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OM-VMS-02-2009
OPERATION MANUAL
for VMS-1600 & VMS-1300
Video Arc Monitoring
Systems
Revised February 2009
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618
Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: [email protected]
VMS-1600/1300 Video Arc Monitoring Systems
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VMS-1600/1300 Video Arc Monitoring Systems
LIMITED WARRANTY
Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects
in material and workmanship for the period of one (1) year, provided that the equipment is installed
and operated according to instructions.
Jetline Engineering’s obligation under this warranty is expressly limited to replacing or repairing
any defective part or correcting any manufacturing defect without charge during the warranty period,
if Jetline’s inspection confirms the existence of such defects. Jetline’s option of repair or replacement
will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of
any kind will be allowed.
The warranty period begins on the date of sale to the original-purchase user of the equipment.
Jetline Engineering will not be liable for any loss or consequential damage or expense accruing
directly or indirectly from the use of equipment covered by this warranty.
This warranty supersedes all previous Jetline warranties and is exclusive with no other guarantees or warranties expressed or implied.
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VMS-1600/1300 Video Arc Monitoring Systems
NOTICE
The installation, operation and maintenance guidelines set out in this manual will enable you to
maintain the equipment in peak condition and achieve maximum efficiency with your welding operation. Please read these instructions carefully to become aware of every advantage.
CAUTION
Only experienced personnel familiar with
the operation and safe practice of welding
equipment should install and/or use
this equipment.
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VMS-1600/1300 Video Arc Monitoring Systems
Table of Contents
Section I
��1
Safety Precautions.................................................................................................................. .1
A.
Arc Welding................................................................................................................. .1
B.
Electric Shock.............................................................................................................. .1
C.
Arc Rays....................................................................................................................... .2
E.Cylinders...................................................................................................................... .2
F.Welding........................................................................................................................ .3
G.
Moving Parts................................................................................................................ .3
H.
EMF Information......................................................................................................... .3
I.
Principal Safety Standards........................................................................................... .4
J.California Proposition 65 Warning.............................................................................. .4
Section II
��5
Introduction............................................................................................................................ .5
A.Unpacking.................................................................................................................... .6
Section III
��9
Specifications.......................................................................................................................... .9
Section IV ��13
Installation.............................................................................................................................. .13
A.
Determine Camera Location........................................................................................ .13
B.
Set-up Light................................................................................................................. .17
C.
CCU Unit..................................................................................................................... .17
D.
Power Up..................................................................................................................... .17
E.
Focus Adjustment........................................................................................................ .18
Section V
��21
Operation................................................................................................................................ .21
Section VI ��23
Maintenance............................................................................................................................ .23
Section VII ��25
System Drawings.................................................................................................................... ��25
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VMS-1600/1300 Video Arc Monitoring Systems
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VMS-1600/1300 Video Arc Monitoring Systems
Section I
Safety Precautions
WARNING
A.
4.Properly install and ground this equipment according to the operation manual
and national, state and local codes.
Arc Welding
5.Always verify the supply ground-check
and be sure that input power cord ground
wire is properly connected to ground
terminal in disconnect box or that cord
plug is connected to a properly grounded
receptacle outlet.
Arc Welding can be hazardous. Protect yourself and others from possible serious injury or
death. Keep children away. Pacemaker wearers keep away until consulting your doctor.
In welding, as in most jobs, exposure to certain
hazards occurs. Welding is safe when precautions are taken. The safety information given
below is only a summary of the more complete
safety information that will be found in the
Safety Standards listed at the end of this section.
Read and follow all Safety Standards.
6.When making input connections, attach
proper grounding conductor first - double-check connections.
7.
Frequently inspect input power cord for
damage or bare wiring. Replace cord immediately if damaged - bare wiring can
kill.
Have all installation, operation, maintenance and
repair work performed only by qualified people.
B.
8.
Electric Shock
9.If earth grounding of the workpiece is required, ground it directly with a separate
cable - do not use work clamp or work cable.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is
on. The input power circuit and machine internal
circuits are also live when power is on. When
using mechanized wire feed, the wire, wire reel,
drive roll housing and all metal parts touching
the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is
a hazard.
1.
Turn off all equipment when not in use.
10.Do not touch electrode if you are in contact with the work, ground, or another
electrode from a different machine.
11.Use only well-maintained equipment.
Repair or replace damaged parts at once.
Maintain unit according to manual.
12. Wear a safety harness if working above
floor level.
Do not touch live electrical parts.
13.Keep all panels and covers securely in
place.
2.Wear dry, hole-free insulating gloves and
appropriate body protection.
14.Clamp work cable with good metal-tometal contact to workpiece or worktable
as near the weld as practical.
3.Disconnect input power before installing
or servicing this equipment. Lockout/
tagout input power according to OSHA
29 CFR 1910.147 (see Safety Standards).
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VMS-1600/1300 Video Arc Monitoring Systems
4.Read the Material Safety Data Sheets
(MSDS) and the manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
C. Arc Rays
Arc rays can burn eyes and skin; noise can damage hearing; flying slag or sparks can injure eyes.
