GE Inspection Technologies Remote Visual Inspection Everest Ca-Zoom 6.2 ® Operating Manual www.ge.
Preface Congratulations! You now have one of the most advanced technology available for remote visual inspection. The Everest Ca-Zoom 6.2 Digital Inspection System is the first fully digital inspection camera system available on the market for industrial applications. With its advanced iVIEW™ software technology, unique features such as your choice of camera head diameter, and ease of operation combine to make the Everest Ca-Zoom 6.
Table of Contents 1. Warning and Precautions...................... 3 13. Measurement Operations ............... 67 2. System Symbol Description ................. 7 14. Maintenance ......................................71 14.1 Cleaning .................................... 71 14.2 Storage & Shipment .................. 71 14.3 Lamp & Lamp Window Replacement - PTZ140............... 71 14.4 Camera Window Replacement - PTZ140............... 72 14.5 Camera Module Replacement - PTZ140..........
1 Warnings and Precautions Please Read To ensure operators safety, be sure to read and understand this User’s Manual before using any of this equipment! Possible Explosion Hazard The Everest Ca-Zoom 6.2 Digital Inspection System camera and its accessories are not explosion-proof, pressurized, or intrinsically-safe. Do not use in hazardous environments as defined in NFPA 70 National Electrical Code, or IEC 79-10, or EN60079-10.
Warning Use of any piece of this equipment in a manner not specified by the manufacturer may impair the product’s ability to protect the user from harm. Warning The Everest Ca-Zoom 6.2 Digital Inspection System and accessories should never come in direct contact with any voltage or current source. Damage to the equipment and/or electrical shock to the operator may result! The Everest Ca-Zoom 6.
1 AVERTISSEMENTS ET PRÉCAUTIONS D’EMPLOI Lisez Pour assurer la sécurité de l’opérateur, prenez bien soin de lire et de comprendre ce manuel de l’utilisateur avant de vous servir de l’appareil. Risque D’Explosion Le système d’inspection digital Everest Ca-Zoom 6.2 et ses accessoires ne sont pas antidéflagrants, pressurisés ou intrinsèquement sans danger. Ne pas utiliser dans un environnement dangereux tel que décrit dans le NFPA 70 du Code National Électrique ou le IEC 79-10 ou le EN60079-10.
Avertissement Toujours fermer le bouton d’alimentation principal avant de débrancher le courant CA. Avertissement L’utilisation de toute pièce de cet équipment d’une façon non décrite par le fabricant risque de nuire à la capacité du produit de protéger l’utilisateur contre des blessures. Avertissement Le systèm d’inspection digital Everest Ca-Zoom 6.2 et ses accessories ne doivent jamais entrer en contact direct avec une cource de courant ou avec du voltage.
2 System Symbol Description CAUTION: REFER TO USER’S MANUAL CAUTION: SURFACES MAY BE HOT 10AF 250V FUSE INFORMATION: REPLACE ONLY WITH SAME TYPE AND RATING Caution - Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure Description des Symboles ATTENTION: REPORTEZ-VOUS AU MANUEL DE L’UTILISATEUR ATTENTION: LES SURFACES PEUVENT ÊTRE CHAUDES 10AF 250V INFORMATION SUR LE FUSIBLE: REMPLACEZ UNIQUEMENT AVEC LE MÊME TYP
3 Features and Benefits Three Camera Head Diameter Options to provide inspection tools for large area viewing and in cases where access is limited to small openings. Camera heads are interchangeable and operate from same camera control unit and Hand-held Controller.
5 Helpful Hints • Prior to any inspection, familiarize yourself with the Hand-held Controller buttons, features, joystick navigation in order to save you time during inspection. • Clean the camera window regularly. In most cases a poor image is due to dirt on the camera window lens. • Always allow sufficient time for camera head to cool before placement in storage/ shipping case. 6 System Overview 6.
10 6.2 Standard System • • • • • • • • • Ca-Zoom camera with integrated lights and pan & tilt Camera Control Unit (CCU) iVIEW Hand-held Controller with LCD monitor 30 m (100 ft.) Camera Cable 5 m (16 ft.) Hand-held Control Cable AC Power Cable Tool Kit Operator Manual and Setup instructions Shipping/Storage Case 6.
11 7 System Components 7.1 Camera Control Unit Camera Connection USB Video Output CompactFlash Drive Keyboard Connection System Power On/Off Coaxial Video Out S-Video Out Coaxial Video In S-Video In 5 3 0ATENTS #OMPLIES WITH #&2 AND EXCEPT FOR THE DEVIATIONS PURSUANT TO ,ASER .OTICE .O DATED *ULY Hand-held Controller Connection RS-232 Cable (Z 6 ! & ! AC Power AC Fuse 2%0,!#% &53% !3 -!2+%$ 7.
12 7.2 Camera Head Options (Continued) Camera lens 8 X 5 Watt Lights Schrader Valve Cap PTZ70 Tilt Mechanism Pan Housing 7.3 Hand-held Controller Speakers Soft Buttons (8 total) Multi-function joystick Save Zoom Freeze :OOM Focus :OOM 3AVE &REEZE &/#53 -%.5 ,)'(43 %.4%2 )-!'% %8)4 Menu Enter Lights Exit Image Power (LCD) Audio Level Microphone Everest Ca-Zoom ® 6.
