Modline 5 ®

Series 52, 56, 5G and

5R Sensors
Infrared Thermometer

Operating Instructions

Rev. L6 Feb 2017

60401
 Contacts

Fluke Process Instruments


Americas
Santa Cruz, CA USA
Tel: +1 800 227 8074 (USA and Canada, only)
+1 831 458 3900
[email protected]

EMEA
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Tel: +49 30 478 0080
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China
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Tel: +86 10 6438 4691
[email protected]

Worldwide Service
Fluke Process Instruments offers services,
including repair and calibration. For more
information, contact your local office.

www.flukeprocessinstruments.com

© Fluke Process Instruments

Specifications subject to change without notice.
 Warranty
IRCON, Inc. warrants equipment manufactured by it to be free from defects in materials and
workmanship for a period of one year from the date of shipment by IRCON. Customer-paid repairs are
warranted for 90 days from date of shipment. If within such period any such equipment shall be proved
to IRCON’s satisfaction to be so defective, such equipment shall be repaired or replaced at IRCON’s
option, provided the defective equipment is returned to IRCON, transportation charges prepaid by
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This warranty shall not apply (a) to equipment not manufactured by IRCON, (b) to equipment which
shall have been repaired or altered by others than IRCON so as, in its judgment, to affect the same
adversely, or (c) to equipment which shall have been subject to negligence, accident or damage by
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actually extended to IRCON by its supplier (the manufacturer). The foregoing warranties do not cover
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to any other obligations or liabilities whatsoever with respect to equipment manufactured by IRCON
or services rendered by IRCON.
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AND IMPLIED WARRANTIES EXCEPT WARRANTIES OF TITLE, INCLUDING BUT NOT
LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
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IRCON Limited Use Software License Agreement and Limited

Warranty
Modline 5 ModView Configuration Software Distributed with Ircon Modline 5 Sensors
IMPORTANT! THE ENCLOSED SOFTWARE IS LICENSED ONLY ON THE CONDITION THAT THE
LICENSEE (REFERRED TO IN THIS AGREEMENT AS "YOU") AGREES WITH IRCON, INC.
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TO INSTALL AND USE THIS SOFTWARE.
LIMITED USE LICENSE AGREEMENT
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LIMITED WARRANTY
Limited Warranty. Ircon warrants that (1) the Software will perform substantially in accordance with
the accompanying written materials, and (2) any media and/or hardware accompanying the Software
will be free from defects in materials and workmanship under normal use and service. Your Limited
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reason, please write: Ircon, Inc., Customer Service, 1201 Shaffer Road, Building 2, Santa Cruz, CA 95060-
5731.
 Content
1 SAFETY INSTRUCTIONS ........................................................................................................................... 11
2 PRODUCT DESCRIPTION.......................................................................................................................... 14
2.1 Modline 5 Sensors, Cable and Interface Accessories ................................................................................. 14
2.1.1 Preliminary Inspection ....................................................................................................................... 14
2.2 Modline 5 Description ................................................................................................................................ 15
2.2.1 Sensor Standard Features ................................................................................................................... 15
2.2.2 Optional Sensor Features ................................................................................................................... 15
2.3 Model Configuration and Required Selections ........................................................................................... 16
2.3.1 Model Configuration .......................................................................................................................... 16
2.4 Modline 5 Model Number Summary .......................................................................................................... 17
2.5 Accessories ................................................................................................................................................. 18
2.5.1 Interconnecting Cable – Required Accessory ..................................................................................... 18
2.5.2 Power and Interface Accessories ......................................................................................................... 19
2.5.3 Installation Accessories ...................................................................................................................... 19
2.6 Specifications ............................................................................................................................................. 20
2.6.1 Sensor Specifications .......................................................................................................................... 20
2.6.2 Accessory Specifications ..................................................................................................................... 21
3 SENSOR INSTALLATION .......................................................................................................................... 22
3.1 Mechanical Installation............................................................................................................................... 22
3.2 Sensors........................................................................................................................................................ 22
3.2.1 Sensor Parts ........................................................................................................................................ 23
3.3 Sighting Methods........................................................................................................................................ 23
3.3.1 Sighting and Focusing ........................................................................................................................ 23
3.3.2 Visual Sight ........................................................................................................................................ 23
3.3.3 Laser Sight .......................................................................................................................................... 24
3.4 Sensor Optical Characteristics .................................................................................................................... 26
3.4.1 Optical Resolution .............................................................................................................................. 26
3.4.2 Lens Focusing Ranges and Optical Resolution Factor ....................................................................... 26
3.4.3 Table of Model and Lens Type Combinations with Focusing Ranges ................................................ 27
3.4.4 Spot Size and Viewing Distance ......................................................................................................... 27
3.5 Measuring Temperature with Brightness and Ratio Sensors ...................................................................... 29
3.5.1 Resolving Targets with Brightness Sensors ....................................................................................... 29
3.5.2 Obstructions in Cone of Vision .......................................................................................................... 29
3.5.3 Resolving Targets with Two Color Ratio Sensors .............................................................................. 29
3.5.4 Signal Reduction ................................................................................................................................ 30
3.5.5 Summary ............................................................................................................................................ 31
3.6 Sensor Installation Planning ....................................................................................................................... 31
3.7 Sensor Mechanical Installation ................................................................................................................... 32
3.7.1 Installation Accessories ...................................................................................................................... 32
3.7.2 Sensor Dimensions ............................................................................................................................. 33
3.7.3 General Installation Requirements ..................................................................................................... 34
3.8 DWD Installation Requirements................................................................................................................. 34
3.9 Modline 5 Mounting, Cooling and Air Purging Accessories ...................................................................... 35
3.9.1 UAA – Universal Adapter Accessory Description and Dimensions.................................................. 35
3.9.2 RAM – Right Angle Mount Description and Dimensions ................................................................ 37
3.9.3 APA – Air Purge Accessory Description and Dimensions ................................................................ 39
3.9.4 MFL – Mounting Flange Large Description and Dimensions ........................................................... 40
 3.9.5 MFS – Mounting Flange Small Description and Dimensions ........................................................... 42
3.9.6 WJA – Water Jacket Accessory Description and Dimensions............................................................. 44
3.9.6.1 WJA Water Cooling Requirements ........................................................................................... 45
3.9.6.2 WJA Air Cooling Requirements. ............................................................................................... 46
3.9.6.3 Sensor Temperature Alarm ....................................................................................................... 46
3.9.7 BMA – Base Mount Accessory Description and Dimensions ............................................................ 47
3.9.8 ESA – Extension Sleeve Adapter Description and Dimensions ......................................................... 48
3.10 Accessory Combinations with Break-out Drawings ................................................................................. 50
3.10.1 Recommended Accessory Groupings ................................................................................................ 50
3.11 Installation Drawings and Illustrations...................................................................................................... 54
3.11.1 Installation Drawing for the UAA – Universal Adapter for Tripod or Custom Mounting ............. 54
3.11.2 Installation Drawing for the RAM – Right Angle Mount ............................................................... 55
3.11.3 Installation Drawing using the WJA – Water Jacket Accessory with Flange Mounts .................... 57
3.11.4 Installation Drawing using the WJA Water Jacket Accessory with the Base Mount Adapter ......... 58
3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling).............................................................. 60
3.12.1 M5WJ5 – Mounting Kit ................................................................................................................... 60
3.13 Sensor Installation Checklist ..................................................................................................................... 62
4 SENSOR WIRING .......................................................................................................................................... 64
4.1 Modline 5 Components ............................................................................................................................... 64
4.2 Modline 5 Sensor System Interfacing ......................................................................................................... 64
4.3 Modline 5 Sensor Cable .............................................................................................................................. 65
4.3.1 Sensor Interconnecting Cable.............................................................................................................. 65
4.4 TSP Terminal Strip Plate ............................................................................................................................ 65
4.4.1 Dimensions and Installation ............................................................................................................... 65
4.5 Sensor Interconnecting Cable Preparation .................................................................................................. 66
4.5.1 Cable Preparation ................................................................................................................................ 66
4.5.2 Interconnecting Cable Assembly Continuity Check ........................................................................... 67
4.6 Terminal Strip Plate – Sensor Interconnecting Cable Installation............................................................... 68
4.7 Connecting Device Cables to Terminal Strip Plate ..................................................................................... 68
4.7.1 Recommended Cable Types ................................................................................................................. 68
4.7.2 Grounding and Shielding .................................................................................................................... 69
4.7.3 System Connections ............................................................................................................................ 69
4.7.4 RS-485 Digital Communications ........................................................................................................ 69
4.7.5 Analog Output Temperature Signal ................................................................................................... 69
4.7.6 Converting the Analog Output from a mA output to a 10 Volt Output ............................................ 70
4.7.7 Current Input for Remote Emissivity, E-Slope or Laser Operation.................................................... 70
4.7.8 Current Input Terminal Connections for Remote Laser ..................................................................... 71
4.7.9 Peak/Hold Switch for Remote Peak Picker Reset, Track and Hold or Laser Operation. ..................... 72
4.7.10 Sensor Alarm Relay Contacts ........................................................................................................... 72
4.8 Selection of a Power Supply for Sensors used with TSP Terminal Strip Plates ......................................... 73
4.8.1 TSP Terminal Strip Plate DC Power Supply Connections ................................................................ 75
4.8.2 Power Supply Common Ground Connection...................................................................................... 75
4.9 RS-485 Multi-Drop Network Power Supply and System Wiring ............................................................... 75
4.9.1 Computer Communications Requirements ......................................................................................... 76
4.9.2 TSP Terminal Strip Plates Multi-drop Wiring .................................................................................. 77
4.10 Sensor and Cable Connection ................................................................................................................... 78
4.10.1 Cable Plug and Sensor Receptacle ..................................................................................................... 78
4.11 System Grounding and Shielding .............................................................................................................. 79
4.11.1 Terminal Strip Plate Diagram .......................................................................................................... 79
4.12 Summary Caution and Warning ................................................................................................................ 80
5 OPERATION ................................................................................................................................................... 82
5.1 Sensor Rear Panel Setup and Operation ..................................................................................................... 82
5.1.1 Introduction ........................................................................................................................................ 82
5.2 Rear Panel Keyboard, Displays and Sight and Laser Aiming .................................................................... 82
5.2.1 Description ......................................................................................................................................... 82
5.3 Navigation and Menus ................................................................................................................................ 83
5.3.1 Enter and Up / Down Arrow Pushbuttons ........................................................................................ 83
5.4 Main Menus ................................................................................................................................................ 83
5.5 Warm-up and Initial Setup.......................................................................................................................... 85
5.5.1 Series 5R, 5G, 52 Power On and Warm-up ....................................................................................... 85
5.5.2 Series 56 Models Power On and Warm-up ........................................................................................ 85
5.5.3 Initial Rear Panel Display .................................................................................................................. 85
5.5.4 Initial Sensor Setup ............................................................................................................................ 85
5.6 ENGR – Setup of Engineering Functions ................................................................................................... 86
5.6.1 LOCK – Panel Lock Security .............................................................................................................. 86
5.6.2 MODL – Sensor Model Number ........................................................................................................ 86
5.6.3 F/C – Selection of Fahrenheit or Celsius Indication (°F or °C) .......................................................... 86
5.6.4 CHK – Initiate Manual System Check ............................................................................................... 87
5.6.5 HOUR– Automatic System Check ..................................................................................................... 88
5.6.6 CHK – Manual System Calibration for 56 Models ............................................................................ 89
5.6.7 HOUR– Automatic Calibration Check for 56 Models........................................................................ 91
5.6.8 WRNL – Dirty Window Detector Option Warning Level ................................................................. 92
5.6.9 VER – Sensor Firmware Version ........................................................................................................ 92
5.6.10 iALM – Selects Ratio Invalid Measurement Condition as an Alarm ............................................... 92
5.6.11 ATTN – Selects Attenuation Alarm Threshold ................................................................................ 93
5.7 AOUT – Setup of Analog Signal Output Current Range and Temperature Scaling ................................... 93
5.7.1 Fatl – Analog Output Operation for Sensor or Dirty Window Detector Malfunction Alarms ......... 94
5.7.2 A–LO – Analog Output Low Temperature Alarm............................................................................. 94
5.7.3 A–HI – Analog Output High Temperature Alarm ............................................................................ 95
5.8 COMM – Setup of RS-485 Digital Communication Configuration ........................................................... 95
5.8.1 CLCK – Communications Lock .......................................................................................................... 96
5.8.2 ADDR – Sets the Sensor Address ...................................................................................................... 96
5.8.3 BRAT – Baud Rate ............................................................................................................................. 96
5.8.4 LASR –Laser Operation (Sensor Firmware Versions 1.08 and Higher) ............................................ 96
5.9 HEAD – Setup of Sensor Operating Functions .......................................................................................... 96
5.9.1 R.T. – Response Time ......................................................................................................................... 97
5.9.2 COLR – Ratio Unit Operation Selection............................................................................................ 97
5.9.3 E-SL – Ratio Unit Two Color Operation E-Slope Adjustment .......................................................... 97
5.9.4 Remote E-Slope Current Input ........................................................................................................... 98
5.9.5 EMIS – Emissivity Adjustment for Brightness Sensors .................................................................... 98
5.9.6 Remote Emissivity Current Input ...................................................................................................... 99
5.9.7 MTCH – E-Slope or Emissivity Selection Based on Temperature Match .......................................... 99
5.9.8 SIGL – Signal Conditioning Selection ............................................................................................... 99
5.10 PSEL – Peak Picker Functions ............................................................................................................... 100
5.10.1 D.R. – Decay Rate Function........................................................................................................... 100
5.10.2 RSET – Manual Peak Picker Reset ................................................................................................. 101
5.10.3 External Switch for Remote Peak Picker Reset ............................................................................... 101
5.10.4 AUTO – Auto Peak Picker Reset.................................................................................................... 101
5.10.5 RBEL – Reset Below Temperature .................................................................................................. 101
5.10.6 DEL – Peak Picker Delay................................................................................................................ 101
 5.11 Laser Sighting Operation ........................................................................................................................ 102
5.12 Out of Range Displays and Error Codes ................................................................................................. 104
5.12.1 Summary ......................................................................................................................................... 106
6 RS-485 DIGITAL COMMUNICATIONS................................................................................................. 107
6.1 Introduction ............................................................................................................................................... 107
6.2 Basic Operation ......................................................................................................................................... 107
6.3 Sensor Rear Panel Setup for RS-485 Communication .............................................................................. 108
6.3.1 CLCK – Communications Lock ......................................................................................................... 108
6.3.2 ADDR – Sets the Sensor Address ..................................................................................................... 108
6.3.3 BRAT – Baud Rate ............................................................................................................................ 108
6.4 Communication Protocol .......................................................................................................................... 108
6.4.1 Command Message Format ............................................................................................................... 108
6.5 Command Codes ....................................................................................................................................... 109
6.5.1 Introduction ...................................................................................................................................... 109
6.6 Engineering Function Command Codes.................................................................................................... 109
6.7 Analog Output Function Command Codes ............................................................................................... 112
6.8 Head Function Command Codes............................................................................................................... 113
6.9 Measurement Condition and Alarm Command Codes .............................................................................. 115
6.9.1 Introduction ...................................................................................................................................... 115
6.10 Command Code Summary ...................................................................................................................... 117
7 MAINTENANCE .......................................................................................................................................... 119
7.1 Routine Maintenance ................................................................................................................................ 119
7.1.1 Maintenance Checklist ...................................................................................................................... 119
7.2 Sensor Optics Cleaning ............................................................................................................................. 119
7.2.1 Cleaning the Optics ........................................................................................................................... 120
7.2.2 Restoring the Sensor to Operation .................................................................................................... 120
7.3 Servicing ................................................................................................................................................... 121
7.4 Factory Calibration and Service ................................................................................................................ 121
7.5 Measurement Condition Displays, Error Codes and Troubleshooting ...................................................... 122
7.6 Status Displays and Error Code Details .................................................................................................... 124
7.6.1 Troubleshooting................................................................................................................................. 127
8 APPLICATIONS GUIDE ............................................................................................................................ 129
8.1 Introduction ............................................................................................................................................... 129
8.2 Analog Outputs ......................................................................................................................................... 129
8.2.1 Analog Output Range Scaling Example ........................................................................................... 130
8.2.2 Measured Temperature Calculations ................................................................................................ 130
8.2.3 Analog Output Operation Notes ...................................................................................................... 131
8.3 Response Time .......................................................................................................................................... 131
8.3.1 Description ........................................................................................................................................ 131
8.3.2 Determining Response Time to Use .................................................................................................. 132
8.4 Emissivity Settings .................................................................................................................................... 133
8.4.1 Using Emissivity Tables ................................................................................................................... 133
8.4.2 Using Emissivity Thermocouple Test ............................................................................................... 134
8.4.3 Setting the Emissivity ....................................................................................................................... 134
8.4.4 Using Relative Readings ................................................................................................................... 134
8.4.5 Practical Limits on Emissivity .......................................................................................................... 134
8.5 Ratio Sensors............................................................................................................................................. 140
8.5.1 E-Slope Settings ................................................................................................................................ 140
8.5.2 Setting the E-Slope ............................................................................................................................ 141
8.6 Peak Picker Signal Conditioning............................................................................................................... 141
 8.6.1 Turning Peak Picker On and Off...................................................................................................... 141
8.6.2 External Switch for Remote Peak Picker Operation ......................................................................... 142
8.6.3 Peak Picker Signal Conditioning ...................................................................................................... 143
8.6.4 Peak Picker Reset .............................................................................................................................. 143
8.6.5 Peak Picker Decay Rate .................................................................................................................... 143
8.6.6 Auto Peak Picker Reset with Reset Below ........................................................................................ 143
8.6.7 Peak Picker Delay ............................................................................................................................. 144
8.7 Track and Hold ......................................................................................................................................... 145
8.7.1 External Switch Control of Track and Hold ..................................................................................... 145
8.8 Avoiding Common Measurement Problems ............................................................................................. 146
8.8.1 Viewing Angle Limitations............................................................................................................... 146
8.8.2 Background Interference ................................................................................................................... 146
8.8.3 Transmission Effects ......................................................................................................................... 147
8.8.4 Transmission Path Effects ................................................................................................................ 148
8.8.5 Reflectance Effects............................................................................................................................. 148
8.9 Use of Mirrors .......................................................................................................................................... 149
8.10 Use of Windows ..................................................................................................................................... 150
8.10.1 Special Considerations for Ratio Units ........................................................................................... 151
8.11 Preventing Sensor Overheating .............................................................................................................. 152
9 NOTICES ....................................................................................................................................................... 154
 Safety Instructions

1 Safety Instructions
This document contains important information, which should be kept at all times with the instrument
during its operational life. Other users of this instrument should be given these instructions with the
instrument. Eventual updates to this information must be added to the original document. The
instrument can only be operated by trained personnel in accordance with these instructions and local
safety regulations.
Acceptable Operation
This instrument is intended only for the measurement of temperature. The instrument is appropriate
for continuous use. The instrument operates reliably in demanding conditions, such as in high
environmental temperatures, as long as the documented technical specifications for all instrument
components are adhered to. Compliance with the operating instructions is necessary to ensure the
expected results.
Unacceptable Operation
The instrument should not be used for medical diagnosis.
Replacement Parts and Accessories
Use only original parts and accessories approved by the manufacturer. The use of other products can
compromise the operation safety and functionality of the instrument.

Modline 5
Rev. L6 Feb 2017 11
Safety Instructions
Safety Symbols

AC (Alternating Current)

DC (Direct Current)

Risk of danger. Important information. See manual.

Hazardous voltage. Risk of electrical shock.

Warning Laser

Helpful information regarding the optimal use of the instrument.

Earth (ground)

Protective earth (ground)

Chassis ground

Switch or relay contact

Conforms to European Union directive.

Disposal of old instruments should be handled according to professional and

environmental regulations as electronic waste.

12
Rev. L6 Feb 2017 Modline 5
 Safety Instructions

Warning
To prevent possible electrical shock, fire, or personal injury follow these guidelines:
 Read all safety Information before you use the product.
 Use the product only as specified, or the protection supplied by the product can be
compromised.
 Carefully read all instructions.
 Do not use and disable the product if it is damaged.
 Do not use the product if it operates incorrectly.
 Do not look directly into the laser with optical tools (for example, binoculars, telescopes,
microscopes). Optical tools can focus the laser and be dangerous to the eye.
 Do not look into the laser. Do not point laser directly at persons or animals or indirectly off
reflective surfaces.
 Do not use laser viewing glasses as laser protection glasses. Laser viewing glasses are used
only for better visibility of the laser in bright light.
 Use the product only as specified or hazardous laser radiation exposure can occur.

Modline 5
Rev. L6 Feb 2017 13
Product Description

2 Product Description
2.1 Modline 5 Sensors, Cable and Interface Accessories
The basic Modline 5 System consists of either a standard Sensor or Sensor with the Dirty Window
Detection option with an interconnecting cable and Terminal Strip Plate. Optional components include
the POI Power Supply/Signal Interface Box and the remote DPM Digital Meter operator interface.

2.1.1 Preliminary Inspection

The Modline 5 is delivered in plastic wrappings, cradled in foam inside rugged cartons. The Sensor and
any accessories you have ordered are shown on the packing list. The photograph below identifies
Modline 5 system components. See Section 3 Sensor Installation, page 22 to identify mounting, air
purging, water cooling and other mechanical accessories.

Figure 1: Sensors, Cable and Interface Accessories

Place all items on a workbench or desk before removing the plastic covers. Inspect each item carefully
to determine if any damage occurred in transit. If you find such damage, promptly inform the freight
agent delivering the components. Save the carton until you are sure you will have no further use for it.
Return items for repair in their original packaging. Contact Ircon before returning any products for
service. See the “Contacts” page at front of the manual on how to contact IRCON.

For Modline 56 sensors: occasionally, a calibration flag that operates during the Sensor
internal Calibrate test may move into the viewing area during shipment. If this occurs,
the viewing area will be dark and appear obstructed. This flag will be positioned
correctly when power is applied to the Sensor.

14
Rev. L6 Feb 2017 Modline 5
 Product Description

2.2 Modline 5 Description

The IRCON Modline 5 is an Infrared Thermometer Sensor. State of the art digital circuitry and firmware
provide excellent measurement accuracy, repeatability and overall performance. New diagnostics check
the status of the Sensor (such as detector temperature, sensor failure) and some of its external
environment (such as analog current output open circuit condition and case temperature). An internal
function check is performed without the need to block the lens. The check tests for and internal circuit
and detector operation. Alarms and Error Codes are outputted when out of limit conditions are sensed.
The Patented Dirty Window Detector option checks the Sensors front window for loss of signal because
a buildup of contaminants.
An easy to read, bright LED alphanumeric temperature display and three pushbuttons on a keyboard
is located at the rear of the Sensor. Each Sensor has a full complement of easy to navigate rear panel
setup and operating functions. Operation as a standalone Sensor is accomplished simply by using its
rear panel keyboard to access and setup operating parameters. The Sensor can display and output
temperature signals, and operates with an external dc power source.
The Sensor optics and electronics are contained in a small, rugged stainless steel NEMA 4 (IP65) rated
housing. Modline 5 accessories for mounting, air purging and cooling the Sensor have been designed
to maintain a small installation footprint.

2.2.1 Sensor Standard Features

Through the lens visible rear focusing and sighting with standard or close focus lenses.
Field selected °F or °C measuring units.
Field selectable analog current outputs, 0 to 20 mA or 4 to 20 mA. Temperatures within the span of the
Sensor can be assigned to the Analog output Zero and Full scale current values to customize the
corresponding output temperature range.
Peak Picker and Track and Hold Signal Conditioning with remote switch input for Peak Picker Reset or
Track and Hold operation.
RS-485 Digital Communications allows interfacing with any RS-485 capable device to setup and operate
the Sensor remotely. This allows use of a Host computer, Programmable Logic Controller (PLC), etc.
with the Sensor
Analog current input for remote adjustment of Emissivity or E-Slope.
Sensor diagnostic Alarm relay contacts are brought out on the interconnecting cable.

2.2.2 Optional Sensor Features

The Dirty Window Detector and Laser Sight are optional features that can be ordered when the Sensor
is purchased.

These options are not field upgradeable.

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2.3 Model Configuration and Required Selections

2.3.1 Model Configuration
The Modline 5 Model number contains seven alphanumeric characters. The first two designate the
Sensor Series. The Series defines the type of Sensor, brightness or ratio, and the operating wavelength.
The next four digits define the Sensor’s temperature range and optical resolution with the standard lens
installed.
Selection of sight, Visible through the lens or optional Laser aiming, is next. Permanent factory
installation is required. Each is exclusive of the other.
The Dirty Window Detector Option (DWD) is the next required selection. Permanent factory installation
is required. The product is covered by Patent Number 5812270 when the Dirty Window Option is
installed.
A Sensor can also be ordered to be used a Transfer Standard to calibrate other Modline 5 Sensors.
ModView Calibration Software and an expanded Calibration Certificate are supplied with this Sensor
Model.
A lens selection is required. Lens types for each Sensor must be specified. Lenses are factory installed
and are not field changeable.
Series designation, temperature range, optical resolution, optional Laser and DWD information is
provided in the tables sections below. Lens focusing ranges are found in Section 3.4 Sensor Optical
Characteristics, page 26. Ordering information and Model Number examples follow the tables.
Two Digit Sensor Series Designation

Sensor Series Sensor Type Spectral Response in μ (microns)

52 Brightness 0.85 to 1.1
56 Brightness Lowest Temperature Range 2.0 to 2.8
Other Ranges: 2.3 to 2.6
5G Brightness 1.6
5R Selectable Modes: Ratio Ratio Mode: 0.75 to 1.05; 1.0 to 1.1
or Brightness (1 Color Mode) Brightness Mode: 1.0 to 1.1

Series 52: Sensor Model Numbers

Model Temperature Range in °C and (°F) Optical Resolution with Type 2A Lens
52-1410 500 to 1400°C (932 to 2552°F) D/100
52-2020 600 to 2000°C (1112 to 3632°F) D/200
52-3024 750 to 3000°C (1382 to 5434°F) D/240

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Series 56: Sensor Model Numbers
Emissivity span is limited to 0.3 to 1.0 for the first 55°C (100°F) for all temperature ranges

Model Temperature Range in °C and (°F) Optical Resolution with Type 6A Lens
56-0315 50 to 300°C (122 to 572°F) D/150
56-0415 100 to 400°C (212 to 752°F) D/150
56-0815 200 to 800°C (392 to 1472°F) D/150

Series 5G: Sensor Model Numbers

Emissivity span is limited to 0.3 to 1.0 for the first 55°C (100°F) for all temperature ranges

Model Temperature Range in °C and (°F) Optical Resolution with Type 2A Lens
5G-1007 250 to 1000°C (482–1832°F) D/75
5G-1415 300 to 1400°C (572–2552°F) D/150
5G-2024 350 to 2000°C (662 – 3632°F) D/240

Series 5R: Sensor Model Numbers

Model Temperature Range in °C and (°F) Optical Resolution with Type RA Lens
5R-1410 600 to 1400°C (1112 – 2552°F) D/100
5R-1810 700 to 1800°C (1292 – 3272°F) D/100
5R-3015 1000 to 3000°C (1832– 5432°F) D/150

Through the Lens Sight – Required Selection

Visible or Optional Laser Sighting.

Lens Types
Lens selection requires matching the lens to specific models. Lens types ending in A are considered
standard focusing range lenses. Lens types ending in B are considered close focus lenses. Lens types
ending in C are considered very close focus lenses. Complete lens focusing ranges and spot size
information are found in Section 3 Sensor Installation, page 22 of this manual.
Dirty Window Detector Option – Required Selection
The selection is Installed or None. The product is covered by Patent Number 5812270 when the Dirty
Window Detector Option is installed.

2.4 Modline 5 Model Number Summary

Modline 5 Model Number as Found on Serial Number Label

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Series Model Sighting: DWD None or Transfer Lens Type
Visible or Laser Installed Standard
(Two Characters) (Four Digits) 0 or 1 0 or 1 0 or T (Two Characters)

Example and Explanation

5 R 1 4 1 0 1 1 0 RA Lens
5R 600 to 1400°C Laser Sight DWD Installed This unit is not Focusing Range:
D/100 a Transfer 13 inches to
Standard infinity D/100

The Model Number explanation information provided above defines a Modline 5 Sensor having the
following characteristics and features:
 Model 5R-1410 is a Series 5R Ratio Type Sensor with the temperature range of 600 to 1400°C (1112
to 2552°F) and D/100 Resolution.
 The Sensor Sight is Laser through the lens (Visible sighting was not selected).
 The Dirty Window Detector Option (DWD) is installed
 The Sensor is not a Transfer Standard. (T = Transfer Standard)
 The installed lens is for the 5R Series and provides the standard focusing range of 13 inches to
infinity. The Sensor Model and lens combination provide a D/100 Optical Resolution

2.5 Accessories
2.5.1 Interconnecting Cable – Required Accessory
An IRCON supplied interconnecting cable with the Sensor mating connector attached on end one and
termination prepared wires on the other end is required. Special assembly of the cable is required and
the cable is only sold with the Sensor connector attached.
Maximum cable length is 350 feet (107 meters). The cable length limitation is due to the power supply
voltage requirements of the Sensor. The power supply voltage drop across this length of cable is low
enough to provide proper Sensor operation. Power supply cable wires are 22 AWG (0.35 mm²). Input
and Output wires are 24 AWG (0.25 mm²).
RS-485, Alarm relay output, and analog outputs, can extend beyond the 107 meter limitation. See Section
4 Sensor Wiring, page 64 for more information.
Sensor Standard Teflon Interconnecting Cable
Maximum temperature: 200°C (392°F)
Maximum cable length: 107 meters (350 feet)
See Red Lion Bulletin PAX – P for completing the specifications for DPM.

The cable must be terminated into a Power Supply/Signal Interface Box (POI) or a
Terminal Strip Plate (TSP) to ensure that the Sensor and cable installation meets RF
immunity and emission standards for CE compliance. These items are described
below.

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2.5.2 Power and Interface Accessories

Model POI – Power Supply/Signal Interface Box.
This box includes a 24VDC power supply, interconnecting cable termination strip, and RF suppression
components. Input power is 100 to 240 VAC 50/ 60 HZ.
Model TSP – Terminal Strip Plate
This plate includes an interconnecting cable termination strip and RF suppression components.
Model DPM – Digital Panel Meter
Digital Temperature Indicator and RS-485 Communication Operator Interface. 85 to 250 VAC 50/ 60 Hz.
The DPM does not provide power to Sensor.

2.5.3 Installation Accessories

Details on the following standard accessories can be found in Section 3 Sensor Installation, page 22. An
extended family of accessories is available and they are referenced in Section 3.
Standard Modline 5 Accessories
Model – MFS Mounting Flange (Small Diameter Pattern)
Model – BMA Base Mount Adapter
Model – APA Air Purge Accessory
Model – WJA Water Jacket Accessory
Model – ESA Dirty Window Detector Extension Sleeve Adapter
(one included with Dirty Window Detector Option)
Model – UAA Universal Accessory Adapter
Model – MFL Mounting Flange Large
Model – RAM Right Angle Mount
Model – M5WJ5 Mounting Kit to mount Sensor in WJ-5 Water Cooling Jacket
Protective Window / Sight Accessory
The EP – 5 with a dimming filter is available for viewing very high temperatures. This window replaces
the standard rear protection / sight window supplied with the Sensor. This filtered window is for
viewing high temperature targets from 1200°C (2192°F) to 2300°C (4172°F).
Spare part standard protection windows are identified as the RPW, rear protection window assembly
with clear sight window. One of these is supplied with every Sensor.

