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Cohu Electronics
5930 Series Thermal Camera User's Manual
Figure 1
–
5935-1000/T100 Thermal Camera
with 100mm Lens Installed
Technical Manual 6X-1060
January 3, 2006
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Phone: 858-277-6700
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Table of Contents
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List of Tables
List of Figures
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Product Description
The Cohu 5930 series is a long wavelength (LWIR) Infrared microbolometer based camera system. The embeddable electronics provides the foundation for the processing and signal generation for the camera.
Below is a description of all the different aspects that make up the complete camera assembly.
1.1 FPA Description
The FPA used in the 5930 is an uncooled 320 x 240 matrix or "staring" array of microbolometer detectors (51um square), sensitive in the 8.0-14.0 micron range. The FPA is enclosed in an allmetal evacuated dewar package, and is thermally stabilized by the electronics using a built in TE cooler. The FPA incorporates internal thermal reference detectors that provide compensation for thermal drift and noise.
1.2 Hardware Description
The camera electronics are comprised of four major circuit boards as described below.
1.2.1 FPA Support PCB
The FPA support PCB provides all the interface signals required to control the FPA. The FPA
Support PCB supports all the FPA functions as listed in Table 1.
Table 1 - 5930 SERIES FPA Support Functions
Specifications
FPA Clocks
FPA Biases (DAC adjustable)
3
1
FPA Adjustable Bias Resolution
8 bit
FPA Biases (Fixed)
1
FPA Power Supplies
FPA Video Outputs
FPA Video Offset Range
FPA Video Offset Resolution
FPA Video ADC Resolution
FPA Video ADC Rate
FPA TEC Setpoints
PCB Size
3
1
0 to +3.25V
8 bit
14 bit
≤
7.37500 MHz
2
2" x 2"
1.2.2 Camera Controller PCB
The camera controller PCB provides all the video processing and control functions for the
camera. The camera controller PCB provides all the functions listed in Table 2.
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Table 2
–
5930 Series Camera Controller Functions
Specifications
FPA Format
FPA Frame Rate
FPA Clock Generation
FPA Adjustable Bias Generation
Nonuniformity Correction
NUC Gain Coefficient Precision
NUC Gain Range
NUC Offset Coefficient Precision
320 x 240
NTSC: 59.94 Hz
PAL: 50 Hz
≤
6
≤
4
2 point gain/offset
16 bit
0 to 2
–
2
-15
16 bit
-16,384 to +16,383.5
16 bit
NUC Offset Coefficient Range
NUC Offset Refresh Precision
NUC Offset Refresh Range
NUC Tables Possible
-16,384 to +16,383.5
≤
12
5 lines / 7 columns
Defective Pixel Replace Kernal
Intensity Transformation Table
Zone Statistic ROIs
Zone Statistical Computations
Dual 14 in / 16 out
4 Zones
Average, Sigma, Max., Min.
Processed FPA Video Output Precision
16 bit
Processed FPA Video Output Selections
Digitized FPA Video
NUC Corrected Video
Pixel Replaced Video
Intensity Transform Video
PCB Size 2" x 2"
1.2.3 Camera Support PCB
The camera support PCB provides all the power supply conditioning and camera interface
functions. The camera support PCB provides all the functions listed in Table 3.
Table 3 - Camera Support Functions
Power Input Range
Smart Battery Pack Interface
+VhiM Output (Bias Power)
+5.XVM Output (Main Board Power)
Video Encoder Formats
Number of Analog Video Outputs
Digital Output Formats
COM Port Interfaces
COM Port Formats
Oscillator Frequency
External Clock Input Format
External Sync Input Format
Calibration Flag Reference Control
Calibration Flag Reference Setpoint
Calibration Flag Motor Control
Cooling Fan Interface
Motorized Focus Interface
PCB Size
Specifications
+5.8V to +28.2V
1 Wire
+7.0V to +12V @ 300mA
+5.0V to +5.5V @ 5.0A
NSTC or PAL
2 Composite and SVID
LVDS (Serialized 4 Pair)
2
RS232C
RS422 (Differential Full Duplex)
RS485 (Differential Half Duplex)
NTSC: 49.09090 MHz
PAL: 59.00000 MHz
NI: 80.00000 MHz
LVDS
LVDS
Dual Temperature, "Heat Only"
8 bit DAC
PWM
PWM (+5V Level)
+5V "H-Bridge"
2" x 2"
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1.2.4 Camera Power Supply PCB
The camera power supply PCB provides all the power conditioning and external interfaces for the camera. The camera power supply PCB provides the following functions:
Configures the following power inputs based on model selection;
5935 Series: 95-250VAC
5934 Series: 20-28VAC
5932 Series: 11-16VDC
Input power conditioning.
