Carlson Void Scanner User manual

Void Scanner user manual H-5914-8501-03-A September 2018
Void Scanner
underground void surveying system
user manual

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Contents
1Customer information.............................................................................................................................................................................4
1.1 Dear customer .............................................................................................................................................................................4
1.2 User manual ................................................................................................................................................................................4
2Laser safety...........................................................................................................................................................................................5
2.1 Void Scanner laser module with red dot laser pointer...................................................................................................................5
3Void Scanner system.............................................................................................................................................................................6
3.1 System overview..........................................................................................................................................................................6
4Void Scannerhardware..........................................................................................................................................................................7
4.1 Void Scanner Probe.....................................................................................................................................................................7
4.2 Interface box..............................................................................................................................................................................10
4.3 Data cable .................................................................................................................................................................................11
4.4 Battery pack...............................................................................................................................................................................12
4.5 Alternative external power connections......................................................................................................................................13
4.6 Main Void Scanner cable...........................................................................................................................................................13
4.7 Boom adaptor and spigot...........................................................................................................................................................14
4.8 Prisms........................................................................................................................................................................................15
4.9 Transit case...............................................................................................................................................................................15
4.10 Void Scanner Wi-Fi box .............................................................................................................................................................16
4.11 Booms and deployment devices.................................................................................................................................................17
5Maintenance and care of the VoidScanner...........................................................................................................................................19
5.1 General......................................................................................................................................................................................19
5.2 In use.........................................................................................................................................................................................19
5.3 Cleaning the Void Scanner.........................................................................................................................................................19
5.4 Storage and transportation.........................................................................................................................................................20
6Cavity Profiler – VS software................................................................................................................................................................21
7Void Scanner Specifications.................................................................................................................................................................22
8Product information..............................................................................................................................................................................24

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1 Customer information
1.1 Dear customer
The Void Scanner system is designed to be easy to operate. However, we would ask you to take the time to read
these operating instructions carefully before using the system, and to keep the manual with the instrument at all
times.
For any feedback or comments, or if there are questions about the Void Scanner system which are beyond the
scope of this manual, contact the product support department at Carlson, or your local Carlson representative.
Alternatively, for information on your local Carlson Software-approved service centre, visit our website at
www.carlsonsw.com.
To ensure best service, please make a note of the serial number. This can be found on a label on the instrument.
1.2 User manual
It is important that you read this manual carefully before using the instrument.
There are three manuals available with the Void Scanner system:
1. This Void Scanner hardware manual which describes the Void Scanner probe and all accessories supplied
with a standard system;
2. A Cavity Profiler – VS software and operations manual;
3. A manual for the Void Scanner Wi-Fi box which is an optional accessory.
It is essential that the accompanying Cavity Profiler – VS software and operations manual is also read and
understood. As well as describing the software, that manual gives a brief overview of a typical deployment. Some
troubleshooting guidelines are also offered which address the most common problems and questions that arise
from users of the Void Scanner.
This manual has been compiled with care. However, should you discover any errors, we would be grateful if you
could contact Carlson directly.
Reproduction in whole or in part, including utilisation in machines capable of reproduction or retrieval, without the
express written permission of Carlson is prohibited. Reverse engineering is also prohibited.
The information in this document is subject to change without notice.

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2 Laser safety
The Void Scanner is supplied with the standard laser module described below which has an integrated red dot laser
pointer.
2.1 Void Scanner laser module with red dot laser pointer
The laser classification of the Void Scanner is a Class 2M laser product in compliance with the British and European
standards for the safety of laser products BS EN 60825-1: 2007.
WARNING: invisible and visiblelaser radiation. Do not stare into thebeam or direct it into theeyes of others.
Do not view directly with optical instruments, e.g. binoculars, theodolite or telescope.
CAUTION: use of controls or adjustments or performance of procedures other that those specified herein
may result in hazardous radiation exposure.
WARNING: opening the protective housing may result in exposure to Class
3B radiation.
All the laser safety labels are located upon the laser module head.
Only qualified and trained persons should be assigned to operate the Void Scanner. When not in use, the laser
should be stored in a location where unauthorized personnel cannot gain access.
We recommend that the instrument is not directly pointed at people’s eyes, especially if they are using optical
instruments. Do not unnecessarily look into the transmitter lens of the Void Scanner laser scanner.
Eye protection, designed to provide adequate protection against specific laser wavelengths (905 nm typically),
should be used in all hazard areas. Any exceptions should only be undertaken with the approval of the laser safety
officer. All laser protective eyewear shall be clearly labelled with information adequate to ensure proper choice with
the particular laser. For the Void Scanner instrument, the recommended CE marked laser eyewear shall be marked
as “R 905 L1”as specified to EN 207, or equivalent. Note that protection shall be afforded to infrared laserradiation,
and not the visible laser radiation.The visible laser is however Class 2 when operated by itself and as such is safe
to use without eyewear (unless deliberately stared at).

