Sensor Therm Polaris PS09 Manual de usuario

Infrared Temperature Switch (Hot Metal Detector)

Polaris PS09 / PI16

User Manual

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

Content

1General...............................................................................................................................................3

1.1 Information to this Manual.........................................................................................................3

1.2 CE Conformity and Standards..................................................................................................3

1.3 Limitation of Liability..................................................................................................................3

1.4 Terms of Warranty ....................................................................................................................3

1.5 Copyright...................................................................................................................................3

1.6 Explanation of Symbols ............................................................................................................4

1.7 Disposal ....................................................................................................................................4

1.8 Intended Use.............................................................................................................................4

1.9 Scope of Delivery......................................................................................................................4

1.10 Model Design............................................................................................................................4

2Safety..................................................................................................................................................5

2.1 General .....................................................................................................................................5

2.2 Electrical Connection ................................................................................................................5

2.3 Laser Targeting Light................................................................................................................5

2.4 Device Labels............................................................................................................................5

2.5 Responsibility of the Operators.................................................................................................5

3Electrical Connection........................................................................................................................6

3.1 Cable Colors and Pin Assignment............................................................................................6

3.1.1 Power Supply.......................................................................................................................6

3.1.1.1 Factory Settings...............................................................................................................6

3.1.2 Switching Outputs................................................................................................................7

3.1.3 Serial Interface RS232 or RS485 ........................................................................................7

3.1.3.1 Interface Converter (Accessory)......................................................................................8

4Mechanical Installation.....................................................................................................................8

4.1 Mounting ...................................................................................................................................8

4.2 Ambient Temperature...............................................................................................................8

4.3 Alignment onto the Measuring Object.......................................................................................8

4.3.1 Alignment with the Laser Targeting Light ............................................................................9

4.4 Setting the Measuring / Focus Distance...................................................................................9

4.5 Spot Size Tables.....................................................................................................................10

4.5.1 Calculation of the Spot Size Diameter outside the Focused Distance ..............................10

4.6 Parameters / Settings .............................................................................................................11

4.6.1 Emissivity ε ........................................................................................................................11

4.6.2 Response Time t90 .............................................................................................................12

4.6.3 Simulate a Switching Temperature....................................................................................12

4.6.4 Baud Rate..........................................................................................................................12

4.6.5 Address..............................................................................................................................12

4.6.6 Interface Delay (Answer Delay).........................................................................................12

5Configuring via SensorTools Software.........................................................................................13

5.1 Program Start..........................................................................................................................13

5.1.1 Connecting the Polaris.......................................................................................................13

5.2 Setting Window.......................................................................................................................13

6Technical Data.................................................................................................................................15

6.1 Storage....................................................................................................................................15

6.2 Dimensions .............................................................................................................................15

6.3 Composition of the Type Number...........................................................................................16

6.4 Accessories.............................................................................................................................16

7Maintenance.....................................................................................................................................17

7.1 Cleaning..................................................................................................................................17

7.2 Calibration...............................................................................................................................17

8Communication via Serial Interface / Interface Commands .......................................................17

Index.........................................................................................................................................................19

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

General

1 General

1.1 Information to this Manual

This manual enables the safe and efficient use with the device. The manual is part of the instrument and

has to be kept in a location where users always have access to.

Read this manual carefully before operating. For secure working all security notes and operation proce-

dures in this manual has to be followed.

Additionally the local accident prevention regulations and common safety regulations of the instruments’

operational area are valid.

The descriptions may differ from the current delivery status, since the device is continuously developed.

Illustrations in this manual are for basic understanding and can differ from the actual construction.

1.2 CE Conformity and Standards

The product conforms to the following standards:

CE conformity: DIN EN 61326-1 (electromagnetic compatibility)

Laser safety: IEC 60825-1, laser class 2

RoHS: 2011/65/EU

1.3 Limitation of Liability

All information and notes in this manual are made under consideration of valid standards and rules,

state of technology and our expert knowledge for many years.

