MeltTools Welding Cameras Made in America AI Welding Tools

Camera System Troubleshooting

Keep calm and troubleshoot. Browse our FAQs below to isolate the problem and resolve it. Feel free to contact us if you have a particularly thorny problem or need spare system components. We guarantee and support every camera system that we make.

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Frequently Asked Questions

  • Why am I seeing only a black and white (or red) image?
    Your camera settings may be in black and white, or your camera is designed to be a monochrome camera. If your camera is a color camera but the image appears in monochrome, use the camera controller to enter the camera menu and select Color Mode> Color (or B&W). If your camera is a monochrome camera, the image will be monchrome when B&W is selected, and the image will be red, due to the red LEDs, when Color is selected.
  • My image looks hazier than when the system was first installed. What has gone wrong?
    When the optical pathway in front of the lens becomes dirty, the light entering the lens will be increasingly scattered, resulting in an image with reduced definition. In some applications you may find that the dust and dirt on the surface can be wiped off with a soft lens cloth or cotton bud; in other applications the material may be discolored from heat exposure, or hot metal may have adhered to the surface. If it can not be cleaned, the spatter shield and/or sealant glass should be replaced. Spatter shields may be made of plastic or glass.
  • Why is my image dark and noisy before welding?
    There is not enough light from the LED reaching the camera sensor. Check for an image by pointing the camera at a light. Adjust the AGC or Brightness on the OSD to high numbers. Also adjust the camera angle or working distance in order to add supplementary light.
  • Why is the camera bright zone not as strong as it used to be?
    Bright zone attenuation can happen because of too much light reaching the sensor or the auto-exposure mechanism is confused. For an auto-exposure issue, restore the factory settings on your MeltTools controller and then set parameters as desired again. With a sensor problem, check the OSD settings for WIDE or PUDDLE are correct and change the field of view via lens or working distance.
  • Why can I not control my camera?
    This problem can occur when the camera ID does not correspond to the controller camera ID. To fix this, change the camera channel to 4 on the advanced camera controller (2 camera or 3 camera system) and push reset. This will reset the camera IDs to the channel that it is plugged into and camera control should be restored.
  • Why are my crosshairs not displaying properly?
    This can happen when crosshair settings on the camera are not in sync with the controller. For Advanced Camera Controllers, hit the crosshair reset button on the controller or reset the power cycle is problem still persists. For other controllers, contact MeltTools for assistance.
  • Why is the camera video intermittent?
    This problem can occur if there is signal interference, if radiated HF enters the system, or if there is a ground loop in the system. Signal interference can happen with long cables in a highly electromagnetic environment. The best resolution is to reduce the video signal to 720p and/or change to EX-SDI format. Other solutions can be to replace the 24V input power to a higher grade or change the fiber system. Radiated HF entering the system can be solved by grounding the control box to a cabinet ground, uncoiling camera cables, and ensuring the camera is correctly isolated. For a ground loop in the system, connect the drain lead to chassis/earth/machine ground and replace the cable. Once completed, power the monitor off the controller to ensure single point grounding and check to make sure all components are isolated.
  • Why is nothing appearing on the screen?
    There are multiple solutions to this issue. There is a chance that power is not reaching the camera. In this case, check the power is on for the controller; the camera LEDs should be on or be able to be turned on in this case. It is also possible that the video signal is not reaching the display. Check the video signal chain to ensure it is connected to the correct input of the monitor and there are no cable failures. There is a possibility that the input channel on display is incorrectly selected. For this, check that the display is set to the correct display type and the resolution and frame rate settings are the same as the camera (e.g., 1080p 60i). This problem also occurs if the display device is not working. Check the power to the display and use alternative HDMI and SDI signal to make sure video is displayed. The camera signal could be mismatched to the display. To resolve, single press the controller reset button to reset the camera and controller. Finally, there is a chance the monitor is in standby mode. Simply switch the monitor to normal operation mode to fix the issue.
  • Why is my DART2 camera's air knife pressure low or non-existent?
    This occurs when there is a blockage in the camera. All DART2 cameras are shipped with a set screw installed under the bottom surface of the camera to it is a deliberate decision by the customer to utilize the air knife (otherwise dust can enter the camera). Remove the installation to use the air knife and use clean and dry air.
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