Xi 640 IP

Protecting the infrared imager Xi 640 in harsh industrial environments is the main goal of this Industrial Package. It combines the Xi 640 infrared camera with a water-cooled stainless-steel housing, laminar air purge, protective window, shutter system, and an industrial process interface into a single, fully integrated solution. This system can handle ambient temperatures of up to 250 °C. It ensures stable and reliable operation of the camera, even in extreme heat where regular camera setups would fail.

The sturdy stainless-steel construction is built for long-term use in tough industrial settings. A carefully designed mounting bracket allows precise positioning of the camera in two axes. This enables optimal alignment with the target for consistent and repeatable temperature measurements. The water-cooled housing is made for a recommended flow rate of 1 to 5 liters per minute using cooling water below 30 °C. This effective thermal management system reliably removes excess heat, protects the camera electronics and optics, and maintains the accuracy and stability of the temperature data over long operating periods.

Additional protective components, such as the laminar air purge and the shutter, help maintain optical performance. In settings with dust, smoke, vapors, or process fumes, these accessories protect the lens from contamination and thermal stress. The shutter can close the optical path during non-measurement phases or critical process events. The air purge creates a clean air barrier in front of the protective window. Together, these features significantly lower maintenance needs and extend the system’s service life.

The Xi 640 IP Industrial Package comes pre-assembled and pre-wired in a designated box, which reduces installation effort and lowers the chance of integration mistakes. At the same time, the package allows configuration flexibility to fit different applications. Customers can choose 5 m or 10 m high-temperature cables rated for ambient temperatures up to 250 °C, along with a range of optics from wide-angle lenses for large-area monitoring to telephoto lenses for precise measurements at greater distances.

The standard calibrated temperature ranges go from -20 °C to 900 °C and are divided into three subranges to improve measurement accuracy. The Xi 640 has a USB interface for easy connection to standard PCs and smooth operation with thermography software. Additionally, the included industrial process interface allows for professional signal integration into automation systems. It offers up to three configurable analog or alarm outputs, as well as an extra fail-safe relay. This allows direct communication with PLCs for process control, alarm handling, and safety functions.

Whether used for continuous thermal monitoring, process improvement, quality control, or early fault detection in high-temperature industrial applications, this Industrial Package provides a reliable, durable, and scalable solution. By combining effective cooling, solid protection, flexible configuration options, and industrial-grade signal interfaces, it ensures that the Xi 640 performs at its best, even in the most challenging operating conditions.

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

How can I implement the package in my control system?

Image data is transferred via Ethernet and needs to be connected to a computer. But the Xi 410 can also be setup for an autonomous operation without computer. Analog outputs as 0/4-20 mA and alarm relay outputs can be easily integrated in all standard PLC and control systems.

Which additional parts do I need for the installation in the plant?

The Xi 640 IP package comes already pre-assembled and pre-wired. You only need to provide screws to fix the cooling enclosure and electronic boxes onto your machine or mounting base.

What kind of maintenance is required for the cooling system?

The cooling system is almost maintenance-free. You should check from time to time the leakproofness of the water hoses.

How accurate are the temperature measurements under extreme conditions?

The Industrial Package provides the best possible protection for the infrared imager and the sensitive optics. Nevertheless, accuracy can get compromised by heavy atmospheric conditions such as dust or steam. Please make sure that for the time you like to measure the camera has an unobstructed view to the object.

What water connections are required for the Xi water cooled housing?

The water cooled housing uses G 1/8″ fittings and are designated for hoses with ID= 6 mm/ OD= 8 mm.

Are there any accessories or add-ons that are available separately?

The Xi 640 IP is a complete package, but you can choose between 5 m and 10 m cable length.

How will the data transfer of the camera be organized (e.g. cable, WLAN, etc.)?

The data transfer from the imager is done via USB 2.0.

Is your infrared camera long-wave (LWIR) or short-wave (SWIR/MWIR)? What’s the typical frame rate? What’s the IFOV (instantaneous field of view / pixel size)? And does it connect to a PC via USB, or what other platforms/interfaces are supported (e.g., Ethernet, etc.)?