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2.6 Specifications1
2.6.1 Sensor Specifications
Spectral Response
Series 52 0.85 to 1.1 microns
Series 56 2.0 to 2.8 microns (Model 56 to 0315 only)
2.3 to 2.6 microns (All other models)
Series 5G 1.6 microns
Series 5R Ratio Mode: 0.75 to 1.05; 1.0 to 1.1 microns
Single Color Brightness Mode 1.0 to 1.1
* All specifications subject to change without notice.
Calibration / Blackbody Accuracy at 25°C
Sensor Series 52 Within 0.3% of reading plus 1°C up to 2800°C (5072°F)
indication up to 3000°C (5432°F)
Sensor Series 5G Within 0.3% of reading plus 1°C
Sensor Series 56 Within 0.3% of reading plus 1°C, or
2C (whichever is greater)
Sensor Series 5R Within 0.5% of reading plus 2°C up to 2800°C (5072°F)
indication up to 3000°C (5432°F)
Repeatability at 25°C Within 0.1% of full-scale temperature (+1 digit)
Response Time for Display and Outputs
Series 5R Adjustable from 0.01 to 60 seconds.
Series 52, 5G Adjustable from 0.0066 to 60 seconds.
Series 56 Adjustable from 0.020 to 60 seconds.
Selectable Analog Current Output 0 to 20 mAdc or 4 to 20 mAdc
600 Ω maximum load including cable resistance
Output is not isolated from power supply common.
Digital Communications RS-485 Digital Interface
Emissivity Range Emissivity is 0.10 to 1.00.
Series 52, 56, 5G and 5R (single color mode)
Emissivity Limitations for Series 5G and 56
Emissivity span is limited to 0.3 to 1.0 for the first 100°F
(55°C) for all temperature ranges of these models
E-SLOPE Range Model 5 R (Two color Ratio Mode) 0.800 to 1.200.
Signal Reduction Range Tolerated Sensor Series 5R will tolerate 95% reduction in radiation
intensity caused by low emissivity, non-resolved or obscured

1 All specifications subject to change without notice.

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targets or combinations of these conditions above target
temperatures of 1500°F (800°C).
System ALARM Relay Contacts 24 V AC/DC at 1 Amp. Resistive
Peak Picker Rise Time Same as selected Response Time
Peak Picker Decay Rate Adjustable 0.00 to 300 degrees F (0.00 to 166 degrees C)
per second
Peak Picker Reset: Internal Reset has two Modes: Manual and Auto.
External Reset: Contact closure greater than .08 second
Track and Hold Tracking Mode is elected with external contact closure
Power Requirements 24 VDC +/- 5%, 8 Watts Maximum
Operating Ambient Temperature
Sensor Series 52, 56, 5R and 5G: 0 to 55°C F (32 to 130°)
With WJA Accessory Air Cooling 0 to 105°C (32 to 220°F)
With WJA Accessory Water Cooling: 0 to 200°C (32 to 400°F)
Sensor Environmental
Sensor Housing NEMA 4 (IP65).
Sensor Cable Plug and
Housing Connector NEMA 4 (IP65).
Humidity 10 to 90% non-condensing
Sensor Dimensions See dimensional drawings in section 3.7.2 Sensor Dimensions,
page 33.
Weight 4 lbs. (1.8 kg) approximate, Model and option dependent
Laser Sight Option Laser: Class II Less than 1 mw at 635 nm
Shock IEC 68 - 2-27
Vibration IEC 68 -2-6

2.6.2 Accessory Specifications

POI Power Supply/Signal Interface Box
Ambient Temperature: 0 to 55°C (32 to 130°F)
Environmental: NEMA 4 (IP65)
Power Requirements: 100 to 240VAC 50/ 60 HZ, 40 VA.
DPM Digital Panel Meter
Ambient Temperature: 0 to 50°C (32 to 122°F)
Environmental: NEMA 4X (IP65) Sealed Front Bezel
Power Requirements: 85 to 250 VAC 50/60 HZ, 15VA.
Terminal Strip Plate
Ambient Temperature: 0 to 55°C (32 to 130°F)

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Sensor Installation

3 Sensor Installation
3.1 Mechanical Installation
This section provides instructions for installing the Modline 5 Sensor. Sighting, aiming, focusing and
resolving targets are explained. Mounting and protection of the Sensor in hot and dirty environments
using installation, air purging and water cooling accessories are presented.

3.2 Sensors

Figure 2: Standard Sensor Figure 3: Sensor with Dirty Window Detector

Two Sensors types are available in the Modline 5 Series, standard Sensor or Sensor with the Dirty
Window Detector option. The front of the standard Sensor consists of a front objective lens only. The
Sensor with the Dirty Window Detector option has internal components and an external protection
window located in front of the objective lens. A hooded mirror extends out in front of protection
window. The sensors are illustrated in the photographs above and below.
The Patented Dirty Window Detector option, IRCON, inc. Patent Number 5812270, checks the Sensors
front window for loss of signal caused by a buildup of contaminants. A Coarse or Sensitive level of
signal loss can be selected. Visual Alarms and a relay output are provided to indicate window
contamination.
Dimensions for the Sensor with the DWD are slightly different because of the additional components.
Measurement of the optical working distance on the standard Sensor is made from the front surface of
the unit. The working distance determination on the Sensor with DWD requires a simple calculation.
Measurement is made from the front tip of the hooded mirror and 66 mm (2.6 inches) is added to the
distance to compensate for the extended optics.

Sensor with DWD

Mirror
Standard Sensor Lens
Window

Figure 4: Standard Sensor Lens and Lens with DWD

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 Sensor Installation

3.2.1 Sensor Parts

The photograph below illustrates the Sensor parts called out in this manual.
Rear Rotating Focusing Section
Focuses the Sensor optical
system on the target.
UAA Universal Adapter
Accessory for mounting Lens Lock Thumb Screw
Locks the focusing section in
place after focusing.
Cable Connection, Match (Do Not Use Tools)
Red Dots to connect
NEMA 4 (IP65) Rear Protection / Visual Sight
environmental rating Window. Threads on focusing
section to cover rear panel
display and keypad. Provides
NEMA 4 (IP65) environmental
rating. See note below about
Figure 5: Sensor Parts
EP-5 window.

The EP – 5 Protective / Visual Sight Window with a dimming filter is available for
viewing very high temperatures. This replaces the standard rear protection and sight
window shown above.

3.3 Sighting Methods

The Modline 5 Sensor is a precision electro-optical instrument that senses infrared radiation. This signal
is processed by the unit’s digital circuits to provide an output proportional to the temperature being
measured. The Sensor’s linear analog current output and RS-485 digital temperature signals are brought
out through a connector on the bottom of the Sensor with a shielded cable. The output signals are then
connected to compatible devices within the process measurement system.

3.3.1 Sighting and Focusing

The Modline 5 is a variable focus instrument that features visual through-the-lens sighting by means of
a viewing sight at the rear panel of the Sensor. An optional internal Laser for through-the-lens aiming
is available. Focusing with either the visible or laser sight is accomplished using the rotating rear section
of the Sensor.

3.3.2 Visual Sight

The Modline 5 visible sight is aimed and focused onto the target to be measured as simply as an ordinary
camera. The rear focus is smooth, utilizing almost one turn of the focusing section.
A circular reticle is contained within the Sensor’s optical system and is visible when viewing through
the sight. During temperature measurement, the target image is superimposed on the reticle. Focusing
is performed by adjusting the rear focusing section while viewing the scene until the target area is clear
and well defined. Illustrated below is a properly focused Sensor viewing an induction heated rod. The
visible sight rear panel is shown below.

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Sensor Installation

Figure 6: Visible Sight Figure 7: Reticle

When properly focused, the area of the target within the reticle will be measured. The Sensor infrared
detector will “see” the same image seen defined by the reticle. Approximately 97% of the measured
energy will come from the area defined by the reticle.
To check or adjust focus, slowly move your head slightly from side to side or up and down. Note
whether the target appears to move with respect to the reticle. If it does, adjust the lens focusing section,
until there is no perceived motion between the reticle and target (hence eliminating parallax between
the two). The instrument is then in sharp focus. Lock the lens rear focusing section in place using the
locking thumbscrew on the bottom of the Sensor.
If looking through a sight tube or sight hole, position, align and rotate the Sensor and Sight tube to
center the reticle in the field of view.

For Modline 56 sensors: occasionally, a calibration flag that operates during the Sensor
Calibrate test may move into the viewing area during shipment. If this occurs, the
viewing area will be dark and appear obstructed. This flag will be positioned correctly
when power is applied to the Sensor.

3.3.3 Laser Sight

With the optional Laser sight, a laser light spot is projected onto the target and used to aim the Sensor.
The same rear focusing method applies and is to be used to adjust for the smallest laser light spot. The
projected focused laser image will be approximately the same diameter “spot” as measured by the
detector. See Section 3.4 Sensor Optical Characteristics, page 26 for determining spot size.
The Laser image is reflected from the target surface. The image can easily be seen on most targets at
distances of 10 feet and further. The visibility of the reflected image is dependent on the reflection
characteristics of the target material as well as the intensity of the ambient lighting. When viewing hot
glowing targets, the visibility of the image also depends upon its temperature. The color and intensity
of a hot glowing object may override the reflected Laser image.
Use of the laser on distant targets or poorly reflecting targets may require some white paint on the target
or a white substitute target such as a sheet of paper to accomplish focusing. Ambient light dimming
may be required for targets that reflect poorly. For difficult conditions, pre-focus the Sensor optics while
aiming the laser at a white reflective target. Then use the Laser to aim the pre-focused Sensor on to the
target.

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Figure 8: Laser Sight

If looking through a sight tube or sight hole, position, align and rotate the Sensor and Sight tube to
center the laser image in the field of view.
The Sensor is a Class II Laser Product with the Laser Sight option installed, see section 5.11 Laser
Sighting Operation, page 102 of this manual for safe and full operating instructions. Install Sensor and
setup Laser operating procedures so that personnel are not exposed to the laser beam at any time
whether the Laser is energized remotely or at the Sensor Rear Panel.

Warning Label

Figure 9: Sensor Laser Label

The sensor label is shown in detail in Figure 10.

Figure 10: Sensor Laser Label in Detail

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3.4 Sensor Optical Characteristics

3.4.1 Optical Resolution
The Sensing Head is sensitive to infrared radiation in the area indicated by the Cone of Vision in the
illustration below.

Focal Point

d=D/F
where:
d = diameter of cone at focal point
D = distance from front of Sensor to focal point.
For Sensors with DWD Option,
add 2.6 inches (66 mm) for distances
measured from tip of front hood.
Cone of Vision F = Resolution Factor of Sensor Model and
Lens combination

Sensor
Figure 11: Cone of Vision and Spot Size Formula

The diameter of the cone at any point will determine the area of measurement at that point. Any part of
the target or other intervening object positioned within the cone will be imaged on the detector.
Anything seen by the detector will become part of the measurement.
When the Sensor is sighted on an object, you are “aiming” or positioning the cone of vision on the object.
When you focus, you are adjusting the optical system elements so the focal point is at the surface of the
object. The measurement area, as seen by the detector, will then be outlined in the reticle. The reticle
only defines the measured area (spot size) in the focused condition.
The formula d = D/F defines the spot size at the focal point. Simply divide the Working Distance (D),
measured from the front of the Sensor to target by the Resolution Factor (F) to determine the Spot Size
(d). Resolution factors for Sensor Model and Lens combinations are provided in the table on the
following page. The focusing range for each lens type is also provided in the table. The focusing range
defines the allowable range for the Working Distance.

For Sensors with the Dirty Window Detector Option, the Working Distance (D) is
calculated by measuring the distance from the front tip of the protruding hood to the
target and then adding 2.6 inches (66 mm).

3.4.2 Lens Focusing Ranges and Optical Resolution Factor

The table below lists Lens Type and Focusing Ranges for the Modline 5 Series 52, 56, 5G and 5R. Two
ranges are shown. The first range is for a Sensor without the Dirty Window Detector Option (DWD)
option. The distance is measured from the front metal surface of the standard Sensor.

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The second range is for a Sensor with the DWD option. This distance is measured from the tip of the
front mirror hood. Very close lens types that include alpha character C are not useable with the DWD
option.
Some installation, cooling and air purging accessories will limit some of the usable close focus range
accessory.
The Model number and installed lens type is found on the Sensor Model number tag. Range tolerance
of is ±10%.

3.4.3 Table of Model and Lens Type Combinations with Focusing Ranges
The Optical Resolution Factor for each Model and Lens combination is given in the table. Use the
formula: d = D / F to calculate the spot size at any working distance within the specified range. The
smallest spot size can be determined using the closest distance within the range.

Model Number Lens Focusing Range in inches “ and millimeters (mm) Resolution
Type Factor
Standard Sensor Sensor with DWD Option
52-1410, 5G-1007 2A 13” to infinity (330 mm to infinity) 10.4” to infinity (264 mm to infinity) D/100, D/75 (5G)
52-2020, 5G-1415 2A 13” to infinity (330 mm to infinity) 10.4” to infinity (264 mm to infinity) D/200, D/150 (5G)
52-3024, 5G-2024 2A 13” to infinity (330 mm to infinity) 10.4” to infinity (264 mm to infinity) D/240
52-1410, 5G-1007 2B 6 to 12 “ (152 mm to 305 mm) 3.4 to 9.4” (86 to 239 mm) D/90, D/67 (5G)
52-2020, 5G-1415 2B 6 to 12 “ (152 mm to 305 mm) 3.4 to 9.4” (86 to 239 mm) D/180, D/135 (5G)
52-3024, 5G-2024 2B 6 to 12 (152 mm to 305 mm) 3.4 to 9.4” (86 to 239 mm) D/216
52-1410, 5G-1007 2C 2.25 to 2.75“ (57 to 70 mm) Not Available with this lens. D/80, D/60 (5G)
52-2020, 5G-1415 2C 2.25 to 2.75“ (57 to 70 mm) Not Available with this lens. D/160, D/120 (5G)
52-3024, 5G-2024 2C 2.25 to 2.75“ (57 to 70 mm) Not Available with this lens. D192
56 – All Models 6A 12” to infinity (305 mm to infinity) 9.4” to infinity (239 mm to infinity) D/150
56 – All Models 6B 6 to 12 “ (152 mm to 305 mm) 3.4 to 9.4” (86 to 239 mm) D/ 135
56 – All Models 6C 2.25 to 2.75“ (44 to 57 mm) DWD Not Available with this lens. D/105
5R-1410, 5R-1810 RA 13” to infinity (330 mm to infinity) 10.4” to infinity (264 mm to infinity) D/100
5R-3015 RA 13” to infinity (330 mm to infinity) 10.4” to infinity (264 mm to infinity) D/150
5R-1410, 5R-1810 RB 7 to 14“ (178 mm to 355 mm) 4.4 to 11.4” (112 to 289 mm) D/90
5R-3015 RB 7 to 14“ (178 mm to 355 mm) 4.4 to 11.4” (112 to 289 mm) D/135
5R-1410, 5R-1810 RC 2.25 to 2.75 “ (57 to 70 mm) Not Available with this lens. D/80
5R-3015 RC 2.25 to 2.75 “ (57 to 70 mm) Not Available with this lens. D/120

Table 1: Model and Lens Type Combinations with Focusing Ranges

3.4.4 Spot Size and Viewing Distance

Viewing distance and spot size is demonstrated in the Distance and Spot Size illustration. A Sensor with
a Resolution Factor of F = 100 is focused on a 0.5 inch (12.7 mm) rod at three distances. The drawings at
the left for each example illustrate a large circle that represents the total area visible in the Sensor sight.
The smaller circle represents the reticle.

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Resolution Factor F = 100

A: Target smaller than Spot Size.

Sensor measures part target and part
background
Move closer and Refocus!

Recticle

Sensor

B: Target equal to Spot Size.

Any shift of target or sensor will
cause sensor to view part target
and part background.
Move closer and Refocus!

C: Target twice Spot Size.

Excellent!
Target is safely resolved.

Figure 12: Distance and Spot Size Illustration

In top example A, the rod is 100 in. (2540 mm) away. The spot is 1 inch (25.4 mm) in diameter. The one
half inch diameter rod does not fill the reticle in the viewing sight. Middle example B illustrates a
viewing distance of 50 inch (1270 mm). The spot is 0.5 inch (12.7 mm) in diameter, the same size as the
rod. Bottom example C illustrates a viewing distance of 25 inch (635 mm). The spot size is 0.25 inch (6.35
mm) one half the one half inch target size. The view in the eyepiece shows the target completely resolved
by the reticle.

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3.5 Measuring Temperature with Brightness and Ratio Sensors

3.5.1 Resolving Targets with Brightness Sensors
When using single color Series 52, 56 and 5G brightness Sensors, best results are obtained when the
resolved portion of the target is two times the diameter of the reticle.
The Sensor measures the average temperature of the target or object seen in the reticle. Targets smaller
than the reticle will result in low temperature readings if the background (object within the cone of
vision beyond the target) is lower that the target temperature. If the background temperature is higher
than the target, the averaged temperature indication will be higher.
Low temperature indications can also be caused by other factors. An out of focus cool object cutting the
cone of vision anywhere between the target and Sensor, or a small target may shift position and move
partially out of the measurement cone.

3.5.2 Obstructions in Cone of Vision

Errors can be caused by objects positioned between the Sensor and target. Evaluate the Sensor’s “Cone
of Vision” and if there is any possibility that an intervening object is within the cone, select a different
viewing position. An object inside the Cone of Vision will be visible to the detector and may cause an
error in the temperature measurement. Obstructions in the cone of vision, whose temperatures are
lower than the target temperature, will generally cause lower temperature readings when using single
color brightness units. The obstruction may not be seen clearly in the instrument sight if it is some
distance away from the target and out of focus. Such an obstruction is illustrated below.
High temperatures can be caused by an out of focus hot object cutting the cone of vision anywhere
between the target and Sensor.
Two color ratio units are usually not affected by obstructions that are significantly lower in temperature
than the target. Ratio units are affected by hot objects in the cone of vision that are much higher in
temperature than the target. If too high, the hot targets can dominate the measurement. If the object
temperature is the same, the measured temperature is not affected.

Obstruction
Target

Cone of Vision
Sensor

Figure 13: Cone of Vision Obstruction

3.5.3 Resolving Targets with Two Color Ratio Sensors

Modline 5 Series 5R Ratio Sensors utilize a dual detector assembly that measures temperature by
comparing infrared radiation levels in two wavelength bands (0.85 to 1.05 microns and 1.0 to 1.1
microns). Temperature readings are based on the ratio of the two signals in these bands.

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Because Series 5R Sensors measure the ratio of radiation intensities at two wavelengths rather than the
absolute intensity of radiation at a single wavelength, they are almost immune to error caused by loss
of signal. Small targets that do not fill the field of view and partial obstructions from bursts of steam,
dust and solid objects in their sight path can be tolerated.

3.5.4 Signal Reduction

Three causes contribute to the loss of signal:
 Low target emissivity.
 The measured object is too small to fill the reticle as seen in the Sensor sight and is not completely
resolve.
 Partial obstruction of the optical path caused by smoke, steam, dust, dirty window or a solid
object.
The total reduction in signal is the sum of the losses from all three causes.
Example: Assume the target emissivity is 0.45. The reduction in signal due to low emissivity is 55%. If the
instrument can operate with a 95% signal reduction, another 40% can be lost due to an unresolved target and/or
obstructions in the cone of vision such as smoke, steam, dust, a dirty window or partial blockage by solid objects.

Target Emissivity = 0.45 Target

Valid Measurement Conditions

Cone of Vision
Smoke in Sight Path Target

Target

Sensor
Invalid Measurement Conditions
Total Signal Loss Greater than 95 %
Sensor
1. Intense Smoke in Sight Path
2. Target too small for Spot Size
Sensor 3. Low Emissivity
Figure 14: Invalid Measurement Conditions

When you reach the maximum allowed reduction, the Sensor will indicate “Invalid”. An Invalid
measurement condition also occurs, without any obstructions, if the target temperature signal is below
a level that can be accurately measured by the instrument.
Signal Reduction Tolerated
The Series 5R Sensors have a limit as to how much the signal from a hot target can be reduced. The
reduction in the signal can be as high as 95% with target temperatures above 800C (1500F). The

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amount of signal reduction that the Series 5R Sensors will tolerate depends upon the Sensor temperature
range and the target temperature. The signal reduction tolerated is less in the bottom portion of the
range. The Sensor will indicate invalid when the measurement is not possible.

3.5.5 Summary
The spot size and target size relationship is not as critical for Series 5R Sensors which use the two color
ratio method. Avoid emitted radiation from objects in the same field of view (cone of vision) either in
the foreground or behind the target that are at temperatures hotter than the target. Reflected or emitted
radiation from these interferences can cause measurement errors. Significantly cooler objects, well
below the target temperature, will not cause measurable errors.
For best results, brightness sensors that measure radiation intensity at a single wavelength should be
installed so the target area is larger than the instrument spot size. If possible, adhere to the target size is
twice the spot size rule for all types of instruments.

3.6 Sensor Installation Planning

Mechanical Installation of the Modline 5 Sensor requires determining sighting and focusing
requirements, locations for installing Sensors, accessories and cable routing. Planning also includes
evaluating environmental conditions that may cause contamination of the Sensor optics or overheating
of the Sensor or other Modline 5 components. Re-location of the installation or air purging and water
cooling accessories may be required to overcome adverse conditions.
Pre-focusing the Sensor’s optical system may be necessary if the Sensor is to be mounted in a difficult
location and not accessible. Pre-focus by setting up a well-defined target such as a printed page at the
exact distance of the target, and then lock the rear focusing section.
Setup of the Sensor parameters can also be pre-determined and set before installation.
The following guidelines will help you in planning the Sensor installation.
Mechanical Mounting Location Requirements
The Sensor is installed using the mounting brackets and flanges, air purging and water cooling
accessories illustrated in the Section 3.9 Modline 5 Mounting, Cooling and Air Purging Accessories,
page 35.
Sensor Mounted to Earth Ground Potential
If the proposed mounting surface is at Earth Ground potential, you can mount the housing directly
to this surface. If the surface is not at Earth Ground potential, electrical insulating material and non-
conducting hardware must be used to isolate the Sensors.
Sensor Interconnecting Cable Length
Maximum cable length between the Sensor and the POI Power Supply/Signal Interface Box or
Terminal Plate is 350 ft. (107 m). Maximum temperature rating of the Sensor Interconnecting cable
is 200 °C (392 °F). Plan the cable route accordingly.
Ambient Temperature Limits for Sensor, POI Box and Terminal Strip Plate
The ambient temperature at the mounting locations for the Sensor, POI Power Supply/Signal
Termination Box and The Terminal Strip Plate must be between 0 and 55°C (32 and 130°F).
If the ambient temperature at the mounting location is beyond these limits, precautions must be
taken to protect the Sensor. A WJA Water and Air Cooling Jacket are available for protection against
excessive temperatures. Use of insulation and reflective shielding for additional protection from

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extreme ambient temperatures and radiated heat are described in Section 8 Applications Guide, page
129.
The POI Power Supply/Signal Termination Box and The Terminal Strip Plate must be re-located to a
location that the ambient temperature is between 0 and 55°C (32 and 130°F).
Lens Protection
Be sure the lens is protected from contamination and is accessible for maintenance. If dust, oil,
vapors, etc. collect on the lens, low temperature indications will result. Use an APA – Air Purge
Accessory to maintain a clean lens. Consider use of a Sensor with the Dirty window if errors caused
by lens contamination can seriously affect the process.
Focal Limits
To permit focusing, the target distance must be within the focal range of the objective lens. Ranges
for the Modline 5 objective lenses are given in Section 3.4 Sensor Optical Characteristics, page 26.
Range limitations for close focus lenses may be encountered with the use of certain mechanical
accessories.
Use of Windows
If it is necessary to view the object through a window, as is the case when the object is being heated
in a vacuum or inert atmosphere, correctly select the window material. The material must have
constant transmission characteristics in the operating wavelength range of the Sensor type being
installed. Information on windows is provided in Section 8 Applications Guide, page 129 of this
manual.
Reflections
Reflections from radiating objects represent a potential source of error in temperature measurement.
The total radiation seen by the Sensor will be a combination of intrinsic, emitted, radiation plus
reflected radiation from a nearby hot object off the target surface.
Examples of interfering sources are hot furnace walls and heating elements that are hotter than or
nearly as hot as the target object.
Most reflection problems can be eliminated by changing the viewing angle or shielding the
reflections. Suggestions for anticipating and eliminating common reflection problems are provided
in Section 8 Applications Guide, page 129.
Indirect Viewing
In some situations, it may be necessary to view the target indirectly by means of a mirror. The
characteristics of the mirror and the positioning of both the Sensor and mirror are critical in this type
of arrangement. Refer to Section 8 Applications Guide, page 129 for more information.
Viewing Angle
Viewing angles are limited in some situations. Guidelines are provided in Section 8 Applications
Guide, page 129.

3.7 Sensor Mechanical Installation

3.7.1 Installation Accessories
The Modline 5 Sensor requires the use if one or more installation accessories to mount, align and aim
the Sensor. The installation accessories also provide for cooling the Sensor and air purging the optics to
keep them free from contamination.

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Presentation of accessories and sensor installation is organized in the Sections below as follows.
 Sensor dimensions and specifications.
 General requirements for all installations including cable clearances, access for aiming,
focusing and setup.
 Description of each accessory accompanied by dimensions and specifications.
 A table of recommended accessory groupings.
 Illustrations of the groupings accompanied by overall dimensions.
Other accessories such as pipe mounts, sight tubes, target tubes window assemblies, etc. is referenced
at the end of this section.

3.7.2 Sensor Dimensions

The dimensions of the Standard and Dirty Window Detector Modline 5 Sensors are given below. These
dimensions are without any mounting accessories.

Figure 15: Standard Modline 5 Sensor

Sensor Front Rear

Size of Cone of Vision at the Lens is 0.95inch (24 mm)

Figure 16: Dimensions Standard Sensor

Figure 17: Sensor with Dirty Window Detector (DWD)

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Sensor with DWD
Front
Rear

Dimensions in inches and (millimeters)

Figure 18: Dimensions Sensor with DWD

3.7.3 General Installation Requirements

 Sensor should be mounted to provide a minimum of 4 inch (101.6 mm) clearance from the
housing for connecting the cable.
 Gently bend the cable into its routing position as shown in the photo below.
 Minimum cable bend radius is 3 inches (76.2 mm).
 Rotate the Sensor to avoid cable obstructions.
 Positioning of any mounting accessory on the Sensor should be as close to the front lens as
possible without extending beyond it. Some accessories require clamping towards the middle of
the body.
 Never clamp on the Dirty Window Detector hooded mirror or the DWD section! (Not shown)
 Never clamp on the rear focusing section of the Sensor.

Figure 19: Interconnecting Cable

3.8 DWD Installation Requirements

The Sensor with the Dirty Window Detector option requires the use of an ESA – Extension Sleeve
Adapter accessory along with other Modline 5 accessories. The ESA, combined with other accessories,
serves as protection for the DWD optics. The photograph (Figure 20) illustrates several of the
accessories.
The ESA is used in the following combinations to provide air purging or to create a dead air space zone
in front of the Sensor optics to help keep them clean. The combinations also provide shielding from
stray radiation emanating from high temperature targets and thermal isolation for the Dirty Window
Detector Components. The APA - Air Purge, used in combinations one and two below, provides the

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best performance. Groupings of accessories are shown in Section 3.10 Accessory Combinations with
Break-out Drawings page 50. Also see Section 3.9.6.1 WJA Water Cooling Requirements page 45.

When using a WJA – Water Jacket Assembly with air cooling, the use of an APA air
purge is required with Sensors with the DWD. The use of an APA is also required when
viewing large targets over 1000 C (1832 F).

Figure 20: DWD with ESA

1. ESA and APA air purge with clean air provides air purging, and shielding.
2. ESA and APA air purge without air provides a dead air space zone, and shielding.
3. ESA with MFL Flange provides a dead air space zone and shielding.
4. ESA with MFL and AA-3 air purge accessory (not shown) provides air purging and shielding.
See Section 3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling), page 60 for AA-3
references.

3.9 Modline 5 Mounting, Cooling and Air Purging Accessories

3.9.1 UAA – Universal Adapter Accessory Description and Dimensions
The UAA is a circular ring that clamps around the Modline 5 Sensor. A M8 screw tightens the clamp
around the Sensor. Three ¼-20 threaded holes on the bottom flat surface allow fastening the UAA to a
tripod; user designed mounting surface or the RAM – Right Angle Mounting Bracket.

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Figure 21: UAA Accessory

Material: Clear Anodized Aluminum

Weight: Approximately 1 Pound (0.5 kg)

3 hex Head Screws and Flat mounting Surface

washers supplied Align with other Asccessoiries

¼ - 20 threaded X.375 (9.5)

deep 3 places
Orientation Holes 2 places

Insert Front of Sensor this Direction

M8 X 30 mm Socket Head Cap Screw

Supplied for clamping Sensor

M6 X 25 mm deep threaded Holes for

IRCON Accessories
3 Places

Figure 22: UAA Dimensions

Dimensions are in inches and (millimeters). Do not scale.

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Qty Part No. Description and use User Supplied Tools
M8 X 30 mm socket head caps screw for sensor 6 mm hex key, long arm L style wrench
1 230830C60 clamping recommended
¼-20 x 5/8 inch (15.9 mm) stainless steel hex
3 202520540 head bolt Adjustable wrench
3 222503200 Stainless steel split ring lock washer
3 260600060 Black oxide flat washer
Table 2: UAA Mounting and Assembly Supplied Parts List

3.9.2 RAM – Right Angle Mount Description and Dimensions

The RAM – Right Angle Mount provides convenience, strength and flexibility in mounting the Modline
5 Sensor. The UAA universal adapter is required to attach the Sensor to the RAM. Two holes and one
slot on the upright side of the mount are for mounting the Sensor and UAA. Use the slot and outer hole
to provide vertical angular adjustment of the Sensor’s optical axis. Use the two holes for fixed axis
mounting. Two holes and one slot for mounting are located in the base of the RAM. Use the slot and
outer hole to provide angular adjustment. Pivoting of the base provides horizontal angular adjustment.
Use just the two holes for fixed axis mounting.

Figure 23 RAM Accessory

Material: Passivated Stainless Steel

Weight: Approximately 1.2 pounds (0.55 Kilogram)

Mounting and Assembly Supplied Parts List:

 No hardware is supplied with the RAM. UAA assembly hardware is supplied with the UAA.
 Two user supplied M6 or ¼-20 mounting bolts and washers are required to mount the base of
the bracket.

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Bolt Arc Radius

Clearance Holes – 4 Places

Diameter 0.266 (6.8)

Optical Axis when

mounted horizontally
Pivot Axis

Figure 24: RAM Dimensions

Dimensions are in inches and (millimeters). Do not scale.

All three axis of rotation (including optical axis) intersect at a common point.
This avoids parallax during target alignment

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3.9.3 APA – Air Purge Accessory Description and Dimensions

IRCON’s specially designed air purge is used to help keep the front optics of the Modline 5 clean. The
purge provides a stream of air away from the Sensor to prevent dust and smoke particles from collecting
on the optics.
The APA is positioned in front of the Sensor with the UAA universal adapter or WJA Water Jacket.
Three through holes in the APA accept mounting hardware to assemble accessories together.
The front of the APA has three threaded holes to attach a MFS or MFL mounting flange. Mounting
hardware is supplied with the flanges.
A ¼ inch NPT threaded air inlet is located on the air purge. A flow rate of 3 SCFM (0.09 m3/min.) clean
air is required for most applications. The flow rate can be increased for difficult environments.
Two drain holes provide an outlet for any condensation accumulation. If necessary, these threaded holes
can be plugged with M3 screws.

Figure 25: APA Accessory

Material: Clear Anodized Aluminum

Weight: Approximately 1.5 pound (0.68 kilograms)

Qty Part No. Description and use User Supplied Tools

1 482202 ¼ inch NPT stainless steel fitting for 0.25 inch (6.4 mm) As needed.
diameter tubing. Note: Can be replaced with more suitable
fitting if desired.
3 230625C60 ¼- M6 X 25 mm socket head cap screw for assembling to 5 mm hex key L style wrench.
the WJA or UAA.
3 230670C60 M6 X 70 mm socket head cap screw for assembling to the 5 mm hex key, long arm L style
WJA or UAA with ESA. Wrench recommended.
Table 3: Mounting and Assembly Supplied Parts List

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Locating PINs 2 Places

1/4 -20 NPT Air Inlet
Drain Holes
2 Places

Flat surface align with flat

Three Counterbore surfaces on other Accessories
Holes for M6 Sockethead Cap Screws
For assembling to UAA or WJA

Three M6 tapped Holes for

mounting MFS or MFL Flanges

Figure 26: APA Dimensions

Dimensions are in inches and (millimeters). Do not scale.

3.9.4 MFL – Mounting Flange Large Description and Dimensions

The larger of the two mounting flange accessories, the MFL has the bolt circle pattern that matches many
of IRCON’s other products and accessories. It provides a simple means of replacing older instruments
and using existing accessories. See Section 3.12 for Other Accessories.
The MFL is mated to the Sensor by attaching it to the threaded holes in the front of the UAA, APA and
WJA accessories. Inner and outer groups of three through holes are used for attachment. These holes
are covered by a metal gasket.

