InterTest iShot Weld-i HD 625 User manual

Weld-iTM HD 625
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
Released 8-20-21

Weld-iTM HD 625 Instruction & Admin Manual
Page 2 of 47
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Table of Contents
Contact Information .............................................................................................................................. 5
Introduction: ......................................................................................................................................... 5
Detail................................................................................................................................................. 5
Cautions and warnings. ......................................................................................................................... 6
Safety Precautions ............................................................................................................................. 6
Operational, General Safety Considerations and Precautions ............................................................. 6
Cautionary Symbols and Symbol Terminology .................................................................................. 6
Warnings ........................................................................................................................................... 6
Disclaimers........................................................................................................................................ 7
Warranty ............................................................................................................................................... 7
Copyrights and Rights of Portrait .......................................................................................................... 8
Registered Trademark Information ........................................................................................................ 8
System Components .............................................................................................................................. 9
Standard ............................................................................................................................................. 9
Options .............................................................................................................................................. 9
Controls and connections .................................................................................................................... 10
Camera Controls ................................................................................................................................. 12
General Operation ............................................................................................................................... 14
Operation & Menu Top Level Camera Imager Control Unit ................................................................ 14
Menu Tree ....................................................................................................................................... 15
Image Quality .................................................................................................................................. 15
Capture Setup .................................................................................................................................. 16
Utility Menu .................................................................................................................................... 17
System Diagnostic ........................................................................................................................... 17
Load Presets .................................................................................................................................... 18
Lens Correction ............................................................................................................................... 18
Pan Tilt Zoom Menu........................................................................................................................ 19
Set to defaults .................................................................................................................................. 19
Weld-I Functions ................................................................................................................................ 19
Iris /Filter Control ............................................................................................................................ 19

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Weld-I 625HD ................................................................................................................................. 20
Focus ............................................................................................................................................... 20
Light Control ................................................................................................................................... 21
Light Source (Optional Lighting) ..................................................................................................... 21
Shutter Control ................................................................................................................................. 22
Shutter Table: ................................................................................................................................... 22
Arc ON/OFF .................................................................................................................................... 23
Preset ............................................................................................................................................... 23
Arc Set ............................................................................................................................................. 23
QNHD Serial Commands: ................................................................................................................... 24
Software Disclaimer ........................................................................................................................ 24
Communication Specifications: ....................................................................................................... 24
Communication Pin-Out .................................................................................................................. 25
QNHD Command List ........................................................................................................................ 25
Inquiries: .......................................................................................................................................... 29
Weld-iTM HD 625 RS232 Commands ............................................................................................. 31
Specifications ...................................................................................................................................... 31
Camera Head ................................................................................................................................... 31
Camera Cable .................................................................................................................................. 32
Camera Control Unit (CCU) ............................................................................................................ 32
Controller & Camera Mechanical Specifications .............................................................................. 33
Imager Control Menu Values & Defaults ......................................................................................... 34
Table of Figures .................................................................................................................................. 36
Care & Maintenance ........................................................................................................................... 36
Overall System ................................................................................................................................ 36
Trouble Shooting ................................................................................................................................ 36
Returns for Repair or Service ........................................................................................................... 37
Return Evaluation Procedure ........................................................................................................... 37
Dip Switch Settings ......................................................................................................................... 40
Main Menu ...................................................................................................................................... 40
Image Menu .................................................................................................................................... 41

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
More Image Quality......................................................................................................................... 41
Capture Menu .................................................................................................................................. 41
Utility Menu .................................................................................................................................... 42
Save Preset ...................................................................................................................................... 42
Load Preset ...................................................................................................................................... 42
Diagnostics ...................................................................................................................................... 43
PTZ Menu ....................................................................................................................................... 43
Reset to Defaults ............................................................................................................................. 44
Lens Correction ............................................................................................................................... 44
SCB300B Firmware Upload Procedure ............................................................................................ 44
SCB300B AEQ Procedure ............................................................................................................... 45
NOTES: .............................................................................................................................................. 46

