Infrared Condition Monitoring Systems

Thermal Asset Monitoring and Early Fire Detection

Optris Thermal Camera Condition Monitoring Package for harsh Climate

A transformer in a substation, an electric motor in a manufacturing plant, and freshly chipped wood pulp in a paper mill all demonstrate how temperature can provide important insights into safety or reliability within a facility. Most maintenance and safety professionals today use handheld thermal cameras to check these key areas occasionally.

Continuous thermal monitoring reveals trends much earlier and more reliably, while also lowering costs. One challenge is packaging these thermal cameras in cases that allow for ongoing temperature monitoring in extreme conditions. They also need an alarming feature that warns of potential problems. Optris Thermal Condition Monitoring systems combine an infrared camera, a visual camera, an Ethernet converter for long-distance data transmission, and rugged enclosures that ensure dependable operation across different plant environments.

Condition monitoring application using Optris infrared cameras for predictive maintenance and asset monitoring

Condition Monitoring Systems

Package for Infrared Condition Monitoring and Early Fire Detection

382 × 288 px
-20 – 900 °C
-40 – 50 °C

Xi 400 CM

The Xi 400 CM infrared package includes a Xi 400 LT thermal camera, a visible camera, a USB-to-Ethernet server, a heater, and an air knife, all pre-assembled in an outdoor housing with a wall mount. The housing features a heater and fan for operation from -40 °C to 50 °C. The thermal camera offers a 382 x 288 resolution, while the HD visible camera provides a 1280 x 720 resolution. The motor focus of the Xi thermal camera allows remote focus adjustment.

Non-reflecting Metals

Ceramics

Semiconductors

Glass

Package for Continuous Outdoor Infrared Monitoring in Hot Climate

Optris Outdoor Protective Housing for PI 450i and PI 640i Thermal Camera for Condition Monitoring

382 × 288 px
-20 – 900 °C
-40 – 60 °C

PI 450i CM

The PI 450i CM package includes a mid-resolution infrared thermal camera, a visible camera, an air knife, and a USB-to-Ethernet Server HT, all housed in an outdoor enclosure with a wall mount. Featuring a built-in heater and fan, it operates continuously from -40 °C to 60 °C, making it ideal for thermal condition monitoring in hot climates, such as electrical utility stations in deserts. The PoE Ethernet capability allows for data transmission and powering the device over a distance of 100m.

Non-reflecting Metals

Ceramics

Semiconductors

Glass

Package for Continuous Outdoor High Resolution Infrared Monitoring

640 × 480 px
-20 – 900 °C
-40 – 50 °C

PI 640i CM

The PI 640i CM package addresses continuous monitoring needs in demanding environments, including industrial settings and fire-prone outdoor locations. The kit includes an infrared camera, an outdoor enclosure with a heater/fan, an air purge, an HD video camera, and a USB-to-Ethernet Gigabit Server. These fixed-install thermal cameras help detect potential failures in substation components and provide early fire detection by visualizing heat distribution with fine resolution.

Non-reflecting Metals

Ceramics

Semiconductors

Glass

Why Optris Thermal Condition Monitoring Systems?

Dedicated product package for outdoor condition monitoring and early fire detection
Radiometric thermal imaging: every pixel delivers calibrated temperature data for precise trending and alarm thresholds
The IP66 environmental rating, integrated air purge, and built-in heater ensure reliable 24/7 operation under harsh conditions
Designed for 24/7 fixed monitoring, these devices feature robust housings, air purge, cooling, and protective windows, ideal for harsh outdoor environments.
Built-in USB-Server Gigabit for easy integration of both camera streams (IR + VIS) in video management systems

Condition monitoring category image for harsh industrial environments using infrared thermal imaging

Scalable Monitoring for Small and Large Processes

Designed for scalable thermal monitoring, the Optris Condition Monitoring Package enables flexible deployment across a wide range of industrial environments. Whether supervising small stationary areas or extensive processes such as rotary kilns, the system adapts effortlessly. Multiple infrared cameras can be networked in series to generate a continuous thermal view of large installations, delivering comprehensive temperature insight and reliable monitoring of complex processes in real time while enhancing operational safety.

