys Horizontal movement is accomplished by moving one side and then the other through use of the Left Right arrows and Shift or no Shift keys Vertical movement is accomplished in similar use of the Shift key and Up and Down arrows instead of Left or Right arrows Cursor as Profile This function constructs line graphs of the temperature variation along a horizontal and vertical line
28. era s mirrors periodically If used in a relatively dust free environment and if the aperture is covered while the system is not in use the mirrors shouldn t require frequent cleaning When the mirrors are visibly dusty clean them as follows Remove the plastic bezel surrounding the camera s aperture With the camera firmly supported and facing you carefully reach inside with your thumbs and press outward on the sides of the bezel while pulling forward When the bezel is off set it aside Turning the focusing knob to the high end of its scale will move the focusing mirror to where it is accessible for cleaning The cleaning techniques for the mirrors are the same as for a high quality camera lens Usually dust can be removed with a blast of clean low pressure air or a soft gentle brush For more thorough cleaning use a non abrasive lint free cloth with a photographic wetting agent or alcohol Replace the bezel by reversing the steps to remove it 29 This page intentionally left blank 30 9 Installation and Operating Instructions For the 100 Lens Introduction The 100 is a collection of accessories for the PC2000 PC2000 e or 2000 usb which together form the PC2100 PC2100 e or 2000 usb respectively and which consists of the following Alternate bezel which holds the magnification lens The magnification lens itself consists of three precision optical elements made of silicon and coated for optimum performance in the 3 to
29. excluding national holidays User support is generally free of charge on issues relating to interpretation of this manual the proper operation of the system routine maintenance and warranty service Consultation is generally not available on image interpretation problems fault diagnosis system modifications or application specific issues particularly those outside the field of electronic test Compix reserves the right to determine at its sole discretion the extent of user support made available to any user A user may be asked to furnish proof of ownership of a Compix PC2000 system before receiving support For phone support call 503 639 8496 identify yourself as a user of the Compix PC2000 system and ask for User Support It may be helpful for you to have the serial number of your PC2000 system and the version number of WinTES available when you call Visit www compix com for technical articles price lists product photos and other information on current products For support by mail write to Compix Incorporated Attn User Support PC2000 P O Box 885 Tualatin OR 97062 0885 If you want to visit us in person please call us at the number above for directions and to make sure the person best equipped to help you will be available when you arrive Our office location shipping address is Compix Incorporated 15824 SW Upper Boones Ferry Rd Lake Oswego OR 97035 4066 39 This page was intentionally left blank 40
30. ions which claim to be TIFF compatible use a limited subset of the TIFF specification and may not import Compix TIFF files so universal compatibility is not assured The most reliable way to export a color image is to use the Copy command from the menu This puts the image into the clipboard from where it can be pasted into the appropriate document Alternatively Print Screen may be used to copy a full Windows screen to the Clipboard or Alt Print Screen will copy only the active window to the clipboard These objects may be pasted into a Word WordPerfect or other word processing document Additionally the TIFF thermal image files may be opened in any of a number of applications programs Finally images may be captured and saved using any of a number of commercially available screen capture programs From these word processing or screen capture programs it is a simple matter to print to a file or printer 27 This page intentionally left blank 28 8 MAINTENANCE Calibration It is recommended that instrument performance be verified once a year The instrument should be compared against a calibrated blackbody source lt is recommended the instrument be returned to the factory for repair and recalibration General The exterior of the camera PC2000 e module and 2000 usb module can be dusted with clean low pressure air or a clean soft cloth For more persistent dirt scrub gently with a damp cloth Mirrors Inspect the cam