Weld-iTM HD 625 Instruction & Admin Manual
Page 5 of 47
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Contact Information
To contact us, please refer to the information below:
Corporate Headquarters
InterTest, Inc.
303 Route 94
Columbia, NJ 07832 USA
Telephone (USA and Canada): 800-535-3626
Telephone (Outside the USA and Canada): 908-496-8008
Facsimile: 908-496-8004
Visit us on the Internet
www.intertest.com
General Information via Email
[e-mail]
InterTest © 2021 All rights reserved
Introduction:
The iShot® Weld-iTM HD 625 Weld Camera Monitoring System by iShot® Imaging combines a
specially housed, high definition color weld camera with air- or water-cooling capabilities to allow it
to withstand the punishing environments of automated welding. Features a 1/6 CMOS 2MP, HD
Camera / CCU capable of a video output of 1080/30P, 720/60P or VGA120. The CCU also has the
ability to be remotely controlled via the rear panel RS-232 connection
EM16595 iShot Weld-i 625 QNHD CCU
Weld-iTM 625 QNHD HS Camera
1. EM17427 iShot Weld-I 625 HD 7.1mm Camera Head with 18" PFA Cable Pigtail
2. EM17428 iShot Weld-I 625 HD 15mm Camera Head with 18" PFA Cable Pigtail
Detail
To view item details for the Weld-iTM 625, use the link provided below
Weld-i 625HD Website Link

Weld-iTM HD 625 Instruction & Admin Manual
Page 6 of 47
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Cautions and warnings.
Safety Precautions
This manual covers the Weld-iTM 625 equipment including, its functions, and use. It also covers
precautions to be taken to ensure safe operation. Please read this manual thoroughly before operating
the equipment. By doing so, you will become familiar with the equipment’s capabilities and better
understand its functions. Save manual for future reference.
Follow all warnings and instructions in the manual and marked on the equipment.
Operational, General Safety Considerations and Precautions
Always observe the guidelines and precautions that follow.
There are no user-serviceable parts inside the controller. Refer all service to the InterTest
Customer Service and Support Group.
IMPORTANT: To ensure operator safety, read and understand this manual before using
the system.
To avoid injury, read and understand the associated documentation of support
components prior to operation. Direct any questions about equipment operation to
InterTest Customer Service and Support Group at 908-496-8008 or via email to
[e-mail].
Cautionary Symbols and Symbol Terminology
Table A describes the various symbols that may be included in this manual and mounted on the
equipment. The severity level of a potential hazard varies. Refer to for hazard level descriptions.
Table A — Manual and Equipment Safety Symbols
Symbols
Definitions
WARNING/CAUTION: Risk of electric shock.
WARNING/CAUTION: Refer to instruction manual.
WARNING/CAUTION: Avoid exposure to water and liquids.
WARNING/CAUTION: Avoid eye and skin exposure to UVA Light.
Warnings
Stop operation immediately when any abnormality or defect occurs. Use during an abnormal
condition; such as emitting smoke, burning odors, after damage from dropping, invasion of foreign

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
objects, etc. may cause fire and/or electrical shock. Disconnect the power plug from the electrical
outlet at once and contact InterTest Inc.
Only use the specified power supply.
Do not use in proximity to energized electrical equipment
Do not connect or disconnect any cable while the unit is energized.
Some surfaces may be warm to the touch. Use caution when handling.
Disclaimers
InterTest Inc. disclaims any responsibility and shall be held harmless for any damages or
losses uncured by the user with the use of this product. Including the following:
1. Fire, earthquake or any other Act of God. Acts by third parties; misuse by the
user, whether intentional or accidental; use under conditions outside of noted
operating range.
2. Malfunction or non-function resulting in indirect, additional or consequential
damage including but not limited to loss of expected income and suspension of
business activities.
3. Use not in compliance with this manual’s instructions.
4. Malfunctions resulting from misconnection.
5. Unauthorized repairs or modifications.
6. Notwithstanding the foregoing, InterTest’s liabilities shall not exceed the purchase
price of the product.
Warranty
InterTest, Inc. guarantees products manufactured by InterTest, Inc. to be free from
defects in materials and workmanship for a period of one (1) year, from the date of
original purchase. All other products not manufactured by InterTest, Inc. will carry the
OEM’s limited warranty, which will be passed to the purchaser through and supported
by InterTest, Inc. InterTest, Inc.’s obligation under this limited warranty shall be
confined to the repair or exchange of any part, or parts thereof, that prove defective
under normal use and service for which the product was intended or designed.
This limited warranty covers products that upon our examination are deemed to be
defective.

