Important Operation Manual For Vms-1600

Transcript

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. Miller Welding Automation, 281 E. Lies Rd., Carol Stream Il 60188 • Telephone: (949) 951-1515 • Fax: (949) 951-9237 Web Site: www.jetline.com • E-mail: [email protected] VMS-1600/1300 Video Arc Monitoring Systems LIMITED WARRANTY Components or parts manufactured directly by Miller Electric Mfg. Co. are subject to Miller’s True Blue® Warranty set forth at www.millerwelds.com/support/warranty. Seller does not make any warranties for components or parts not manufactured directly by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company; such components or parts are subject to the warranty terms of the respective manufacturer. Components and parts manufactured by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company are subject to the following warranty terms. Terms and Conditions of Sale Seller warrants to Purchaser that the components or parts manufactured by Seller or Panasonic Welding Systems Company shall be free from defects in material and workmanship, and shall conform to the Seller’s specifications for the following periods: a. 12 months from the date of shipment of the Products for components and equipment manufactured by Panasonic Welding Systems Company including robot manipulator, controller and connecting cables; external axis components (external axis base unit, servo amplifiers, motors, connecting cables and pre-engineered positioners); peripheral devices (high voltage touch sensors, thru arc seam trackers); welding power sources (internally built into the robot controller cabinet); wire feeders (separated design or integrated design, i.e. Active Wire Torch/Feeder); or b. 12 months from date of shipment of the Products for equipment manufactured by Jetline Engineering or Miller Welding Automation. In the event of a breach of the warranties set forth above, Seller will, at Seller’s option and as Seller’s sole liability and Purchaser’s sole remedy, repair, replace or credit Purchaser’s account for, any Product that fails to conform to the above warranty, provided that (i) during the applicable warranty period Seller is promptly notified in writing upon discovery of such failure with a detailed explanation of any alleged deficiencies; (ii) Seller is given a reasonable opportunity to investigate all claims; and (iii) Seller’s examination of such Product confirms the alleged deficiencies and that the deficiencies were not caused by accident, misuse, neglect, improper installment, unauthorized alteration or repair or improper testing. No Products may be returned to Seller until inspection and approval by Seller. All warranty work performed shall be FOB Seller’s facility (Incoterms 2010) and freight for returned Products shall be paid for by Purchaser. The above warranty against defects does not apply to: (1) consumable components or ordinary wear items including but not limited to torches; or (2) defects due to (i) failure to install and perform maintenance set forth in Product documentation, (ii) the use of components, parts, peripherals, attachments, accessories, or perishable tooling not approved by Seller, (iii) accident, misuse, neglect, abuse, mishandling, misapplication, modification, alteration, acts of God, or (iv) improper installation, service or maintenance. Purchaser and/or the operator of the Products are in full control of the weld process. Seller makes no warranty regarding the quality or the success of the welds on the Products due to factors under Purchaser’s and/or operator’s control including but not limited to welding procedures, material types, material coatings, joint/part fit, part geometry, metallurgy, welding gases, proper machine/process maintenance, and operator skill. EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OR REPRESENTATION OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE). - See more at: https://www.millerwelds.com/automation-terms-of-sale#sthash.l5oRebWB.dpuf - ii - 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. - iii - VMS-1600/1300 Video Arc Monitoring Systems Table of Contents CONTENTS Section I.................................................................................................................................................... 1 SAFETY PRECAUTIONS – READ BEFORE USING .............................................................................. 1 1.1 Symbol Usage ..................................................................................................................................... 1 1.2 Arc Welding Hazards .......................................................................................................................... 1 1.3 Additional Symbols for Installation, Operation, And Maintenance .................................................. 4 1.4 California Proposition 65 Warnings ................................................................................................... 6 1.5 Principal Safety Standards ................................................................................................................. 6 1.6 EMF Information ................................................................................................................................ 6 Section II................................................................................................................................................... 7 Introduction ............................................................................................................................................. 7 A. Unpacking .......................................................................................................................... 9 Section III................................................................................................................................................ 12 Specifications ......................................................................................................................................... 12 Section IV ............................................................................................................................................... 16 Installation ............................................................................................................................................. 16 A. Determine Camera Location ............................................................................................ 16 B. Set-up Light ...................................................................................................................... 22 -1- VMS-1600/1300 Video Arc Monitoring Systems C. CCU Unit ........................................................................................................................... 22 D. Power Up.......................................................................................................................... 22 E. Focus Adjustment ............................................................................................................ 24 Section V ................................................................................................................................................ 