PSC-SSS IR Sensor

Operation manual

CE-Conformity
The product complies with the following
standards:
EMC:
EN 61326-1
Safety Regulations:
EN 61010-1:1993/ A2:1995
The product accomplishes the requirements of the EMC Directive 89/336/EEC
and of the low-voltage directive 73/23/EEC.

Scope of supply
SSS electronic box,
pre-installed sensing head (cable length according to order),
operators manual
You will find the serial number on a label on the electronic box. The cable is
labeled with the serial number of the head.
Always use these numbers when you contact the customer service concerning
maintenance, additional order of components, spare parts or repairs.

CTGEN-MA-E2005-08-B

Warranty
Each single product passes through a quality process. Nevertheless, if failures
occur please contact the customer service at once.
The warranty period covers 24 months starting on the delivery date. After the
warranty is expired the manufacturer guarantees additional 6 months warranty for
all repaired or substituted product components. Warranty does not apply to
damages, which result from misuse or neglect. The warranty also expires if you
open the sensing head. The manufacturer is not liable for consequential damage.
If a failure occurs during the warranty period the product will be replaced,
calibrated or repaired without further charges. The freight costs will be paid by
the sender. The manufacturer reserves the right to exchange components of the
product instead of repairing it. If the failure results from misuse or neglect the
user has to pay for the repair. In that case you may ask for a cost estimate
beforehand.

CTGEN-MA-E2005-08-B

Content
Page
1

Quick Reference

2
2.1
2.2
2.3
2.4
2.5
3
4
4.1
4.2
4.3
4.4
4.5
5
6
6.1
6.2
6.3
6.4
6.4.1

Technical Data
General Specifications
Electrical Specifications
Measurement Specifications
Optical Charts
CF-Optics
Mechanical Installation
Electrical Installation
Cable Connections
Exchange of the Sensing Head
Outputs
Digital Interfaces
Functional Inputs
Operation
Software SSS connect
Installation
Starting the Software
Diagram Functions
Configuration of the SSS
Signal Processing

10
10
11
12
13
14
16
19
19
21
22
23
25
26
29
29
30
31
37
38

CTGEN-MA-E2005-08-B

6.4.2 Output Signals

6.4.3 Advanced Settings

45
48

7
8
9

Principle of Operation
Emissivity
Maintenance

50
51
52

Appendix A Visual Alarms

Appendix B Emissivity Tables

53
54

CTGEN-MA-E2005-08-B

1 Quick Reference
Thank you for choosing the PSC-SSS Infrared sensor.
In this chapter you will find concentrated information for a quick start with the
CT sensor.
Comments to this manual
Read the manual carefully before the initial start-up.
You will find important information and notes in the grey colouredIMPORTAN
boxes.
The producer reserves the right to change the herein described specifications in
case of technical advance of the product.

Mechanical Installation
SSS heads are equipped with a metrical M12x1-thread and can be installed either
directly via the sensor thread or with the help of the hex nut (delivered as
standard) to the mounting bracket available.
Various mounting brackets,
The sensing head is a sensitive optical
which make the adjustment of
system. Please use only the thread for
the sensing head easier, can be
mechanical installation.
additionally ordered as
Avoid mechanical violence on the head this
accessories. Make sure to keep
may destroy the system (expiry of warranty)
the optical path clear of any
obstacles when adjusting the head to the object (see chapter 2.4).
CTGEN-MA-E2005-08-B

 More information in chapter 3

Electrical Installation
Please open at first the cover of the SSS electronic box (4 screws). Below the
display are the screw terminals for the cable connection.

Use shielded cables only.

The sensor shield has to
be grounded

Please use a power supply unit with an output voltage of 8 36 VDC/ 100 mA.
The standard delivery includes the connected cable of the sensing head to the
electronic box. You may shorten but never lengthen the cable.
More information in chapter 4.1
Head exchange
Sensing heads of the SSS series are exchangeable. Every head has a specific
calibration code, which is printed on the head cable. For a correct temperature
measurement and functionality of the SSS this calibration data must be stored in
the electronic box.
The calibration code consists of three blocks with 4 characters each.
CTGEN-MA-E2005-08-B

Example:

EKJ0 0OUD 0A1B

block 1

block 2

block 3

For entering the code please press the Up- and Down-key (keep pressed) and then
the Mode-key.
The display shows HCODE and then the 4 signs of the first block. With Up and Down
each sign can be changed, Mode switches to the next sign or next block.
You will find the calibration code on
a label fixed on the head cable (near
the electronic box). If you shorten
the cable, please make sure to note
the calibration code. The code is
More information in chapter 4.2
Analog Outputs
You can select the desired analog output via the programming keys (see Tab. 5-1).
Output

Range

Voltage

0 ... 5
V
0 ... 10

Voltage

Connection-Pin on
CT-Board
OUT-mV/mA
OUT-mV/mA

According to the chosen

output signal there are
different connection pins on
th CT b
d (OUT V/ A

CTGEN-MA-E2005-08-B

Current
Current
Thermocouple
Thermocouple

V
0 ... 20
mA
4 ... 20
mA
TC J
TC K

OUT-mV/mA
OUT-mV/mA
OUT-TC
OUT-TC

Factory default setting is 0-5 V (temperature range 0-500 C).

More information in chapter 4.3
Digital Interfaces (optional)
If you want to install an interface, please do the following:
plug the interface board into the place provided, which is located beside the
display
use both M3x5 screws for fixing it onto the electronic box
plug the preassembled interface cable with the terminal block into the male
connector of the interface board
If you use the USB-interface, the CT needs
If no
youexternal
use the USB-interface board or the
power supply for operation it will be powered
by the board and your own RS232-toRS232-interface
USB-adaptor you will see the COM port as a
USB-interface.
virtual COMin
port (VCP) in your system.
Please install the software CTconnect as described
During the installation of the USB driver a
chapter 6.1.
More information in chapter 4.4

COM port number will be assigned to the VCP

(open the Device Manager to figure out).
After starting CTconnect please enter the

CTGEN-MA-E2005-08-B

Operation
The programming keys Mode, Up and Down enable the user to
set the sensor on-site. The current measuring value or the
chosen feature is displayed. With Mode the operator obtains
the chosen feature, with Up and Down the functional
parameters can be selected. If no key is pressed for more
than 10 seconds the display automatically shows the
calculated object temperature (according to the signal
processing).

