Cavitar C400 Series User manual

CAVITAR
Welding Camera C400-H
Operating Manual

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Contents
1INTRODUCTION.........................................................................................................................1
2SAFETY INFORMATION..........................................................................................................2
3PROPERTIES...............................................................................................................................5
4INSTALLATION........................................................................................................................12
4.1 SOFTWARE INSTALLATION ........................................................................................................12
4.2 HARDWARE INSTALLATION.......................................................................................................16
5OPERATION ..............................................................................................................................19
5.1 TEMPERATURE WARNING UNIT ................................................................................................19
5.2 CAVITAR CAPTURE SOFTWARE ..............................................................................................20
5.2.1 Registration ....................................................................................................................21
5.2.2 Opening the camera........................................................................................................23
5.2.3 Overview of CAVITAR Capture......................................................................................24
5.2.4 Camera settings ..............................................................................................................26
5.2.5 Image adjustment............................................................................................................27
5.2.6 Guidelines.......................................................................................................................29
5.2.7 Calibration......................................................................................................................31
5.2.8 Recording settings ..........................................................................................................35
5.2.9 Recording images ...........................................................................................................36
5.2.10 Viewing and saving recorded images ........................................................................36
5.2.11 Snapshot.....................................................................................................................38
5.3 STARTING AND STOPPING LASER ILLUMINATION.......................................................................38
5.4 AFTER OPERATION ....................................................................................................................39
5.5 TROUBLESHOOTING ..................................................................................................................39
6MAINTENANCE AND SERVICE INFORMATION.............................................................40
7SUPPORT AND END OF LIFE................................................................................................41
8LIMITED WARRANTY............................................................................................................42
Cavitar Welding Camera, model C400-H
Operating Manual, Revision 1.0.0
© 2022 Cavitar Ltd.
All rights reserved. All unauthorized copying strictly prohibited.
Cavitar®is a registered trademark of Cavitar Ltd.

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1 Introduction
Thank you for choosing Cavitar Welding Camera C400-H (later: Welding Camera)!
Welding Camera is a Finnish quality product developed and manufactured by Cavitar Ltd.
We hope you will be satisfied with your product.
Welding Camera is a highly compact and easy-to-use visualization system for the online
monitoring of various welding processes, including MIG, MAG and TIG processes.
Welding Camera contains several unique features to enable highest possible image quality.
These features include, among other things, spectral filtering combined with active laser
illumination.
The laser source of the system doesn’t require any control by the operator. Therefore, from
the operation point of view, the system doesn’t differ from a normal machine vision camera
system. Welding Camera is a class 3R laser product with a nominal ocular hazard distance
(NOHD) of 3 meters.
Please read this operating manual carefully before using Welding Camera.
Chapter 2 contains important safety information for the safe operation of Welding Camera.
Chapter 3 describes the properties of Welding Camera and Chapter 4 deals with the
installation of the system.
Chapter 5 describes the operation of Welding Camera.
Chapters 6 to 8 cover issues related to maintenance, service, support and warranty.
The actual appearance of software or components may vary.
The symbols below are applied throughout this operating manual:
NOTE! indicates useful tips for easier operation
CAUTION! indicates potential risk of serious damage to the device
WARNING! indicates potential risk of serious injury to the user

