PTZ-275 Inspection System Operation & Service Manual - EM11721 To avoid injury, read and understand documentation for each system component prior to operation. Direct any questions about operation to InterTest at (908) 496-8008 or service@intertest.com
Table of Contents 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 Introduction 3 Customer Support 4 Warranty Information 5 Unpacking & Inspection 6 Assembly 7 Operation 9 Care & Maintenance 14 Safety 16 Service Records 17 2013 ishot and Intertest are registered trademarks of InterTest, Inc. - 2 -
1.0 Introduction Congratulations on your investment in the ishot PTZ-275 Camera System; InterTest Inc. s pan, tilt and zoom visual inspection system for the world s most challenging remote vision applications. All ishot systems combine high resolution RVI instrumentation with precision inspection camera positioning mechanisms to cover a wide range of visual inspection needs. An operator can conduct high quality inspections at long distances with the PTZ-275 Camera System. InterTest Inc. s engineers designed it with functionality, ruggedness and ease-of-use in mind. The camera is designed and built to fit in small openings (as small as 3 inches in diameter) and inspect large, low-lit vessels and containers. Many features enhance the ishot PTZ-275 Camera System s performance and versatility. These include: Camera Control from a Singular Camera Control Unit All camera movement controls and camera functions are controlled from the PTZ-400 Camera Control Unit. Camera Movement options include Pan, Tilt and Pan/Tilt speed control. Camera Controls Options include Auto Focus, Auto Shutter, Iris, Gain, Zoom and Focus control. Illumination Control To attain a thorough remote visual examination of container internals, the PTZ-275 Camera System was designed with illumination intensity control capability. Spot and Flood lighting is remotely controlled in conjunction with the camera s shutter, exposure and gain control to ensure a properly illuminated image. High-Quality, Robust Video Camera The PTZ-275 Camera System uses a Sony FCB-IX11A block camera that delivers crisp, high-resolution video images. Using a high-quality1/4" CCD image sensor and a 10x optical zoom lens (and 4x digital zoom), the FCB-IX11A delivers color video at a resolution 470 horizontal TV lines (NTSC). This camera module is housed in a durable, anodized aluminum housing that can withstand many hazardous environments. Movement Control with Generous Movement Envelope With Pan and Tilt motor control, the PTZ-275 Camera head can rotate continuously 360 degrees and tilt a total of 270 degrees. The total operating envelop from a fixed mount is a 3.00 inch diameter and 12.00 cylinder. - 3 -
2.0 Customer Support Service and support for all InterTest products is available by calling (908) 496-8008. We welcome comments, suggestions and technical inquiries by fax at (908) 496-8004 or email: service@intertest.com. Refer to page 5 for InterTest s one-year limited warranty on parts and materials. Be sure to 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 our Customer Service team at: InterTest, Inc. 303 Route 94 Columbia, NJ 07832 Office: 908-496-8008 Toll free in USA - 800-535- 3626 Fax: 908-496-8004 service@intertest.com - 4 -
3.0 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 original 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. 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 -
4.0 Unpacking & Inspection Before setting up the PTZ-400, verify that all components are present and that none has suffered physical damage in transit. Remove all tape and packing material from the components. Next, carefully inspect each piece for damage and/or missing parts. Inspect all control panel knobs and switches for proper operation. If any portion of the system has suffered damage during shipment, please notify InterTest at once. Retain all packing material for use in the event that the system or system components need to be shipped in the future. The Shipment Contains: C B D A E F A. PTZ-275 Camera Control Unit B. 100 PTZ-275 Camera Cable (cable shown on reel) C. Impulse Connector H D. PTZ-275 Motor Assembly G E. PTZ-275 Camera Assembly F. PTZ-275 Lamps G. PTZ-275 Camera Cable Reel H. PTZ-275 Carrying Case FIGURE 1(Not To Scale) - 7 -
