PI 640i CM

Ensuring the uninterrupted operation of distribution grids is essential for maintaining industrial assets and infrastructure. Energy companies face immense pressure from aging infrastructure and increasing demand for affordable energy, which strain substations and grids, heightening the risk of costly and disruptive brownouts and blackouts. Effective monitoring solutions for retrofit installations are necessary to prevent utility failures, enhance capacity, maintain reliability, and manage costs.

Understanding how heat is distributed within substation components is critical. Electrical resistance causes these components to deteriorate over time, sometimes rapidly. When electrical current flows through these degraded parts, it generates heat. Thermal imaging technology can visualize these issues, enabling early detection of potential failures. However, utilities increasingly find that handheld infrared scanning is inadequate for continuously monitoring critical substation components. Deploying thermographers in every substation, especially during peak loads when issues are most likely to surface, is impractical.

Thermal imaging cameras, as part of a preventive maintenance strategy, can detect problems in electrical utilities before they escalate, thereby controlling costs. Failures in critical substations, such as overheating transformers, can be catastrophic. Fixed-install infrared cameras provide round-the-clock monitoring of crucial components, identifying signs of wear or potential failure through temperature changes. Previously, the widespread use of infrared cameras was hindered by high costs.

Another application is early fire detection in outdoor environments such as paper mills, sawmills, biomass power plants, scrap metal facilities, and waste recycling plants, where the risk of fire is particularly high. Annual financial losses from fires in these settings are significant due to inadequate early detection systems. Infrared cameras are highly effective for monitoring vast areas, providing early warnings that are essential for implementing fire emergency plans.

Industrial settings often require equipment monitoring and early fire detection in extreme temperatures. For example, conveyor systems transporting coal or wood chips in cold climates face the risk of overheating bearings, which can jeopardize operations and increase fire hazards. In wood chip processing, friction can generate sparks, igniting fires in wood pulp operations. Additionally, large piles of decomposing mulch or biomass can spontaneously combust, posing severe risks to nearby factories or residential areas.

The PI 640i CM package meets the need for continuous monitoring in these demanding environments. This package includes all necessary components for effective equipment and fire hazard monitoring, providing early alarms when overheating or fire risks are detected. The package comprises an infrared camera, an outdoor enclosure with a heater and fan, a front window air purge, a high-definition video camera, and a USB Gigabit Server for long-distance video transmission.

The PI 640i CM Package features a PI 640i infrared imager, a visible camera, and the USB Server HT, all pre-assembled in an outdoor housing with a wall mount. The redesigned Optris housing, equipped with a built-in heater and fan, allows operation at temperatures ranging from -40 °C to 50 °C (-40 °F to 122 °F) without compromising measurement accuracy.

With a frame rate of 32 Hz and a resolution of 640 x 480 pixels, the PI 640i can detect even the smallest temperature differences, thanks to its 40 mK thermal resolution. The HD VIS camera, offering a resolution of 1280 x 720 pixels, a 30 Hz frame rate, and a 65 field of view, enhances combined thermal and visual condition monitoring and early fire detection.
The PI 640i CM Package delivers substantial savings compared to custom installations by integrating these elements into a single, cost-effective package. It enhances fire safety by enabling the monitoring of more areas from multiple locations. Its affordability supports comprehensive area coverage and more effective early fire detection solutions.

The PI 640i CM Package’s advanced detection strategy pinpoints hot spots using every pixel in the high-resolution 640 x 480 infrared camera. The PI 640i’s high-speed processors continuously scan the field of view for temperatures exceeding set thresholds. The infrared camera’s process interface port can send alarm signals to external control devices or sprinkler systems. Additional modules can be added to set fire alarm temperatures across different camera views, further enhancing the system’s ability to detect and respond to potential fire hazards.