AC Power Fusing.
Power illumination (internal LED).
Configures COM port interface (RS422).
External interface connectors (through cable assemblies) to main Camera electronics
(includes power, COM, analog video and digital video).
Expansion connectors for auxiliary camera functions (not used on base Camera model).
1.3 Camera Operation
This Camera has a multitude of operational and configuration settings which can be adjusted via software control. Typically only a few settings or adjustments require attention once the Camera is embedded into a specific application. A complete list of adjustable settings and software features can be found in Paragraph 3 of this Document.
Cohu Electronics provides a host software application (Camera Control Interface) that can be used for generic camera control and camera setup. For specific information on the capabilities of this application please refer to Cohu CCI manual. Cohu Electronics also sells a developer's software guide for end-users that intend on designing a custom software interface for their own application. Contact the Cohu
’ s Product Manager for more information on how to develop you own application for this camera.
1.4 Lens Options
The camera is equipped with a lens mount with a specific internal thread to accept a series of watertight, fixed focus, f/1.4 Infrared lenses. See Table 4 for the f/1.4 lens options. The lenses are designed with the front lens element sealed for NEMA 4 and IP67 water resistance rating. All these lenses have the front lens element Diamond Carbon Coated for added resistance against weather and scratching.
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Cohu Part
Number
T013
T025
T050
T075
T100
T200
Table 4 - Fixed Focus Lenses
Focal Length Minimum Focus
Distance
13mm
25mm
50mm
75mm
100mm
200mm
2 inches
12 inches
24 inches
30 inches
36 inches
120 inches
Field of View (H x V)
69
º
x 53
º
36
º
x 28
º
18
º
x 14
º
13.5
º
x 10.5
º
9
º
x 7
º
4.5
º
x 3.5
º
The front lens plate has a machined groove designed specifically to interface to an O'Ring
installed on the f/1.4 lenses to ensure the water resistance rating of the camera. See Figure 2 for
lens mounting interface specifications.
1.5
Figure 2 - Lens Mechanical Interface
Camera Performance
The Camera meets the performance parameters listed is Table 5.
Table 5- Camera Performance
Performance Requirement
Non-Uniformity Correction
Noise
NEDT (f/1.4 Optic and FPA)
Operability
Specification
< 0.0025
< 3 Counts
< 100 mKelvin
>99.5%
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1.6 Mechanical Characteristics
The Camera dimensions are as shown in Figure 3. These dimensions show the Camera without
a lens or mating connector. The mating connector adds about 2.0" to the rear of the camera which includes room for the cable's bend radius. The different focal length lenses are larger as they go up in focal length. This will add to the length of the camera depending on the lens focal length.
Figure 3 - Camera Dimensions
2. Installation
This section describes everything from removing the camera from the box to how to connect the camera to external devices.
2.1 Unpacking and Receiving Inspection.
The camera was tested and carefully packed at Cohu Electronics. Upon acceptance by the carrier, they should assume responsibility for its safe arrival. Should you receive this item in damaged condition, claims for shipping damage must be filed against the carrier.
To return the camera to the factory for any other service, please contact Cohu Electronics
Customer Service Department for a Return Authorization Number.
2.2 Lens Cleaning.
The lens provided with this Camera has the front lens element diamond carbon coated. Even though this coating is very tough, the following cleaning procedures should be adhered to. A light dusting of air should be enough to dislodge most dust particles, although small amounts of dust should not affect camera performance. If necessary to clean the front surface, use 75% isopropyl
alcohol and a lens tissue. Use a clean section of tissue with each swipe so as to not drag dirt back on the front lens surface.
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2.3
2.4
Electrostatic Discharge (ESD) Precautions.
The installation procedures in this user's manual do not require entry into the Enclosure of the
Camera. However in the event that the camera needs to be opened as directed by Cohu
Electronics , the following ESD precautions should be followed:
Use a conductive pad on whatever work space used.
Connect the conductive pad to earth ground through a 1M
Ω
resistor.
Use a wrist strap connected to earth ground through a 1M
Ω
resistor when working with the equipment.
Maintain the relative humidity above 30%. Working on this circuitry with a relative humidity below 30% requires more extreme ESD precautions not specified in this document.
Use antistatic bags to store and transport any electronic components or circuit board assemblies removed from this Camera. Use new antistatic bags as old antistatic bags can lose their static protection after use.
