Jireh CX0344, User Manual

Page 1: ...NAVIC 2 Automated Steerable Scanner CX0344 Rev 05 3 ...

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 39 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 40 for additional ...

Page 3: ...e 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 MATERIAL The installation removal mat see Scanner Installation Removal Mat Use ...

Page 4: ...ION 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 175 for additional details EMERGENCY STOP This symbol indicates emergency stop button ...

Page 5: ...ts 8 2 1 5 Environmental Sealing 8 2 1 6 Performance Specifications 9 2 1 7 Encoder Interface Specifications 9 2 2 Compatible Components 10 2 2 1 Low Profile Probe Holder Frame 10 2 2 1 1 Intended Use 10 2 2 1 2 Operating Limits 10 2 2 2 Vertical Probe Holder Frame 10 2 2 2 1 Intended Use 10 2 2 3 Pivoting Probe Holder Frame 11 2 2 3 1 Operating Limits 11 2 2 4 Frame Bar 11 2 2 4 1 Intended Use 11...

Page 6: ...der Adapter 15 2 2 15 1 Intended Use 15 2 2 16 3 Axis Nozzle Scanner Add On Kit 15 2 3 Child Products 16 2 3 1 Motorized Couplant Pump 16 2 3 2 Motorized Raster Arm 16 2 3 3 Actuated Probe Lift 16 2 3 4 Optical Guide 16 2 3 5 Tracker 16 2 3 6 Preamp 17 Chapter 3 Definitions 18 3 1 Definition of Symbols 18 3 2 Definitions of Terms 18 3 3 Safety Symbols 19 3 4 Safety Signal Words 19 Chapter 4 System...

Page 7: ... Profile Probe Holder Frame 34 4 4 2 Vertical Probe Holder Frame 34 4 4 3 Pivoting Probe Holder Frame 34 4 4 4 Frame Bar 34 4 4 5 Slip Joint Probe Holder 34 4 4 6 Vertical Probe Holder 35 4 4 7 Heavy Duty Vertical Probe Holder 35 4 4 8 Corrosion Thickness Probe Holder 35 4 4 9 HydroFORM Cart 35 4 4 10 Preamp Bracket 35 4 4 11 NAVIC Backpack 36 4 4 12 NAVIC Camera Mount 36 4 4 13 Battery Powered Op...

Page 8: ...3 Axis Nozzle Scanning 58 5 6 Right Drive Module 60 5 6 1 Swivel Mount 60 5 6 2 Umbilical 61 5 6 3 Handle 63 5 6 4 Dovetail Accessory Mount 64 5 7 Left Drive Module 65 5 7 1 Swivel Mount 65 5 7 2 Umbilical Connection 66 5 7 3 Handle 66 5 7 4 Dove tail Accessory Mount 66 5 7 5 Connecting Disconnecting Left and Right Modules 67 5 7 6 Probe Holders 69 5 7 7 Vertical Probe Holder 69 5 7 7 1 Probe Hold...

Page 9: ...ential Only 106 5 10 2 Low Profile Probe Holder Frame Flat or Circumferential Only 110 5 10 3 Pivoting Probe Holder Frame 114 5 10 3 1 Mounting a Pivoting Probe Holder Frame 115 5 10 3 2 Pivoting Probe Holder Frame Setup Longitudinal Scanning 116 5 10 3 3 Pivoting Probe Holder Frame Circumferential Scanning 117 5 10 3 4 Pivoting Probe Holder Frame Flange Scanning 118 5 10 3 5 Optical Guide Pivot M...

Page 10: ...eftDrv Right Drv 141 6 2 6 3 Touch Calibration Screen 143 6 2 6 4 Joystick Calibration Screen 144 6 2 6 5 Draw 145 6 2 7 High Internal Temperature Screen 145 Chapter 7 Maintenance 146 7 1 Safety Precautions Before Maintenance 146 7 2 Cleaning 146 7 3 Maintenance Schedule 147 Chapter 8 Troubleshooting 148 8 1 Startup Issues 148 8 1 1 Joystick Off Center 148 8 1 2 Checking Network 148 8 2 Startup Ov...

Page 11: ...6 10 11 3 Axis Nozzle Scanner Add On Kit 167 10 11 1 Slider PPS Encoded Leadscrew 168 10 12 Probe Holder Components 168 10 12 1 Arm Style 168 10 12 2 Yoke Style 168 10 12 3 Swing Arm Style 168 10 12 4 Heavy Duty Yoke Style 168 10 12 5 Pivot Button Style 169 10 13 Probe Holder Receptacle and Wear Plate 169 10 14 Variable Components 170 10 14 1 Frame Bar 170 10 14 2 Cable Management 170 10 14 2 1 Ca...

Page 12: ...PAGE 1 of 177 CX0344 Rev 05 3 ...

Page 13: ...erence 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 radiate ...

Page 14: ...ean Union 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 15: ...atible Components on page 10 and see Child Products on page 16 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 unintend...

Page 16: ... in Minimum 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 he...

Page 17: ...avic is intended to be used by two people 1 a person who is trained in rigging and fall protection and is able to effectively apply the same safety principles to the crawler and 2 a person who is trained to operate the Navic 2 1 2 Unintended Use The NAVIC is NOT intended for use outside of its intended use lifting lowering objects or people i e using the Navic as a crane elevator driving into over...