Pressing the Mode button again recalls the last called

function on the display.
h
i
l
i
f
k h ld
d
ll
h ld
More information in chapter 5
Factory default setting
To set the SSS back to the factory default settings, please press at first the
Down-key and then the Mode-key and keep both pressed for approx. 3 seconds.
The display shows RESET for confirmation.
Error messages
The display of the CT can show the following error messages:
CTGEN-MA-E2005-08-B

OVER
UNDER
^^^CH
vvvCH

temperature overflow
temperature underflow
head temperature to high
head temperature to low

CTGEN-MA-E2005-08-B

10

2 Technical Data
2.1 General Specifications
Sensing head
Environmental rating
Ambient temperature
Storage temperature
Relative humidity
non condensing

Electronic box

IP65 (NEMA-4)
-20 180 C (20:1/ 15:1 head)
-20 130 C (2:1 head)
-40 180 C (20:1/ 15:1 head)
-40 130 C (2:1 head)
10 95 %, non condensing

IP65 (NEMA-4)
0 65 C

Material
Dimensions
Weight

stainless steel
28 mm x 14 mm
40 g

Vibration
Shock

IEC 68-2-6: any axis, 11 200 Hz, 3G

IEC 68-2-27: any axis, 11 ms, 50G

Cable length
Cable diameter

-40 85 C
10 95 %,

die casting zinc

89 mm x 70 mm x 30 mm
420 g

1 m (Standard), 3 m, 8 m, 15 m
2,8 mm

CTGEN-MA-E2005-08-B

11

2.2 Electrical Specifications

Power supply
Current draw

8 VDC 36 VDC
max. 100 mA

Outputs/ analog
Channel 1 (Object temperature)
0 20 mA or 4 20 mA or 0 5 V or 0 10 V
or thermocouple type J or K
Channel 2 (Head temperature)
0 5 V or 0 10 V; 10 mV/ K or alarm output
Relais
2 x 60 VDC/ 42 VACRMS, 0,4 A; optically isolated
(optional module)
Output impedances
mA
mV
Thermocouple
Functional inputs
functions:

max. loop resistance 500 (at 8 -36 VDC),

min. 100 K load impedance
20
F1 F3; software programmable for the following
- external emissivity adjustment,
- ambient temperature compensation,
- trigger (reset of hold functions)

Digital interface

USB, RS232, RS485 (optional modules)

CTGEN-MA-E2005-08-B

12

2.3 Measurement Specifications

Sensing head 20:1
Spectral range
8 14 m
Temperature range -40 900 C
600 C
Optical resolution
20:1

Sensing head 15:1

Sensing head 2:1

8 14 m
-40 600 C

8 14 m
-40

15:1

2:1

Response time
150 ms (95 %)

150 ms (95 %)

150 ms (95 %)

System accuracy 1), 2)

1 % or 1 C
Repeatability 1)
0,5 C

1 % or 1 C

1 % or 1 C

0,5 % or 0,5 C

0,5 % or 0,5 C

Temperature resolution 3)
0,1 C
0,1 C
Temperature Coefficient1), 4)
0,05 %/ K or 0,05 K/ K
0,05 K/ K
0,05 %/ K or 0,05 K/ K

0,5 % or

0,1 C
0,05 %/ K or

Signal processing
peak hold, valley hold, average
Emissivity
0,100 1,100 (manual or digital adjustable)
CTGEN-MA-E2005-08-B

13

Transmission
1)
2)

3)
4)

0,100 1,100 (manual or digital adjustable)

whichever is greater
T> -20 C; ambient temperature 23 C 5 C
at a temperature span of 300 C, e.g. temperature range 0 C 300 C
at head temperature 0 180 C (0 130 C at 2:1)

CTGEN-MA-E2005-08-B

14

2.4 Optical Charts

The following optical charts show the diameter of the measuring spot in dependence
on the distance between measuring object and sensing head. The spot size refers to
90 % of the radiation energy.
The size of the measuring object and
the optical resolution of the infrared
thermometer determine the maximum
distance between sensing head and
measuring object.
In order to prevent measuring errors
the object should fill out the field of
view of the optics completely

Fig. 2-1: Optical charts sensing head 20:1, 15:1 and 2:1
CTGEN-MA-E2005-08-B

15

2.5 CF-Optics
The optional CF-lens allows the measurement of small objects. The minimum spot
size depends on the used sensing head:
2:1
15:1
20:1
1)

2,5
2,5
0,8
0,8
0,6
0,6

mm@
mm@
mm@
mm@
mm@
mm@

23 mm
21 mm with laminar air purge1)
10 mm
8 mm with laminar air purge 1)
10 mm
8 mm with laminar air purge 1)

If the CF-lens is used, the

transmission has to be set to
0,78 (see chapter 5 and

measured from front edge of the laminar air purge

Fig. 2-2: CF-lens

Fig. 2-3: laminar air purge with integrated CF-lens

CTGEN-MA-E2005-08-B

16

Fig. 2-4: 2:1-head with CF-lens

Fig. 2-5: 15:1-head with CF-lens

Fig. 2-6: 20:1-head with CF-lens

CTGEN-MA-E2005-08-B

17

3 Mechanical Installation
CT heads are equipped with a metrical M12x1-thread and can be installed either
directly via the sensor thread or with the help of the hex nut (delivered as
standard) to the mounting bracket available. Various mounting brackets, which make
the adjustment of the sensing head easier, can be additionally ordered as
accessories.
Make sure to keep the optical
path clear of any obstacles

Fig. 3-1: Dimensions CT head and electronic box

CTGEN-MA-E2005-08-B

18

The mounting fork can be

combined with the mounting
bracket with the M12x1-thread.