Tripod Mounting Interface
The camera has a tripod mounting plate clamped to the bottom of the Camera. The Tripod mount
has five mounting threads (0.250-20UNC-2B) separated as shown in Figure 4. This provides two
center-to-center mountings, being 1.75
”
and 1
”
bolt patterns. Insure the mounting arm/fixture supports one of these mounting bolt patterns.
2.5
Figure 4 - Tripod Mounting Locations
Main Rear Panel Signal Connector
The main signal input/output connector is located on the rear panel of the Camera as shown in
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Figure 5 - Camera Rear Panel
2.5.1 Camera Main Signal Connector
The main signal connector that is mounted to the rear panel of the Camera is manufactured by
Amphenol and the part number is PT07H-14-18P. This connector is hermetically sealed which means it is gastight therefore exceeds the NEMA 4 and IP67 water resistance rating of the
Camera. This connector is equipped with 18 contacts. See Table 6 for main signal pin
descriptions.
Direction
Table 6 - Main Signal Pin Descriptions
Signal Name Signal Description Pin
Number(s)
G
U
Input
Input
T
B
C
R
P
L
A
K
M
N
S
Input
Input
Input
Input
Input
Input
Output
Output
Input
Output
Output
Chassis
AC Line
Chassis Ground
AC Line high side power input. Camera will function on voltage inputs of 90-250VAC, 47-63Hz.
AC Neutral/24VAC Lo AC Line and 24VAC return (Neutral).
24VAC Hi 24VAC high side power input. Camera will function on voltage inputs of 20-28VAC, 47-63Hz.
+12VDC DC Camera positive power input. The Camera can function on voltage inputs of 11-16VDC.
-12VDC
RX+
RX-
TX+
TX-
Ground
Video
Video Ground
DC Camera power common.
RS422: Camera receive data positive (+).
RS422: Camera receive data negative (-).
RS422: Camera transmit data positive (+).
RS422: Camera transmit data negative (-).
Data/Power Ground
Video
Video Ground
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2.5.2 Mating Rear Panel Connector
The connector that mates with the main signal connector of the Camera is manufactured by
Amphenol and the part number is a PT06A-14-18S-SR. This connector must be manufactured to the assembly procedure provided by Amphenol.
2.6 Main Rear Panel Digital Signal Connector
The main digital signal connector is located on the rear panel of the Camera as shown in Figure
2.6.1 Camera Digital Signal Connector
The digital signal connector that is mounted to the rear panel of the Camera is manufactured by fischer and the part number is DBPE 1031 A019-139. This connector is hermetically sealed which means it is gastight therefore exceeds the NEMA 4 and IP67 water resistance rating of the
Camera. This connector is equipped with 19 contacts. See Table 7 for digital signal pin
descriptions.
11
12
13
14
15
16
17
18
19
Pin
Number(s)
6
7
8
9
10
Direction
Table 7 - Digital Signal Pin Descriptions
Signal Name Signal Description
Input
Input
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
Output
Output
ExtClk+
ExtClk-
ExtSync+
ExtSync-
ExtClkEn_n
PGND
SprcFpaVid0+
SprcFpaVid0-
SprcFpaVid1+
SprcFpaVid1-
SprcFpaVidSync+
SprcFpaVidSync-
SprcFpaVidClk+
SprcFpaVidClk-
Positive (+) LVDS external clock input.
NTSC: 49.09090 MHz.
PAL: 59.00000 MHz.
Negative (-) LVDS external clock input.
NTSC: 49.09090 MHz.
PAL: 59.00000 MHz.
Positive (+) LVDS external sync input.
Negative (-) LVDS external sync input.
External clock enable. This input determines whether the Camera boots with an external or internal clock.
Low (tied to PGND): external clock, Open: internal clock.
Power Ground.
Positive (+) LVDS serialized 16 bit processed FPA video data bits 0-7.
Negative (-) LVDS serialized 16 bit processed FPA video data bits 0-7.
Positive (+) LVDS serialized 16 bit processed FPA video data bits 8-15.
Negative (-) LVDS serialized 16 bit processed FPA video data bits 8-15.
Positive (+) LVDS serialized digital processed FPA video sync.
Negative (-) LVDS serialized digital processed FPA video sync.
Positive (+) LVDS serialized digital processed FPA video clock.
Negative (-) LVDS serialized digital processed FPA video clock.
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2.6.2 Mating Digital Signal Connector
The connector that mates with the digital signal connector of the Camera is manufactured by fischer and the part number is S 1031 A019-150+. All the signals in this connector are Low
Voltage Differential (LVDS) which requires a mating cable that uses 100
Ω
twisted pairs. Belden cable 9808 (7 100
Ω
twisted pair with overall foil/braided shield) will work for this application or any equivalent cable.