13 8 System Setup Before setting up the system for use make sure the CCU, Camera Head and Hand-held Controller are placed on a sturdy surface. 8.1 Attaching Hand-held Controller Cable Step 1. Remove the Hand-held Controller and Hand-held Controller’s cable from the system’s case. Step 2. Attach the Hand-held Controller cable to the Hand-held Controller by aligning the red dot on the cable to the small keyway on the Hand-held Controller and push in.
14 8.2 Attaching Camera Cable to Camera and CCU Step 1. Align the small key on the cable connector with the keyway inside the connector on the camera head. Push the cable in and turn the nut until it comes to a hard stop (fig. 2). Note: If the nut does not reach a hard stop, the cable may not be aligned correctly. Realign the cable with camera head and repeat Step 1. Step 2. Align the wide key on the cable connector (fig.
15 8.4 Attaching Slip Ring Cable Reel (Optional) Step 1. Align the wide key on the female end of the patch cable (fig. 5) with the wide notch on the top of the connector on the cable reel. Push the cable in and turn the nut until it locks in place (fig. 6). Step 2. Align the wide key on the cable termination with the top of the cable connector on the CCU. Push the cable in and turn the nut until it locks into place. Figure 5 Figure 6 8.
16 8.7 Laser Accessory Installation (PTZ100) Step 1. Locate the Schrader air valve on the pan and tilt section of the camera. Remove the Schrader air valve cover. Step 2. Release the pressure from the camera head Step 3. Remove the screw from the laser mounting port on camera head (fig. 8) Figure 8 Figure 7 Step 4. Step 5. The laser accessory has a wire and connector assembly. Place the mounting plate over the end of the harness.
17 8.8 Laser Accessory Installation (PTZ140) Step 1. Locate the Schrader air valve on the pan and tilt section of the camera. Remove the Schrader air valve cover. Step 2. Release the pressure from the camera head (fig. 11) Step 3. Remove the three screws from the laser mounting plate on camera head (fig. 12) Figure 12 Figure 11 Step 4. The laser accessory has a wire and connector assembly. Connect to mating con- nector from camera head (fig. 13) Step 5.
18 9 Operation Procedures 1. Place Ca-Zoom PTZ case on sturdy surface. 2. Take out AC power cable and connect to power outlet. If possible, use AC power cord in combination with a GFI protector. 3. Connect Hand-held Controller cable to Hand-held Controller and CCU. 4. Connect camera cable to camera and CCU. 5. Attach strain relief cable. 6. Place camera on mounting pole. 7. Insert new a CompactFlash® card into the CompactFlash drive. 8. Connect other peripherals as needed.
19 10 Hand-held Controls Joystick Overview The joystick is used to control the PTZ camera motion and navigate through the menu selection on the hand-held contoller’s LCD. The left and right joysticks will both be simultaneously active. Hence, contradictory joystick movement will result in the camera dithering (camera moving back and forth). Both joysticks will also operate identically, which will enable right-handed or lefthanded operation.
20 Joystick - Text Generator The joystick is used to scroll through text characters in the on-screen keyboard to be entered. Usage • The joystick may be used to create text for text annotation overlay onto live or frozen images (see “Text Annotation”). • The joystick may be used to name files or folders (see “File Management Menu Folders”). • The joystick may be used to set the time and date (see “Setup Menu -Time/Date”).
21 Zoom Usage • The Zoom Plus (Zoom +) button will make the camera zoom in on a live screen only. The Zoom Minus (Zoom -) button will make the camera zoom out from an inspection subject. Access • Press Zoom Plus (Zoom +) button while in live video mode to zoom in on an inspection subject. Press Zoom Minus (Zoom -) button while in live video mode to zoom out from an inspection subject.
22 Focus Usage • Camera will convert to manual focus mode. For use in live screen mode only. Access • Press FOCUS (+ or -) while in live screen mode. Operation • Provides manual focus operation to adjust an out-of-focus image. • Displays focus indicator gauge in top right corner of screen for 3 seconds after FOCUS (+ or -) button has been pressed. • Camera will stay in manual focus mode after the indicator gauge disappears.
23 Lights Usage • Adjust light output level from lamp. • Turn lamp On/Off. Access (PTZ70) • Press Light (Spot) to operate 4-spot light. • Press Light (Flood) to operate 4-flood light. Access (PTZ100) • Press Light (left) to operate top light. • Press Light (right) to operate bottom light. Access (PTZ140) • Press Light (left) to operate left-hand light. • Press Light (right) to operate right-hand light.
24 Image Usage • Controls the brightness of the image displayed on the LCD. Access • Press Image (+ or -) to increase or decrease the brightness of the image displayed on the LCD. Operation • Displays brightness level gauge in top right corner of screen showing relative image brightness. • Soft button “FULL AUTO” will be displayed. • Pressing soft button will return image brightness control to auto mode. Exit • Wait for soft button operation to time out.
25 Volume Usage • Adjust volume level on Hand-held Controller’s speaker. Access • Press the volume (+) to increase volume output level or volume (-) to decrease volume output level. Operation • Volume indicator will be displayed in top right corner of screen showing relative volume for 3 seconds after buttons have been pressed. Freeze Frame - Button and Menu Usage • Freezes live image currently displayed onscreen. Access • Press the FREEZE button while any live image is displayed on the LCD.
