Jireh NAVIC User Manual Download

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NAVIC

Automated Steerable Scanner

CX0540 Rev 00.1

Summary of Contents for NAVIC

Page 1: ...NAVIC Automated Steerable Scanner CX0540 Rev 00 1 ...

Page 2: ... area below a crawler must be kept clear at all times A clearly marked NO ENTRY ZONE must be cordoned off directly below the area of crawler operation see Preparation for Safe Use on page 42 for additional details WARNING Do NOT operate or place crawler on a surface higher than 2 m 6 ft without a proper tether held taut at all times see Tether Requirements and Attachment on page 43 for additional ...

Page 3: ...m 4 in away WARNING MAGNETIC MATERIAL When the carrying case contains the crawler a magnetic field exists outside the case which may cause failure or permanent damage to items such as watches memory devices CRT monitors medical devices or other electronics People with pacemakers or ICD s must stay at least 10 cm 4 in away from the carrying case when it contains the crawler WARNING MAGNETIC MATERIA...

Page 4: ...manent damage to electronics could occur CAUTION Do NOT operate the NAVIC crawler on an inspection surface which is electrically connected to a component that is being welded The WEEE symbol indicates that the product must not be disposed of as unsorted municipal waste but should be collected separately see Disposal on page 183 for additional details EMERGENCY STOP This symbol indicates emergency ...

Page 5: ... 6 2 1 1 2 Operating Environment 7 2 1 1 3 User 7 2 1 2 Unintended Use 7 2 1 3 Dimensions and Weight 8 2 1 4 Power Requirements 10 2 1 5 Environmental Sealing 10 2 1 6 Performance Specifications 10 2 1 7 Encoder Interface Specifications 11 2 2 Compatible Components 12 2 2 1 Low Profile Probe Holder Frame 12 2 2 1 1 Intended Use 12 2 2 1 2 Operating Limits 12 2 2 2 Vertical Probe Holder Frame 12 2 ...

Page 6: ...Operating Limits 16 2 2 13 Battery Powered Optical Guide 16 2 2 13 1 Intended Use 16 2 2 13 2 Operating Environment 16 2 2 13 3 Power Requirements 16 2 2 13 4 Environmental Sealing 16 2 2 14 Medium Temperature Add On Kit 17 2 2 14 1 Intended Use 17 2 2 14 2 Operating Limits 17 2 2 15 Encoder Adapter 17 2 2 15 1 Intended Use 17 2 2 16 3 Axis Nozzle Scanner Add On Kit 17 2 3 Child Products 18 2 3 1 ...

Page 7: ... 3 3 Encoder Signal Isolation 34 4 3 4 Handheld Controller 34 4 3 5 Auxiliary Cable 35 4 3 6 J300 Encoder Cable 35 4 3 7 Installation Removal Mat 36 4 3 8 Lifting Sling 36 4 3 9 Irrigation Kit 36 4 3 10 Cable Management 36 4 3 11 Cap Plug 37 4 3 12 Tools 37 4 3 13 Cases 37 4 4 Compatible Components 37 4 4 1 Low Profile Probe Holder Frame 37 4 4 2 Vertical Probe Holder Frame 37 4 4 3 Pivoting Probe...

Page 8: ...equirements and Attachment 43 5 2 3 Lifting Sling Setup 44 5 2 4 Lifting Sling Low Profile Setup 46 5 3 Preparation of Inspection Surface 46 5 4 System Connectivity 47 5 5 Configurations 49 5 5 1 Single Drive Module with Frame Bar 49 5 5 2 Crawler with Actuated Probe Lift 51 5 5 3 Crawler with Multiple Probe Holders 53 5 5 3 1 Vertical Probe Holder Frame 53 5 5 3 2 Low Profile Probe Holder Frame 5...

Page 9: ... 8 6 4 Probe Holder 90 Adjustment 90 5 9 3 Axis Nozzle Scanning 91 5 9 1 Scanner Preparation 91 5 9 2 3 Axis Nozzle Operation 96 5 9 3 Encoded Skew Vertical Probe Holder 100 5 9 4 Probe Holder Setup 100 5 9 5 Skew Encoder Cable 102 5 9 6 Encoded Skew Vertical Probe Holder Adjustment 102 5 9 6 1 Latch Pin 103 5 9 7 Skew Angle Adjustment 104 5 9 7 1 Ratchet Lever 105 5 9 8 Pivot Buttons 105 5 9 9 Ca...

Page 10: ...134 6 3 Operation 136 6 3 1 Handheld Controller Layout 136 6 3 1 1 Touchscreen 137 6 3 1 2 D pad 137 6 3 1 3 Joysticks 137 6 3 2 Mode Select Screen 138 6 3 3 Jog Mode 138 6 3 4 Latched Jog Mode 140 6 3 5 1 Axis Scan Mode 141 6 3 5 1 1 Axis Scan Screen 142 6 3 6 System Utilities Screen 144 6 3 6 1 User Settings Screen 145 6 3 6 2 Diagnostics Screens 146 6 3 6 2 1 Detected Modules 146 6 3 6 2 2 Syst...

Page 11: ...omponents 164 10 2 1 Encoder Connector Type 166 10 2 2 Power Cord Type 166 10 3 Probe Holder Frame 167 10 4 Low Profile Probe Holder Frame 168 10 5 Pivoting Probe Holder Frame 169 10 6 Slip Joint Probe Holder Parts 170 10 7 Vertical Probe Holder Parts 171 10 8 Heavy Duty Vertical Probe Holder 172 10 9 Corrosion Thickness Probe Holder 173 10 10 Encoded Skew Vertical Probe Holder 174 10 11 3 Axis No...

Page 12: ...agement 178 10 14 2 1 Cable Management Sleeving 178 10 14 3 Automated Crawler Medium Temperature Add On Kit 179 10 15 Accessories 180 10 15 1 Preamp Bracket 180 10 15 2 NAVIC Backpack 180 10 15 3 Battery Powered Optical Guide 181 10 16 Cases 182 Chapter 11 Disposal 183 Chapter 12 Limited Warranty 184 ...

Page 13: ...PAGE 2 of 185 ...

Page 14: ...y interference received including interference that may cause undesired operation This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can ...

Page 15: ...n CE Declarations Jireh Industries hereby declares that the NAVIC product complies with the essential requirements and other relevant provisions of the following European Union directives 2014 30 EU EMC Directive 2014 35 EU Low Voltage Directive 2012 19 EU Directive on Waste Electrical and Electronic Equipment 2011 65 EU Directive on Restriction of Hazardous Substances RoHS ...

Page 16: ...see Compatible Components on page 12 and see Child Products on page 18 2 1 1 Intended Use The NAVIC s primary purpose is to perform inspections of ferrous assets such as pipes vessels or storage tanks by moving an inspection tool over a ferrous surface It is intended for industrial use only WARNING FALLING OBJECT HAZARD The NAVIC is intended for a specific use Read and understand the intended and ...

Page 17: ...mum OD longitudinal driving 305 mm 12 in Maximum surface temperature 50 C 122 F Category Parameter Specification Scanner Maximum umbilical length 30 m 100 ft Maximum payload performance may vary with surface condition 10 kg 23 lb Umbilical and attachments are considered payload Attachments Restricted to those listed in compatible components or child products Orientation while driving at height 2 m...

Page 18: ... temperatures are reached which might damage the system see High Internal Temperature Screen on page 151 2 1 1 3 User The NAVIC is intended to be used by persons who have read and understand the user manual The intended user is to be a person without limitations in the physical abilities of the upper and lower limbs sight hearing or anyone with a pacemaker For operating at a height greater than 2 ...

Page 19: ...he umbilical connection 2 1 3 Dimensions and Weight Crawler height 12 5 cm 4 9 in Crawler width 28 2 cm 11 1 in Crawler depth 30 8 cm 12 1 in Crawler height handles removed 8 1 cm 3 2 in Crawler width right drive module 16 1 cm 6 3 in Crawler weight 7 7 kg 17 lb Crawler weight right drive module 4 2 kg 9 3 lb 30 8 cm 12 1 in Fig 1 Crawler dimensions ...

Page 20: ...l module configuration excluding case attachments umbilical power controller and handheld controller 28 2 cm 11 1 in 12 5 cm 4 9 in 8 1 cm 3 2 in Fig 2 Dual module dimensions 16 1 cm 6 3 in 8 1 cm 3 2 in Fig 3 Single module dimensions ...

Page 21: ...Connections must be secured to prevent accidental disconnection Power failure may cause the crawler to freewheel down when operating in a vertical orientation Portable generator usage is not recommended unless accompanied by the use of an uninterruptible power supply WARNING Proper grounding of the power supply is important for safe operation When a generator is used to supply power to the system ...

Page 22: ...hannel quadrature 5VDC RS422 compatible Power Power must be supplied to the interface 5VDC 10 power limited to 15w 9 Enc 5V Enc A Enc A Enc B Enc B Enc Com Aux Enc A Aux Enc B Aux Enc B Shield Aux Enc A 3 4 1 2 10 6 5 8 7 H 9 4 3 1 7 2 5 6 10 Fig 4 JIREH Industries pin out configuration ...

Page 23: ...ation to inspection surfaces that a lat or driven on in the circumferential direction 2 2 1 2 Operating Limits Category Parameter Specification Inspection Surface Minimum OD longitudinal driving Not recommended Maximum number of probe holders Slip joint probe holders 4 2 2 2 Vertical Probe Holder Frame CXG007 2 2 2 1 Intended Use The Vertical Probe Holder Frame is intended to be mounted in the NAV...