A combination of mounting
bracket and bolt forms a
mounting bracket, which is
adjustable in two axes

Mounting bracket, adjustable in

with thread M 12x1,
one axes
2 axes

Mounting bolt with M12x1 thread,

Mounting fork

adjustable in one axes

adjustable in

Fig. 3-2: Mounting Brackets

CTGEN-MA-E2005-08-B

19

The lens must be kept clean at all times from dust, smoke, fumes and other
contaminants in order to avoid reading errors.
These effects can be reduced by using an air purge collar. Make sure to use oilfree, technically clean air, only.
The CT-high-temperature sensing heads are designed to measure temperatures while
tolerating ambient temperatures ranging between
0 and 180 C (20:1/ 15:1 head) or 0 and 130 C (2:1 head). The cable between head and
i
i
i
i
The needed amount of
air (approx. 2...10
l/ min.) depends on
the application and
the installation
A combination of the
laminar air purge
collar with the
bottom section of the
mounting fork forms a
unit which is
Standard air purge collar, may be combined
outlet

Laminar air purge collar the side air

CTGEN-MA-E2005-08-B

20

with mounting bracket; hose connection: 3x5 mm

prevents a cooling down of the
object in short
distances; hose connection: 3x5 mm
Fig. 3-3: Air purge collars

CTGEN-MA-E2005-08-B

21

4 Electrical Installation
4.1 Cable Connections
For the electrical installation please open at first the cover of the CT
electronic box (4 screws). Below the display are the screw terminals for the cable
connection.
Designation:
+8 ... 36VDC
GND
GND
outputs
OUT-AMB
OUT-TC
OUT-mV/mA
or mA)
F1-F3
PINK
GRAY
BROWN
WHITE
GREEN
YELLOW

Power supply
Ground (0V) of power supply
Ground (0V) of internal in- and
Analog output head temperature (mV)
Analog output thermocouple (J or K)
Analog output object temperature (mV
Functional inputs
Power supply laser (+)
Power supply laser ()
Temperature probe head
Temperature probe head
Detector signal ()
Detector signal (+)

Fig. 4-1: Open CT electronic box with

screw terminals

Power supply:
CTGEN-MA-E2005-08-B

22

Please use a power supply unit with an output voltage of 8 36 VDC/ 100 mA.
Cable assembling:
The cable gland M12x1,5 allows the use of cables with a diameter of 3 to 5 mm.
Remove the isolation from the cable (40 mm power supply, 50 mm signal outputs, 60
mm functional inputs). Cut the shield down to approximately 5 mm and spread the
strands out. Extract about 4 mm of the wire isolation and tin the wire ends.
Place the pressing screw, the rubber washer and the metal washers of the cable
gland one after the other (according Fig. 4-2) onto the prepared cable end. Spread
the strands and fix the shield between two of the metal washers. Insert the cable
into the cable gland until the limit stop. Screw the cap tight.
Every single wire may be connected to the according screw clamps according to
their colors.

CTGEN-MA-E2005-08-B

23

Use shielded cables only.

The sensor shield has to be
grounded

Fig. 4-2: Cable assembling

4.2 Exchange of the Sensing Head

The standard delivery includes the connected
cable of the sensing head to the electronic
box. You may shorten but never lengthen the
cable. To shorten the cable may cause
additional measuring errors of about 0,1 K/
m. The head is exchangeable.

After exchanging a head the

calibration code of the new head
must be entered into the
l t
i

Entering the calibration code:

CTGEN-MA-E2005-08-B

24

Sensing heads of the CT series are exchangeable. Every head has a specific
calibration code, which is printed on the head cable. For a correct temperature
measurement and functionality of the CT this calibration data must be stored in
the electronic box.
The calibration code consists of three blocks with 4 characters each.
Example:

EKJ0 0OUD 0A1B

block 1

block 2

block 3

For entering the code please press the Up- and Down-key (keep pressed) and then
the Mode-key.
The display shows HCODE and then the 4 signs of the first block. With Up and Down
each sign can be changed, Mode switches to the next sign or next block.
You will find the calibration code on a
label fixed on the head cable (near the
electronic box). If you shorten the
cable, please make sure to note the
calibration code. The code is needed if

4.3 Outputs
The CT has two output channels. Output channel 1 is used for the object
temperature. The CTconnect software allows the programming of this output as an
alarm output.

CTGEN-MA-E2005-08-B

25

Output

Range

Voltage

0 ...
V
0 ...
V
0 ...
mA
4 ...
mA
TC J
TC K

Voltage
Current
Current
Thermocouple
Thermocouple

Connection-Pin on
CT-Board
OUT-mV/mA

10

OUT-mV/mA

20

OUT-mV/mA

20

OUT-mV/mA

According to the chosen output

signal there are different
connection pins on the CT board
(OUT V/ A
OUT TC)

OUT-TC
OUT-TC

Tab. 4-1: Analog outputs

Output channel 2 (connection pin OUT AMB) is used for the head temperature (-20
180 C as 0 5 V or 0 10 V) or as alarm output. Activating this channel as
alarm output requires the CTconnect software. Additionally to the head temperature
also the object or electronic box temperature can be selected as alarm source.

4.3 Digital Interfaces

CTGEN-MA-E2005-08-B

26

POWER - rot / red

DM - wei / white
DP - grn / green
GND - schwarz / black

CT sensors are optionally equipped with an USB-,

RS232-, RS485- or relais-interface.
If you want to install an interface, plug the
interface board into the place provided, which is
located beside the display (see Fig. 4-1). In the
correct position the holes of the interface match
with the thread holes of the electronic box. Now
press the board down to connect it with the CT and
use both M3x5 screws for fixing it. Plug the
preassembled interface cable with the terminal block
into the male connector of the interface board. In
case you want to use the delivered cable gland
M12x1,5 for the preassembled cable, the terminal
block has to be disassembled/ assembled. Make sure
the wiring is correct (Fig. 4-3).

Schraubklem m e
term inal block

Fig. 4-3: Interface cables:

USB (left), RS232 (right)

USB-interface:

CTGEN-MA-E2005-08-B

27

If you use the USB-interface, the CT needs no external power supply for operation
it will be powered by the USB-interface.
If an external power supply has already been installed, this will have no effect
on the functionality of the CT. After the interface board has been installed and
the USB-cable has been connected to your PC, please install the USB driver as
described in
chapter 6.1. After this you can start the CTconnect software and the communication
will be established.
RS232-interface:
If the RS232-interface is used, the CT unit in any case needs an external power
supply for operation. After the interface board has been installed and the RS232cable has been connected to your PC, the communication will be established.
Relais-interface:
After installing the interface board as described above please connect the
electrical circuit with the terminal block. A red LED shows the closed current
switch. The relais board provides two fully isolated switches, which have the
capability to switch max. 60 VDC/ 42 VACRMS, 0,4 A DC/AC.
The factory default settings for the switching thresholds (alarm values) are:
Alarm 1 = 30 C/ norm. closed (low alarm) and Alarm 2 = 100 C/ norm. open
(high alarm). To make advanced settings (change of low- and high alarm) a
i i
i
i

CTGEN-MA-E2005-08-B

28

RS485-interface:
Please install the interface board as described above and connect the RS485-USBadapter via the supplied USB cable with your computer. After it has been connected
the computer will recognize a new USB-device and (if connected the first time)
will ask for installation of the according driver software. Select Search and
install the RS485-adapter USB-driver from the software CD.
The RS485-USB-adapter provides a 2-wire half-duplex mode. Please connect terminal
A of the adapter with terminal A of the RS485-interface of the first CT and from
there to terminal A of the next CT and so on. With the B terminals proceed as
well.