Arc rays from the welding process produce
intense visible and invisible (ultraviolet and
infrared) rays that can burn eyes and skin. Noise
from some processes can damage hearing. Chipping, grinding and weld cooling throw off pieces
of metal or slag.
5.Work in a confined space only if it is
well ventilated, or while wearing an airsupplied respirator. Always have a trained
watch person nearby.
6.Do not weld in locations near degreasing,
cleaning, or spraying operations. The heat
and rays of the arc can react with vapors
to form highly toxic and irritating gases.
1.Use approved ear plugs or ear muffs if
noise level is high.
2.Use a welding helmet fitted with a proper
shade of filter to protect your face and eyes
when welding or watching.
7. Do not weld on coated metals, such as
galvanized, lead or cadmium plated steel,
unless the coating is removed from the
weld area, the area is well ventilated, and
if necessary, while wearing an air-supplied
respirator. The coatings and any metals
containing these elements can give off
toxic fumes if welded.
3.Wear approved safety glasses with side
shields.
4.Use protective screens or barriers protect
others from flash and glare; warn others
not to watch the arc.
E.Cylinders
5.Wear protective clothing made from durable, flame-resistant material (wool and
leather) and foot protection where necessary.
Cylinders can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
D. Fumes and Gases
Fumes and gases can be hazardous to your
health.
1.Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag,
open flames, sparks, and arcs.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
2.Install cylinders in an upright position by
securing to a stationary support or cylinder
rack to prevent falling or tipping.
1.Keep your head out of the fumes. Do not
breathe the fumes.
3.Keep cylinders away from any welding or
other electrical circuits.
2.If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes
and gases.
4.Never weld on a pressurized cylinder explosion will result.
3.If ventilation is poor, use an approved airsupplied respirator.
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VMS-1600/1300 Video Arc Monitoring Systems
5.Use only correct shielding gas cylinders,
regulators, hoses and fittings designed for
the specific application; maintain them and
associated parts in good condition.
6.Do not weld on closed containers such
as tanks, drums, or pipes, unless they are
properly prepared according to AWSF4.1
(see safety Standards).
6.Turn face away from valve outlet when
opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected
for use.
7.Connect work cable to the work as close
to the welding area as practical to prevent
welding current traveling long, possibly
unknown paths and causing electric shock
and fire hazards.
8.Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in
Safety Standards.
8.Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
G. Moving Parts
F. Welding
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
Welding can cause fire or explosion.
1.Keep all doors, panels, covers, and guards
closed and securely in place.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.
Sparks can fly off from the welding arc. The
flying sparks, hot workpiece, and hot equipment
can cause fires and burns. Accidental contact
of electrode to metal objects can cause sparks,
explosion, overheating, or fire. Check and be
sure the area is safe before doing any welding.
2.Have only qualified people remove guards
or covers for maintenance and troubleshooting as necessary.
H. EMF Information
Considerations About Welding and the Effects of Low Frequency Electric and Magnetic
Fields
1.Protect yourself and others from flying
sparks and hot metal.
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-53
(Washington, DC: U.S. Government Printing
Office, May 1989):
2.Do not weld where flying sparks can strike
flammable material.
3.Remove all flammables within 35 ft. (10.7
m) of the welding arc. If this is not possible, tightly cover them with approved
covers.
4.Be alert that welding sparks and hot materials from welding can easily go through
small cracks and openings to adjacent
areas.
“.... there is now a very large volume of scientific
findings based on experiments at the cellular
level and from studies with animals and people
which clearly establish that low frequency
magnetic fields can interact with, and produce
changes in, biological systems. While most of
this work is of very high quality, the results are
complex. Current scientific understanding does
5.Watch for fire, and keep a fire extinguisher
nearby.
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VMS-1600/1300 Video Arc Monitoring Systems
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That
Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from
American Welding Society, 550 N.W. LeJeune
Rd, Miami, FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
Sales Practices for Occupation and Educational
Eye and Face Protection, ANSI Standard Z87.1,
from American National Standards Institute,
1430 Broadway, New York, NY 10018
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite
conclusions abut questions of possible risk or to
offer clear science-based advice on strategies to
minimize or avoid potential risks.”
To reduce magnetic fields in the work place, use
the following procedures:
1.Keep cables close together by twisting or
taping them.
2.Arrange cables to one side and away from
the operator.
3.Do not coil or drape cables around the
body.
4.Keep welding power source and cables as
far away as practical.
5.Connect work clamp to workpiece as close
to the weld as possible.
About Pacemakers:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
I.
J.California Proposition 65
Warning
Principal Safety Standards
This product contains chemicals, including lead,
known to the state of California to cause cancer,
and birth defects or other reproductive harm.
Wash hands after use. §248224
Reference as applicable
Safety in Welding and Cutting, ANSI Standard
Z49.1, from American Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126
Safety and Health Standards, OSHA 29 CFR
1910, from Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C.
20402
National Electric Code, NFPA Standard 70 from
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
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VMS-1600/1300 Video Arc Monitoring Systems
Section II
Introduction
and then at the weld joint ahead of the puddle
for tracking.