5.0 Assembly 5.1 Equipment Placement When not in use, ensure the PTZ-275 Camera system remains in its carrying case for protection. When in use, the control unit should be within easy reach for an operator and within sight of the monitor. Both control box and monitor should be placed on a clear, flat surface. Mind the power and video cables as well as the 100 foot control cable. Keep the cables clear of walk ways and avoid potential pinch points at all times. 5.2 PTZ-275 Camera System Setup **Refer to Figure 2 & 3, page 8 and Figure 1, page 6 ** 1) Turn the Main Power Switch (A) to OFF on the front of the control unit. 2) Connect the power cable to A/C Power Inlet (L) on the back of the control unit. Plug the other end of the power cable to an electrical socket. 3) Connect the PTZ-275 Camera Cable s large Mil Spec, bayonet-style connector to the Camera port (M) on the back of the control unit. The PTZ-275 Camera Cable s Mil Spec connector is keyed and must be lined up properly to connect. Once in line, turn the bayonet locking ring ¼ turn clockwise to ensure the proper connection. 4) Connect the PTZ-275 Camera Cable s Impulse connector to the base of the PTZ-275 Camera Head. The Impulse connector (C) is keyed and must be lined up properly to attach. Once in line, thread the locking ring clockwise until snug to ensure the proper connection. 5) Connect the composite video cable to the BNC Composite Video port (N) on the back of the control unit. 6) Connect the Y/C video cable to the S-Video port (O) on the back of the control unit. 7) Connect the opposite ends of the BNC Composite and S-Video cables to the proper monitor inputs. 8) Turn the Main Power Switch (A) to ON and turn the monitor ON. Wait 15 seconds for the PTZ- 275 head to initialize and to produce a picture on the monitor before use. The pan, tilt, zoom, and other camera controls will now operate the PTZ-275 Camera System. - 7 -
5.0 Assembly A B FIGURE 2 C D G H E I J F K A. Main Power ON/OFF B. Menu and Frame Freeze C. Shutter Speed Control D. Auto Focus/Exposure Set E. Pan & Tilt Speed Control F. Pan & Tilt Control G. Gain Control H. Iris Control I. Main/Spot Lamp Intensity J. Aux/Flood Lamp Intensity K. Zoom and Focus Control FIGURE 2 N K L M O P L. AC Power Inlet and Fuse M. Camera Control Cable Connector N. Composite Video Connector O. S-Video Connector P. RS-232 Port FIGURE 3-8 -
6.0 Operation 6.1 Pan & Tilt Functions The pan and tilt function of the PTZ-275 Camera head can be controlled using the 4-way toggle switch (Figure 4.1), on the front panel of the Control Box. UP tilts the camera head up to +95 degrees from origin (Figure 4.1), DOWN tilts the camera head down to -15 degrees from origin (Figure 4.1). RIGHT pans the entire motor and camera head assembly continuously 360 degrees to the right. LEFT pans continuously to the left (Figure 4.1). The speed of these functions can be adjusted using the Speed control knob (E). Turn the knob clockwise to increase the pan & tilt speed. Turn the knob counter-clockwise to decrease the speed (Figure 4.2) NOTE: The 4-way Pan & Tilt switch (F) can be continuously held down to operate the positioning of the camera head. When the head hits its limit on tilting in the UP or DOWN direction, there is a slip clutch to prevent any motor damage. 1 2 FIGURE 4-9 -
6.0 Operation 6.2 Zoom & Focus Control The Zoom function of the PTZ-275 Camera head can be controlled using the 4-way toggle switch (K) on the front panel of the Control Box. UP zooms in on picture, DOWN zooms out on picture (Figure 5.1). To manually adjust the focus, use the 4-way toggle switch (Figure 5.1). RIGHT focuses near and LEFT focuses far. To return the camera to Auto Focus, push UP on the Auto Focus/Auto Exposure rocker switch (Figure 5.2). 1 2 FIGURE 5 6.3 Automatic Exposure Control It is recommended that the PTZ-275 Camera System be operated in Auto Exposure mode. This can be toggled by pressing DOWN on the Auto Focus/Auto Exposure rocker switch (D) (Figure 6). This mode takes control of the camera s shutter, iris, and gain to deliver the best possible image to the display based upon current operating conditions. NOTE: The camera will leave Auto Exposure mode when any of the Shutter, Iris, or Gain switches (C, H, and G) are manually adjusted. - 10 -
6.0 Operation FIGURE 6 6.4 Lamp Intensity Control The PTZ-275 head uses 4 x 6-watt argon lamps, 2 spot and 2 flood lamps, which are installed in the front face of the camera assembly. To adjust the intensity of the 2 spot lamps, turn the Main Lamp Intensity knob (Figure 7/Figure 2, I) clockwise to brighten, and turn counter-clockwise to dim. To adjust the intensity of the 2 flood lamps, turn the Aux. Lamp Intensity knob (Figure 7/ Figure 2, J) clockwise to brighten, and turn counterclockwise to dim. FIGURE 7-11 -