Make sure, that you always connect A to A and B to B, not reverse. You may run up
to 32 CT units on one RS485-USB-adapter. The 120R-switch is to be turned to ON at
one of the connected CT units, only. Each CT unit connected to the RS485 needs a
different multidrop address between 1 and 32 (see chapter 6.4.3).
Independend from the used
the setting for baud rate
software must be the same
CT unit (factory default:

interface
in the
as on the
9 6

4.5 Functional Inputs

The three functional inputs F1 F3 can be programmed with the CTconnect software,
only.

CTGEN-MA-E2005-08-B

29

F1 (digital):
trigger (a 0 V level on F1 resets the hold functions)
F2 (analogue):
external emissivity adjustment (0 10 V: 0 V =0,1; 9 V
=1; 10 V =1,1)
F3 (analogue):
external compensation of ambient temperature (0 10 V -40
900 C; the range is scalable via CTconnect
software/ preset range:
-20 200 C)
F1 F3 (digital):
emissivity (digital choice via table, non-connected input
represents high-level)
high-level: +3 V+36 V
low-level: +0,4 V36 V

CTGEN-MA-E2005-08-B

30

5 Operation
The programming keys Mode, Up and Down enable the user to set the sensor on-site.
The current measuring value or the chosen feature is displayed. With Mode the
operator obtains the chosen feature, with Up and Down the functional parameters
can be selected. If no key is pressed for more than 10 seconds the display
Pressing the(according
Mode button
recalls
automatically shows the calculated object temperature
to again
the signal
the last called function on the
processing).
display.
The signal processing features Peak
hold and Valley hold cannot be
Factory default settings:
Signal output object temperature 0 5 V
Emissivity
0,970
Transmissivity
1,000
Average time
0,2 s
Peak hold
inactive
Valley hold
inactive
Lower limit temperature range
0 C
Upper limit temperature range
500 C
Lower limit signal output
0 V
Upper limit signal output
5 V
Temperature unit
C
Lower alarm limit
30 C (norm. closed)
Upper alarm limit
100 C (norm. open)
Ambient temperature compensation head temperature
(0-5 V/ -20 180 C)

CTGEN-MA-E2005-08-B

31

Baud rate
programming keys
Display

9,6 kBaud

142.3C
127CH
25CB
142CA
0-20

Mode [Sample]
Object temperature (after signal
processing) [142,3 C]
Head temperature [127 C]
Box temperature [25 C]
Current object temperature [142 C]
Signal output channel 1 [0 - 20 mA]

E0.970
T1.000
A 0.2
P---V---u .0
n500.0

Emissivity [0,970]
Transmissivity [1,000]
Signal output average [0,2 s]
Signal output peak hold [inactive]
Signal output valley hold [inactive]
Lower limit temperature range [0 C]
Upper limit temperature range [500 C]

[ 0.00 Lower limit signal output [0 mA]

]20.00
U C
| -40.0
||900.0
XHEAD

Upper limit signal output [20 mA]

Temperature unit [C]
Lower alarm limit [-40 C]
Upper alarm limit [900 C]
Ambient temperature compensation [head

Fig. 5-1: Display and

Adjustment Range
fixed
fixed
fixed
fixed
0-20
0 20 mA Current loop
4-20
4
20 mA Current loop
MV5 0 5 V Voltage output
MV10
0
10 V Voltage output
TCJ
Thermocouple type J
TCK
Thermo couple type K
0,100 ... 1,100
0,100 ... 1,100
A---- = inactive/ 0,1 999,9 s
P---- = inactive/ 0,1 999,9 s/ P = infinite
V---- = inactive/ 0,1 999,9 s/ V = infinite
-40,0 900,0 C/ inactive at TCJ- and TCK-output
-40,0 900,0 C/ inactive at TCJ- and TCK-output
according to the range of the selected output
signal
according to the range of the selected output
signal
C/ F
-40,0 900,0 C
-40,0 900,0 C
XHEAD = head temperature/ -40 900 C as fixed

CTGEN-MA-E2005-08-B

32

temperature]

value for compensation/ returning to XHEAD (head

temperature) by pressing Up and Down together

Multidrop address [1] (only with RS485

M 01 Interface)
B 9.6 Baud rate = 9,6 kBaud

01 32
9,6/ 19,2/ 38,4/ 57,6/ 115,2 kBaud

Tab. 5-1: Adjustment modes

Factory default setting:

To set the CT back to the factory default settings, please press at first the
Down-key and then the Mode-key and keep both pressed for approx. 3 seconds.
The display shows RESET for confirmation.

Error messages:
The display of the CT can show the following error messages:
OVER
temperature overflow
UNDER temperature underflow
^^^CH head temperature to high
vvvCH head temperature to low

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33

6 Software CTconnect
6.1 Installation
Features:
configure CT sensors
setup parameters and adjust the
sensor to your application
display and record temperature
trends

System requirements:
Windows XP, 2000
RS232 or USB interface (depends
on the interface board plugged
in the CT)
Hard disk with at least 30
MByte free space
At l
t 128 MB t RAM

Insert the CTconnect Installation CD.

If the auto run option on your computer is activated the installation wizard will
start automatically. Otherwise please start setup.exe on the CD-ROM. Follow the
instructions of the wizard until the installation is finished.
The installation wizard will place a launch icon on the desktop and in the start
menu [Start]\Programs\optris gmbh\ct connect.
If you want to uninstall the software from your system please use the uninstall
icon in the start menu.
USB driver:
To use the CT unit with USB interface please connect the sensor via the supplied
USB connection cable with a free USB slot of your computer. The operating system
will auto detect the new hardware and open a wizard. Chose the automatic
CTGEN-MA-E2005-08-B

34

installation and follow the instructions. The drivers will be copied to your
computer.