Page 24: ... number of probe holders Vertical probe holders 6 2 2 4 Frame Bar BG0038 2 2 4 1 Intended Use The Frame Bar is intended to be mounted in the NAVIC s swivel mount to provide mounting of multiple probe holders Its use limits the NAVIC s operation to inspection surfaces that are either flat or driven on in the circumferential direction 2 2 4 2 Operating Limits Category Parameter Specification Inspect...

Page 25: ...tical Probe Holder is intended to a provide probe holding solution for larger heavier probes It is mounted in the dovetail groove of any probe holder frame or frame bar 2 2 8 Corrosion Thickness Probe Holder PHS046 PHS056 The Corrosion Thickness Probe Holder is intended to a provide probe holding solution for specific probes or wedges that do not have pivot button holes It is mounted in the doveta...

Page 26: ... Bracket Maximum weight of mounted object 1 36 kg 3 lb Scanner Required radial clearance handles removed circumferential driving Dependent on object mounted on Preamp Bracket 2 2 11 NAVIC Backpack CXS077 2 2 11 1 Intended Use The NAVIC Backpack is intended to mount objects such as preamps splitters etc on the NAVIC crawler The mounted object is to be attached to the NAVIC with a lanyard or probe c...

Page 27: ...ide CXS080 2 2 13 1 Intended Use The Battery Powered Optical Guide is intended to provide a point of reference useful for guiding the NAVIC along a given path i e a weld cap It is intended to be mounted in the dovetail groove of any probe holder frame or frame bar 2 2 13 2 Operating Environment Category Parameter Specification Scanner Required radial clearance Dependent on mounted orientation of B...

Page 28: ...ial clearance Dependent on object mounted to Backpack 2 2 15 Encoder Adapter UMA010 2 2 15 1 Intended Use The Encoder Adapter adapts a scanner s existing encoder cable connector to a different instrument s encoder input 2 2 16 3 Axis Nozzle Scanner Add On Kit CXG028 Mounted on a single NAVIC pod the 3 axis nozzle scanner add on kit includes a specialized probe holding system for inspection of nozz...

Page 29: ...e in various lengths the Motorized Raster Arm can carry many different probes for various types of corrosion scans The Motorized Raster Arm is intended to be mounted in the NAVIC s swivel mount 2 3 3 Actuated Probe Lift CXG030 The Actuated Probe Lift allows the user to raise and lower a corrosion thickness probe holder remotely from the handheld controller This allows the probe to avoid obstacles ...

Page 30: ...nce for guiding scanners along a given path i e a weld 2 3 6 Tracker DRG001 The Tracker uses advanced laser guidance to follow elevated profiles i e a weld on a ferrous surface It intended to be mounted in the dovetail groove of any probe holder frame or frame bar 2 3 7 Battery Kit DVG001 The battery provides portable power to the crawler Fig 25 Optical guide Fig 26 Tracker Fig 27 Battery ...

Page 31: ...ion in a specified direction Indicates alignment axis Alerts user that view has changed to a reverse angle 3 2 Definitions of Terms Circumferential Direction of scan travel is around the circumference of the pipe tube Fig 28 Longitudinal Direction of scan travel is lengthwise of the pipe tube Fig 29 Fig 28 Circumferential scanning Fig 29 Longitudinal scanning ...

Page 32: ...R signal word indicates an imminently hazardous situation It calls attention to a procedure practice or the like that if not correctly performed or adhered to will result in death or serious personal injury Do not proceed beyond a DANGER signal word until the indicated conditions are fully understood and met WARNING The WARNING signal word indicates a potentially hazardous situation It calls atten...

Page 33: ...16 Fig 31 Power controller CXA040 Fig 32 Umbilical UMA030 Fig 33 Handheld controller DMA006 Fig 34 Auxiliary cable UMA017 06 Fig 35 Encoder cable UMA025 Fig 36 Installation removal mat AAS061 Fig 37 Lifting sling CXA009 Fig 38 Irrigation kit CMG009 Fig 39 Cable management CXS046 Fig 40 Cap CXS066 Fig 41 Plug CX0174 ...

Page 34: ...Fig 44 3 mm flat driver EA480 Fig 45 Case NAVIC crawler CXA044 Fig 46 Umbilical probe holder frame case CXA023 Fig 47 Umbilical case EA421 Fig 48 Motorized pump umbilical case CMA016 Fig 49 Motorized pump umbilical case CXA042 Fig 50 Battery DVA001 Fig 51 Charger and Power Adapter DVG002 ...

Page 35: ...obe holder frame CXG013 Fig 55 Frame bar BG0038 Fig 56 Slip joint probe holder PHA012 Fig 57 Vertical probe holder PHA015 Fig 58 Heavy duty vertical probe holder PHS043 Fig 59 Corrosion thickness probe holder PHS046 Fig 60 Corrosion thickness probe holder PHS056 Fig 61 HydroFORM cart PHS044 Fig 62 Preamp bracket CES029 Fig 63 NAVIC backpack CXS077 ...

Page 36: ...Rev 00 1 Fig 64 NAVIC camera mount CXS067 Fig 65 Battery powered optical guide CXS080 Fig 66 Automated crawler medium temperature add on kit CXG031 Fig 67 Encoder adpater UMA010 Fig 68 3 axis nozzle scanner add on kit CXG028 ...

Page 37: ...Child Products Fig 69 Motorized Couplant Pump CMA015 Fig 70 Motorized raster arm CWG002 Fig 71 Actuated probe lift CXG030 Fig 72 Preamp kit CXG032 Fig 73 Optical guide CXG035 Fig 74 Tracker DRG001 Fig 75 Battery Kit DVG001 ...

Page 38: ...is used to remove and install probe holder pivot buttons The included 3 mm flat driver Fig 78 is useful for releasing the flaps of the raster arm s cable tray 4 2 2 Optional Tools Some specialized adjustments require tools that are not included with this kit Fig 76 3 mm hex driver Fig 77 3 8 in wrench Fig 78 3 mm flat driver Fig 79 1 5 mm hex wrench Fig 80 2 mm hex wrench Fig 81 2 5 mm hex wrench ...

Page 39: ... the NAVIC scanner is able to steer on an inspection surface NOTE The ability to effectively steer the crawler in the circumferential direction decreases as pipe diameters decrease below 300 mm 12 in It is possible to use the right drive module independently to carry out weld scanning when steering is not required and or overall scanner size is a concern 4 3 1 1 1 Encoder Fig 83 Right drive module...

Page 40: ...ns scan surface contact through all listed scan diameter sizes see Operating Limits on page 6 Adjustment of the encoder wheel is not required 4 3 1 2 Left Drive Module The left drive module is only used in conjunction with the right drive module Combining both modules allows the NAVIC scanner to steer on an inspection surface NOTE Steering is limited on smaller diameter inspection surfaces Fig 85 ...

Page 41: ...DC power supply 2 Release button Unlatch the AC DC power supply or battery from the power controller 3 Power button Activate system power by pressing and releasing the silver button CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occur 6 7 8 1 9 4 3 2 5 Fig 86 Power controller WARNING There are no user serviceable compone...

Page 42: ... off NOTE Before use always inspect the power cable and plug for damage The power controller should not be used if visible damage is present Use of damaged components may be a safety hazard 4 3 2 1 AC DC Power Supply The 1 AC DC power supply Fig 86 is used to connect the power controller to a suitable 100 240VAC 50 60Hz grounded power source capable of supplying a minimum of 5 amps The safety of t...

Page 43: ... 30 m 16 4 ft to 98 4 ft long NOTE Before use inspect the cable and connectors for damage When any damage is evident the cable must NOT be used Using a damaged cable may be a safety hazard and could also put other system components at risk 4 3 3 1 Umbilical Connections WARNING FALLING OBJECT HAZARD Ensure the umbilical can freely uncoil during operation and does not become snagged If umbilical bec...

Page 44: ... ENC 8 pin Lemo will transmit encoder signals through the umbilical as the 2nd encoder axis Typical usage Optional raster arm 3 8 pin connector The unlabeled 8 pin Lemo does not support encoder signals Typical usage Left drive module 4 8 pin expansion connector The module that is connected to the X ENC 8 pin Lemo transmits encoder signals through the umbilical as the 1st encoder axis Typical usage...

Page 45: ... umbilical with the auxiliary cable The handheld controller is not watertight and is not intended to be used in extremely wet environments The handheld controller utilizes a resistive touch screen care should be taken to not use sharp or gritty objects on the screen as the touch membrane can scratch If the screen is damaged all programmed functions can still be accessed using the D pad NOTE Do NOT...

Page 46: ...nt the cable must NOT be utilized Use of a damaged cable may be a safety hazard and could also put other system components at risk 4 3 6 J300 Encoder Cable The encoder cable connects the NAVIC system to the user s instrument This cable allows transmission of two axis position signals from the NAVIC to the instrument The encoder cable also provides 5VDC from the user s instrument to the encoder iso...

Page 47: ...When operating a NAVIC at a height greater than 2 m 6 ft the crawler MUST be tethered with a proper tether system to prevent the crawler from falling see No Entry Fall Zone on page 42 4 3 9 Irrigation Kit The irrigation kit provides a variety of hoses fittings connectors and splitters commonly used during non destructive inspection 4 3 10 Cable Management The cable management provides a means of p...