Page 18: ... in Crawler depth 30 8 cm 12 1 in Crawler height handles removed 81 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 28 2 cm 11 1 in 12 5 cm 4 9 in 8 1 cm 3 2 in Fig 2 Dual module dimensions ...

Page 19: ...t 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 not recommended...

Page 20: ...ncoder resolution left module motor encoder 872 5 counts mm 22161 8 counts in 2 1 7 Encoder Interface Specifications Output type 4 channel 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 pi...

Page 21: ...le probe holders Its use limits the NAVIC s operation 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 H...

Page 22: ...he 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 1 Intended Use Category Parameter Specification Inspection Surface Minimum OD longitudinal driving Not recommended Maximum number of probe holders Slip joint probe holders 2 Vertical probe holders ...

Page 23: ...er 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 dovetail groove of any probe holder frame or frame bar 2 2 9 HydroFORM Cart with ...

Page 24: ...cification Preamp 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 l...

Page 25: ... 2 13 Battery Powered Optical Guide 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 Depen...

Page 26: ...aximum surface temperature 150 C 302 F Scanner Required radial 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 include...

Page 27: ...s 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 and large welds preventing damage and unnecessary wear to the probe The Actu...

Page 28: ...PAGE 17 of 177 CX0344 Rev 05 3 2 3 6 Preamp CXG032 The Preamp is used to amplify the return signal from an ultrasonic transducer and improve the signal to noise ratio for transmission over long cables ...

Page 29: ...ction 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 5 Longitudinal Direction of scan travel is lengthwise of the pipe tube Fig 6 Fig 5 Circumferential scanning Fig 6 Longitudinal scanning ...

Page 30: ...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 31: ...016 Fig 8 Power controller CXA019 Fig 9 Umbilical UMA030 Fig 10 Handheld controller CXA008 Fig 11 Auxiliary cable UMA017 06 Fig 12 Encoder cable UMA025 Fig 13 Installation removal mat AAS061 Fig 14 Lifting sling CXA009 Fig 15 Irrigation kit CMG009 Fig 16 Cable management CXS046 Fig 17 Cap CXS066 Fig 18 Cap CX0174 ...

Page 32: ...414 Fig 20 3 8 in wrench EA470 Fig 21 3 mm flat driver EA480 Fig 22 Case NAVIC crawler CXA037 Fig 23 Umbilical probe holder frame case CXA023 Fig 24 Umbilical case EA421 Fig 25 Motorized pump umbilical case CMA016 Fig 26 Motorized pump umbilical case CXA042 ...

Page 33: ...obe holder frame CXG013 Fig 30 Frame bar BG0038 Fig 31 Slip joint probe holder PHA012 Fig 32 Vertical probe holder PHA015 Fig 33 Heavy duty vertical probe holder PHS043 Fig 34 Corrosion thickness probe holder PHS046 Fig 35 Corrosion thickness probe holder PHS056 Fig 36 HydroFORM cart PHS044 Fig 37 Preamp bracket CES029 Fig 38 Backpack CXS077 ...

Page 34: ...CXS080 Fig 41 Automated crawler medium temperature add on kit CXG031 Fig 42 Encoder adpater UMA010 Fig 43 3 axis nozzle scanner add on kit CXG028 Fig 44 Motorized Couplant Pump CMA015 Fig 45 Motorized raster arm CWG002 Fig 46 Actuated probe lift CXG030 Fig 47 Optical guide CXG035 Fig 48 Tracker DRG001 Fig 49 Preamp CXG032 ...

Page 35: ...to remove and install probe holder pivot buttons The included 3 mm flat driver Fig 52 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 50 3 mm hex driver Fig 51 3 8 in wrench Fig 52 3 mm flat driver Fig 53 1 5 mm hex wrench Fig 54 2 mm hex wrench Fig 55 2 5 mm hex wrench Fig 56 3...

Page 36: ...e module 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 57 Right driv...

Page 37: ...surface contact through all listed scan diameter sizes see Operating Limits on page 5 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 59 Left dri...

Page 38: ...and physical ON and CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occur WARNING There are no user serviceable components inside the power controller Dangerous voltages can be present inside the case Do NOT open Return to manufacturer for repair 1 2 3 Fig 60 Power controller 4 5 6 7 Fig 61 Power controller ...

Page 39: ...rough the power controller cable umbilical and the crawler s emergency stop button power will shut 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 Power Connection The 3 power connection Fig 60 of the power controller is used to connect the power cont...

Page 40: ...ould also put other system components at risk 4 3 3 1 Umbilical Connections Multiple 4 pin and 8 pin Lemo receptacles are located on both ends of the umbilical Any 4 pin connector can be plugged into any 4 pin receptacle Any 8 pin connector can be plugged into any 8 pin receptacle System power and network wiring are identical on each type of plug The only difference being the 8 pin receptacle enco...

Page 41: ... 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 Right drive module 5 Emergency stop button see Emergency Stop Button on page 30 4 3 3 2 Emergency Stop Button The 5 red button Fig 63 located on the umbilical provides an emergency off button to the entire system When pressed all power to t...

Page 42: ...liary cable The handheld controller contains the complete system program and must be connected for the system to operate When a software upgrade is necessary the handheld controller is the only component required 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 no...