The producer assume no liability for damages due to:

Non-observance of this manual

Usage out of intended use

Assignment of unskilled personnel

Unauthorized modifications

Technical modifications

Usage of spare parts not approved

The responsibilities of the delivery contract are valid as well as our general terms and conditions and

terms of delivery and the valid statutory rule at date of the conclusion of contract.

1.4 Terms of Warranty

A warranty period is 24 months from date of shipment form the Sensortherm facility. The seller will re-

pair or replace the device at its own discretion. Further claims of the buyer against the seller or its

agents are excluded, especially claims for damages that are not incurred in the delivery itself. This shall

not apply in cases of intent, gross negligence, or the absence of assured properties. Damage or misuse

of the product will be determined and void the warranty coverage. Repairs paid by the customer will in-

clude a 180 days warranty from date of shipment. Transportation costs are to be paid by the customer.

Any claims for damage caused by misuse, neglect or tampering with the sensor are excluded.

1.5 Copyright

This manual is protected by copyrights and are intended solely for internal purposes.

It is not permitted to transfer these instructions to third parties, duplication in any kind and form - includ-

ing excerpts - as well as recovery and / or notification of contents without written permission of the man-

ufacturer, except are internal purposes.

Contraventions are liable for damages. All other rights reserved.

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

General

1.6 Explanation of Symbols

The following symbols are used in this manual for restrictions, preventive measures and security notes.

Please pay attention to this symbols for safety reasons.

CAUTION: This combination of symbol and signal word indicates a potentially dangerous

situation that can result in minor or moderate injury if not avoided.

CAUTION, LASER RADIATION: This combination of laser radiation symbol and signal

word indicates the dangers of a laser targeting light.

INFO: This symbol indicates useful tips, recommendations and information for efficient and

trouble free operation.

1.7 Disposal

Dispose of the product properly when it is no longer usable: infrared measuring devices include electri-

cal and electronic waste and have to be recycled or disposed environmentally friendly or to send to the

manufacturer for disposal.

1.8 Intended Use

The infrared temperature switches Polaris are mainly used for non-contact detection of hot metal parts

and triggering a switching operation. They are equipped with 2 switching contacts with adjustable

switching temperatures. Also the switching status is indicated by LEDs on the rear panel. A laser target-

ing light can be used to align the devices to the measuring object.

Polaris-temperature switches measure in the short wave spectral range and are therefore mainly used

for measuring of metals, ceramics, graphite, etc.

A serial interface connection to to a PC is required configure the devices. The configuration itself will be

done via PC and SensorTools software or via interface commands.

1.9 Scope of Delivery

Infrared switch, SensorTools software, allen key 1.5 mm, user manual.

(A connection cables is not included in scope of delivery and has to be ordered separately).

1.10 Model Design

Focusable optics

Mounting thread

with mounting nut

M 40 x 1.5

Type label

LEDs to indicate system ready (middle)

or active switching outputs (left / right)

Laser targeting light button

Power supply and switching outputs

Serial interface connection

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

Safety

2 Safety

2.1 General

Any person who is tasked to carry out work with the device must have read and understood the operat-

ing instructions before beginning. Operation and maintenance of the system may only be performed by

trained personnel.

2.2 Electrical Connection

When connecting or when working on the mains voltage, the general safety guidelines are observed,

e.g. when connecting power transformers. Supply voltage can be lethal when touching. Improper instal-

lation can cause serious injury or physical damage. Only qualified personnel are allowed to work with

mains voltage.

2.3 Laser Targeting Light

For easy alignment, the devices are equipped with a laser targeting light, Laser Class 2 (according to

IEC 60825-1-3-4) and has a sticker shown on the right. The laser emits a visible red light with a maxi-

mum power of < 1 mW and a wavelength around 650 nm.

Safety precautions:

Never look into the direct or reflected laser beam.

Do not point the laser to anyone.

