PTZ-550 Inspection System Operation & Service Manual - EM15669

PTZ-550 Inspection System Operation & Service Manual - EM15669
®
PTZ-550 Inspection
System
Operation & Service Manual - EM15669
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 [email protected]
®
®
Table of Contents
1.0
Introduction
3
2.0
Customer Support
4
3.0
Warranty Information
5
4.0
Unpacking & Inspection
6
5.0
Assembly
8
6.0
Operation
9
7.0
Care & Maintenance
14
8.0
Safety
16
9.0
Service Records
17
Replacing Camera Module*
18
*4-page appendix
©2013 iShot and Intertest are registered trademarks of InterTest, Inc.
Product specifications are subject to change without notice.
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1.0 Introduction
Congratulations for your investment in the iShot® PTZ-550 Camera System; InterTest’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-550
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
5.50 inches in diameter) and inspect large, low-lit vessels and containers.
Many features enhance the iShot® PTZ-550 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-550
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-550 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-550 Camera System uses a Sony FCB-EX1020 camera that delivers crisp,
high-resolution video images. Using a high-quality 1/4" CCD image sensor and a 36x
optical zoom lens (and 12x digital zoom), the FCB-EX1020 delivers color video at a
resolution 550 horizontal TV lines (NTSC). This camera module is housed in a durable,
anodized aluminum housing that can withstand many hazardous environments. The
camera head uses an IP-67 rated connector which allows submersion in water up 100’.
Movement Control with Generous Movement Envelope
With Pan and Tilt motor control, the PTZ-550 Camera head can rotate continuously 360
degrees and tilt a total of 245 degrees. The total operating envelop from a fixed mount is a
7.25 inch diameter sphere.
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REV 1 V-1, 10.24.13
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: [email protected]
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
[email protected]
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REV 1 V-1, 10.24.13
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, or use outside the
specified range of environmental operating conditions.
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.
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REV 1 V-1, 10.24.13
4.0 Unpacking & Inspection
Before setting up the PTZ-550, 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:
E
B
D
C
A
A. 100’ PTZ-550 Camera Cable
F
(cable shown on reel)
B. Impulse Connector
C. PTZ-550 Motor Assembly
H
D. PTZ-550 Camera Assembly
E. Flood and Spot Lamps
G
F. PTZ-550 Camera Control Unit
G. PTZ-550 Camera Cable Reel
H. PTZ-550 Carrying Case
FIGURE 1
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REV 1 V-1, 10.24.13
5.0 Assembly
5.1
Equipment Placement
When not in use, ensure the PTZ-550 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-550 Camera System Setup
**Refer to the back and front Control Panel Layout in the 6.0 Operation Section (Figure 2 & 3 page 8) **
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-550 Camera Cable’s large Mil Spec, bayonet-style connector to the Camera port
(M) on the back of the control unit. The PTZ-550 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-550 Camera Cable’s Impulse connector to the base of the PTZ-550 Camera
Head. The Impulse connector 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 PTZ550 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-550 Camera System.
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6.0 Operation
C
D
E
F
I
A
B
G
H
J
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. Flood Lamp Intensity
J. Spot Lamp Intensity
K. Zoom and Focus Control
FIGURE 2
N
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
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6.0 Operation
6.1
Pan & Tilt Functions
The pan and tilt function of the PTZ-550 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 +195 degrees from origin (Figure 4.3), DOWN tilts the camera head down to -50
degrees from origin (Figure 4.3).
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)
1
3
2
FIGURE 4
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6.0 Operation
6.2
Zoom & Focus Control
The Zoom function of the PTZ-550 Camera head can be controlled using the 4-way toggle
switch (J) 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-550 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.
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REV 1 V-1, 10.24.13
6.0 Operation
FIGURE 6
6.4
Lamp Intensity Control
The PTZ-550 head uses 2 35-watt halogen lamp modules, one spot and one flood, which
are installed on the top of the camera head. To adjust the intensity of the Flood Lamp, turn
the Main Lamp Intensity knob (Figure 7) clockwise to brighten, and turn counterclockwise to dim.
To adjust the intensity of the Spot Lamp, turn the Aux. Lamp Intensity knob (Figure 7)
clockwise to brighten, and turn counter-clockwise to dim.
FIGURE 7
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REV 1 V-1, 10.24.13
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-550 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.
FIGURE 8
6.6
Camera Shutter Control
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.
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REV 1 V-1, 10.24.13
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
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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. (EM62685) The control unit
uses a 4 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-550 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 Slow Blow fuse.
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).
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REV 1 V-1, 10.24.13
7.0 Care & Maintenance
7.3
35-Watt Halogen 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 lamp cap and remove the front piece (Figure 1, E).
3) Remove the lamp from the socket by pulling it directly outward.
4) Replace the lamp with a new one purchased through InterTest Inc. (EM142540 for the Flood
Lamp, EM63004 for the Spot Lamp)
5) Inspect the O-ring for damage. Replace the O-ring if there is any question to its integrity (this is
essential to waterproof the unit).
6) Clean the O-ring to ensure it is free from dirt and debris.
7) Re-lubricate the O-ring using silicone lubrication.
7.4 Camera Module Replacement
*See PTZ-550 Replacing Camera Module Appendix (page 18)
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8.0 Safety
Use in Radiated Environment
If putting the PTZ-550 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-550 is used in a radiated environment. The unit cannot
be sent to Intertest Inc.’s facility for repair.