If you use the USB-interface board or the

RS232-interface board and your own RS232-toUSB-adaptor you will see the COM port as a
virtual COM port (VCP) in your system.
During the installation of the USB driver a
COM port number will be assigned to the VCP
(open the Device Manager to figure out).
After starting CTconnect please enter the

Fig. 6-1: COM-Port number in Device manager window

6.2 Starting the Software

Please connect your CT with the USB cable to a free USB
port or with the serial cable (9-pin-plug) to a free
RS232 port (choose the connection according to the
plugged interface board).
CTGEN-MA-E2005-08-B

35

Launch the CTconnect software.

The default setting for the communication is: COM1 with 9600 baud.
The setting for baud rate in the software must be the same as on
If you use the CT on a different port or with a different
baud rate you have to change the interface settings under
Setup/ Interface.
Adress mode:
no address: Single sensor operation via USB/ RS232
auto scan: automatic address search (RS485
operation)
fixed address:
input of a known address
Deactivating Checksums allows compatibility to older CT sensors (presetting:
activated).
Connection state:
In the lower left corner the current connection state will be
displayed:
Online:
Application is properly connected with
the CT/ normal data exchange
Offline:
No connection to the CT/ no data exchange
Connecting: Connection to a CT unit will be established
Addr. xx:
only during network operation (RS485): shows the current CT
address
CTGEN-MA-E2005-08-B

36

6.3 Diagram Functions

The diagram will be started by pressing the Start button or by opening a stored
data file. In any case the graph shows the object temperature.

Temperature displays:
TObj: The big display and the assigned temperature bar show
the object temperature.
If no measuring is started this temperature will be
actualized every 200 ms
(after starting the measurement: every 20 ms).
TBox: Display and temperature bar show the temperature of
the electronic box
THead:
Display and temperature bar show the temperature of the CT head
The values for TBox and THead will be actualized every
second.
Fig. 6-2: Temperature displays

Temperature bars:
The temperature values on the left and on the right
side indicate the range of the bar graph. Above the
CTGEN-MA-E2005-08-B

37

bar you will find two markers for low alarm and high alarm. If low alarm is active
the color of the bar will change from green to blue, if high alarm is active from
green to red.
Both alarms have nothing to do with the alarm
values from the CT unit.
The values for temperature range and alarm can be set in the menu item
Setup/ Display Ranges.

Fig. 6-3: Temperature bar graphs

and display ranges

CTGEN-MA-E2005-08-B

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Fig. 6-4: Displays and setting features of the software

CTGEN-MA-E2005-08-B

39

Time axis:
To zoom the x-axis set the cursors according to the time
in. Use both sliders under the diagram. After you pushed
marked range will expand to full size. With the Zoom-out
the opposite effect. With the scroller of the x-axis you
range of the diagram. The full range button
|<- ->| helps you to zoom-out of the diagram to the full
data.

range you are interested

the Zoom-in button + the
button you will reach
can move through the time
range of the available

The temperature
values in the
diagram will be
d t d

Fig. 6-5: Time axis below the diagram

Freeze and Continue:

Any action with the time axis will set the diagram into the Freeze modus. If you
want to continue with the live data please press the button Continue. The button
changes its function between Freeze and Continue. Stopping the diagram with the
CTGEN-MA-E2005-08-B

40

Freeze button will only stop the updating. The application proceeds with data
collecting in the background. To stop the measurement you have to press the button
Stop.
Temperature axis:
The range adjustment of the y-axis depends on the selected scaling settings under
View/ Settings. Only if Manual scaling is activated, both sliders are enabled to
set the upper and lower temperature range of the diagram (Fig. 7-4). Both ysliders are of equal rank. The prevailing higher slider represents the high range
of the diagram and vice versa.

Recording and play-back of data:

To record temperature data, please activate the Recording checkbox. Under
Recording Interval you can define the time interval of the recorded values
(shortest time: 20 ms).
After the Start button was pressed the application will record the temperatures
(TObj, TBox and THead) to an appropriate data file. After you stopped the
measuring the program will ask you for a path and filename to store the file. The
stored data file (*.dat) is readable with any text editor and can easily be
imported into MS Excel. To play back the recorded data open the data file with the
menu item File/ Open. To zoom the x- and y-axis proceed in the same way like with
live data.
Example:
Date:
Time:

[CT-Connect DataFile][1.0]
08.04.2004
10:18:13.879

CTGEN-MA-E2005-08-B

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Unit:

Time
00:00:00.020
00:00:00.040
00:00:00.060
00:00:00.080
00:00:00.100
00:00:00.120
00:00:00.140

TObj
19.9
20.1
19.8
19.8
19.9
19.7
19.8

TBox
28.4
28.4
28.4
28.4
28.4
28.4
28.4

THead
26.7
26.7
26.7
26.7
26.7
26.7
26.7

Scaling settings:
The scaling of the diagram can be set with the menu item View/ Settings. This menu
item will open the following dialog:
For the scaling of the y-axis three
alternatives are available:
Auto-Scale (global):
If a value exceeds the
shown diagram range, the range will be extended
to fit the diagram curve. The range will not be
reduced again. The sliders on the right side of
the diagram are inactivated.
Auto-Scale (local):
If a value exceeds
the shown diagram range, the range will be
extended to fit the diagram curve. The range will
be reduced again if the peak value is not
displayed in the diagram anymore. This option
ensures the best fitting of the curve to the
CTGEN-MA-E2005-08-B

42

diagram but it can cause flickering if the signal is noisy. The sliders on
the right side of the diagram are inactivated.
Manually:
If this option is active the scaling can be performed by hand using the sliders on the right-hand side of the diagram.

To prevent odd values on the temperature axis (y-axis) check the option Round
temperature axis.

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6.4 Configuration of the CT

An essential part of the software is the parameterization of the CT. For this
purpose use the menu item Setup/ Sensor.
In the top line you will find the serial-number of the connected CT and the
firmware revision.