26 Exit Usage • Terminates current button or menu activated functions. Access • Press EXIT button. • If in an operation from a live screen, returns operation to basic live view. • If in an operation associated with a frozen image, returns to the FREEZE FRAME image screen. A second press of the EXIT button returns to a live view screen. Onscreen Menu Features • • • • • • Advanced features are accessed through a combination of button activations and onscreen menu selections.
27 11 Menu Features 11.1 Save Image and Video Overview • The system stores images in folders in either flash memory or on a CompactFlash (CF) card. A default folder name of “MAIN” is initially created by the PTZ system. New folders may be created using the file manager menu (see “File Manager - Folders”). • Each image is placed in a folder with an image file name based on date, i.e., YYMMDDXX.BMP, .JPG or .MPG for video, where YY is year, MM is month, DD is day, and .bmp, .jpg and .
28 Video File Storage Capacity Table Video File Format Typical File Size per Image Internal Flash Memory 512MB CF Card (notes 1,2) Capacity - 64MB (note 3,5) (note 3,5) MPEG2 high 3.2Mbs 160 secs 21 mins MPEG2 low 2.1Mbs 480 secs 33 mins MPEG1 high 2.8Mbs 180 secs 24 mins MPEG1 medium 1.5Mbs 350 secs 47 mins MPEG1 low 0.8Mbs 640 secs 85 mins Notes: 1. File size varies by image content. 2. Table is based on NTSC images - PAL images and videos will be 10% larger. 3.
29 Quick Image Save to Last Folder • The PTZ system assumes you would like save the current image to the same drive and folder as the previous save. After pressing SAVE the menu screen which appears has the path to the last saved folder highlighted. To save to that folder, just press ENTER (you do not need to move the cursor pointer).
30 Adding Audio to a Previously Captured Image • In a live or FF screen, press MENU, Highlight FILE MANAGER and press ENTER. • Use the joystick to move the arrow pointer to the A:\ or C:\ memory location and press ENTER. • Use the joystick to select and ENTER button to recall an image to full-screen size. • Press MENU. • Highlight AUDIO. A drop-down menu will appear. • Use the arrow pointer to select RECORD AUDIO. • Press ENTER.
31 When Text May Be Added to Images • Text may be added to images at any one of the following times: • When an image is frozen, text may be added to the image prior to storing the image by: - Using the keyboard or joystick - Recalling preset text • Whenever an image is recalled from memory, text may be added and saved with the image by: - Using the keyboard or joystick - Recalling preset text • At any time during live image viewing.
32 Saving Preset Text with New or Recalled Images Note: To create preset text, see SET-UP MENU - PRESETS. When a recalled image is displayed on the Hand-held Controller’s LCD monitor, or when a frozen image is displayed: • Press MENU. A menu will appear which contains STILL ANNOTATION. • Highlight STILL ANNOTATION. A drop-down menu will appear. • Use the arrow pointer to select STILL ANNOTATION ADD PRESET. • Press ENTER. • The last preset text entered will appear on-screen.
33 Live Image Annotation Text and arrow annotation can be created and displayed on the live images shown on the Handheld Controller, and provided on the video output connectors of the CCU. • Text and arrow annotation shown on live images will be captured and stored on images which are frozen and stored to internal or CompactFlash card. Live Annotation Menu Figure 19 Creating Live Annotation Text • In a live screen, press MENU. • Use the arrow pointer to highlight LIVE ANNOTATION ADD TEXT.
34 Clearing Live Annotation Text • Live annotation text may be cleared by: • Press MENU. • Use the arrow pointer to highlight LIVE ANNOTATION CLEAR TEXT. • Press ENTER. Hiding/Showing Text Annotation • Display of live text annotation may be turned on or off in any screen using the show option. - Press MENU. - Highlight STILL ANNOTATION. - Move arrow pointer to SHOW (on or off). - Press ENTER.
35 Clearing Arrow Annotation At any time for live image arrow annotation, or prior to saving a frozen image, all current text and arrow annotation may be cleared by: • Press MENU. • Highlight LIVE ANNOTATION or STILL ANNOTATION. • Move the arrow pointer to CLEAR ARROWS. • Press ENTER. Everest Ca-Zoom ® 6.
36 12 Main Menu Operation Usage Provides access to the following sub-menus and image functions in live screen mode: • • • • • • • • • GO TO HOME CAMERA SETUP LASERS (option will only appear if laser measurement accessory is installed on camera head) POSITIONS SPLIT SCREEN LIVE ANNOTATION VIDEO RECORD FILE MANAGER SETUP MENU Live Main Menu Screen Figure 20 Access Main Menus • While in live or FF viewing mode, press MENU button. • Use cursor to select menu or function.
37 12.1 GO TO HOME (position) Access • Press the MENU button • Highlight GO TO HOME • Use pointer to select GO TO HOME and PRESETS. Operation • Camera will move to Home Postion configured in Presets Home Position Set Home. 12.2 CAMERA SETUP Menu Usage • The Camera Setup Menu is used to change the PTZ’s camera configurations. Access • Press MENU. • Highlight CAMERA SETUP • Press ENTER. Operation • A menu titled CAMERA SETUP (see example screen shown below) will appear.
38 Digital Zoom Usage • Turn digital zoom On/Off Access • Highlight Digital Zoom Operation • Move pointer arrow to Permanent • Move pointer arrow to either ON or OFF • Press ENTER. A check mark will appear next to your selection To Accept • Press MENU Operation to setup Digital Zoom • Press Zoom (+) or Zoom (-) button. Soft button labeled “Toggle Digital Zoom” will appear. If “Permanent ON” was selected • Camera will operate with optical and digital zoom.