Page 48: ...ofile probe holder frame carries up to four probes during limited access circumferential weld inspection Removal of the NAVIC handles and the use of the low profile probe holder frame allows inspection when radial clearance is limited 4 4 2 Vertical Probe Holder Frame The vertical probe holder frame carries up to six probes during circumferential weld inspection Available in a myriad of configurat...

Page 49: ...wedges Available with various types of yokes arms and pivot buttons The vertical probe holder features several different adjustment options for each unique probe wedge setup 4 4 7 Heavy Duty Vertical Probe Holder The heavy duty vertical probe holder is designed to carry larger probes Available with various arm yoke and pivot buttons the heavy duty vertical probe holder exerts more down force on a ...

Page 50: ...4 11 NAVIC Backpack The NAVIC backpack provides a means of carrying equipment hardware on a NAVIC crawler 4 4 12 NAVIC Camera Mount The NAVIC camera mount provides a mounting point for cameras on a NAVIC crawler 4 4 13 Battery Powered Optical Guide The battery powered optical guide provides a red colour point of reference useful for guiding scanners along a given path i e a weld Fig 107 HydroFORM ...

Page 51: ... kit mounts to the right drive module of the NAVIC crawler to offer encoded inspection of nozzle and fitting welds 4 5 Child Products 4 5 1 Motorized Couplant Pump The motorized couplant pump is a powered pumping unit used for supplying couplant fluid to the scanning surface 4 5 2 Motorized Raster Arm The motorized raster arm is available in various lengths and offers programmable speed and travel...

Page 52: ...rom an ultrasonic transducer and improve the signal to noise ratio for transmission over long cables 4 5 5 Optical Guide The optical guide mounts to any dovetail and provides a green colour point of reference useful for guiding scanners along a given path i e a weld 4 5 6 Tracker The tracker is mounted atop any probe holder frame and uses advanced laser guidance to follow elevated profiles i e wel...

Page 53: ...ig 122 CAUTION PINCH CRUSH HAZARD BE CAREFUL when passing the NAVIC crawler through narrow ferrous magnetic openings such as man holes The magnetic drive wheels can cause bodily harm if allowed to slam onto the walls of the opening WARNING FALLING OBJECT HAZARD The area below a crawler must be kept clear at all times A clearly marked NO ENTRY FALL ZONE must be cordoned off directly below the area ...

Page 54: ...cidental disconnection The hook must be free of sharp edges that may cut or abrade the provided lifting sling Before placing the crawler on the surface to be inspected e g tank attach the provided lifting sling to the NAVIC and then hook the tether hook to the lifting sling WARNING FALLING OBJECT HAZARD Failure to comply with the warnings instructions and specifications in this manual could result...

Page 55: ...ere 1 Lift the two tether attachment points Fig 123 IMPORTANT Carefully inspect the lifting sling for damage prior to each use Ensure the tether hook does not have sharp edges that may cut the lifting sling Fig 123 Lift tether attachment points Fig 124 Press release button Fig 125 Pull pin from ...

Page 56: ...e shackle around the tether attachment point Fig 126 4 Align the tether attachment point and shackle Insert the pin while pressing the pin s release button Fig 127 NOTE Ensure proper orientation of the shackles Fig 129 Fig 126 Align shackle with tether holes Fig 127 Insert pin Fig 128 Proper shackle setup x Fig 129 Incorrect shackle setup ...

Page 57: ...essive build up will cause the wheels to lose magnetic attraction which may lead to wheel slippage or crawler detachment Ensure that no obstructions other than standard butt welds or voids are in the drive path Obstructions and voids could cause the crawler to fall if driven into or over Ensure that there are no patches of non ferrous material in the drive path of the crawler If the crawler drives...

Page 58: ...PAGE 47 of 185 CX0540 Rev 00 1 5 4 System Connectivity 1 2 8 9 7a 6 3 4 7b 5 10 Fig 132 Standard crawler configuration ...

Page 59: ... crawler 2 Connect 8 umbilical to 9 power controller 3 Connect 6 handheld controller to 9 power controller using the 7a auxiliary cable NOTE The 6 handheld controller may also be connected directly to the 8 umbilical using the 7b auxiliary cable 4 Connect 4 encoder cable from the 5 user s instrument to the 9 power controller 5 Insert 10 AC DC power supply into the 9 power controller 6 see Configur...

Page 60: ... 5 Configurations 5 5 1 Single Drive Module with Frame Bar BOM ID Description 1 Frame bar 2 Right drive module 3 Umbilical 2 1 3 Description BOM ID Frame Bar 1 Right Drive Module 2 Umbilical 3 Fig 133 Single drive module configuration ...

Page 61: ...ive modules see Connecting Disconnecting Left and Right Modules on page 71 2 Mount and connect the 3 umbilical to 2 right drive module 3 Attach a configured 1 frame bar to the 2 right drive module see Swivel Mount on page 68 CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occur ...

Page 62: ...00 1 5 5 2 Crawler with Actuated Probe Lift BOM ID Description 1 Actuated probe lift 2 Auxiliary cable 3 Right drive module 4 Left drive module 5 Umbilical 2 3 4 5 1 Fig 134 Standard NAVIC configuration with actuated probe lift ...

Page 63: ...nnect the 5 umbilical to 3 right drive module of the crawler 2 Attach the 1 actuated probe lift see Actuated Probe Lift user manual to the 3 right drive module see Swivel Mount on page 63 3 Connect the 2 auxiliary cable to the 1 actuated probe lift and to the 5 umbilical CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occ...

Page 64: ...Probe Holders 5 5 3 1 Vertical Probe Holder Frame BOM ID Description 1 Tracker 2 Tracker cable 3 Vertical probe holder frame 4 Right drive module 5 Left drive module 6 Umbilical 4 5 6 3 1 2 Fig 135 Standard crawler configuration with vertical probe holder frame ...

Page 65: ...ler 2 Attach a configured 3 vertical probe holder frame see Vertical Probe Holder Frame Flat or Circumferential Only on page 110 to the crawler see Swivel Mount on page 63 3 Optional Attach the 1 tracker see Tracker user manual to the front of the 3 vertical probe holder frame Connect the 2 tracker cable to the 6 umbilical s 4 pin expansion connector CAUTION DO NOT DISCONNECT UNDER LOAD Shut off p...

Page 66: ... 1 5 5 3 2 Low Profile Probe Holder Frame BOM ID Description 1 Low profile probe holder frame 2 Right drive module 3 Left drive module 4 Umbilical 1 2 3 4 Fig 136 Standard crawler configuration with low profile probe holder frame ...

Page 67: ...ial Only on page 114 1 Mount and connect the 4 umbilical to 2 right drive module of the crawler 2 Attach a configured 1 low profile probe holder frame see Low Profile Probe Holder Frame Flat or Circumferential Only on page 114 to the crawler see Umbilical on page 64 CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occur ...

Page 68: ... Pivoting Probe Holder Frame BOM ID Description 1 Tracker 2 Tracker cable 3 Pivoting probe holder frame 4 Right drive module 5 Left drive module 6 Umbilical 4 5 6 3 1 2 Fig 137 Standard crawler configuration with pivoting probe holder frame ...

Page 69: ...ler 2 Attach a configured 3 pivoting probe holder frame see Pivoting Probe Holder Frame on page 118 to the crawler see Swivel Mount on page 63 3 Optional Attach the 1 tracker see Tracker user manual to the front of the 3 pivoting probe holder frame Connect the 2 tracker cable to the 6 umbilical s 4 pin expansion connector CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or dis...

Page 70: ...0 1 5 5 3 4 Flange BOM ID Description 1 Flange probe holder frame 2 Right drive module 3 Left drive module 4 Umbilical 4 1 2 3 Fig 138 Standard crawler configuration with pivoting probe holder frame configured for flange scanning ...

Page 71: ...r Frame Flange Scanning on page 122 1 Mount and connect the 4 umbilical to 2 right drive module of the crawler 2 Attach a configured 1 flange probe holder frame see Pivoting Probe Holder Frame Flange Scanning on page 122 to the crawler see Swivel Mount on page 63 CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occur ...

Page 72: ...PAGE 61 of 185 CX0540 Rev 00 1 5 5 4 3 Axis Nozzle Scanning 10 5 9 8a 7 8b 6 4 1 3 2 Fig 139 Single module with nozzle scanner configuration ...

Page 73: ...mbilical at a 90 angle to 3 right drive module 3 Connect the 5 umbilical to the 9 power controller 4 Connect the 7 handheld controller to the 9 power controller using the 8a auxiliary cable NOTE The 7 handheld controller may also be connected directly to the 5 umbilical using the 8b auxiliary cable 5 Mount the appropriate 3 axis nozzle configuration to the swivel mount of the crawler 6 Connect the...

Page 74: ...e the two black wing knobs to clamp the frame system raster arm in place Alternatively accessories can also be mounted straight to the swivel mount Rotate the black wing knobs aligning the dovetail jaws with the mount s grooves Fig 142 Press the frame bar or accessory to the swivel mount Fig 143 and tighten the black wing knobs The swivel mount utilizes two levers Fig 141 to lock the swivel mount ...