Most of the parameters have an

immense effect on the signal
output and functionality of
the sensor. Please doublecheck that the settings you

CTGEN-MA-E2005-08-B

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Fig. 6-6: Setup dialog window Signal Processing

The setup dialog consists of three parts:

Signal processing:
emissivity and transmissivity control, ambient
control, post processing
Output signals :
output channels and alarm settings
Advanced settings: head parameters, device adjustment, multidrop address

6.4.1 Signal Processing

If the setup dialog is open, the following parameters can be adjusted (part Signal
processing):
Emissivity adjustment:
There are three options to set the emissivity:
Fixed value:
The value can be set
Emissivity.
External:
The value is determined by
functional input pin F2.
(010 V: 0 V =0,1/ 9 V
=1,1)
Table:
Input of up to eight
and corresponding alarm values
emissivity value) in a material table.

by the edit box

a voltage on the
=1,0/

10 V

emissivity values
(two for each
The selection of

CTGEN-MA-E2005-08-B

45

the

tabular values occurs by a combination of low- and high-levels on the

functional inputs F1 to F3 (non-connected input represents high-level).
high-level: +3 V+36 V
low-level: +0,4 V36 V

Editing the material table:

Pushing the button Edit material table calls the material table dialog:
An emissivity value and two alarm values can be set for each
entry. Both alarms A and B are logical entities and must be
assigned to one of four possible alarm channels concerning
the following criteria:
If you do not want to use an alarm with the table please
activate not specified.
Only one alarm (A or B) can be assigned to each alarm
channel.
An assigned alarm value overwrites the alarm value setting
of the appropriate alarm on the Output signals tab.
Other properties like normally open/close, alarm source must
be defined on the Output signals tab.
Output channel 1 and 2 are only useable in this table if
they are configured as digital on the Output signals tab.

CTGEN-MA-E2005-08-B

46

Emissivity calculation:
If the current object temperature is the only value known to you, you may
determine the emissivity as follows:
Set the Emissivity mode to Fixed Value and press the button Calculate Emissivity:

Type the known object temperature in the edit box

Required temperature. Press the button Acquire data and
calculate emissivity.
The field Current Temperature should display the object
temperature and the field Emissivity the calculated
emissivity. Press the OK button the window will be
closed and the emissivity value transferred.

Transmissivity adjustment:
In this edit box you can enter a value for transmissivity (e.g. if a protective
window is used or if the CF-lens is mounted).

Ambient temperature compensation:

In dependence on the emissivity value a certain amount of ambient radiation will
be reflected from the object surface. To compensate this impact, the CT Connect
CTGEN-MA-E2005-08-B

47

software provides the feature Ambient control (middle of the window Signal
processing):
internal (Head):
The ambient temperature will be taken from the headinternal Pt1000 probe (factory default setting).
external:
The ambient temperature will be determined by a voltage on
the functional input-pin F3
(0 10 V -40 900 C; range scalable). With an external
probe or with a second CT a real-time
ambient temperature
compensation can be realized.
fixed value: In the edit box Value a fixed value can be entered (if the
ambient radiation is constant).
Especially if there is a big
difference between object and head
temperature the use of Ambient
t l ith
t
l i
t
Post processing:
The post processing supplies some functions to process data after the basic
temperature calculation. The following table shows these functions:
Modus
Off
Averaging
Peak hold
Valley hold
Advanced peak
hold
Advanced valley
hold

Average Time

Hold Time

X
X
X
X

X
X

Threshold

Hysterese

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Tab. 6-1: Post processing modes and the used parameters

With the menu item Measuring/

Signal Processing Monitor you can
open a utility to monitor the
behavior of the signal post
processing.
It always shows the Current
Temperature (w/o post processing)
and the Process Temperature (with

If the post processing mode is Off

no post processing will be done.
Averaging:
In the mode Averaging a plain arithmetic algorithm will be performed to smoothen
the signal. The Avg. time is the time constant. This function can be combined with
all other post processing functions.
Peak hold:
In the mode Peak hold the CT unit is waiting for descending signals. If the signal
descends the algorithm maintains the previous signal peak for the specified hold
time.
CTGEN-MA-E2005-08-B

49

Signal with Post processing

Object temperature (without Post processing)

Fig. 6-7: Signal graph with Peak hold (left) and Valley hold (right)/ Hold time = 3 s

Valley hold:
In the mode Valley Hold the CT unit waits for ascending signals. If the signal
ascends the algorithm maintains the previous signal valley (minimum) for the
specified hold time.

Advanced Peak hold:

In the mode Advanced Peak Hold the CT unit waits for local peak values. The signal
must drop below the Threshold value to detect the next peak (which must be
CTGEN-MA-E2005-08-B

50

threshold). Furthermore, the Hysterese causes to only accept a new peak, if the
signal descends by the value of the hysterese.

Fig. 6-8: Signal graph with Advanced Peak hold: Threshold = 20 C (left)/ Threshold = 25 C
and Hysterese = 12 C (right)

Advanced Valley hold:

The mode Advanced Valley hold is the inverted function of Advanced Peak hold. The
CT unit waits for local minima. The signal must exceed the Threshold value to
detect the next valley (which must be threshold). Furthermore, the Hysterese
causes to only accept a new valley, if the signal ascends by the value of the
hysterese (Fig. 6-9 right).

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Fig. 6-9: Signal graph with Advanced Valley hold: Threshold = 30 C (left)/ Threshold = 25
C and Hysterese = 12 C (right)

6.4.2 Output Signals

If the setup dialog is open, the output- and alarm settings can be done in the
window Output signals.

CTGEN-MA-E2005-08-B

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Overview Alarm functions:

Output channel 1 and 2 (if set
digital)
Visual Alarms (= color of LCD-

Fig. 6-10: Setup dialog window Output signals

Output channel 1:
The output channel 1 is used for the object temperature. To define it as alarm
output, activate digital. With the selection Normally open/ closed you can define
the output as High- or Low-alarm.

Edit the threshold in the menu box Alarm to set the trigger of the alarm.
The source of output channel 1 can not be chosen it is always TObj (object
temperature).
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53

The following analog outputs (if analog is activated) are available:

0-5 V
0-10 V
0/4-20 mA
Thermocouple (TCJ or TCK)
After you have selected the desired output (edit box: Output mode), you can adjust
the temperature range of the CT by pushing the button Adjust output slope.

Fig. 6-11: Example for setting of the ranges

In the example (Fig. 7-11) the measurement range was defined as follows:
10 C = 2 V
CTGEN-MA-E2005-08-B

54

 330 C = 7 V
After you have entered the values push the Check button. The result will be
visualized in the diagram. You may additionally check the ranges in the field
Limits (temperature and output signal).