31. ith a lower emissivity will appear to be closer to ambient than a black body having the same temperature The Emissivity setting corrects for this effect and provides the user with the correct temperature reading for that object Values can be selected from 1 00 to 0 01 Lens factor This correction compensates for the attenuation introduced when the system is operated with the 7 5x lens Without the correction temperatures read by the system would appear lower than their true temperatures Each lens comes with its lens factor specified on its serial number label Nominally this is around 65 Focus in Temperature readings can be affected by the distance of the camera from the object being measured This setting represents the distance in inches from the front of the camera to the object and corrects for any distance related errors 19 FOV Field of View This is an indication of the approximate size of the area being scanned ColorMap editor The three color scales display colors that represent temperatures between the indicated minimum and maximum values There are two bands of colors one above the Max temp and one below the Min temp called Over Range and Under Range The operator in a way which emphasizes different aspects of the thermal data may change their colors To edit the colors place the cursor on the color scale and double click A window called ColorMap editor will appear Double clicking on either the Over Range or Und
32. k at the lens surface under magnification you will probably notice a few tiny defects in the coating that have no measurable effect on the performance of the lens But if you mistake such a defect for debris and try to remove it you can make the defect larger Preventative Maintenance Whenever you remove or install the lens assembly onto the camera check to make sure the inner lens retainer hasn t turned and that the beveled portion of the retaining ring is exactly aligned along the bottom Newer lenses have no beveled portion in which case this check may be ignored Occasionally inspect all parts of the lens assembly bench top stand and X Y positioner for damage and for accumulation of dust and debris Clean and lubricate using a light oil all moving parts as needed 36 Repackaging for Shipment DO NOT SHIP THE CAMERA WITH THE LENS INSTALLED Use the lens covers and provide plenty of packing material Refer to the PC2000 manual for camera packing instructions To ship the bench top stand it is recommended that the X Y positioner be removed and packed separately Make sure the support arm and safety clamp are tight and use plenty of packing material 37 This page was intentionally left blank 38 10 USER SUPPORT User support is available by phone mail e mail or in person at Compix offices in Lake Oswego Oregon Support will normally be available from 8 00 A M to 5 30 P M Pacific Coast Time Monday through Friday
33. lace the PC with the computer to camera interface on a table or other suitable surface near the camera Mount the camera head firmly on its tripod or tabletop stand Threaded mounting nuts 1 4 20 are provided on both the back and bottom of the camera See Section 10 for proper tripod setup Connecting the Camera NOTE POWER TO THE PC AND PC2000 E MODULE SHOULD BE OFF ANYTIME THE CAMERA IS BEING DISCONNECTED OR CONNECTED The camera is connected to the computer to camera interface through a 3 meter cable Connect one end of the cable to the DB44 connector on the back of the camera then e For the PC2000 installation connect the cable to the DB44 connector on the PC2000 interface card e For the PC2000 e installation connect the cable to the DB44 connector the PC2000 e interface module e For the 2000 usb installation connect the camera cable to the DB44 connector on the 2000usb interface module Turn on the computer s power or connect the power module to a suitable source of 110 250VAC 50 60 Hz power in the case of the PC2000 e or 2000usb As the computer boots up there may be a brief flutter of the camera mirror if everything is working properly Starting WinTES Click on the Windows Start button In Programs find WinTES and click on it If this is the first time the system has been operated it will report that the camera is not installed see figure below Selecting Install Camera will launch WinTESCheck compix
34. left blank 2 SYSTEM DESCRIPTION and OPERATING REQUIREMENTS The Compix amp PC2000 has three principal components the camera head the computer to camera interface and the Thermal Evaluation Software WinTES see fig 1 The camera head contains the infrared sensor mirrors motors and circuitry required to scan capture and digitize the image data The interface card contains the camera control electronics and digital circuitry required for communicating with the PC Calibration parameters are stored in the camera head allowing cameras to be interchanged between interface types ISA USB LPT without compromising calibration Other than the personal computer no other accessories or supplies are required IR Camera IR Camera Aperture Aperture Camera Control Module PC2000 PC2000 e Fig 1 The PC2000 system has been designed to operate in a typical engineering factory or sheltered field environment The system requires a stable surface and well ventilated workspace at normal room temperatures The camera head must be mounted on a tripod or other stable fixture The standard fittings are for a 1 4 20 threaded male connector the type normally found on photographic equipment The PC2000 e and 2000 usb require AC power and will work with line voltages from 90 VAC 50 Hz to 240 VAC 60 Hz The camera head should be located within ten feet three meters of the imaging computer PC2000 e module or 2000 usb module An interfac