39 Long Exposure Usage • The PTZ’s embedded computer will allow the camera’s electronic shutter to remain open until the image being acquired has a brightness level that matches a factory preset value. Access • Highlight CAMERA SETUP Operation • Move pointer arrow to either ON or OFF • Press ENTER. A check mark will appear next to your selection.
40 Sensor Units Usage • Allows user to set temperature to set pressure to PSIG, BAR or Zero Access • Highlight Sensor Units Operation • Move pointer arrow to either PRESSURE or RADIATION • Or PSIG, BAR or SET TO ZERO in Pressure • Or krad or Gy in Radiation • Press ENTER. A check mark will appear next to your selection.
41 • Move the pointer arrow to AUDIO WARNING. A drop-down menu with ON/OFF appears. • Press ENTER. A check mark will appear next to your selection. To Accept • Press MENU DISPLAY TEMP (On/Off) • Allows temperature in Celsius to be turned on or off. Access • Highlight TEMP SENSOR. • Move the pointer arrow to DISPLAY TEMP. A drop-down menu with ON/OFF appears. • Press ENTER. A check mark will appear next to your selection. To Accept • Press MENU Notes: 1. There are two temperature warning levels.
42 Camera Stabilization (PTZ140 camera head only) Usage • Helps to stabilize the video image when the camera is in vibrating environment. Access • Highlight CAMERA STABILIZATION Operation • Move pointer arrow ON or OFF • Press ENTER. A check mark will appear next to your selection. To Accept • Press MENU White Balance Usage • Allows user to set white balance of the camera based on the lighting of current image.
43 12.3 LASERS Turns the Parallel Laser accessory mounted on the camera head ON and OFF. The Parallel laser accessory provides a reference measurement on a perpendicular surface. Warning • Prevent direct eye exposure to beam • Ensure that the beam is always terminated at a suitable non-specular (i.e.
44 • Move pointer arrow to ZERO POSITION • Move pointer arrow to SET ZERO • Press ENTER. Preset Soft Keys Display Menu Feature • Allows Preset (1-10) to be utilized as soft buttons. HOME and ZERO Positions are always ON. Go to Preset Soft Keys • Move pointer arrow to PRESET SOFT KEYS • Move pointer arrow to ON or OFF • Press ENTER. Access Preset Soft buttons • Press any soft button in live video mode.
45 To Accept • Press ENTER. Set Preset (position) • Use joystick to position camera to desired preset position. • Move pointer arrow to PRESET button (1-10) • Move pointer arrow to SET PRESET • Press ENTER. 12.5 Split Screen Operation Usage • Allows a frozen or recalled image to be viewed alongside a live or frozen image in any com- bination of live, frozen, and recalled images (except live/live). Access • Press MENU button while in the live, freeze frame, or recalled image modes.
46 Operations Live/FF Split Screen • Initially, the left half screen is active with a live image present. Split Screen Menu Options Pressing the MENU button while in split screen allows you to choose to: • Switch active sides • Close either side • Select either side for a full-screen view. Split Screen Menu Figure 23 Activating Other Half Screen • Press MENU button. The split screen menu options screen will appear. • Highlight SPLIT OPTIONS (RIGHT or LEFT) ACTIVE.
47 Split Screen Menu Saving One Side of the Split Screen Image • Insure the desired half screen is “ACTIVE”. • Press MENU. • Highlight SPLIT OPTIONS (RIGHT or LEFT) FULL SCREEN. • Press ENTER. • Press MENU. • Highlight SAVE IMAGE. • Select a save destination (A: or C:). • Press ENTER. Recalling a Stored Image to a Half Screen • Activate the side into which you want to recall an image. • Press MENU. • Highlight FILE MANAGER. • Press ENTER. The FILE MANAGER menu will appear. • Highlight RECALL IMAGE.
48 12.6 Video Record Operation Usage • The Video Record mode allows live video displayed on the hand-piece LCD to be stored to Internal Flash Memory or CompactFlash card.. Access • Press MENU while in live mode. • Highlight VIDEO RECORD by using the cursor to move the joystick up or down. • Highlight Start Recording. • Press ENTER. Operation • A flashing red recording icon appears in the upper right of the LCD monitor. Pause Recording • During recording press any of the soft buttons.
49 Audio On/Off (Option) • Allows audio to be turned On/Off during video recording. Access • Prior to recording video press highlight Audio and select ON/OFF. • During recording press MENU and select VIDEO RECORD. • Highlight Audio and select ON/OFF. or • During recording press any of the soft buttons. The video record settings will appear. • Press Turn Audio ON/OFF soft button. Save Location (Option) • Allows user to choose into which drive the video file is to be stored.
50 12.7 FILE MANAGER Menu File Manager Menu Screen Figure 25 Usage • The File Manager menu is used for recalling, copying, or deleting images and videos from, or between, the internal flash memory (the C:\ drive), and the CompactFlash (the A:\ drive) drive. • If an image file has an associated .WAV file, it will also be operated on in the same manner as the image file which is selected. • File folder creation, renaming and deletion are accessed through this menu.