If laser radiation hits the eye, the eyes must be intentional-

ly closed and the head immediately moved out of the

beam.

2.4 Device Labels

A nameplate and a laser targeting light warning label is to find on the Polaris housing.

The device must be mounted in a manner that the labels after installation are still clearly visible.

Keep the warning signs in always legible condition

Replace damaged labels

2.5 Responsibility of the Operators

If the device is used in the commercial sector the operator is subject to the legal responsibilities for

workplace safety.

In addition to the safety instructions in this manual follow the regulations of safety, accident prevention

and environmental protection.

Laser

beam

direction

Laser warning label

on top of the device

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

Electrical Connection

0 V

Brown

Blue

+24 V

AK30

3 Electrical Connection

3.1 Cable Colors and Pin Assignment

The electrical connection of the Polaris (supply voltage and switch-

ing signals) will be done via the connectors on the rear panel. For

this purpose, connection cables are available as accessory (see

6.4 Accessories). To prevent accidental short circuits, not used

cable wires need to be placed, for example to the supplied screw

terminals.

Cable AK32: Power Supply and Switching Output Connector

Cable color

Function

Brown

+ 24 V DC power supply (possible range 12–30 V DC)

(to be fused by 250 mA slow blow)

View on device

plug

Blue

0 V DC power supply (ground)

White

Output 1

Each transistor output switches the positive

supply voltage to the output (positive switching),

max. current 30 mA

Black

Output 2

Cable AK31: Serial Interface Connector

Cable color

Function

Brown

RS232: TxD (to PC receive line RxD)

RS485: A (-)

View on device

socket

Black

RS232: RxD (to PC send line TxD)

RS485: B (+)

Blue

DGND (ground, electrically isolated)

3.1.1 Power Supply

With connection of the supply voltage (standard 24 V DC, possible range 12–

30 V) the unit is ready for operation with the following factory settings (changing

the settings is possible via software (see 5) or interface commands (see 8).

Interrupt the power supply to turn off the device, e.g. by disconnecting the connector.

Status LEDs:

Green (middle) when the device is ready to use.

Yellow (left and right) illuminates when the corresponding

transistor output is switched.

3.1.1.1 Factory Settings

Data transmission speed (baud rate).... 19.2 kBd

Emissivity ε............................................ 100%

Response time t90 ................................. 4 ms

Device address ..................................... 00

Lower switch temperature output 1....... 790°C

Upper switch temperature output 1....... 800°C

Lower switch temperature output 2....... 890°C

Upper switch temperature output 2....... 900°C

Pin 5

Pin 3

Pin 2

AK31: Serial

interface

AK32: Power supply /

switching outputs

LED Output 1

LED Operating

status

LED Output 2

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

Electrical Connection

Max. 30 mA

0 V

Output

+24 V

100 kΩ

Brown

Blue

0 V

100 kΩ

White

Max. 30 mA

Black

Output

3.1.2 Switching Outputs

The switching outputs are used to detect if a certain temperature

threshold is exceeded or falling below.

The output logic is invertible, see under 5.2 Setting window in the

SensorTools Software).

3.1.3 Serial Interface RS232 or RS485

Polaris are available with RS232 or RS485 interface, the built-in version is to find on the device label.

The serial interface is used for digital communication of the device with another computer, for example a

PC for data transmission to the software SensorTools.

The maximum transmission speed (in Baud) is limited by the cable length, it is halved with each dou-

bling of the transmission path.

RS232: about 7 m cable length with 19.2 Bd. Adjustable are values from 1.2 and 57.6 kBd.

RS485: about 2 km with 19.2 kBd. Adjustable are values between 1.2 and 57.6 kBd.

Connecting one Polaris

via RS232 or RS485:

In a short RS232 or RS485 connection to the mas-

ter (computer receiving the data), the Polaris is

connected directly as a point-to-point connection

with the master.

Connecting several Polaris via RS485:

For a reflection-free operation with longer cables, pay attention to the correct cable termination. Termi-

nation at the physical bus is on front and rear.