35. ng system is Windows XP the following screens will appear once the interface module has power and a connection to the host s USB for the first time As the screens are presented you will need to respond as depicted by the highlighted button on each of the screen Found New Hardware Wizard Welcome to the Found New Hardware Wizard This wizard helps you install software for Compix Incorporated 2000USB If your hardware came with an installation CD QE or floppy disk insert it now What do you want the wizard to do ically Recommended Install from a list or specific location Advanced Click Next to continue Hardware Installation The software you are installing for this hardware Compix Incorporated 2000056 has not passed Windows Logo testing to verify its compatibility with Windows me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing STOP Installation Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished installing the software for Incorporated 200015 Click Finish to close the wizard 10 Mounting the Camera to its Stand or Tripod P
36. ove of using an incandescent lamp or other infrared source is also useful for framing Make a reflected IR image using that technique Then with the lamp off make a normal thermal image Watch the display as the thermal image overlays the reflected IR image and you will see which points correspond 24 Temperature Measurement The Compix PC2000 is a sensitive instrument that has the capability to detect small temperature differences within the range typically encountered by engineers However non contact temperature measurements are affected by a number of variables that can change the accuracy of temperature measurements The following techniques will help improve the accuracy of measurements made with the PC2000 system Be Consistent Often all that s needed are good relative measurements The engineer wants to know how one temperature compares with another Consistency is the key Maintain the same environmental conditions e g ambient temperatures ventilation and the presence of other heat sources in the room Maintain the same physical set up for the system Put the boards in the same orientation flat or upright the same distance from the camera and the same relative position on the display Maintain the same electrical set up same power inputs same program to exercise it While a circuit board may take several minutes to reach thermal stability it is not necessary to wait for the board to stabilize but comparative r
37. own and Emissivity Across 100 90 80 70 60 50 40 30 20 10 0 30 29 1 28 3 27 4 26 5 25 6 24 7 23 8 22 9 21 9 21 0 The background noise reported with a 10095 efficiency setting 100 emissivity and 100 lens factor will typically span two to three degrees Suppose a particular instrument reports background noise of 21 C to 22 9 C Suppose these values were converted with a lens factor of 20 By definition 21 C is converted to the same value 21 C But 22 9 C as shown in the table fragment above would be reported as 30 0 C resulting in a 9 degree span for the temperature equivalent background noise 41
38. se as you raise it To maintain constant tension turn both knobs together Connect the camera cable apply power and proceed to operate in the normal manner see PC2000 manual Raise the camera several inches above the object being imaged and remove the lens cover A CAUTION Never touch the lens or allow any object to touch or strike the lens Set the focus distance knob on the camera to 15 inches 375mm Carefully lower the camera to within 0 3 inches 7 5mm of the object to be imaged This distance is measured from the forward most lowest surface of the lens housing to the plane of the object Set the Lens Factor according to value printed on the label on the inside of the lens bezel assembly To set the lens factor in WinTES click on the Image Data button This will expand the WinTES window and add a Thermal Correction section in which Lens Factor and Emissivity can be set Focus distance should be set to 15 inches 375mm The FOV Field of View is not valid when using the magnification lens In the case of the DOS base TES software the Lens Factor is entered using the corresponding item in the TES Display menu The use of the Lens Factor is necessary to compensate for the attenuation introduced by the lens See Appendix A for further discussion of the Lens Factor If the device is powered or illuminated from a small nearby incandescent source an image should be obtained To adjust the focus adjust the height of the camera
