Operation & Service Manual
Contents
1. IShot Wiele Wi ZOOM HD WELD MONITORING CAMERA SYSTEM Operation amp Service Manual Welai SeN HD gt LED AUTO EXP INTENSITY up MENU FOCUS IRIS ZOOM Melclzi DOWN EXIT GAIN SHUTTER FOCUS k SISMI HDO www intertest com e 303 Route 94 e Columbia NJ 07832 e 908 496 8008 Table of Contents Introduction Customer Support Warranty Information System Overview Assembly Connection Diagram Spatter Shield Setup Optional Filter Setup Camera Head Control Unit Setup Operation Manual Camera Settings Menu Settings Changing Menu Settings Care amp Maintenance To avoid injury read and understand documentation prior to operation Direct any questions about operation to InterTest at 908 496 8008 or service intertest com 11 13 15 16 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 that2. Zoom HD Spatter Shield Kit G EM16410 Weld i Zoom HD Magnifying Kit H EM68282 25 Weld i Zoom HD Power Cable Optional Not EM19372 25 Weld i Zoom HD LED Illumination Kit Pictured 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 Assembly ccu CONTROLS LED AUTO EXP INTENSITY UP MENU FOCUS IRIS ZOOM CAMERA HEAD not FS88858 DOWN EXIT GAIN SHUTTER FOCUS LED Brackets RS 232 Optional e 12V DC IN LED OUT optional BUE NL ON OFF 12V Power 12V Power Power Strip SOL u Power Outlet EM19104 Weld i Zoom HD Camera Head 3G SDI 2 EM19107 Weld i amp Zoom HD Camera Control Unit e EM68278 25 foot 3G SDI Video Cable Component in Cable Kit EM19183 o EM68276 25 foot Communication Cable with RS232 Connection Component in Cable Kit EM19183 5 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 O EM68286 25 foot Power Cable Camera to Power Adapter Component in Cable Kit EM19183 Q EM10065 Power Adapter Connecting Camera Power Cable to Power Strip 8 EM10065 Power Adapter Connecting CCU to Power S
3. 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 Customer Support Service and support for all InterTest Inc and iShot Imaging products is available by calling 908 496 8008 We also welcome comments suggestions and technical inquiries by fax at 908 496 8004 or E mail at mail intertest com 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 service intertest com or 908 496 8008 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 ou
4. ess 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 11 Operation 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 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 intensi
5. 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 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 gt 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 2OFF 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 amp Maintenance 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 came
6. ra 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
7. ssembly 5 10 11 12 13 14 Plug Communication Cable into rear of Camera Head Connection 4 Plug Communication Cable to RS 232 connector on rear of Camera Control Unit Connection 4 Plug 3G SDI Cable into rear of Camera Head Connection 3 Plug 3G SDI Cable into Monitor with 3G SDI input Connection 3 Monitor not included Plug Power Cable into rear of Camera Head Connection 6 Plug Power Cable into Power Adapter Connection 6 to 7 Plug Power Adapter into Power Strip Connection 7 Power Strip not included Power on Monitor and video will appear Turn ON Power Switch on rear of Camera Control Unit Wait 10 seconds or until VERSION 1 1 disappears from the top left of the picture before using Camera Control Unit 10 Operation 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 C D WE LED AUTO EXP INTENSITY UP FOCUS IRIS ZOOM ike powwN GAIN SHUTTER FOCUS Zoom HD Figure 7 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 1 or Focus J will cause the camera to leave Auto Exposure Focus mode Gain Control To manually adjust Gain pr
8. trip Power Strip Illumination Kit and Monitor Sold Separately 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 Figure 2 Figure 3 Figure 4 Figure 5 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 Assembly Optional Optical Filter Setup Figure 6 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 V4 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 A
9. tside of the box of the returned items Warranty Warranty Statement InterTest Inc guarantees the custom 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 Any andeall 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
10. ty 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 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
11. 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 System Overview LIST OF COMPONENTS FOR STANDARD WELD I ZOOM HD SYSTEM EM19191 FIGURE 1 Component Part Description A and A 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 A F G E EM68278 25 Weld i Zoom HD 3G SDI Video Cable F EM19182 Weld i
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