Page 75: ... to the scanning surface Fig 146 Fig 145 Align swivel mount with etched line WARNING FALLING OBJECT HAZARD For operating at heights greater than 2 m 6 ft ensure the umbilical strain relief is aligned according to the below instructions and never points upwards as shown in Fig 148 The crawler could fall SEVERE INJURY or DEATH could result Fig 146 Align umbilical mount x Fig 147 Incorrect use x Fig ...

Page 76: ... 5 Align the umbilical to the umbilical mount of the drive module Fig 150 6 Fasten the umbilical to the crawler s umbilical mount by tightening the black wing knob Fig 151 7 Unlock the umbilical mount lock lever align the umbilical parallel to the scan surface Fig 153 and lock Fig 152 Fig 149 Connect to umbilical Fig 150 Align with drive module mount Fig 151 Tighten knob Fig 152 Adjust umbilical m...

Page 77: ...ve the handle Lift the handle lock latch Fig 154 Pivot the handle down Fig 155 and then pull the handle up to remove from the drive module Fig 156 To reinstall the handle reverse the preceding steps Fig 154 Lift handle lock latch Fig 155 Pivot handle nose down Fig 156 Lift handle from module ...

Page 78: ...PAGE 67 of 185 CX0540 Rev 00 1 5 6 4 Dovetail Accessory Mount Affix optional accessories to the crawler such as a NAVIC backpack using the dovetail accessory mount Fig 157 Dovetail accessory mounts ...

Page 79: ...ccessory s frame bar along the dovetail jaws Rotate the two black wing knobs to clamp the frame system raster arm in place The front mount pivots freely Fig 159 and cannot be locked in a fixed position When a frame bar is connected to both dovetail mounts on the two modules this free movement allows the scanner to flex while steering TIP Alternate mounting procedure is possible see Swivel Mount on...

Page 80: ...onnection 1 Connect the left drive module s connector to umbilical see Umbilical on page 32 for additional details 5 7 3 Handle see Handle on page 66 5 7 4 Dovetail Accessory Mount see Dovetail Accessory Mount on page 67 Fig 160 Connect to umbilical ...

Page 81: ...ld controller produces a strong magnetic field which may cause failure or permanent damage to items such as watches memory devices CRT monitors medical devices or other electronics People with pacemakers or ICD s must stay at least 10 cm 4 in away CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occur Fig 161 Mount to ferr...

Page 82: ...e supplied 3 mm hex driver press the pin while rotating the two modules Fig 163 2 Once the two modules are 90 perpendicular Fig 164 gently pull the two modules apart Fig 165 CAUTION PINCH POINT HAZARD Keep fingers clear of pinch points when connecting disconnecting left and right modules Fig 162 Press release pin Fig 163 Press pin and rotate modules Fig 164 Rotate modules to 90 Fig 165 Pull module...

Page 83: ...ivots thoroughly Once the pivot connections are completely free of debris apply a liberal amount of anti seize compound e g Kopr Kote to the connection pivots of both modules WARNING MAGNETIC MATERIAL The wheels of the crawler produce an extremely strong magnetic field which may cause failure or permanent damage to items such as watches memory devices CRT monitors medical devices or other electron...

Page 84: ...b allows the probe holder to be attached to a frame bar as well as horizontal positioning on a frame bar Fig 169 2 Vertical adjustment knob allows the vertical probe holder height adjustment Fig 170 3 Position the pivot buttons where necessary When a narrow scanning footprint is required use the pivot button holes closet to the yoke Fig 171 TIP Probe pivoting may be impeded when closer to the yoke...

Page 85: ...he supplied 3 mm hex driver Fig 76 5 Loosen the probe holder arm adjustment knob Fig 173 and slide the probe holder arm along the yoke pinching the wedge in place 6 Tighten the probe holder arm adjustment knob Fig 174 5 8 4 2 Probe Holder Vertical Adjustment To adjust the probe holder vertically follow these steps 1 Ensure the probe holder is in the latched upper position Lift the probe Fig 172 Ad...

Page 86: ...ton Fig 177 then slowly lower towards scanning surface to apply spring pressure to the wedge Fig 178 TIP If less spring force is desired refer to step 2 and place the wedge approximately 20 mm in above inspection surface 5 8 4 3 Probe Holder Transverse Adjustment To adjust the probe holder s transverse angle follow these steps 1 Ensure the probe holder is in latched upper position Fig 175 Fig 177 ...

Page 87: ...sverse adjustment screw 5 8 4 4 Probe Holder Longitudinal Adjustment To adjust the probe holder s vertical angle for longitudinal scanning follow these steps 1 Ensure the probe holder is in latched upper position Fig 175 2 Using the supplied 3 mm hex driver Fig 76 loosen the longitudinal adjustment screw Fig 182 3 Rotate the main body of the probe holder until it is at the desired angle Fig 183 4 ...

Page 88: ...x driver Fig 76 unscrew the yoke pivot screw and remove yoke Fig 185 3 Loosen the probe holder arm adjustment knob and the arm clamp screw Slide the probe holder arms off the yoke Fig 186 4 Flip the yoke 180 and reverse the probe holder arms Fig 187 5 Place the pivot buttons on the inside of the probe holder arms Fig 188 using a 3 8 in wrench Fig 77 Fig 185 Unscrew yoke pivot screw Fig 186 Remove ...

Page 89: ...d M3 screw stop post on the bottom of the probe holder Unscrew the stop post using a 1 5 mm hex wrench until it has cleared all obstructions Do not remove stop post Fig 190 8 Raise the stop post on the opposite side until the side of the post clearly contacts the 90 stop point on the probe holder s base Fig 191 Fig 189 Screw yoke to opposite side Fig 190 Lower 90 stop post Fig 191 Raise opposite 9...

Page 90: ...mp Screw I Pivot Buttons 5 8 5 1 Probe Holder Setup To mount a UT wedge in the probe holder follow these steps 1 Rotate the probe holder adjustment knob and attach probe holder to a frame bar Fig 194 2 Use the probe holder adjustment knob to position the probe holder along the frame bar Fig 195 F I A C B D E G H Fig 193 Slip Joint Probe Holder Fig 194 Attach to frame bar Fig 195 Adjust on frame ba...

Page 91: ...est from the yoke for maximum wedge clearance TIP If narrow scanning footprint is required use pivot button holes closest to the yoke Wedge pivoting may be impeded when closer to the yoke 5 Loosen the probe holder arm adjustment knob Fig 198 and remove outer probe holder arm from yoke 6 Adjust inner probe holder arm as required to best centre the probe on the yoke s pivot axis Fig 198 Fig 196 Adju...

Page 92: ...long the yoke pinching the wedge in place 9 Tighten probe holder arm adjustment knob Fig 200 5 8 5 2 Probe Holder Adjustment To adjust the probe holder follow these steps 1 Ensure probe holder is in latched upper position Fig 201 If the probe holder is already latched it will only move within the slip joint adjustment range and have no spring tension 2 Push the probe holder yoke down toward the in...

Page 93: ...4 lb Heavy 3 kg 6 lb When configured correctly these settings exert the indicated spring force on the Probe To adjust the probe holder s force follow these steps NOTE Do not perform this operation on scanning surface 1 Ensure the probe holder is in the upright latched position Fig 201 2 Lift probe holder slightly and press the latch button Fig 205 to release the probe holder the full 45 degrees 3 ...

Page 94: ...screw but do not remove it Fig 208 6 Gently apply pressure on the long leg of the 3 mm hex wrench until the force adjustment marker lines up with the desired spring tension While keeping the markers in line tighten the force adjustment screw Fig 209 Fig 207 Insert hex tools Fig 208 Press 3 mm hex wrench down Heavy Medium Light Force Adj Marker Heavy Medium Light Force Adj Marker Fig 209 Choose des...

Page 95: ... Slide the arms from the yoke Fig 211 3 Flip the yoke 180 and reverse the probe holder arms Fig 212 4 Place the pivot buttons on the inside of the probe holder arms Fig 213 using a 3 8 in wrench Fig 77 Slide the arms onto the yoke and tighten the probe holder arm adjustment knob and the arm clamp screw Fig 210 Unscrew yoke pivot screw Fig 211 Remove arms Fig 212 Flip yoke and reverse arms Fig 213 ...

Page 96: ...et Fig 214 or preferred position Tighten swing arm knob 6 Using the 3 mm hex driver screw the yoke pivot screw into the opposite side of the probe holder swing arm Fig 215 Ensure the yoke is level to avoid issues with the plunger set screw Fig 214 Position swing arm Fig 215 Install yoke to swing arm Fig 216 Reversed probe holder ...

Page 97: ...e Holder Setup 1 Loosen the probe holder adjustment knob Fig 218 and mount the heavy duty vertical probe holder s dovetail jaw to the carrier 2 The vertical adjustment knob Fig 219 allows the heavy duty vertical probe holder s height adjustment This adjustment also controls the probe holders spring tension F G H B A C D E Fig 217 Heavy duty vertical probe holder Fig 218 Mount probe holder to carri...

Page 98: ...e on the pivot button of the inner probe holder arm Fig 221 6 Align the middle of the wedge with the centre of the yoke Fig 222 7 Tighten both the probe holder adjustment knob and the arm clamp screw Fig 222 while ensuring the wedge remains centred with the yoke Fig 220 Remove outer arm Fig 221 Adjust inner arm Fig 222 Align probe with yoke Fig 223 Tighten knob and screw ...