51 RECALL IMAGE and AUDIO Usage • Allows the user to recall images and their associated audio files, and videos stored in system memory or on CompactFlash card. Up to six thumbnails at a time can be displayed. From the thumbnail list, a specific image or video can be selected and displayed full-size. Access • Access the FILE MANAGER screen. • Highlight RECALL from the File Manager menu. • A sub-menu will appear which allows you to recall the image from either C:\ or A:\ memory.
52 VIDEO PLAYBACK CONTROLS Usage • During video playback mode. Operation • Press joystick right to fast forward the video. • Press joystick left to rewind the video. • Press MENU to pause the video clip. Video playback menu will appear. • Press joystick up or down to seek to any position in the video clip. • Press EXIT to stop playback and return to live video. AUDIO PLAY • If there is an audio file associated with a stored image, a speaker icon will be shown in the image.
53 • Once a desired image has been located, press ENTER. A check mark will appear in the top, left corner of the image. To remove a check mark, hit ENTER again. • Repeat the process until all images that need to be copied have been checked. • Press MENU. The images will copy to the A:\ drive. You will then be returned to the screen from which File Manager was selected. • If the same image is already on the card, a message will appear. Press ENTER to overwrite or MENU to skip.
54 • Use the cursor to highlight the location of the images or videos (C:\ or A:\), and whether you wish to delete all images and videos or selected images and videos. • Press ENTER. Operation for Deleting All Images and Videos If either DELETE IMAGES C:\ SELECTED or DELETE IMAGES A:\ SELECTED was chosen from the menu: • A page of thumbnail images and videos will appear. • Navigate to the images or videos to be deleted by moving the joystick left/right or up/down.
55 FOLDER Operations • The PTZ system supports the creation and modification of file folders in the internal C:\ memory and the A:\ disk drive. Initially the PTZ system creates a folder named MAIN in the C:\ and A:\ memory locations. The user may create additional folders on either on the C:\ or A:\ memory locations. Folder Menu Screen Figure 27 CREATE FOLDER Access • Highlight FOLDER in the FILE MANAGER menu. Operation • Move the arrow pointer to either C:\ or A:\.
56 RENAME FOLDER Access • Highlight FOLDER in the FILE MANAGER menu. Operation • Move the arrow pointer to either C:\ or A:\. A drop-down menu with CREATE/RENAME/CHOOSE/ DELETE will appear. • Move the arrow pointer to RENAME. • Press ENTER. A thumbnail screen of all the folders located on the selected drive appears. • Use the joystick to highlight the folder you wish to re-name. • Press ENTER. The name of the chosen folder will be erased and replaced with a blinking cursor.
57 DELETE FOLDER Access • Highlight FOLDER in the FILE MANAGER menu. Operation • Move the arrow pointer to either C:\ or A:\. A drop-down menu with CREATE/RENAME/CHOOSE /DELETE will appear. • Move the arrow pointer to DELETE. • Press ENTER. A screen will appear asking if you are sure you want to delete the folder. • Press ENTER to complete the folder delete process. • You may continue to delete folders using the above process, or press EXIT to return to the previous screen.
58 12.8 SETUP Menu Usage • The SETUP MENU is used to change various basic system settings. • The settings you choose are stored and recalled at power-up. Access • Press the MENU button. • Use the joystick to select SETUP MENU from the onscreen display. • Press ENTER. A list of user modifiable fields will appear. Operation • Move the joystick such that the small arrow pointer is located next to the setting you would like to modify or the process you wish to activate.
59 LANGUAGE Feature Summary • The PTZ system can be configured to display all on-screen menus and instructions in English, or any one of five other languages. • The PTZ system is shipped from the GE Inspection Technologies’ factory with the English language set as the active language.
60 Changing to Other Language • If the language being shown on the hand-held controller is not the desired language, you can access the language selection menu by performing the following steps. • From a live screen, press MENU. • Move the arrow pointer down to the menu option at the bottom of the screen. • Press ENTER. A drop-down menu appears listing the installed language files. • Move the arrow pointer to the desired language. Press ENTER. • Press MENU to accept language selection.
61 To Accept • Press MENU. MPEG QUALITY SELECTION Access • Highlight IMAGE, a drop-down menu appears. • Move pointer arrow MPEG QUALITY. Operation • Move pointer arrow to MPEG2 HIGH, MPEG2 LOW, MPEG1 HIGH, MPEG1 MED, MPEG1 LOW. • Press ENTER. A check mark will appear next to your selection. To Accept • Press MENU. MPEG LIMITS Access • Highlight IMAGE, a drop-down menu appears. • Move pointer arrow MPEG LIMIT. Operation • Move pointer arrow to NONE, 1 MIN, 5 MIN, 10 MIN, 20 MIN. • Press ENTER.
62 Delete Existing Preset Text Overlay Access • Highlight GRAPHICS. A drop-down menu will appear. • Move the pointer arrow to PRESETS. • Press ENTER. The last preset text created will be displayed. Option • Move joystick Up/Down to scroll through existing preset text screens. • Press MENU. A drop-down menu appears. • To delete, move cursor arrow to DELETE, and press ENTER. To Accept • The screen will display a message asking if you are sure you want to delete the selected preset text screen.
63 LOGO Allows up to a 200 pixel x 200 pixel, 16-color Bitmap graphic to be imported into the PTZ system, and displayed on live or stored images. (See “Appendix M” for instructions on creating a logo file.) Access • Highlight GRAPHICS. A drop-down menu will appear. • Move the pointer arrow to LOGO. A second drop-down menu will appear with options SHOW and LOAD. • Insert a CompactFlash card containing a valid file named “logo.bmp” into the CCU disk drive. • Move the pointer arrow to LOAD.