The Jetline VMS-1600 and VMS-1300 are color
video monitoring systems capable of viewing
the electrode, welding arc, weld puddle and
weld joint while welding with GTAW (TIG),
PAW (Plasma), and most GMAW (MIG) weld
processes. Because of the magnification of the
system, details of the weld puddle and wire can
be viewed that would otherwise be impossible
to see.
The focus and iris (aperture) adjustments are
motorized and are made locally at the lens controller box.
A halogen setup light is provided for weld zone
illumination prior to and after welding.
The most common applications for the VMS1600/1300 include weld environments that are
hostile and/or dangerous or with difficult access
(e.g. inert gas weld chambers, large diameter
pipe where the operator would normally need
scaffolding, welding radioactive or potentially
explosive parts).
The VMS-1600 camera is designed to be mounted 6” (152 mm) from the welding torch and is
usually air cooled although there is provision for
water or gas cooling if needed. This camera is
used when there are few restrictions on the weld
head envelope size, or if there is additional welding apparatus attached to the welding torch such
as magnetic arc oscillator and/or wire feeder,
etc., or deep groove welding.
Because the VMS-1600/1300 systems use the
NTSC color format with both composite and
S-Video outputs, a standard video tape recorder
or a computer with video input board and DVD
recorder can be added to the system to record the
welds for archival or training purposes.
The VMS-1300 camera is designed to be
mounted 3” (76 mm) (nominal) from the welding torch and is usually water cooled due to the
proximity of the welding arc. It has the same
features as the VMS-1600 except the magnification is reduced.
NOTE: There are also optional PAL versions
available.
The Jetline VMS-1600/1300 Video Monitoring
System consists of the following components:
The VMS-1600/1300 incorporates an electronic
shutter CCD micro camera with an ND spot
filter. The spot filter is brought in prior to the
weld using the iris switch on the lens controller
box. At the end of the weld, the dot is reduced
by opening the iris. The purpose of the ND spot
is to filter out the direct arc light while allowing
light from the surrounding scene to pass around
the spot with relatively light filtering. As a result
of this, both the high intensity arc/weld puddle
and the surrounding weld zone can be viewed
together without having to make any filter adjustment when looking first at the weld puddle
1.
A solid state color camera assembly
2.
A camera control unit (CCU)
3.A solid state color monitor - CRT (Jetline
supplied in sealed case); or LCD (customer supplied enclosure mounting and
plexiglass screen cover)
-5-
4.
A lens controller box
5.
A halogen setup light
6.
Interconnecting cables
VMS-1600/1300 Video Arc Monitoring Systems
The camera head assembly is supplied with a
universal mounting bracket which is designed
to be attached to the welding torch.
A.Unpacking
When the system is received, check the boxes
for any signs of shipping damage. This should
be done immediately upon receiving so that
the trucking paperwork can be marked as “possible hidden damage” if necessary. Some of the
components are relatively fragile, such as the
monitor itself. If the boxes have crushed corners
or holes from forklifts or other obvious signs of
damage, follow standard receiving procedures:
The CCU contains the electronics to drive the
micro-camera assembly. Selector switches on
this unit and on-screen menus control the AGC
and color levels as well as the electronic shutter
speed. Once set up, there are no further adjustments necessary on the CCU. The operator will
not normally need access to this control.
The standard color monitor is a 14 inch (355
mm) CRT type with metal enclosure suitable
for most shop environments. This is a table top
model but there is a an optional rack mount
adapter available. A 14 inch (355 mm) LCD
type is also available which should be mounted
inside a user supplied enclosure or rack for
protection from the welding environment. Some
mounting bracketry may have to be fabricated
by the user.
If the shipment is by UPS and there is
damage, contact Jetline. We will call UPS
who will send an inspector to your facility. Save all the packaging for the UPS
inspector.
If the shipment is by truck and there is
damage, you must contact the trucking
company to have an inspector come to
your facility. Save all the packaging for
the inspector.
The lens controller box has power, setup light,
iris and focus switches for controlling camera
lens functions during the weld. The LC type of
enclosure (5 1/4”H x 17”W x 15 1/2”D / 133H
x 432W x 394D mm) is designed to be used as
table top model or can be rack mounted with 19
inch rack mount adapters (supplied). It also has
provisions for optional joysticks to control motorized wire guide and motorized slide functions
if these devices are used on the system.
After receiving the system with no damage, it
is advisable to set it up on a table, connect all
of the components and to test the system before
beginning installation procedures.`
The VMSC lens controller is a smaller, compact
version (2 1/2”H x 5”W x 7”D / 64H x 127W x
178D mm) used where space is restricted.