Output channel 2:
This channel is normally used as output for the head temperature (THead), which
equals the ambient temperature. The source can also be set to TObj or TBox. The
channel can also be used as alarm channel (same procedure as output channel 1).
The Range can be switched between 0-10 V and 0-5 V for analog mode and alarm
mode (digital) respectively.

Alarm 1 and 2 (Visual Alarms):

The alarms, set under Visual alarms are available via the optional relay interface
board and as visual alarms (change of color of the LCD backlight). The selection
normally open/ close defines the alarm as High- or Low-alarm. In Source you can
choose between the signals TObj, THead and Tbox.
Both alarms will cause a color change of the LCD display:
blue: alarm 1 active
red:
alarm 2 active
green: no alarm active

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55

In Appendix A you will find a table with all possible alarm combinations. The
standard mode for the visualization of the alarms can be reset with the button
Standard visual alarms.
The button Blue backlight is a presetting to achieve a permanent blue backlight on
the LCD display. Pushing this button will cause the following:
both alarms will be set to normally open,
alarm limits will be set to the lower and upper measurement range limit of
the connected CT,
Now alarm 1 is permanent active [blue] and alarm 2 is permanent inactive.
All alarms (alarm 1, alarm 2, output
channel 1 and 2 if used as alarm output)
have a fixed hysterese of 2 K.

6.4.3 Advanced Settings

If the setup dialog is open, the window Advanced settings allows the setting of
the following parameters:
Head-parameters:
This function allows the exchange of sensing heads. The 12-digit code contains the
calibration data of the head. For a correct temperature measurement make sure to
enter the code (labeled on each head cable) into the electronics without mistakes.
The factory setting includes the entering of the code a change of this setting
(button Change Head Parameter) is only necessary, if the head will be exchanged.

CTGEN-MA-E2005-08-B

56

Fig. 6-12: Advanced settings Change of the head parameters

Unit adjustment:
For certain applications or under certain circumstances a temperature offset or a
change of the gain for the temperature curve may be useful. The factory default
settings for Offset and Gain are:
Offset:
0,0 K
Gain: 1,000

Multidrop-address:

CTGEN-MA-E2005-08-B

57

In combination with the RS485 interface you can build a network of several CTs
(max. 32 sensors).
For the digital communication each sensor must have its own address.

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7 Principle of Operation
Basics of Infrared Thermometry:
Depending on the temperature each object emits a certain amount of infrared
radiation. A change in the temperature of the object is accompanied by a change in
the intensity of the radiation. For the measurement of thermal radiation
infrared thermometry uses a wave-length ranging between 1 and 20 m.
The intensity of the emitted radiation depends on the material. This material
contingent constant is described with the help of the emissivity which is a known
value for most materials (see enclosed table emissivity).
Infrared thermometers are optoelectronic sensors. They calculate the surface
temperature on the basis of the emitted infrared radiation from an object. The
most important feature of infrared thermometers is that they enable the user to
measure objects contactless. Consequently, these products help to measure the
temperature of inaccessible or moving objects without difficulties. Infrared
thermometers basically consist of the following components:
- lens
- spectral filter
- detector
- electronics (amplifier/ linearization/ signal processing)
The specifications of the lens decisively determine the optical path of the
infrared thermometer, which is characterized by the ratio Distance to Spot size.

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59

The spectral filter selects the wavelength range, which is relevant for the
temperature measurement. The detector in cooperation with the processing
electronics transforms the emitted infrared radiation into electrical signals.

8 Emissivity
Finding the Emissivity of an Object:
The intensity of infrared radiation, which is emitted by each body, depends on the
temperature as well as on the radiation features of the surface material of the
measuring object. The emissivity ( Epsilon) is used as a material constant
factor to describe the ability of the body to emit infrared energy. It can range
between 0 and 100 %. A blackbody is the ideal radiation source with an
emissivity of 1,0 whereas a mirror shows an emissivity of 0,1.
If the emissivity chosen is too high, the infrared thermometer may display a
temperature value which is much lower than the real temperature assuming the
measuring object is warmer than its surroundings. A low emissivity (reflective
surfaces) carries the risk of inaccurate measuring results by interfering infrared
radiation emitted by background objects (flames, heating systems, chamottes). To
minimize measuring errors in such cases, the installation should be performed very
carefully and the sensor should be protected against reflecting radiation sources.

To determine an unknown emissivity use the following procedure:

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First, determine the actual temperature of the measuring object with a

thermocouple or contact sensor. Second, measure the temperature with the
infrared thermometer and modify the emissivity until the displayed result
corresponds to the actual temperature.
If you monitor temperatures of up to 260 C you may place a special plastic
sticker onto the measuring object, which covers it completely. Now set the
emissivity to 0,95 and take the temperature of the sticker. Afterwards,
determine the temperature of the adjacent area on the measuring object and
adjust the emissivity according to the value of the temperature of the
sticker.
Cove a part of the surface of the measuring object with a black, flat paint
with an emissivity of 0,98. Adjust the emissivity of your infrared
thermometer to 0,98 and take the temperature of the colored surface.
Afterwards, determine the temperature of a directly adjacent area and modify
the emissivity until the measured value corresponds to the temperature of
the colored surface.

Characteristic Emissivities:
In case none of the methods mentioned above help to determine the emissivity you
may use the emissivity table in Appendix B. These are average values, only. The
actual emissivity of a material depends on the following factors:
- temperature
- measuring angle
- geometry of the surface
- thickness of the material
- constitution of the surface (polished, oxidized, rough, sandblast)
CTGEN-MA-E2005-08-B

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spectral range of the measurement

transmissivity (e.g. with thin films)

9 Maintenance
In case of problems or questions which may arise when you use the CT, please
contact our service department. The customer service staff will support you with
questions concerning the optimization of the work with the infrared thermometer,
calibration procedures or customer related adjustments of the product and with
repairs.
The lens of the head can be cleaned with a soft, humid tissue. Never use cleaning
compounds which contain solvents (neither for the head, nor for the cable and
electronic box).

