WELD-I EM19191 Installation and operating instructions

www.intertest.com • 303 Route 94 • Columbia, NJ 07832 • 908.496.8008
®
Operation & Service Manual
®
EM19191

Table of Contents
Introduction 3
Customer Support 4
Warranty Information 5
System Overview 6
Assembly
Connection Diagram 7
Spatter Shield Setup 8
Optional Filter Setup 9
Camera Head/Control Unit Setup 9
Operation
Manual Camera Settings 11
Menu Settings 13
Changing Menu Settings 15
Care & Maintenance 16
To avoid injury, read and
understand documentation
prior to operation. Direct
any questions about operation
to InterTest®at [phone]
or [e-mail]
2

Introduction
Congratulations on your investment in our Weld-i®Zoom HD
camera system! We are pleased that you selected the Weld-i®Zoom
HD from iShot Imaging for your in-process weld monitoring needs.
The Weld-i®Zoom HD represents one of the finest high-definition weld
monitoring systems in the world for manual and automated weld
quality control.
Many additional features of the Weld-i®Zoom HD will enhance your
“in-process” inspection. Call your InterTest®Sales Representative for
more information at 908-496-8008.
High Definition with Zooming Capability
The Weld-i®Zoom HD camera system uses the state of the
art zoom camera that boasts Full HD picture at 1080/60p
(1920 x 1080) and has a 10x Zoom capability.
Special Spot Filtering and Wide Dynamic Range
The Weld-i®Zoom HD camera system uses advanced
camera technology along with a special spot filtered lens in
order to adapt to the bright white and UV light produced by
various weld types and conditions.
Intuitive Control Box
The intuitive control box allows the user to adjust the
Weld-i®Zoom HD camera head during use. Placed at the
operator’s fingertips, all controls are safely away from the
harmful environments.
3

Customer Support
Service and support for all InterTest Inc. and iShot Imaging products
is available by calling [phone]. We also welcome comments,
suggestions and technical inquiries by fax at [phone] or E-
mail at [email protected].
Page 5 explains InterTest’s one-year limited warranty on parts and
materials. Read all warranty information; register your product on-line
at www.intertest.com and save this manual for future reference.
If your system requires service, please contact Customer Service at
[e-mail] or [phone]. In order to return a product
for service you must have an RMA (Return Merchandise Authorization)
number. To obtain one, please contact the Customer
Service Team at the number above. Have the product name and serial
numbers ready for the Customer Service Representative. RMA
numbers must appear on related paperwork and be clearly marked on
the outside of the box of the returned items.
4

Warranty
Warranty Statement
InterTest®, Inc. guarantees the custom products manufacture
®
d 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. Any and®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 and/or designed for.
This limited warranty covers conditions that upon our examination, at our
facility, shall disclose, to our satisfaction, to be defective.
This limited warranty is in lieu of all other warranties, express or implied,
including the warranties of merchantability and fitness for use and of all other
obligations or liabilities on our part, and 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 shall 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.
Additionally, InterTest®, Inc. assumes no responsibility, either expressed or
implied, regarding the improper usage of this equipment or interpretation of test
data derived from this product. InterTest, Inc.’s responsibility and obligations, in
all cases, are limited strictly to the repair and/or replacement costs outlined
above. All sales will be considered final and all orders are non-cancellable, non-
returnable and non-refundable.
The laws of the State of New Jersey shall govern this warranty.
Note: In the event that the equipment cannot be returned to InterTest, Inc., for
whatever reason, the customer agrees to pay for all travel and living expenses
incurred to have an InterTest, Inc. Representative evaluate, assess or affect a
warranty repair in the field.
5

System Overview
LIST OF COMPONENTS FOR STANDARD WELD-I ZOOM HD SYSTEM - EM19191
FIGURE 1
Component Part#
Description
A1and A2
EM10065
Power Supply
B
EM19107
Weld-i®Zoom HD Camera Control Unit
C
EM68276
25’ D-SUB 9-pin RS-232 Communication Cable
D
EM19104
Weld-i®Zoom HD Camera Head (includes A2, F, G)
E
EM68278
25’ Weld-i®Zoom HD 3G-SDI Video Cable
F
EM19182
Weld-i®Zoom HD Spatter Shield Kit
G
EM16410
Weld-i®Zoom HD Magnifying Kit
H
EM68282
25’ Weld-i®Zoom HD Power Cable
Optional/Not
Pictured
EM19372
25’Weld-i®Zoom HD LED Illumination Kit
EM16414
#10 Full Field Weld Glass Filter
EM16413
#8 Full Field Weld Glass Filter
EM16400
0.5 ND Filter
EM16402
1.0 ND Filter
EM16403
1.5 ND Filter
EM16404
Polarizing Filter
EM15915
0.04 –2.0 ND Gradient Filter
EM15914
UV Cut Band Pass Filter
A1
B
D
C
A2
G
F
E
H
6