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2 Safety information
PLEASE CAREFULLY READ AND UNDERSTAND THE FOLLOWING SAFETY
INSTRUCTIONS BEFORE USING WELDING CAMERA. IT IS OF UTMOST
IMPORTANCE TO STRICTLY OBEY THESE INSTRUCTIONS. OTHERWISE SERIOUS
DAMAGE TO THE USER OR TO THE DEVICE MAY OCCUR.
ONLY A PERSON, WHO HAS CAREFULLY READ AND UNDERSTOOD ALL SAFETY
INSTRUCTIONS BELOW AND THE REST OF THIS OPERATING MANUAL, IS
QUALIFIED FOR USING WELDING CAMERA. CAVITAR LTD. IS NOT LIABLE FOR
ANY DAMAGE CAUSED BY THE IMPROPER USE OF WELDING CAMERA.
CAUTION--USE OF CONTROLS OR ADJUSTMENTS OR PERFORMANCE OF
PROCEDURES OTHER THAN THOSE SPECIFIED HEREIN MAY RESULT IN
HAZARDOUS RADIATION EXPOSURE.
CAUTION--USE OF OPTICAL INSTRUMENTS WITH THIS PRODUCT WILL
INCREASE EYE HAZARD.
WARNING!
CAUTION!
•Welding Camera is a class 3R laser system
olaser class is indicated by the warning label on top of the camera unit (see the
label above)
olaser aperture is indicated by the yellow aperture label on top of the camera
unit (see the label above)
oNominal Ocular Hazard Distance (NOHD) is 3 meters
•Do not look into the direct, reflected or scattered laser beam
ocamera unit emits visible red laser light at 645 ± 10 nm wavelength band
olaser beam is emitted from the front of the camera unit (from the mirror-like
window in Fig. 3.2). The beam generates approximately 30 mm diameter spot
at the design working distance (200 mm)
ouse of appropriate laser safety goggles is recommended for eye-safe operation.
Suitable laser safety goggles must have an optical density of at least 3 (OD3) at
the wavelength band 645 ± 10 nm
•The accidental exposure to direct/reflected/scattered laser beam has to be prevented:
otrain personnel not to stare at the laser output
opay special attention to possible bystanders or persons passing by

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•Other instructions:
oChanges or modifications not expressly approved by Cavitar Ltd could void
the user's authority to operate the equipment
oWelding Camera is not certified for medical use
oDo not make ANY modifications to the device by yourself
oDo not try to repair the device by yourself
oIt is strictly forbidden to open the cover of the camera unit. Otherwise serious
damage or injury to the user or to the device may occur. Camera unit contains
gallium arsenide, which is a known human carcinogen
oBefore powering the system, ensure all connections are made according to this
manual and all cables are intact. Broken cables can create a risk of electric
shock which can cause serious damage or injury to the user or to the device
oWelding Camera is intended for indoor use only
oDo not expose the system to moisture, rain or condensing environment as this
can create a risk of electric shock. Electric shock can cause serious damage or
injury to the user or to the device
oDo not expose the system (especially the signal inputs) to electrical shock or
static discharge as this can create a risk of unintended laser emission, resulting
in eye hazard
oExcessive vibration or strong mechanical impact may damage the equipment.
oThe operating temperature of Welding Camera is +10…+40 °C with proper
mounting. Do not expose the device to excessively low or high temperatures
without appropriate means for controlling the temperature of the device
oPeople prone to epileptic seizures are not allowed to operate the system nor be
exposed to the laser emission (blinking frequency 100 Hz or less)
oIf you are uncertain about any issue related to safety or proper operating
conditions, please contact your vendor or Cavitar
oIt is not allowed to dispose Welding Camera as unsorted municipal waste. The
system must be returned to your vendor or to Cavitar for proper disposal at the
end of their life. Alternatively one can consult local, state and federal
regulations for proper disposal. Welding camera contains Gallium Arsenide.
Gallium Arsenide is toxic and must not be released to the environment