This system also supports transmitting high-resolution thermal and video images to a control room PC equipped with PIX Connect Software. The software can display multiple images from various locations, enabling real-time thermal video analysis to identify false positives, such as exhaust pipes or solar reflections, preventing unnecessary fire control activations or evacuations.

Engineered and manufactured in Germany, the PI 640i CM Package is a comprehensive and affordable early fire detection solution. Global engineering support ensures effective installation and operation in various industrial settings. The PI 640i CM Package’s reliability, affordability, and advanced features make it an ideal choice for utilities seeking to enhance their continuous long-term monitoring capabilities.

Thermography software optris PIX Connect is included and license-free.All infrared cameras are delivered with the thermography software optris PIX Connect, developed specifically for the extensive documentation and analysis of thermal images. The Windows-based PIX Connect software enables users to tailor the infrared cameras to meet specific requirements. It analyses live and recorded temperature data and triggers alarm signals for process integration.The key to leveraging the Optris infrared camera is a correct configuration. This includes detailed device-specific configurations such as frame rate, measurement range adjustments, external communication settings, and USB/Ethernet configurations. Moreover, PIX Connect facilitates firmware updates and the download of configuration files over the Internet. PIX Connect Optris offers several different SDKs for our Xi and PI thermal imaging cameras. Depending on the operating platform, the infrared camera, the coding language, and the hardware platform, different software interfaces can be utilized: SDK The Optris IRmobile allows users to set up and commission an Optris infrared pyrometer or infrared camera with an Android smartphone or tablet. This tool becomes handy for commissioning and aligning the infrared camera’s field of view or adjusting the configuration. The app analyzes the connected infrared camera’s live infrared image stream with auto hot and cold spot detection. For pyrometers, a temperature-time diagram or the video signal is displayed. This app works on most Android devices running 5.0+ with a USB port supporting USB-OTG (On The Go). Google Play

Is the PI 640i CM export controlled?

The PI 640i’s high resolution qualifies it for export control in the EU and US markets. Check with local compliance authorities for procedures to manage exports outside the U.S. or European markets.

Can I use the PI 640i CM to measure metal temperatures?

Most metal targets have low emissivity and tend to reflect heat temperatures from any area incident upon the target. IR cameras with long wave detectors like the PI 640i are particularly vulnerable to this low emissivity effect. For this reason, it is best to use a short wavelength camera like the Optris PI 1M (link here) when measuring metal targets unless it is possible to coat or paint the metal part to improve surface emissivity. Emissivity can also be improved on metal surfaces when rough textured or when there are holes or crevices where measurements can be made inside the cavity.

Where is the PI 640i CM made, and do its memory components come from outside the U.S. or the European Union?

The PI 640i CM is designed, manufactured, and calibrated in Berlin, Germany. Some electronic components may be sourced from outside the EU or the US. Still, it is important to note that the PI 640i does not store any thermal images or temperature values in volatile memory. The PI 640i only stores full thermal images, thermal video (.ravi files), and temperature values in the customer PC hosting the PIX Connect software necessary to operate the camera. The camera uses memory components inside the camera electronics, which may be sourced outside the EU or the US to store a reference picture (also called dark picture) of the non-uniformity correction paddle or flag and some reference temperatures used to correct temperature drift. All these memory elements are deleted when the power to the camera head is terminated.

Can the PI 640i CM operate without a connection to a computer?

The PI 640i must be connected to a PC loaded with Optris PIX Connect software to produce thermal images and remote temperature measurements. By eliminating processing in the camera head and leveraging PC processing power, the camera head size can be reduced, and the ambient operating temperature can be increased. Autonomous operation (without the use of a PC) is supported in Optris Xi-series infrared cameras.

Can the PI 640i send temperature information from spots or areas to my PLC?