6.0 Operation 6.5 Camera Iris Control The iris is a physical opening within the lens that controls how much light reaches the camera sensor. In some conditions it may be beneficial to manually adjust the iris on the PTZ-275 Camera System. To open the iris, press UP on the Iris Control rocker switch (Figure 8), to close the iris press DOWN. NOTE: The camera will leave Auto Exposure mode when any of the Iris, Shutter, or Gain switches (C, H, and G) are manually adjusted. Incremental pushes are required to operate this switch. Holding down the switch will NOT continuously make adjustments. 6.6 Camera Shutter Control FIGURE 8 The shutter speed electronically controls exposure time and frame rate of the camera. A slow shutter speed provides a brighter image with a slower refresh rate. A fast shutter speed provides a dimmer image with a faster refresh rate. To increase the shutter speed, press UP on the Shutter Control rocker switch (Figure 9) and to decrease the shutter speed, press DOWN. NOTE: The camera will leave Auto Exposure mode when any of the Iris, Shutter, or Gain switches (C, H, and G) are manually adjusted. Incremental pushes are required to operate this switch. Holding down the switch will NOT continuously make adjustments. - 12 -
6.0 Operation FIGURE 9 6.7 Camera Gain Control The gain electronically controls the brightness of the image. Increased gain provides a brighter picture with a more noise or graininess of the image. Decreased gain provides a dimmer picture with less noise or graininess of the image. Some application conditions might require the camera to operate with more or less gain. To increase the gain, press UP on the Gain Control rocker switch (G) and to decrease the gain, press DOWN. NOTE: The camera will leave Auto Exposure mode when any of the Iris, Shutter, or Gain switches (C, H, and G) are manually adjusted. Incremental pushes are required to operate this switch. Holding down the switch will NOT continuously make adjustments. FIGURE 10-13 -
7.0 Care & Maintenance 7.1 Overall System When not in use, store system in carrying case. Do not force any connector on cables into sockets on the control unit. All connectors are keyed and must be lined up properly to connect. Always replace blown fuses with fuses provided by InterTest Inc. (EM63087) The control unit uses a 2 amp Slow Blow Fuse. Refer to section 7.2. Never bypass the grounding circuits of system components. Bundle all excess cordage to prevent snagging To ensure long life of the PTZ-275 Camera System, keep system clean and free of corrosive materials. With the exception of lamp, fuse replacements, and camera module refer all service to InterTest technicians. 7.2 AC Fuse Replacements 1) Turn the power to the system to OFF using the rocker switch (Figure 2, A) on the front panel of the Control Box. 2) Unplug the cable from the main power outlet and from the back panel (Figure 3, L). 3) Push down on the fuse holder located on the bottom of the plug receptacle on the rear of the Control Box (Figure 3, L). 4) Remove the fuse holder and the defective fuse. 5) Replace the fuse with a new 2 amp Slow Blow fuse (EM63087). 6) Push the fuse holder back into place. 7) Plug the power cable into the receptacle and into the main power. 8) Power the system back to ON and resume inspection (Figure 2, A). - 14 -
7.0 Care & Maintenance 7.3 6-Watt Argon Lamp Replacement 1) Verify the camera is completely dry and the power is OFF (Figure 2, A) and unplugged (Figure 3, L). 2) Unscrew the front face of the camera assembly (Figure 1, E) by removing the 4 Phillips head screws. Remove the front face. 3) Remove the lamps from the socket by pulling it directly outward with provided tweezers 4) Replace the lamp with a new one purchased through InterTest Inc. (EM10939 for all 4 lamps). 5) CAUTION: Be sure there is no dirt of finger prints on the reflectors or lamps, as it may cause smoking and overheating of the lamps. 6) Replace the front plate of the camera assembly (Figure 1, E) and tighten the 3 Phillips head screws. - 15 -
8.0 Safety Use in Radiated Environment If putting the PTZ-275 into a radiation environment, take all necessary and lawful precautions to care and store the hot unit after removal. Intertest Inc. s Warranty (page 5) is void if the PTZ-275 is used in a radiated environment. The unit cannot be sent to Intertest Inc. s facility for repair. Moving Components The PTZ-400 Camera Inspection System contains moving parts. Keep clear of all moving components to prevent injury. Hot Surfaces The 35-watt lamp becomes very hot after prolonged use. Do not handle the lamp enclosures or attempt to replace lamps after prolonged use. - 16 -
9.0 Service Records Product: EM Number: PTZ-275 Camera System EM11721 Serial Number: Date of Purchase: Date Service Performed / / / / / / / / / / - 17 -