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VMS-1600/1300 Video Arc Monitoring Systems
LCD Video Monitor
VMS-1121-IT
Camera Control Unit
LC-IT Operator Lens Controller
(Shown with optional joystick controls)
Camera and Lens Assembly with halogen
setup light and swivel head assembly
VMS-1600-1300 VIDEO ARC MONITORING SYSTEM
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VMS-1600/1300 Video Arc Monitoring Systems
LCD Video Monitor
VMS-1121-IT
Camera Control Unit
LCC-IT Compact Operator
Lens Controller
Camera and Lens Assembly with halogen
setup light and swivel head assembly
VMSC-1600-1300 COMPACT VIDEO ARC MONITORING SYSTEM
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VMS-1600/1300 Video Arc Monitoring Systems
Section III
Specifications
VMS-1121-IT Camera Control Unit
•Electronic Shutter Speed: 1/60 to 1/10,000
second
• Automatic Gain Control
• Automatic White Balance Control
• S/N Ratio: 46db
• NTSC Output: 1 Volt p-p
• Horizontal Resolution: 470 lines
•Vertical Resolution: 350 Lines
INPUT VOLTAGE
115V/230V, 1 phase, 50/60 Hz
DIMENSIONS
VMS-1121-IT Camera Control Unit
Height:
10” (254 mm)
Width:
8” (203 mm)
Depth:
6” (152 mm)
Weight:
10.1 lb (4.6 kg)
Camera Head
• Camera type: NTSC or optional PAL formats
• Diameter: 25.4 mm (1”)
•Sensor: 768 horizontal pixels, 494 vertical
pixels
Camera and Lens Assembly
Diameter:
1” (25.4 mm)
Length:
3.5” (89 mm)
Weight:
.25 lb (0.11 kg)
LC-IT Operator Lens Controller
Height:
5.25” (133 mm)
Width:
17” (430 mm)
Depth:
15.5” (394 mm)
Weight:
11.9 lb (5.4 kg)
Mounting:
Table or 19” (483 mm) rack
Lens - VMS-1600
• Focal Length: 30 mm (1.2”) - Fixed
•Focus Distance: 4.75” to 8.7” (120 to 220
mm); 6.25” (150 mm) nominal
•Image Size: Approximately 0.8” (20 mm)
horizontal field of view at 6.25” (150 mm)
object distance
•Remote Adjustments: Motorized mechanical iris, motorized focus
LCC-IT Compact Operator Lens Controller
Height:
2.5” (64 mm)
Width:
5” (127 mm)
Depth:
7” (178 mm)
Weight:
1.5 lb (0.68 kg)
Mounting:
Table only
Lens - VMS-1300
• Focal Length: 18 mm (0.7”) - Fixed
•Focus Distance: 2.5” to 4.5” (64 to 114
mm); 3” (76 mm) nominal
•Image Size: Approximately 0.8” (20 mm)
horizontal field of view at 6.25” (150 mm)
object distance
•Remote Adjustments: Motorized mechanical iris, motorized focus
-9-
- 10 -
LENS CABLE IS TYPICALLY SAME LENGTH AS COAX OR FIBER OPTIC.
10 METERS STANDARD LENGTH
HAS NO OPERATOR CONTROLS
2
3
4
FIBER OPTICS RECOMMENDED FOR SYSTEMS WITH MONITOR CABLE
OVER 10 METERS AND/OR HIGH NOISE ENVIRONMENTS.
110/220 VAC
50/60 HZ
110/220 VAC
50/60 HZ
(10" x 8" x 4" BOX)
VIDEO OUT
(BNC)
OPERATOR STATION
110/220 VAC
50/60 HZ
RG59/U COAX
3 METERS
4
FIBER OPTIC
RECEIVER
VMS-FOR
1
NOTES:
2-1/2" x 5" x 7" (HWD)
LCC-IT
LENS
CONTROLLER
VIDEO IN
(BNC)
LCD
MONITOR
2-1/2" x 5" x 7" (HWD)
LCC-IT
LENS
CONTROLLER
VIDEO IN
(BNC)
LCD
MONITOR
OPERATOR STATION
(10" x 8" x 6" BOX)
FIBER OPTIC
TRANSMITTER
VMS-1121-IT-FO
LENS CABLE
RG59/U COAX
5, 10, OR 20 METERS
2
1
3
3
(10" x 8" x 6" BOX)
VIDEO OUT
(BNC)
VMS-1121-IT
CAMERA 4
CONTROL UNIT
(CCU)
CAMERA SYSTEM
WITHOUT FIBER OPTICS
LENS CABLE
2
FIBER OPTIC CABLE
5, 10, 20, OR 30 METER
1
CAMERA 4
CONTROL UNIT
(CCU)
CAMERA SYSTEM
WITH FIBER OPTICS
110/220 VAC
50/60 HZ
CAMERA CABLE
3 METERS
110/220 VAC
50/60 HZ
CAMERA CABLE
3 METERS
PRESSURE
REGULATOR
OPTIONAL
WATER
CIRCULATOR
®
OPTIONAL
WATER
CIRCULATOR
e n g i n e e r in g
IN
OUT
SETUP
LIGHT
etline
SET TO
15 PSI
PRESSURE
GAUGE
CAMERA
VMS-1600-1
OR
VMS-1300-1
IN
OUT
SETUP
LIGHT
CAMERA HEAD
PRESSURE
REGULATOR
SET TO
15 PSI
PRESSURE
GAUGE
CAMERA
VMS-1600-1
OR
VMS-1300-1
CAMERA HEAD
VMS-1600/1300 Video Arc Monitoring Systems
- 11 -
JOG
RAPID
ON
LEFT
DOWN
JOG
RAPID
LEFT
DOWN
JETVIEW VIDEO MONITORING SYSTEM - LENS CONTROLLER
DOWN
OPTIONAL
UP
UP
RIGHT LEFT
WIRE
TORCH
OPTIONAL
OPEN
®
NEAR
O
FAR
FOCUS
RIGHT
OUT
IN
ZOOM
OPEN
O
CLOSE
IRIS
engineering
®
NEAR
O
FAR
FOCUS
etline
110 OR 220 VAC
INTERNAL
VOLTAGE SELECT
110 OR 220 VAC
INTERNAL
VOLTAGE SELECT
LENS CABLE IS TYPICALLY SAME LENGTH AS COAX OR FIBER OPTIC.