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3 Void Scanner system
3.1 System overview
The Void Scanner is a ruggedised field instrument designed to produce fast, efficient 3D laser scans of underground
voids where access is limited, dangerous or prohibited. The instrument can be mounted on booms, tripods or user-
customised deployment devices. The small, lightweight size of the Void Scanner gives flexibility in the nature of the
deployment and means that volumes and dimensions which have previously been guessed or estimated can be
accurately quantified.
The Void Scanner’s laser employs the ‘time of flight’ technique to measure ranges to rock faces and other objects
without the need to place reflectors on the target. This allows measurements to be taken from a safe distance. Two
hundred such measurements are made every second, up to a range of 150 m.
Data from the internal pitch and roll sensors are collected in addition to the scan data. This means that all points
collected can be accurately geo-referenced and multiple scans can be stitched together. The output data can then
be plotted against design drawings or as-built data to help build an invaluable picture of the project site.
The Void Scanner is controlled remotely from a PC or handheld device running Cavity Profiler – VS software which
plots the data on-screen in real time. Cavity Profiler – VS allows the finished scan to be analysed, edited,
transformed, combined with other datasets and exported to third-party software.
The Void Scanner is just one of many laser systems that have been designed by Carlson. Other products such as
the C-ALS (Cavity Auto-scanning Laser System), Quarryman and Boretrak have all been proved over many years
of demanding use around the world. These products complement the Void Scanner and provide a wide range of
advanced measurement solutions within the mining, quarrying and geotechnical industries.
Figure 1 Void Scanner unit

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4 Void Scanner hardware
This section details the full range of components that are available in a Void Scanner system.
Various models of the Void Scanner have been produced and supplied, and the technology is constantly evolving
and improving. Therefore, some components described below may not feature in your Void Scanner system, or
may differ in some way.
4.1 Void Scanner Probe
The Void Scanner instrument consists of a laser module held between two pivots within a yoke. The yoke itself is
held on the end of the horizontal housing.
The laser module houses the optical and electronic components that allow distance measurements to be recorded
to reflectorless targets up to 150 m from the instrument. The laser rotates vertically within the yoke.
Two large lenses are visible in the laser module which represent the transmitting and receiving optics. The infrared
measuring laser is fired through the transmitting optics. Its reflected light is then received back into the instrument
through the receiving optics. A smaller window protects the visible red dot laser pointer which can be switched on
to assist aiming of the Void Scanner distance measurement laser. The pathway of the visible and infrared lasers is
co-linear, but not co-axial.
The yoke which holds the laser module contains the vertical motor which drives the movement of the laser module
between the pillars of the yoke. It also houses the vertical encoder which measures the angle through which the
laser is rotated.
The horizontal housing contains the horizontal motor which drives the rotational movement of the yoke. It also
houses the horizontal encoder which measures the angle through which the yoke is rotated.
Figure 2 Component parts of the Void Scanner
Vertical pivot
Horizontal pivot
Horizontal housing
Main cable
connector
Collar
Yoke
Laser module

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The combination of the two axes of rotation gives the Void Scanner a view encompassing 360° horizontal and 270°
vertical rotations respectively. The yoke itself prevents the laser from viewing a 90° sector of the vertical rotational
sweep.
Both motors are protected with clutches. This means that, if the unit is rotated by hand or
prevented from moving by an obstruction, the motors will not be damaged. It is advisable,
however, to minimise any manual movement of the unit and to keep the instrument away from
potential obstructions so the motors may turn freely. Nevertheless, the possibility of finger or
clothing entrapment exists. Users should not obstruct the operation of the motors or allow
clothing to come into contact with the device.
The horizontal housing incorporates four threads which provide flexibility in the method of deployment used and the
mounting position of the prism. Two 5/8 in threads – one on the base of the unit and one on the underside of the
collar – allow the boom adaptor bracket to be attached to the unit.
One other 5/8 in thread, together with an M6 × 1 thread, are located along the topside of the horizontal housing and
allow two alternative positions to mount a prism during horizontal boom deployment. See section 4.8.
Power and data communications with the Void Scanner are via a 13.6 m Void Scanner power/data cable. The cable
connects to a 6-pin connector on the side of the probe’s horizontal housing. A 4-pin connector on the other end of
the cable connects directly to either an interface box or a Wi-Fi box.
Transmitting
optics
Red dot laser
pointer
Receiving
optics
Figure 3 The Void Scanner laser module