27 Operation ............................................................................................................................................... 27 Section VI ............................................................................................................................................... 28 Maintenance .......................................................................................................................................... 28 Section VII .............................................................................................................................................. 29 System Drawings .................................................................................................................................... 29 -1- SECTION I SAFETY PRECAUTIONS – READ BEFORE USING (som 2013-09) Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions. 1.1 Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE − Indicates statements not related to personal injury.  Indicates special instructions. This group of symbols means: Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1.2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. 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. In semiautomatic or automatic wire welding, 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. • Do not touch live electrical parts. • Wear dry, hole-free insulating gloves and body protection. • Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. • Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. • Use AC output ONLY if required for the welding process. • If AC output is required, use remote output control if present on unit. • Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the work piece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! • Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). • Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. • 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. • When making input connections, attach proper grounding conductor first − double-check connections. • Keep cords dry, free of oil and grease, and protected from hot metal and sparks. • Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. • Turn off all equipment when not in use. -1• Do not use worn, damaged, undersized, or repaired cables. • Do not drape cables over your body. VMS-1600/1300 Video Arc Monitoring Systems • • • • • • • • • • If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use. Use GFCI protection when operating auxiliary equipment in damp or wet locations. SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power. • Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. • • • Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. • Keep your head out of the fumes. Do not breathe the fumes. • If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. • If ventilation is poor, wear an approved air-supplied respirator. • Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. • Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. • 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. • 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. • Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). • Wear approved safety glasses with side shields under your helmet. • Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc. • Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. -1- WELDING can cause fire or explosion. 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. • Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. • Do not weld where flying sparks can strike flammable material. • Protect yourself and others from flying sparks and hot metal. • Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. • Watch for fire, and keep a fire extinguisher nearby. • Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. • Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards). • Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). • Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. • Do not use welder to thaw frozen pipes. • Remove stick electrode from holder or cut off welding wire at contact tip when not in use. • Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. • Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. • After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. • Use only correct fuses or circuit breakers. Do not oversize or bypass them. • Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL or DIRT can injure eyes. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. • Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. • Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. • • Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices. • • Wearers of Pacemakers and other Implanted Medical Devices should keep away. Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. NOISE can damage hearing. • • Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. -1- VMS-1600/1300 Video Arc Monitoring Systems CYLINDERS can explode if damaged. Compressed 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. • • • • • • • • • • • Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result. Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1.3 Additional Symbols for Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. • • • Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. • • • • • Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment. OVERUSE can cause OVERHEATING • • • Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. FLYING SPARKS can injure. • • • Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires — keep flammables away. STATIC (ESD) can damage PC boards. • • Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. MOVING PARTS can injure. -1- • • Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can injure. • • Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. BATTERY EXPLOSION can injure. • Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose. MOVING PARTS can injure. • • • • Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. READ INSTRUCTIONS. • • • Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. H.F. RADIATION can cause interference. • • • • • • High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. • • • • • • Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. -1- VMS-1600/1300 Video Arc Monitoring Systems 1.4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1.5 Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global EngineeringDocuments (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 1.6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. -1- SECTION II INTRODUCTION The Miller Welding Automation 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 surrounding weld zone can be viewed together without having to make any filter adjustment when looking first at the weld puddle and then at the weld joint ahead of the puddle for tracking. 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 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 weld- ing apparatus attached to the welding torch such as magnetic arc oscillator and/or wire feeder, etc., or deep groove 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-1300 camera is designed to be mounted 3” (76 mm) (nominal) from the weld- ing 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 magnifica- tion is reduced. 