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Figure 27: MFL Accessory

Material: Clear Anodized Aluminum
Weight: Approximately 1 pound (0.5 kilograms)

Qty Part No. Description and use User Supplied Tools

1 482172 Metal Gasket Cover
2 230312C60 M3 X 12 mm flat head cap screw to secure gasket cover 2 mm hex key wrench
3 230630C60 M6 x 30 mm flat head cap screw to assemble the MFL with the APA 5 mm hex key, long arm
air purge L style wrench
3 230670C60 M6 x 70 mm socket head cap screw to assemble the MFL to the UAA 5 mm hex key, long arm
and ESA extension sleeve. (Not for use with the WJA. Use last item L style wrench
below)
3 230620C60 M6 x 20 mm socket head cap screw to assemble the MFL directly to 5 mm hex key, long arm
the WJA water jacket or the UAA adapter. L style wrench
3 230665C60 M6 x 65 mm socket head cap screw to assemble the MFL to WJA 5 mm hex key, long arm
water jacket with ESA extension sleeve. L style wrench
Table 4: MFL Mounting and Assembly Supplied Parts List

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Remove Metal Cover Gasket to expose two
Groups of three trough Holes for attaching
Mounting Holes 3 Places Modline 5 Accessories

Outside

Gasket mount

Hole

Mounting bolt circle

Locating
PINs
Back 2 Places
Modline 5 Accessories
mount to this side Front
Other Accessory
interface side

Figure 28: MFL Dimensions

Dimensions are in inches and (millimeters). Do not scale.

3.9.5 MFS – Mounting Flange Small Description and Dimensions

The MFS is a scaled down version of the MFL flange with a smaller diameter bolt circle pattern. This
flange provides strength in mounting with a smaller profile. This flange also provides a means of
mounting to accessories of other manufacturers.
The MFS is used by first bolting it to the APA air purge. In the photograph is shown the MFS mounted
to the APA.

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Figure 29: MFS Accessory

Material: Clear Anodized Aluminum

Weight: Approximately 1 Pound (0.5 kilograms)

Qty Part No. Description and use User Supplied Tools

3 230630C60 M6 X 30 mm flat head cap screws to assemble the MFS with the 5 mm hex key wrench
APA air purge
Table 5: MFS Mounting and Assembly Supplied Parts List

Front Side

Hole

Mounting Bolt Circle

Countersink holes for APA Air Purge

3 Places M6 flat head screws

APA Air Purge mounts to Back Side

Figure 30: MFS Dimensions

Dimensions are in inches and (millimeters). Do not scale.

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3.9.6 WJA – Water Jacket Accessory Description and Dimensions

The WJA uses water or air to cool the Modline 5 Sensor in high ambient temperatures. Water cooling
can protect the Sensor in ambient environments up to 200°C (400°F). Air cooling can provide protection
to 105°C (220°F).
To properly mount the WJA, the BMA – Base Mounting Bracket, MFL –Mounting Flange, or the APA
purge with an MFS or MFL flange should be used. The use of an APA – Air Purge Assembly is
recommended with the WJA.
Trunions (pivoting shafts) on the side of the WJA are used to securely mount to the BMA. Threaded
holes in the front of the WJA are used to mount an APA air purge or MFL Flange. The WJA can be
mounted in any position.
The WJA has 1/4” NPT inlet and outlet pipe fitting openings for water or air. See the drawings and
information on the next page for water and cooling air requirements, and installation configurations.
Designed Maximum water or air pressure: 100 PSIG (6.9 BAR)

Figure 31: WJA Accessory

Material: 300 series passivated stainless steel

Empty Weight: Approximately 6 pounds (2.7 Kilograms)

Qty Part No. Description and use User Supplied Tools

2 ---------- M8 X 16 mm long case hardened steel hex head bolts Adjustable wrench
2 ---------- Extra-large diameter 3/16 “ thick case hardened flat washers
2 482202 ¼ inch NPT stainless steel fitting for 0.25 inch (6.4 mm) diameter tubing As needed
1 142152 Safety Clamp Assembly with captive and permanent mount screws Blade Screwdriver
Table 6: Mounting and Assembly Supplied Parts List

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Optical Axis is the same as the Mechanical Axis

Safety Clamp

Figure 32: WJA Dimensions

Dimensions are in inches and (millimeters). Do not scale.

Tapped Holes on both ends for Ircon, Inc. Accessories.

3.9.6.1 WJA Water Cooling Requirements

Adequate water flow for a 200C (400F) ambient is 15 gallons/hr. (57 liters/hr.). Cooling water
temperature should be 32C (90F) or lower. Use the opening closest to the hottest point on the mounted
Sensor assembly as the water inlet. Typically this is the opening at the front of the assembly. Use only
cooling water compatible with Series 300 stainless steel.
When using water to cool a Sensor with the Dirty Window Detector (DWD), an ESA extension with
either a MFL mounting flange or an APA air purge must be part of the assembly. An APA air purge is
highly recommended for all installations and must be used when viewing large targets over 1000C
(1832 F). A typical water cooling installation for a Sensor is shown below. APA purge air temperature
should be 30C (86F) or lower.

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Air IN at 30C (86F) Ambient Maximum is 200C (400F)
Water IN
Water OUT at 32C (90F)

APA Air Exit

WJA

APA

Add an ESA for Sensor with DWD

Figure 33: Water Cooling Standard Sensor

3.9.6.2 WJA Air Cooling Requirements.

Adequate cooling air for a 105C (220F) ambient is 4 SCFM (114 liters/min). Air temperature should be
30C (86F) or lower.
When using air to cool a Sensor with the Dirty Window Detector (DWD), an APA air purge must be
part of the assembly and the installation should reflect the drawing below.
Ambient Maximum is 105C (220F)

Air IN at 30C (86F) Air OUT

APA Air IN
APA Air Exit
WJA

ESA with APA

Figure 34: Air Cooling Sensors with DWD

3.9.6.3 Sensor Temperature Alarm
The Modline 5 Sensor provides Alarms when the Sensor’s internal temperature exceeds its allowed
limit. Error Code X105 signifies the outside influences have caused the internal temperature to rise
above its limit. Error Code X103 signifies outside influences have caused the detector to rise above its
limit. If these alarms are triggered, check the installation for proper flow of air or water.
Higher than rated ambient temperature can also be the cause. Other possible causes of overheating
include radiant and conductive transfer of heat. Insulation, shielding and thermal isolation may be
necessary. See Section 8 Applications Guide, page 129 for more information.

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3.9.7 BMA – Base Mount Accessory Description and Dimensions

This trunion style U mounting bracket is used as a base mount for the WJA –Water Jacket Accessory. Trunions
(pivoting shafts) on the sides of the WJA are placed into the matching BMA mounting slots. The WJA is held
in a vertical position, with the Sensor side down, and placed into the slots. The BMA and WJA final assembly
can be mounted in any position.
Vertical angular movement of the WJA and Sensor is provided by the pivoting shafts. The BMA mounting
slots (gimbals) are shaped to keep the shaft in place and provide secure mounting. Two bolts and two washers
are supplied with the WJA to lock it in the final position.
The BMA base mount surface has one clearance hole and two radial slots for mounting bolts. Three M8 or
5/16 inch user supplied bolts and washers are required. Approximately plus and minus 10 degrees of
horizontal angular movement is provided to aim the Sensor.

Figure 35: BMA Accessory

Material: Nickel Plated Steel

Weight: Approximately 5.6 pounds (2.5 Kilograms)

Mounting and Assembly Supplied Parts List:

 No hardware is supplied with BMA. UAA assembly hardware is supplied with the UAA.
 Three user supplied M8 or 5/16 mounting bolts and washers are required to mount the base of
the bracket.

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Bolt mount ARC

Figure 36: BMA Dimensions

Dimensions are in inches and (millimeters). Do not scale.

Use 5/16 inch or M8 mounting Bolts (3 Places).

3.9.8 ESA – Extension Sleeve Adapter Description and Dimensions

This is a special accessory for Sensors with the Dirty Window Detector (DWD) option. The ESA serves
as protection sleeve over the DWD optics and as the mechanical interface between the Sensor and other
Modline 5 accessories. The ESA is used in the following combinations to provide air purging or create
a dead air space zone in front of the Sensor optics to help keep them clean. The combinations also
provide shielding from stray radiation emanating from high temperature targets. The APA air purge,
shown in combinations one and two, provides the best performance. The use of an APA is required for
large targets over 1000 C.
1. ESA and APA air purge with clean air (air purging and shielding).
2. ESA and APA air purge without air (dead air space zone and shielding).
3. ESA with MFL Flange (dead air space zone and shielding)
4. ESA with MFL and AA-3 air purge accessory (air purging and shielding).
See Section 3.8 DWD Installation Requirements for DWD and Section 3.12 Other Accessories (Sight
Tube, Window, WJ-5 Water Cooling), page 60 for AA-3 references.

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Figure 37

The ESA is also used with the MFL Flange when as an interface with the Right Angle Mounting Bracket.

Material: Clear Anodized Aluminum

Weight: Approximately 1 Pound (0.5 kg)
Mounting and Assembly Supplied Parts List:
 No hardware is supplied with the ESA.
 Assembly screws are supplied with the APA and MFL.

Locating PINs
DIA. 2 Places.

Flat mounting Surface

Align with other Accessories

Through Holes for M6 Screws

3 Places

Figure 38: ESA Dimensions

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Dimensions are in inches and (millimeters). Do not scale.

3.10 Accessory Combinations with Break-out Drawings

3.10.1 Recommended Accessory Groupings
The table below lists the eighteen recommended accessory groupings. Exploded views of the groups
are shown on the following two pages.
The recommended groupings for Sensors with the Dirty Window Detector are identified in the DWD
column. See Section 3.8 DWD Installation Requirements, for more information. Groups are illustrated
with dimensions in Section 3.11 Installation Drawings and Illustrations.

DWD
Group Mounting Option Required Accessories
See Notes
1 ¼-20 Bolt Pattern Mount UAA N. R. (1)
2 Large Flange Interface Mount UAA MFL Add ESA (3)
3 Air Purge with ¼-20 Bolt Pattern Mount UAA APA Add ESA (2)
4 Air Purge with Small Flange Mount UAA APA MFS Add ESA (2)
5 Air Purge with Large Flange Mount UAA APA MFL Add ESA (2)
6 Right Angle Base Mount UAA RAM N. R. (1)
7 Right Angle Mount with Air Purge UAA RAM APA Add ESA (2)
Right Angle Mount with Large Flange.
This group requires an ESA for clearing the MFL & ESA Included
8 RAM UAA RAM ESA Note 3
9 Right Angle Mount with Air Purge UAA RAM APA MFS Add ESA (2)
10 Right Angle Mount with Air Purge UAA RAM APA MFL Add ESA (2)
11 Water Jacket, Air Purge and Small Flange APA WJA MFS Add ESA (2)
Add ESA
12 Water Jacket with Large Flange Mount WJA MFL (3 and 5)
13 Water Jacket, Air Purge and Large Flange APA WJA MFL Add ESA (2)
14 Water Jacket, Base Mount WJA BMA N. R. (1)
15 Water Jacket, Base Mount, Air Purge APA WJA BMA Add ESA (2)
Add ESA
16 Water Jacket, Base Mount and Large Flange WJA BMA MFL (3 and 5)
Water Jacket, Base Mount, Air Purge
17 and Small Flange APA WJA BMA MFS Add ESA (2)
Water Jacket, Base Mount, Air Purge
18 and Large Flange APA WJA BMA MFL Add ESA (2)
DWD is Dirty Window Detector Option. See ESA on previous page for more information. Also see Sections 3.8 DWD Installation
Requirements and 3.9.6 WJA – Water Jacket Accessory Description and Dimensions.
Notes:
1. N. R. = Group Not Recommended for Sensors with DWD.
2. USE the ESA and APA air purge with clean air for air purging and stray radiation shielding. Use APA without air to
create a dead air space zone and shielding. The use of an APA is required for large targets over 1000 C.
3. The ESA with MFL provides dead air space and stray radiation shielding. Add an AA-3 air purge accessory for air
purging. See Section 3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling), page 60 for AA-3
information. These combinations not recommended for large targets over 1000 C.

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4. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
5. Use water for cooling only. Do not use air for cooling with DWD unless the APA air purge accessory is used. See
information in Section 3.9.6 WJA – Water Jacket Accessory Description and Dimensions.
Table 7: 3.10.1 Recommended Accessory Groupings

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Accessory Illustrations for Groups using UAA:

Front of Sensor

Figure 39: Sensor without DWD – UAA Accessory Groups 1 through 10

Front of Sensor

Figure 40: Sensor with DWD – UAA Accessory Groups 2, 3, 4, 5, 6, 7, 8, 9, 10

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Accessory Illustrations for Groups using WJA:

Front of Sensor

Figure 41: Sensor without DWD – WJA Accessory Groups 11 through 18

Front of Sensor

Figure 42: Sensor with DWD – WJA Accessory Groups 11, 12, 13, 15, 16, 17, 18

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3.11 Installation Drawings and Illustrations

3.11.1 Installation Drawing for the UAA – Universal Adapter for Tripod or Custom
Mounting
Group Mounting Option Required Accessories. See Individual Accessory DWD
Descriptions and Dimensions. See Notes
1 ¼-20 Bolt Pattern Mount UAA N. R.
2 Large Flange Interface Mount UAA MFL Add ESA (3)
3 Air Purge with ¼-20 Bolt Pattern Mount UAA APA Add ESA (2)
4 Air Purge with Small Flange Mount UAA APA MFS Add ESA (2)
5 Air Purge with Large Flange Mount UAA APA MFL Add ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with
Break-out Drawings. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
Table 8: Recommended Accessory Groupings UAA

Figure 43: Front mounted Figure 44: UAA with APA

When using the MFL (Group 2) or APA (Group 3, 4, 5), assemble these accessories to
the UAA first. Place Sensor fully into assembly and rotate Sensor to desired position.
Tighten clamping screw.

Sensor front surface will be positioned at the back end of the APA or MFL. To determine working
distance (D) for spot size formula d=D/F, measure or calculate from that point.

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¼ hex Head Screws (3)

with flat and lock washers
supplied for mounting.

Dia.
Dia.

M8 X 30 mm Socket Head Cup Screw

supplied for clamping Sensor.

Optical Axis

Figure 45: UAA

Dimensions are in inches and (millimeters). Do not scale.

Group 1 shown (UAA and Sensor).
See UAA description and Dimensions.
Sensor Front inserted Level with UAA Front.

3.11.2 Installation Drawing for the RAM – Right Angle Mount

Required Accessories. See Individual DWD

Group Mounting Option Accessory Descriptions and Dimensions. See Notes
6 Right Angle Base Mount UAA RAM N. R.
7 Right Angle Mount with Air Purge UAA RAM APA Add ESA (2)
Right Angle Mount with Large Flange.
This group requires an ESA for
8 clearing the RAM UAA RAM ESA MFL Note 3
8 Right Angle Mount with Large Flange UAA RAM MFL Add ESA (3)
9 Right Angle Mount with Air Purge UAA RAM APA MFS Add ESA (2)
10 Right Angle Mount with Air Purge UAA RAM APA MFL Add ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with
Break-out Drawings, page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
Table 9: Recommended Accessory Groupings RAM

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Figure 46 Figure 47

When using the MFL (Group 8) or APA (Group 7, 9, 10), assemble these accessories
to the UAA and RAM first. Place Sensor fully into assembly and rotate Sensor to
desired position to clear table. Tighten clamping screw.

Sensor front surface will be positioned at the back end of the APA or MFL. To determine working
distance (D) for spot size formula d=D/F, measure or calculate from that point.

Axis of Rotation
Optical Axis Coincident with Axis of Rotation

Figure 48: Group 7 shown (UAA RAM and APA).

Dimensions are in inches and (millimeters). Do not scale.

See individual Accessory drawings.

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3.11.3 Installation Drawing using the WJA – Water Jacket Accessory with
Flange Mounts

Group Mounting Option Required Accessories. See Individual DWD

Accessory Descriptions and Dimensions. See Notes
11 Water Jacket, Air Purge and Small Flange APA WJA MFS Add ESA (2)
12 Water Jacket with Large Flange Mount WJA MFL Add ESA (3)
13 Water Jacket, Air Purge and Large Flange APA WJA MFL ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with Break-
out Drawings, page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.
Table 10: Recommended Accessory Groupings WJA with Flange Mounts

Figure 49WJA with Flange Mounts

Insert Sensor into the WJA assembly with moderate force until it “snaps” into the
spring catch. Secure the Sensor rear protection and sighting window. Swing safety
clamp into position and tighten.

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Dia.

Dia.

Front of Sensor without DWD with

Reference to WJA

Safety Clamp
Figure 50: Group 13 shown WJA, APA and MFL Flange

Dimensions are in inches and (millimeters). Do not scale.

Total Lengths Dimension shown with and without MFL Flange.
Mechanical and optical Centerlines are coincidental.

3.11.4 Installation Drawing using the WJA Water Jacket Accessory with the Base
Mount Adapter

Group Mounting Option Required Accessories. See Individual DWD

Accessory Descriptions and Dimensions. See Notes
14 Water Jacket, Base Mount WJA BMA N. R. (1)
15 Water Jacket, Base Mount, Air Purge APA WJA BMA Add ESA (2)
16 Water Jacket, Base Mount and Large Flange WJA BMA MFL Add ESA (3)
Water Jacket, Base Mount, Air Purge and
17 Small Flange APA WJA BMA MFS Add ESA (2)
Water Jacket, Base Mount, Air Purge and
18 Large Flange APA WJA BMA MFL Add ESA (2)
DWD is Dirty Window Detector Option. Refer to notes with grouping table in Section 3.10 Accessory Combinations with Break-out Drawings,
page 50. The ESA adds 1.82 in. (46.2 mm) to length of the assembled group.

Table 11: Recommended Accessory Groupings WJA with BMA

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Figure 51

Insert Sensor into the WJA assembly with moderate force until it “snaps” into the
spring catch. Secure the Sensor rear protection and sighting window. Swing safety
clamp into position and tighten.

Dia. Front of Sensor (without DWD) with Reference to WJA

Sensor Axis of
Rotation
(Also Optical Axis)

Through Holes for 5/16 Inch or M6 Bolts (3 Places)

WJA Mounting Axis

Figure 52: Group 18 shown (BMA, WJA and MFL).

Dimensions are in inches and (millimeters). Do not scale.

See individual Accessory drawings.

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Total Lengths Dimension shown with and without MFL Flange.

3.12 Other Accessories (Sight Tube, Window, WJ-5 Water Cooling)

These other accessories are described in Product Bulletin PB-0070. Specification and mounting
configuration changes are required for certain items when used with the Modline 5.
Consult the IRCON factory for information about using these accessories with the Modline 5 Sensor.

Other Accessory Model / Part Compatibility and main interface

AA-3 Requires MFL Flange to interface.
Requires MFL Flange to interface.
AP-Q, AP-CF Consult Ircon, Inc. with application details.
MF-1, MF-2 Threaded collars for threaded
1-1/2 inch NPT sight tubes and 2-1/2 inch
NPT sight tube. Requires the MFL Flange to interface. See note below.

PM-2 Pipe Mounts for use with

STSC and STA Sight and Target Tubes Requires the MFL Flange to interface. See note below.
STM Sight Tubes with Flange Surface Requires the MFL Flange to interface. See note below.
Not compatible with Modline 5 Sensors.
WA-3 Water Cooling Accessory Do not use to provide cooling.
A mounting kit, UAA, and MFL is required to install Modline 5 Standard
Sensor in WJ-5. Maximum ambient temperature limited to 160 C (320
F).
Note: Not compatible with Modline 5 Sensor with Dirty Window Detector
Option (DWD) installed.
WJ-5 Water Cooling Jacket with Air Purge. See installation details below.
Table 12: Compatibility with other Accessories

Focus Sensor with rear rotating focus section. If looking through a sight tube or sight
hole, position, align and rotate the Sensor and Sight tube to center the reticle or laser
image in the field of view.

3.12.1 M5WJ5 – Mounting Kit

The M5WJ5 Mounting Kit is used with UAA and MFL Mounting Accessories to install a Modline 5
Sensor in an Ircon Model WJ-5 Water Cooling Jacket. The jacket provides cooling through a stainless
steel coiled pipe embedded in the jacket walls. A flow rate of 20 gallons per hour (75 liters per hour) of
water with a temperature of 90F (32C) or less is required.
An air purge is included on the front of the WJ-5. Clean, dry purge air should be provided at a flow rate
6 ft3/min. (0.17m3/min.).
The jacket protects the Modline 5 Sensor in ambient temperatures up to 160C (320F). Complete
specifications, installation and piping instructions are included with the kit. The Modline 5 Sensor cable
is rated to 200C (400F).

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The Modline 5 Sensor with the Dirty Window Detector Option (DWD) cannot be
installed in a WJ-5 Jacket because of its additional length.

Figure 53: M5WJ5 – Mounting Kit

Accessories and kit required for mounting Modline 5 Sensor in WJ-5 Water Cooling Jacket:
 Model WJ-5 Water Cooling Jacket with Air Purge Supplied with its own mounting
hardware (M5WJ5 Kit is not included.)
 UAA Universal Adapter Accessory Supplied with its own mounting hardware
 MFL Mounting Flange Large Accessory Supplied with its own mounting hardware
 M5WJ5 Mounting Parts Kit: Consisting of the following. (Note: These parts are sold only as a
kit.)

Item Qty. Part Number Description Function

Complete specifications, cautions and
1 1 050501 INST: WJ-5 Rev. C installation instructions
2 1 482322 Mod 5 WJ5 Spacer Block Spacer between UAA and Plate
3 1 456862 Mod 5 WJ5 Mounting Plate Slides assembly into WJ-5
4 2 202524660 ¼-20 X ¾ inch long Socket Head Cap Screw Mount Spacer Block to UAA
Mounting Plate to Spacer (2)
5 4 202524540 ¼-20 X ¾ inch long Hex Head Screw Mounting Plate to WJ-5 (2)
Use with ¼-20 X ¾ inch long Hex Head
6 4 222503030 1/4 in. Split-ring lock washers Screws (4)
Table 13
Assembly and Sighting Instructions:
Refer to Installation Instructions for WJ-5, Included in M5WJ5 Kit
1. Assemble as indicated in drawing to the right and at top of page.
2. Slide assembly into WJ-5 and tighten rear mounting plate screws.
3. Focus Sensor with rear rotating focus section.
4. If looking through a sight tube or sight hole, position, align and rotate the Sensor and Sight tube
to center the reticle or laser image in the field of view.

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5. Route the cable either through the center opening in the mounting plate or along the side walls
of the WJ-5 and out through the insulated opening in the back door.

MFL Mounting Flange Large Accessory

UAA Universal Adapter Accessory

Modline 5 Sensor (without DWD option)

Spacer Block
(Item 2)
Socket Head
Cap Screws (Qty 2)
Sensor Cable
(Item 4)
Mounting Plate (Item 3)

Lock washers (Qty 4)

(Item 6)

Hex Head Screws

(Qty 4) (Item 5)
Figure 54: Mounting Kit

3.13 Sensor Installation Checklist

To ensure accurate, reliable, and trouble-free operation, check the installation for the following:
Sensor is properly mounted and aligned with no obstructions in optical path.
Sensor lens is focused on target. If possible, target size is at least twice diameter of reticle size as seen in
the viewing sight (i.e. twice the calculated spot size at the viewing distance).
Rear Protective window has been securely installed on back of Sensor. After completing the sighting
and focusing routines, screw the protection window back onto the Sensor to maintain the NEMA 4
(IP65) environmental rating.
Sensor lens is protected by air purge and clean purge air if atmosphere is dirty, oily or corrosive. Do not
use purge air with oil or water. Use instrument air or filter adequately.
Sensors with the Dirty Window Detector Option require an APA air purge or other protection as
explained in Section 3.8 DWD Installation Requirements, page 34. If the purging air quality is poor, use
an efficient filter. In worst cases, leave the air purge assembled to the Sensor, but disconnect the air
supply.
Sensor is adequately protected by water or air cooling and/or additional insulation if ambient
temperature exceeds safe limits.
Sensor is not subjected to direct or reflected radiated heat from oven walls, flames, etc. that cause it to

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exceed its temperature rating.
The Sensor mounting surface is grounded (Earth Ground). If not, electrically insulate the housing from
the mounting surface. See information in Section 4.11 System Grounding and Shielding, page 79.

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4 Sensor Wiring
4.1 Modline 5 Components
The basic Modline 5 system consists of either a standard Sensor or Sensor with Dirty Window Detector
option, interconnecting cable, a POI Power Supply/Signal Interface Box or Terminal Strip Plate and as
possible option, the DPM Digital Panel Meter Interface.

Figure 55: Modline 5 Components

4.2 Modline 5 Sensor System Interfacing

The following figure shows a block diagram overview for interfacing the Modline 5 into a process
monitoring and control system.

100 - 240Vac 50/60Hz (POI)

or 24Vdc (TSP)
T Interconnecting Cable Sensor Alarm Relay Contacts
A
R
POI Peak Picker / Track & Hold Remote
G Sensor
Box Switch Input
E
T
or Input 4-20 mAdc for Remote
Emissivity/E-Slope or Laser Switch
Terminal Strip
24Vdc Sensor Power Supply limited Plate
to 2 Amps RS-485 Digital Communication to
Modline 5 DPM, PLC, Host
Analog Current Output Computer or other Device
Selectable 0 - 20 mA or 4 - 20 mA
Scaled to Sensor temperature span or customized for process
Single or multiple series connected differential input devices,
Digital Indicators, Recorders, Controllers, Control Systems
600 Ohm maximum load resistance, including cable resistance

Figure 56: Block diagram

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4.3 Modline 5 Sensor Cable

4.3.1 Sensor Interconnecting Cable
The Interconnecting cable carries all inputs, outputs and the 24 VDC power for the Sensor. The cable is
routed from the Sensor to the POI Power Supply/Signal Interface Box or the Terminal Strip Plate
supplied with each cable.
All IRCON Modline 5 interconnecting cables are supplied assembled with the Sensor connector on one
end and the wires stripped, tinned and ready for termination on the opposite end. The cable shield is
also prepared and ready to assemble with the Ircon supplied EMI shielding strain reliefs. All cable wires
are 24 AWG (0.25 mm²), except the 24 V power supply wires that are 22 AWG (0.35 mm²).
Maximum Cable Temperature Cable temperature not to exceed 200C (392F).
Maximum Cable Length 350 feet (107 meters), Minimum Bend Radius 3 inches (76 mm).
Cable Diameter Nominal Diameter 0.310 inch (7.6 mm).
Cable Routing Within conduit or low-level signal plenum or cable tray.
Location Away from high power and high frequency sources and high
temperature sources.
Consider the cable route. The cable should be protected from plant traffic and any hostile environments.
Avoid high temperature zones or areas subject to electrical or high frequency interference.

4.4 TSP Terminal Strip Plate

The TSP is required when the POI Power Supply/Signal Interface Box is not used. This plate mounted
terminal strip with terminal identification label and suppression components allows use of the Modline
5 Sensor and Cable with user-supplied enclosures and power supplies. The TSP ensures Sensor and
cable operation meets RF emission and immunity standards required for CE certification.
The 24Vdc Sensor Power Supply should be limited to 2 Amps.
An earth ground wire is to be connected to the ground stud at the bottom of the Terminal Plate.
Minimum size wire is 18 AWG (1 mm²). A crimp terminal is supplied to mount on the stud.

To prevent possible electrical shock, fire, or personal injury make sure that the sensor
is grounded before use.

4.4.1 Dimensions and Installation

The Terminal Plate must be installed in a suitable user-supplied grounded enclosure for protection from
electrostatic discharge (ESD).
Four 0.196 inch (5mm) diameter holes are used to mount the plate. See photo below for mounting
dimensions.
The approximate overall rectangular plate dimensions are 5.39 inches (136.9 mm) long by 3.42 inches
(86.9 mm) wide and 0.8 inches (20.3 mm) high.
Plan access for cables and working space. Minimum Sensor interconnecting cable bend is 3 inches (76
mm).

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Wiring, grounding and shielding instructions are in the sections that follow.

2.32 “(58.9mm)

5.03 “
(127.8 mm)

Figure 57: Dimensions TSP

4.5 Sensor Interconnecting Cable Preparation

4.5.1 Cable Preparation
It is very important that the cable shield be properly prepared and installed. If the Terminal Strip Plate
is used, the shielding must be clamped to the ground shield clamps on the plate.
All cables must be properly dressed for shield grounding. Twisted pair wires must remain twisted and
kept as short as possible. The IRCON Sensor cable is supplied with the connector attached on one end.
The opposite wiring end is prepared and supplied as per the following procedure. If the cable is
shortened, the preparation procedure must be followed. User supplied cables require similar
preparation.
A. Strip off 10 in. (254 mm) of the outer jacket.
B. Partially cut back the outer braided shield. Leave 1 inch (26 mm) of shield exposed to attach a
strain relief or connection to a Terminal Strip Plate shield clamp.
C. Keeping wire pairs twisted, cut wires to lengths shown in the following table. Strip all wire pairs
ends 3/8 inch (10 mm) and tin with solder.

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Wire Pair Wire Length

color coded inches (mm)
YEL & YEL/WHT 3.0 (76)
BLU & BLU/WHT 2.2 (56)
ORG & ORG/WHT 1.4 (36)
VIO & VIO/WHT 2.2 (56)
BLK & BLK/WHT 3.0 (76)
RED & RED/WHT 10.0 (254)

Table: 14

D. Select Next Step. If the preparation is for a POI Box, see the separate POI manual for cable
preparation and installation instructions. If the preparation is for a Terminal Strip Plate, pull back
and comb out the exposed shield. Preparation is now complete. Route and install the
interconnecting cable. Refer to Section 4.6 Terminal Strip Plate – Sensor Interconnecting Cable
Installation, page 68.

4.5.2 Interconnecting Cable Assembly Continuity Check

If desired, a continuity check of the cable can be made. The table below identifies the receptacle pin and
the color coded wire connected to the pin. The illustration below identifies the pin locations on
the cable plug end.

Cable Shield is connected to the plug shell.

Pin 1 Black/White
Pin 2 Red
Pin 3 Black
Pin 4 Violet
Red Dot Up
Pin 5 Blue
Pin 6 Yellow/White
Pin 7 Blue/White
Pin 8 Red/White and Violet/White
Pin 9 Orange
Pin 10 Yellow
Pin 11 Orange/White

Figure 58

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4.6 Terminal Strip Plate – Sensor Interconnecting Cable Installation

Clamp the cable shield to the shield clamp on the left side of the Terminal Strip Plate.
Insert the 9.5 inches (241.3 mm) long Red and Red/White twisted pair through the ceramic ferrite core
supplied with the plate. Keep the exposed wire length between the shielded cable end and the ferrite
core as short possible. Maintain enough length to allow the core to be inserted into its mounting clip.
Bring the Red and Red/White pair around the outside of the core as tight and as close to the core surface
as possible. Repeat until 2 wraps have been completed as shown.
Cut the pair to the required length for connection to the terminal strip. Strip wire 3/8 inch (10 mm) and
tin with solder.
Route all twisted wire pairs to their corresponding terminals identified by wire color. Insert the tinned
wire ends of each color coded wire into its terminal and tighten.
The 100 Ohm 1 watt fusible resistor placed from the ground stud to power supply common is not shown
in these illustrations.

Figure 59 Figure 60

4.7 Connecting Device Cables to Terminal Strip Plate

4.7.1 Recommended Cable Types
To maintain signal integrity and reduce noise pick-up, twisted pair shielded cables with overall foil and
braid shielding should be used for connecting to all Sensor inputs and outputs. Belden low capacitance
computer cable types 9829, 9830, 9831, 9832, 9839 and 9833, or equivalent cables are recommended. Each
of these cables has a different number of wire pairs varying in quantity from 2 to 7 pairs.
The cable selected should have a twisted pair nominal impedance of 100 ohms and nominal capacitance
between conductors should not exceed 15.5 pF/ft. (50.9 pF/m).
Prepare the cables as explained in Section 4.5 Sensor Interconnecting Cable Preparation, page 66.
Ground cable shields on the Terminal Strip Plate by inserting the prepared braid under the shield
clamps.

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4.7.2 Grounding and Shielding

Follow all grounding and shielding instructions provided below. Proper connection of the cable shields
is important to avoid noise and ground loop problems that may cause errors. Do not connect cable
shields at both ends. The illustration below shows the shield not connected at the other end.

Sensor System
Input/Output Device

Figure 61

Refer to Section 4.11 System Grounding and Shielding, page 79 before beginning wiring. The section
presents an overview on grounding and shielding and contains important information for wiring
system cables.

4.7.3 System Connections

Refer to Manual Sections 5 Operation and 6 RS-485 Digital Communications, page 107, for Operation
Information.