Page 43: ...rom the NAVIC to the instrument The encoder cable also provides 5VDC from the user s instrument to the encoder isolation circuitry Various encoder styles are available for various instruments NOTE Inspect the cable and connectors for damage before use When damage is evident the cable must NOT be used 4 3 7 Installation Removal Mat The installation removal mat is used for installation and removal o...

Page 44: ...des a means of protecting and organizing cables tubes and hoses 4 3 11 Cap x2 Caps prevent contamination and damage to the NAVIC s connection pivots When the left and right modules are separated it is imperative the connection pivots remain free of dirt sand mud etc see Connecting Disconnecting Left and Right Modules on page 67 for additional details 4 3 12 Tools Several tools are included for var...

Page 45: ...robe holder frame carries up to six probes during longitudinal weld inspection Available in a myriad of configurations and lengths the pivoting probe holder frame may also be used for circumferential weld inspection 4 4 4 Frame Bar Frame bars use dovetail grooves into which probe holders and accessories may be attached Available in various lengths 4 4 5 Slip Joint Probe Holder The slip joint probe...

Page 46: ...l probe holder exerts more down force on a large footprint probe wedge 4 4 8 Corrosion Thickness Probe Holder The corrosion thickness probe holder carries various probes for the purpose of corrosion inspection and is available with either a flat or curved wear plate 4 4 9 HydroFORM Cart The HydroFORM Cart carries an Olympus HydroFORM probe The HydroFORM cart is designed to be used in conjunction w...

Page 47: ...reference useful for guiding scanners along a given path i e a weld 4 4 14 Automated Crawler Medium Temperature Add On Kit The automated crawler medium temperature add on kit enables a NAVIC crawler to operate on an inspection surface with a temperature up to 150 C 302 F 4 4 15 Encoder Adapter The encoder adapter changes the scanner s built in encoder connector style Fig 84 NAVIC backpack Fig 85 N...

Page 48: ...rogrammable speed and travel settings 4 5 3 Actuated Probe Lift The actuated probe lift allows the probe to be lifted from the inspection surface preserving the life or the probe as well as allowing travel over small obstacles and large welds The actuated probe lift is compatible with various probe styles and is available with either a flat or curved wear plate 4 5 4 Optical Guide The optical guid...

Page 49: ...der frame and uses advanced laser guidance to follow elevated profiles i e welds 4 5 6 Preamp The Preamp is used to amplify the return signal from an ultrasonic transducer and improve the signal to noise ratio for transmission over long cables Fig 94 Tracker Fig 95 Preamp ...

Page 50: ...hown in Fig 96 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 t...

Page 51: ... 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 in SEVE...

Page 52: ...ndicated here 1 Lift the two tether attachment points Fig 97 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 97 Lift tether attachment points Fig 98 Press release button Fig 99 Pull pin from ...

Page 53: ... around the tether attachment point Fig 100 4 Align the tether attachment point and shackle Insert the pin while pressing the pin s release button Fig 101 NOTE Ensure proper orientation of the shackles Fig 103 Fig 100 Align shackle with tether holes Fig 101 Insert pin Fig 102 Proper shackle setup x Fig 103 Incorrect shackle setup ...

Page 54: ...rive Excessive 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 crawle...

Page 55: ...PAGE 44 of 177 5 4 System Connectivity 1 2 4a 3 5 4b 9 7 6 8 Fig 106 Standard crawler configuration ...

Page 56: ...mbilical to 5 power controller 3 Connect 7 handheld controller to 5 power controller using the 4b auxiliary cable NOTE The 7 handheld controller may also be connected directly to the 3 umbilical using the 4a auxiliary cable 4 Connect 9 encoder cable from the 8 user s instrument to the 5 power controller 5 Plug the 6 power cable into an appropriate power source see Power Requirements on page 8 6 se...

Page 57: ...gurations 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 107 Single drive module configuration ...

Page 58: ...right drive modules see Connecting Disconnecting Left and Right Modules on page 67 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 65 CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occur ...

Page 59: ... 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 108 Standard NAVIC configuration with actuated probe lift ...

Page 60: ...t and connect 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 60 3 Connect the 2 auxiliary cable to the 1 actuated probe lift and to the 6 umbilical CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics c...

Page 61: ... Probe Holders 5 5 3 1 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 109 Standard crawler configuration with probe holder frame ...

Page 62: ...of the crawler 2 Attach a configured 3 probe holder frame see Vertical Probe Holder Frame Flat or Circumferential Only on page 106 to the crawler see Swivel Mount on page 60 3 Optional Attach the 1 tracker see Tracker user manual to the front of the 3 probe holder frame Connect the 2 auxiliary cable to the 6 umbilical s 4 pin expansion connector CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power ...

Page 63: ... 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 110 Standard crawler configuration with low profile probe holder frame ...

Page 64: ...umferential Only on page 110 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 110 to the crawler see Umbilical on page 61 CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could ...

Page 65: ... Probe Holder Frame BOM ID Description 1 Tracker 2 Auxiliary cable 3 Pivoting probe holder frame 4 Right drive module 5 Left drive module 6 Umbilical 4 5 6 3 1 2 Fig 111 Standard crawler configuration with pivoting probe holder frame ...