10 METERS STANDARD LENGTH
HAS NO OPERATOR CONTROLS
2
3
4
FIBER OPTICS RECOMMENDED FOR SYSTEMS WITH MONITOR CABLE
OVER 10 METERS AND/OR HIGH NOISE ENVIRONMENTS.
OFF
110/220 VAC
50/60 HZ
5-1/4" x 17" x 15-1/2" (HWD)
ON
0
VIDEO IN
(BNC)
OUT
O
IRIS
CLOSE
engineering
IN
etline
ZOOM
110/220 VAC
50/60 HZ
(10" x 8" x 4" BOX)
VIDEO OUT
(BNC)
OPERATOR STATION
RIGHT
LENS CONTROLLER
LC-IT
LIGHT
l
DOWN
OPTIONAL
JETVIEW VIDEO MONITORING SYSTEM - LENS CONTROLLER
RIGHT LEFT
UP
UP
OPTIONAL
WIRE
TORCH
MONITOR
OFF
0
l
LIGHT
5-1/4" x 17" x 15-1/2" (HWD)
4
FIBER OPTIC
RECEIVER
VMS-FOR
1
NOTES:
POWER
POWER
110/220 VAC
50/60 HZ
RG59/U COAX
3 METERS
LENS CONTROLLER
LC-IT
VIDEO IN
(BNC)
MONITOR
OPERATOR STATION
2
1
2
1
3
3
JOYSTICK TO OPTIONAL
MOTORIZED WIRE GUIDE POSITIONER CONTROL
JOYSTICK TO OPTIONAL
MOTORIZED SLIDE CONTROL
LENS CABLE
RG59/U COAX
5, 10, OR 20 METERS
CAMERA SYSTEM
WITHOUT FIBER OPTICS
JOYSTICK TO OPTIONAL
MOTORIZED WIRE GUIDE POSITIONER CONTROL
JOYSTICK TO OPTIONAL
MOTORIZED SLIDE CONTROL
LENS CABLE
FIBER OPTIC CABLE
5, 10, 20, OR 30 METER
CAMERA SYSTEM
WITH FIBER OPTICS
(10" x 8" x 6" BOX)
VIDEO OUT
(BNC)
VMS-1121-IT
CAMERA 4
CONTROL UNIT
(CCU)
(10" x 8" x 6" BOX)
FIBER OPTIC
TRANSMITTER
VMS-1121-IT-FO
CAMERA 4
CONTROL UNIT
(CCU)
110/220 VAC
50/60 HZ
CAMERA CABLE
3 METERS
110/220 VAC
50/60 HZ
CAMERA CABLE
3 METERS
PRESSURE
REGULATOR
OPTIONAL
WATER
CIRCULATOR
®
OPTIONAL
WATER
CIRCULATOR
engineering
IN
OUT
SETUP
LIGHT
etline
SET TO
15 PSI
PRESSURE
GAUGE
CAMERA
VMS-1600-1
OR
VMS-1300-1
IN
OUT
SETUP
LIGHT
CAMERA HEAD
PRESSURE
REGULATOR
SET TO
15 PSI
PRESSURE
GAUGE
CAMERA
VMS-1600-1
OR
VMS-1300-1
CAMERA HEAD
VMS-1600/1300 Video Arc Monitoring Systems
VMS-1600/1300 Video Arc Monitoring Systems
- 12 -
VMS-1600/1300 Video Arc Monitoring Systems
Section IV
Installation
1)
This section should be read completely before
any installation is actually started.
The field of view is dependent on the distance
between the camera and the weld puddle.
It will be helpful to read this section to determine the mounting scheme and to temporarily
clamp the camera in the determined position,
then to operate it to confirm that the position
will provide the desired function.
For the VMS-1600:
At a distance of 6” (152 mm), the field of view
should be 3/4” (19 mm) horizontal (an object
of 3/4” (19 mm) will fill the monitor screen
horizontally). If the camera is mounted at 9”
(228 mm), the FOV will be 1 1/8” (29 mm).