Master at the

beginning:

Master in the

middle:

When operating multiple devices (up to 32 are possible), each device needs to assign its own address

(directly on the device or via software SensorTools), under which it can be addressed later. For this

purpose, initially, each device must be connected individually and provided with an address (00-97). Af-

ter that, all devices can be connected.

If specific parameters for all devices should be changed simultaneously, the global address 98 is used

(there is no response from the device). If the address of a device is unknown, you have the opportunity

to address each device independently of the set address with the global address 99 (connect only one

device).

RxD

TxD

GND

TxD Brown

RxD Black

DGND Blue

RS232 (PC)

Pin 2

Pin 3

Pin 5

A (-)

B (+)

GND

A (-) Brown

B (+) Black

DGND Blue

RS485

(Master /

PC)

Master

A (-)

B (+)

DGND

120 Ω

... Device

Terminating

resistor 120 Ω

Device 2

Device 1

Terminating

resistor 120 Ω

in the master

or manually

GND

120 Ω

... Device n

Terminating

resistor 120 Ω

Device 1

GND

120 Ω

Master

A (-)

B (+)

DGND

GND

Terminating

resistor 120 Ω

GND

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

Mechanical Installation

3.1.3.1 Interface Converter (Accessory)

Using an interface converter DK3000 or DK4000 (RS232USB or RS485USB) is a quick and easy

way to connect the infrared switch to a PC (see 6.4 Accessories). Via the sub-D connector this is simp-

ly connected to the cable AK31.

Depending on the operating system, suitable drivers are installed automatically or can be found on the

CD supplied with the software SensorTools in the directory Drivers FTDI_USB_COM, or after in-

stalling SensorTools in the installation directory (updated driver for Windows from the FTDI website:

http://www.ftdichip.com/Drivers/VCP.htm).

4 Mechanical Installation

4.1 Mounting

Note that the installation lecation is free of vibrations. If necessary, helps the use of rubber absorbers

when mounting.

The device can be mounted in a drilling hole of 41 mm Ø and fixed with the included nuts (M40x1.5).

For easy installation a mounting angle is available as accessory (see 6.4 Accessories).

4.2 Ambient Temperature

Polaris switches are designed for ambient temperatures between 0 and 70°C. Operation outside this

temperature leads to incorrect measurements and may damage the unit.

To comply with the permitted ambient temperature, sufficient distance from the (hot) object to detect is

observed.

To prevent laser targeting light overheating, the targeting light is deactivated at a device temperature

from 55°C. Below that temperature it can be used again

Accessory: The use in ambient temperatures outside the permissible ambient temperature is possible

with an additional cooling housing (see 6.4 Accessories).

4.3 Alignment onto the Measuring Object

To detect the temperature correctly, the infrared switch must be aligned properly to the measuring ob-

ject. In the focus point of the optics (focus distance) the spot size diameter is the smallest. Also meas-

urements in the defocused area can be done to determine the average temperature of a bigger spot. If

the target under measurement is smaller than the spot size produced by the lens, the colder or warmer

border is also measured and results in a lower or higher temperature.

The optical path between infrared switch and the target must be free of interfering objects and va-

pors, fumes or dust (if necessary, use air purge or sight tube).

A viewing window between Polaris and the measured

object should have constant transmission properties in

the spectral range of the Polaris (e.g. BK7 crown

glass). The transmission loss must be compensated

by correction of the emissivity.

If the target is smaller than the spot size, there will be

measuring errors because background temperatures

go with the measurement.

Spot size smaller than meas-

ured object, measurement OK

Measuring object

Spot size larger than measured

object, enter fill factor, observe

background radiation!

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

Mechanical Installation

4.3.1 Alignment with the Laser Targeting Light

The laser targeting light is a conical red laser beam with

the largest diameter directly at the lens and the smallest

and sharpest in the focused distance, i.e. at the point

where the measuring field is the smallest.