Flexible Installation in Any Environment

The Optris Condition Monitoring Package is engineered for straightforward installation in demanding environments. Each package includes coordinated accessories such as wall mounting, protective housings, and connection components required for rapid setup. The robust, weather-resistant enclosures allow reliable indoor and outdoor operation, even in harsh industrial surroundings. This integrated concept simplifies system installation, reduces engineering effort and ensures dependable monitoring performance across diverse applications worldwide with consistent long term reliability standards.

Condition monitoring category image for hardware environments using infrared thermal imaging

Condition monitoring category image for USB-connected infrared monitoring hardware

Easy Ethernet integration

The USB Server Gigabit makes it easy to combine both IR and VIS streams into video management or monitoring systems using standard network infrastructure. Its compatibility with common switches and industrial PCs allows for flexible setups. Remote access also allows users to configure, update firmware, and run diagnostics without requiring physical access to the housing.

Dual IR + HD visual streams

Integrated optionally with a 1280 × 720 px video camera that supports visual verification, documentation, and more straightforward interpretation of thermal alarms. You can view thermal and visual images side by side or overlaid. This makes it easier to find hot spots on complex machinery or structures. The HD stream also simplifies incident review, reporting, and communication with non-thermal experts because faults, access points, and surrounding conditions are clearly visible in the visual channel.

Condition monitoring category image for frost environments using infrared thermal imaging

Integrated heater prevents fogging and freezing

The built-in PTC heater keeps the inside of the housing and the front window above the dew point. This reduces condensation, ice build-up, and start-up problems in cold climates. Clear optics from the first frame ensure reliable hot-spot detection, even during sudden temperature drops or after cooling at night. By preventing frost and fogging, the heater lowers the need for manual cleaning, protects the camera, and supports round-the-clock monitoring in winter, high-altitude, or maritime environments.

Air purge keeps the field of view clean

A constant air purge across the front window helps prevent dust, moisture, and insects from landing on the optics. This action maintains image quality and reduces the need for manual cleaning. A controlled airflow creates a protective barrier in front of the window. This is especially helpful in dusty conveyor systems, bulk material handling, and outdoor setups. Cleaner optics lead to more stable temperature readings, fewer false alarms, and longer maintenance intervals for the monitoring system.

Condition monitoring category image for air purge environments using infrared thermal imaging

The Optris outdoor protective housing turns fixed infrared sensors into weatherproof monitoring systems for harsh environments. It is designed for PI and Xi thermal cameras, along with CSlaser LT and CTlaser LT pyrometers. It also holds a USB to Ethernet server and an industrial Process Interface, creating a compact, integrated field station for permanent use.

A robust aluminum enclosure with an IP66 rating safeguards the optics and electronics against dust, dirt, moisture, and rain. Sealed cable glands route power, network, and I/O connections. An optional wall mount makes it easy to align on building façades, masts, or steel structures. Depending on the thermal camera type, the housing can sport either a protective window or a foil window, supporting fields of view up to 90° for broad thermal monitoring.

Various protective window materials are available to fit different spectral ranges, including germanium, zinc sulfide, and Borofloat glass. This ensures high transmission for long-wave infrared, glass-optimized bands, or short-wave models, maintaining measurement accuracy despite the added protective layer in front of the lens. Foil options provide a budget-friendly solution for particularly harsh or dirty environments, where quick replacement is essential.

An integrated PTC heater and fan keep a stable internal climate from –40 °C to +60 °C. The heater activates automatically at low temperatures, and the fan evenly distributes warm air throughout the enclosure. This helps prevent condensation and icing on the front window while minimizing cold-start issues. Powered by a single 24 V DC supply through an internal connection board, the housing also supplies power to the USB-to-Ethernet server and the industrial PIF module.

The built-in air purge collar delivers a steady stream of clean, oil-free air across the viewing window. This airflow keeps dust, smoke, and insects away from the optics, stabilizing long-term measurement performance and reducing the need for manual cleaning in outdoor or dusty industrial settings.

Infrared Condition Monitoring Systems