Assembly
EM19104 - Weld-i® Zoom HDCamera Head / 3G-SDI
EM19107-Weld-i®ZoomHDCameraControlUnit
EM68278 - 25 foot 3G-SDI Video Cable (Component in Cable Kit EM19183)
Power Outlet
EM68276 - 25 foot Communication Cable with RS232 Connection (Component in Cable Kit EM19183)
EM19372 - (Optional) Illumination Kit - Includes 25 foot LED Power and Intensity Control Cable, 2
Pre-wired LED lights with connector, 2 LED brackets, 4 screws, 25 foot LED Cable, and Allen Key
EM68286 - 25 foot Power Cable, Camera to Power Adapter (Component in Cable Kit EM19183)
EM10065 - Power Adapter, Connecting Camera Power Cable to Power Strip
EM10065 - Power Adapter, Connecting CCU to Power Strip
*Power Strip, Illumination Kit, and Monitor Sold Separately
2 CCU CONTROLS
LED AUTO EXP/
INTENSITY UP MENU FOCUS IRIS ZOOM
1
CAMERA HEAD
Front
DOWN EXIT GAIN SHUTTER FOCUS
LED
Brackets*
(Optional)
RS-232
12V/DC IN
LED OUT
(optional)
Back
ON/OFF
FUSE
RS232
LED (Optional)*
3G-SDI
3
4
5
6
12V Power
12V Power
7
8
Power Strip*
Monitor*
1
2
3
4
5
6
7
8
7

Assembly
Spatter Shield Setup:
NOTE: Although the Weld-I Zoom HD camera head is generally
mounted away from the welding target, it is recommended to use a
spatter shield in front of the zoom lens.
Follow Spatter Shield Setup steps before completing Camera
Head/Control Unit Setup.
1. Drop/Place spatter shield in front of camera lens (Figure 2).
2. With fingers, begin threading on the retaining ring (Figure 3).
3. Once started, finish threading on the retaining ring with the
retaining ring tool (Figure 4). DO NOT OVERTIGHTEN THE
RETAINING RING. This may cause damage to the spatter shield.
4. If further magnification is required, thread on the applicable close
up lens by hand (Figure)
Figure 2
Figure 4
Figure 3
Figure 5
8

Assembly
Optional Optical Filter Setup:
1. Drop/Place applicable optional optical filter in front of camera lens
(Figure 6).
2. Follow Spatter Shield Setup steps on page 8.
Camera Head/Control Unit Setup:
Refer to page 7 connection diagram.
1. Position the Camera Head where needed. Mounting puck is a
¼-20 thread.
2. Position the Camera Control Unit within the distance of
cabling. Be sure camera control box Main Power is OFF.
3. Connect Power Adapter to 12V/DC connector on rear of
camera control box (Connection 8).
4. Plug Power Adapter into Power Strip* (Connection 8) (*Power
Strip not included).
Figure 6
9

Assembly
5. Plug Communication Cable into rear of Camera Head
(Connection 4).
6. Plug Communication Cable to RS-232 connector on rear of
Camera Control Unit (Connection 4).
7. Plug 3G-SDI Cable into rear of Camera Head (Connection 3).
8. Plug 3G-SDI Cable into Monitor* with 3G-SDI input
(Connection 3) (*Monitor not included).
9. Plug Power Cable into rear of Camera Head (Connection 6).
10. Plug Power Cable into Power Adapter (Connection 6 to 7).
11. Plug Power Adapter into Power Strip* (Connection 7) (*Power
Strip not included).
12. Power on Monitor and video will appear.
13. Turn ON Power Switch on rear of Camera Control Unit.
14. Wait 10 seconds or until “VERSION 1.1” disappears from the
top left of the picture before using Camera Control Unit.
10

Operation
OPT
Camera Control Unit Operation:
BEFORE USING CAMERA CONTROL UNIT: Be sure to follow the Camera
Head/Control Unit Setup steps on page 9. The Camera Head must be
powered on BEFORE the Camera Control Unit to function.
SWITCHES FOR MANUAL CAMERA SETTINGS
For all switch settings, refer to Figure 7
Auto Exposure/Auto Focus:
Press up once on (C) to enter Auto Exposure and Auto Focus
mode. Using Gain (H), Iris (D), Shutter (I), or Focus (J) will
cause the camera to leave Auto Exposure/Focus mode.
Gain Control:
To manually adjust Gain, press down once on GAIN (H) rocker
switch. Then incrementally press UP (A) or DOWN (F) to adjust
gain.
UP (A) increases gain, DOWN (F) decreases gain.
*
E
D
C
B
A
Figure 7
F G H JI
11