Page 66: ...he crawler 2 Attach a configured 3 pivoting probe holder frame see Pivoting Probe Holder Frame on page 114 to the crawler see Swivel Mount on page 60 3 Optional Attach the 1 tracker see Tracker user manual to the front of the 3 pivoting probe holder frame Connect the 2 auxiliary cable to the 6 umbilical s 4 pin expansion connector CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connecti...

Page 67: ...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 112 Standard crawler configuration with pivoting probe holder frame configured for flange scanning ...

Page 68: ...be Holder Frame Flange Scanning on page 118 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 118 to the crawler see Swivel Mount on page 60 CAUTION DO NOT DISCONNECT UNDER LOAD Shut off power before connection or disconnecting Permanent damage to electronics could occ...

Page 69: ...PAGE 58 of 177 5 5 4 3 Axis Nozzle Scanning 3 1 5 6 10 7a 9 4 4 8 2 7b Fig 113 Single module with nozzle scanner configuration ...

Page 70: ... 5 umbilical at a 90 angle to 3 right drive module 3 Connect the 5 umbilical to the 6 power controller 4 Connect the 8 handheld controller to the 6 power controller using the 7b auxiliary cable NOTE The 8 handheld controller may also be connected directly to the 5 umbilical using the 7a auxiliary cable 5 Mount the appropriate 3 axis nozzle configuration to the swivel mount of the crawler 6 Connect...

Page 71: ...wo 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 116 Press the frame bar or accessory to the swivel mount Fig 117 and tighten the black wing knobs The front mount utilizes two levers Fig 115 to lock the front mount at the de...

Page 72: ...t heights greater than 2 m 6 ft the umbilical must be set Fig 119 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 120 The crawler could fall SEVERE INJURY or DEATH could result Fig 120 Align umbilical mount x Fig...

Page 73: ...lical Fig 123 5 Align the umbilical to the umbilical mount of the drive module Fig 124 6 Fasten the umbilical to the crawler s umbilical mount by tightening the black wing knob Fig 125 7 Unlock the umbilical mount lock lever align the umbilical parallel to the scan surface Fig 127 and lock Fig 126 Fig 123 Connect to umbilical Fig 124 Align with drive module mount Fig 125 Tighten knob Fig 126 Adjus...

Page 74: ... To remove the handle Lift the handle lock latch Fig 128 Pivot the handle down Fig 129 and then pull the handle up to remove from the drive module Fig 130 To reinstall the handle reverse the preceding steps Fig 128 Lift handle lock latch Fig 129 Pivot handle nose down Fig 130 Lift handle from module ...

Page 75: ...PAGE 64 of 177 5 6 4 Dovetail Accessory Mount Affix optional accessories to the crawler such as a NAVIC backpack using the dovetail accessory mount Fig 131 Dovetail accessory mounts ...

Page 76: ...de the accessory 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 133 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 ...

Page 77: ...n 1 Connect the left drive module s connector to umbilical see Umbilical on page 29 for additional details 5 7 3 Handle see Handle on page 63 5 7 4 Dove tail Accessory Mount see Dovetail Accessory Mount on page 64 Fig 134 Connect to umbilical ...

Page 78: ...e supplied 3 mm hex driver press the pin while rotating the two modules Fig 136 2 Once the two modules are 90 perpendicular Fig 137 gently pull the two modules apart Fig 138 CAUTION PINCH POINT HAZARD Keep fingers clear of pinch points when connecting disconnecting left and right modules Fig 135 Press release pin Fig 136 Press pin and rotate modules Fig 137 Rotate modules to 90 Fig 138 Pull module...

Page 79: ...s 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 electronics ...

Page 80: ...b allows the probe holder to be attached to a frame bar as well as horizontal positioning on a frame bar Fig 142 2 Vertical adjustment knob allows the vertical probe holder height adjustment Fig 143 3 Position the pivot buttons where necessary When a narrow scanning footprint is required use the pivot button holes closet to the yoke Fig 144 TIP Probe pivoting may be impeded when closer to the yoke...

Page 81: ...he supplied 3 mm hex driver Fig 50 5 Loosen the probe holder arm adjustment knob Fig 146 and slide the probe holder arm along the yoke pinching the wedge in place 6 Tighten the probe holder arm adjustment knob Fig 147 5 7 7 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 145 Ad...

Page 82: ...ton Fig 150 then slowly lower towards scanning surface to apply spring pressure to the wedge Fig 151 TIP If less spring force is desired refer to step 2 and place the wedge approximately 20 mm in above inspection surface 5 7 7 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 148 Fig 150 ...

Page 83: ...sverse adjustment screw 5 7 7 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 148 2 Using the supplied 3 mm hex driver Fig 50 loosen the longitudinal adjustment screw Fig 155 3 Rotate the main body of the probe holder until it is at the desired angle Fig 156 4 ...

Page 84: ...x driver Fig 50 unscrew the yoke pivot screw and remove yoke Fig 158 3 Loosen the probe holder arm adjustment knob and the arm clamp screw Slide the probe holder arms off the yoke Fig 159 4 Flip the yoke 180 and reverse the probe holder arms Fig 160 5 Place the pivot buttons on the inside of the probe holder arms Fig 161 using a 3 8 in wrench Fig 51 Fig 158 Unscrew yoke pivot screw Fig 159 Remove ...