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CERTIFICATIONS AND COMPLIANCE
•Cavitar Ltd. is an ISO 9001:2015 certified company
•CE declaration of conformity
oWelding Camera, if installed and operated in accordance with the
manufacturer’s instructions, is in conformity with the following European,
harmonized and published directives and standards:
▪2011/65/EU (RoHS 2)
▪2014/30/EU (Electromagnetic Compatibility)
▪2014/35/EU (Low Voltage Directive)
▪BS/EN 60825-1:2014 (Laser Safety)
•Declaration of conformity with 21 CFR 1040.10 and 1040.11
oComplies with 21 CFR 1040.10 and 1041.11 except for conformance with IEC
60825-1 Ed. 3., as described in Laser Notice No. 56, dated May 8, 2019.
•Safety
oWelding Camera meets the requirements of the following electrical equipment
safety standards:
▪IEC 61010-1:2010 + Am1:2016
▪EN 61010-1:2010
▪UL 61010-1: 3rd Edition
▪CSA C22.2 No. 61010-1-12
•Electromagnetic compatibility (EMC)
oWelding Camera meets the requirements of the following EMC standards:
▪IEC 61326-1:2020: Immunity in an industrial electromagnetic
environment
▪CISPR 11:2015/AMD2:2019: Group 1, Class A emissions
▪FCC 47 CFR Part 15B: Class A emissions
▪ICES-003 Issue 7: Class A emissions
Group 1 equipment is any industrial, scientific, or medical equipment that does not
intentionally generate radio frequency energy in the frequency range 9 kHz to 400 GHz for
the treatment of material or inspection/analysis purposes.
Class A equipment is suitable for use in all establishments other than domestic and those
directly connected to a low voltage power supply network which supplies buildings used for
domestic purposes.
Warning: This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense. This device complies with part 15 of the FCC Rules.
Operation is subject to the following two conditions: (1) This device may not cause harmful
interference, and (2) this device must accept any interference received, including interference
that may cause undesired operation.

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3 Properties
Welding Camera C400-H system typically consists of the following components:
CAMERA UNIT
•laser aperture label
•laser class 3R warning label
•easy-to-replace protective window
•adjustable working distance
•mounting threads
•integrated channels for air or liquid cooling
TEMPERATURE WARNING UNIT (TWU)
•generates audible and visible warning if camera temperature exceeds specified
boundaries
•power on/off button for the camera system
•sound off button for muting audible warning
•enables the use of an optional warning light system
POWER SUPPLY
•power supply DC 24 V, max 40 W, including 1,8 m long fixed cable
CABLES
•GigE cable (between camera unit and computer), standard length 10 m
•power cable (between camera unit and TWU), standard length 10 m
•power supply cable (between power supply and AC mains), standard length 2 m
ACCESSORIES
•2x spare protective window
•2x cooling hose connector with O-ring
•2x hose clamp for cooling connector
•1x hex key (1,5 mm) for working distance adjustment
INSTALLATION CD
•CAVITAR Capture-H software for controlling Welding Camera
•Operating manual
•Additional instructions:
OGuide for cooling
OGuide for external control via COM-port
OGuide for working distance adjustment

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Table 3.1. Welding Camera C400-H specifications.
Camera related
Default working distance
200 mm (good image quality within ± 15 mm)
Field of view (at default working distance)
approx. 40 mm x 30 mm
Max resolution
1440 pxl x 1080 pxl
Max frame rate (at full resolution)
Typically approx. 70 fps (computer dependent)
Max frame rate (with laser illumination)
100 fps
Optical
Wavelength
645 ± 10 nm
CW/Pulsed
Pulsed
Max average power
< 5 mW
Max pulse energy
< 22,9 J
Max pulse duration
< 2,7 s
Laser class (according to BS/EN 60825-1:2014)
3R
Nominal ocular hazard distance (NOHD)
3 m
Audial
TWU warning sound frequency
2900…3500 Hz
TWU warning sound pressure level
max 100 dB at 30 cm distance
Electrical
Power supply input voltage
AC 100-240 V, 47-63 Hz
Power supply output voltage
DC 24 V
Power supply power rating
Max 40 W
Mechanical
Camera unit dimensions (W x H x L)
38 mm x 48 mm x 99 mm (excl. connectors)
Camera unit weight
~ 360 g
Camera unit attachment
6x M3 and 4 x M4 mounting threads
TWU dimensions (W x H x L)
80 mm x 40 mm x 120 mm (excl. connectors)
TWU weight
~ 400 g
TWU attachment
4 x M3 and 2x M4 mounting threads
Environmental
Storage temperature
0…+50 °C
Operation temperature
+10…+40 °C (1)
Indoor/outdoor use
Indoor use only
Humidity
max 80 % RH non-condensing
Altitude
max 2000 m above sea level
Pollution degree
PD2
Supply voltage fluctuations
±10 %
Overvoltage category
II
Pressure in integrated cooling circuitry
max 4 bar
Cooling liquid
mixture of pure water and inhibited glycol (2)
Inner diameter of the cooling hose
6 mm