This connector requires a mating environmental clamp set sold by fischer to ensure the sealing
between the connector and cable used. See Table 8 for fischer environmental cable clamp part
numbers for corresponding cable diameter ranges. The connector and environmental cable clamp must be assembled as described on page N2 in the fischer General Catalogue, Edition 5.
Table 8 - Environmental Cable Clamps
Fischer Part Number:
E3 1031.2/2.7
E3 1031.2/3.2
E3 1031.2/3.7
E3 1031.2/4.2
E3 1031.2/4.7
E3 1031.2/5.2
E3 1031.2/5.7
E3 1031.2/6.2
E3 1031.2/6.7
Cable Diameter Range (mm)
2.2-2.7mm
2.7-3.2mm
3.2-3.7mm
3.7-4.2mm
4.2-4.7mm
4.7-5.2mm
5.2-5.7mm
5.7-6.2mm
6.2-6.7mm
2.7 Power Input Selection
The camera input power is specified by model configuration when originally ordered from Cohu
Electronics, and is delivered to accept the specified voltage configuration of 120VAC, or 24VAC
or 12VDC. Refer to Table 6 for connector pin assignments.
Cohu Electronics offers a suite of field cable assemblies for providing connections from the camera to the users control/monitoring system or transmission backbone. Refer to Cohu
Electronics CA290 series data sheet for selection of the proper cable to meet specific requirements.
2.7.1 AC Line Input Voltage Connections
The Camera is delivered to accept 120VAC or 24VAC Line voltage. If it is determined the ordered/delivered voltage format of the camera system is not the desired voltage level, the input voltage can be changed. A connector should be plugged into header J1 or J2 located as shown in
Figure 6 (Figure 6 is drawn without Transformer Support Plate and mating connectors for clarity).
Warning: Never power the Camera up with a connector plugged into headers J1 and J2 simultaneously. This may provide a risk of electric shock on the main rear panel connector.
2.7.2 24VAC Input Voltage Connections
The Camera can be configured to accept 24VAC instead of AC Line voltage. To accomplish this, the connector plugged into header J1 should be unplugged. The two position connector that is
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lying inside the Camera must be plugged into header J2 as shown in Figure 6 (Figure 6 is drawn
without Transformer Support Plate and mating connectors for clarity).
Warning: Never power the Camera up with a connector plugged into headers J1 and J2 simultaneously. This may provide a risk of electric shock on the main rear panel connector.
Figure 6 - Voltage Input Selection
3. Camera Software Features
the software features available in this Camera.
Table 9 -Software Features
Camera Software Feature
Selection of up to 8 Operational Modes
Selection of up to 16 NUC Modes
Automatic Refresh on Operational Mode or NUC Mode
Switch
Automatic Refresh on Camera Boot
Automatic Refresh on Timer
Automatic Refresh on Camera Internal Temperature
Change
Commanded Refresh
Selection of up to 16 Video Color Palettes
Host Application
Control (C) or
Monitor (M)
C
C
C
C
C
C
C
C
Notes
Configured at factory.
Configured at factory.
Configured at factory but user can create custom palettes. Contact
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Camera Software Feature Host Application
Control (C) or
Monitor (M)
Notes
Video Color Bar Enable
Video Polarity Invert
Video Color Gamma Boost
Video Zoom
Video Freeze
Video Disable
Selection of up to 8 Video Overlay Palettes
Commanded Overlay Refresh
Overlay Mode Selection
Foreground and Background Color Selection
Two Standard Reticles with Intensity Readout
One Range Reticle
Configured Lens Select
Focus Control
Zoom Control
Sync Mode Selection
Frame Counter Reset
FPA Temperature
FPA Support Board Temperature
Two Available Internal Remote Temperatures
Calibration Flag Temperature
Fan Mode
Camera Power
Two (AGC/ALC) Automatic Gain and Level Control Modes
Up to 8 Region of Interest Areas
AGC/ALC Brightness
AGC/ALC Contrast
AGC/ALC Low and High Limit Settings
Four AGC/ALC Lag Filter Rates
Multiple Linear AGC/ALC Mapping Settings
Automatic NUC Switching Capability
Reticle Size and Position
Radiometric Capability
Built-In Tests
Camera Operation Statistics
Field Upgradeable Operational Software
Field Upgradeable FPGA Configuration
Production and Manufacturing Information
C
M
C
C
C
C
C
C
C
C/M
C
M
C
C
C
C
C
C
C
C
C
C
C
C
M
C
C
C
C
C
C
C
M
M
M
C
C
C/M
Lumitron for specific information.
Gamma boost built into color palette.