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-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 NOTE: There are also optional PAL versions available. The Miller Welding Automation VMS1600/1300 Video Monitoring System consists of the following components: 1. 2. 3. -7- A solid state color camera assembly A camera control unit (CCU) A solid state color monitor - CRT (Miller Welding Automation supplied in sealed VMS-1600/1300 Video Arc Monitoring Systems 4. 5. 6. case); or LCD (customer supplied enclosure mounting and plexiglass screen cover) A lens controller box A halogen setup light Interconnecting cables -8- The camera head assembly is supplied with a universal mounting bracket which is designed to be attached to the welding torch. 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. 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 “pos- sible 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 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 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. 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 mo- torized wire guide and motorized slide functions if these devices are used on the system. If the shipment is by UPS and there is damage, contact Miller Welding Automation. We will call UPS who will send an inspector to your facil- ity. 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. 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. -9- VMS-1600/1300 Video Arc Monitoring Systems VMS-1600-1300 VIDEO ARC MONITORING SYSTEM - 10 VMSC-1600-1300 COMPACT VIDEO ARC MONITORING SYSTEM - 11 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 • Camera Head • • • Camera type: NTSC or optional PALformats Diameter: 25.4 mm (1”) Sensor: 768 horizontal pixels, 494 vertical pixels 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 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 - 12 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 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 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 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 - 13 VMS-1600/1300 Video Arc Monitoring Systems - 10 - VMS-1600/1300 Video Arc Monitoring Systems - 11 - VMS-1600/1300 Video Arc Monitoring Systems SECTION IV INSTALLATION This section should be read completely before any installation is actually started. 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. 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. Determine Camera Location The first step in the installation is to determine exactly what you want to see in your appli- cation. 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 -28- 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. 1) Field of View The field of view is dependent on the distance between the camera and the weld puddle. 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). 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 VMS-1600/1300 Video Arc Monitoring Systems additional focus adjustment may be necessary, see “Focus Adjustment”, later in this section. The us- able focus distance range is 2” to 6” (52 to 152 mm). Because the screen format is 4:5, whatever 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). - 17 - engineering etline ® VMS-1600/1300 Video Arc Monitoring Systems -28- VMS-1600/1300 Video Arc Monitoring Systems - 19 - VMS-1600/1300 Video Arc Monitoring Systems that the gas cup or nozzle covers up the weld puddle when in the welding position. 2) Viewing Angle 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. In some applications, the camera can be placed to look under the wire. Once the approximate position is determined, the camera position can be finalized while welding with a live arc. 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. 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. b. c. Convection - This would actually be ambient air temperature. 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. 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. 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 -28- VMS-1600/1300 Video Arc Monitoring Systems This should work for all but very long weld times. 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 - 21 - VMS-1600/1300 Video Arc Monitoring Systems pressures may cause water leakage. The VMS package may be ordered from Miller Welding Automation 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. 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 Miller Welding Automation for details. C. 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. 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 located 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. Normally the CCU requires no adjustment after initial set-up. The nominal adjustments are as follows: 4) 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. Set-up Light 1) CCU Set-up After installation, check that the CCU controls are set up as follows: FRONT PANEL POWER ON AGC ON WHITE BALANCE MANUAL 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 weld- ing arc for maximum lamp life. This light will have no effect on the picture during the weld. -28- 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. Move the welding torch into the welding position over the piece part. VMS-1600/1300 Video Arc Monitoring Systems 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. 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: For the VMS-1600, it should be 6” (152 mm) For the VMS-1300, it should be 3” (76 mm) - 23 - VMS-1600/1300 Video Arc Monitoring Systems If the camera must be at a different distance, perform the Initial Focus Adjustment, as below. 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 camera E. Focus Adjustment focuses on the tungsten tip, hold the sensor in position and tighten the Cam- era 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 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: 1) 2) 3) 4) With the camera mounted in the desired position, make sure the iris is fully open. 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, be- tween the farthest point and the closest point. You can tell when this happens by carefully observing the picture while holding the switch in. 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 -28- 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. VMS-1600/1300 Video Arc Monitoring Systems - 19 - VMS-1600/1300 Video Arc Monitoring Systems - 34 - VMS-1600/1300 Video Arc Monitoring Systems 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. - 35 - VMS-1600/1300 Video Arc Monitoring Systems 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. - 34 - VMS-1600/1300 Video Arc Monitoring Systems SECTION VII SYSTEM DRAWINGS - 35 - VMS-1600/1300 Video Arc Monitoring Systems - 26 - 34 - VMS-1600/1300 Video Arc Monitoring Systems - 37 - VMS-1600/1300 Video Arc Monitoring Systems - 28 - VMS-1600/1300 Video Arc Monitoring Systems - 29 - VMS-1600/1300 Video Arc Monitoring Systems - 30 - VMS-1600/1300 Video Arc Monitoring Systems - 33 -