Yellow   RS485 + RS485 Digital Communications

Yellow/White   RS485 –
Blue   Analog Out + 4 – 20 or 0 – 20 mA output
Blue/White   Analog Out –
Orange   mA In + Remote Emissivity or E-Slope current input
Orange/White   mA In –
Violet   Pk/Hd Switch Can be used for Peak Picker Reset or Track Mode select or Remote
Laser operation.
Violet/White   Pk/Hd Switch
Black   Alarm Relay Invalid Condition, Dirty Window and Sensor Error Code Alarm relay
Black/White   Alarm Relay
Red   +24VDC 24Vdc Sensor Power Supply
Red/White   Common
Table 15: Sensor Interconnecting Cable / Function

4.7.4 RS-485 Digital Communications

Connections are made on the terminal strip RS485+ (DATA) and RS485 – (DATA*) terminals. The Power
Supply Common (-) terminal is used as the ground reference.
See Section 4.9 for detailed wiring of Sensors in a RS-485 multi-drop network. Section 6 of this manual
details the RS-485 operation.
Maximum cumulative RS-485 cable length, from sensor to the actual process device, is 4000 feet (1220
meters).

4.7.5 Analog Output Temperature Signal

This current loop temperature signal is 4 to 20 mADC or 0 to 20 mADC, user selectable, linear with

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measured temperature. The corresponding temperature span is adjustable. Temperature signal
connections are made to the Analog Output + and Analog Out – terminals.
Single or multiple series connected indicators, recorders or other instruments can be connected. The
total current loop series DC resistance of all devices and wiring should not exceed 600 ohms.

І OUT = 0 to 20 mA or 4 to 20 mA

600 Ohm
Sensor Maximum
Including Cable
Resistance

Figure 62

The minus side of the Analog Output is connected to power supply common (see section 4.11 System
Grounding and Shielding, page 79). Use instruments with ungrounded differential inputs. If
instruments with grounded inputs are connected in the loop, the output may be inoperable or
inaccurate.
If the Analog output is not used, insert a jumper wire or 100 Ohm to 500 Ohm value resistor across the
output terminals. This will prevent an Analog Loop malfunction Alarm (Error X108) from occurring.

4.7.6 Converting the Analog Output from a mA output to a 10 Volt Output

To convert the Analog mA output to 0 to 10 Vdc Output, place a 500 Ohm resistor across the output
terminals. The Sensor Analog output (SOUT) should be set to 0 to 20mA range.
The minus side of the Analog Output is connected to earth ground. Use instruments with ungrounded
differential inputs. If instruments with grounded inputs are connected, the output may be inoperable
or inaccurate.

І OUT = 0 to 20 mA

500 Ohm @ 0,1%

Sensor

Figure 63

4.7.7 Current Input for Remote Emissivity, E-Slope or Laser Operation

You may make remote adjustments of the Emissivity or E-Slope by sending a scaled analog input of 4
to 20 mAdc. The Modline 5 senses an input and overrides any Sensor rear panel or RS-485 settings of
Emissivity, E-Slope or Match.

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The input can also be used for remote Laser operation.
Example for Emissivity:
A 4 mAdc signal corresponds to an emissivity setting of 0.100. A 20 mAdc corresponds to an
emissivity of 1.000. The relationship for the values in between is linear.
Example for E-Slope:
For the E-Slope settings, the 4 to 20 mAdc signals correspond to settings of 0.800 to 1.200. The
relationship for the values in between is linear.
Connections are made to Terminals mA In + and mA In –. Input impedance is 120 Ohms. Use Shielded
cable at the TSP Terminal Strip Plate ground terminal.
The (–) terminal of the mA input current input is isolated, but will only tolerate a difference of
approximately 2 Volts between it and Sensor Common.
Remote Laser Operation is selected in COMMS – LASR Menu. See manual Sections 5.8 and 5.11 for
selecting and operating this function. To configure and wire for remote I IN current/switch Laser
operation follow the instructions given below. When selected for remote Laser Operation, Emissivity
and E-Slope are not changed by the input current.

4.7.8 Current Input Terminal Connections for Remote Laser

Use a DC power supply with a maximum output of 24 volts. Maximum input current allowed is 20 mA.
Overloading the input can cause a Sensor Fail alarm.

When calculating a series resistor value to use with a supply voltage, subtract the 120
ohm Sensor internal circuit impedance from the calculated value. See Table below. On
threshold is 15 mA.

DC Voltage Supply Resistor Value

10 Volts 560 ohms (Plus 120 Internal = 680 ohms total) for 15 mA
24 Volts (Can be Sensor Supply) 1500 Ohms (Plus 120 Internal = 1620 ohms total) for 15 mA
Table 16
Connect the supply circuit as shown in the wiring diagram. The I IN – terminal can be connected to a
floating or earth grounded power supply terminal. In either case, it must be connected directly to the
power supply.
Mount the ½ Watt resistor in a series circuit on the switch or at the external power supply location.

1/2 Watt
Resistor

Orange Remote
Laser Switch
Orange/White

Figure 64

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4.7.9 Peak/Hold Switch for Remote Peak Picker Reset, Track and Hold or Laser
Operation.
An external switch connected to the Pk/Hd Switch terminals will control signal conditioning of the
Modline 5. These terminals can also be used for remote Laser activation.
Switch action for the Peak Picker will provide the following control. Momentary closure of the switch
(>0.08 second) immediately resets the Peak Picker. If the switch is continuously closed, the Temperature
Display will show direct readings without any Peak Picker signal conditioning. The switch may be
manually operated or it may be a contact on a timer, relay, or any other process operated switch.
Switch action for Track and Hold will provide the following control. With the switch open, temperature
tracking continues (Track). With the switch closed, the displayed temperature will be held at the last
reading (Hold). The switch may be manually operated or it may be a contact on a timer, relay, or any
other process-operated switch.
Remote Laser Operation is selected in COMMS – LASR Menu. See manual Sections 5.8 COMM – Setup
of RS-485 Digital Communication Configuration, page 95 and 5.11 Laser Sighting Operation, page 102
for selecting and operating the remote laser function. The PkHd terminals are dedicated to Laser
operation when selected. To wire for remote PkHd switch operation follow the diagram given below.

Violet Pk/Hd Switch

Remote
Laser Switch
Violet/White Pk/Hd Switch

Figure 65

4.7.10 Sensor Alarm Relay Contacts

The sensor tests its case temperature, detector assembly temperature, output current flow, etc. The
Check function checks internal circuit and detector operation. The optional Dirty Window Detector
measures the Sensor’s window condition. One or more out of limit conditions sensed by these tests
triggers an Alarm and operates the Alarm relay within the Modline 5. The relay contacts may be used
in the process control system to indicate measurement conditions do not allow process temperature
measurements or Sensor operation may be impaired. Appropriate action for the various conditions can
then be initiated.
Alarm Relay contact connections are made to the Alarm Relay Terminals. The relay contact is rated for
24 Volts AC or DC, 1 AMP resistive loads only.
The Alarm relay can be configured for Normally Open or Normally Closed operation. The configuration
can be performed at the Sensor Rear panel with the Engineering RELY function, or with RS-485 digital
communications.
Set the relay operation to correspond to proper and safe use of the contacts in your overall measurement
system.
Select N C. for closed relay operation with Sensor not in Alarm condition (open in alarm state).

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Select N.O. for closed relay operation with Sensor in Alarm condition (open when not in alarm
condition).
Contacts are held open for both N.O. and N.C. operation when the Sensor is not powered, and, for 3 to
5 seconds after power is applied to the Sensor during the initiate period. Normally Closed N.C,
operation is considered fail-safe operation.
The table below details the alarms and measurement conditions that trigger the Alarm Relay. Details
about these Alarms are found in Section 7 Maintenance, page 119.
Sensor Error Code Alarms

X101 Dirty Window Detection

X102 Out of calibration
X103 Detector block too hot
X104 Detector block too cold
X105 Case temperature too high
X106 Case temperature too low
X107 Sensor failure FAIL may be seen on the Sensor TEMP display
X108 Analog Output Current loop malfunction (open circuit)
X109 Dirty Window Detection malfunction

Measurement Condition Alarms

INV Measurement Conditions are invalid for two color ratio temperature measurement.
When the Invalid Alarm (iALM) function is set to ON, this measurement condition becomes an alarm
and triggers the Alarm relay and the ALARM word on the Sensor rear panel

pINV pINV is only displayed when the Invalid Alarm (iALM) function is set to ON and Peak Picker or Tra
and Hold is On, this condition becomes an alarm and triggers the Alarm relay and the ALARM wor
on the Sensor rear panel.
Temperature displayed is Peak Picked or Hold Mode Temperature values from prior valid
measurement conditions.

4.8 Selection of a Power Supply for Sensors used with TSP Terminal
Strip Plates
When using a Modline 5 Sensor with the TSP Terminal Strip Plate, select a switching type power supply
that will provide reliable startup. The power supply output should remain at rated voltage during the
Sensor current loading that occurs at startup. Sensor displays and alarms will not properly start with
low voltage.
A dedicated Power supply for each Sensor is the simplest and best configuration. Section 4.9 RS-485
Multi-Drop Network Power Supply and System Wiring, page 75, provides instructions for using a
chassis mount 15 watt, 24 Volt DC Switching Power Supply supplied by IRCON. The part number for
this power supply is 551632.
Multiple Sensor installations may require more than one power supply. A single supply will not be able
to properly provide startup power to a large number of sensors. Limit the number of Sensors supplied
from a single power supply to no more than 2 or possibly 3. Dividing the Sensors into groups can

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eliminate long cable runs when sensors are installed at distant locations. This is especially the case when
AC power is available locally.
The standard Modline 5 cable that is routed between the Sensor and TSP Plate is limited to 350 Feet (107
meters). The power supply wires in this cable are 22 gauges. This maximum cable distance and wire
gauge assures enough voltage will be available at the sensor. The voltage drop developed across the
power supply wire pair will be small and not cause a low voltage condition.
Whether powering a single Sensor or multiple Sensors, there may also be significant voltage drops
across the wires connecting the power supply to each TSP. Keep the wire lengths between the power
supply and Terminal Strip Plate short. The voltage drops developed are dependent upon length and
gauge of the wire.
A qualified electrician or technician should apply power with the all sensors connected and measure 24
VDC, +/– 5%, at the Red and Red/White power supply terminal connections on the left side of each TSP
Terminal Strip Plate.
A 100 Ohm1 Watt fusible resistor is supplied with all TSP plates to connect power supply common to
earth ground as shown in the diagrams.
To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor

Power Supply Power Supply Power Supply

24 VDC 24 VDC 24 VDC

Figure 66: Sensor Wiring one 24 VDC Supply for each Sensor

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To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor

Power Supply
24 VDC

Figure 67: Sensor Wiring one 24 VDC Supply and Three Sensors

4.8.1 TSP Terminal Strip Plate DC Power Supply Connections

These instructions are for the Terminal Strip Plate only. For the POI Box, see the separate POI manual
for mounting instructions, wiring requirements, and specifications.
See Section 4.4 to review Terminal Strip Plate enclosure, power supply and ground connection
requirements.
The external 24 VDC power is wired to the right side of the Terminal Strip. Use 22 AWG (0.35 mm²)
wire. Total power supply cable run using 22 AWG (0.35 mm²) wire is 107 meters (350 feet). Shielded
cable is recommended. Paralleling two pairs of 24 AWG (0.25 mm²) cabling is equivalent to using
22 AWG (0.35 mm²) cable.
Connect the positive side of the 24 VDC power source to the +24VDC Terminals.
Connect the common or negative side of the source to the Common Terminal.

4.8.2 Power Supply Common Ground Connection

The Common side of the power source must be connected to earth Ground. If the dc power source
common is not already connected to ground at some point in the system, make the connection at the
Terminal Strip Plate.
The recommended and preferred method of making the ground connection to is to connect the power
supply Common Terminal to Ground through a 100 Ohm 1 Watt fusible resistor. The resistor is inserted
between the Ground Stud and the Common Terminal.

4.9 RS-485 Multi-Drop Network Power Supply and System Wiring

Multiple Modline 5 Sensors communicating via RS-485 with a Host device are installed in a multi-drop
network configuration. The Modline 5 MSI Multiple Sensor Interface, a PC, a PLC or other Control
system are Host devices. A block diagram of a multi-drop network is shown in the adjacent illustration.
It is important to wire the network properly to prevent noise pickup and have reliable operation.

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Sensors should be wired in tandem as shown in the diagram. The RS-485 terminals from the Sensor
furthest from the host device are wired to the next closest Sensor. Then the RS-485 Terminals of that
Sensor should be wired back to the next closest sensor. Do this until all sensors are wired. Do not use
any other configuration.
A 120 ohm termination resistor should be placed across the RS-485 terminals of the Sensor furthest from
the Host device as shown in the diagram. Consult the manual for the Host device to determine if any
termination resistor is required at its terminals. The IRCON Model MSI Interface does not require a
termination resistor at its input.
To maintain signal integrity and reduce noise pick-up, twisted pair shielded cables with overall foil and
braid shielding should be used for connecting to all Sensor inputs and outputs. Belden low capacitance
computer cable types 9829, 9830, 9831, 9832, 9839 and 9833, or equivalent cables are recommended. Each
of these cables has a different number of wire pairs varying in quantity from 2 to 7 pairs.
The cable selected should have a twisted pair nominal impedance of 100 ohms and nominal capacitance
between conductors should not exceed 15.5 pF/ft. (50.9 pF/m).

Select power supplies and install cables as instructed in previous sections of the
manual.

To Sensors RS-485 Multi-drop Network

Sensors with TSP Terminal Strip Plates

Power Supply
More than one
Required,
see Manual Ground TX-A TX-B
RS-485 Serial Port
IRCON Multiple Sensor Interface (MSI)
or PC, PLC, Control System

Figure 68

4.9.1 Computer Communications Requirements

The Host device communicating with The Modline 5 Sensor should have an RS-485 communication
port. If not, an RS-232 Port and a RS-485 to RS-232 converter can be used. An RS-485 to USB converter
can also be utilized. The combined communications port and converters used must have the capability
to communicate over a 2 wire, half duplex RS-485 network at speeds fast enough to handle command
requests with reply turnaround times of one-millisecond or less.
The following converters will provide satisfactory performance when used with Modline 5 Sensors.

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CyberResearch Inc.
Contact: www.cyberresearch.com
SuperverterTM Model 285 R-422/RS-485 to RS-232 Converter.
CyMODTM Model CM 4530 USB to RS-232/422/485 Converter with isolation.
(Superverter and CyMOD are trademarks of CyberResearch Inc.)

DGH Corporation
Contact: www.dghcorp.com
A1000 and 2000 Series (The A1000 will also provide 24 Volt DC power for 3 Sensors)
RS-232/RS-485 Converters and RS-485 Repeaters

Black Box Corporation

Contact: www.blackbox.com
RS-422/485 PCMCIA Serial I/O Adapters, Single-Port
Product Code IC114A-R2 (for laptop computers)

See section 6 RS-485 Digital Communications, page 107, for Modline 5 Sensor communications details
and commands.

4.9.2 TSP Terminal Strip Plates Multi-drop Wiring

These illustrations indicate the proper wiring when using TSP Terminal Strip Plates. A power supply
for each Sensor and TSP pair is shown in the first illustration. This is the preferred method.
A single power supply is shown powering three Sensors in the second illustration. A power supply
should not power more than 2 or 3 Sensors.
Use the shielded cable specified in the previous manual sections and install termination resistors as
required.

To Modline 5 Sensor To Modline 5 Sensor

Termination Resistor
at furthest Box

RS-485
Power Supply Power Supply Modline 5 MSI Multi-Sensor Interface Ground
24 VDC 24 VDC or PLC, PC, System TX-A
TX-B

Figure 69: Multidrop Sensor Wiring with 24 VDC Supply for each Sensor

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To Modline 5 Sensor To Modline 5 Sensor To Modline 5 Sensor

Termination Resistor
at furthest Box

RS-485
Power Supply Modline 5 MSI Multi-Sensor Interface Ground
24 VDC or PLC, PC, other System TX-A
TX-B

Figure 70: Three Sensor RS-485 Multi-drop with 24 VDC Supply and TSP Terminal Strip Plates

4.10 Sensor and Cable Connection

4.10.1 Cable Plug and Sensor Receptacle
Position the red dot on the interconnecting cable plug on connector to match the red dot on the Sensor
housing receptacle. Push the connector firmly and completely in to the Sensor receptacle.
The cable plug and Sensor receptacle combination are NEMA 4 (IP65) rated. However, provide
protection for the plug and receptacle if they are disconnected and the contacts and pins are exposed to
harsh environments.
Make sure the 24Vdc power to the Modline 5 Sensor is turned off whenever connecting and
disconnecting the cable.
Make sure the rear protection window is in place after making adjustments to maintain the Sensor’s
NEMA 4 (IP65) environmental rating.

Figure 71

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4.11 System Grounding and Shielding

4.11.1 Terminal Strip Plate Diagram

Mounting surface not

at ground potential
Insulation Terminal Strip Plate

Analog
output
1) Ground Cable clamp (3 Places)
4) Grounded shield
mA IN
Interconnecting cable EMIS/E-SLOPE

Mounting surface at 4) Shield to clamp 4) Grounded shield

ground potential Peak Picker/Track &
Hold Reset switch

4) Grounded shield
24 VDC
Power supply 3)
1) Ground
4) Grounded shield
11) Place Terminal Stripe Plate in metal enclosure
for protection from ESD (electrostatic discharge)
2) Ground lead

Figure 72: Terminal Strip Plate

1) The Sensor mounting surface should be at earth ground potential . Provide electrical
insulation between the Sensor and mounting surface if the surface is not at ground
potential. Use non-conductive hardware for mounting. Mounting surfaces not at
ground potential could be hazardous for personnel operating and maintaining the
Sensor.

2) Insure earth ground is properly connected to the Terminal Strip Plate as previously
instructed in this Section.
3) For the Terminal Strip Plate: Connect a regulated power supply.
4) If the Terminal Strip Plate is used, the interconnecting cable shield is connected to
ground with the shield clamp on the plate.
Twisted pair shielded computer cable is required for all connections.
If the Terminal Strip Plate is used, cable shields are connected to ground with ground
clamps on the plate.
This manual specifies the shields of cables connecting between the Terminal Strip
Plate and system devices be connected to ground only at the plate. The recommended
shield connections are shown in the drawing below. This recommendation is to
prevent ground loops due to the difference in ground potential between locations of
components and provide adequate shielding of cables.
Some devices call for connecting the shield to ground at the device input. If ground
loops develop with this connection, it may be necessary to experiment with shield

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connections. The ground connection at the Terminal Strip Plate and the
interconnecting cable shield should always be connected!

Sensor System
Input/Output Device

Figure 73: Sensor shield

5) Several Sensor circuits are connected to an internal common. The minus (–) or common
terminals for the 24 VDC Power Supply, Peak Picker/Track and Hold Switch, and
Analog Output are connected internally.
A.) Connect the Analog Output to devices with differential inputs that have not been
grounded.
B.) The ( – ) terminal of the mA input for remote Emissivity and E-Slope current input
is isolated but will only tolerate a difference of approximately 2 Volts between it and
Sensor Common. Input impedance is 120 Ohms.
See Note 8 for connecting Common to ground
6) The RS485 Data connection is not isolated. Use an external isolator if isolation is
required.
7) Alarm Relay contacts are isolated from ground and Sensor internal common.
8) For the Terminal Strip Plate: Depending on the installation, the internal common will
be connected to ground through a 100 Ohm 1 Watt fusible resistor.
See Section 4.8 for details.
9) The Terminal Strip Plate is supplied with a transient suppressor across the Red and
Red/White power supply wires on the left side of the terminal strip.
10) The Terminal Plate is supplied with a ceramic ferrite bead for the Red and Red/White
power supply wires.
11) The Terminal Strip Plate must be placed in a metal enclosure for protection from
electrostatic discharge (ESD).

4.12 Summary Caution and Warning

Inspect the installation for proper wiring, possible loose connections or potential shorts.
The installation of the Sensor described in Section 3 Sensor Installation, page 22 should be complete.
The wiring of the Sensor and system devices described in this Section 4 Sensor Wiring, page 64, should
also be complete. The Modline 5 Sensor can now be powered and the initial setup for operation
performed as described in Section 5 Operation.
Look for any signs of overheating or smoking when applying power. Investigate any signs of improper
installation
Please read the following important Caution and Warning.

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If you observe any signs of malfunctions smoke or overheating; complete lack of any
indication; etc. - turn off power immediately. Recheck all wiring, and refer to
Section 7.6.1 for troubleshooting.

Critical Process Safety Guideline

Risk of Personal Injury

When this instrument is being used in a critical process that could cause property
damage and personal injury, the user should provide redundant device or system that
will initiate a safe process shutdown in the event that this instrument should fail.

The user should provide a redundant system or device that will initiate a safe process shutdown in
the event that this instrument or associated system should fail. The control of a process should not
be solely dependent upon this instrument and its peripheral components. Other measuring and
controlling safe-guards should be included in a redundant system designed to provide warning of
conditions that may cause personal injury or property damage. These safeguards should be in place
at all times, including startup and shutdown, as well as normal operation.
Procedures should be in place that verifies proper instrument and system operation after service,
maintenance or replacement to insure the instrument and peripheral components are returned to service
properly. All alignments, settings and connections required for proper operation must be performed or
verified.
A computer with specialized software may be used as an operator interface for setup and operation of
the system. Digital and analog communication with alarms and controllers may be part of the system
making it a more complex system. Changing software configurations and settings requires that process
performance be verified.

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5 Operation
5.1 Sensor Rear Panel Setup and Operation
5.1.1 Introduction
Become familiar with the displays, pushbutton controls, menus and the functions required for Sensor
setup and operation as described below. Modline® 5 instruments are thoroughly tested and calibrated
to factory specifications before shipment and should require no more than brief function selections and
adjustments to meet the requirements for measurement of process temperatures.

5.2 Rear Panel Keyboard, Displays and Sight and Laser Aiming
5.2.1 Description
Located on the rear of the Modline 5 Sensor are: a keyboard panel with three setup pushbuttons, three
red word indicators for Setup, Alarm and Window (for the Dirty Window Detector optional feature),
and a four character green alphanumeric Light Emitting Diode dot matrix display with adjacent green
°F and °C indicators.
The display is identified as the Temperature (TEMP) display in this manual. The TEMP display and °F
and °C indicators are used for temperature indication in Fahrenheit or Celsius. LOW or HIGH is
displayed when viewing target temperatures below or above the Sensor temperature range. INV is
presented on the display for Invalid ratio temperature measurement conditions. Setup parameters will
be shown on the TEMP display during setup and error codes displayed in response to an Alarm inquiry.
Two of the pushbuttons are Down / Up Arrows labeled ▼ and ▲. The third is an Enter pushbutton
labeled ENT with the keyboard enter symbol . These buttons are identified as ▼▲ and  in this
manual.
A sight for visually aiming the Sensor is located in the center of the keyboard. The process target and
Sensor circular reticle can be seen when viewing through the sight. Sensors with the Laser aiming option
have a pushbutton to energize a laser in place of the sight.
Access to the keypad requires removal of a screw on protective window with O-ring gasket. The
protective window must be in place during temperature measurement to maintain the NEMA 4 (IP65)
Sensor housing rating.

Temperature in °C or °F
LOW = Below zero scale temperature
HIGH = Above full scale temperature
INV = Invalid Condition for Ratio
Temperature Measurement

Figure 74: Sensor with Visual Through the Lens Sight

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Figure 75: Sensor with Laser Through the Lens Aiming Option

Laser pushbutton is located on the edge of rear panel. Visual sight is not available with this option
installed. LED above pushbutton is on when laser is energized.
See Section 5.11 Laser Sighting Operation, page 102 for complete Laser operation and safety instructions.

5.3 Navigation and Menus

5.3.1 Enter and Up / Down Arrow Pushbuttons
Up and Down Arrows ▼▲ are inoperative during valid temperature measurement. Arrows are
operable when an Alarm Condition has been sensed and the ALARM indicator is lit. Depressing the UP
Arrow ▲ will display an error code. The Up Arrow should be depressed multiple times to view
simultaneous multiple Error Codes that might occur. If multiple errors have been displayed, the
Down Arrow ▼ will scroll backwards through the errors. To return to the TEMP display while
viewing an Error Code, press Enter . If no button is pressed after 15 seconds, the display returns to the
temperature display.
The ENT () pushbutton is also used to navigate from the TEMP display to the Main Setup Menus. Up
and Down Arrows ▼▲ and the ENT pushbutton are used to View, Select and Adjust Sensor Functions.

ENT () must be momentarily depressed (less than 5 seconds) when changing function
values and making selections. If ENT () is held depressed for 5 seconds, all
adjustments made in the current menu are canceled and the unit returns to the TEMP
Display.

5.4 Main Menus

Navigate from TEMP display, by pressing ENT  once. The last selected Main Menu will be displayed.
USE the UP / Down Arrows ▲▼ to step through and view the following four Main Menus. Menus are
displayed for 15 seconds before returning to the TEMP display if no further selection is made.
ENGR (Engineering)
AOUT (Analog Output)
COMM (RS-485 Communications)
HEAD (Operation Functions)
At a Main Menu, Press ENT  once to enter the Menu. One of the Function selections will be displayed.
USE the UP / Down Arrows ▲▼ to view a different function. Functions are displayed for 15 seconds

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before returning to the TEMP display if no further selection or adjustment is made. The main menu
functions are shown below. Some functions are model specific and only appear for those models.
ENGR (Engineering Functions)
LOCK (Panel Access Security Setup)
VER (Sensor Firmware Version)
MODL (Model Number Scrolling)
RELY (Alarm Relay Operation Setup)
F/C (°F and °C Selection)
CHK (Initiate System Check)
HOUR (Automatic System Check Setup)
WRNL (Optional Dirty Window Detector Setup)
iALM (Sets Ratio Sensor Invalid Condition as Alarm)

AOUT (Analog Signal Output Selection and Scaling)

SOUT (Select Analog Output Current Range)
ZERO (Set Analog Zero Scale Temperature)
FULL (Set Analog Full Scale Temperature)
Fatl (Set Output Current for Sensor or DWD Error)
A–LO (Set Alarm Current Output for Temperature Below ZERO)
A–HI (Set Alarm Current Output for Temperature Above FULL)

COMM (RS485 Digital Communications)

CLCK (Communications Lock, Read Only or Read and Write Setup)
LASR (Select Laser Sight Activation Mode)
ADDR (Set Sensor Address)
BRAT (Set Baud Rate)

HEAD (Sensor Operating Functions)

EMIS (Set Emissivity for Brightness or 1 Color Sensor)
E-SL (Set E-Slope for 2 Color Ratio Sensor)
R.T. (Set Response Time)
SIGL (Signal Conditioning Peak Picker or Track/Hold)
PSEL (Peak Picker Sub Function Settings)
COLR (Set Ratio Unit for 2 Color or 1 Color Operation)
MTCH (Match Known Temperature)

SUB FUNCTION PSEL (Peak Picker Function Settings)

D.R. (Decay Rate in ºF or ºC per Second)
AUTO (Auto Peak Picker Reset)
RSET (Manual Peak Picker Reset)
RBEL (Reset Below Temperature)
DEL (Peak Signal Conditioning Delay)

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5.5 Warm-up and Initial Setup

5.5.1 Series 5R, 5G, 52 Power On and Warm-up
When power is applied to the Sensor, a three to five second initiate condition occurs. All segments of
the dot matrix TEMP display and all word and symbol indicators are lit. The alarm relay is always held
open during this short period.
After application of power, a warm-up time of approximately 5 to 15 minutes is required for the Sensor’s
infrared detector and/or electronics. The Sensor Rear Panel Alarm indicator will be lit and Error Code X104
(Detector Cold) displayed when the ▲ arrow is depressed. During the warm-up time, temperature
measurements can be made and outputs are operational. However, the Alarm signifies that the
temperature indication may not be accurate. Temperature indications will be accurate after the Alarm
indicator has turned off when warm-up is completed. If there is a brief power outage, Sensors may restart
and go into the initiate and warm-up conditions described above.
The Sensor Check function should not be initiated until the Sensor has warmed up and the Alarm indicator
has turned off. An Out of Calibration Alarm (X102) may occur if initiated during warm-up. If this Alarm
occurs, repeat the Check.

5.5.2 Series 56 Models Power On and Warm-up

Series 56 Models include a Self-Calibration feature which is performed as part of the power on routine.

5.5.3 Initial Rear Panel Display

After the warm-up period is over, you should observe one or more of the Modline 5 Sensor responses
described below on the TEMP display and at the outputs. During initial setup, because the Sensor is not
adjusted for the process, these initial displays are expected.
1.Target Within Range — If the Sensor is viewing a temperature within its range, it will display a
temperature value. Equivalent analog signals will be supplied to any devices connected to the analog
outputs (e.g., recorder or remote indicator). If initial setup has not been set to match operation to the
process, the displayed temperature and analog outputs will not be a true measurement of the target
temperature.
2. LOW / HIGH Indication — If the measured temperature is below or above the Sensor temperature
range limits LOW or HIGH will be shown on the temperature display. The Alarm Indicator does not
light because these are normal conditions.
3. INVALID — An Invalid condition will be indicated any time the sensed infrared radiation is
considered to be inadequate for two color Ratio Sensor measurement. The word INV is indicated on the
TEMP display. If the Invalid Alarm (iALM) is set to On, the Alarm Relay will be in alarm condition and
the word Alarm lit on the Sensor rear panel.

5.5.4 Initial Sensor Setup

Initial Sensor setup should follow the menu orders indicated in the following instructions. Menu
navigation is shown using the  &▲▼ symbols for Enter and Up / Down arrows. The menus and
functions available and the sequence in which they appear depends on the Sensor Model and the
purchased options.
A function variable is expressed as a word or as a number. A function variable may be changed from
State A to State B or from a higher or lower numerical value by using the Up / Down arrows.

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Momentarily depress the Up or Down Arrow pushbutton to make single digit changes starting with the
least significant digit. Keep the pushbutton depressed to quickly change values.
All values are retained in non-volatile memory and are automatically reloaded, in the event of a power loss.
Temperature measurement continues during menu operations and changing of function values. The Analog
Output and RS-485 temperature indications continue to reflect changes in target temperatures. When a
changed function value that affects the measured and displayed temperature is entered with the ENT 
pushbutton, the temperature reading at the outputs updates in about 150 milliseconds.

5.6 ENGR – Setup of Engineering Functions

5.6.1 LOCK – Panel Lock Security
In the Panel Lock “Off” state viewing and adjustment access to all menus and functions is allowed. In
the “ON” state, viewing all menus and functions is allowed, but changes are not allowed. This prevents
unauthorized changes. Panel lock does not interfere with temperature measurement.
Panel Lock can be controlled with an external RS485 device using the KL Command. Changes can be
made using the RS 485 Interface or the Auxiliary Current Input (for Emissivity or E-Slope adjustment)
when LOCK ON has been selected. The Password is fixed and cannot be changed.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to LOCK

Display Instructions Display and Limits

LOCK Press ENT to view Panel Lock state, OFF or ON. OFF, ON, 0 to 999
Use Up / Down Arrows to enter numerical Password 751. Press ENT.
Use Up / Down Arrows to turn Panel Lock OFF or ON.
Press ENT to enter and save selection and return to TEMP display.

5.6.2 MODL – Sensor Model Number

The MODL function reports the Modline 5 Sensor Model Number as an eight character alphanumeric display.
The Sensor Model number is explained in Section 2 Product Description, page 14. The Sensor series,
temperature range, optical resolution, and Dirty Widow Detector and Laser Sight options are defined in the
Model Number. This information is used during the selection and setup of various functions.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to MODL

Display Instructions Display and Limits

MODL Press ENT to view Model. Use Up / Down Arrows to scroll forward and Eight Alphanumeric
backward through model number shown in the display. Character Scroll
XX-XXXXXX
Press ENT  to return to TEMP display.

5.6.3 F/C – Selection of Fahrenheit or Celsius Indication (°F or °C)

Modline 5 Sensors are specified and delivered in Celsius temperature ranges. The F/C function allows
changing the temperature display to indicate in either Celsius or Fahrenheit. The conversion of the Sensor
temperature span from Celsius to Fahrenheit follows the formula: F= (1.8 x Celsius) + 32. Example, a 600°C
to 1400°C span converts to 1112°F to 2552°F. All outputs and function settings will be in the same units and
correspond to the temperature range selected for display. The appropriate °F or °C indicator will be lit for
temperature display and setup adjustments when applicable.

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After changing the Sensor operation from F to C, or C to F, fine-tuning of the

parameters that are related to the F and C measuring units is required. These include:
Analog output ZERO and FULL functions in the AOUT Menu; the DR peak picker
decay rate and the RBEL reset below temperature functions in the Head Menu.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to F/C

Display Instructions Display and Limits

F/C Press ENT to view ºF or ºC selection. ºF or ºC
Use Up / Down Arrows to change the setup.
Press ENT  to save and return to TEMP display.