Moving Components
The PTZ-550 Camera Inspection System contains moving parts. Keep
clear of all moving components to prevent injury.
Hot Surfaces
The 35-watt flood and spot lamps become very hot after prolonged use. Do not handle the
lamp enclosures or attempt to replace lamps after prolonged use.
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9.0 Service Records
Product:
PTZ-550 Camera System
EM Number:
EM15669
Serial Number:
Date of Purchase:
Date
Service Performed
/
/
/
/
/
/
/
/
/
/
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REV 1 V-1, 10.24.13
18
Camera Head Assembly
ITEM # EM NUMBER
DESCRIPTION
QUANTITY
2
EM142592
FCB-EX1020 Camera Assembly
1
20
4
EM142503
Rear Camera Cap
1
25
10
EM142506
Camera Mounting Bar
1
11
EM142507
Seal Plate
1
12
EM142508
Camera Mount
1
18
EM64714
#4-40 x 3/8" L, 18-8 S/S, Phillips, 82 Deg, Flat Head Screw
4
20
EM64829
#4-40 x 1" THD, 1" L, 18-8 S/S, Socket Cap Screw
2
23
EM66697
O-Ring, Round, AS568A-041
2
25
EM66699
O-Ring, Round, 1mm x 14mm
1
30
EM66606
O-Ring, Round, AS568A-016
1
31
EM142536
Purge Cap
1
FIGURE 1.
PTZ-550 Camera Change
Drawing 142599 Rev F, Sheet 2
23
2
30
10
12
®
InterTest, Inc.
303 Route 94
Columbia, NJ 07832
Office: 908-496-8008
Fax: 908-496-8004
[email protected]
www.intertest.com
EM16521 - CAMERA REPLACEMENT KIT
- Denotes part of kit
Items 2,10, and 12 are supplied preassembled
Items 18, 20, 23, 25, and 30 are included
#
*Descant bag not
pictured
1
PTZ-550 Service - Camera Module Replacement Utilizing EM16521 Kit
In the event of camera failure (typically due to excessive radiation exposure in the nuclear environment), the PTZ-550 permits
simple field change of the camera module. The replacement
camera kit, EM16521, includes the camera preassembled with
the related mounting components, replacement hardware and
replacement O-rings required to perform the change. Reference
drawing 142599 Rev F Figure 1. for item numbers.
Tools Required:
• Strap wrench
• #1 Phillips screw driver
• 3/32” Allan wrench (hex)
• Blue Loctite
• O-ring grease
Work should be performed in clean, dry, work place.
®
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
Figure 2. Molex connections have yellow & brown
and red & black wires.
Office: 908-496-8008 • Fax: 908-496-8004
[email protected] • www.intertest.com
2
PTZ-550 Service - Camera Module Replacement
Instructions Utilizing EM16521 Kit
1. Unscrew the Rear Camera Cap [item 4] (tight fit, a strap wrench is recom
mended) Discard old O-ring.
2. Remove 4 flat head screws [item 18]. Phillips #1 screw driver.
3. Remove Seal Plate [item 11]. This exposes O-ring [item 25]. Dispose of
old O-ring a new unit is included in the kit.
4. Remove 2, 4-40 cap head screws [item 20]. Hex key 3/32”. The camera is
free on removal of these screws. Hold on to the module from this point on.
5. Disconnect 2 Molex type connections, see fig 2. Note: several lamp
wires need to be moved aside. These are not connected to the camera
board; they loop around through the top to the lamps. These wires are
routed through two grooves in the Camera Mounting Bar (item 10) and
need to be seated there when installation is completed.
6. Disconnect the 2 Molex connectors on interface board (see fig 2).
7. On the new camera module connect 2 Molex connectors.
8. Insert the new module into the housing and install 2, 4-40 cap screws
[item 20]. Use Blue Loctite on the mount screw threads.
Continue to page 4
®
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
Office: 908-496-8008 • Fax: 908-496-8004
[email protected] • www.intertest.com
3
PTZ-550 Service - Camera Module Replacement
Instructions Utilizing EM16521 Kit
9. Install the new O-ring [item 25] (apply light amount of grease) in the
O-ring groove of Seal Plate [item 11].
10. Replace the 4 flat head screws [item 18]. Use Blue Loctite on the
mount screw threads.
11. Insert the descant bag in camera area (discard old one). Bag not shown.
12. Replace Rear Camera Cap. Use new O-Ring [item 23]. Apply O-ring
grease. Place the wires against the back of the camera module while
tightening the Rear Camera Cap. Avoid pinching the wires.
13. Screw Rear Camera Cap [item 4] on securely. Avoid pinching O-ring.
14. If use in wet application perform a pressure test. Remove Purge Cap.
Discard old O-ring [item 23] from the back cap install new O-ring using
grease.
15. Pressurize unit by Schrader Valve [item 29] located under Purge Cap
[item 30]. Pressurize to 5 psi using dry N2. Submerge in water bath
and look closely for bubbles.
16. Recommended practice: perform dry N2 purge. Evacuate and back fill
with dry (-30 F DP) N2 Three cycles.
®
InterTest, Inc. • 303 Route 94 • Columbia, NJ 07832
Office: 908-496-8008 • Fax: 908-496-8004
[email protected] • www.intertest.com
4
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