64 SET TIME/DATE Usage • Allows time and date to be set. Access • Highlight TIME/DATE. • Move pointer arrow to SET. A dropdown text box will appear with the current time and date setting. • Press ENTER. A new screen which allows the time and date to be modified appears. • Use the joystick to select and modify the time and date settings. To Accept • Press ENTER. MEASURE Menu Feature • UNITS (inches or millimeters) Usage • Allows the measurement system to display results in inches (in.
65 AUDIO Usage • Enables sound when buttons on the PTZ Hand-held Controller is pressed. Access • Press the MENU button. • Use the joystick to select SETUP MENU from the on-screen display. • Press ENTER. A list of user modifiable fields will appear. • Move the arrow pointer to AUDIO • Move the arrow pointer to BUTTON BEEP • Move the arrow pointer to ON or OFF and press ENTER to make selection To Accept • Press MENU.
66 UPDATE SOFTWARE Menu Feature • Allows software updates to be loaded from CompactFlash card into the PTZ system. Usage • Software updates may be performed in the field without the need for the product to be sent back for factory service. Access Operation • Highlight UPDATE SOFTWARE. • Locate the CompactFlash card to be used to update the PTZ system. • Install the main program memory card into the CompactFlash drive on the CCU. • Press ENTER. • The PTZ system will search for updated software.
67 13 Measurement Operations Feature Summary The Everest Ca-Zoom 6.2 System supports five types of comparison measurements. • Length • PT-Line (Point-to-Line) • Area • Multi-Length (Multi-Segment Length) • Circle Gauge • Comparison measurement uses the size of a known object to measure other objects in the same view and plane. • Such measurements are made using zoomed or unzoomed frozen or recalled images.
68 Comparison Measurement - General Operation For all comparison measurements, the first steps are the same. • Press FREEZE to freeze an image. • Press Menu and select Measure • Select the Comparison measurement type and press ENTER • Make sure camera head is perpendicular to object being measured • Two cursors will appear. Position them to mark a known reference dimension. Use the joystick to increase or decrease the value and press ENTER.
69 Comparison Measurement - Point-to-Line Usage • Measure the distance from a reference line to a point perpendicular to that line, based on a known reference dimension on the image. Operation • Set the reference dimension as described in General Operation. • The first of three cursors will appear. The first two cursors establish the reference line. The third cursor sets a point perpendicular to the reference line for the distance measurement.
70 Comparison Measurement - Multi-Segment Length Usage • Measure the total length of a multi-segmented or non-linear line, based on a known refer- ence dimension on the image Operation • Set the reference dimension as described in General Operation. • The first of up to 24 cursors will appear. Position the cursor as the first point on the feature to be measured and press ENTER. • Continue to place cursors along the feature. A minimum of two cursors must be placed.
71 14 Maintenance 14.1 Cleaning Please clean camera head after an inspection. Use regular water to wipe down cables. Use 70% alcohol to water solution to wipe down the camera head. 14.2 Storage and Shipments The PTZ system should always be stored in a clean and dry condition. Storage should be in areas protected from extreme temperature and high humidity. Storage temperature specification: -13° to 140°F (-25° to 60°C), 95% humidity. 14.
72 Lamp Replacement: • Remove the metal cap from the lamp housing by grasping the lamp housing cap and turning counter clockwise. • Grasp the lamp firmly and pull straight out of the socket, making note of which type of lamp (spot or flood) is being removed (this is written on the side of the lamp). • Replace with the same type of lamp (10° spot, 20° medium, or 30° flood).
73 14.5 Camera Module Replacement - PTZ140 CAUTION ! Before performing any maintenance task, be sure to de-pressurize the camera unit via the shrader valve (see page 11). Follow these steps to replace the camera module in the event of camera failure: • Remove Front and Back covers from camera housing by unscrewing them counterclockwise (fig. 37). • Remove 2 small camera module mounting screws found on the bottom of the camera hous- ing (fig.
74 • Plug the wire harnesses into the new camera module and slide the new module into the housing. CAUTION. Make sure not to pinch the laser wire harness when securing the camera module. • Make sure to put the Desiccant packs back into the camera housing. One on each side of the camera (fig. 42). Laser wires Figure 41 Figure 42 • Replace the 2-camera module mounting screws. • Replace front and back cover of housing. Make sure o-rings are clean, lubricated and seated properly in the grooves.
75 14.6 Lamp Window Replacement - PTZ100 CAUTION! Before performing any maintenance task, make sure camera system is turned off and be sure to de-pressurize the camera unit via the Schrader valve (see page 11). To replace the lamp window, follow these steps: • • • • • Remove the lamp window retainer by unscrewing the five screws with a Phillips screwdriver. Carefully remove the o-ring and windows using the supplied o-ring pick. Clean o-ring groove thoroughly. Replace lamp window.
76 14.7 Camera Window Replacement - PTZ100 CAUTION! Before performing any maintenance task, be sure to de-pressurize the camera unit via the Schrader valve (see page 11). Make sure unit is cooled down completely. Lamps are extremely hot.