Page 85: ...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 163 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 164 Fig 162 Screw yoke to opposite side Fig 163 Lower 90 stop post Fig 164 Raise opposite 9...

Page 86: ...mp Screw I Pivot Buttons 5 7 8 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 167 2 Use the probe holder adjustment knob to position the probe holder along the frame bar Fig 168 F I A C B D E G H Fig 166 Slip Joint Probe Holder Fig 167 Attach to frame bar Fig 168 Adjust on frame ba...

Page 87: ...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 171 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 171 Fig 169 Adju...

Page 88: ...long the yoke pinching the wedge in place 9 Tighten probe holder arm adjustment knob Fig 173 5 7 8 2 Probe Holder Adjustment To adjust the probe holder follow these steps 1 Ensure probe holder is in latched upper position Fig 174 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 89: ...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 174 2 Lift probe holder slightly and press the latch button Fig 178 to release the probe holder the full 45 degrees 3 ...

Page 90: ...screw but do not remove it Fig 181 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 182 Fig 180 Insert hex tools Fig 181 Press 3 mm hex wrench down Heavy Medium Light Force Adj Marker Heavy Medium Light Force Adj Marker Fig 182 Choose des...

Page 91: ...w Slide the arms from the yoke Fig 184 3 Flip the yoke 180 and reverse the probe holder arms Fig 185 4 Place the pivot buttons on the inside of the probe holder arms Fig 186 using a 3 8 in wrench Fig 2 Slide the arms onto the yoke and tighten the probe holder arm adjustment knob and the arm clamp screw Fig 183 Unscrew yoke pivot screw Fig 184 Remove arms Fig 185 Flip yoke and reverse arms Fig 186 ...

Page 92: ...et Fig 187 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 188 Ensure the yoke is level to avoid issues with the plunger set screw Fig 187 Position swing arm Fig 188 Install yoke to swing arm Fig 189 Reversed probe holder ...

Page 93: ...e Holder Setup 1 Loosen the probe holder adjustment knob Fig 191 and mount the heavy duty vertical probe holder s dovetail jaw to the carrier 2 The vertical adjustment knob Fig 192 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 190 Heavy duty vertical probe holder Fig 191 Mount probe holder to carri...

Page 94: ...e on the pivot button of the inner probe holder arm Fig 194 6 Align the middle of the wedge with the centre of the yoke Fig 195 7 Tighten both the probe holder adjustment knob and the arm clamp screw Fig 195 while ensuring the wedge remains centred with the yoke Fig 193 Remove outer arm Fig 194 Adjust inner arm Fig 195 Align probe with yoke Fig 196 Tighten knob and screw ...

Page 95: ...e probe holder Slowly lower the probe holder towards the scan surface Fig 198 5 7 9 3 Probe Holder Left Right Conversion 1 Using the supplied 3 mm driver unscrew the yoke Fig 199 2 Position the yoke and arms to the opposite side of the probe holder Fig 200 Fig 197 Press up and pull latch Fig 198 Lowered toward scan surface Fig 199 Remove yoke Fig 200 Orient to opposite side ...

Page 96: ...older arm adjustment knob allowing removal of the probe holder arms Fig 201 4 Position removed arms to opposite sides of the yoke Fig 202 Fig 201 Remove probe holder arms Fig 202 Reverse position around yoke Fig 203 Position pivot buttons Fig 204 Place arms back onto yoke ...

Page 97: ...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 7 9 4 Probe Holder 90 Adjustment 1 Remove the yoke using the supplied 3 mm hex driver Fig 50 2 Orient the yoke to the front of the probe holder and screw the yoke into the threaded hole provided Fig 206 Fig 20...

Page 98: ...ting Left and Right Modules on page 67 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 wh...

Page 99: ...nector to the umbilical Fig 208 4 Mount cable management to the umbilical see Mounting Cable Management on page 122 5 Mount the probe wedge Fig 210 to the long stroke vertical probe holder see Probe Holder Setup on page 96 Fig 208 Mount the umbilical at 90 from standard mounting angle Fig 209 Mount cable management to the umbilical Fig 210 Probe wedge affixed to probe holder ...

Page 100: ... frame 90 Fig 211 Tighten the pivot tapered lock 7 Ensure the swivel mount of the NAVIC is horizontally aligned Fig 212 with the etched line on the crawler see Swivel Mount on page 60 for additional details Fig 211 Adjust pivot tapered lock to 90 angle Fig 212 Align swivel mount with etched line ...

Page 101: ...Mount on page 60 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 214 through the cable management see Cable Management on page 122 1 1 2 Fig 213 Mount the umbilical at 90 from standard mounting angle Fig 214 Route the 3 axis encoder cable through the cable management ...

Page 102: ...nstrument see 3 Axis Nozzle Scanning on page 58 14 Using the cable clips route the encoder cable from the slider pps to the 3 axis encoder cable Fig 216 15 Using the cable clips route the encoder cable from the probe holder to the 3 axis encoder cable Fig 216 16 Plug the encoder Fig 215 Plug 3 axis encoder cable into the power controller Fig 216 Connect encoder cables to 3 axis encoder cable ...

Page 103: ... handheld controller to the power controller using the auxiliary cable Fig 217 5 8 2 3 Axis Nozzle Operation NOTE The encoder cabling removed for illustration purposes Fig 217 Connect handheld controller to power controller Fig 218 Place scanner on surface using installation removal mat ...