39. t value for Delay is 20 seconds This is the time from the start of one scan to the start of the next scan The user can select values to best suit their application While the system is scanning you may improve the focus by making small adjustments of the focusing knob until edges appear sharp Remember that heat will flow from one object to another thus thermal images may appear smeared when compared to photographic images See Section 6 for suggestions on focusing and framing Single scan will take one image then stop Continual scan will periodically scan depending upon delay until commanded to Stop You can stop either process at any time by selecting STOP Selecting single scan while in the middle of a multi scan will cause the scanning to stop at the end of the current scan 21 This page intentionally left blank 22 6 OPERATING SUGGESTIONS Focusing The optical system of the Compix amp PC2000 camera operates in the same way as a photographic camera One implication of this is that the system s large aperture results in a short depth of field Near the middle of its focal range 12 15 a depth of field around 1 2 would be typical At two inches the depth of field may be less than 1 4 In any case focusing is important to image quality as well as temperature accuracy Generally items seen in a thermal image are not as crisp as when viewed in a video image As a result when first viewing an image it may be hard
40. the system for physical damage If you find shipping damage stop inform the carrier and call Compix Customer Service If possible store the shipping carton and packing materials for future use There are three distinct steps in the installation procedure software installation interface board PC2000 or module PC2000 e or 2000 usb installation camera connection and set up You should perform all of these steps before proceeding to the verification phase NOTE You may install WinTES on additional computers to allow others to view images WinTES will run without a camera thus letting you load display and manipulate previously stored images If camera initialization parameters are specified in a configuration file a warning message relating to those parameters may appear WinTES Software Installation WinTES allows an operator to control the camera acquire store analyze and display current or previously acquired images Install WinTES on your hard disk To do this run the setup exe program in the root directory of the WinTES CD ROM Follow the prompts Programs will be installed in the folder stipulated by the user After completing the installation store the WinTES CD ROM in a safe place as a back up Hardware Installation PC2000 Card The PC2000 interface board may be installed in any 8 or 16 bit ISA slot To ensure proper cooling leave an empty slot on the component side of the card or install as the top card in tower
41. ther use or distribution of this software without consent of Compix Incorporated is prohibited Copyright 2002 by Compix Incorporated Tualatin Oregon All rights reserved Compix is a registered trademark of Compix Incorporated TES and WinTES are trademarks of Compix Incorporated IBM is a registered trademark of International Business Machines Corp Microsoft MS DOS Windows Windows95 98 2000 NT Me XP are trademarks or registered trademarks of Microsoft Corporation All other brand and product names are trademarks or registered trademarks of their respective companies This page was intentionally left blank Table of Contents 1 INTRODUCTION mr PRR 1 2 SYSTEM DESCRIPTION AND OPERATING REQUIREMENTS eere ee ee eene eee ense etta 3 3 INSTALLATION AND SET UP wccsisccccsssssssssevecsesenescessescesecosscessscnsecbevcedcobessossviscsosscveessbectesesisbicessbaecesessesses 6 WINTES SOFTWARETNSTALEATION ettet eov ye e HY RT E Cete e Rt 6 HARDWARE INSTALLATION edipi ete e Pe e e c C Cete ttd et t a ed 6 2000 6 HE MT IEEE 6 PG2000 8 i e e teh vec etes ite set ter EEE SE EE Rd 8 2000 8 WinTES version 1 05 0014 or newer is required for proper functionality of the 2000 usb Mounting the Camera to its Stand or Tripod sesei cci qd ete tee ee uer rove p eue niece eb peeve RR 8 Mounting the Camera to its Stand or Tripod
42. to determine whether the camera is well focused or not This will become easier with practice The PC2000 camera utilizes a manual focusing mechanism The first step in focusing is to measure or estimate the distance from the forward edge of the aperture bezel to the subject If the subject isn t flat use the average distance or use the distance to the area of greatest interest With the focus index set to match the camera to object distance take a Single Scan After the scan is completed click Min Max This will set the Min and Max temperatures so that the range displayed encompasses the temperatures in the scanned area You should now see an image from which you can begin to fine tune the Focus In the Camera Control window set the scan for Continual and start scanning While the system is scanning make a series of small focusing adjustments and observe the changes Look for improvements in the definition of the outlines of components such as crystal cans IC legs or board mounting hardware and mounting holes Straight edges of larger components are also good guides Entering this focus distance in the Correction window will indicate the camera s field of view FOV as well as provide a correction factor to compensate for variations introduced when the camera is moved away from the 10 inch focal length used in calibrating the instrument Many users find this process easier with the Grayscale colormap since black and white images tend to appear mor
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