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(1) The camera heats up during operation. Please follow these guidelines to ensure proper cooling:
a. Immediate action is needed if Temperature Warning Unit (TWU) generates an alarm (for
more details, see Section 5.1). Warranty doesn’t cover damage caused by overheating
due to inadequate cooling of the camera. More detailed information about cooling can be
found from separate document “Guide for cooling”
b. Remarks for passive cooling (low heat load and low ambient temperature):
i. The camera must be mounted/clamped in such a way that heat can be removed
from the camera housing as efficiently as possible. In some cases it is possible to
use a metallic (e.g. aluminium) mounting plate/arm with a good thermal contact to
a larger heat sink such as metallic body of machinery
ii. For optimal heat transfer, the mounting/clamping should cover as large portion of
the camera side(s) as possible (good thermal contact to both camera sides is the
most efficient passive cooling configuration)
iii. It is strongly recommended to apply a thin thermally conductive sheet between the
camera side(s) and the mounting as well as between mounting and larger heat
sink to maximize heat transfer
iv. If the mounting doesn’t enable efficient heat transfer from the camera to a larger
heat sink and if the ambient temperature doesn’t exceed ~30…35 ºC, separate
heat sinks mounted to camera sides can be applied (Cavitar offers dedicated heat
sinks as optional items)
c. Remarks for active air and/or liquid cooling (high heat load or high ambient temperature):
i. Never cool the camera to temperatures below dew point to prevent condensation
(warranty doesn’t cover damage caused by condensation). 25…30 ºC is usually a
safe temperature for the coolant to enter the camera
ii. Ensure continuous and sufficient flow of the coolant (a clear warning is needed if
the flow is reduced/stopped to avoid damage to the camera)
iii. Carefully insulate the camera and the cables from the environment with
appropriate thermally insulating protective sleeves. Also place the cooling hoses
inside the same protective sleeve as this will keep the other cables cooler and
reduce the required cooling power
iv. Vortex pipes enable efficient air cooling. However, with vortex pipes special care
must be taken not to cool the camera to temperatures below dew point
(2) The camera contains integrated cooling channels for liquid cooling. Please follow these guidelines
to ensure appropriate liquid cooling:
a. Cooling channels inside the camera are made of aluminium. Only use cooling liquids and
cooling equipment that are compatible with aluminium
b. Always ensure that the cooling connectors are properly fastened and free from any leaks.
Leaking cooling liquid can get in contact with the back of the camera and may enter the
camera, thus breaking the camera. Such damages are not covered by warranty
c. A mixture of pure water and inhibited glycol is recommended to avoid corrosion and algae
growth
i. Pure water can be distilled, demineralised, de-ionised or reverse osmosis water
1. Never use pure water without inhibited glycol since this causes corrosion
ii. Glycol must be inhibited (to avoid corrosion) and the glycol content in the mixture
must be at least 20 volume % (to prevent algae growth)
1. Ethylene glycol has better cooling performance than propylene-based
glycol but is more toxic
2. Modern industrial glycols contain inhibitors alongside a pH buffer and
biocide to prevent corrosion, algae growth and rust
3. Never mix different glycols
d. The cooling system must be properly flushed and cleaned before adding suitable inhibited
glycol and pure water mixture as well as when the mixture needs to be changed
e. Prevent any contamination of the cooling liquid and cooling circuitry
f. A chiller with temperature and flow rate monitoring and alarm feature is recommended
g. Regular maintenance intervals are needed to ensure proper operation (e.g. checking the
condition of filters and cooling liquid)
h. Never use automotive antifreeze liquids