The recommended distance is 6” (152 mm) ±
½”(12 mm). If the camera is mounted closer
or further than the recommended distance, an
additional focus adjustment may be necessary,
see Focus Adjustment, later in this section. The
usable focus distance range is 4 ½” to 9” (114
to 228 mm).
Normally the camera will be mounted to view
the leading edge of the weld puddle. If the
torch is mounted to a motorized slide or an arc
length control, the camera and light should be
mounted to the slide as well so that the camera
moves with the torch for tracking out-of-round
or irregularly shaped parts.
A.
Field of View
Determine Camera Location
The first step in the installation is to determine
exactly what you want to see in your application. The camera should be mounted, with
suitable bracketry, to the welding torch or to
the slide to which the torch is mounted. The
camera must move horizontally and vertically
with the torch. In a single camera application,
the camera is normally mounted to view the
leading edge of the weld puddle. In the final
setup, the welding arc should be horizontally
centered on the monitor screen. The vertical
position depends somewhat on the downward
angle of the camera. The idea here is to have
the dot cover the weld puddle, arc and tip of
the tungsten while the torch cup covers the rest
of the tungsten in the upper half of the monitor
screen. This can usually be accomplished by
making adjustments to the camera angle. The
final adjustment should always be made while
welding and watching the monitor.
For the VMS-1300:
At a distance of 3” (76 mm), the field of view
should be 3/4” (19 mm) horizontal (an object
of 3/4” (19 mm) will fill the monitor screen
horizontally). If the camera is mounted at 6”
(152 mm), the FOV will be 1 ½” (38 mm). The
recommended distance is 3” (76 mm) ± ½” (12
mm). If the camera is mounted closer or further
than the recommended distance, an additional
focus adjustment may be necessary, see “Focus Adjustment”, later in this section. The usable focus distance range is 2” to 6” (52 to 152
mm).
Because the screen format is 4:5, what ever
the horizontal FOV is, the vertical FOV will
be 80% of the horizontal. In other words if the
horizontal field of view is 1” (25.4 mm), the
vertical field of view will be 0.8” (20 mm).
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2)
Viewing Angle
Once the approximate position is determined,
the camera position can be finalized while
welding with a live arc.
The normal viewing angle is between 20 and
45 degrees from horizontal. The viewing angle
is related to the camera distance from the torch
and the camera height above the work piece.
The final viewing angle should be an angle
that results in as much of the tungsten stickout
being blocked from view as possible (by the
torch nozzle), but still allowing the electrode
tip, weld puddle and unwelded joint ahead of
the puddle to be viewed.
3)
Heat Considerations
The operating temperature range of the camera
is from 20° to 140° F (-6.6° to 60° C). Under
most conditions the camera will not see temperatures outside of the range. If the application is for very high amperage arcs and long
weld times, or pre-heated parts, the upper temperature limit should be evaluated.
The ND dot is located in the center of the monitor screen. The spot will appear to be about two
thirds the screen size when the iris is near fully
closed. Try to adjust the camera so that the dot
covers the electrode tip, arc column and weld
puddle, leaving the weld joint to be welded in
the lower half of the screen.
There are three ways in which heat can enter
the camera assembly:
a.
Convection - This would actually be
ambient air temperature.
b.
Radiation - This is infrared radiation
from the arc and the piece part. The
camera head incorporates a reflective
infrared filter so IR radiation does not
enter through the lens. However, IR
radiation can heat the case which, in
turn, could conduct heat to the camera
inside.
Another viewing angle to be considered is
the horizontal angle. Normally, the camera is
mounted in line with the weld joint so that the
weld joint is in the center of the screen. When
using cold filler wire, the wire guide positioner
normally feeds wire in at the center of the leading edge of the puddle which would obstruct
the camera view. In this case, the camera is rotated about the torch slightly in one direction
while the wire guide is rotated in the other direction until a compromise is found that results
in a satisfactory view and in satisfactory wire
feed.
c.
Conduction - This is not normally a
factor. Conduction would be a factor
if the camera case were mounted to or
touching a hot object.
If the ambient air temperature is over 140° F
(60° C) where the camera is to be placed due
to a pre-heated piece part, determine if the
camera can be moved away from the heat zone
and brought in only when ready to weld. This
should work for all but very long weld times.
In cases where there is no room to rotate the
camera or wire feed, it will be necessary to raise
the camera height until the camera is looking
over and down on the filler wire. It is important
not to raise the camera so high that the gas cup
or nozzle covers up the weld puddle when in
the welding position.
If the camera is to be exposed to high temperatures for extended periods, it must be cooled.
There are two 1/8” (3 mm) hose barbs located
at the rear of the camera head. A water circulator can be connected to allow cooling water to
flow through the camera body. A water pressure regulator is required to keep the pressure
at 10 to 15 psi (0.7 to 1 kg/cm) max. Higher
In some applications, the camera can be placed
to look under the wire.