Page 99: ...e probe holder Slowly lower the probe holder towards the scan surface Fig 225 5 8 6 3 Probe Holder Left Right Conversion 1 Using the supplied 3 mm driver unscrew the yoke Fig 226 2 Position the yoke and arms to the opposite side of the probe holder Fig 227 Fig 224 Press up and pull latch Fig 225 Lowered toward scan surface Fig 226 Remove yoke Fig 227 Orient to opposite side ...

Page 100: ...older arm adjustment knob allowing removal of the probe holder arms Fig 228 4 Position removed arms to opposite sides of the yoke Fig 229 Fig 228 Remove probe holder arms Fig 229 Reverse position around yoke Fig 230 Position pivot buttons Fig 231 Place arms back onto yoke ...

Page 101: ...sing a standard yoke length position the yoke in the threaded hole closest to the frame bar When using a long yoke length position the yoke in the threaded hole furthest from the frame bar 5 8 6 4 Probe Holder 90 Adjustment 1 Remove the yoke using the supplied 3 mm hex driver Fig 76 2 Orient the yoke to the front of the probe holder and screw the yoke into the threaded hole provided Fig 233 Fig 23...

Page 102: ...g Left and Right Modules on page 71 WARNING MAGNETIC MATERIAL The wheels of the crawler produce an extremely strong magnetic field which may cause failure or permanent damage to items such as watches memory devices CRT monitors medical devices or other electronics People with pacemakers or ICD s must stay at least 75 cm 30 in away CAUTION PINCH POINT HAZARD Keep fingers clear of pinch points when ...

Page 103: ...nector to the umbilical Fig 235 4 Mount cable management to the umbilical see Mounting Cable Management on page 126 5 Mount the probe wedge Fig 237 to the long stroke vertical probe holder see Probe Holder Setup on page 100 Fig 235 Mount the umbilical at 90 from standard mounting angle Fig 236 Mount cable management to the umbilical Fig 237 Probe wedge affixed to probe holder ...

Page 104: ... frame 90 Fig 238 Tighten the pivot tapered lock 7 Ensure the swivel mount of the NAVIC is horizontally aligned Fig 239 with the etched line on the crawler see Swivel Mount on page 63 for additional details Fig 238 Adjust pivot tapered lock to 90 angle Fig 239 Align swivel mount with etched line ...

Page 105: ...Mount on page 63 10 Tighten the swivel mount s black wing knobs NOTE Reposition the slider pps if the probe holder contacts right drive module 11 Route the 3 axis encoder cable Fig 241 through the cable management see Cable Management on page 126 1 1 2 Fig 240 Mount the umbilical at 90 from standard mounting angle Fig 241 Route the 3 axis encoder cable through the cable management ...

Page 106: ... encoder cable Fig 242 14 Plug the encoder cables into the 3 axis encoder cable connectors Fig 242 15 Plug the opposite end of the 3 axis encoder cable into the power controller s encoder receptacle Fig 243 16 Connect the 3 axis encoder cable into the user s instrument see 3 Axis Nozzle Scanning on page 61 Fig 242 Connect encoder cables to 3 axis encoder cable Fig 243 Plug 3 axis encoder cable int...

Page 107: ...2 3 Axis Nozzle Operation NOTE The encoder cabling removed for illustration purposes 1 Place the configured scanner on the inspection surface see Scanner Installation Removal Mat Use on page 134 Fig 244 Connect handheld controller to power controller Fig 245 Place scanner on surface using installation removal mat ...

Page 108: ...ertical probe holder see Encoded Skew Vertical Probe Holder Adjustment on page 102 3 Using the handheld controller drive the crawler around the nozzle as required see Jog Mode on page 138 Fig 246 Unlatch encoded skew vertical probe holder Fig 247 Drive crawler ...

Page 109: ...PPS as required Fig 248 to position the probes distance from the weld 5 Ensure the A slider lock knob is tight and rotate the main knob to position the slider Fig 249 Fig 248 Adjust the slider PPS as required A Fig 249 Slider positioning ...

Page 110: ...PAGE 99 of 185 CX0540 Rev 00 1 6 Adjust the skew angle of the probe as required see Skew Angle Adjustment on page 104 Fig 250 Adjust skew angle ...

Page 111: ... buttons to the probe holder arms Fig 252 A Probe Holder Adjustment Knob B Extension Bracket C Encoder Cable D Pivot Buttons E Probe Holder Arm Adjustment Knob F Skew Adjustment Indicator G Ratchet Lever H Probe Holder Arms I Cable Clip J Latch Pin C D A B H G F E I J Fig 251 Encoded skew vertical probe holder identification Fig 252 Attach pivot buttons ...

Page 112: ...s slider Fig 254 Tighten the probe holder adjustment knob when positioning is complete To mount a UT wedge in the probe holder follow these steps 4 Loosen the two probe holder arm adjustment knobs and move the arms apart to create space for the probe Fig 255 5 Align the probe to be used with the centre of yoke pivot Fig 256 Fig 253 Mount to slider pps Fig 254 Mount to slider pps Fig 255 Loosen kno...

Page 113: ...le routing is at the discretion of the user Cable clips have been provided to assist with cable management 1 Route the skew encoder cable through any required cable clips 2 Plug the skew encoder cable into the 3 axis encoder cable 5 9 6 Encoded Skew Vertical Probe Holder Adjustment To lower the probe and probe holder to the scan surface follow these steps TIP The skew encoder cable removed for ill...

Page 114: ... probe holder Fig 261 3 Release latch pin and probe holder will lock when lifted to the upper most position Method two allows free movement of the probe holder along the entire length of the stroke without locking in place at the upper most position 4 Slightly lift the probe holder Fig 258 5 Pull the latch pin and slightly rotate the latch pin left or right Fig 262 6 Release the latch pin and prob...

Page 115: ... the yoke Fig 263 2 Rotate the yoke Up to 90 in either direction to the angle required Fig 264 3 Tighten the ratchet lever to lock the yoke in place Should the ratchet lever be unable to fully tighten or release the yoke see Ratchet Lever on page 105 for more information 4 The engraved arrow above the yoke may be used to align the yoke to the required degree Fig 263 Loosen ratchet lever Fig 264 Ad...

Page 116: ...the base of which it is connected Fig 266 2 Continue to pull while rotating the lever in the appropriate direction Fig 267 3 Release the lever and utilize the new tightening position Fig 268 5 9 8 Pivot Buttons Available in a variety of shapes and sizes fitting various wedge dimensions Use the supplied 3 8 in wrench Fig 77 to remove and install pivot buttons Fig 269 Fig 266 Pull ratchet handle Fig...

Page 117: ...le Clips Cable clips have been provided to assist with cable management Simply pinch the clip and press it into the dovetail groove of the frame bar or the probe holder Fig 270 Pinch clip Fig 271 Cable clip Fig 272 Route cables ...

Page 118: ...rame bar and push to into position Fig 273 The slider s friction fit requires an appropriate amount of force to position the slider 2 Loosen the slider s lock knob Fig 273 note red highlight 3 Loosen the main knob s hexagonal screw and lock screw Fig 274 note red highlight 4 Align dovetail nut of the main knob with the frame bar and slide into position Fig 274 Fig 273 Place slider on frame bar and...

Page 119: ...Fig 275 6 Position the slider and main knob where required along the frame bar 7 Tighten the the main knob s hexagonal screw and lock screw as well as tighten the slider lock knob Fig 276 note red highlight Fig 275 Insert leadscrew into main knob and slider Fig 276 Tighten screws ...

Page 120: ...oose 2 Slide the encoder s dovetail nut onto the frame bar Fig 277 continue sliding the encoder towards the leadscrew until the leadscrew is pressed snuggly into the encoder s coupling Fig 278 3 Tighten the encoder s lock screw Fig 278 note red highlight 4 Route the PPS encoder cable as required to plug into the 3 axis encoder cable Fig 279 Fig 277 Loosen and slide post in place Fig 278 Align and ...

Page 121: ...imperative that the steps below be followed to properly set the height of the probe holder frame If the height of the probe holder frame is set too low the crawler may fall and SEVERE INJURY or DEATH could result WARNING FALLING OBJECT HAZARD When the Probe Holder Frame is mounted in both the left hand and right hand swivel mounts operation must be limited to driving in the circumferential directi...

Page 122: ... place the primary probe holders at the rear of the 2 frame bar Fig 281 TIP Due to their larger size scan results are generally improved when pulling or dragging phased array wedges 3 Mount the probe holder frame to the crawler see Swivel Mount on page 68 for additional details When mounting the probe holder frame ensure the attachment knobs Fig 281 are at the front non crawler side 1 2 Fig 281 Po...

Page 123: ...sen the rear rotational adjustment knob to lower the weld scan frame towards the inspection surface Ensure gap B Fig 284 is no smaller than gap A Fig 283 6 Loosen the front rotational adjustment knob Fig 284 to lower the weld frame towards the inspection surface while ensuring gap C Fig 285 is no smaller than gap A Fig 283 A Fig 283 Set rear rotational adjustment knob B Fig 284 Set front rotationa...

Page 124: ...PAGE 113 of 185 CX0540 Rev 00 1 7 Lower the probe holders to the inspection surface see Probe Holder Vertical Adjustment on page 74 C Fig 285 Align probes with the scan surface tangent ...