Page 104: ...2 Unlatch the encoded skew vertical probe holder see Encoded Skew Vertical Probe Holder Adjustment on page 98 3 Using the handheld controller drive the crawler around the nozzle as required see Jog Mode on page 134 Fig 219 Place scanner on surface using installation removal mat Fig 220 Place scanner on surface using installation removal mat ...

Page 105: ...er PPS as required Fig 221 to position the probes distance from the weld 5 Ensure the slider lock knob Fig 223 A is tight and rotate the main knob to position the slider Fig 221 Place scanner on surface using installation removal mat ...

Page 106: ... 95 of 177 CX0344 Rev 05 3 6 Adjust the skew angle of the probe as required see Skew Angle Adjustment on page 100 Fig 222 Place scanner on surface using installation removal mat A Fig 223 Slider positioning ...

Page 107: ...buttons to the probe holder arms Fig 225 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 224 Encoded skew vertical probe holder identification Fig 225 Attach pivot buttons ...

Page 108: ...s slider Fig 227 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 228 5 Align the probe to be used with the centre of yoke pivot Fig 229 Fig 226 Mount to slider pps Fig 227 Mount to slider pps Fig 228 Loosen kno...

Page 109: ...g 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 ENC 2 at the rear of the low profile link 5 8 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...

Page 110: ... probe holder Fig 234 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 231 5 Pull the latch pin and slightly rotate the latch pin left or right Fig 235 6 Release the latch pin and prob...

Page 111: ... the yoke Fig 236 2 Rotate the yoke Up to 90 in either direction to the angle required Fig 237 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 101 for more information 4 The engraved arrow above the yoke may be used to align the yoke to the required degree Fig 236 Loosen ratchet lever Fig 237 Ad...

Page 112: ...the base of which it is connected Fig 239 2 Continue to pull while rotating the lever in the appropriate direction Fig 240 3 Release the lever and utilize the new tightening position Fig 241 5 8 8 Pivot Buttons Available in a variety of shapes and sizes fitting various wedge dimensions Use the supplied 3 8 in wrench Fig 51 to remove and install pivot buttons Fig 242 Fig 239 Pull ratchet handle Fig...

Page 113: ...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 243 Pinch clip Fig 244 Cable clip Fig 245 Route cables ...

Page 114: ...rame bar and push to into position Fig 246 The slider s friction fit requires an appropriate amount of force to position the slider 2 Loosen the slider s lock knob Fig 246 note red highlight 3 Loosen the main knob s hexagonal screw and lock screw Fig 247 note red highlight 4 Align dovetail nut of the main knob with the frame bar and slide into position Fig 247 Fig 246 Place slider on frame bar and...

Page 115: ...Fig 248 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 249 note red highlight Fig 248 Insert leadscrew into main knob and slider Fig 249 Tighten screws ...

Page 116: ... loose 2 Slide the encoder s dovetail nut onto the frame bar Fig 250 continue sliding the encoder towards the leadscrew until the leadscrew is pressed snuggly into the encoder s coupling Fig 251 3 Tighten the encoder s lock screw Fig 251 note red highlight 4 Route the encoder cable as required to plug into the 3 axis encoder cable Fig 252 Fig 250 Loosen and slide post in place Fig 251 Align and mo...

Page 117: ...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 118: ... place the primary probe holders at the rear of the 2 frame bar Fig 254 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 65 for additional details When mounting the probe holder frame ensure the attachment knobs Fig 254 are at the front non crawler side 1 2 Fig 254 Po...

Page 119: ...the rear rotational adjustment knob to lower the weld scan frame towards the inspection surface Fig 256 Ensure gap B Fig 257 is no smaller than gap A Fig 256 6 Loosen the front rotational adjustment knob Fig 257 to lower the weld frame towards the inspection surface while ensuring gap C Fig 258 is no smaller than gap A Fig 256 A Fig 256 Set rear rotational adjustment knob B Fig 257 Set front rotat...

Page 120: ...PAGE 109 of 177 CX0344 Rev 05 3 7 Lower the probe holders to the inspection surface see Probe Holder Vertical Adjustment on page 70 C Fig 258 Align probes with the scan surface tangent ...

Page 121: ... 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 259 Low profile probe holder frame WARNING FALLING OBJECT HAZARD It is imperative that the steps...

Page 122: ... 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 65 for additional details When mounting the low profile frame ensure the attachment knobs Fig 260 are at the front non crawler side 4 Release the two swivel mount levers Fig 261 to position the swivel mount parallel to the scan surface Fig ...

Page 123: ...ame towards the inspection surface Fig 262 Ensure gap B Fig 263 is no smaller than gap A Fig 262 6 Loosen the front rotational adjustment knob Fig 263 to align the frame bar parallel with the scan surface Fig 264 A Fig 262 Set rear rotational adjustment knob B Fig 263 Align probe holder tangent with scan surface ...

Page 124: ...PAGE 113 of 177 CX0344 Rev 05 3 7 Lower the probe holders to the inspection surface see Probe Holder Adjustment on page 77 Fig 264 Low profile probe holder frame ...

Page 125: ...inal 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 265 Pivoting Probe Holder Frame ...