RELY – Alarm Relay Operation

The RELY function configures the operation of the Modline 5 Alarm relay for Normally Open or
Normally Closed operation. The Sensor internal relay contacts are available on the Black and
Black/White twisted wire pair of the Sensor cable. The Alarm Relay contacts are used to report a Sensor
alarm condition.
The sensor self-tests its case temperature, detector assembly temperature, output current flow, etc. The
Check function checks internal circuit and detector operation. The optional Dirty Window Detector
measures the Sensor’s window condition. One or more out of limit conditions sensed by these tests
triggers an Alarm.
Set the relay operation to correspond to proper and safe use of the contacts in your overall measurement
system. Select N C. for closed relay operation with Sensor not in Alarm condition (open in alarm state).
Select N.O. for closed relay operation with Sensor in Alarm condition (open when not in alarm
condition).
Contacts are open for both N.O. and N.C. operation when the Sensor is not powered, and, for the 3 to 5
seconds after power is applied during the initiate period.
Normally Closed N.C, operation is considered fail-safe operation.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to RELY

Display Instructions Display and Limits

RELY Press ENT to view Alarm Relay Operation. N.O. or N.C.

Use Up / Down Arrows to select Normally Open, N.O., or Normally Closed, N.C.
Press ENT  to save and return to TEMP display.

5.6.4 CHK – Initiate Manual System Check

 for 52, 5G, 5R models
The CHK and Auto Cal Hour functions are different for the Series 56 Models. Separate explanations
and instructions are provided for Series 56 Models on the pages that follow.

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Refer to the instructions for your Model!

This function checks the Modline 5 Sensor performance by initiating a System Check. When this
function is initiated, the Sensor’s infrared detector output, internal gain and offset voltages are checked.
The check cycle lasts less than ten seconds. During the Check, the Sensor TEMP display indicates CAL.
The Alarm Led indicator and Alarm Relay remain at their last condition. Target temperature
measurement is suspended. The Analog Output readings are not derived from real time temperature
measurement during Check function. The Analog Output is held at its last output value. Peak Picker,
Track and Hold and Response time functions are suspended. At the end of the cycle, operation returns
to normal and temperature measurement resumes.
If the Check does not pass, the ALARM Indicator on the Sensor rear panel will light. Press an Up/Down
Arrow to view an Error Code on the Display. See Section 7 Maintenance, page 119, for information about
alarms and error codes.
Checks can be made manually or scheduled automatically with the HOUR function that follows. Process
temperature measurement is interrupted for 5 to 10 seconds during the check period.

After application of power, a warm-up time of approximately 5 to 15 minutes is

required for the Sensor’s infrared detector and/or electronics. The Sensor Rear Panel
Alarm indicator will be lit and Error Code X104 (Detector Cold) displayed when the
▲ arrow is depressed.
The instrument Check function should not be initiated until the Alarm indicator has turned off. An Out
of Alarm (X102) may occur if initiated during warm-up. If an X102 Alarm occurs, repeat the Check after
warm-up.

On Sensors with firmware Versions 1.08 and higher, the Cal Check function will not
operate during Sensor Alarms X107, X106, X105, X104, X103, X101. See Section 5.12
Out of Range Displays and Error Codes, page 104, for error code explanations.
The Check should not be initiated when a single Alarm or multiple Alarms for Error Codes X103
(Detector block too hot), X104 (Detector block too cold), X105 (Internal case temperature too high), X106
(Internal case temperature too low) are active.
Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to CHK

Display Instructions Display and Limits

CHK Press ENT to initiate Check. Sensor cycles through 10 second check and then CAL
returns to the TEMP display.

5.6.5 HOUR– Automatic System Check

 for 52, 5G, 5R models

Refer to the instructions for your Model!

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The CHK and Auto Cal Hour functions are different for the Series 56 Models. Separate explanations
and instructions are provided for Series 56 Models on the pages that follow.
The HOUR function provides for selection of an automatic System Check. This function automatically
initiates the check described above. A selection of OFF or a time interval in hours between checks is
offered.
A manual Check from the Sensor Keyboard, as explained above, or by RS-485 Communication will start
a new period, but not change the value of the interval. This will start a new interval.
Process temperature measurement and control requirements need to be considered when using this
automatic function. Real time process temperature measurement and signal conditioning is suspended
for up to ten seconds.
Continuous interval setting should be 8 hours or greater. A 168 hour, 1 week, (or greater) automatic
interval and manually initiated checks are the recommendations that will provide minimal
measurement interruption.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to Hour

Display Instructions Display and Limits

HOUR Press ENT to view Automatic Check selection, OFF or numerical value OFF or
representing hours between Checks. Value 1 to 9999
Use Up / Down Arrows to change selection and setting.
See above recommendations.
Press ENT  to save and return to TEMP display.

5.6.6 CHK – Manual System Calibration for 56 Models

This function checks a Model 56 Sensors performance by initiating a System Calibration Check. When
this function is initiated, the Sensor’s infrared detector signal, internal gain and offset voltages are
checked. First, a flag is closed inside of the unit to block the optical path of the instrument. Operation of
the Sensor is determined with no target in the field of view of the infrared detector. Second, a calibration
source with a known radiance is activated inside the Sensor and the radiance is “seen” by the infrared
detector. The response of the sensor electronics to the radiance is compared to an expected value.
If the Calibrate Check determines a Model 56 Sensor requires recalibration, the sensor firmware
performs a Self-Calibration adjustment. Typically, only small changes in calibration will occur.
During the Calibration Check, the Sensor Rear Panel TEMP display indicates CAL. The Alarm Led
indicator and Alarm Relay remain at their last condition. Target temperature measurement is
suspended. The Analog Output is held at its last output value. The Analog Output readings are not
derived from real time temperature measurement during Calibration Check function. Peak Picker,
Track and Hold and Response time functions are suspended. At the end of the cycle, operation returns
to normal and real time temperature measurement resumes.

Temperature indications may shift slightly upon return to normal operation.

A Calibrate Check is required for to insure accurate operation of the Series 56 Sensors and should be
performed routinely, every 168 hours or less. The check can be initiated by any of the three methods

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described below.
Upon Sensor Turn On
If the Sensor has not been powered for 15 minutes or more, a Calibration Check will be performed after
the unit is powered and warmed up and stabilized, approximately 15 to 20 minutes after powering on.
Automatically
A Calibrate Check can be initiated every 168 hours using the Sensor Auto Calibrate HOUR function. An
OFF setting is also available. If the OFF is selected, Manual Calibrate Checks must be initiated every at
least every 168 hours.
Manually
Initiate a Manual Calibrate Check using the Sensor Rear Panel Keypad or Modline 5 accessory.
Accessories include the Model DPM Panel Meter, Model MSI multiple sensor interface, ModView
software or an RS-485 communication command.

Series 56 Manual and Automatic (HOUR Function) Initiated Calibration Check Summary
Calibration Check Initiation Alarm Display RS485 and 20mA
Condition Temperature Outputs

Manually Initiated Calibration Check Alarms Off CAL Last Temperature

with Self Calibration, if required. (Sensor, ModView, reading held
Note 1
It is not recommended to perform a Manual DPM, MSI)
check more once than every 24 hours.
HOUR Parameter (168 Hours or OFF) Alarms Off CAL Last Temperature
User Selected Time Interval 168 hours only. (Sensor, ModView, reading held
Note 1
(Factory default setting = 168) DPM, MSI)
OFF
User must perform Manual Cal every 168
hours or less.

The Calibrate Check function will not operate with Sensor Alarms X107, X106, X105,
X104, X103, X101. A Detector Hot or Cold alarm must be off for at least 15 minutes
before a Cal Check can be initiated. See Section 5.12 Out of Range Displays and Error
Codes, page 104 for error code explanations.

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Series 56 Self Calibration at Power On or After Power Interruption of 15 minutes or longer
Calibration Check Initiation Alarm Temperature RS485 and 20mA
Condition Display Temperature Outputs

Sensor is within Operating Temperature 15 minute warm- Detector Hot / Cold Temperature is Displayed
Range (0 to 55°C /32 to 131°F)) at Power On up and Self Cal Alarms on and provided at outputs but
cycle time is not accurate until alarms
are off and after Self Cal
cycle
At Power On: Warm-up and Self Detector Hot / Cold Temperature is Displayed
Sensor is outside Operating Temperature Cal requires Alarms on and provided at outputs but
Range (0 to 55°C /32 to 131°F)) but in warm-up within is not accurate until alarms
Storage Temperature range Operating are off and after Self Cal
(-20°C to 0°C or 55°C to 65°C / -4 to 32°F or Temperature f cycle
131 to 149 °F).
Power Interruption of less than 15 minutes Operation
Power Interrupt (ON-OFF-On) Fifteen minute Detector Hot / Cold Temperature is Displayed
Off Time Less Than 15 minutes warm-up time Alarms on for 2 but may not be Accurate
starts on return to minutes Accurate after 2 minutes
power on.
Self-Calibration is
not Initiated

Initiate a Manual Cal Check

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to CHK

Display Instructions Display and Limits

CHK Press ENT to initiate Calibration Check. Sensor cycles through Sensor Check and CAL
Self Calibration, if necessary, and then returns to the TEMP display.
It is not recommended to perform a Manual check more once than every 24 hours

If the Check and Self Calibration does not pass, the ALARM Indicator on the Sensor rear panel will light.
Press an Up/Down Arrow to view an Error Code on the Display. Multiple arrow entries may be required
to view all error codes. Error Code X102 is an Out of Calibration Alarm. See Section 7 Maintenance,
page 119 for information about alarms and error codes.

5.6.7 HOUR– Automatic Calibration Check for 56 Models

Refer to the instructions for your Model!

The HOUR function provides for selection of an automatic System Calibration Check and Self
Calibration if needed. This function automatically initiates the calibration check described above.
A Manual or power on Calibration Check will start a new period, but not change the value of the HOUR
interval.

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Process temperature measurement and control requirements need to be considered when using this
automatic function. Real time process temperature measurement and signal conditioning are suspended
for 15 seconds.
RS485 and Current Loop Outputs are held at the last reading during the Self Calibration.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to Hour

Display Instructions Display and Limits

HOUR Press ENT to view Automatic Calibration Check. Selection is a numerical value Value in hours =
representing hours between a Check with Self Calibration. 168
168 hours only or OFF (Factory setting)
Press ENT  to save and return to TEMP display. or OFF
If OFF is selected, user must perform Manual Cal every 168 hours or less.

5.6.8 WRNL – Dirty Window Detector Option Warning Level

The Dirty Window Detector Option is specified at the time the Sensor is ordered and must be factory
installed. The WRNL function is only viewed on Sensors with the option. Select OFF, CORS or SENS.
OFF turns the dirty window detection off. Coarse and sensitive Warning Levels select a greater (CORS)
or lesser (SENS) amount of Sensor window transmission loss required to trigger an alarm.
Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to WRNL

Display Instructions Display and Limits

WRNL Press ENT to view Dirty Window Detector Warning Level selection, OFF, CORS, SENS.
OFF, SENS (Sensitive) or CORS (Coarse)
Use Up / Down Arrows to select.
Press ENT  to save and return to TEMP display.

5.6.9 VER – Sensor Firmware Version

The VER function reports the Sensors installed firmware version. A four-digit numerical value is
displayed. The version information is useful when discussing operation with factory personnel. The
firmware cannot be updated in the field.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to VER

Display Instructions Display and Limits

VER Press ENT to view Sensor Firmware Version. Numerical Value
Press ENT  to return to TEMP display. XX.XX

5.6.10 iALM – Selects Ratio Invalid Measurement Condition as an Alarm

Selects the Ratio Unit Invalid Measurement Condition as an Alarm.
Alarm and Invalid Condition selection sets both the Error Codes and Invalid Measurement Conditions
to operate the Alarm rely and ALARM word on the Sensor rear panel. Invalid Measurement Conditions
do not trigger the Alarm relay or the Alarm word with Error Code Alarms Only selected.

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Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to iALM

Display Instructions Display and Limits

iALM Press ENT to view Invalid Condition Alarm selection. OFF or ON
OFF = Error Code Alarms only (includes the optional Dirty Window Detector
alarms)
ON = Error Code Alarms and Invalid Condition (INV and pINV) activated as
Alarms. This function also turns on the Attenuation Alarm.
Use Up / Down Arrows to select.
Press ENT  to save and return to TEMP display.

5.6.11 ATTN – Selects Attenuation Alarm Threshold

Set the percent attenuation alarm threshold. Any attenuation greater than this value will turn on the
alarm and also turn on the Dirty Window LED on the back panel. Setting this to 95 will turn this alarm
off since that is the invalid threshold. The iALM must be set on in order to enable this alarm.

Navigate from TEMP display with  &▲▼to ENGR then use  & ▲▼ to ATTN

Display Instructions Display and Limits

ATTN Press ENT to view Attenuation Threshold. 10% - 95%
Use Up / Down Arrows to select.
Press ENT  to save and return to TEMP display.

Background:
With most two-color infrared thermometers, an invalid indication is reached when the reduction in
signal from the target is greater than 95 percent. When the signal reduction is too great, an invalid
condition occurs. This variation can be caused by emission characteristics of the target or the target
being too small to completely resolve, as well as obstructions in the sight path (i.e., certain types of
smoke). When an invalid condition occurs, an alarm output is provided to indicate the signal variation
is too great between the two detectors. While this type of detection method is suitable for many
applications, there are some instances where the user wants to adjust the sensitivity level of attenuation.
The Modline 5 attenuation adjustment alarming feature operates independent from the optional dirty
window detector, which will monitor the sensor window for contamination. It enables users to monitor
any kind of signal attenuation caused by dirty viewports or other external windows. Attenuation alarm
settings are configurable from 5 to 95 percent, from either the back panel of the sensing head or from
the Ircon ModView program. When an alarm condition is detected, relay outputs provide notification
to external process control instrumentation.
When the attenuation adjustment alarming feature is enabled, the user can monitor attenuation levels
in a graphical format in the ModView program providing a historical view of the levels. In addition,
attenuation levels are available through the Modline 5 RS-485 output fed into an external device.

5.7 AOUT – Setup of Analog Signal Output Current Range and

Temperature Scaling
Modline 5 Sensors provide selection of the analog output current range and scaling of the selected range
to temperature. Scaling establishes a temperature span to correspond to the analog output current

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range. The span can be equivalent to the Sensor’s specified span or narrower. See Section 4 Sensor
Wiring, page 64 for detailed information on analog output signals.
This signal is available from the Blue and Blue/White twisted wire pair of the Sensor cable. See Section
4 Sensor Wiring, page 64 for wiring details.
SOUT – Analog Output Current Range Selection
Modline 5 Sensors provide a selection of one of two analog output direct current ranges, 0 to 20 mA or
4 to 20 mA. This function selects the desired range.
ZERO – Analog Output Zero Scale Temperature Scaling
This function sets a temperature to correspond to the selected Analog Output Current Range minimum
value (0 or 4 mA). This temperature must be within the Sensor’s specified temperature range and is
limited to a maximum value equivalent to 10°F (-12.2°C) below the Sensor full scale temperature, or,
10°F (-12.2°C) below the adjusted Analog Output Full Scale temperature value (explained below).
Minimum setting is the Sensor specified zero scale temperature. See notes after FULL explanation for
ZERO – FULL °C operation and span setting information.
FULL – Analog Output Full Scale Temperature Scaling
Sets a temperature to correspond to the Analog Output Current Range maximum value (20 mA).
Temperature must be within the Sensor specified temperature range and is limited to a minimum value
10°F (-12.2°C) above the Sensor’s specified zero scale temperature, or, 10F° (-12.2°C) above the adjusted
Analog Output Zero Scale temperature value (explained above). Maximum setting is the Sensor
specified full scale temperature.

For ZERO – FULL span setting.

°F and °C operation: The minimum 10° span is calculated by the Sensor in °F.
When using °C units, the span will be less than 10° because the Sensor first calculates in °F
and then converts to °C. The narrower equivalent °C span is allowed.
Spans more than 30°C (60°F) may be required to obtain acceptable results. Longer response
times may be necessary for very narrow spans to smooth magnified temperature variations
and noise.

5.7.1 Fatl – Analog Output Operation for Sensor or Dirty Window Detector
Malfunction Alarms
Sets the Analog Output current to a specified value when unit is in one of two alarm conditions. A
Sensor failure (Error Code X107) or Dirty Window Detector operation failure (Error Code X109) will
trigger this alarm.
Selectable range is from 0 mA to 24 mA

5.7.2 A–LO – Analog Output Low Temperature Alarm

Sets the Analog Output current value if the measured temperature is below the temperature that
produces Analog Zero Scale Output as determined by the Analog Output Zero Scale Temperature
Scaling explained above. Selectable range is 0 mA to 4 mA for the 4 to 20 mA current output range.

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If the current loop is set for 0 to 20 mA operation, the A–LO function will not appear as a
menu item. The analog output always goes to 0 mA if the measured temperature is below
the Analog Output Zero Sale temperature.

5.7.3 A–HI – Analog Output High Temperature Alarm

Sets the Analog Output current value if the measured temperature is above the temperature that
produces Analog Full Scale Output as determined by the Analog Output Full Scale Temperature Scaling
explained above. Selectable range is 20.0 mA to 24.0 mA.
Analog Output Settings
Navigate from TEMP with  &▲▼to AOUT then use  &▲▼ to SOUT or ZERO or FULL or Fatl or
A-LO or A-HI
Press ENT  to save and return to TEMP display after each function.

Display Instructions Display and Limits

SOUT Press ENT to view the SOUT output current range, 0 to 20 mA or 4 to 20 mA 0-20 or 4-20
Use Up / Down Arrows to select output current range.
ZERO Press ENT to view temperature corresponding to the selected Analog Output Temperature Value
Current Range minimum value (0 or 4 mA) Maximum is 10 F below the
Use Up / Down Arrows to set Temperature within the Sensor temperature selected FULL temperature
range and high limit shown. (see below)
See note above for °C
operation.
FULL Press ENT to view Temperature Corresponding to the Analog Output Temperature Value
Maximum value (20 mA) Minimum is 10 F above the
Use Up / Down Arrows to set Temperature within the Sensor temperature selected ZERO temperature
range and low limit shown. (see above)
See note above for °C
operation.
Fatl Press ENT to view the Analog Output selected mA current value. 00.0 to 24.0
Use Up / Down Arrows to set the current value.
A–LO This function does not appear if the SOUT selected range is 0 to 20 mA. 00.0 to 4.00
Press ENT to view the Analog Output selected mA current value.
Use Up / Down Arrows to set the current value.
A–HI Press ENT to view the Analog Output selected mA current value. 20.0 to 24.0
Use Up / Down Arrows to set the current value.

5.8 COMM – Setup of RS-485 Digital Communication Configuration

The Modline 5 RS-485 Digital Communication interface permits interchange of ASCII coded
information between the Modline 5 Sensor and a host computer, PLC (Programmable Logic Controller),
or any other RS-485 device.
The RS-485 data signal is transmitted on the Yellow and Yellow/White twisted wire pair of the Sensor’s
interconnecting cable. All communication is via half-duplex two wires.
Refer to section 6 RS-485 Digital Communications, page 107, for the complete explanation of the RS-485

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Digital Communications operation and commands.

5.8.1 CLCK – Communications Lock

Communications Lock provides for the configuration of the Modline 5 RS-485 Communications.
Communication can be configured to allow selection and adjustment of functions in Read and Write (R
/ W) operation, or in Read Only (R / O) operation. Read Only operation does not allow external RS-485
devices to change settings in the Sensor.

R / O operation still allows the unit to respond to the RS485 AC Automatic Calibrate
Command to initiate a check (CHK) and the PR Peak Picker Reset Command to perform a
reset.

5.8.2 ADDR – Sets the Sensor Address

The Unit Address is a one digit number or single letter code. It ranges from a single numeric 0 to 9 to an
upper case A to Z. The Address factory-default setting is 0 (zero).

5.8.3 BRAT – Baud Rate

The Sensor Baud Rate must match that of the other RS-485 device. Four baud rates are supported: 9600,
19200, 38400, and 57600 bits of information per second (Baud). The factory setting is 57.6K Baud.

5.8.4 LASR –Laser Operation (Sensor Firmware Versions 1.08 and Higher)
Selects Sensor Rear Panel or RS485 operation only or remote switch operation using the I IN or PkHd
functions. See Section 5.11 Laser Sighting Operation, page 102.
RS485 Communication
Navigate from TEMP with  &▲▼to COMM then use  &▲▼ to ADDR or BRAT or CLCK
Press ENT  to save and return to TEMP display after each function.

Display Instructions Display and Limits

CLCK Press ENT to view Communications LOCK. R / O or R / W
Use Up / Down Arrows to select R / O (Read Only)
or R / W (Read and Write) operation.
ADDR Press ENT to view Sensor Address. 0 to 9 and A to Z
Use Up / Down Arrows to set to one of thirty-six addresses.
BRAT Press ENT to view baud rate. 9600 or 19.2K or 38.4K or 57.6K
Use Up / Down Arrows to select 9600, 19.2K, 38.4K or 57.6K Baud.
LASR Press ENT to view Laser operation Selection. PANL or I IN or SWIT
Use Up / Down Arrows to select

5.9 HEAD – Setup of Sensor Operating Functions

The HEAD menus and functions set up the Modline 5 Sensor for process temperature measurement.
The initial setup should follow the order given below. It is useful to perform the setup while the Sensor
is sighted on the actual target, but not necessary. Preset of the function selections is possible and may

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be required if the access to the Sensor is not possible or safe conditions to perform adjustments do not
exist.

5.9.1 R.T. – Response Time

The Modline 5 Sensor Response Time function provides signal filtering for meaningful temperature
information while eliminating unwanted temperature variations. Refer to Section 8 Applications Guide,
page 129 for Response Time Application Information. See section 2 Product Description, page 14 for
Model specific response time information.
If you determine that your Response Time must be greater than 30 seconds, it is recommend that you
trial your process. Long Response Time settings are close approximations and may vary from the
selected value.
The Response Time selected affects the temperature signal input to Temperature Display, Analog
Output, RS-485 Communications and the Peak Picker and Track and Hold signal conditioning
functions.
The Response Time setting for a Ratio Sensor in the two-color ratio mode takes effect under valid
measurement conditions. Under Invalid measurement conditions, the Sensor response time is preset for
a fast response regardless of the Response Time function setting.
Navigate from TEMP display with  &▲▼to Head then use  &▲▼ to R.T.

Display Instructions Display and Limits

R. T. Press ENT to view Response Time in Seconds. 0.01 to 60.0 Seconds for * 5R Ratio Sensors
Use Up / Down Arrows to adjust Response Time.
0.006 to 60.0 Seconds for Series 52 and 5G
Press ENT  to save and return to TEMP display. .006 = 6.6 milliseconds
0.02 to 60.0 seconds Model 56 Sensors*

5.9.2 COLR – Ratio Unit Operation Selection

The COLR function sets the Modline 5 Ratio Sensor operation in the two color mode for ratio
temperature measurement or in the single color mode for brightness temperature measurement.
Navigate from TEMP display with  &▲▼to Head then use  &▲▼ to COLR.

Display Instructions Display and Limits

COLR Press ENT to view Color Selection. 1 or 2
Use Up / Down Arrows to select: 1 for single color
brightness operation or 2 for two color ratio operation

5.9.3 E-SL – Ratio Unit Two Color Operation E-Slope Adjustment

Ratio Sensors require the correct E-Slope value selection for measuring temperatures of both non-graybody
and graybody/blackbody targets. To get a true measure of the temperature you must select the E-Slope values
to match the material being measured. The value can be set in “real time” while viewing the process. The
adjustable range for this function is 0.800 to 1.200.

• Determine the E-Slope value by referring to Section 8 Applications Guide, page 129 or other
reliable source.

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• Enter the proper E-Slope value in the E-SL function.
If you change materials or if the material characteristics change, re-determine the E-Slope for the
material and readjust the E-SL function if necessary.

If you are viewing your target through a window, consider the effect of window
transmission as described in Section 8 Applications Guide, page 129.

Navigate from TEMP display with  &▲▼to Head then use  &▲▼ to E-SL.

Display Instructions Display and Limits

E-SL Press ENT to view E-Slope. Use Up / Down Arrows to adjust. 0.800 to 1.200
Press ENT  to save and return to TEMP display.

5.9.4 Remote E-Slope Current Input

You may make remote analog adjustments of the E-Slope value by sending a scaled input of 4 to 20 mAdc.
This signal is inputted using the Orange and Orange/White twisted wire pair of the Sensor’s interconnecting
cable. The Modline 5 senses an input and the overrides any rear panel or RS-485 settings of E-Slope or Match.
Wiring connection and scaling information are in Section 4 Sensor Wiring, page 64.

5.9.5 EMIS – Emissivity Adjustment for Brightness Sensors

Modline 5 brightness sensors and one color operation of ratio sensors require Emissivity adjustment for
accurate temperature measurement. The Emissivity value is set to the characteristics of the material
being measured using the EMIS function. Ratio sensors that are using the Attenuation Alarm feature
will need to set the sensor to a single color mode, set the correct emissivity for the target, then set the
sensor back to 2 color mode (When using the Attenuation Alarm feature, you must set the emissivity
and also the e-slope for the sensor)
1. Determine the Emissivity value of your target by referring to the instructions in Section 8
Applications Guide, page 129.
2. Select the proper Emissivity value, from the Tables in Section 8 Applications Guide, page 129 for
the surface finish.
3. The adjustable range of the Emissivity is 0.100 to 1.000. See Section 2.3 Model Configuration and
Required Selections, page 16 for Emissivity restrictions.
If the material changes characteristics or you change materials, re-determine the Emissivity for the new
material and adjust the Emissivity value.
If you are viewing your target through a window, consider the effect of window transmission loss as
described in Section 8 Applications Guide, page 129.

Navigate from TEMP display with  &▲▼to Head then use  &▲▼ to EMIS.

Display Instructions Display and Limits

EMIS Press ENT to view Emissivity Value. Use Up / Down Arrows to adjust. 0.100 to 1.000
Press ENT  to save and return to TEMP display.

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5.9.6 Remote Emissivity Current Input

You may make remote analog adjustments of the Emissivity value by sending a scaled input of 4 to 20
mAdc. This signal is inputted using the Orange and Orange/White twisted wire pair of the Sensor’s
interconnecting cable. The Modline 5 senses an input and overrides any rear panel or RS-485 settings of
Emissivity or Match. Wiring connection and scaling information are in Section 4 Sensor Wiring, page
64.

5.9.7 MTCH – E-Slope or Emissivity Selection Based on Temperature Match

The MTCH function of the Modline 5 Sensor provides for adjusting the E-Slope or Emissivity values by
setting and matching the Sensor’s temperature display to the known temperature of a process target.
The Match temperature should be set with a Sensor Response Time of 100 milliseconds or faster. Peak
Picker or Track and Hold must be Off. The Match function should be set with stable process
temperatures. After setting the Match temperature, the response time, Peak Picker and Track and Hold
can be set to the values required for process temperature measurement.
Navigate from TEMP display with  &▲▼to Head then use  &▲▼ to MTCH.

Display Instructions Display and Limits

MTCH While viewing process target, Press ENT to view Match temperature. Use Up / Temperature in ºC or ºF
Down Arrows to adjust to the known target temperature. XXXX
Emissivity or E-Slope, if within allowed limits, will be automatically adjusted for a
matching TEMP display. During the adjustment, the Response Time should be
set to 100 milliseconds, or faster, and Peak Picker or Track and Hold signal
conditioning set to Off.
If the resulting Emissivity or E-Slope is not within allowed limits, the Match value
cannot be inputted and ERR will be seen on the display after pressing ENT .
Return to EMIS or E-SLP to view resulting value if desired.

The MATCH function will not operate during Sensor Alarms X107, X106, X105, X104,
X103, X101 or a CAL (CHK). See Section 5.12 Out of Range Displays and Error Codes,
page 104, for error code explanations.

5.9.8 SIGL – Signal Conditioning Selection

The Modline 5 Sensor can provide Peak Picking or Track and Hold Signal Conditioning. The SIGL
function sets the signal condition to Peak Picker, Track and Hold or Off.
Peak Picker signal conditioning is used to obtain the peak measured temperature value and ignore
momentary decreases in measured temperature. This eliminates erratic measurements due to gaps in
workpieces, bursts of smoke, or steam, or other intermittent interferences in the sight path of the Sensor.
Signal conditioning affects all displays and outputs.
Track and Hold signal conditioning is used to track process temperature when required and then hold
the temperature measurement at some point in time as determined by the process requirements. This
eliminates erratic measurements due to process measurement delays or other undesired measurement
periods.
Peak Picker and the Track and Hold signal conditioning functions are explained in Section 8
Applications Guide, page 129.

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Peak Picker PSEL Functions
Peak Picker Signal Conditioning selection activates the PSEL Peak Function menu. This menu is used
to adjust Peak Picker functions necessary for obtaining the peak measured temperature value. These
functions must be adjusted to match the process for proper operation.
External Switch Control of Track and Hold Operation
The Modline 5 has provisions for a remote process controlled input switch be wired to the Violet and
Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Track and Hold signal
conditioning is selected, the switch input is required to change from Track temperature operation
(switch open) to Hold mode (switch closed) as required in the process system.
Wiring and switch operation for the Track and Hold feature are described in Section 4 Sensor Wiring,
page 64.
Navigate from TEMP display with  &▲▼to Head then use  &▲▼ to SIGL.

Display Instructions Display and Limits

SIGL Use Up / Down Arrows to select OFF / PEAK / TRAK OFF = No Signal Conditioning
TRAK = Track and Hold
Note:
PEAK = Peak Picker
– Use external control switch to operate Track and Hold modes.
– Adjust PSEL Parameters if Peak Picker selected.
– Use external control switch for remote Peak Picker reset and
operation.
Press ENT  to save and return to TEMP display.

5.10 PSEL – Peak Picker Functions

The PSEL Functions are for Peak Picker Operation. Refer to Section 8 Applications Guide, page 129 for
a description of Peak Picker signal conditioning operation including these functions

5.10.1 D.R. – Decay Rate Function

The Decay Rate range is 0.00 to 300.00°F or 0.00 to 166.66°C per second depending on Fahrenheit or
Celsius unit’s selection. The Decay Rate must be set to retain peak measured temperature value and
ignore momentary decreases in measured temperature caused by process conditions. The goal is to
eliminate erratic measurements due to gaps in workpieces, bursts of smoke, or steam, etc. in the sight
path of the Sensor while allowing the peaked value to decay down to lower process temperature values
as they occur.
Sensor Firmware Version Operation Summary
Original Sensors with firmware versions less than 1.02 have unit-less degree units that
range 0.00 to 300.00 for both F and C unit’s selection. The instructions provided on the
next page are for Sensors with firmware versions 1.02 and higher.

DPM – Digital Panel Meter Interface firmware version operation:

For DPM Interfaces with firmware versions 1.2 used with Sensor firmware version less than 1.02. Sensor
set for °C, DPM will read, but not enter values higher than 166. Sensor can be set to 300.
Sensor set for °F, DPM and Sensor are compatible.
For DPM Interfaces with firmware versions 1.1 used with Sensor firmware 1.02 and higher:
Sensor set for °C, DPM will read or enter values to 300. Sensor can be set to 166.66 maximum.

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Sensor set for °F, DPM and Sensor are compatible.

5.10.2 RSET – Manual Peak Picker Reset

Performs a manual Peak Picker reset. The Peak Picker Reset “clears” the stored peak information. The
Sensor begins to measure temperature in the Peak Picker mode again after a manual reset.

5.10.3 External Switch for Remote Peak Picker Reset

The Modline 5 has provisions for a remote process controlled input switch to be wired to the Violet and
Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Peak Picker signal conditioning
is selected, the remote switch can enable or disable the Peaking action. With no switch or the switch
maintained in the open position, Peaking action is enabled. With the switch closed, peaking action is
disabled and the Sensor continuously indicates actual temperature variations as they occur.
A momentary closure of the switch resets the Peak Picker function to the current temperature reading.
The peaking action begins again when the switch returns to the open position.
Wiring and switch operation for the Peak Picker are described in Section 4 Sensor Wiring, page 64.

5.10.4 AUTO – Auto Peak Picker Reset

With Peak Picker On, the Auto Peak Picker Reset function will cause a Reset when the measured
temperature matches or is below the selected Reset Below temperature. As long as the measured and
displayed temperature remains below the selected temperature, the Peak Picker remains in reset
condition and the Sensor continuously measures and indicates temperature without any peaking
picking action.
This function is affected by the Response Time function. It is possible for a long response time to delay
a Reset triggered by the Reset Below temperature even though the target temperature has decreased.

5.10.5 RBEL – Reset Below Temperature

Automatic Peak Picker Reset must be on for this function to appear in the menu. Sets the Reset Below
Temperature that causes Automatic Peak Picker Reset with the Peak Picker On and Auto Peak Picker
Reset On. When the target temperature matches or is below the selected value, Automatic Peak Picker
Reset will take place and the Sensor indicates temperature without any peaking action.