Page 125: ... When the Probe Holder Frame is mounted in both the left hand and right hand swivel mounts operation must be limited to driving in the circumferential direction Only very slight corrective steering is permitted Excessive steering may cause the crawler to fall and SEVERE INJURY or DEATH could result Fig 286 Low profile probe holder frame WARNING FALLING OBJECT HAZARD It is imperative that the steps...

Page 126: ... results are generally improved when pulling or dragging phased array wedges 3 Mount the low profile probe holder frame to the crawler see Swivel Mount on page 68 for additional details When mounting the low profile frame ensure the attachment knobs Fig 287 are at the front non crawler side 4 Release the two swivel mount levers Fig 288 to position the swivel mount parallel to the scan surface Fig ...

Page 127: ...ame towards the inspection surface Fig 289 Ensure gap B Fig 290 is no smaller than gap A Fig 289 6 Loosen the front rotational adjustment knob Fig 290 to align the frame bar parallel with the scan surface Fig 290 A Fig 289 Set rear rotational adjustment knob B Fig 290 Align probe holder tangent with scan surface ...

Page 128: ...PAGE 117 of 185 CX0540 Rev 00 1 7 Lower the probe holders to the inspection surface see Probe Holder Adjustment on page 81 Fig 291 Low profile probe holder frame ...

Page 129: ...ircumferential direction NOTE A minimum OD of 305 mm 12 in is required for longitudinal scanning WARNING FALLING OBJECT HAZARD It is imperative that the steps below be followed to properly set the height of the probe holder frame If the height of the probe holder frame is set too low the crawler may fall and SEVERE INJURY or DEATH could result Fig 292 Pivoting Probe Holder Frame ...

Page 130: ...cing the primary probe holders at the rear of the 2 frame system Fig 293 TIP Phased array wedges are designed to be pulled along a scan surface 3 Mount the pivoting probe holder frame to the crawler see Swivel Mount on page 68 for additional details WARNING FALLING OBJECT HAZARD The Pivoting Probe Holder Frame is to be mounted only in the right hand swivel mount Mounting it in both the left hand a...

Page 131: ... at the centre of the frame system Fig 294 Lower the left side of the frame system to align with the tangent of the scan surface Tighten the pivot wing knobs WARNING FALLING OBJECT HAZARD When scanning in the longitudinal direction with the Pivoting Probe Holder Frame operation must be limited to driving in the longitudinal direction only Only very slight corrective steering is permitted Excessive...

Page 132: ...er arms are parallel to the scan surface see Probe Holder Longitudinal Adjustment on page 76 5 11 3 3 Pivoting Probe Holder Frame Circumferential Scanning see Vertical Probe Holder Frame Flat or Circumferential Only on page 110 for additional details Fig 295 Tighten pivot wing knobs Fig 296 Correct probe holder longitudinal adjustment ...

Page 133: ...s and the like The following steps explain setup of this configuration 1 Disassemble the pivoting probe holder frame to achieve the setup shown Fig 297 Ensure proper placement of the frame bar with attached mounting point in relation to the NAVIC TIP When the scanning surface is circumferential only one frame bar with two probes can be used Fig 297 Configure assembly and mount to NAVIC Fig 298 Lif...

Page 134: ... crawler on scan surface see Placement of Crawler on Inspection Surface on page 133 3 Release the front swivel mount adjustment levers to align the swivel mount parallel to the scan surface Fig 299 4 Loosen the pivot wing knob and align the frame bar parallel with the scan surface Fig 300 Fig 299 Align swivel mount with scan surface Fig 300 Align frame bar with flange scan surface ...

Page 135: ...m one of the sets of 1 frame bars Fig 301 The choice of which dovetail bar pivot to remove is at the user s discretion 2 Attach the optical guide pivot mount to the 2 frame bars Fig 301 tighten the dovetail knobs and the dovetail screws Ensure a flush alignment of the pivot mount and the frame bars to achieve proper centering of the optical guide pivot mount 3 To mount an optical guide see the app...

Page 136: ...ivot to direct the laser beam as required Fig 304 4 Loosen the optical guide knob to adjust the side to side position as required Retighten the optical guide knob 5 The included perpendicular mount allows for alternate mounting positions when required NOTE The battery powered optical guide requires 1 AA battery for operation WARNING LASER RADIATION The battery powered optical guide contains a Clas...

Page 137: ...ollow these steps 1 Align the cable management clamp with the appropriate mounting position on the umbilical Fig 306 2 Tighten the cable management clamp wing knob Fig 307 5 12 2 2 Cable Management Setup 1 Open the cable management tube Begin at the clamp end and start placing the cabling in the tube Fig 308 2 Follow the cable placement zipping the tube closed Fig 309 Fig 306 Align with umbilical ...

Page 138: ... these instructions to reattach the tube and clamp Loosen the clamp screw using the supplied 3 mm hex driver Slide the clamp around the tube first and then slide the tube around the outside of the cable management mount Fig 312 Align the tube opening and the cable management clamp opening Slide the clamp over the tube and cable management mount pinching the tube in between Fig 313 Tighten the clam...

Page 139: ...and use the backpack follow these steps NOTE The backpack is only compatible with NAVIC crawlers manufactured after the spring of 2015 1 Allow the NAVIC crawler to pivot exposing the inside of the left drive module Fig 315 2 Slide the dovetail nuts of the backpack into the accessory dovetail groove Fig 315 3 Tighten the two backpack screws using the supplied 3 mm hex driver Fig 316 4 Pull the Velc...

Page 140: ...ables strong enough to prevent the object from falling have smooth edges so as not to cut bracket s velcro strap 5 12 4 1 Mounting Preamp Bracket The preamp bracket mounts to any dovetail groove 1 Loosen the knob and align with dovetail groove Fig 318 2 Tighten the knob to lock preamp bracket in place Fig 319 5 12 4 2 Attaching Preamp with Screws Use the adjustable screw mounting channel on the bo...

Page 141: ...hese steps 1 Slide the velcro strap through the bracket s holes Fig 321 2 Centre and place the preamp on the bracket wrapping the velcro around the preamp Fig 322 3 Secure the preamp to the bracket attaching each side of the velcro Fig 323 Fig 321 Insert velcro straps Fig 322 Place preamp and wrap velcro Fig 323 Velcro wrapped around preamp ...

Page 142: ...ig 324 into power controller dock 2 Connect the components see Configurations on page 49 3 Locate the 2 red emergency stop push button on the power controller Rotate this button clockwise to unlatch Fig 325 4 The 1 power button Fig 325 on the power controller activates the system Fig 324 Insert power source 1 2 Fig 325 Power controller ...

Page 143: ...n established see Preparation for Safe Use on page 42 and tether requirements are met see Tether Requirements and Attachment on page 43 Acknowledge this warning by touching Yes Once the system is initialized the Mode Select screen will appear see Mode Select Screen on page 138 The system is now ready for operation DANGER SEVERE INJURY OR DEATH HAZARD READ AND UNDERSTAND USER MANUAL AND HEED ALL WA...

Page 144: ...he inspection surface is required during scanner placement This is necessary to protect the electronic components within the crawler from damaging shock should the crawler be slammed directly onto the inspection surface WARNING MAGNETIC MATERIAL The wheels of the crawler produce an extremely strong magnetic field which may cause failure or permanent damage to items such as watches memory devices C...

Page 145: ...s used in place of cable management see Cable Management on page 126 NOTE The manufacturer recommends two persons install the crawler on an inspection surface when using the scanner installation removal mat Once crawler preparation is complete see Preparation for Use on page 42 Raise the front swivel mounts see Swivel Mount on page 63 and umbilical mount see Umbilical on page 64 to ensure they wil...

Page 146: ...efully drive Fig 333 the crawler off the installation removal mat and onto the inspection surface Fig 334 5 Once the crawler is securely on the inspection surface the user may let go of the crawler Fig 334 TIP Avoid the drive modules slamming to the inspection surface This can occur when all four wheels are not in contact with the installation removal mat while the crawler is driven onto the inspe...

Page 147: ...le to place the crawler on the inspection removal mat and manually push the crawler off the mat and onto the inspection surface 7 Align front swivel mounts and umbilical mount to appropriate relationship to the scan surface Fig 335 6 3 Operation 6 3 1 Handheld Controller Layout Fig 335 Align swivel mounts parallel to scan surface 1 2 4 5 3 Fig 336 Handheld Controller ...

Page 148: ...d on screen with a red border 6 3 1 2 D pad The 5 D pad Fig 336 provides a redundant system control that may be utilized as an alternative to the touchscreen A blinking box around a button indicates the D pad selection Pressing the outer buttons of the D pad selects different buttons on screen Press the centre button of the D pad to choose the button currently selected 6 3 1 3 Joysticks The joysti...

Page 149: ...trols the system movement using the joysticks 1 Scan Rapid Button Fig 339 Used to quickly switch between crawler speeds The speed in either mode can be manually set to the users preference Rapid mode also changes the steering sensitivity according to the user settings TIP Fine adjustments of speed and steering can be made in the User Settings see User Settings Screen on page 145 Mode Select Jog La...

Page 150: ...handheld controller It does not zero the position used in the data acquisition instrument 4 Module Rate Button s Displays the current maximum rate for the selected speed mode Press to set the maximum rate using the Edit screen The movement commanded by the joysticks will be limited to the indicated rate When a rate is modified the rate will be modified for all other system modes 5 Exit Button Exit...