Operation
OPT
Iris Control:
To manually adjust Iris, press up once on IRIS (D) rocker
switch. Then incrementally press UP (A) or DOWN (F) rocker
switch to adjust iris.
UP (A) opens the iris, DOWN (F) closes the iris.
Shutter Speed Control:
To manually adjust Shutter Speed, press down once on
SHUTTER (I) rocker switch. Then incrementally press UP (A) or
DOWN (F) rocker switch to adjust the shutter speed.
UP (A) increases shutter speed, DOWN (F) decreases shutter
speed.
Zoom Control:
To adjust the camera zoom, press up once on ZOOM (E) rocker
switch. Then continually press UP (A) or DOWN (F) rocker switch
to adjust camera zoom.
UP (A) zooms in, DOWN (F) zooms out.
Focus Control:
To manually adjust the picture focus, press down once on FOCUS
(J) rocker switch. Then continually press UP (A) or DOWN (F)
rocker switch to adjust picture focus.
UP (A) focuses far or beyond the subject, DOWN (F) focuses
near or in front of the subject.
12

Operation
OPT
Optional LED Control:
IF EM19372 Illumination kit is purchased, LED Intensity is
adjusted using the control knob (*) on the front panel of the
Control Box labeled ‘LED Intensity’.
Twisting the knob to the clockwise will increase intensity while
twisting the knob to the counter-clockwise will decrease the
intensity. Turn LEFT until the knob clicks to turn lights off.
NOTE: All of the previous camera adjustment settings will work
independently with each other. If any of the following Menu
settings are adjusted, the manual settings will be restored to
default.
MENU SETTINGS
To access the MENU, press up on the MENU (B) rocker switch up (Figure
7).
INITIAL MENU SETTINGS (appears in upper left corner of
picture)
DEFOG OFF
WIDE DYNAMIC OFF
INFRARED OFF
AUTO SLOW SHUT OFF
BACKLIGHT OFF
STABILIZE N/A
PICTURE FLIP OFF
MIRROR OFF
13

Operation
OPT
MENU SETTING DESCRIPTIONS
DEFOG –Defog mode is a camera function for when the
surrounding area of the subject in the image is foggy and has low
contrast. This mode will automatically make the subject appear
clearer.
WIDE DYNAMIC –Wide Dynamic Range mode is a camera function
that divides the image into several blocks and corrects the blocked-
up shadows and blown-out highlights. This is very useful for
viewing welding applications. It makes the high and low light
intensities more homogenous in the image.
INFRARED –Infrared mode turns the image black and white.
AUTO SLOW SHUT –Auto Slow Shutter mode automatically makes
the shutter speed slow if the image has low light.
BACKLIGHT –Backlight mode is a function that makes the subject
appear clearer if the background is too bright.
PICTURE FLIP –A picture-altering mode that flips the image over
the X-axis.
MIRROR –A picture-altering mode that flips the image over the Y-
axis.
Recommendation: For most welding applications, keep the
Wide Dynamic Range ON (listed as “WIDE DYNAMIC” in the
Menu settings). This generally will provide the best quality
picture.
14

Operation
OPT
CHANGING MENU SETTINGS
Refer to Figure 7 for changing menu settings
1. Use the UP (A) and DOWN (F) rocker switch to cycle the Menu
settings.
2. The setting that is highlighted will blink repeatedly.
3. To change setting from OFFON or ONOFF, press up on the
MENU (B) rocker switch.
4. Once a change is made, the Menu will exit automatically.
5. To leave the Menu without making changings, press down on the
EXIT (G) switch.
6. To initialize the camera settings, power down the Camera Control
Unit and Camera Head. Power on Camera Head then Camera
Control Unit in that order.
NOTES:
The following Menu settings turns off GAIN, IRIS, or SHUTTER
settings:
-Wide Dynamic Range
-Auto Slow Shutter
-Backlight
The following Menu setting will not work with each other
simultaneously. Each will override the current setting from
ON  OFF:
-Wide Dynamic Range
-Auto Slow Shutter
-Backlight
(Example: If Wide Dynamic Range is ON, and Auto Slow Shutter is
turned ON, Wide Dynamic Range will turn OFF)
15

Care & Maintenance
OPT
General Care:
To ensure a long life for your Weld-i®Zoom HD, it is important to
keep it clean and free of corrosive materials. Wipe down the
camera head and cable regularly, keep all connectors free of debris
and dust, use a spatter shield in front of the lens, and always follow
the instructions as described in this manual.
AC Fuse Replacement:
1) Turn the power to the system ‘Off’ using the rocker switch on the
rear panel of the Camera Control Unit.
2) Unplug the cable from main power and from the rear panel.
3) Turn the Fuse Holder counter clockwise until fuse holder is free.
4) Remove the fuse holder and remove the defective fuse.
5) Replace the fuse with a new 1 amp Slow Blow fuse.
6) Turn the Fuse Holder clockwise until tightened.
7) Plug the power cable into power strip and into the Camera
Control Unit
8) Power the system ’On’.
16