77 14.8 Camera Module Replacement - PTZ100 CAUTION ! Before performing any maintenance task, be sure to de-pressurize the camera unit via the shrader valve. Follow these steps to replace the camera module in the event of camera failure: • Remove the back cover from camera housing by unscrewing the 8 Phillips screws around the edges (fig. 51). • Lift off cover by applying some pressure to slide it sideways. • Locate the video harness and pull free from camera housing (fig.
78 • Locate the laser power harness and unplug from the circuit board by gently pulling on the wires (fig. 55) • Gently pull harness to the right side of the housing out of the way. Figure 55 Figure 56 • Pull the module out through the back of the camera housing (fig. 57). • As the module is removed, pull to the left to clear the internal wiring. • Make sure the internal wiring is tight along the sides of the housing before inserting a new module (fig. 58).
79 14.9 Lamp Replacement - PTZ70 CAUTION! Before performing any maintenance task, make sure camera system is turned off and be sure to de-pressurize the camera unit via the Schrader valve (see page 12). To replace the camera window, follow these steps: • • • • • • • • • Remove the four Phillips screw from the front of the camera housing (fig. 59). Remove the lock screw from the rear of the camera housing (fig. 60). Unthread the knurled ring on the back of the camera housing (fig. 61).
80 Figure 63 14.10 Figure 64 Camera Window Replacement - PTZ70 CAUTION! Before performing any maintenance task, be sure to de-pressurize the camera unit via the Schrader valve (see page 12). To replace the camera window, follow these steps: • Remove the four Phillips screw from the front of the camera housing (fig. 59). • Using a pointed object, such as a pick, gently pry the o-ring loose from the outer edge of the window that needs to be replaced. The window will come loose with the o-ring (fig.
81 14.11 Camera Module Replacement - PTZ70 CAUTION ! Before performing any maintenance task, make sure camera system is turned off and be sure to de-pressurize the camera unit via the Schrader valve (see page 12). Follow these steps to replace the camera module in the event of camera failure: • • • • • Remove the four Phillips screw from the front of the camera housing (fig. 59). Remove the four screws on the face of the camera housing. Remove the lock screw from the rear of the camera housing (fig. 60).
82 14.12 Purging If moisture gets into the camera housing fogging may occur on lenses and windows. To eliminate the fogging, purge the camera head by following the steps outlined below. Pressure Test Port 1. Run system with both lights on maximum for about one hour. For best results, put the pan & tilt in the upright position with the camera aimed vertically down. 2. Turn off the system. Remove the rear-housing cap from the camera housing. Remove the cap from the Schrader valve on the pan & tilt.
83 15 Troubleshooting Problem Cause System will not turn on • Not plugged in Remedy • No power to camera head • CCU may have been turned on with no cable attached. • Turn system power off for 2 minutes to allow circuit to reset. • Cable may have been disconnected with power on.
84 16 Service To obtain service for your system, call one of the Service Centers below. If the problem cannot be corrected over the phone, you will be given a return materials authorization number for shipment to the nearest service center. ALWAYS contact a GE Inspection Technologies Service Center for a Return Materials Authorization Number (RMA Number) prior to returning any product for service or repair.
85 17 Warranty GE Inspection Technologies warrants its Everest Ca-Zoom 6.2 digital inspection system components, when new, to be free from defects in material and workmanship and to perform in accordance with manufacturer’s specifications under normal use and service for a period of one year from the date of purchase from GE Inspection Technologies or its authorized distributors.
86 18 Appendices Appendix A – Specifications Operating / Storage Environment Operating temperature: -18° to 49°C (0° to 120°F) Pressure: Waterproof to 45.0 m (150.0 ft.) or 65 PSI (4.
87 Camera Control Unit / Processor (Continued) Video Recording: MPEG2: High and Low Quality Settings Up to 42 minutes recording on High w/1GB CF card MPEG1: High, Medium and Low Quality Settings Up to 92 minutes recording on Med w/1GB CF card Video Output: Composite, S-Video and USB 2.
88 PTZ100 Camera Type: Resolution: Zoom: Field-of-View: Focus: Iris: Electronic Shutter: Sensitivity: Construction: 1/4” Color EX-View HAD® CCD (NTSC and PAL) 470 HTV Lines NTSC, 460 HTV Lines PAL 10x optical optical, 4x digital, 40x total (f=4.2 mm - 42 mm) In-air: 4.6° H x 3.5° V in tele: min distance of 1 m (3.28 ft) In-air: 46° H V x 35° in wide angle: min distance of 10 mm (.
89 PTZ70 Camera Type: Resolution: Zoom: Field-of-View: Focus: Iris: Electronic Shutter: Sensitivity: Construction: 1/4” Color EX-View HAD® CCD (NTSC and PAL) 470 HTV Lines NTSC, 460 HTV Lines PAL 10x optical optical, 4x digital, 40x total (f=4.2 mm - 42 mm) In-air: 4.6° H x 3.5° V in tele: min distance of 1 m (3.28 ft) In-air: 46° H V x 35° in wide angle: min distance of 10 mm (.
90 Appendix B – Software Zoom: Camera Setup: Positions: On-Screen Info.
91 Appendix C – Legacy The Everest Ca-Zoom 6.2 CCU, cable and camera heads are compatible to legacy PTZ 4.0, 4.2 and 4.3 camera systems. In addition 4.0, 4.2 and 4.3 systems and camera heads will operate with the PTZ 6.2 camera control units. Certain camera functions will not be accessible. The table below summarizes features availability. Features Camera Heads PTZ 4.0 PTZ 4.2 PTZ 4.3 PTZ 6.