Page 151: ...he crawler tab Press the FWD or REV button to drive the crawler at the current maximum scan rate When the crawler is in motion the steering joystick is still enabled Touching the handheld controller screen or pressing the D pad stops crawler movement NOTE The FWD REV Buttons will not be present in rapid mode Jog SCAN Exit Crawler 0 mm Zero 200 mm s FWD REV 7 7 Fig 341 Latched jog mode Jog SCAN Exi...

Page 152: ...ton Enables the 1 Axis Scan screen see 1 Axis Scan Screen on page 142 5 Point C The finish point of the overall scan travel 6 Setting D The distance the system will advance The 1 Axis Scan Setup screen indicates the scan functions that may be entered Each point and setting A B C D corresponds to a coordinate entry button on the screen A typical scan begins at the A position and moves to the B posi...

Page 153: ...ed for reference This encoder is not used for positioning as per the User Settings but is only for reference see User Settings Screen on page 145 3 Start Stop button Start or stop the scan sequence When a scan has been stopped while in progress the start button resumes the scan 4 Reset Return the scanner to the A position Press the start button to begin the scan sequence from the initial setting 5...

Page 154: ... motion When the scanner is not in the A position a warning appears Fig 346 The warning alerts that the A position of the scanner will be changed to the current position Press Back to return to the 1 Axis Scan screen to reset scanner and maintain original A position Press Continue to exit to 1 Axis Scan Setup screen 12 Scanner position The blinking cross hair indicates the scanner position 1 Axis ...

Page 155: ...tics and user preference settings User Settings Button Fig 347 Access the User Settings screen allowing for various user preferences to be adjusted Diagnostics Button Enters the Diagnostic screens to monitor system components and function Touch Cal Button Used to initiate the Touch Calibration screen Joystick Cal Button Used to enter the Joystick Calibration screen Draw Button Enters mode used to ...

Page 156: ...tick less sensitive and more accurate enabling better control following a guide or feature Units are a percentage of the maximum system allowed 0 100 100 Rapid Steering Sets the steering limit maximum when using the Rapid setting within Jog mode Recommended to be left at 100 to allow maximum crawler maneuverability 0 100 100 Crawler Scan Sets the crawler scan rate in the current units second This ...

Page 157: ...the actual crawler position error as the idler encoder is not affected by drive wheel slippage on the surface Disabled or Enabled Enabled 6 3 6 2 Diagnostics Screens Several diagnostic screens allow various system functions to be monitored Navigate to different diagnostic screens using the PREV and NEXT buttons The Exit button returns to the System Utilities screen NOTE The diagnostic information ...

Page 158: ... the System 2 screen An empty button is provided to allow testing of the D pad Free Timer Value from a free running system timer If this timer is static an internal controller issue is present Button State Shows the state of the pushbuttons in the D pad Button Timer Shows the timer associated with the D pad Diagnostics System 1 Exit NEXT PREV PowerOnTime ResetCause ResetInt EEpromCheck Joysticks T...

Page 159: ...put of the module to the motor The current mA displayed is directly proportional to the motor s output torque This reading can be used to check if the control system is responding to forces on the modules motor Temperature Internal temperature reading of the module in degrees Celsius Diagnostics System 3 Exit NEXT PREV IntAddr Timer IPC0 IFS0 IFC0 0000 0000000000000000 0000000000000000 0000 0000 2...

Page 160: ... screen Typically this should not be necessary Touch the screen as the markers appear in the four corners of the screen TIP It is recommended that the markers be touched with a small object to enhance the touch position accuracy during calibration The new calibration is stored immediately when the fourth marker is pressed The calibration utility exits and return to the System Utilities screen To a...

Page 161: ...ppear to be properly centred Current readings of the joysticks are displayed in the Joystick Calibration screen Fig 357 When the numbers are not near zero press the Calibrate button to recalibrate to 0 The new calibration is stored when the Exit button is pressed Left joystick off centre and will be disabled Ok Fig 356 Joystick error Joystick Calibration Exit Calibrate Calibrate Left Right 3 3 Fig...

Page 162: ...will display When this alert screen is displayed all motor and system function will cease Press OK to reactivate the system to remove NAVIC from the scan surface Fig 358 Draw utility CAUTION HOT SURFACE The handles of the crawler and crawler body may be hot to the touch Use appropriate protective equipment when removing a crawler from a high temperature surface HIGH INTERNAL TEMPERATURE Please rem...

Page 163: ...continue operating the crawler the HIGH TEMPERATURE warning will continue to display until the temperature falls below the set temperature limit Jog SCAN Exit Crawler 0 mm Zero 200 mm s HIGH TEMPERATURE Fig 360 High internal temperature screen ...

Page 164: ...se components are NOT submersible NOTE Never use strong solvents or abrasive materials to clean your scanner components WARNING ELECTRICAL SHOCK HAZARD Disconnect the power controller when servicing the equipment The power controller is powered even when the E Stop push button is latched in the off position WARNING MAGNETIC MATERIAL The wheels of the crawler produce an extremely strong magnetic fi...

Page 165: ...his debris before every use An effective cleaning method uses adhesive backed tape e g duct tape to pull the debris off the wheels Every Use Inspect cables and connectors Inspect the umbilical cable the power controller cable and the power cable for damage Have any damaged cable repaired by a qualified person or replace the cable assembly as necessary Inspect all connectors for damage or moisture ...

Page 166: ...normally with the exception of movements that require joystick operation Ensure the handheld controller s joysticks are free of interference and reset the system power to enable joystick control If no interference of the joystick is present the joystick calibration may need to be performed see Joystick Calibration Screen on page 150 8 1 2 Checking Network During startup the system initializes the ...

Page 167: ...moving one device at a time from the system to isolate the problem device NOTE Always turn off the system power before connecting or disconnecting any devices 8 2 Startup Override A system maintenance mode may be accessed to correct system issues Enter the maintenance mode by pressing the handheld controller D pad while system power is activated Continue pressing the handheld controller D pad unti...

Page 168: ...ifferent umbilical port and perform the scan again to confirm the device is faulty Normal network speeds will be 2 for all devices When a device is not operating at the correct speed the internal software attempts to correct the device speed When a device is not operating at the correct speed it may disrupt communications of the system network Power should be cycled and the scan restarted TIP With...

Page 169: ...control a variety of functions These parameters can not be modified However special circumstances may occur when modification of these parameters could be recommended by the manufacturer Instructions for making changes to the system parameters will only be provided when deemed necessary by the manufacturer 8 2 4 Device Address Each device type in the system is factory assigned a unique identifier ...

Page 170: ...encoder accuracy To output the motor encoder s signal 1 Ensure power to the system has been turned off 2 Plug the L left drive module s connector into the umbilical s 1 X ENC socket Fig 367 3 Plug the R right drive module s connector into the remaining L socket Fig 367 4 Ensure instrument receiving encoder signals is programed with motor encoder s resolution see Performance Specifications on page ...

Page 171: ... clean and connector pins are not bent Umbilical cable not properly connected Check umbilical cable connections at both ends Ensure connectors are dry clean and connector pins are not bent NAVIC system not started Start the NAVIC system see System Startup on page 131 Damaged components in handheld controller crawler power controller or cabling Contact manufacturer see Jireh Industries Ltd on page ...

Page 172: ...e 155 If troubleshooting does not rectify the issue it may be necessary to retrieve the crawler manually To do so 1 Press the E Stop push button This will turn the crawler power off NOTE Under normal conditions the crawler should begin descending slowly 2 If the crawler stops descending due to some kind of impediment use a ladder man lift or scaffolding to retrieve the crawler NOTE FALLING OBJECT ...

Page 173: ...rawler produce an extremely strong magnetic field which may cause failure or permanent damage to items such as watches memory devices CRT monitors medical devices or other electronics Tools magnets and metal objects can cut pinch or entrap hands and fingers HANDLE WITH CARE Those with pacemakers or ICD s must stay at least 75 cm 30 in away at all times WARNING DO NOT DISASSEMBLE No user serviceabl...

Page 174: ...or your NAVIC system contact Jireh Industries Ltd on page 3 NOTE These drawings are for parts order This is not a list of kit contents 10 1 Crawler BOM ID Part Description 1 CX0061 Handle 2 CXA016 NAVIC Crawler BOM ID Part Description 1 CX0061 Handle 2 CXA016 NAVIC Crawler 2 1 Fig 368 Crawler parts ...

Page 175: ...300 Encoder cable see Encoder Connector Type 10 5 BOM ID Part Description 1 CXA019 X NAVIC Power Controller see Power Cord Type 2 3 4 UMA017 06 Auxiliary Cable 5 UMA030 X Umbilical Various lengths available 6 EA470 7 JP069 8 JP070 9 CMG009 X 10 CXA008 11 12 13 CXA009 EA480 EA414 14 15 CX0174 CXS066 3 mm 0 118 in Flat Driver 10 mm 3 8 in Wrench Plug Lemo Receptacle 10 mm 3 mm 0 118 in Hex Driver Pl...

Page 176: ... controller see Power Cord Type 2 DY0011 Rubber bumper 3 CXS122 Power supply 4 DM0067 L Handheld controller bumper left 5 DM0067 R Handheld controller bumper right 6 DMS005 Handheld controller magnet holder 7 DMA006 Handheld controller 1 2 6 4 5 7 3 Fig 370 Kit components ...