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
This limited warranty is in lieu of all other warranties, express or implied, including the
warranties of merchantability and fitness for use. We neither assume, nor authorize any
other person to assume for us, any other liabilities in connection with the sale of
InterTest, Inc. equipment. This warranty does not apply to any equipment that has been
subject to accident, negligence, alteration, abuse, unauthorized repair, improper storage,
or other misuse.
This limited warranty applies only to the original purchaser and cannot be assigned or
transferred to any third party without express written consent from InterTest, Inc.
This limited warranty does not apply to consumable items, expendable items or normal
wear and tear, nor does it apply to failure due to radiation, overheating and / or below
freezing temperatures.
InterTest, Inc. assumes no responsibility, either expressed or implied, regarding the
improper usage of this equipment or interpretation of test data derived from the use of
this equipment. InterTest, Inc.’s responsibility and obligations, in all cases, are limited
strictly to the repair and/or replacement costs outlined above.
The laws of the State of New Jersey shall govern this warranty.
Note: In the event the equipment cannot be returned to InterTest, Inc. The customer
agrees to pay all travel and living expenses incurred to have an InterTest, Inc.
representative evaluate, assess or affect a warranty repair in the field.
Copyrights and Rights of Portrait
There may be a conflict with the Copyright Law and other laws when a customer uses,
displays, distributes or exhibits an image picked up by a television camera without
permission from the copyright holder. Please also note that transfer of an image or file
covered by copyright is restricted to use with the scope permitted by the Copyright Law.
Registered Trademark Information
InterTestTM is a registered trademark of InterTest, Inc.
iShotTM is a registered trademark of InterTest, Inc.
iShotTM ImagingTM is a trademark of InterTest, Inc.
IMPORTANT: If you are in possession of a printed or electronic version of
this document, be aware that it may not be the current revision. To ensure

Weld-iTM HD 625 Instruction & Admin Manual
Page 9 of 47
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
that you are using the most up-to-date revision of this document, contact the
InterTest Customer Service and Support Group or reference the downloads
portal under this product on www.intertest.com.
System Components
Standard
1. CCU Camera Control Unit,
2. Camera Weld-iTM 625 Welding Camera and flexible umbilical up to 15M
3. Lighting LED (Weld-iTM 625)
4. Power Supplies AC
5. DVI Cable Cable that carries display images to external
monitor
Options
1. RS232 Cable Cable connecting to the RS 232 comm port
2. Lens Filter(s) Spot filter(s) for camera

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Controls and connections
Figure 1 Control Unit Connections & Controls Front
Figure 2 Power Connections Rear CCU, ON/OFF & Remote Switch
Note: Main & Remote Switch
See light control Section
Main is used for standard system operation.
Remote is used for custom application only.

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Figure 3 ON/Off Controls Light Control
Figure 4 Labeled Front of Camera CCU.
Note: See Operation & Menu Top Level Camera Imager Control Unit Section for Menu Tree Structure

Weld-iTM HD 625 Instruction & Admin Manual
Page 12 of 47
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Camera Controls
Weld-I 625HD
Button Number Function Options Notes
1 Iris/Filter On / Off Up for On / Down for Off
2 Arc On/Off On / Off Push Up Arc On Push Down Off
3 Preset Up / Down Up for Preset 1 Down for Preset 2
4 Shutter +/-
Up increases up Shutter Speed / Down
Decreases
5 Arc Set Up/Down
Push up to set Arc On to current value. Down to
return to Factory Default
Figure 5 Front of Control Unit Weld-I 625HD Functions

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Figure 6 Weld-iTM 625 HD Connections
Figure 7 Connected System

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
General Operation
After power is applied to the control unit & turned ON, Right indicator LED will light
up on the front of the Camera CCU See Figure 2 & 3, wait 5 seconds, until the Main
Menu appears in the CCU Screen. Turn on the light source(s) as needed. White/UV
If faster response time is needed operate in 720p with Zoom On (crop mode) rather than
Off (scale mode). Scale mode still reads the whole sensor array thus running as if in
1080p.
Settings changes will be saved automatically on power down. Note, if any parameter is
changed a back step in menu is required for it to be saved on power down.
Change of settings is performed by moving through menu to desired function then
pressing the appropriate button for one step increments of value change or if the button
is held down rapid steps through multiple values will occur.
Operation & Menu Top Level Camera Imager Control Unit
Figure 8 HD CCU Menu Tree