5.10.6 DEL – Peak Picker Delay

Peak Picker signal conditioning may be delayed. The Peak Picker Delay time is selectable in the range
of 0.01 to 10.00 seconds. Its primary use is with the Auto Peak Picker Reset and Reset Below Temperature
functions. The Peak Picker Delay function is used to delay the start of the peaking action for up to 10
seconds following the detection of the leading edge of a new target. See Section 8 Applications Guide,
page 129 for a detailed explanation.
It has limited operation when used with Peak Picker signal conditioning without the Auto Peak Picker
Reset function. It will provide the selected delay after any Peak Picker Reset. The reset can be from the
Sensor rear panel, a reset from a momentary closure of the Peak Picker Reset external switch or a reset
from the RS485 PR command.

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Navigate from TEMP display with  &▲▼to Head then use  &▲▼ to PSEL, then use  & ▲▼ to
D.R. or RSET or AUTO or RBEL or DEL.
Press ENT  to save and return to TEMP display after each function.
Display Instructions Display and Limits
PSEL Use Up / Down Arrows to select D.R. or RSET or AUTO or RBEL or
D.R. or RSET or AUTO or RBEL or DEL DEL
Then press ENT to view, select and adjust Function.
D.R. Instructions for Sensors with firmware versions 1.02 and higher. 0.00 to 166.66 (°C Sensor)
Or
Press ENT to view and then use UP / Down Arrows to adjust
0.00 to 300.00 (°F Sensor)
Decay Rate will is in degrees per second depending on the
measuring units selected.
RSET Press ENT to trigger Manual Peak Picker Reset.
Display will automatically return to TEMP.
AUTO Press ENT to view. Use Up / Down Arrows to select Auto Peak ON, OFF
Picker Reset operation ON or OFF
RBEL Press ENT to view. Use Up / Down Arrows to set Reset Below Numerical Value XXXX
Temperature within Sensor’s specified temperature Range. Temperature in ºC or ºF
DEL Press ENT to view. Use Up / Down Arrows to Select Off or set OFF or
Peak Picker Signal Conditioning Delay in seconds. 0 .01 to 10.00

5.11 Laser Sighting Operation

The Laser Sighting Option is specified at the time the Sensor is ordered and must be factory installed.
A pushbutton labeled LASER is supplied on the rear panel to energize the laser. The pushbutton is
located in the center of the rear panel in place of the visible sight. Press the LASER pushbutton once to
energize the laser, press the pushbutton once again to de-energize the laser. A red LED located above
the pushbutton is illuminated when the laser is energized. The Laser also can be operated remotely
using a switch. See Section 5.8 COMM – Setup of RS-485 Digital Communication Configuration, page
95 for selecting remote switch operation. See next page for operating instructions.
The Laser will not energize during the CHK or the MATCH function. In addition, if the Laser is
energized and a manual (CHK function) or automatic (HOUR function) system check or MATCH
Function is initiated, the Laser will turn off.
Refer to Section 3.3.3 Laser Sight, page 24, for information on using the Laser to aim and focus the
Sensor.

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Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or
other devices using RS– 485 Communications, or a remote switch, insure there are no
personnel in the path of the beam.

Display Instructions Display and Limits

Manual Normal Rear Panel Operation. See next page for Remote Switch LED above LASER
Pushbutton Operation: Button Lights
Under safe operating conditions, Momentarily depress LASER
pushbutton to energize the Class 2 Laser. Press pushbutton again to
de-energize. Laser will automatically turn off after 20 minutes if not de-
energized.

Remote Laser Operation (Sensor Firmware Versions 1.08 and Higher)

Remote operation is selected from the COMMS – LASR Menu. The operation for PANL, I IN and SWIT
modes of operation are explained below.

COMM Menu Sensor Rear Panel RS-485 Peak/Hold Switch I – IN Current Input
LASER Switch LS Command (Remote SPST (Remote SPST Switch
LASR Mode (ModView, DPM, Switch Required) Required)
Selection MSI)
PANL Energizes and turns Energizes and turns Not Enabled for Laser Not Enabled for Laser
Laser Off. Laser Off. Operation. Operation.
Operation
I IN Can de-energize Laser Can de-energize Laser Not Enabled for Laser 15 mADC input current
anytime. anytime. Operation in I IN (Switch Closed)
Remote Current mode. energizes Laser.
Input Operation Can Energize Laser. Can Energize Laser.
Condition Set One Condition Set One Current disconnected
applies. applies. (Switch open) de-
energizes laser.
Condition Set One
applies

SWIT Can de-energize Laser Can de-energize Laser PkHd Switch operates Not Enabled for Laser
anytime. anytime. Laser. Operation in SWIT mode
Remote Pk/Hd
Switch Can Energize Laser. Can Energize Laser. Condition Set Two
Operation Condition Set Two Condition Set Two applies.
applies. applies.

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Laser I IN Operation
When Laser I IN operation is selected, remote current input of Emissivity and E-Slope is not operational.
The required SPST switch can be an actual toggle or a press and hold type switch that would de-energize
the laser when released.
I IN Operation - Condition Set One
1.A If Sensor is powered up with I IN current applied (remote switch closed), the Laser will not operate
until the remote switch is opened and then closed again. The Laser will only operate with switch closed.
1.B When the Laser is energized by closing the remote switch, the laser can be de-energized with a RS-
485 Command, the Rear Panel Laser Switch or by disconnecting I IN current (remote switch open). If
none of these occur, the Laser de-energizes after the 20 minute time out period.
1.C If Laser has been de-energized by a RS485 Command, the Rear Panel Laser Switch or the 20 minute
timeout period, the I-In current must be disconnected (switch open) and re-applied (switch closed) to
energize the Laser with the remote switch. However, the laser can be activated with the Sensor Rear
Panel Laser switch or RS485 command without opening and closing the switch.
1.D The Laser can be energized by the Rear Panel Laser Switch or a RS485 command only when the
remote switch is closed and condition 1A has been satisfied.
PkHd Switch Operation
When Laser PkHd switch operation is selected, remote switch Reset of the peak picker, and, the Track
and Hold function are not operational. The SPST switch can be an actual toggle or a press and hold type
switch which would de-energize the laser when released. The Peak Picker can be reset at the Sensor
Rear or with a RS-485 command.
Condition Set Two
2.A If Sensor is powered up with the PkHd switch closed, the Laser will not operate until the switch is
opened and then closed again. Laser will only operate with PkHd switch closed.
2.B When the Laser is energized with a PkHd switch closure, the laser can be de-energized with the
Rear Panel Laser Switch, a RS-485 Command, or by opening the PkHd switch. If none of these occur,
the Laser de-energizes after the 20 minute time out period.
2.C If the Laser has been de-energized by a RS485 Command, the Rear Panel Laser Switch or the 20
minute timeout period, the PkHd switch must be opened then closed to energize the Laser with the
PkHd switch. However, the laser can be activated with the Rear Panel or RS485 command without
opening and closing the switch.
2.D The Laser can be energized by the Rear Panel Laser Switch or a RS485 command only when the
PkHd switch is closed and condition 2.A has been met.
PkHd Switch wiring
The switch is wired directly across the PkHd Switch terminals on the TSP Terminal Strip Plate or the
POI Power Supply/Signal Interface Box.

5.12 Out of Range Displays and Error Codes

The Modline 5 displays word messages on its rear panel display to indicate Sensor diagnostic results.
Below are explanations of the reported measurement status and error codes.

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Measurement status displays for Out of Range and Invalid measurement conditions are defined as
follows:

LOW Conditions do not allow measurement because the infrared temperature signal is too low.
The target temperature is too low for the range of the Sensor.

HIGH Conditions do not allow measurement because the infrared temperature signal is too high.
The target temperature is too high for the range of the Sensor.

INV Measurement Conditions are invalid for two color ratio temperature measurement.
When the Invalid Alarm (iALM) function is set to ON, this measurement condition
becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear
panel. If INV is the only Alarm, pressing the ▲ pushbuttons will show no other Error
Codes.

The above conditions may relate to improper installation or adjustment of Sensor

Functions. Avoid reflections from surrounding hot objects, unresolved targets, and
obstructions in the Sensor’s optical path. True temperature measurement is dependent
on correct setting of Emissivity or E-Slope.
Use of Pick Picker or Track and Hold signal conditioning may be necessary to capture
temperature signals because of process interferences.

The Rear Panel ALARM indicator signals an error has been detected. Press Up Arrow ▲ to view Error
Codes. Press Up Arrow ▲ multiple times to view all simultaneous Error Codes.
Error Codes for Sensor diagnostic information are summarized as follows:
X101 Dirty Window Detection
X102 Out of calibration
X103 Detector block too hot
X104 Detector block too cold
X105 Internal Case temperature too high
X106 Internal Case temperature too low
X107 Sensor failure. FAIL may be seen on the Sensor TEMP display
X108 Analog Output Current loop malfunction
X109 Dirty Window Detection malfunction
pINV pINV is only displayed when the Invalid Alarm (iALM) function is set to ON and Peak
Picker or Track and Hold is On. This condition becomes an alarm and triggers the Alarm
relay and the ALARM word on the Sensor rear panel.
Temperature displayed is Peak Picked or Hold Mode Temperature values from prior valid
measurement conditions.
Environmental conditions can cause Sensor errors. High or low ambient
temperatures can cause Sensor case temperature too high or too low errors. Dirty
lens conditions can be avoided using air purging.

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See Section 7 Maintenance, page 119 for possible causes of problems and
troubleshooting.

Investigate all alarms indicated by the ALARM word indicator. Temperature

readings on rear panel display, at Analog Output or from RS-485 Communications
may be inaccurate with Error Codes X101 through X109 alarms.
Ratio Temperature measurement conditions are invalid with INV and pINV alarms.

5.12.1 Summary
The initial setup procedure is complete and the Sensor should provide accurate display of the process
temperature. Auxiliary equipment connected to outputs will respond to the measured temperature.
1. The system should measure process temperatures viewed by the Sensor. Response to changes in
temperature will depend on the Response Time, Peak Picker or Track and Hold Signal
Conditioning Functions.
2. During start-up routines, observe measured temperature closely to insure proper measurement.
If necessary, fine-tune Sensor operating functions. Refer to Section 8 Applications Guide, page
129 for applications and measurement information.
3. Allow the proper amount of time for the display to settle when making measurements. Settling
time depends on the Response Time selected. Response time also affects the analog outputs and
when the sensor is used as input to a closed loop control system consideration should be given
to the effects of response time.
4. Investigate Alarms and Error Codes to determine if there are installation problems or Sensor
malfunctions.
5. The Sensor rear screw on protective window must be in place during temperature measurement
to maintain the NEMA 4 (IP65) Sensor housing rating and protect the keyboard and internal parts
from contamination.

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6 RS-485 Digital Communications

6.1 Introduction
The MODLINE 5 Sensor permits RS-485 digital signal interchange of ASCII coded information with a
host computer, PLC (Programmable Logic Controller), or any other RS-485 device. The external device
can obtain information from the Sensor and modify Sensor settings.
Be thoroughly familiar with operation of the sensor as explained in Section 5 Operation, page 82 of
this manual!
The Yellow and Yellow/White twisted wire pair of the standard Sensor interconnecting cable carries the
signal .See Section 4 Sensor Wiring, page 64 of this manual for wiring, termination and use of extension
cables.

6.2 Basic Operation

The RS-485 Digital Communications interface allows an external device to communicate with the Sensor
by sending messages it can understand. Any messages the Sensor sends back will also be in its own
“language”. The messages are based on a list of commands described in this section. Any values
included in the messages are in decimal and bit mapped values.
Whenever there is a need to change a Sensor parameter or to obtain information from the Sensor, the
external device must send a properly coded and formatted message. If there is any error, the Sensor will
ignore the message. In turn, when the Sensor transmits information back to your external device, the
response message will be in the same standard message format. The external device must be able to
interpret the response message.
Command Codes are the part of the message that request work (change values, etc.) to be done by the
Sensor. Commands that request work are “Write” commands. The same codes used Read commands
request the Sensor to report the status of the work. Command Codes are listed later in this section. All
except one of the command codes can be used as Read commands to obtain the current status of
functions and readings. Many commands are write compatible and are used to change settings.
Read request command messages sent from the external RS-485 device cause the Sensor to automatically
send back a status message. For example, if the external device (host/PLC) sends a read command to
the Sensor to report the Emissivity value, the Sensor sends a response message containing the current
Emissivity setting.
Write command messages sent by an external device include value or other information. These
messages will cause a change of Sensor parameters. The Sensor replies with a status message.
Note: Writing new values into the unit will cause it to stop updating the temperature the temperature
for up to 200 milliseconds.

Please note that an automatic process that repeatedly sends Write commands to the
sensor can shorten the sensor’s lifetime due to the limited write endurance of the
internal flash memory.

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6.3 Sensor Rear Panel Setup for RS-485 Communication

The following Sensor RS-485 Communication attributes must be correctly selected at the Sensor Rear
Panel for communications to take place. RS-485 Commands for these functions are not provided. The
instructions are in manual Section 5 Operation, page 82 for these functions.

6.3.1 CLCK – Communications Lock

Communications Lock provides for the configuration of the Modline 5 RS-485 Communications.
Communication can be configured to allow selection and adjustment of functions for Read and Write
(R / W) operation or Read Only (R / O) operation. Read Only operation causes write commands sent to
the Sensor to be turned into Read Commands.

R / O operation does allow the RS485 AC Automatic Calibrate Command to initiate a

CHK and the PR Peak Picker Reset Command to perform a reset.

6.3.2 ADDR – Sets the Sensor Address

The Unit Address is a one digit number or single letter code. It ranges from a single numeric 0 to 9 to
and upper case A to Z. The Address factory default setting is 0 (zero).

6.3.3 BRAT – Baud Rate

The Sensor Baud Rate must match that of the other RS-485 device. Four baud rates are supported: 9600,
19200, 38400, and 57600 bits of information per second.

6.4 Communication Protocol

Communication is half-duplex, two wire. The Sensor does not support simultaneous transmit and
receive. Four baud rates are supported: 9600, 19200, 38400, and 57600 bits of information per second.
All characters are ASCII 7 bits, even parity, 1 stop. Commands have a response. Another command
should not be sent until a response has been completely received. There is a 1-millisecond minimum
delay between receipt of command and response. The maximum delay is less than 200 milliseconds.

6.4.1 Command Message Format

All command messages have the same format:
<Start Bit> <Sensor Address> <Channel Number> <Command Code> [<Value>] <Carriage Return>

Example: #A0CCXXXXX<CR> Where:

Start Bit = # Always the pound sign character.
Sensor Address = A A single alphanumeric character address of the Sensor, 0 to 9, A to Z
0 (zero) is the factory-default setting. The wild card address of ‘ ? ‘ is accepted
by the MODLINE 5 regardless of its set address. Do not use the “?” address
if more than one Sensor is connected.
Channel Number = 0 Is always the 0 (zero) character.
This one-digit entry value is not used in the MODLINE 5. SET to 0 (zero) for
future use.

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Command Code = CC Is one of the two alpha character command codes from the list below.
All the commands are detailed below.
Value = XXXXX Is the value included with a Write message and reported in the Sensor reply.
The range of acceptable input value is given for each command code. If the
value is omitted, execution of the instruction will return the present value of
the parameter involved. If a value is included, execution of the instruction will
store the specified value to in the Sensor’s non-volatile memory.
Carriage return = <CR> All messages are concluded with ASCII code CR, “Enter” on computer
keyboard.

6.5 Command Codes

6.5.1 Introduction
The Command Codes allow operation and setup of the Modline 5 Sensor similar to the Rear Panel
pushbuttons. Refer to the manual section referenced for configuration and operation information as
directed for each code.
The Command Codes have been separated into four categories as follows:
• Engineering Functions
• Analog Output Functions
• Head Functions
• Measurement Conditions and Alarms
If the command is fully recognized, the command will be echoed back as “#A0CCXXXXX<CR>”, where
XXXXX will be the value sent if the command sent parameters that changed something, or the current
setting, if no parameters were sent. If the parameters sent are out of range or otherwise not allowed, the
current setting will be returned.
The message format must be correct for the sensor to reply. If the “#A0” is followed by any number of
characters and a carriage return character is not received, the unit will not respond at all. If at least a
fragment of the command is received, but the command code is not recognized, a response of
“#a0cc?HUH?” will be returned.

6.6 Engineering Function Command Codes

KL – Keyboard Lock (Read / Write)
Locks or unlocks the Sensor’s rear panel keyboard. When the keyboard is locked, all functions work
and can be viewed, but not changed, at the Sensor. The keyboard can also be locked and unlocked
from the Sensor rear panel. RS-485 Write commands are not locked out with this command.
Range: 0 or 1 (0 = Unlocked; 1 = locked)
MD – Model Number (Read Only)
Returns the model number of the sensor.
Value: An eight character Model Number is returned.
UN – Units Select (Read / Write) See Section 5.6 ENGR – Setup of Engineering Functions, page 86 for
important information when changing units.
Sets the temperature units the Sensor uses for measurement and display.
Range: 0 to 1 (0 = Fahrenheit) (1 = Celsius)

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UZ – Unit Zero Scale (Read Only)
Returns the Sensor’s zero scale temperature as defined its Model Number. An F or C is put on the
end as appropriate.
UF – Unit Full Scale (Read Only)
Returns the unit’s full-scale temperature as defined by its Model Number. An F or C is put on
the end as appropriate.
AC – Auto and Immediate Calibration Initiate (Read / Write) For 52, 5G, and 5R models.
See next paragraph for Models begging with 56. See Section 5.5 Warm-up and Initial Setup, page 85.
Sets the number of hours between Systems Checks. A manual Check from the Sensor Keyboard or
by RS-485 Communication will start a new time period. Continuous interval setting should be 8
hours or greater. A 168 hour, 1 week, (or greater) automatic interval and manually initiated checks
are the recommendations that will provide minimal measurement interruption.
Range: 0 to 9999, 65535
A zero value disables this function. Values between 1 to 9999 sets the time period in hours.
A value of 65535 (FFFF16) causes an immediate Check to occur without changing the previously set
time period value.
AC – Auto and Immediate Calibration Initiate (Read / Write) For Models begging with 56.
Series 56 Models include a Self-Calibration feature performed as part of the power on routine.
Explanation of this feature is provided in Section 5.5 Warm-up and Initial Setup, page 85, under the
explanations for sensor parameters: CHK - (Models Beginning with 56) and HOUR - (Models
Beginning with 56).
Range: 0 or 168, 65535
A zero value disables this function (a Manual Initiation must be performed at least every 168 hours).
A value of 168 sets the time period between calibration checks to 168 hours (Factory setting)
A value of 65535 (FFFF16) causes an immediate Calibration to occur without changing the previously
set time period value. This is equivalent to a Manual Calibration at the Sensor Rear Panel.
RP – Relay Polarity (Read / Write)
Sets the polarity of the alarm relay. Set to 1 for “fail safe” operation. Contacts are held open with
power off or power on and in the brief warm-up state for either polarity.
Range: 0 or 1 (0 = N.O; to 1 = N.C.)
DT – Dirty Window Detector Warning Level (Read / Write)
This command is available only with the Dirty Window Detector option.
This command is the same as the Sensor Rear Panel WRNL. OFF turns the dirty window detection
function off. Course and Sensitive Warning Levels select a greater (CORS) or lesser (SENS) amount
of Sensor window transmission loss required to trigger a dirty window alarm.
Range: 0 to 2
Message Value:
0 = Dirty Window Detection Alarm Off
1 = Sensitive (SENS)
2 = Coarse (CORS)
SW – Switch Input Status (Read Only)
Command Returns the Sensor’s external switch status (Peak Picker reset and Hold mode select).
Range: 0 or 1 (0 = closed; 1 = open)

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BT – Report Isoblock Temperature (Read Only)
Returns the infrared detector isoblock temperature in °C.
Typical Value Range: 0 to 65
RC – Instrument Temperature (Read Only)
Returns the unit’s internal case temperature in °F or °C.
Range: N/A
Expected value is within the Range: 0 to 65 °C.
VR – Firmware Version (Read Only)
The VR command returns the Sensor’s firmware version number in the format: VV.RR.
VV is the major version number, RR is the revision number.
Range: N/A
TP – Controller Type (Read Only) – Reserved for future use.
Always returns zero.
Range: Not Applicable
LS – Laser Control
Command is available with Laser sighting option only. Turns the sighting laser on or off. Note that
the laser has an automatic timeout of twenty minutes.
Range: 0 or 1
Values: Turns on the laser (1) or turns off the laser (0).
The Laser will not energize during the System Check. Also, if the Laser is energized and a manual
(CHK function) or automatic (HOUR function) system check is initiated, the Laser will turn off.
Observe and follow cautions below and operating instructions in Section 5.11 Laser Sighting
Operation, page 102 of this Modline 5 Manual.

Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or
other devices using RS– 485 Communications, insure there are no personnel in the path
of the beam.

FT – Features Matrix (Read Only)

Returns the features that this unit supports.
Note: When bits 1 and 2 are not set, Sensor is 52 Series Brightness Unit. Range: N/A
Bit Values:

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Two color detector (R-series) 0x0001 1
LASER pointer 0x0002 2
Dirty window detector 0x0004 4
G-series 0x0008 8
Transfer Standard 0x0010 16
Unit is chopped 0x0020 32
Unit has TEC 0x0040 64

Ignoring LASER, DWD and Transfer Standard:

5R-series = 1
52-series = 0
5G-series = 8
56-series = 96 (60Hex)
57-series = 32 (20Hex)
SN – Sensor Unit Serial Number (Read Only)
Range: N/A
Message Value: Returns the serial number string of the unit.
RR – Alarm Operation (Read / Write)
Command is only available with Series 5R ratio units. When this is turned on, it also enables the
Attenuation alarm.
AT – Attenuation Alarm Threshold (Read / Write)
Set the percent attenuation alarm threshold. Any attenuation greater than this value will turn on the
alarm and also turn on the dirty window LED on the back panel. Setting this to 95 will turn this
alarm off since that is the invalid threshold. The relay response (see command RR) must be set on in
order to enable this alarm

6.7 Analog Output Function Command Codes

AO – Analog Output Current Range (Read / Write)
Sets the Analog Output Current loop range to either 0 to 20 mA or 4-20 mA
Range: 0 or 1 (0 = 4 to 20 mA; 1 = 0 to 20 mA)
AZ – Analog Zero Scale (Read / Write)
Analog Zero Scale command specifies the measured temperature that will produce the Analog
Output Zero Scale current. See Section 5.7 AOUT – Setup of Analog Signal Output Current Range
and Temperature Scaling, page 93 about minimum spans and F / C operation.
Message Value Range: Sensor’s zero scale temperature to 10F below its full scale temperature.
The Sensor’s selected measurement units, “F” or “C”, are ignored in the Write command. Sensor
Reply Returns with an “F” or “C” to show which units are selected.
AF – Analog Full Scale (Read / Write)
Analog Full Scale command specifies the measured temperature that will produce the Analog
Output full scale current. See Section 5.7 AOUT – Setup of Analog Signal Output Current Range and
Temperature Scaling, page 93 about minimum spans and F / C operation.
Message Value Range: Sensor’s zero scale temperature + 10 to its full scale temperature.
The Sensor selected measurement units, “F” or “C”, are ignored in the Write command. Sensor Reply
Returns with an “F” or “C” to indicate which units are selected.

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AA - Analog Output Alarm (Read / Write)
Sets the Analog Output current to a specified value when unit is in any of two alarm conditions. A
Sensor failure (Error Code X107) or Dirty Window Detector circuit failure (Error Code X109) will
trigger this alarm.
Scaled Message Value Range: 0 to 240
Actual Range 0.0 mA to 24.0 mA
AL – Analog Output Low Temperature (Read / Write)
This command is used to set the value of the current loop output as an alarm if the measured
temperature is below the scaled or default temperature that produces Analog Zero Scale Output
current.
Scaled Message Value Range: 0 to 40
Actual Range is 0.0 mA to 4.0 mA for the 4 to 20 mA current output range.

If the current loop is set for 0 to 20 mA operation, the AL command setting is

overridden and the analog output always goes to 0 mA if below zero scale
temperature.

AH – Analog Output High Temperature (Read / Write)

This command is used to set the value of the current loop output as an alarm if the measured
temperature is above the scaled or default temperature that produces Analog Full Scale Output
current.
Scaled Message Value Range: 200-240
Actual Range: 20.0 mA to 24.0 mA

6.8 Head Function Command Codes

CL – Select Mode of Ratio Sensor Operation (Read / Write)
Command is for 5R ratio units only. The CL command selects One Color or Two Color operation for
a Series 5R ratio Sensor.
Message Value Range: 1 or 2 (1 selects single color brightness mode; 2 selects two color ratio mode).
RT - Response Time (Read / Write)
Sets the Sensor Response Time.
Scaled Message Value Range: 0 to 6000
(Scaled value = actual value times 100 above Sensor minimum Response Time limit)
Range for Series 52 or 5G Sensors: 0 (Minimum) to 6000 (60 Seconds)
(Zero = somewhat less than .006 second; Zero = not valid for 5R, 56 Sensors)
Range for Series 5R Sensors: 10 (.01 second) minimum to 6000 (60 Seconds)
Range for Series 56 Sensors: 20 (.02 second) minimum to 6000 (60 Seconds)
ES – E-Slope (Read / Write)
Command is for 5R ratio units only. Sets the E-Slope for Ratio Sensors operating in the 2 color ratio
mode. Function is not active for single color mode.
If the Sensor’s remote scaled E-Slope input current is active, the Sensor returns that setting ignoring
any ES Write command or Rear Panel keyboard entry.
Scaled Message Value Range: 800 to 1200 (Scaled value = actual value times 1000)
Actual Range: .8 to 1.2

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EM – Emissivity (Read / Write)
Sets Emissivity for single color units or Ratio units in 1 color mode. If the Sensor’s remote scaled
Emissivity input current is active, Sensor returns that setting ignoring any EM write command or
Rear Panel keyboard entry.
Scaled Message Value Range 100 to 1000 (Scaled value = actual value times 1000)
Actual Range: 0.1 to 1.0
MT – Match Temperature (Read / Write)
Alternative method of selecting the value for Emissivity or E-Slope. The Write Message Value is the
known temperature of the target the Sensor is measuring. The unit will change Emissivity (single
color units) or E-Slope (two-color ratio units) to a value to that produces a displayed temperature
equivalent to the target temperature. The Sensor returns the required Emissivity, or E-Slope value,
if the result is in range. If the unit is unable to match the temperature then the return value is “ERR”.
The Match temperature should be set with a Sensor Response Time of 100 milliseconds or faster.
Peak Picker or Track and Hold must be Off. The Match function should be set with stable process
temperatures. After setting the Match temperature, the Response Time, Peak Picker and Track and
Hold can be set to the values required for process temperature measurement.
Write Message Range: Unit’s zero scale to full scale temperature
Reply Message Value: Emissivity or E-Slope value or ERR
TT – Temperature (Read Only)
Returns the temperature the unit is reading in the current units. An F or C is put on the end as
appropriate. The temperature resolution is 1°F or °C.
Message Value Range: From the low end to the high end of the Sensor temperature range.
Some special readings are:
-32768(800016) – Sensor Failure
-32512(810016) – Unit not warmed up.
-32256(820016) – Invalid
-32000(830016) – Temperature too low, below Sensors range
-31744(840016) – Temperature too high, above Sensor range
TO – Temperature Only (Read Only) (Sensor firmware Versions 1.07 and higher)
Returns the temperature the unit is reading in the current units. An F or C is put on the end as
appropriate. The temperature resolution is 1°F or °C.
Message Value Range: This command only reports values that are within the Sensors temperature
range. Actual reported values are from approximately three degrees below the low end of the Sensor
temperature range to approximately three degrees above the high end of the Sensor temperature
range. Values below zero scale or above full scale are not accurate and should not be used.
There are no special readings to indicate that the temperature is out of range (too high or too low) or
invalid. Use the ST Status command to sense the temperature TO Value is under range (below the
sensor zero scale temperature) or the TO value is over range (above the full scale temperature) or
Invalid for ratio measurements.
SG – Signal Conditioning Usage (Read Only)
Turns Peak Picker or Track and Hold on and off. Only one can be turned on at time.
Range: 0 to 2
Message Values:
0 – Peak picker and track & hold are both off.
1 – Peak picker on.
2 – Track & Hold on.

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PR - Peak Picker Reset (Write Only)
This function is used to reset the Peak Picker. It is a write only command and no value is given. By
sending the PR Command, with or without a message value, a Peak Picker reset is performed.
Message Value Range: Not Applicable
Actual value: Always returns #A0PR<CR>, where A =the sensor
DR – Peak Picker (Read / Write)
Sets the peak picker decay rate. Zero (0) sets the unit to never decay. Otherwise decay is in selected
measurement units, °F or °C. See Section 5.10.1 D.R. – Decay Rate Function, page 100 for more
information.
For Sensors with firmware versions 1.02 and higher
Scaled Message Value Range: 0 to 30000 (°F per second times 100)
Scaled Message Value Range: 0 to 16666 (°C per second times 100)
Actual Value: .01 to 300.00 (°F per second), except 0 which = Off
Actual Value: .01 to 166.66 (°C per second), except 0 which = Off

Sensor Firmware Version Operation Summary

Original Sensors with firmware versions less than 1.02 have unit-less degree units that
range 0.00 to 300.00 for both F and C unit’s selection. For those Sensors, the following
operation applies.
Sets the peak picker decay rate. Zero (0) sets the unit to never decay. Otherwise decay
is in °F or °C per second.
Scaled Message Value Range: 0 to 30000 (°F or °C per second times 100).

PS – Peak Picker Auto Reset (Read / Write)

Selects Peak Picker Auto Reset operation
Scaled Message Value Range: 0 to 2
Actual Value: .0 to 2: Zero (0) Sets Auto Reset to Off: 1sets it to On. (2 is reserved for future use).
PK –Peak Picker Reset Below Temperature (Read / Write)
Sets the temperature below which the peak picker signal conditioning is in reset or direct reading
mode. Sensor is measuring temperature without peaking action in this mode. Function is used with
Auto Peak Picker Reset.
Message Value Range: Unit’s Zero Scale Temperature to Unit’s Full Scale Temperature (°F or °C)
PD –- Peak Delay (Read / Write)
Sets the delay time before Peak Picker action starts.
Message Value Range: 0 to 1000 – Zero (0) turns off any delay. Above 0, this is a scaled value. (Scaled
input above 0 = actual value times 100).
Actual Delay Range in Seconds: 0.010 to 10 seconds.

6.9 Measurement Condition and Alarm Command Codes

6.9.1 Introduction
This section identifies measurement and alarm status commands and defines the reported errors and
measurement conditions.
TI – TS – Temperature, Status, and Attenuation (Read Only)

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Returns the temperature the unit is reading, followed by a comma, then the current status (see the
ST command for details), another comma, and then the current attenuation percent (expressed as a
number from 0 to 100)
Range: N/A
TS – TS – Temperature and Status (Read Only)
Returns the temperature the unit is reading followed by a comma, and then either a 0 (no alarm
conditions), or a number with the same format as the “ST” Command.
Range: measured temperature in degrees C or F and –32768 to 32767.
ST - System Alarm and Measurement Condition Status (Read Only)
The Sensor returns a message indicating the current measurement condition status and the status of
alarms.
Range: Not Applicable
Values: Bit mapped values for alarm and measurement status.