Page 177: ...2 U Sonatest Veo Prisma E Olympus OmniScan SX MX2 X3 M2M MANTIS GEKKO LEMO V Pragma PAUT F TD Technology Design AD Sonatest Veo Prisma Single Axis NOTE Additional encoder connector types available contact Jireh Industries Ltd on page 3 10 2 2 Power Cord Type N SL032 E SL039 U SL059 Z No Cord United Kingdom European North American Connector Type Connector Type Part Power Cord Power Cord Fig 371 Enc...

Page 178: ...ame bar see Frame Bar 6 CXS072 R Arm mount block right 7 CXS042 Vertical probe holder side arm right BOM ID Part Description 1 CX0125 CXS043 Vertical Probe Holder Side Arm Left Knob M4 x 16 mm 2 CX0126 Knurled Knob M4 x 0 7 x 11 5 mm 3 mm hex 4 mm stand off SST 3 CXS072 L Arm Mount Block Left 4 BG0038 X Frame Bar see Frame Bar 5 CXS072 R Arm Mount Block Right 6 CXS042 Vertical Probe Holder Side Ar...

Page 179: ... 3 mm hex 4 mm stand off SST 5 BG0038 Frame bar see Frame Bar 6 CXS072 R Arm mount block right BOM ID Part Description CXS023 Low Profile Side Arm CX0125 Knob M4 x 16 mm Arm Mount Block Left CXS072 L CX0126 Knurled Knob M4 x 0 7 x 11 5 mm 3 mm hex 4 mm stand off SST BG0038 X Frame Bar see Frame Bar 1 2 3 4 CXS072 R Arm Mount Block Right 6 5 2 1 3 4 5 6 4 2 1 Fig 373 Low profile probe holder frame ...

Page 180: ... Knob M4 x 0 7 x 11 5 mm 3 mm hex 4 mm stand off SST 3 CX0126 4 BG0038 X Frame Bar see Frame Bar 5 6 CXS055 Frame Bar Pivot CXS064 NAVIC Front Spacer Mount 7 CXS059 Optical Guide Pivot Mount 8 CXS042 Vertical Probe Holder Side Arm Right 10 9 CXS072 R Arm Mount Block Right Arm Mount Block Left CXS072 L 2 4 1 9 3 3 6 5 7 8 3 2 3 10 Fig 374 Pivoting probe holder parts ...

Page 181: ...H0104 Knurled Knob M4 x 0 7 x 18 mm 4 mm stand off SST 4 see Swing Arm Style 5 PH0082 Knurled Knob M4 x 0 7 x 10 mm 3 mm stand off SST 6 see Yoke Style 7 see Arm Style 8 PH0011 X Pivot Button Style see Pivot Button Style PHS022 Slip Joint Probe Holder Subassembly 5 4 7 2 1 3 6 8 7 Fig 375 Slip joint probe holder parts ...

Page 182: ...M ID Part Description 1 PHS028 Vertical Probe Holder Subassembly 2 3 see Arm Style 4 5 see Yoke Style 6 MD050 010 SHCS M4 x 0 7 x 10 mm SST PH0082 Knurled Knob M4 x 0 7 x 10 mm 3 mm stand off SST PH0011 X Pivot Button Style see Pivot Button Style Fig 376 Vertical probe holder parts ...

Page 183: ...5 x 0 8 x 20 mm SST 2 PHS049 Heavy Duty Probe Holder Subassembly 3 EA154 Probe Holder Arm Adjustment Knob 4 See Heavy Duty Yoke Style 5 PH0165 Heavy Duty Probe Holder Arm Standard Drop 6 PH0011 X Pivot Button Style See Pivot Button Style 2 1 3 5 6 4 3 Fig 377 Heavy duty vertical probe holder parts ...

Page 184: ...0 1 10 9 Corrosion Thickness Probe Holder BOM ID Part Description 1 2 BG0091 Cable Clip 3 See Probe Holder Receptacle and Wear Plate MA264 SHSS M8 x 1 25 x 12 mm dog point SST 1 3 3 2 Fig 378 Corrosion thickness probe holder parts ...

Page 185: ...p 2 PH0082 Knurled Knob M4 x 0 7 x 10 mm SST 3 mm stand off SST 3 PH0011 X see Pivot Button Style 4 PH0237 Arm Style Nozzle Extra Short 5 PHS069 Encoded Skew Vertical Probe Holder Subassembly 6 PHS068 Encoded Skew Vertical Probe Holder Slide 7 BTS018 Brake Handle 2 Fig 379 Encoded skew vertical probe holder parts ...

Page 186: ...G0090 35 Frame Bar with Ruler 35 cm 6 CEA029 3 Axis Nozzle Case 7 UMA038 X 07 5 3 Axis Encoder Cable 7 5 m see Encoder Connector Type 8 CEG039 Nozzle Spare Parts Kit 9 CJS017 S 0 6 Slider PPS Encoder 10 CJS008 Slider PPS Slider 11 EA212 Knurled Knob M4 x 0 7 x 8 mm SST 12 CJS001 Slider PPS Main Knob BHCS M5 x 0 8 x 16 mm SST 13 MD074 016 14 BT0014 Dovetail Nut 16 see Slider PPS Encoded Leadscrew F...

Page 187: ...e Size Wedge Type Wide Standard PHS048 8 3 cm 3 26 in 12 2 cm 4 79 in Length Yoke Style Yoke Style Part PHS047 Part Length S W S W Yoke Style Wide Standard PHS063 PHS052 Part 6 3 cm 2 47in Length 7 9cm 3 06in Length Yoke Style Part Fig 383 Probe holder yoke selection Part BG0038 15 BG0038 05 15cm 5 91in 5cm 1 97in BG0038 35 BG0038 25 35cm 13 78in 25cm 9 84in BG0038 55 BG0038 45 55cm 21 65in 45cm 1...

Page 188: ...s PA 06 07 08 09 2 3 mm 0 09 in Conical Head 5 mm 0 20 in Internal 3 0 mm 0 12 in Zetec PA TOFD Wedge Type Pivot Hole Size Wedge Type Wide Standard PHS048 8 3 cm 3 26 in 12 2 cm 4 79 in PHS047 S W Long Short PH0069 4 1 cm 1 61 in 4 6 cm 1 81 in Length Swing Arm Style Swing Arm Style Part PH0100 Part Length B C Connector Type Olympus Focus LT Zetec Z Scan Eddyfi Ectane 2 Olympus OmniScan MX Zetec Z...

Page 189: ...Length 06 07 08 09 2 3 mm 0 09 in Conical Head 5 mm 0 20 in Internal 3 0 mm 0 12 in Zetec PA TOFD Long Short PH0069 4 1 cm 1 61 in 4 6 cm 1 81 in Length Swing Arm Style Swing Arm Style Part PH0100 Part Length B C Connector Type Olympus Focus LT Zetec Z Scan Eddyfi Ectane 2 Olympus OmniScan MX Zetec ZIRCON TOPAZ Company Instrument G M Connector Type GE USM Vision Sonotron Isonic D F TD Focus Scan H...

Page 190: ...M ID Part Description 1 CXG031 04 5 Automated Crawler Medium Temperature Add On Kit 2 CXS102 Medium Temperature Installation Removal Mat 3 CX0371 04 5 Medium Temperature Sleeving 4 CXS114 Medium Temperature Clamp 5 CXS112 Medium Temperature Mount Fig 391 Automated Crawler Medium Temperature Add On Kit ...

Page 191: ...10 15 1 Preamp Bracket 10 15 2 NAVIC Backpack Part Description CES029 Preamp Bracket CES029 V Preamp Bracket with Velcro Fig 392 Preamp bracket Part Description CXS077 Backpack with Velcro CXS063 Velcro Strap 1 2 Fig 393 NAVIC backpack ...

Page 192: ...Rev 00 1 10 15 3 Battery Powered Optical Guide BOM ID Part Description 1 BGS068 2 3 CXS082 Optical Guide Clamp Perpendicular Dovetail Mount JV024 Line Laser Battery Powered Class 1 1 2 3 Fig 394 Battery powered optical guide ...

Page 193: ...PAGE 182 of 185 10 16 Cases BOM ID Part Description 1 CXA044 2 CXA023 Case NAVIC Accessories Case NAVIC Crawler 3 CMA016 4 EA421 Case Motorized Pump Umbilical Case 1 2 3 4 Fig 395 Carrying cases ...

Page 194: ...h European Directive on Waste Electrical and Electronic Equipment WEEE this symbol indicated that the product must not be disposed of as unsorted municipal waste but should be collected separately Refer to Jireh Industries for return and or collection systems available in your country ...

Page 195: ...xchanged any replacement item becomes your property and the replaced item becomes Jireh s property When a refund is given your product becomes Jireh s property OBTAINING WARRANTY SERVICE To utilize Jireh s warranty service you must ship the product at your expense to and from Jireh Industries Before you deliver your product for warranty service you must phone Jireh and obtain an RMA number This nu...

Page 196: ...l brands are trademarks or registered trademarks of their respective owners and third party entities Changes or modifications to this unit or accessories not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment All specifications are subject to change without notice 2021 Jireh Industries Ltd ...

Page 197: ...Jireh Industries Ltd 53158 Range Road 224 Ardrossan Alberta Canada T8E 2K4 780 922 4534 jireh com ...

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