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Fig. 3.1. Camera unit (top view).
Fig. 3.2. Camera unit (front view). Fig. 3.3. Camera unit (back view).
A
B
C
D
E
F
G
H
I
J
K

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In Figs. 3.1-3.3:
A Laser aperture label
B Laser warning label (laser hazard symbol and explanatory label)
C Camera unit device label
D Working distance adjustment screw (for more details see separate document “Guide
for working distance adjustment”)
E Protective window (slide to either side to replace)
F Mounting threads (2x M4, see Fig. 3.4 for more details)
G Power led (green)
H Connector for power cable (M12, A-coded, 8-pin, male)
I Connector for GigE cable (M12, X-coded, 8-pin, female)
J Threads (2x M6x0.75) for air or liquid cooling (do not use for mounting!)
K Chassis ground (2x M4 mounting threads)
Fig. 3.4. Camera unit mechanical drawing.

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Fig. 3.5. Temperature warning unit (top view).
Fig. 3.6. Temperature warning unit (front view). Fig. 3.7. Temperature warning unit (back view).
In Figs. 3.5-3.7:
A POWER led (green)
B CAM OK led (green)
C CHECK COOLING led (orange)
D CRITICAL ERROR led (red)
E CAM ON/OFF button
F SOUND OFF button
G Connector for power supply (M12, A-coded, 8-pin, male)
H Connector for power cable (M12, A-coded, 8-pin, female)
I Connector for optional warning light system (WLS) (M12, A-coded, 5-pin, female)
J Temperature warning unit device label
A
B
C
D
E
F
G
H
I
J

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Fig. 3.8. Temperature warning unit mechanical drawing.

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4 Installation
4.1 Software installation
Recommended computer properties are listed in Table 4.1:
Table 4.1. Recommended computer properties.
Operating system
Windows 10
Processor
Intel i5 or higher, preferably latest generation multicore processor
RAM memory
8 GB or more (depending on the recording requirements)
Hard disk
SSD with sufficient capacity (depending on the recording requirements)
Display
High quality display with wide viewing angle
Ethernet adapter
Intel ethernet adapter (I350/I210 or similar); at least two connectors, if two
cameras are to be connected to the same computer
Cooling
Efficient cooling (e.g. ventilation or conductive cooling) to prevent heating
If applicable, please uninstall old software version completely before installing new software
version!
Insert the CAVITAR Capture-H software CD into the CD drive and run the setup file (if the
setup doesn’t start automatically).
In some cases it may be necessary to disable firewall and/or virus software. As an example, in
Windows 10 the “Check apps and files” feature under Windows Security App & Browser
Control may need to be turned off. Please consult your IT support if needed.
The screenshots below show a typical installation procedure for Windows 10. The actual
appearance of the windows may vary.
Fig. 4.1. Select language and click “OK”.

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Fig. 4.2. Close all other applications and click “Next” to start installation.
Fig. 4.3. Click “I Agree” to continue.

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Fig. 4.4. Select “Support for two cameras” if two systems will be used with
the same computer. Click “Next” to continue.
Fig. 4.5. Choose install location and click “Next” to continue.

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Fig. 4.6. Choose start menu folder and click “Install” to continue.
Fig. 4.7. After installation is completed, click “Next” to continue.