Value Condition Equivalent Display or Error Code

0 None to Report None
1 Out of calibration Same as Error Code X102
2 Signal invalid (may not be set in Peak Picker mode) Invalid 1 Same as INV on rear panel
4 Case temperature too low Same as Error Code X106
8 Case temperature too high Same as Error Code X105
16 Detector block cold Same as Error Code X104
32 Detector block hot Same as Error Code X103
64 Current loop fault Same as Error Code X108
128 Dirty window detection Same as Error Code X101
256 Sensor failure Same as Error Code X107 or FAIL on rear panel
display
512 DWD failure Same as Error Code X109
1024 Signal invalid (Always set regardless of Peak Invalid 2 Same as Error Code pINV on rear panel
Picker mode). Measured Signal too low for ratio display when Alarm button pushed
measurement, Displayed Temperature is Peak
Picked or Hold mode Temperature
2048 RS485 Communications Lock RS485 Communications Locked out, In read only
4096 Temperature reading under range Same as LOW on rear panel TEMP display
8192 Temperature reading over range Same as HIGH on rear panel TEMP display
16384 Laser pointer is on Same as Laser LED on Sensor rear panel
–32768 Unit under Cal test Same as CAL on rear panel TEMP display

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6.10 Command Code Summary

Code Command Type Group Notes
Description
AA Analog alarm output R/W Analog Sets the Analog Output to a specified value when unit is in any of
Out two alarm conditions. (Error Codes X107, X109).
AC Auto cal time period R/W Eng. Sets the number of hours between Automatic Checks or performs
(in hours) immediate check.
AF Analog full scale R/W Analog Analog Full Scale command specifies the measured temperature
Out that will produce the Analog Output full scale current.
AH Analog output high R/W Analog Sets alarm condition at the Analog Output if the measured
temperature alarm Out temperature is above the value for Analog Full Scale Output.
AL Analog output low R/W Analog Sets alarm condition at the Analog Output if the measured
temperature alarm Out temperature is below the value for Analog Zero Scale Output.
AO Analog output mode R/W Analog Sets the Analog Output Current loop range to either 0 to 4 mA or 4-
Out 20 mA.
AT Attenuation R/W Eng. Set the percentage value for the attenuation alarm threshold.
Alarm threshold
AZ analog zero scale R/W Analog Sets the measured temperature that produces the Analog Output
Out Zero Scale current.
BT Report Isoblock R/O Eng. Returns the infrared detector isoblock environment temperature in
temperature °C.
CL Set to 1 or 2 color R/W Head Selects One Color or Two Color operation for a Series 5r ratio
mode Sensor.
DR Peak picker decay rate R/W Head Sets the peak picker decay rate in F or C. Zero (0) sets the unit to
never decay.
DT dirty window threshold R/W Eng. Dirty Window Detector Sensitivity Warning Setting
EM Emissivity R/W Head Sets Emissivity for single color or ratio units in one color mode
ES E slope R/W Head Sets the E-Slope for Ratio Sensors in the 2 color ratio mode
FT Features Matrix R/O Eng. Returns bit values for the features the Sensor supports.
KL Keyboard lock R/W Eng Locks or unlocks the Sensor’s rear panel keyboard.
LS Laser Control R/W Eng Turns the sighting laser on or off.
MD Model R/O Eng Returns the Model number of the Sensor.
MT Match Temp Display R/W Head Writes temperature value to be displayed to match target.
Read replies Emissivity or E-Slope value
PD Peak delay R/W Head Sets the delay time before Peak Picker action starts.
PK peak picker reset R/W Head Sets the temperature at which Peak Picker action starts with Auto
below Peak Picker Reset Function
PR Peak and reset write Head Write Only Command, Resets the Peak Picker
PS Peak picker auto reset R/W Head Selects Peak Picker Auto Reset operation
RC Case temperature R/O Eng Returns Sensor’s internal Case temperature.
RP Relay polarity R/W Eng Sets the polarity of the alarm relay.
RR Alarm Operation R/W Eng When this is turned on, it also enables the attenuation alarm.
RT Response time R/W Head Sets the Sensor Response Time.
SG Signal Conditioning R/W Head Turns Peak Picker or Track and Hold on or off.
SN Serial Number R/O Eng. Returns the serial number string of the unit.
ST System alarm status R/O Alarm Sensor returns bit mapped values for alarms and the current
measurement condition status.

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Code Command Type Group Notes
Description
SW Switch input status R/O Head Returns the Sensor’s external Peak Picker reset and Hold mode
select switch status.
TI Temperature, status R/O Head Returns the temperature, current status and the current attenuation
and attenuation percentage.
TO Temperature Only R/O Head Returns the temperature the unit is reading. No alarm or special
values are reported for over range and under range conditions.
TP Controller type R/O Eng. Reserved for future use. Always returns 0.
TS Temperature and R/O Alarm. Returns the temperature the unit is reading and the Presence of an
Status alarm.
TT Temperature R/O Head Returns the temperature the unit is reading in the current units (F or
C) Special bit mapping messages for measurement status.
UF Unit full scale R/O Eng. Returns unit’s full-scale temperature as defined by Model No.
UN Units select R/W Eng. Sets the units the Sensor uses for measurement (F or C).
UZ Unit zero scale R/O Eng. Returns Sensor’s zero scale temperature as defined Model No.
VR Firmware version R/O Eng. Returns the Sensor’s firmware version number

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7 Maintenance
7.1 Routine Maintenance
7.1.1 Maintenance Checklist
The Modline 5 Sensor is a precision temperature measuring instrument built for rugged service and
ease of operation.
When installed and maintained with reasonable care, it will give you reliable service in a wide variety
of applications. Routine Maintenance is essential for reliable, trouble-free operation. It consists of a
thorough inspection at regular intervals to keep the instrument working efficiently and to head off
problems before they occur.
Most “service problems” are caused by incorrect function setup, improper Sensor sighting and focusing,
dirty optics, and overheating of the sensor and other conditions that can be found and corrected by a
maintenance program.
The following checklist will help you develop a maintenance routine suitable for your installation:
 Perform Sensor Check (CHK) as instructed under Engineering functions menu for Sensor setup
in Section 5 Operation, page 82.
 Check Sensor function settings. A record of the correct settings for process being measured
should be made.
 Check Sensor for proper alignment and focus. Make sure there are no obstructions in the optical
path between Sensor and target. Process viewing windows should be clean.
 Check Sensor lens and clean if necessary. Refer to cleaning instructions below.
 Make sure Sensor is not overheated. If water cooling and/or air purge accessories are used, make
sure there is adequate flow of cooling water and clean, dry air.
 Check Sensor interconnecting cable for any signs of mechanical damage or overheating. Make
sure all connections are secure.

7.2 Sensor Optics Cleaning

Inspect the standard Sensor lens or the front window and mirror on the Sensor with the Dirty Window
Detector option on a routine schedule. Clean this optics of any dust or residue that may have
accumulated. If this requires removing the Sensor from its mounting, make sure you note the mounting
alignment and lens focus position so you will be able to restore the Sensor to its correct operating
position. Always verify focusing as instructed in Section 3 Sensor Installation, page 22.
If the Sensor includes the Laser aiming option, see the Laser option cautions on Section 2.3 Model
Configuration and Required Selections, page 16 and Section 5 Operation, page 82.
Protect the Sensor interconnecting cable plug pins from liquids and dirt if disconnected from the Sensor.
Clean the front surface of the lens, or window and mirror as often as necessary. The frequency of the
lens cleaning will depend on the environment at the point of installation. Air purging will reduce the
necessity of frequent cleaning in dusty, dirty areas.

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Treat the Modline 5 Sensor optics with care.

Scratches or harmful solvents can destroy the lens or the Dirty Window Detector
window and mirror. Lenses may be slightly soluble in water and other liquids. Do not
soak any lens in water or any other liquid for long periods of time.

Sensor with DWD Mirror and Window

Standard Sensor Lens

Figure 76: Sensor optics

7.2.1 Cleaning the Optics

Clean the front surface of the Standard lens, or Sensor with DWD window and mirror as often as
necessary. Use a soft dry cotton cloth or swab moistened with laboratory grade isopropyl alcohol. Wipe
gently to remove residue. Inspect and re-wipe as necessary to remove any film.

7.2.2 Restoring the Sensor to Operation

Always re-install the Sensor in its original position. Always verify focusing as instructed in section 3
Sensor Installation, page 22. Lock the lens by tightening the lens locking screw on the bottom of the unit
with your fingers and thumb. Never use a tool.
Place the rear protection window on the back of the Sensor and perform any operational checks that
may be necessary to make sure the instrument is functioning properly.

Rear Focusing Section

Lens Lock Thumb Screw Do Not Use Tools

Cable Connection, Match Red Dots

Rear Protection Window

Figure 77

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For Modline 56 sensors: occasionally, a calibration flag that operates during the Sensor
internal Calibrate test may move into the viewing area during shipment. If this occurs,
the viewing area will be dark and appear obstructed. This flag will be positioned
correctly when power is applied to the Sensor.

The Modline 5 Sensor with Laser sighting option is a Class II Laser product. When restoring a Sensor
with this option back to service, follow the Cautions outlined below and the operating instructions in
Section 5.11 Laser Sighting Operation, page 102 of this manual.

Before turning on the Laser remotely with the DPM Digital Panel Meter Interface or
other devices using RS– 485 Communications, insure there are no personnel in the path
of the beam.

7.3 Servicing
There are no user adjustable controls or serviceable parts within the Sensor Housing. Units must be
returned to the factory for calibration and adjustments. Do not disassemble the unit!

To prevent possible electrical shock, fire, or personal injury have an approved

technician repair the product.

7.4 Factory Calibration and Service

Instruments are calibrated against precision laboratory standards and are "burned in" for before
shipment to ensure accurate temperature measurements throughout the operating range. To preserve
this accuracy, each instrument should be recalibrated periodically on a Blackbody standard. We
recommend recalibration of this type on a yearly basis. There are the following methods of calibrating
IRCON Modline 5 units:
 You can have your instruments calibrated at our Service Center. An available option is
calibration traceable to the National Institute of Standards and Technology (NIST).
 Field Service Agreements geared to your requirements are also available. Options include
periodic maintenance (with provisions for guaranteed emergency service rates) and field
maintenance with emergency service and parts replacement.

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 Using the ModView Calibration software (not available for M56). This software is for sale and
allows you to calibrate the Modline 52, 5G, and 5R as long as the calibration does not require a
change of more than 30% of the range. You basically need a black body and while the instrument
is aimed at the black body you allow the software to set the calibration of the instrument. You
only do one set point with the software but you can make as many checks as you want.
 The fourth method is to use a sensor that is titled a transfer standard. This is a Modline 5, usually
the same model as the customers equipment and it is specially calibrated at 10 specific points
on the temperature scale of the instrument. A NIST certificate of calibration is furnished with
the instrument. With the transfer standard you also get the ModView calibration software. You
aim the transfer standard at the black body and read and record the temperature that is
indicated on the transfer standard. By using the transfer standard you eliminate any potential
errors that may have occurred in the black body such as a defective thermocouple or an
inaccurate cavity. Next, you take the instrument to be calibrated and aim it at the black body
and with the software install the corrected calibration temperature. Again it is a one point
calibration but you can check as many points as you want to insure the best accuracy.

7.5 Measurement Condition Displays, Error Codes and

Troubleshooting
The Modline 5 displays word messages on its rear panel display to indicate Sensor diagnostic results.
Below are explanations of the reported measurement status and error codes.
Measurement status displays for Out of Range and Invalid measurement conditions are defined as
follows
LOW. Conditions do not allow measurement because the infrared temperature signal is too low.
The target temperature is too low for the range of the Sensor.
HIGH Conditions do not allow measurement because the infrared temperature signal is too high.
The target temperature is too high for the range of the Sensor.
INV Measurement Conditions are invalid for two color ratio temperature measurement.
When the Invalid Alarm (iALM) function is set to ON, this measurement condition
becomes an alarm and triggers the Alarm relay and the ALARM word on the Sensor rear
panel. If INV is the only Alarm, pressing the ▲ pushbuttons will show no other Error
Codes.

The above conditions may relate to improper installation or adjustment of Sensor

Functions. Avoid reflections from surrounding hot objects, unresolved targets, and
obstructions in the Sensor’s optical path. True temperature measurement is dependent
on correct setting of Emissivity or E-Slope. Use of Pick Picker or Track and Hold signal
conditioning may be necessary to capture temperature signals because of process
interferences.

The Rear Panel ALARM indicator signals an error has been detected. Press Up Arrow ▲ to view Error
Codes. Press Up Arrow ▲ multiple times to view all simultaneous Error Codes.

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Error Codes for Sensor diagnostic information are summarized as follows:
X101 Dirty Window Detection (or attenuation alarm if using a 5R series with the Attenuation
Alarm turned on)
X102 Out of calibration
X103 Detector block too hot
X104 Detector block too cold
X105 Sensor internal Case temperature too high
X106 Sensor internal case temperature too low
X107 Sensor failure: FAIL may be seen on the Sensor TEMP display
X108 Analog Output Current loop malfunction (open circuit)
X109 Dirty Window Detection malfunction
pINV pINV is only displayed when the Invalid Alarm (iALM) function is set to ON and Peak
Picker or Track and Hold is On. This condition becomes an alarm and triggers the Alarm
relay and the ALARM word on the Sensor rear panel.
Temperature displayed is Peak Picked or Hold Mode Temperature values from prior
valid measurement conditions.

Environmental conditions can cause Sensor errors. High or low ambient

temperatures can cause Sensor case temperature too high or too low errors. Dirty lens
conditions can be avoided using air purging.

Investigate all alarms indicated by the ALARM word indicator. Temperature readings
on rear panel display, at Analog Output or from RS-485 Communications may be
inaccurate with Error Codes X101 through X109 alarms.
Ratio Temperature measurement conditions are invalid with INV and pINV alarms.

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7.6 Status Displays and Error Code Details

Status Display Error Code Details

The temperature display is  The display shows LOW when the measured temperature is below
LOW or HIGH the Sensor Zero Scale Temperature by a few degrees.
Is the Emissivity or E-Slope setting correct?  The display shows HIGH when the measured temperature is
Is the field of view blocked? above the Sensor Full Scale value by a few degrees.

Are reflections or background energy  The display remains LOW or HGH as long as the measured
causing high readings? temperature is out-of-range.

For Sensor Series 5R  This is an Invalid Alarm display. The process measurement
Temperature Display is INV conditions are invalid. The infrared energy reaching the Sensor is
too low to provide reliable temperature measurement.
Note: iALM must be set to ON for this
Alarm condition to be displayed on Sensor
rear panel and for the Alarm Relay to
operate.

For Sensor Series 5R  This is an Invalid Alarm with the Peak Picker On. It is displayed, if
Alarm condition is pINV the infrared energy reaching the Sensor is too low to provide
reliable temperature measurements.
Note: iALM must be set to ON for this
Alarm condition to be displayed on Sensor  Displayed temperature readings are peaked values or hold values
rear panel and the Alarm Relay operates. from Peak Picker or Track and Hold signal conditioning.

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Status Display Error Code Details

Error Code X101  Dirty front Sensor optics detected. Clean Sensor front window and
Dirty Window Detected mirror. This will only be seen on Sensors with the Dirty Window
Detector Option

Error Code X102 Out of calibration (M56)  Calibration check has sensed Sensor out of calibration condition
Do not Initiate a Calibration Check during  Note: An out of calibration error may be encountered if the Sensor
warm-up. See Section 5.5 Warm-up and temperature is too high or too low. Do not calibrate when an
Initial Setup, page 85, for M52, 5G, and 5R Alarms for error codes X103, X104, X105, X106 exist.
models.
 Caution: Any temperature readings at Analog Output or from RS-
485 Communications must be considered inaccurate
 Check Sensor Calibration on a Blackbody Standard

Error Code X103 Detector block too hot  Detector Temperature is too high.
 Check ambient temperature (55 °C maximum) and Sensor internal
case temperature using the RS485 RC Command or with a
temperature measuring device such as a fine thermocouple. If
these temperatures are okay and alarm continues Sensor may
have a malfunction.
 Caution: Any temperature readings on rear panel display, at
Analog Output or from RS-485 Communications may be
inaccurate.

Error Code X104 Detector block too cold  Detector Temperature is too low
Note: This Error Code is normal during  Check ambient temperature (0°C minimum) and Sensor internal
Sensor warm-up. Warm-up typically lasts case temperature using the RS485 RC Command or with a
from just a few minutes to 15 minutes. temperature measuring device such as a thermocouple.
 If these temperatures are okay and alarm continue, check the
24VDC supply voltage. Sensor may have a long warm-up time if
the voltage not within 5%.
 If the power supply is remotely installed, insure the voltage drop
across power supply wires is not causing a low voltage level at the
Sensor.
 Caution: Any temperature readings on rear panel display, at
Analog Output or from RS-485 Communications may be
inaccurate.

Error Code X105 Case temperature too high  Sensor case temperature is below is above specification.
 Check ambient temperature (55 °C maximum) and Sensor internal
case temperature using the RS485 RC Command or with a
temperature measuring device such as a thermocouple. If these
temperatures are okay and alarm continues Sensor may have a
malfunction.
 Caution: Any temperature readings on rear panel display, at
Analog Output or from RS-485 Communications may be
inaccurate

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Status Display Error Code Details

Error Code X106 Case temperature too low  Sensor case temperature is below is below specification.
 Check ambient temperature and Sensor internal case temperature
using the RS485 RC Command or with a temperature measuring
device such as a thermocouple. If these temperatures are okay
and alarm continues Sensor may have a malfunction.
 Caution: Any temperature readings on rear panel display, at
Analog Output or from RS-485 Communications may be
inaccurate

Error Code X107  Serious problem with Sensor operation exists

Sensor failure
 Caution: Any temperature readings at Analog Output or from RS-
FAIL may be seen on the Sensor TEMP 485 Communications must be considered inaccurate.
display.
 Replace Sensor

Error Code X108  Sensor has sensed external analog output current flow is not
Analog Output Current loop malfunction. accurate. Note: this Error Code only will be seen for errors
Analog Output current not correct value detected when output current is greater than 0 mA.
Caution: Inaccurate temperature readings  Connected devices should have differential inputs; neither input
may be displayed or used by external terminal should be grounded.
devices connected to Analog Output.
 Check cables and external devices.
 See symptom number three in Troubleshooting Table below.
 If analog output is not used, place a jumper wire across the output
terminals to prevent the X108 alarm from occurring.

Error Code X109  Dirty Window circuit operation malfunction.

Malfunction of Sensor Dirty Window
 Replace Sensor
Detection.

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7.6.1 Troubleshooting
If troubles develop in the initial installation or after periods of normal operation, these troubleshooting
suggestions may help to identify certain trouble symptoms and possibly correct the problem. If trouble
persists, call or contact IRCON Technical Services for help.

Symptom Possible Cause / Corrective Action

Symptom Number One: 1. Check 24 Vdc Sensor power supply

Completely inoperative 2. Check AC line voltage supply connections on power supply
 No display of any kind. 3. Check any line fuse, switch or circuit breaker for power supply.
 No RS-485 Communications 4. Inspect interconnecting cable and connections for damage.
Replace Cable if problem found.
 No Analog Output
5. Replace Sensor.

Symptom Number Two: 1. Sensor warmed up. See Section 5.5 Warm-up and Initial Setup,
page 85.
Incorrect Temperature Indications
2. Check Sensor sighting and focusing. Is target resolved?
 No temperature indication or incorrect
temperature indication. (Target 3. Check for obstruction in sight path.
temperature known to be within system
4. Check for background interference (reflections) causing high
temperature range.)
temperature readings.
 Under-range (LOW) or Over-range 5. Check lens and clean if necessary. (If system includes window or
(HIGH) indication displayed. mirror, check and clean.)
 For Sensor Series 5R Ratio series 6. Check ambient temperature of Sensor. If water cooling is used,
instruments. Invalid (INV or pINV) make sure coolant is flowing at recommended rate.
indication displayed.
7. Check all control settings, particularly Emissivity or E-Slope for
Series
8. Perform Calibration Check. (M56)

Symptom Number Three: 1. Check wiring between the analog output terminals and external
devices.
No Analog Output, or incorrect Output
2. Device inputs should be differential type and not grounded.
 Accurate temperature displayed on rear
panel. 3. Make sure device is connected and adjusted correctly, and is
compatible with Modline 5 specifications.
 RS-485 Communications temperature
output okay. 4. Check grounding of external devices. Improper grounding could
prevent proper signals at external devices.
5. Check Analog output Zero and Full Scale Adjustment.
6. Check F / C measurement units’ selection of Sensor and external
device to make sure they are compatible.
7. Series resistance of all devices and cable pairs on Analog Output
should not exceed 600 Ohms.

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Symptom Possible Cause / Corrective Action

Symptom Number Four 1. Check for recurrent interruptions in sight path e.g. bursts of smoke
or steam, moving equipment.
Erratic temperature display and outputs.
2. Use air purge to clear some obstructions, If using air purge check
 Target and measurement conditions air flow and operation
unknown. Actual temperature variations
may sense. 3. Vary the Response Time to see if the symptom changes.
4. Use Peak Picker signal conditioning with suitable decay rate.
5. Use Track and Hold signal conditioning.

Symptom Number Five 1. Check Sensor cable connections. Also, check the signal cable
shield connection at the Grounded Strain Relief Fitting.
Erratic display and outputs.
2. Check for proper grounding of all system components.
 Target temperature and measurement
conditions known to be stable 3. Check cable routing. Signal cables must not run in the
same conduit as noisy power lines or power lines with transients.
4. Check ambient temperature of Sensor Add water cooling
and/or heat shielding to Sensor, if necessary.

No Invalid Measurement Condition Alarm 1. Check iALM function under Engineering Menu.

Cannot adjust or select functions at the 1. Check Panel Lock function in Engineering Menu.
Sensor rear panel.

RS-485 Communications problems 1. Check Communications Lock setting in COMMS Menu. Selections
are Read Only and Read / Write.
2. Check Baud Rate setting in COMMS Menu.
3. Check Address setting in COMMS Menu.

Laser will not energize 1. Laser will not energize when CAL function is operating or initiated

Peak Picker signal conditioning not 1. Check if the Auto Peak Picker Reset is On. If ON, evaluate the
functioning Reset Below Temperature settings. Peak Picker may be Auto
reset with Reset Below temperature too low

Peak Picker Delay not operating 1. Peak Picker Delay only operates after a Peak Picker Reset or after
the first temperature indication displayed after an Invalid (INV)
condition or below Sensor temperature range (LOW) condition.
2. Delay timing starts immediately after the reset or the Invalid or
LOW condition.

Cannot adjust AOUT ZERO or FULL Scale 1. Check both ZERO and FULL settings. Minimum 10°F span is
required (or equivalent °C span values)

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8 Applications Guide
8.1 Introduction
This section offers guidelines to assure measurement accuracy and reliability. Although it is impossible
to cover every application in detail, the general information provided can be adapted to most situations.
If you run into other situations that may cause problems, consult the IRCON Applications Engineering
Department.

8.2 Analog Outputs

All Modline 5 Sensors provide an analog current signal output of 0 to 20 mAdc or 4 to 20 mAdc. The
output range is selected using the Sensors rear panel AOUT and SOUT function menus or RS-485 Digital
Communications command codes. This current output will drive remote current meters, recorders and
other devices calibrated to read dc milliamps and scaled to convert the analog signals to temperature.
Multiple devices (Loads) can be connected in a series current loop configuration. The maximum series
resistance that can be connected in the loop is 600 Ohms. This maximum includes the resistance of all
devices and cables. See Figure 78.
The minus side of the Analog Output is connected to power supply common (See Section 4.9 RS-485
Multi-Drop Network Power Supply and System Wiring, page 75 of this manual about Sensor
Grounding). Use instruments with ungrounded differential inputs. If instruments with grounded
inputs are connected in the loop, the output may be inoperable or inaccurate.
If the Analog output is not used, insert a jumper wire across the output terminals. This will prevent an
Analog Loop malfunction (open circuit) Alarm (Error X108) from occurring.
The current signal varies linearly with the measured temperature. There are several schemes for
temperature scaling these outputs current. The standard scaling is when the output zero scale current
and full scale current is scaled to equal the Sensor’s zero scale and full temperatures. Alternate
temperature scaling can be accomplished using the Sensor’s AOUT Main Menu the ZERO and FULL
functions. See Section 5 Operation, page 82 of this manual for instructions. The paragraphs and diagram
below provide further explanation.
The ZERO function sets a temperature to correspond to the selected Analog Output Current Range
minimum value (0 or 4 mA). This temperature must be within the Sensor’s specified temperature range
and is limited to a maximum value 10° below the Sensor’s specified full scale temperature. Minimum
setting is the Sensors’ specified zero scale temperature.
The FULL Sets a temperature to correspond to the Analog Output Current Range maximum value (20
mA). Temperature must be within the Sensor specified temperature range and is limited to a minimum
value 10° above the Sensors’ specified zero scale temperature. Maximum setting is the Sensor’s specified
full scale temperature.

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SENSOR LOAD(S)

600 Ohm Maximum Current Loop Resistance)

Figure 78: Analog Output Configuration

8.2.1 Analog Output Range Scaling Example

The Sensor temperature range example shown in Figure 79 is 500 degrees to 2500 degrees. The minimum
analog output, at 0 or 4 milliamps as selected, can be set to equal the Sensor’s 500 degree zero scale
temperature or to an alternate value, such as the 1000 degrees illustrated in the figure. The maximum
analog output, 20 milliamps, can be set to equal the Sensor’s 2500 degree full scale temperature or to an
alternate value, such as the 1800 degrees illustrated in the figure.
When scaled to equal the Sensor’s complete range, the analog current output corresponds to a 500 to
2500 degree range and a temperature span of 2000 degrees. With the alternate temperature scaling, the
analog current output corresponds to a 1000 to 1800 degree range and a temperature span of 1000
degrees.
A minimum 10 degree F (6 degree C) span between zero scale and full scale is required.

Sensor temperature span = 2000

Scaled analog Scaled analog

output zero scale output full scale

Figure 79: Analog Output Scaling

8.2.2 Measured Temperature Calculations

An analog current signal output of 0 to 20 mA provides a full 20 mA current span. The 4 to 20 mA
output provides a 16 mA current span. To convert the output current to temperature, you must know
the current output span and corresponding temperature span to calculate the resultant temperature.

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Zero current output (0 or 4 mA), as selected, equals the corresponding zero scale temperature. A 20 mA
reading corresponds to the full scale temperature. Since the output current varies linearly with
temperature, equal increments in current will provide equal increments in temperature between these
range limits.
Expressed as a formula for the 4-20 mA analog output is:
TIND = ( ( (I – 4)  16) X (TF.S. – TZ.S.)) + TZ.S.
Expressed as a formula for the 0 -20 mA analog output is:
TIND = ( (I  20) X (TF.S. – TZ.S.) ) + TZ.S.
Where I is the current loop output in milliamps, TF.S. is the corresponding full scale temperature and TZ.S.
is the Zero Scale Temperature,
Example: For a 4-20 mA analog output, with a 16 mA span, corresponding to the 500 to 2500 degree range
and an output current of 8 mA:
TIND = ( ( (8 – 4)  16 ) X (2500 – 500) ) + 500 = 1000 degrees
Example: For a 0-20 mA analog output, with a 20 mA span, corresponding to the 800 to 1800 degree range
and an output current of 8 ma:
TIND = ( (8  20 ) X (1800 – 800) ) + 800 = 1200 degrees

8.2.3 Analog Output Operation Notes

1. The Analog Signal Output is affected by the selected Response Time Value and by any Peak
Picker or Track and Hold signal conditioning selections.
2. Three Analog Output related alarm functions can be used to set the Analog Current Output to a
specified value for certain conditions. A–LO, A–HI and FATL alarm functions will force the
current output to specific values for Zero Scale, Full Scale and two alarm conditions (Sensor
failure and Dirty Window Detector operation Failure). See Section 5 Operation, page 82 of this
manual for setup instructions.
3. A 10 Volt d.c. full scale signal can be developed by shunting the analog current output with a
precision 500 ohm resistor. See Section 4 Sensor Wiring, page 64 of this manual for more
information.

8.3 Response Time

8.3.1 Description
Response Time is the length of time it takes for the displayed temperature, the analog current output
signal, and digital output to reach approximately 95% of a step change in measured temperature.
The Response Time in the Modline 5 Sensor has an adjustable range from 6.6 or 10 milliseconds
minimum, depending on Model, to 60 seconds Maximum. See section 2 Product Description, page 14 of
this manual for Response Time restrictions by Model. The Response time can be set using the HEAD
menu RT function and RS-485 Digital Communications.
If you find that process temperature variations or signal noise is interfering with your measurement or
control system, increase the Response Time as required.

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8.3.2 Determining Response Time to Use

The Response Time is factory set for the fastest response time allowed for its Model. You may wish to
select a slower response time that is more suitable for the process.
To follow temperature variations as they occur, select a fast response time. If you prefer to "filter out"
temperature variations, select a slower response time. In most applications, the practical approach is to
observe the temperature display or analog current output and adjust the response time for the most
meaningful temperature information without distracting variations. Observe the temperature
indications on a Temperature Display, or chart recorder. Figure 80 illustrates the general effects of
response times as if plotted by a chart recorder.

The combination of low target temperature and fast response time will cause unstable
temperature indications. When measuring low target temperatures, adjust the
Response Time slowly to obtain stable temperature readings. Measurements below
400°F (200°C) may require a response time of one second or more. A Response Time
setting of 30 milliseconds usually provides good starting point for higher process
temperatures.

Fast Response Medium Response Slow Response

Time

Time
Time

Temperature Temperature Temperature

Temperature display and output Rapid temperature variations are Sensor tracks slow variations in
signals follow temperature “filtered out“ and system follows temperature ans effects of
variations as fast as minimum general trends in temperature, temperature spikes are
response time of instrument. with small amounts of “ripple“. eliminated.

Figure 80: Effects of Response Time

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8.4 Emissivity Settings

An ideal infrared radiator, called a blackbody, emits the maximum amount of infrared energy possible at
a given temperature. It has an Emissivity (E) that equals 1.0. However, targets measured in processes
are non-blackbodies. Their emissivity values are less than 1.0, which means they emit a fraction of the
infrared energy a blackbody would emit at a given temperature.
All Modline 5 Sensors are factory calibrated using blackbody standards. For accurate measurements, you
must compensate for the difference between the emissivity of your target and that of a blackbody
radiator.
Modline 5 Series Sensors, except the Series 5R, are single color brightness thermometers. Brightness
thermometers depend upon the intensity of the infrared radiation. Since most process targets have an
emissivity of less than 1.0, setting the Emissivity value to match the emissivity of the target material is
necessary.
Series 5R Sensor use the two color ratio measurement described in Section 8.5 Ratio Sensors, page 140.
Methods of determining emissivity are described below.

8.4.1 Using Emissivity Tables

One way to determine an approximate Emissivity setting is to refer to a set of emissivity tables.
Table 17, Table 18, Table 19 and Table 20 are provided for this purpose. Emissivity values in the tables
are based on actual tests on samples of the materials. Because the emissivity of most materials changes
with wavelength, a separate column of emissivity values is provided for each Sensor series. To use the
tables, locate your target material and obtain a value from the column for the Sensor series you are
using. Adjust the Emissivity value setting to this value.
Most table values are in the form of ranges. This is because the details of an object’s form and
characteristics affect its reflectance (R) and transmittance (T). These factors in turn reduce the emissivity
(E) value, as shown in the following general equation relating the three characteristics:

E= 1 – R – T
Figure 81 shows how a target’s surface characteristics affect its reflective properties, hence its emissivity.
It is assumed in the figure that each sample of Material A is thick enough to be completely opaque (T =
0). Notice that a cavity in an opaque object comes very close to having blackbody characteristics; E = 1
when both R = 0 and T = 0.
From Figure 81, you can see why the lower value of a given range represents a flat, highly polished
sample of the material. The upper value represents a sample of the material that has a flat surface that
is as rough as might be expected when in its “crude” or “unfinished” form.
Some entries in Table 19 and Table 20 are marked with asterisks (*) to signify that the range of values
results from more than just the target's reflective characteristics. These materials, in their specified
forms, are partially transparent to infrared radiation. In spectral regions where the materials transmit
energy, the emissivity typically increases with target thickness.
Follow the guidelines in the tables to estimate the emissivity of your target. Even a rough estimation
can significantly improve the accuracy of your measurements over only using “averaged” values. Note
that table entries having a single value represent targets in forms that are clearly specified.

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You may wish to read the IRCON publication “Spectrum Reprint SR100 - Product Temperature
Solutions — Temperature Errors Caused by Changes in Emissivity.

8.4.2 Using Emissivity Thermocouple Test

If your material is not listed in the table, or if you want to verify the emissivity value being used, you
can test the emissivity of a target sample in the following lab setup.
1. Embed a thermocouple (30 or 36 gauge wire recommended) just under the surface to be viewed
and heat the target to the desired temperature range. Allow the temperature indication from the
thermocouple to stabilize.
2. Aim the thermometer sensor at the surface of the target sample (close to where the thermocouple
is installed). Observe the temperature indication and adjust the Emissivity value setting so that
this temperature indication matches the thermocouple reading. The value of the setting is the
target emissivity.

8.4.3 Setting the Emissivity

The Emissivity may be set at the Sensor Rear Panel using the HEAD Menu EMIS function or with the
RS-485 EM Command. An indirect method of setting the Emissivity is to use the MATCH function or
RS-485 MT Command. MATCH allows inputting a temperature value known to be the true target
temperature. The Sensor then automatically adjusts the Emissivity so that the temperature display
indicates the same temperature. Instructions for setup are found in Section 5 Operation, page 82 of this
manual.
A third way to adjust the Emissivity is to send a scaled input of 4 to 20 mAdc via the Orange and
Orange/White twisted wire pair of the Sensor’s interconnecting cable. The Modline 5 senses an input
and overrides any other setting of Emissivity or Match. Wiring and scaling information is in Section 4
Sensor Wiring, page 64 of this manual.