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Appendix A Visual Alarms

Alarm 1

Alarm 2

Alarm
status

Blue
LED

Green
LED

Red
LED

Preset

Standard visual
alarms
Standard visual
alarms
Standard visual
alarms
Standard visual
alarms

normall
y
Close

temperatu
re
Below

normall
y
Open

temperatu
re
Below

On

Off

Off

Close

Below

Open

Above

On

Off

On

Close

Above

Open

Below

Off

On

Off

Close

Above

Open

Above

Off

Off

On

Close

Below

Close

Below

On

Off

On

Close

Below

Close

Above

On

Off

Off

Close

Above

Close

Below

Off

Off

On

Close

Above

Close

Above

Off

On

Off

Open

Below

Open

Below

Off

On

Off

Open

Below

Open

Above

Off

Off

On

Open

Above

Open

Below

On

Off

Off

Open

Above

Open

Above

On

Off

On

Open

Below

Close

Below

Off

Off

On

Open

Below

Close

Above

Off

On

Off

Open

Above

Close

Below

On

Off

On

Open

Above

Close

Above

On

Off

Off

Blue backlight

The first four lines represent the standard mode for visualizing the alarms (in
connection with TObj as source) on the LCD-display (alarm 1: Low-alarm [blue];
alarm 2: High-alarm [red]). If no alarm is activated the display color is green.
CTGEN-MA-E2005-08-B

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Appendix B Emissivity Tables

METALS
Material
Aluminium
non oxidized
oxidized
Leg. A3003, oxidized
roughened
polished
Lead
polished
rough
oxidized
Chrome
Iron
oxidized
non oxidized
molten
Iron, casted
oxidized
non oxidized
molten
Iron, forged
blunt
Gold
Magnesium
Haynes

Emissivity
1,0 m
0,1-0,2

1,6 m
0,02-0,2

5,1 m
0,02-0,2

8 14 m
0,02-0,1

0,4
0,4
0,2-0,6
0,02-0,1
0,05-0,2

0,2-0,4
0,4
0,1-0,4
0,02-0,1
0,05-0,2

0,2-0,4
0,3
0,1-0,3
0,02-0,1
0,05-0,1

0,4
0,7-0,9

0,6
0,3-0,7
0,4
0,5-0,9

0,4
0,2-0,7
0,03-0,3
0,6-0,9

0,4
0,2-0,6
0,02-0,2
0,5-0,9

0,35
0,35
0,9

0,1-0,3
0,4-0,6
0,7-0,9

0,05-0,25

0,05-0,2

0,65-0,95

0,6-0,95

0,35
0,35
0,9

0,3
0,3-0,4
0,9

0,25
0,2-0,3
0,9

0,2
0,2-0,3
0,9

0,3
0,3-0,8
0,5-0,9

0,01-0,1
0,05-0,3
0,6-0,9

0,01-0,1
0,03-0,15
0,3-0,8

0,01-0,1
0,02-0,1
0,3-0,8

0,4
0,2-0,8
0,1-0,2
0,35
0,65

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alloy
Inconel
oxidized
sandblast
electro polished
Copper
polished
Material
roughened
oxidized
Brass
polished
rough
oxidized
Molybdenum
oxidized
non oxidized
Monel (Ni-Cu)
Nickel
oxidized
electrolytic
Platinum
black
Mercury
Silver
Steel
cold-rolled
heavy plate
polished plate
molten
oxidized

0,4-0,9

0,6-0,9

0,6-0,9

0,7-0,95

0,3-0,4
0,2-0,5
0,05

0,3-0,6
0,25
0,03

0,3-0,6
0,15
0,03

0,3-0,6
0,15
0,03

Emissivity
1,0 m
0,05-0,2
0,2-0,8
0,35

1,6 m
0,05-0,2
0,2-0,9
0,01-0,05

5,1 m
0,05-0,15
0,5-0,8
0,01-0,05

8 14 m
0,05-0,1
0,4-0,8
0,01-0,05

0,65
0,6
0,5-0,9

0,4
0,6
0,4-0,9

0,3
0,5
0,3-0,7

0,3
0,5
0,2-0,6

0,25-0,35
0,3
0,8-0,9

0,1-0,3
0,2-0,6
0,4-0,7

0,1-0,15
0,1-0,5
0,3-0,6

0,1
0,1-0,14
0,2-0,5

0,2-0,4

0,1-0,3
0,95

0,1-0,15
0,9

0,05-0,15
0,9

0,04
0,8-0,9

0,05-0,15
0,02
0,8-0,9

0,05-0,15
0,02
0,8-0,9

0,05-0,15
0,02
0,7-0,9

0,35
0,35
0,8-0,9

0,25
0,25-0,4
0,8-0,9

0,5-0,7
0,1
0,1-0,2
0,7-0,9

0,4-0,6
0,1
0,7-0,9

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rustless
Titanium
polished
oxidized
Wolfram
polished
Zinc
oxidized
polished
Tin
non oxidized

0,35
0,5-0,75

0,2-0,9
0,3-0,5

0,15-0,8
0,1-0,3

0,1-0,8
0,05-0,2

0,35-0,4

0,6-0,8
0,1-0,3

0,5-0,7
0,05-0,25

0,5-0,6
0,03-0,1

0,6

0,15

0,1

0,1

0,5
0,25

0,05
0,1-0,3

0,03
0,05

0,02
0,05

NON METALS
Material
Asbestos
Asphalt
Basalt
Concrete
Iron
Soil
Paint (non alkaline)
Gypsum
Glass
plate
melt
Rubber
Wood, natural
Limestone
Carborundum

Emissivity
1,0 m
0,9

2,2 m
0,8

0,65

0,9

5,1 m
0,9
0,95
0,7
0,9

0,2

0,4-0,97
0,98

8 14 m
0,95
0,95
0,7
0,95
0,98
0,9-0,98
0,9-0,95
0,8-0,95
0,85

0,9
0,9
0,9-0,95
0,4-0,98
0,9

0,95
0,9-0,95
0,98
0,9

0,4-0,9

0,95

CTGEN-MA-E2005-08-B

66

Ceramic
Grit
Carbon
non oxidized
graphite
Plastic transparent
>0,5 m
Paper (any color)
Sand
Snow
Fabric
Water

0,4

0,8-0,95
0,8-0,9
0,8-0,9

0,8-0,95
0,95
0,8-0,9

0,95
0,95
0,8-0,9

0,7-0,9
0,95

0,7-0,8
0,95

0,95
0,9

0,95
0,9
0,9
0,95
0,93

0,95

CTGEN-MA-E2005-08-B

67