Page 126: ...cing the primary probe holders at the rear of the 2 frame system Fig 266 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 65 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 127: ... at the centre of the frame system Fig 267 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 128: ...er arms are parallel to the scan surface see Probe Holder Longitudinal Adjustment on page 72 5 10 3 3 Pivoting Probe Holder Frame Circumferential Scanning see Vertical Probe Holder Frame Flat or Circumferential Only on page 106 for additional details Fig 268 Tighten pivot wing knobs Fig 269 Correct probe holder longitudinal adjustment ...

Page 129: ...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 270 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 270 Configure assembly and mount to NAVIC Fig 271 Lif...

Page 130: ... crawler on scan surface see Placement of Crawler on Inspection Surface on page 129 3 Release the front swivel mount adjustment levers to align the swivel mount parallel to the scan surface Fig 272 4 Loosen the pivot wing knob and align the frame bar parallel with the scan surface Fig 273 Fig 272 Align swivel mount with scan surface Fig 273 Align frame bar with flange scan surface ...

Page 131: ...m one of the sets of 1 frame bars Fig 274 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 274 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 132: ...ivot to direct the laser beam as required Fig 277 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 133: ...ollow these steps 1 Align the cable management clamp with the appropriate mounting position on the umbilical Fig 279 2 Tighten the cable management clamp wing knob Fig 280 5 11 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 281 2 Follow the cable placement zipping the tube closed Fig 282 Fig 279 Align with umbilical ...

Page 134: ... 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 285 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 286 Tighten the clam...

Page 135: ...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 288 2 Slide the dovetail nuts of the backpack into the accessory dovetail groove Fig 288 3 Tighten the two backpack screws using the supplied 3 mm hex driver Fig 289 4 Pull the Velc...

Page 136: ...ables strong enough to prevent the object from falling have smooth edges so as not to cut bracket s velcro strap 5 11 4 1 Mounting Preamp Bracket The preamp bracket mounts to any dovetail groove 1 Loosen the knob and align with dovetail groove Fig 291 2 Tighten the knob to lock preamp bracket in place Fig 292 5 11 4 2 Attaching Preamp with Screws Use the adjustable screw mounting channel on the bo...

Page 137: ...these steps 1 Slide the velcro strap through the bracket s holes Fig 294 2 Centre and place the preamp on the bracket wrapping the velcro around the preamp Fig 295 Secure the preamp to the bracket attaching each side of the velcro Fig 296 Fig 294 Insert velcro straps Fig 295 Place preamp and wrap velcro Fig 296 Velcro wrapped around preamp ...

Page 138: ...e 8 2 Connect the components see Configurations on page 46 3 Locate the 1 red emergency stop push button on the power controller Rotate this button clockwise to unlatch Fig 297 4 The 2 green push button on the power controller activates the system Fig 297 2 1 Fig 297 Power controller Fig 298 Handheld controller Ok SEVERE INJURY OR DEATH HAZARD READ AND UNDERSTAND USER MANUAL AND HEED ALL WARNINGS ...

Page 139: ...ay requesting assurance that a no entry fall zone has been established see Preparation for Safe Use on page 39 and tether requirements are met see Tether Requirements and Attachment on page 40 Acknowledge this warning by touching Yes Once the system is initialized the Mode Select screen will appear see Mode Select Screen on page 133 The system is now ready for operation Yes HAVE YOU IMPLEMENTED FA...

Page 140: ...the 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 ...

Page 141: ...s used in place of cable management see Cable Management on page 122 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 39 Raise the front swivel mounts see Swivel Mount on page 60 and umbilical mount see Umbilical on page 61 to ensure they wil...

Page 142: ...efully drive Fig 305 the crawler off the installation removal mat and onto the inspection surface Fig 306 5 Once the crawler is securely on the inspection surface the user may let go of the crawler Fig 306 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 143: ...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 307 6 2 2 Handheld Controller Layout Fig 307 Align swivel mounts parallel to scan surface 4 5 3 2 1 BOM ID Description 1 Steering Raster Joystick 2 Fwd Rev Joystick 3 Click Wheel 4 Controller Cable Connector 5 Touchscreen Fig ...

Page 144: ...e click wheel selection Rotating the click wheel selects different buttons on screen Press the click wheel to choose the button currently selected 6 2 3 Mode Select Screen The Mode Select screen offers four modes of operation for the system Jog Mode see Jog Mode on page 134 Latched Jog Mode see Latched Jog Mode on page 136 System Utilities see System Utilities Screen on page 137 Exit NEXT PREV Net...

Page 145: ...Rapid Button Fig 311 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 137 2 Zero Button Fig 311 Sets the current position to zero for all modules...

Page 146: ...oes not zero the position used in the data acquisition instrument 4 Module Rate Button s Fig 311 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 Fig 311 Exits the jo...

Page 147: ...ns The FWD and REV buttons are located in the 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 click wheel stops crawler movement NOTE The FWD REV Buttons will not be present in rapid mode Jog Exit SCAN Screen or Knob to STOP Craw...

Page 148: ... initiate the Touch Calibration screen 4 Joystick Cal Button Fig 316 Used to enter the Joystick Calibration screen 5 Draw Button Fig 316 Enters mode used to test the touch screen accuracy and response 6 2 6 1 User Settings Screen Allows user to customize the system to their preferences Utilities Exit Draw Bounce Touch Cal Joystick Cal Diagnostics User Settings Fig 316 Utilities screen User Setting...