Optris provides different types of IR cameras with different wavelengths. Here you can find an overview of the different camera types regarding the spectral ranges, the typical frame rates and the interface versions (USB or Ethernet (ETH)):

Long-wave (LWIR) cameras (spectral range 8-14 µm):

• PI400i LT (80Hz, switchable to 27 Hz)
• PI450i LT (80Hz, switchable to 27 Hz)
• PI640i LT (32 Hz, 640×120 px @ 125 Hz)
• Xi80 LT ETH (50 Hz)
• Xi400 LT USB (80Hz, switchable to 27 Hz)
• Xi410 LT ETH (25 Hz connected via Ethernet, 4 Hz connected via USB)
• Xi640 LT USB (32 Hz)

Long-wave (LWIR) cameras (spectral range 7.9 µm):

• PI450iG7 (80Hz, switchable to 27 Hz)
• PI640iG7 (32 Hz, 640×120 px @ 125 Hz)

Middle-wave (MWIR) cameras (spectral range 3.9 µm):

• Xi320MT (30 Hz)

Short-wave (SWIR) cameras:

• PI1M (0.85–1.1 µm), 32 Hz (382×268 px @ 80 Hz, switchable to 27 Hz / 72×56 px / 764×8 px @ 1 kHz)
• PI08M (780–820 nm), 32 Hz (382×268 px @ 80 Hz, switchable to 27 Hz / 72×56 px / 764×8 px @ 1 kHz)
• PI05M (500–540 nm), 764×480 px @ 32 Hz / 382×288 px @ 80 Hz (switchable to 27 Hz) / 72×56 px / 764×8 px @ 1 kHz
• Xi1M ETH (0.85–1.1 µm), 396×300 px, 20 Hz, 396×8 px (autonomous: 396×1 px), 500 Hz, Ethernet, USB 2.0 (20 Hz only), autonomous operation
• Xi05M ETH (500–540 nm), 396×300 px, 20 Hz, 396×8 px (autonomous: 396×1 px), 500 Hz, Ethernet, USB 2.0 (20 Hz only), autonomous operation

The following digital interface kits are available for the Xi 80 / 410 / 05M / 08M cameras:

• Ethernet TCP/IP / Modbus TCP interface kit
• EtherNet/IP interface kit
• Profinet kit

You can see the IFOV (instantaneous field of view / pixel size) for your IR camera with the different available optics in the optics calculator on the Optris website: Optris IR Camera Calculator (https://optris.com/optris-calculator/camera/)
Example:

What is the bit depth of our camera?

The bit depth of our cameras is 14 bit. The data has 16 bit but only 14 bit are used for the Temperature Data and the other 2 bits are not used

Can we send the raw ADU data from the camera to another commercial software for processing?

As a rule, we do not disclose any information about raw data. The only option is to use the Connect SDK to output the camera’s ADU values as a matrix. However, these ADU values are uninterpreted. The cameras can send the temperature information and the color information to another commercial software for processing.

Does changing the mode from Temperature to ADU in the Connect SDK change the way that the image is displayed?

No, the way the image is displayed does not change. You can see this in the software examples provided with the PIXConnect software (See the menu HELP => Connect SDK => Examples). Under the configuration menu => External communication => ConnectSDK. You can change the mode from “Temperatures” to “ADU”. This has no influence on the displayed image.

Our company designs and supplies camera systems for steelmaking processes and is exploring different camera types. For this application, would you recommend long-range, near-infrared, or short-wave infrared models?

For steelmaking processes we recommend short-wave infrared cameras as the PI 1M camera, PI 08M camera, PI05M camera , Xi1M camera or Xi 05M camera. Use the lowest wavelength / spectral range as possible!

Which Optris infrared cameras support integration with machine learning frameworks? Do they provide raw thermal image data access via SDK/API (e.g., the OTC SDK), allowing developers to apply custom ML models for tasks like segmentation, classification, or predictive thermal analysis?

The IR cameras do not provide any raw thermal image data access. You get the temperature data via the SDK (OTC SDK) from the camera to your process.

Which Optris infrared camera is best for measuring temperatures during welding processes?

• The choose of the correct Optris infrared camera depends on the temperature range and the type of the welding process.
• For plastic welding , a PI/Xi LT camera can be used (8-14 µm)
• For metal (e.g. steel applications) a short wavelength camera PI 1M/08M/05M , Xi 1M , Xi05M should be used (0.85-1.1 µm , 780-820 µm , 500-540 µm)
• For laser welding applications Optris provides IR cameras with a blocking filter.

After connecting the Optris Xi410 to PIX Connect via Ethernet, I get a “frame timeout” error and the infrared image doesn’t appear at all. The camera has the correct IP address and responds to ping. What could be causing this?

Go to Settings/Camera or via search and type in „camera“ and then activate the button “allow apps to access your camera”.

• Xi 640 infrared imager
• Water cooled housing
• Air purge laminar incl. protective window
• Shutter for lens protection
• USB cable
• Industrial PIF
• All cables in 5 m or 10 m length