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Main cable
connected to
probe
Boom
adaptor
Figure 4 Connector port location with boom adaptor
M6 x 1 thread
for prism
5/8 in thread
for prism
Figure 5 Threaded hole locations for choice of prism mounting location

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4.2 Interface box
The Void Scanner unit is supplied with an interface box. This box acts as a power/data splitter.
5/8 in thread
for adaptor
5/8 in thread for boom
adaptor spigot or
boom fitting
Main cable
connector to probe
Figure 6 Threaded hole locations on the underside of the Void Scanner used for the supplied boom adaptor or other
mounting devices and booms
Power input
Connection with Void
Scanner
Serial data cable to
PC
Figure 7 Void Scanner interface box

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The interface box has three bayonet lock connectors:
•A 4-pin connector labelled Scanner which connects to the Void Scanner data/power cable. This cable
delivers power to the Void Scanner and also enables two-way data communications between the Void
Scanner and the controlling PC.
•A 6-pin connector labelled Power which accepts power, either from the dc power cable with crocodile clip
battery connectors, or from an ac source with the power supply unit (PSU). See section 4.5.
•A 3-pin connector labelled Data which connects to the supplied serial data cable, which in turn connects to
the operating PC serial port to establish serial-based communications. See section 4.3.
The interface box is not required if the optional Wi-Fi box is used. See section 4.10.
4.3 Data cable
The Void Scanner is operated and controlled via a PC or handheld device operating Cavity Profiler – VS software.
A cable is supplied to connect the PC to the interface box or to the battery pack.
A 9-pin D-type connector interfaces with the serial communications port on the PC. A 3-pin bayonet connector then
fits to either the interface box Data port or the battery pack Data port.
A USB-serial adaptor is also supplied in case no serial port is available on the PC. If this adaptor is used, the
accompanying driver should be loaded before it is used: see the Cavity Profiler – VS software and operations
manual for details.
If using the optional Wi-Fi box, data communications occur wirelessly, so the data cable is not required.
Figure 8 PC to interface box RS232 data cable
Figure 9 USB-serial adaptor

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4.4 Battery pack
The Void Scanner requires a 12 Vdc power source to operate. A dedicated 12 Vdc battery pack is supplied with the
system. The sealed lead acid battery pack is rated to 7 Ah, and will allow continuous operation for up to six hours
before recharging, depending upon the type of operations conducted.
The battery pack is supplied with two bayonet connectors: one with three pins and one with four pins. The 4-pin
connector is labelled Power/Scanner. This will accept the main Void Scanner cable which runs from the Void
Scanner probe. It is also the port to which the mains battery charger is attached when recharging the battery. The
3-pin connector is labelled Data. This will accept the supplied serial data cable which runs from the PC.
When the battery pack is used to operate the Void Scanner, the interface box is not required.
Serial cable to
controlling PC
Cable to Void Scanner
Figure 11 Power and data connection when using the battery pack instead of the interface box
Figure 10 Battery pack and battery pack charger