Configured at factory but user can create custom palettes. Contact
Lumitron for specific information.
Designed for use with 100mm lens.
Based on factory configuration.
If hardware is present.
Not yet implemented.
Resets frame header value.
Contact Lumitron for ADC to temperature equation.
Contact Lumitron for ADC to temperature equation.
Contact Lumitron for ADC to temperature equation.
Contact Lumitron for ADC to temperature equation.
Contact Lumitron for ADC to voltage equation.
Linear and Histogram equalization.
Can be disabled.
First ROI reserved for full frame.
Reported in automatic mode, can be set in manual mode.
Reported in automatic mode, can be set in manual mode.
Not yet implemented.
Requires custom OEM software.
Contact Lumitron before upgrading camera operational software.
Contact Lumitron before upgrading
Xilinx FPGA configuration file.
Modification of stored production/manufacturing data reserved for specific OEM
’ s.
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Camera Software Feature
Static Configuration Data
Individual Operational Mode Configuration
Individual NUC Mode Configuration
Motorola DSP Register Settings
Xilinx FPGA Register Settings
Access to DSP Memory
Access to SPI FLASH Memory
Access to NUC FLASH Memory
Access to NVM RAM
Access to Real Time Clock
Access to operational software configuration variables/settings.
Host Application
Control (C) or
Monitor (M)
C/M
C/M
C/M
C/M
C/M
C/M
C/M
C/M
C
C
C
Notes
Modification of factory static configuration data reserved for specific OEM
’ s.
Modification of factory operational mode data reserved for specific
OEM
’ s.
Modification of factory NUC mode data reserved for specific OEM
’ s.
Modification of any DSP registers is not suggested except for advanced users. Changes may prevent camera from operating properly.
Modification of any FPGA registers is not suggested except for advanced users. Changes may prevent camera from operating properly.
Read/Write access reserved for specific OEM
’ s.
Read/Write access reserved for specific OEM
’ s.
Read/Write access reserved for specific OEM
’ s.
Camera operational state is stored in NVM via operational software.
Do not modify directly.
Contact Lumitron for specific information.
4. Environmental Specifications
4.1
4.2
4.3
Temperature
The storage temperature range is -40
º
C to 85
º
C.
The operating temperature range is -40
º
C to 60
º
C.
Water Resistance
The Camera as shipped from factory with Lens meets or exceeds the NEMA4 and IP67 water resistance rating.
Relative Humidity
The Camera as shipped from factory with Lens meets a relative humidity of 10% to 95%, noncondensing.
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4.4 Shock and Vibration
NEMA TS-2 Compliance;
Vibration: 5-30 Hz with 0.5G applied in three perpendicular planes.
Shock: 10G applied in three perpendicular planes
COHU ELECTRONICS WARRANTY
Cohu, Inc., Electronics Division warrants equipment manufactured to be free from defects of material and workmanship. Any part or parts will be repaired or replaced when proven by Cohu examination to have been defective within two years from date of shipment to the original purchaser for standard CCD cameras and one year from date of shipment to the original purchaser for intensified CCD cameras and all other Cohu manufactured products.
Pressurized Housings: Pressurized camera products include a lifetime pressurization warranty. Cohu will re-pressurize at no charge returned environmental cameras not exhibiting evidence of physical damage due to misuse. All warranty repairs will be performed at the factory or as otherwise authorized by
Cohu in writing. Transportation charges to Cohu shall be prepaid by purchaser.
Extended IR Cameras: Cameras utilizing extended infrared (extended IR) sensors found to exceed acceptable white blemish specifications within one month of delivery shall be repaired without charge.
This warranty does not extend to Cohu equipment subjected to misuse, accident, neglect, improper application, or repaired or altered by other than Cohu or those authorized by Cohu in writing. Cameras utilizing extended IR sensors are not warranted for use in areas of elevated levels of cosmic radiation.
Television image pickup tubes, image intensifiers, lenses, and products manufactured by companies other than Cohu are warranted by the original manufacturer.
This warranty is in lieu of all other warranties, express, implied, or statutory, including warranties of fitness for a particular purpose and merchantability, and sets forth buyers sole remedy in connection with such warranties. Cohu, in no event, whether as a result of breach of contract or warranty, tort (including negligence) or otherwise, shall be liable for any penalties regardless of reason; collateral, consequential, incidental, or exemplary damages, including without limitation, any loss of profit or revenues, loss of use of any equipment or goods, or removal or re-installation of equipment without prior written approval.
A Return Authorization (RA) Number must be obtained from Cohu prior to returning any item for warranty repair or replacement.
4/03 man.
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