The PI 640i can send temperature information or temperature alarms from the Process Interface connection on the back of the camera. A cable with integrated electronics and a terminal block is included with the camera. It can be programmed in PIX Connect software as an Analog Input (AI) and Digital Input (DI) to control the camera or as an Analog Output (AO) to control the process. The signal level is always 0-10 V (DI = 24 V). An optional industrial process interface is also available, delivering up to three independent temperature values or alarms to a user-supplied PLC. USB-RS485 adapters are available for applications with output requirements for more than three areas.

Is temperature measurement important for infrared camera-based early fire detection systems?

Yes, particularly when automatic alarming is required. In some markets, accreditation bodies are establishing requirements for temperature measurement capabilities that accurately signal temperature increases of 20 °C (68 °F).

Can I use a thermal security imager and alarm on the hot spots?

While it may be easy for thermal imagers developed for security applications to identify a hot spot on an image, it can be more challenging for cameras not designed to measure temperature to deliver alarms on a series of targets with unique temperature alarm thresholds. Because some potential ignition areas will get warm before they ignite, it may be prudent to establish lower alarm or “pre-alarm” temperature thresholds in some cases. A camera designed and calibrated to deliver accurate temperature measurements on ambient temperature targets may be a better solution when even subtle temperature increases can signal a potential fire threat.

Is infrared camera resolution important?

Almost always. Most infrared cameras can be programmed to deliver an alarm when a pixel or grouping of pixels has exceeded a user-set threshold. If the target to be monitored (e.g., a small wood chip) is very hot but comprises only a portion of the thermal imager pixel, the camera will report a temperature measurement that is the average of the wood chip temperature and the surrounding ambient temperatures.

When will a lower resolution and more affordable infrared camera work for a given application?

When the spot size to be monitored is the same size as a pixel or group of pixels, an example may be a measurement on the side of a large furnace, where it is important to understand the average temperature but not necessary to measure a small spot on the furnace wall.

How do I know the pixel is too large for an accurate measurement?

Infrared camera suppliers who make thermal imagers for temperature measurement will typically host a spot size calculator on their website. The calculator should present the geometric size of a single pixel (IFOV) when the camera, the optics, and the distance from the target are input into the optics calculator.

Will a single pixel or IFOV always be large enough for an IR camera to deliver a measurement consistent with the camera specification?

No. While it is possible to detect a temperature increase with a single pixel, all infrared cameras need more than one pixel to measure temperatures accurately. A 3 x 3-pixel matrix has been used as a rule of thumb to define the pixel coverage necessary for a measurement compliant with specified camera accuracy. However, this can vary significantly depending on the camera and the infrared detector pitch (size). To determine the true Measurement Field of View (MFOV), use the Optris Optics Calculator or check with the manufacturer to determine MFOV.

I have used handheld cameras to measure the temperatures of important mechanical and electrical equipment in my facility. Can I use the PI 640i CM system for these applications?

Yes. Many facilities use fixed-install infrared cameras to monitor critical electrical and mechanical systems, reducing manpower and providing more comprehensive temperature data. Infrared temperature measurements on transformers, fuses, cable trays, rotating equipment, power cables, motor control centers, and switch gear are routinely measured with infrared cameras. They can be measured with properly calibrated fixed-install infrared cameras. In the U.S., the NFPA 70B-2023 Standard for Electrical Maintenance covers important details about using infrared equipment to monitor these systems. It is an excellent guide for any company or facility interested in establishing an internal standard for electrical equipment maintenance. The document references the importance of properly calibrated infrared camera equipment and the use of comparative thermography and small temperature rise to indicate equipment health or future fire hazards. The PI 640i CM is developed and produced in Germany and is calibrated according to government standards. Calibration certificates are available for customers requiring traceability on calibration standards.

Can I connect Optris Infrared cameras to the Video Management System I use for my security cameras?

The signal produced by the camera and converted to ethernet in the USB converter is not formatted for display on standard video management system.

• Process imager PI 640i
• HD video camera
• Outdoor protective housing
• USB Server Gigabit HT
• Air purge collar
• Software package optris PIX Connect
• Outdoor Protective Housing Manual