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A separate battery charger is supplied, which plugs directly into the mains and connects to the battery pack through
the 4-pin Power/Scanner connection. A fully discharged battery requires around 8 to 12 hours to fully recharge from
the mains supply. The battery charger is supplied with a selection of plug types to fit mains sockets around the
world. An LED on the charger will show an amber light while charging and a green light when the battery is fully
charged.
All batteries contain highly reactive, poisonous and corrosive chemicals, which are
hazardous if released due to physical damage. Should the battery or battery charger approach
end-of-life, become non-functional or damaged, stop using it and procure a replacement unit
from a Carlson-approved source.
4.5 Alternative external power connections
As well as the supplied battery pack, the Void Scanner may be powered from any 12 Vdc battery using the blue
cable supplied. This cable incorporates two crocodile clips with which to connect to the positive (red) and negative
(black) terminals of the battery.
A mains power supply unit (PSU) is also supplied which is rated for use at 110 Vac – 240 Vac. A standard ‘kettle’
cable connects the PSU to the mains socket.
Both the dc and mains cables are supplied with 6-pin connectors that connect to the Power port on the interface
box.
Any voltage source connected to the Void Scanner and/or any accessory must be from a
regulated supply, and must be within the specified voltage range. This includes car batteries
as an acceptable stand-alone power source but does not include a car battery connected to a
powered vehicle, or a dc power generator.
4.6 Main Void Scanner cable
The Void Scanner is supplied with a 13.6 m toughened power/data cable. The cable incorporates a right-angled 6-
pin bayonet connector which attaches to the Void Scanner probe.
At the other end of the cable is a 4-pin bayonet connector which attaches to the interface box, the battery pack, or
Figure 12 Blue dc power cable and black mains cable

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the Wi-Fi box, depending on how the unit is being used.
4.7 Boom adaptor and spigot
A boom adaptor is supplied to allow the Void Scanner probe to be deployed on various platforms, e.g. a boom or
standard survey tripod. The boom adaptor is in two parts: the main bracket and a separate cylindrical spigot.
The main bracket incorporates a brass screw which connects to the 5/8 in thread on the underside of the Void
Scanner probe. The accompanying spigot screws into the back of the boom adaptor and then into the 5/8 in thread
on the base of the Void Scanner horizontal housing.
To attach the boom adaptor to the Void Scanner probe, locate the probe on the bracket and screw the spigot into
the 5/8 in thread located on the base of the probe. Then screw the single brass screw on the bracket into the 5/8 in
thread on the underside of the probe.
The boom adaptor itself has a single standard 5/8 in female thread to enable the probe to be mounted horizontally
on a survey tripod or boom.
The spigot can be used to mount the Void Scanner on a number of third-party booms and customised deployment
devices.
Figure 13 Main cable
Brass screw for
mounting on Void
Scanner
Spigot
5/8 in thread for mounting
Figure 14 Boom adaptor and spigot

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4.8 Prisms
The Void Scanner is supplied with a 360° mini prism. This prism can be used to position and orientate the scanner
when the instrument is deployed on a boom or tripod. The prism has a 5/8 in thread at one end and an M6 × 1
thread on the other end. These match with a 5/8 in thread on the collar of the probe and an M6 thread on the end
of the horizontal housing.
A surveyor can target the prism on the Void Scanner to establish the position of the unit. A second prism may be
attached to the far end of the deployment boom. Shooting to both prisms will then give the azimuth of the
deployment. Functionality in Cavity Profiler – VS software can assist with these calculations.
The position where the prism is mounted on the Void Scanner is configured in Cavity Profiler – VS software to
ensure the coordinates of the instrument are correctly calculated. The origin of all angle and range information from
the unit is a position in the centre of the vertical axis of rotation inside the laser module.
4.9 Transit case
The Void Scanner system is supplied in a rugged transit case designed to transport the instrument, surface unit,
boom adaptor, battery and cables. The case helps to protect the instrument from minor shocks and from the
environment. It is recommended that the transit case be used at all times when transporting and storing the
equipment.
Take care to dry the Void Scanner probe and accessories before packing them into the transit case.
Figure 15 The 360° prism mounted on different locations on the Void Scanner

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4.10 Void Scanner Wi-Fi box
The Void Scanner Wi-Fi box is an optional accessory that houses a rechargeable battery and wireless module. The
Void Scanner Wi-Fi box negates the need for a separate battery pack, power cable, data cable and interface box.
The Void Scanner Wi-Fi box can be used to allow personnel to retreat further from the scanner. The unit may also
be attached to the probe boom that is extended into the unsafe area, or placed on an unmanned vehicle that is
remotely driven into the unsafe area. You can be situated in a safe area nearby, receiving scan data wirelessly,
directly to your laptop.
The Void Scanner Wi-Fi box connects to the Void Scanner probe via the standard 13.6 m power/data cable, or via
the 1.5 m power/data cable supplied with the box. Connection to the PC is then via wireless data communications.
A separate Void Scanner Wi-Fi box manual is available which contains set-up and operational instructions together
with full hardware specifications.
Figure 16 System transit case
Figure 17 Void Scanner with Wi-Fi box