92 Appendix D – New System Default Settings Function Default Settings Focus Auto/Manual Auto Digital Zoom On/Off On Long Exposure Off Manual Camera Controls Off White Balance Auto Image Stabilization Off Flip Joystick Off Flip Image Off Lasers Off IR Filter Off Appendix E – Accessories Standard Accessories • AC Power Cord (North America) V9000-5026 • Tool Kit PTZ140-TOOL, PTZ100-TOOL, PTZ70-TOOL • User Manual PTZ6.
93 Appendix F - Manual Image Control Features Auto White Balance This mode computes the white balance value output using the color information from the entire image. It outputs the proper value using the color temperature radiating from a black subject based on a range of values from 3000K to 7500K as a reference. One Push WB Is a fixed WB mode that can be adjusted by the user.
94 Appendix G - PTZ Parallel Measurement Laser Calibration • Setup PTZ system. Refer to “System Setup” on page 12. • Point the camera with the laser attachment tilted away from the PTZ body to allow access to the laser housing. • Remove the front cap off each laser (fig. 70). • Turn the lasers on via the camera menu (fig. 71). Figure 70 Figure 71 • Using a 0.050 in. (1.3 mm) hex key, turn the screw on the side of the laser housing to steer the laser dot in the horizontal plane.
95 • Adjust the zoom to the highest optical level until both laser dots are as large as possible in the image. Do not use digital zoom. • Again, center the laser dots in the image 2 in. (50 mm) apart. Figure 75 • Replace the front cap on each laser • The parallel laser dots are now ready for use with the measurement feature. See “Measurement” section on page 67. Note: Using the procedure above, the dots will be centered when the camera is 30 ft. (10 m) from its target.
96 Appendix H – Agency Certifications EUROPEAN EQUIPMENT CLASSIFICATION Group 2, Class A The CE mark on this product indicates it has been tested to conform to provisions noted within the 89/336/EEC Electromagnetic Compatibility Directive. The Everest Ca-Zoom 6.2 system is in conformance with the following standards: EN61010-1 EN61326 Declarations of Conformity are held by GE Inspection Technologies’ European Representative.
97 Appendix I – System Configurations (with cable) PTZ X.X XXX X XXX X X PRODUCT GENERATION A = Version A VIDEO FORMAT N = NTSC video format P = PAL video format CABLE (CCU to HEAD) 030 = 30m (100 ft) CONSTRUCTION (FINISH) A = Anodized Aluminum S = Stainless Steel (PTZ140 only) CAMERA HEAD DIAMETER 140 = 140 mm (25x optical, 12x digital zoom) 100 = 100 mm (10x optical, 4x digital zoom) 70 = 70 mm (10x optical, 4x digital zoom) PTZ VERSION 6.
98 Appendix J – System Configurations (no cable) PTZ X.X XXX X X X PRODUCT GENERATION A = Version A VIDEO FORMAT N = NTSC video format P = PAL video format CONSTRUCTION (FINISH) A = Anodized Aluminum S = Stainless Steel (PTZ140 only) CAMERA HEAD DIAMETER 140 = 140 mm (25x optical, 12x digital zoom) 100 = 100 mm (10x optical, 4x digital zoom) 70 = 70 mm (10x optical, 4x digital zoom) PTZ VERSION 6.2 = Series PRODUCT TYPE PTZ = Pan Tilt Zoom EXAMPLE PTZ 6.
99 Appendix K - Spare Parts List Description Part Number Hand-held Controller (includes 5 m [16 ft.] cable) Hand-held Controller Cable 5 m (16 ft.
100 O-Ring Kit (PTZ140 Camera Head) O-Ring Kit (PTZ70 Camera Head) V4400-1003 PTZ6.0070SEALKT 12” Slip Ring Cable Reel with 10 ft. patch cable Stores up to 38 m (125 ft.) cable V4400-3000 15” Slip Ring Cable Reel with 10 ft. patch cable Stores up to 91 m (300 ft.) cable V4400-3001 19” Slip Ring Cable Reel with 10 ft. patch cable Stores up to 152 m (500 ft.) cable V4400-3002 3 m (10 ft.) Main Cable - Camera Head to CCU 15 m (50 ft.
101 Appendix L - Chemical Compatibility Chemical compatibility to the Everest Ca-Zoom 6.2 system’s ability to come into contact with various liquid substances and not be damaged. There are far too many different liquids in the industrial environment for GE Inspection Technologies to test each one, so customers must determine for themselves if the Everest Ca-Zoom 6.2 system is compatible with their specific chemicals. However, GE Inspection Technologies has tested the Everest Ca-Zoom 6.
102 Appendix M - Creating a LOGO Bitmap File The Everest Ca-Zoom 6.2 system allows for a bitmap image file to be displayed on live images, and stored with captured images. Typically this bitmap image will be a corporate logo. The bitmap image which may be used by the Everest Ca-Zoom 6.2 system must not exceed 200 x 200 pixels, and must be 16 colors. Most graphics programs (such as Microsoft® MS Paint) allow images to be saved with the size and color attributes required by the Everest Ca-Zoom 6.2 system.
103 Appendix N - Environmental Compliance The equipment that you bought has required the extraction and use of natural resources for its production. It may contain hazardous substances that could impact health and the environment. In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources, we encourage you to use the appropriate take-back systems.
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