Page 149: ...pid setting within Jog mode Recommended to be left at 100 to allow maximum crawler maneuverability 0 100 100 Crawler Scan unit s Sets the crawler scan rate in the current units second This setting can also be changed through the Jog or Two Axis Scan Speed screens 0 254 mm s 0 10 in s 76 mm s 3 0 in s Crawler Rapid unit s Sets the crawler rapid rate in the current units second This setting can also...

Page 150: ...ies and programming in the system Not all functions and information is explained in this manual 6 2 6 2 1 Detected Modules Screen indicates the system software version and displays which modules were detected when the system was activated Diagnostics Detected Modules Left Right Raster Exit NEXT Fig 318 Detected modules screen ...

Page 151: ... An empty button is provided to allow testing of the click wheel Free Timer Value from a free running system timer If this timer is static an internal controller issue is present Scrollwheel Counter indicating the rotary position of the click wheel Scrollbutton Indicates the status of pressing the click wheel Diagnostics Exit System 1 PowerOnTime Reset Cause ResetInt EEpromCheck Joysticks Touchscr...

Page 152: ...the output 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 Exit NEXT PREV System 3 IntAddr IFS0 IFC0 IPC0 Timer 0000 0100100000000000 1000000000001000 5444...

Page 153: ...umber will change When the encoder is moved from its current position and then back to that exact same position this number will also return to its original position EncPos The position of the module s motor encoder in counts Diagnostics Exit NEXT PREV RightDrv AuxEncPos EncPos Stator Commutation Motor Stat 1 15 255 45 00000000 Fig 323 Diagnostic screen ...

Page 154: ...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 abort the calibration the system power may be turned off before the last marker is pressed Fig 324 Touch ca...

Page 155: ...ppear to be properly centred Current readings of the joysticks are displayed in the Joystick Calibration screen Fig 326 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 Center and Will be Disabled Ok Fig 325 Joystick error Joystick Calibration Exit Calibrate Calibrate Left Right 1 5 Fig...

Page 156: ...en 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 327 Draw utility Ok Please remove system from hot environment or allow to cool HIGH INTERNAL TEMPERATURE Fig 328 High internal temperature screen CAUTION HOT SURFACE The handles of the crawler and crawler body may be hot to the tou...

Page 157: ...nents 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 field whic...

Page 158: ...Remove this 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 m...

Page 159: ...All system functions will work 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 144 8 1 2 Checking Network Left Joysti...

Page 160: ...k the connections of the devices or try removing 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 click wheel while system power is activated Cont...

Page 161: ... a different 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 ...

Page 162: ... set to 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 ide...

Page 163: ... To output the motor encoder s signal 1 Ensure power to the system has been turned off 2 Plug the left drive Fig 334 L module s connector into the umbilical s X ENC socket Fig 334 1 3 Plug the right drive Fig 334 R module s connector into the remaining socket Fig 334 2 4 Ensure instrument receiving encoder signals is programed with motor encoder s resolution see Performance Specifications on page ...

Page 164: ...are dry 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 127 Damaged components in handheld controller crawler power controller or cabling Contact manufacturer see Jireh Industries Ltd o...

Page 165: ... 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 HAZARD I...

Page 166: ...er 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 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 Th...

Page 167: ...NAVIC system contact Jireh Industries Ltd on page 2 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 335 Crawler parts ...

Page 168: ...fting sling 13 AAS061 Installation removal mat 14 CX0174 Cap 15 CXS066 Cap NAVIC hinge cover 14 15 9 1 12 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 Wre...

Page 169: ...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 2 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 337 Enc...

Page 170: ...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 171: ... 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 339 Low profile probe holder frame ...

Page 172: ... 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 340 Pivoting probe holder parts ...

Page 173: ...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 341 Slip joint probe holder parts ...

Page 174: ...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 342 Vertical probe holder parts ...

Page 175: ...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 343 Heavy duty vertical probe holder parts ...

Page 176: ...5 3 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 344 Corrosion thickness probe holder parts ...

Page 177: ...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 345 Encoded skew vertical probe holder parts ...

Page 178: ...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 179: ...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 349 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 180: ...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 181: ...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 182: ...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 357 Automated Crawler Medium Temperature Add On Kit ...

Page 183: ...10 15 1 Preamp Bracket 10 15 2 NAVIC Backpack Part Description CES029 Preamp Bracket CES029 V Preamp Bracket with Velcro Fig 358 Preamp bracket Part Description CXS077 Backpack with Velcro CXS063 Velcro Strap 1 2 Fig 359 NAVIC backpack ...

Page 184: ...Rev 05 3 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 360 Battery powered optical guide ...

Page 185: ...PAGE 174 of 177 10 16 Cases BOM ID Part Description 1 CXA037 2 CXA023 Case NAVIC Accessories Case NAVIC Crawler 3 CMA016 4 EA421 Case Motorized Pump Umbilical Case 1 2 3 4 Fig 361 Carrying cases ...

Page 186: ...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 187: ...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 188: ...rands 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 2017 2020 Jireh Industries Ltd ...

Page 189: ...Jireh Industries Ltd 53158 Range Road 224 Ardrossan Alberta Canada T8E 2K4 780 922 4534 jireh com ...