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4.11 Booms and deployment devices
The Void Scanner is designed to be deployed on a boom for surveys of stopes and inaccessible areas. Carlson can
offer a standard boom as an optional accessory with the unit. Alternatively, many users design their own boom or
other deployment device to suit their specific operational and site requirements. In some cases the probe fits directly
to the deployment device. In other cases, where there are different mechanical configurations, the boom adaptor
may be required.
Due to the wide range of possible ways of deploying the Void Scanner, this manual does not describe any method
of attachment in detail. For further advice and information, contact your local Carlson-approved service and support
centre.
If you wish to design your own customized deployment device, the relevant drawings and dimensions of the probe
and the boom adaptor are reproduced below.
Figure 18 Void Scanner mounted on a boom

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Figure 19 Void Scanner probe and boom adaptor dimensions

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5 Maintenance and care of the Void Scanner
5.1 General
Attempts to dismantle or repair the Void Scanner and accessories can be hazardous and costly if attempted by
untrained personnel. Unauthorised attempts to carry out maintenance work on the equipment will void all warranty
cover. Maintenance carried out by the operator therefore, should be restricted to the cleaning and inspection of
external surfaces, lens windows and operating controls.
In addition, you should carry out regular functional testing of the system. Detect and report damage, malfunctions
or poor performance to Carlson or a local Carlson representative.
Arrange a yearly calibration for your Void Scanner system to ensure that it is kept in optimum condition and to
ensure the highest possible quality of data.
A troubleshooting guide which outlines some of the most common support questions is included in the
accompanying Void Scanner software and operations manual. For other issues, contact Carlson or a local Carlson
representative for further assistance.
5.2 In use
Avoid directing the Void Scanner laser towards the sun or other high-power infrared light sources.
Avoid mechanical shock.
Avoid manually moving the scan head, either horizontally or vertically, as this can strain the mechanics within the
probe.
Ensure the boom or other mounting system is securely set up and on stable ground to avoid the instrument being
disturbed or knocked over. When moving from one instrument set-up to another, always detach the Void Scanner
from the boom or tripod and carry the two items separately.
The supplied battery pack will benefit from being kept fully charged and receiving steady use. Recharging the battery
after a short period of use will not affect its performance or life expectancy.
Inspect and check the probe and accessories for wear, tear and damage after each use.
Always clean and dry the equipment after use. See below for details.
5.3 Cleaning the Void Scanner
Always ensure that the Void Scanner and all accessories are thoroughly cleaned and dried before packing them in
the transit case after a deployment.
Use clean water to remove mud, grit and other materials from the main body of the probe after use. Do not immerse
the Void Scanner in water. The Void Scanner is rated IP66: it is dust-tight and protected against high pressure water
spray from all directions, but not against submersion.
For further cleaning of the Void Scanner metalwork and side panels, Carlson recommends that you use a product
such as Amberclens anti-static foam cleaner. If this is not available then use a generic, mild dishwashing liquid
diluted in warm water (0.001%, i.e. 1 ml for every 1l of water). Do not use paint solvents or any other personal,
laundry, or household cleaning detergents as they may contain chemicals that could corrode seals in the Void
Scanner. Apply the diluted detergent with a non-abrasive, lint-free cloth.

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Rinse the unit with plain water after using a detergent.
Dry the unit thoroughly after cleaning. Where possible, leave the unit unpacked until it is dry. In case the system is
packed before it has dried, the equipment should be unpacked at the earliest opportunity. Clean and dry the system,
and the inside of the transit case, before repacking the Void Scanner for storage.
To clean the lens windows and the red dot laser pointer window on the laser module, use HPLC-grade (> 99.8%)
acetone in combination with lint-free cotton wool buds or wipes.
NOTE: repeated exposure to acetone may cause skin dryness or cracking. It is recommended that personal
protective equipment (PPE) such as eye-shields and/or face-shields as well as protective gloves is used when
dispensing and using HPLC-grade acetone.
5.4 Storage and transportation
Dry the system thoroughly before storing.
If the instrument remains unused for several weeks, it is advisable to remove power sources from the instrument.
Store within the environmental temperature limits of -25° C to +70° C.
Before transporting the Void Scanner system, pack the equipment correctly in the supplied transit case.
Secure the transit case to prevent the possibility of shock or vibration.
Do not allow the transit case to slide around inside transport vehicles or containers.