8.4.4 Using Relative Readings

True temperature readings are not always necessary. Relative temperature readings may suffice in
applications where temperature variations, rather than precise temperature values, are of interest. It is
not necessary to know the target's emissivity for relative temperatures. Meaningful relative
temperatures can be obtained if (a) the Emissivity value setting is kept constant and (b) the target objects
to be viewed are of similar form and composition. For relative readings, we suggest an Emissivity
setting of 1.000.

8.4.5 Practical Limits on Emissivity

While all MODLINE 5 instruments are capable of emissivity settings of 0.100 to 1.000 it is not always
advisable to use the lower emissivity settings. Potential temperature measurement errors due to
background reflections are aggravated by a combination of decreasing target emissivity and decreasing
target temperature. Temperature indications may become "noisy" due to the higher amplification at low
emissivity settings.
For Series 56 and 5G Sensors it is recommended that the Emissivity setting be limited to 0.3 to 1.0 for
the first 55C (100F) for all temperature ranges.

The more times reflected radiation “bounces” on a surface, the less reflective the target. This is because
the surface absorbs more of the radiation at each “bounce”, leaving less and less radiation to be reflected

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away from the surface.
Since targets that are less reflective have higher Emissivity, the rough surface and the cavity, illustrated
in Figure 81, represent increasingly higher emissivity values—even though they are made from the
same material as the polished surface.
It is best to measure targets with high emissivity values. High reflectance off or transmittance through
the target introduces the possibility of measurement error due to background interference. Avoid
reflections when measuring targets with Emissivity less than about 0.8.

Highly Reflective
Low Emissivity:

1. Polished surface of material

A

Highly Reflective
Good Emissivity:

2. Rough surface of material A

Very poor Reflector

Approaching blackbody condition
Best Emissivity:

3. Cavity surface of material

A

Figure 81: Surface Finish affects Emissivity

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Emissivity Values of Metals and Alloys (Flat, Unoxidized Surfaces)
 Emissivity ranges shown represent differences in surface finish: mirror quality finish to dull,
mill finish.
 Values for low-emissivity entries can be significantly greater than shown if surfaces are even
slightly contaminated.

Material Emissivity Range by Sensor Series

52, 5R 5G 56
(One Color Mode)
Alumel 0.40-0.60 0.35-0.50 0.20-0.35
Aluminium 0.05-0.20 0.04-0.16 0.03-0.15
Brass 0.15-0.30 0.10-0.25 0.08-0.20
Bronze 0.20-0.40 0.15-0.30 0.10-0.25
Chromel 0.40-0.60 0.35-0.50 0.20-0.35
Chromium 0.40-0.60 0.35-0.50 0.30-0.45
Cobalt 0.25-0.40 0.20-0.35 0.15-0.25
Constantan 0.25-0.40 0.20-0.35 0.15-0.25
Copper 0.05-0.20 0.04-0.16 0.03-0.15
Gold 0.05-0.20 0.04-0.16 0.03-0.15
Inconel 0.40-0.60 0.35-0.50 0.20-0.35
Iron 0.35-0.50 0.25-0.40 0.20-0.35
Iron, Cast 0.35-0.50 0.25-0.40 0.20-0.35
Lead 0.25-0.40 0.15-0.25 0.10-0.20
Molybdenum 0.35-0.50 0.25-0.40 0.20-0.35
Monel 0.40-0.60 0.35-0.50 0.20-0.35
Nichrome 0.40-0.60 0.35-0.50 0.20-0.35
Nickel 0.30-0.50 0.25-0.40 0.15-0.30
Platinum 0.25-0.35 0.20-0.30 0.15-0.25
Silver 0.05-0.20 0.04-0.16 0.03-0.15
Steel, Carbon 0.35-0.50 0.35-0.40 0.20-0.35
Steel, Stainless 0.40-0.60 0.35-0.50 0.20-0.35
Tantalum 0.20-0.60 0.15-0.30 0.10-0.30
Titanium 0.40-0.60 0.30-0.50 0.20-0.35
Tungsten 0.35-0.50 0.25-0.40 0.10-0.25
Vanadium 0.35-0.50 0.30-0.40 0.25-0.35
Zinc, molten 0.20-0.40 0.15-0.30 0.10-0.25
Code 1

Table 17: Emissivity Values of Metals and Alloys

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Emissivity Values of oxidized Metals and Alloys (Flat Surfaces)
 Emissivity ranges shown represent differences in surface finish: smooth finish to rough, grainy
finish
 Oxide film assumed to be sufficiently thick to avoid thin film interference effects

Material Emissivity Range by Sensor Series

52, 5R 5G 56
(One Color Mode)
Alumel, oxidized 0.60-0.85 0.60-0.85 0.60-0.85
Aluminium, anodized – – –
Brass, oxidized 0.50-0.80 0.50-0.80 0.50-0.80
Bronze, oxidized 0.50-0.80 0.50-0.80 0.50-0.80
Chromel, oxidized 0.60-0.85 0.60-0.85 0.60-0.85
Chromium, oxidized 0.40-0.80 0.40-0.80 0.40-0.80
Cobalt, oxidized 0.40-0.80 0.40-0.85 0.40-0.80
Constantan, oxidized 0.60-0.85 0.60-0.85 0.60-0.85
Copper, oxidized 0.40-0.80 0.40-0.80 0.40-0.80
Inconel, oxidized 0.80-0.90 0.80-0.90 0.80-0.90
Iron, oxidized 0.80-0.95 0.80-0.95 0.80-0.95
Iron, Cast, oxidized 0.80-0.95 0.80-0.95 0.80-0.95
Molybdenum, oxidized 0.50-0.80 0.50-0.80 0.50-0.80
Monel, oxidized 0.60-0.85 0.60-0.85 0.60-0.85
Nichrome, oxidized 0.60-0.85 0.60-0.85 0.60-0.85
Nickel, oxidized 0.80-0.95 0.80-0.95 0.80-0.95
Steel, Carbon, oxidized 0.80-0.95 0.80-0.95 0.80-0.95
Steel, Stainless, oxidized 0.80-0.95 0.80-0.95 0.80-0.95
Tantalum, oxidized 0.40-0.80 0.40-0.80 0.40-0.80
Titanium, oxidized 0.50-0.80 0.50-0.80 0.50-0.80
Code 2

Table 18: Emissivity Values of oxidized Metals and Alloys

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Emissivity Values of miscellaneous Materials (Bulk, Normal Form)
 Unless otherwise noted, these materials have no transmittance in their normal form.
 Emissivity ranges shown for opaque materials represent differences in surface finish: smooth,
polished finish to rough, uneven finish.
 Emissivities of partially transparent materials (*) will also increase with sample thickness.

Material Emissivity Range by Sensor Series

52, 5R 5G 56
(One Color Mode)
Asphalt, Tar, Pitch – – 0.95-1.00
Carbon, Graphite 0.75-0.90 0.70-0.85 0.65-0.80
Cinders, Slag, Cinkers 0.85-0.95 0.85-0.95 0.85-0.95
Coke 0.95-1.00 0.95-1.00 0.95-1.00
Firebrick¹, ~2" thick¹
high purity alumina* < 0.20 < 0.20 < 0.20
high purity aluminum* silicate (Mullite)* < 0.20 < 0.20 0.20-0.50
Foods, bulk (fruits, vegetables, oils, meats,
bakery goods, etc.) – – –
Gallium Arsenide solid polished, 0.5 mm-
thick water – – –
Glass, commercial soda-lime¹
0.05" thick* < 0.05 < 0.05 0.05-0.10
> 4" thick 0.95-1.00 0.95-1.00 0.95-1.00
Oil, animal or vegetable 0.040" – – –
Oil, mineral 0.040" – – –
Paints, oil or water base²
on metal* – – –
on plastic or wood* – – –
Code 3
¹ Highly variable. Values for low emissivity entries can be significantly greater than shown if even small
amounts of impurities are present.
² Paints with metallic pigments may have much lower emissivities.
Table 19: Emissivity Values of miscellaneous Materials

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Material Emissivity Range by Sensor Series
52, 5R 5G 56
(One Color Mode)
Plastics
all 1/8" thick – – 0.90-1.00
polyester film (mylar), 0.0002" thick* – – ~ 0.10
polyethylene film, 0.0002" thick* – – ~ 0.10
Rubber – – 0.95-1.00
Salt Baths 0.95-1.00 0.95-1.00 0.95-1.00
Silicon, solid polished 0.5 mm-thick wafer – – –
Silicon, molten ~ 0.30 ~ 0.30 –
Silicon, Carbide 0.80-0.85 0.80-0.85 0.80-0.85
Textiles, Fabrics
Carpet (cotton, wool, synthetic) – – –
Fabrics, close weave (cotton, wool,
synthetic)*³ – – –
Leather – – –
Water, 0.0002" film – – –
Wood – – –
Code 4
³ Emissivity values may be significantly lower than shown for very sheer materials.
4 Note that objects with even a very thin coating of water have very high emissivities.

Table 20: Emissivity Values of miscellaneous Materials (Continued)

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8.5 Ratio Sensors

Modline 5 Series 5R Sensors utilize a dual detector assembly that measures temperature by comparing
infrared radiation levels in two wavelength bands (0.85 to 1.05 microns and a narrow band centered at
1.0 to 1.10 microns). They have the capability to measure temperature by comparing the relative infrared
radiance at two different wavelengths and computing the ratio of the two. Temperature readings are
based on the ratio of the two signals in these bands.
See Section 3 Sensor Installation, page 22 of this manual for more information about signal reduction,
resolving targets and other factors about using ratio sensors.

8.5.1 E-Slope Settings

When using a Series 5R Sensor as a two color ratio Sensor you must properly select the E-slope value.
An E-Slope adjustment is provided to allow you to calibrate the Sensor to measure the temperature of
the target material accurately.
Series 5R Sensors are commonly used for applications involving materials in one of two main
classifications:
1. Greybody materials have an Emissivity that is the same at both detected wavelengths.
2. Materials with emissivities that are not the same at both detected wavelengths (a slope or variance
in the emissivity at the two wavelengths exists).
The first of these, the class of graybody materials, contains those materials that have emissivities that
are the same at both detected wavelengths. The most common graybody materials are described below.
When your target is made from any of these materials and are oxidized, set the E-Slope Control of the
Sensor to a value of 1.00.
Materials which require an E-Slope setting of 1.0:
 Blackbody calibration standard.
 Cavities in any opaque, isothermal body.
 The following metals when worked in air are subject to oxidizing: Iron, Cobalt, Steel, Nickel,
and Stainless Steel.
The second main classification is a family of metals with emissivity that exhibit a non-linearity (or slope)
of approximately 1.06.
Materials which require an E-Slope setting of 1.6:
 Clean, smooth, unoxidized surfaces of the following metals: Iron, Molybdenum, Molten Grey
Iron, Platinum, Cobalt, Rhodium, Nickel, Steel, Tungsten, Stainless Steel, Tantalum
If the materials in your process do not fall into either of these categories, you will have to test your
product to find the appropriate E-Slope setting. To do this, sight the instrument on a sample target
having a temperature that you have accurately determined by some other means (such as a reliable
thermocouple). For best accuracy, select a temperature near the center of the instrument's range, or
better still, carry out the test at several points throughout its range.
Adjust the E-Slope Setting until the indicated temperature matches the value you have previously
determined. Set the E-Slope control to this value whenever measuring this type of target. If you use
several tests, average the results and use the averaged value as your E-Slope setting.

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8.5.2 Setting the E-Slope

The E-Slope may be set at the Sensor Rear Panel using the HEAD Menu E–SL function or remotely with
the RS-485 ES Command. An indirect method of setting the Emissivity is to use the MATCH function
or RS-485 MT Command. MATCH allows inputting a temperature value known to be the true target
temperature. The Sensor then automatically adjusts the Emissivity so that the temperature display
indicates the same temperature. Instructions for setup are found in Section 5 Operation, page 82 of this
manual.
A third way to adjust the Emissivity is to send a scaled input of 4 to 20 mAdc via the Orange and
Orange/White twisted wire pair of the Sensor’s interconnecting cable. The Modline 5 senses an input
and overrides any other setting of Emissivity or Match. Wiring and scaling information is in Section 4
Sensor Wiring, page 64. of this manual.

8.6 Peak Picker Signal Conditioning

Peak Picker signal conditioning is advisable for certain measurement situations.
 If the workpiece you are measuring is moving and is in the field of view for only a brief period
of time.
 If a succession of small parts is to be viewed with variable spacing between them.
 If the temperature of a moving work-piece varies because of slag, oxides, etc. Using the Peak
Picker allows measuring the highest temperature.
 If the line of sight between the instrument and the work piece is momentarily or periodically
interrupted, as by a moving piece of machinery or by bursts of steam or smoke.
Figure 82 illustrates the Peak Picker action. The Peak Picker circuitry responds to the highest
instantaneous value of temperature and holds this value even if the temperature source is interrupted
by one of the conditions listed above.
The indicated temperature (solid line) rises almost instantly, depending on the selected Response Time,
to follow the peaks in actual temperature (dashed line). The indicated temperature decays at a rate
determined by the setting of the Peak Picker Decay Rate. Figure 82 shows the effect of changing the
decay rate.

The Peak Picker action affects the Temperature Display, Analog Current Output and
RS-485 responses to commands.

8.6.1 Turning Peak Picker On and Off

The Peak Picker can be turned on and off by using the following:
1. The Sensor Rear Panel HEAD menu with the SIGL function. When the Peak Picker is selected,
the PSEL function menu appears for setting of all the Peak Picker operating parameters.
Operation of the SIGL, Peak Picker, PSEL, Decay Rate, Automatic Reset Below, Reset Below and
Delay functions are explained in Section 5 Operation, page 82 of this manual.
2. Remotely using the RS-485 PK and related Commands. See section 6 RS-485 Digital
Communications, page 107.

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When the Peak Picker function is turned on by using 1 or 2 above, a remote switch, as explained below,
can enable or disable the Peak Picking signal conditioning.

8.6.2 External Switch for Remote Peak Picker Operation

The Modline 5 has a provision for a remote process controlled input switch to be wired to the Violet
and Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Peak Picker signal
conditioning is selected, the remote switch can enable or disable the Peaking action. With no switch or
the switch in maintained in the open position Peaking action is enabled. With the switch closed, peaking
action is disabled and the Sensor continuously indicates actual temperature variations as they occur.
This can be called the Direct operating mode.
A momentary closure of the switch, greater than 0.08 seconds, resets the Peak Picker function to the
current temperature reading. The peaking action begins again when the switch returns to the open
position. Wiring and switch operation for the Peak Picker are described in Section 4 Sensor Wiring, page
64 of this manual.

Peak Picker Off

Interference Gap in Hot spot in
in sight path workpiece workpiece Actual temperature shown as a solid
line.
Temperature

Indicated temperature tracks changes in

actual temperature, including
interferences in sight path. Limited only
by Response Time of Modline 5.

Time
Peak Picker On Fast Decay
Peak Picker conditioning shown as a
solid line.
Temperature

Use this setting to concentrate on

temperature trends, and to reduce the
effect of momentary interruptions or
interference in the sight path.

Time
Peak Picker On Slow Decay
Peak Picker conditioning shown as a
solid line.
Temperature

Use this setting to concentrate on peak

temperature and ignore gaps between
workpieces or interference in the sight
path, but still catch “hot spots” on a
workpiece.

Time
Figure 82: Peak Picker Operation

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8.6.3 Peak Picker Signal Conditioning

Peak Picker signal conditioning takes place with the Peak Picker on. Temperature readings may be
returned to instantaneous values at any time by setting the SIGL function to OFF. The system then
follows actual temperature variations as they occur.
Both Peak Picking signal conditioning and direct instantaneous temperature indication are affected by
the selected Response Time.

8.6.4 Peak Picker Reset

The Peak Picker signal conditioning can be reset by any of the following actions:
• Manual reset using the Sensor rear panel PSEL menu RSET function.
• Remote reset with a momentary switch closure across the Sensor’s interconnecting cable Violet
and Violet/White twisted wire pair.
• Automatic reset using the Auto Peak Picker Reset function with Reset Below Temperature
selection.
• Remote reset with the RS 485 PS Command

8.6.5 Peak Picker Decay Rate

The Decay Rate is set to retain peak measured temperature value and ignore momentary decreases in
measured temperature caused by process conditions. The goal is to eliminate erratic measurements due
to gaps in work pieces, bursts of smoke, or steam, etc. in the sight path of the Sensor.
The Decay Rate range is 0.00 to 300 degrees. The Decay Rate setting is unit-less. The units are defined
by the selected Sensor measurement units, Fahrenheit or Celsius.
The fastest decay rate is 300 degrees per second. The slowest decay rate is 0 degrees per second. This
slowest decay, for practical purposes, can be considered as a Peak Hold with the highest peak measured
temperature held until a Reset occurs.
Select a Decay Rate that will yield the decay needed for meaningful process measurement. Refer to
Figure 82.

8.6.6 Auto Peak Picker Reset with Reset Below

An automatic reset is accomplished with the Auto Peak Reset and Reset Below functions. These
functions are turned on with the Sensor rear panel PSEL menu AUTO and RBEL functions or the RS-
485 PS and PK Commands. Figure 83 illustrates Auto Peak Picker Reset.
This reset action is triggered when the measured temperature goes below the selected Reset Below
Temperature.
When the measured temperature is below this temperature, the displayed temperature indication will
be the measured temperature unaffected by the Peak Picker signal conditioning, subject to any Response
Time selection.

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Target Temperature

Sensor Output
Signal

Reset Below Temperature

Time
Figure 83: Automatic Peak Picker Reset

When the measured temperature is above the selected Reset Below Temperature the displayed
temperature will be the measured temperature with the Peak Picker signal conditioning action applied
subject to the selected Response Time. The Auto Peak Picker Reset can effectively be used to turn ON
the Peak Picker function when the target is in view and to turn it OFF when the target is out of view.

The Reset Below temperature must be properly selected to provide the measurement
conditions wanted. Too high of a selected temperature may cause the peaking action not
to be activated if the target is cooler than the selected temperature. If the Reset Below
temperature selected is too low Peak Picker action will continuously take place with
higher background temperatures.

Auto Reset can be affected by long response times. The selected Response Time should be fast enough
to allow the selected Reset Below Temperature captured and be used to accomplish the reset.

8.6.7 Peak Picker Delay

The Peak Picker Delay function is used to delay the start of the peaking action for up to 10 seconds
following the detection of the leading edge of a new target. This function is turned on with the Sensor
rear panel PSEL menu DEL function or the RS-485 PD Command. It operates independently of the Auto
Reset and reset below functions.
It has limited operation when used with Peak Picker signal conditioning without the Auto Peak Picker
Reset function. It will provide the selected delay for the first hot target seen after any Peak Picker Reset.
The reset can be from the Sensor rear panel, a reset from a momentary closure of the Peak Picker Reset
external switch or a reset from the RS485 PR command
The primary use of Peak Picker Delay is with the Auto Peak Picker Reset and Reset Below Temperature
functions as explained below.
The Peak Picker Delay time-out will be not begin until a target whose temperature is above the selected
Reset Below Temperature comes into view and remains in view. Figure 84 shows the delay time in
relation to the target temperature and the reset below temperature level. The Peak Picker action will
begin after the selected delay time and will continue until the actual measured temperature goes below

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the selected Reset Below temperature. The system will then return to direct temperature indication until
a new target comes into view. The Decay Cycle will repeat as describe above.
Delaying the start of the peaking action allows peaked temperature measurement of targets with hot
leading edges and cooler middle temperatures without peaking on the hotter leading edge. The delay
time selected determines at what position or point on the target peaking action begins. This function
may be affected by a slow Response Time which could further delay the start of peaking action.
Example: Before a moving work piece enters the target viewing area, the System may be sensing a
measured temperature below the selected Reset Below temperature. As the target comes into view, the
hotter temperature is sensed and the Peak Picker Delay time-out begins. When the delay is completed,
the system will begin peaking action on the measured temperature until the work piece passes the
Sensor.

Peak Picker with Delay Time

Sensor Output

Signal
Target Temperature

Reset Below Temperature

Delay Time Time

Figure 84: Peak Picker Delay

The Delay Time can be used with the Auto Reset turned off. In this case, the Delay will
only begin after a reset occurs. See sub section Peak Picker Reset above for how to
initiate a reset.

8.7 Track and Hold

The Modline 5 includes a Track and Hold function that allows continuous temperature measurement
in the Track mode and suspended measurement in the Hold mode with the last temperature reading
held. Selection of the Track and Hold function is made with the Sensor rear panel SIGL menu and TRAK
function or the RS-485 TS Command.

8.7.1 External Switch Control of Track and Hold

The Modline 5 has provisions for a remote process controlled input switch be wired to the Violet and
Violet/White twisted wire pair of the Sensor’s interconnecting cable. If Track and Hold signal operation
is selected, the switch input is required to change from Track temperature operation to Hold
temperature mode as required in the process system. Figure 85 illustrates Track and Hold operation.
The Sensor will be in the Track Mode with the switch open and in the Hold mode with the switch closed.
• The remote switch may be manually operated or it may be a contact on a timer, relay, or
movement of a target or its timing in the process to close the remote switch.

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• Track and Hold temperature readings are affected by the Response Time setting.

Target Temperature

Signal Sensor Output

Time
Hold

Track

Figure 85: Track and Hold

Example: you may want to scan the surface of a moving workpiece and hold the temperature reading
at middle point on the workpiece, while ignoring the readings at the beginning and the end of the
workpiece.
Another Example: the temperature tracking can be made to hold a temperature even after the
temperature in the sighted area has dropped. It will hold the value without any decay until the switch
is opened.

Peak Picker and Track and Hold Signal conditioning cannot be simultaneously
selected. Use of Peak Picker with zero or very low Decay rates and an external reset can
accomplish similar results.

8.8 Avoiding Common Measurement Problems

8.8.1 Viewing Angle Limitations
Acute viewing angles can present the problem of reduced emissivity values, particularly if you are
dealing with smooth target surfaces.
Figure 86 shows the permissible angles (for all Sensor Series) when viewing smooth surfaced objects
such as metals, glass or plastics. Angles up to 45° from the perpendicular usually will not appreciably
affect the measurement, although the smaller the angle from the perpendicular the better. In general,
angles greater than 45° should be avoided. An increase in reflectance occurs when smooth surfaces are
viewed at large angles, and consequently the target emissivity decreases.

8.8.2 Background Interference

Under ideal circumstances, the radiant energy being measured should be from the target only. This is
why you must center the Cone of Vision on the target and make sure that its cross-section (spot size) is
smaller than the target. That way the sensor can't "see" past the target into the background. Although

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the Sensor Models 5R have somewhat looser restrictions on filling the field of view, it is still affected by
background interference if significant sources of background radiation are present.
Significant background radiation comes from comparable temperature or hotter objects in the target's
surroundings. This background radiation may be reflected off, or transmitted through, the target adding
to the radiant energy detected by the instrument related to the target temperature. This results in
measured temperature error. For all Modline 5 Sensor Series, except the Series 5R, this extra radiation,
if detected, causes a temperature indication that is higher than the target's true temperature.
For Series 5R Sensors, background interference that is slightly cooler than the target results in
temperature indications that are too low. When the background temperature is much lower than that
of the target, however, the indicated temperature is unaffected. If the interfering background sources
are hotter than the target, the indicated temperature is too high. There is no error in the indicated
temperature, with a Series 5R Sensor, when the background temperature matches the target
temperature.

Sensor Lens

Max = 45

Target

Figure 86: Viewing Angle

When the environment includes unfiltered background light or heat sources, select a viewing
arrangement that minimizes these problems. In general, the higher the target's Emissivity, the less
susceptible the measurement is to errors.
Emissivity (E), Reflectance (R), and Transmission (T) are related as follows:
E = 1 - T - R
Maximum accuracy is possible when E = 1.0 (blackbody condition). In this condition, there is no
reflection and no transmission of background energy to cause measurement errors.
As emissivity decreases it is harder to get accurate readings because reflectance and/or transmittance
become more pronounced. Use caution when attempting to measure materials with emissivity values
known to be 0.2 or less.

8.8.3 Transmission Effects

If the target has some transmission at the operating wavelength, it can act as a window for infrared
emission from objects behind it (e.g. an oven wall or heating element). Such problems can sometimes
be corrected by changing the viewing angle so that the background source is not directly behind the

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target, by selecting a different measurement point away from the background source, or by inserting a
cooled shield behind the workpiece. See Figure 87 for examples. These considerations apply to all Sensor
series.

Problem: Sensor Lens ″sees″ radiation from Solution: Change viewing angle, or measuring location, so
heating element transmitted through workpiece. heating element is not in field of view of sensor.

Sensor Lens

Workpiece

Heating Element

Problem: Sensor Lens ″sees″ radiation from hot Solution: Install heat insulating shield between workpiece
furnace wall transmitted through workpiece. and furnace wall.

Sensor Lens

Workpiece

Cooled Shield

Furnace Wall

Figure 87: Solving Common Transmission Problems

8.8.4 Transmission Path Effects

Materials in the transmission path may absorb infrared radiation, reducing the amount of radiant
energy an instrument receives. This is less of a problem for Series 5R Ratio Sensors, as long as the
radiance at both detected wavelengths is reduced equally. For any other Sensor Series, a poor
transmission path causes the indicated temperature to be lower than the target's true temperature. These
problems may be minimized by keeping the System's optical components clean, and by selecting a sight
path for which the entire optical cone between the target and the instrument is free of solid objects, dust,
smoke, and evaporates. Sight tubes, shown in Figure 88 can be used for this purpose. For information
on the use of windows, refer to Section 8.10 Use of Windows, page 150.

8.8.5 Reflectance Effects

If the target has some reflectance, it acts as a mirror and reflects infrared energy generated by other
sources (e.g. a furnace wall or heating element). If the Sensor picks up the reflection, measurement errors
will result. Reflectance depends on the target material and the condition of its surface. Flat, smooth
surfaces tend to have larger reflectance values than roughened surfaces of the same material.
Reflectance problems may be reduced by changing the viewing angle so that the reflection is not picked
up by the Sensor, or by the use of sight tubes or some other form of shielding. (See Figure 88 examples.)
These considerations apply to all Sensor Series.

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Viewing at furnace exit
Problem: Sensor Lens ″sees″ reflections of furnace
roof or wall. Solution 1: Change viewing angle.

Furnace Roof Sensor Lens

Sensor Lens

Workpiece

Solution 2: Install shield to block reflection.

Cooled Shield

Sensor Lens

Viewing through furnace roof or wall

Problem: Sensor Lens ″sees″ reflections from hot Solution: View through sight tube with tip spaced close to
of furnace roof. surface of workpiece.

Sensor Lens Sight Tube Sensor Lens

Furnace

Workpiece

Cautions: 1. I.D. of sight tube must be wider than Cone of Vision along entire length. (See Section 3)
2. Sight tube walls may radiate infrared if furnace atmosphere is very hot. May require cooled sight tube. Consult
IRCON for recommendations.
Figure 88: Solving Common Reflection Problems

8.9 Use of Mirrors

In rare situations it may be difficult, if not impossible, to position the Sensor for a direct view of the
desired target surface. You may then find it necessary to view the target indirectly by means of a mirror.
Mirror material, surface area and alignment are critical in this application. In all cases the mirror must
be a first surfaced (front surfaced) mirror, and ideally it should be a perfect reflector at the operating
wavelength of the Sensor.
A first surfaced, flat, aluminized or gold mirror may be used for all Sensor Series except Series 5R. This
type of mirror is readily available from optical supply houses. For 5R Sensors, the mirror must be a front
surfaced, gold coated mirror. (Aluminum coated mirrors show a small coloring effect in the Series 5R
spectrum, causing the instrument to read low. This low reading error may be corrected by the E-Slope
adjustment, but a gold mirror is preferred.).

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As indicated in Figure 89, the Cone of Vision extends from Sensor-to-mirror-to-target. The mirror
effectively bends the cone but does not change its shape.
There are two spot sizes to consider in Figure 89: spot size d1 at the mirror surface (distance D1) and
spot size d2 at the target surface (distance D2). Mirror and target areas must be at least twice the cone
diameter at their respective distances.
The mirror must be positioned (and angled) so that the axis of the reflected target image coincides with
the optical axis of the Sensor. You should be able to accomplish the alignment without difficulty by
sighting through the viewing telescope.
Be sure to lock the mirror firmly in position, and check the alignment on a regular basis. Also, inspect
and clean the mirror (in manner recommended by the manufacturer) as part of your regular
maintenance routine. If you have any trouble in obtaining an appropriate mirror or in erecting your
system, please contact IRCON for recommendations.

Target

Mirror
Cone of Vision

Sensor Lens

Figure 89: Effect of Using a Mirror on Optical Cone

8.10 Use of Windows

To view an object in an inert atmosphere or vacuum chamber, you must use an infrared transmitting
window. Selection of an appropriate window material will depend on the Sensor's spectral response.
Some suggested window materials for various Modline 5 Sensor Series are listed in the Window
Selection Guide Table 21.

Available Windows
(Specifications: Optical Grade, 1/8 inch thick, Polished to ″Plate Glass″ Finish)
Series Pyrex #7740 Fused Quartz Synthetic Calcium Fluoride Cleartran (ZnS)
(G.E. #124 or eqiv.) Sapphire
52, 5G Suitable T=0.92 Recommended T=0.94 Suitable T=0.85 Suitable T=0.94 Suitable T=0.94
5R No Recommended T=0.94 Suitable T=0.85 Suitable T=0.94 Suitable T=0.94
56 No Recommended T=0.94 Suitable T=0.85 Suitable T=0.94 Suitable T=0.94
Table 21: Window Suitability and Transmission Factor T

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The window material must be highly transparent in the Sensor's infrared spectral region. Yet, there is
always some signal loss due to reflection or absorption when using a window. To compensate for this
loss, first multiply the emissivity of the target object by the window's transmission factor (T) shown in
the Window Selection Guide. Then adjust the emissivity setting to this value.
Example:
Emissivity of object = 0.8
Transmission factor of window = 0.92
Emissivity setting = 0.8 X 0.92 = 0.74
The window specifications given at the top of the chart are suitable for most applications. However,
high pressure or vacuum chamber applications may require windows that are thicker than 1/8" (3 mm).
Be aware that transmission of thicker windows may be significantly degraded.
It is good practice to use a window at least twice the diameter of the Cone of Vision at the point where
the window is to be installed. Note that the dimensions of the Cone of Vision can be changed by focusing
the optics. It is essential for all Sensor Series except Series 5R that you never allow any part of the Cone
of Vision to be obstructed. Figure 90 illustrates the correct use of windows. Keep the window clean to
prevent low temperature indications.

Sight Hole

Target
Sensor Lens Cone of Vision

Window

Figure 90: Viewing a Target through a Sight Hole and Window

8.10.1 Special Considerations for Ratio Units

Because Modline Series 5R ratio Sensors compare the radiation detected at two separate wavelengths,
the best windows for these units have the same transmission value at both wavelengths. All acceptable
Series 5R windows specified in the Guide have this characteristic. No additional E Slope adjustment is
required when these windows are used.
Note that certain materials, which are transparent to the human eye, can cause serious measurement
errors when with a 5R Ratio Sensor. For instance, it almost always causes problems if any of soda-lime
plate glass, "PLEXIGLASTM", water, or "PYREXTM" glass lies between the Sensor and the target during
a measurement. Similarly, if you need to reflect your target's radiation in order to measure it with a 5R
Ratio Sensor, use a front surface gold mirror, not a mirror with an aluminum reflecting surface.
The materials listed in the Guide are not all common optical materials and you may have some difficulty
locating a source for windows. If you do, here are some suggestions.

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Adolph Meller Optics Karl Lambrecht Corp. Janos Technology Inc.
P.O. Box 6001 4204 Lincoln Ave. Route 35, Townshend
Providence, Rhode Island Chicago, Illinois 60618 Vermont 05353, 802-365-7714
02940, 401-331-3717 773 -472-5442 www.janostech.com
www.klccgo.com

8.11 Preventing Sensor Overheating

The Modline 5 Sensor can be cooled with the WJA accessory presented in Section 3 Sensor
Installation, page 22. Do not use a WA-3 accessory for cooling.
Under extreme conditions, it may be necessary to provide insulation and reflective shielding for
additional protection from high ambient temperatures and radiated heat using materials available
at the installation site.
Figure 91 shows one means of providing insulation protection. In this example, a Sensor is mounted
at a sight hole cut into a furnace wall. The Sensor is protected from the atmosphere by a water cooling
accessory and is insulated from the atmosphere near the wall by aluminum-backed insulation.
A radiant heat shield can be any reflective metal shield in the path between the heat source and the
Sensor, as in Figure 92. It should be close enough to the Sensor to block random reflected radiation,
but with a space between it and the unit to allow air to circulate between them.

Figure 91: Sensor Water or Air Cooling with Added Insulation Wrap

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Heat Shield
Sight Hole

Hot Target

Figure 92: Protection Using Reflective Heat Shield

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9 Notices

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