The focus distance (=measuring distance at the smallest

spot size) is easy to find where the laser dot is the small-

est.

INFO: The size of the laser point does not match to the spot size, spot sizes are given in the

spot size tables (see 4.5)

CAUTION, Laser Radiation, Laser Class 2:

Never look into the direct or reflected laser beam.

Do not point the laser to anyone.

If laser radiation hits the eye, the eyes must be intentionally closed and the head immedi-

ately moved out of the beam.

Turn on / off via the targeting light button on the rear side or via Sen-

sorTols software (see 5.2).

The targeting lightwill automatically switched off after 2 minutes (if not

switched off manually).

INFO: The laser targeting light is turned off at a device

temperature above 55°C.

If the targeting light does not turn on, probably the device's

internal temperature is too high. In this case, the installation

place should be checked (excessive heat radiated from the

measuring object). When temperature falls below 55°C the

laser is working again.

4.4 Setting the Measuring / Focus Distance

The focal distance is the distance at which the optics achieves its smallest spot size. In most cases, this

distance is also the required measuring distance.

With the focusable optics the focus distance can be changed continuously within a predetermined range

(see 4.5 Spot size tables), so the smallest possible spot size is always achieved.

Loosen locking screws (allen key 1.5 mm)

Adjust measuring distance by turning the optics in or out un-

til the measuring distance is found

- Optics screwed out: short measuring distances

- Optics screwed in: long measuring distances

Fix locking screws (hand-screwed).

Optics locking

screws

Focus point

Spot size and

Laser dot bigger

Laser targeting

light button

Infrared Temperature Switch (Hot Metal Detector) Polaris PS09 / PI16

Mechanical Installation

4.5 Spot Size Tables

The following tables show the optical data of the different device types. The values in the tables are ex-

emplary, intermediate measurement distances must be determined by interpolation. If the measuring

distance differs from the adjusted or specified, a measurement is also possible, but the spot size

changes (usually it is larger, see 4.5.1 Calculation of the Spot Size Diameter outside the Focused

Distance). The measuring distances are specified from lens front.

Optics

Measuring

(focus)

distance

a [mm]

Optics pull-out

S [mm]

Spot size M [mm]

Aperture Ø

D [mm]

PI16

250–1000°C

PS09 and PI16

all other

temp. ranges

OP09-A0

170

1.7

1.3

14 mm

185

14.7

1.8

1.35

200

13.4

1.9

1.4

220

12.1

1.95

1.45

245

1.5

OP09-B0

260

2.1

1.6

14 mm

280

2.4

1.85

300

13.3

2.7

2.1

350

12.9

2.9

2.25

400

12.1

3.3

2.5

450

11.2

3.7

2.9

500

4.3

3.2

OP09-C0

480

3.3

14 mm

500

15.7

4.3

3.2

600

14.6

4.8

3.6

800

13.3

6.1

4.6

1000

12.5

1250

11.9

9.3

1500

11.5

8.3

1750

11.2

2000

14.5

4.5.1 Calculation of the Spot Size Diameter outside the Focused Distance

The spt size diameter determines the area on the measurement object from which 90% of the tempera-

ture radiation is detected by the pyrometer; therefore the spot size tables specify spot sizes for different

measuring distances (or focused distances).

For calculating intermediate values in front of and behind the focused measuring distance, the following

formula can be used or the Spot size calculator integrated in SensorTools (under 5.2):

a Focused distance

M Spot size diameter in the focused measuring

distance

a1Measuring distance longer than focused meas-

uring distance

M1Resulting spot size on measuring distance a1

a2Measuring distance shorter than focused

measuring distance

M2Resulting spot size on measuring distance a2

D Aperture (specifies the spot size directly on the

optics’ lens, it differs depending on the optics

pull-out. The largest value applies at a fully extended optics, the lowest value is with inserted lens)

M1= (M+D)-D

M2= (M-D)+D

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