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VMS-1600/1300 Video Arc Monitoring Systems
ed near the weld head. Cable lengths between
the CCU and the camera head are typically 6ft
or 15 ft (2 or 5 m). The cable lengths between
the CCU and the lens controller and monitor
are typically 33 ft (10 m). Other lengths can be
supplied as special order.
pressures may cause water leakage. The VMS
package may be ordered from Jetline with the
necessary items for water cooling.
Alternatively, gas cooling can be used. A clean,
dry source of inert gas such as argon or nitrogen can be connected to the hose barbs instead
of water if temperatures are not too severe.
Normally the CCU requires no adjustment after initial set-up. The nominal adjustments are
as follows:
If there is enough IR radiation in the arc and/
or piece part to cause the camera case to heat to
more than 140° F (60° C), heat shielding around
the camera case is recommended. The shielding can be made from light steel and should be
shiny on the heated side. Contact Jetline for details.
4)
1)
After installation, check that the CCU controls
are set up as follows:
FRONT PANEL
POWERON
AGCON
WHITE BALANCE MANUAL
Mechanical Considerations
Any brackets that may have to be fabricated
should be made light and as strong as required
to prevent the camera from vibrating or oscillating as the weld process is taking place. Due
to the magnification of the system, even relatively small movements can look large on the
monitor.
B.
D.
Power Up
When all the components have been mounted
and connected, apply power to the monitor,
light and camera power supply box. Be sure the
set-up light is on. After a short warm up period,
an image should appear on the monitor screen.
Set-up Light
Move the welding torch into the welding position over the piece part.
The 6 watt halogen set up light is mounted integral with the camera head mounting ring. There
is an intensity adjustment knob located on the
panel inside of the VMS-1121-IT CCU box. It
is recommended to adjust the intensity only as
high as needed for good viewing with no welding arc for maximum lamp life. This light will
have no effect on the picture during the weld.
C.
CCU Set-up
Loosen the adjustment locking knob and adjust
the camera until the torch nozzle and electrode
are centered in the upper half of the monitor
screen as described in the “Determine Camera
Location” section above. Bring the ND dot in
by closing the iris switch. The dot should be
visible in the center of the screen. The lower
edge of the dot should be covering the lower
edge of the anticipated weld puddle location.
CCU Unit
Cable routing and connections for the CCU unit
and the system in general should be as shown
in the VMS-1600/1300 drawing found in the
drawings section of this manual.
If the image is out of focus, adjust the Focus
Control. If the camera will not focus, check
that the nominal camera distance is correct:
The VMS-1121-IT Camera Control unit is
housed in a 10” x 8” x 6” (254 x 203 x 152 mm)
steel enclosure. The CCU unit should be locat-
For the VMS-1600, it should be 6” (152 mm)
For the VMS-1300, it should be 3” (76 mm)
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VMS-1600/1300 Video Arc Monitoring Systems
era focuses on the tungsten tip, hold the
sensor in position and tighten the Camera Adjustment screw. Be careful not to
rotate the camera sensor or the picture
on the monitor will appear tilted. Now
you should be able to touch up the focus using the focus rocker switch.
If the camera must be at a different distance,
perform the Initial Focus Adjustment, as below.
E.
Focus Adjustment
If the camera is at a distance where it will not
focus within the range of the motorized focus
adjustment switch, the camera sensor position
must be adjusted within the camera head housing. Refer to drawing VMS-1600-1. Do the following procedure:
4)Hold the focus switch down until the
eccentric makes another half cycle, if
necessary, so that when you press Focus
Near, the camera will focus on nearer
objects.
1)With the camera mounted in the desired
position, make sure the iris is fully
open.
2)Even though there are “Focus Far” and
“Focus Near” positions on the focus
rocker switch, the focus mechanism is
on an eccentric cam so that if the switch
is held in the Focus Far position, it will
focus first farther away then turn around
and focus closer. If the switch is held
indefinitely, it will cycle so the focus
distance will be first farther then closer
then farther. Hold the switch down until
the focus adjustment is mid stroke, between the farthest point and the closest
point. You can tell when this happens
by carefully observing the picture while
holding the switch in.
3)
With 0.050” hex wrench, loosen the
Camera Adjustment screw. Refer to the
drawing to make SURE you are loosening the Camera Adjustment screw, NOT
the motor mounting screws! Move the
camera sensor in or out of the housing by holding and moving the camera
cable at the rear of the camera body.
Moving the camera out of the body will
cause the camera to focus on closer objects, moving the camera sensor into
the body will cause the camera to focus
on objects further away. When the cam- 18 -
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TOP
FRONT
LEFT SIDE
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Section V
Operation
Operation of the VMS-1600/1300 is straight
forward as there are no adjustments to be made
after the camera system is properly set up except for the iris.
Prior to striking the arc, the iris should be closed
up until the proper size dot appears on the monitor screen. During the weld, closing the iris will
make the ND dot appear larger and more dense
(darker). Opening the iris will decrease the dot
size and make the dot appear lighter.
After the weld, the iris can be fully opened to
view the welded part and to set up the next part
to be welded. No damage to the camera will occur if the camera is exposed to direct arc light
for brief periods with the iris opened.