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Menu Tree
Menu tree home.
Image Quality
Brightness: 0 to 255, Default: 128
Contrast: 0 to 63, Default: 16
Saturation: 0 to 63, Default: 31
Sharpness: 0 to 31, Default: 5
More continues to options on More Image Quality page.
Return to Main: returns to top of menu tree and saves settings.
White Balance: Auto or Set Set mode allows user to select fixed value.
WB Level: 0 to 255 Default: Auto

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
50 appears to be about neutral in fluorescent lighting.
Gamma: 0, 1, or 2 Default: 1
Hue: -180 to 180 Default: 0
Return to Img Qual: returns to previous page, Image Quality.
Capture Setup
Mirror: No, H, V, HV. Default: No
Frame Rate: Auto, 1 to 30 Hz in 1080 Default: Auto
1 to 60 Hz in 720
1 to 120 Hz in VGA
Exp ROI: Full, Middle, Center Exposure Region Of Interest. Area
analyzed to adjust Image
Exp ROI: Full, Middle, Center Exposure Region Of Interest. Area analyzed to
adjust Image
EXP Sec: Auto, 1, ½, 1/3, ¼, 1/5, 1/6, Default: Auto
Length of time image is exposed in seconds
1/7, 1/8, 1/9, 1/10, 1/15

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
1/20, 1/25, 1/30, 1/50,
1/60, 1/100, 1/120, 1/250
1/500, 1/1000, 1/5000,
1/10000, 1/20000, 1/30000
Utility Menu
LED: 0 to 10 Light intensity level
Show Diagnostics Displays system diagnostics status
Save Presets Allows current settings to be stored for later recall
Load presets Allows previously stored settings to be restored
Lens Correction For setting color correction of the lens installed
System Diagnostic
1080/30 (H1): Locked/Failed Camera type attached
1080/60 (H2): Locked/Failed Camera type attached
Note: Only one camera type will read as “Locked. The other will
indicate fail
UART Comms: Pass/Fail USB communication functioning
PCB Temp: xx-xx C typ Temp on PCB
I2C Error: 00xx

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Ev#.### Pv#.## firmware revision loaded in CCU.
Allows up to 4 sets of camera settings to be stored for later recall and use.
Load Presets
Allows recall and use of any of 4 previously store sets of camera settings.
Lens Correction
Allows setting lens installed and color temp for image correction.
LENS TYPE: A, B, C, D, E
Color Temp: 2800K, 4500K or 6500K

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Pan Tilt Zoom Menu
Resolution:
DVI output 1080p, 720p
In 1080p Pan, Tilt & Zoom Disabled
Zoom: On/Off Default: Disabled
Pan: +/- 320 in 720p Default: Disabled
+/- 640 in 480
Tilt: +/-180 in 720p Default: Disabled
+/- 300 in 480
Set to defaults
Confirm: changes settings to the factory default settings and returns to Main Menu.
Return to Main: Returns to top of Menu Tree (Main Menu), without changing settings.
Weld-I Functions
Iris /Filter Control
During weld conditions you will need to close the iris which restricts amount of light passing to the
camera sensor. To close the iris, push DOWN on the rocker switch labeled ‘Iris’. (Figure 9) Push
DOWN in increments to slowly close the iris until the best image is obtained.

Weld-iTM HD 625 Instruction & Admin Manual
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InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
[phone] • [e-mail] • www.intertest.com Released 8-20-21
Figure 9 Iris / Filter
Weld-I 625HD
When the Weld-I 625HD system is not in use under weld conditions (during weld setup) it is best to
disengage the filter to allow more light to pass to the camera sensor. To Close the filter, push UP on the
rocker switch labeled ‘Iris/Filter’. (Figure 10) To remove the filter, push down
Focus
Loosen the camera retention screw using a 0.035” Hex Key while holding the camera cable. This will
help prevent the camera from rotating. Changes in camera rotation may change the relative position of
the internal filters which may induce unwanted reflections. Adjust / rotate the internal camera as
needed.
To adjust the focus near/far. Turn the focus adjustment screw using a 5/64” hex key after loosening the
camera retention screw. Focus Far, counterclockwise, Focus Near clockwise. Tighten the camera
retention screw
Figure 10 Focus Adjustment