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Fig. 4.8. Click “Finish” to complete installation.
4.2 Hardware installation
Installation of camera unit
The camera unit should be mounted or clamped with an appropriate fixture in such a way that
the object is located at the working distance of the camera unit. The mounting must enable
as efficient conductive (low ambient temperature or heat load from process) or active (high
ambient temperature or heat load from process) cooling of the camera unit as possible.
In case of conductive cooling, it is important to apply thermally conductive sheets between
the camera side(s) and the mounting as well as between the mounting and larger heat sink
(such as the body of machinery). Optimal thermally conductive sheets are offered by Cavitar
as optional accessories. It is also beneficial to maximize the area between camera side(s) and
mounting. The mounting should be made of material with high thermal conductivity (such as
aluminium).
If active cooling is applied, connect the cooling connectors (see Fig. 4.9H) to the threads of
the camera unit (see Fig. 3.3J, ensure the O-rings are in place; maximum torque 1 Nm) and
attach appropriate cooling system (air or liquid) to the connectors (suitable for hoses with
inner diameter of 6 mm). Always ensure that the cooling connectors and cooling hoses are
properly fastened and free from any leaks. Leaking cooling liquid can get in contact with
the back of the camera and may enter the camera, thus breaking the camera. Only use cooling
liquids and cooling equipment that can be in contact with aluminium (electro-chemical
corrosion must be prevented). The coolant must be sufficiently warm (e.g. 25-30 ˚C) to
avoid problems related to condensation. For more details, see Table 3.1 and the notes
related to it as well as the separate document “Guide for cooling”.

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In order to minimize the effects of external electromagnetic fields, connect the chassis of
the camera to an appropriate grounding point via the grounding threads (see Fig. 3.3K).
The same grounding point should be used for both the camera and the computer to avoid
ground loops. If the machinery chassis is in different ground than the computer, the camera
should be electrically isolated from the machinery chassis. If the camera is powered by the
power supply provided with the camera, camera will not be grounded via the power supply
(attach grounding wire to the grounding threads of the camera and the other end of the
grounding wire to the same grounding point as the computer).
The camera unit must be properly protected from excessive radiation, heat/cold, condensation,
vibration or mechanical forces (see Table 3.1 for more detailed specifications). If you feel
uncertain about the correctness of the installation and/or about the suitability of the
environment, please contact your vendor or Cavitar. Warranty does not cover damage caused
by improper installation.
Installation of temperature warning unit
Temperature warning unit should be mounted to an appropriate fixture in such a way that the
indicator leds and buttons are visible and accessible to the operator. If this is not possible, an
additional warning light system (optional) should be applied to ensure that possible alarms
will be noticed and reacted on without delay.
Electrical connections
The electrical connections shall be made in the following way:
•connect the power cable (Fig. 4.9A) between camera unit (Fig 3.3H) and temperature
warning unit (Figs. 4.9B and 3.6H)
•connect the power supply output cable (Fig. 4.9C) to temperature warning unit (Fig.
3.6G)
•connect the power supply input cable (Fig. 4.9E) to the power supply (Fig. 4.9D)
•connect the GigE cable (Fig. 4.9F) between camera unit (Fig. 3.3I) and computer
(computer is not included in the standard system)
•ensure the camera unit housing (Fig. 3.3K) is firmly connected to an appropriate
grounding point. Also ensure the computer is grounded to the same grounding point to
avoid ground loops
Fig. 4.9 shows a typical welding camera system configuration after the connections have been
made. Also spare protective windows (Fig. 4.9G), cooling connectors for air or liquid cooling
(Fig. 4.9H), heat sinks for passive cooling (Fig. 4.9I, optional), thermally conductive sheets
for heat sinks (Fig. 4.9J, optional) and installation CD (Fig. 4.9K) are shown.

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Fig. 4.9. Welding Camera system after the connections have been made.
WARNING!
•Ensure the locations of all operation and adjustment controls as well as other system
components are such that neither the operator nor anybody else can be accidentally
exposed to laser radiation. Pay special attention to the placement of camera unit,
temperature warning unit and computer.
•Ensure all system components are placed in such a way that the applicable mains plugs
are always easily removable from the electrical network.
A
B
D
C
G
F
E
H
K
J
I
CAUTION!
•Do not connect other than the provided power supply to temperature warning unit.
•Only connect the power supply to a wall socket with protective grounding.
•Power supply can be disconnected from the mains supply by removing the power
supply plug from the wall socket.