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Section VI
Maintenance
There is no regular maintenance required on
the VMS-1600/1300 other than keeping the
camera assembly as clean as possible. The
spatter guard on the front of the camera head
can be replaced if it becomes dirty or coated
with spatter.
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VMS-1600/1300 Video Arc Monitoring Systems
Section VII
System Drawings
- 25 -
CCU
SW1
- 26 3
4
5
6
4
5
6
7
2
2
P2 J2
4
3
2
1
PWM 111691-02
TB3
J3
MOTOR CONTROL
TB2
PWM 111676-02
LAMP CONTROL
TB1
P1 J1
3
CR1
R2
LAMP
INTENSITY
CR1
1
4
3
2
1
1
HIROSE
RM12BRD-7PH
ELMO CC431E (12076)
TOSHIBA IK-CU44A (12188)
F1
P1
CINCON CFM40S120
(63477)
PS1
POWER SUPPLY
12V / 40W
3
4
5
6
1
2
3
4
2
1
HIROSE
RM12BRD-6S
LENS
CONTROLLER
Y/C
S-VIDEO
OUT
110 / 220 VAC
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VIDEO
OUT
ENCLOSURE, BOTTOM
ENCLOSURE DOOR,
FRONT
VMS-1600/1300 Video Arc Monitoring Systems
VIDEO MONITOR CONTROLLER
WITH FIBER OPTIC OPTION
VMS-1600/1300 Video Arc Monitoring Systems
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IRIS
FOCUS
LIGHT
G PL1
SW1
POWER
LCC-IT
LENS CONTROL
BOX
MONITOR
CONTROL
- 28 5
4
2
3
1
7
6
VMS-1121-IT
CAMERA
CCU CONTROL ASSY
WELD HEAD
P10 RC10
NOTES:
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IRIS
FOCUS
LIGHT
G PL1
SW1
POWER
LCC-IT
LENS CONTROL
BOX
FOR 1
- 29 MONITOR
FIBER OPTIC
RECEIVER
CONTROL
5
4
2
3
1
7
6
FIBER OPTIC
TRANSMITTER
VMS-1121-IT-FO
CAMERA
CCU CONTROL ASSY
WELD HEAD
NOTES:
P10 RC10
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NOTES:
TB
SW1
FOR1
F1
FIBER OPTIC
RECEIVER
DOOR,
INTERIOR VIEW
TB
PS1
F2
TB
TB
PS1
F2
ENCLOSURE INTERIOR,
WITH PANEL INSTALLED
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SW1
F1
VMS-1600/1300 Video Arc Monitoring Systems
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NOTES:
IRIS
FOCUS
SW2
SW5
SW4
LIGHT
G PL1
SW1
POWER
LCC-IT
LENS CONTROL BOX
RC10 P10
REF ONLY
MONITOR
5
4
2
3
1
7
6
P1
VMS-1121-IT
REF ONLY
CAMERA
CCU CONTROL ASSY
®
COMPACT LENS CONTROLLER
ASSEMBLY, IT INTERFACE
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IRIS
SW5
SW4
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TORCH
JOYSTICK
WIRE GUIDE
JOYSTICK
FOCUS
SW2
LIGHT
G
PL1
SW1
POWER
FRONT PANEL
TB2
TB2
PC
BOARD
PS1
POWER SUPPLY
BOTTOM PANEL
RFI
TB1
RC2
RC1 (S8)
F3
F1
REAR PANEL
F
E
C
D
B
A
G
3102A-16S-1S
S3 P3
E
C
D
B
A
3102A-14S-5S
S2 P2
5
4
B
A
2
C
1
3
7
D
E
6
H
P11
J
3102A-20-33S
S1 P1
RC10 P10
MONITOR
UNPLUG UNIT
BEFORE CHECKING FUSES.
CAUTION:
NOTES:
9080F
(REF ONLY)
MOTORIZED SLIDE
CONTROL
9045A
(REF ONLY)
WIRE GUIDE
POSITIONER (WGP)
CONTROL
VMS-1121-IT
CAMERA ASSY
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IRIS
SW5
SW4
TORCH
JOYSTICK
WIRE GUIDE
JOYSTICK
FOCUS
SW2
LIGHT
G
PL1
SW1
POWER
FRONT PANEL
TB2
TB2
PC
BOARD
PS1
POWER SUPPLY
BOTTOM PANEL
RFI
TB1
F2
RC1 (S8)
F3
F1
REAR PANEL
F
E
C
D
B
A
G
3102A-16S-1S
S3 P3
E
C
D
B
A
3102A-14S-5S
S2 P2
5
4
B
A
2
C
1
3
7
D
E
6
H
P11
J
3102A-20-33S
S1 P1
RC10 P10
UNPLUG UNIT
BEFORE CHECKING FUSES.
CAUTION:
9080F
(REF ONLY)
MOTORIZED SLIDE
CONTROL
9045A
(REF ONLY)
WIRE GUIDE
POSITIONER (WGP)
CONTROL
VMS-1121-IT
CCU ASSY
MONITOR
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