CUES flexitrax C550c User manual

flexitrax ™ C550c OperationManual
CUES’s advanced, crawler-based digital video
inspection system
Operation Manual
[C550c-OPMAN-ENG/06]
Rev 06
June 2020

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Preface
Before you begin
Please read this operation manual before using the C550c system.
The C550c system is a modular system that can be purchased as a full system package or as individual
components. Contact your CUES representative to ensure you are purchasing the appropriate product for your
needs.
The contents of this manual are subject to change. CUES products are under continuous development. CUES
reserves the right to modify any product, including this manual, without notice and some product changes may
have taken place after publication of this manual.
For the latest information about the flexiprobe product family, including all accessories, documentation and
software updates, contact your local CUES dealer or visit www.cuesinc.com.

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Copyright © 2020 CUES Ltd. All rights reserved.
CUES is a subsidiary of SPX Corporation.
Trademarks
CUES and Accupoint are considered trademarks of Cues Inc. Radiodetection, flexiprobe, flexitrax, and
flexicoiler are considered trademarks of Radiodetection Ltd. Radiodetection Ltd is a subsidiary of SPX
Corporation. Due to a policy of continued development, we reserve the right to alter or amend any published
specification without notice. This document may not be copied, reproduced, transmitted, modified or used, in
whole or in part, without the prior written consent of CUES Inc.
Other trademarks or registered trademarks mentioned in this document belong to their respective owners.
Disclaimer
Any third-party products (including hardware, software and services) mentioned in this manual are for
instructional purposes only and are not an endorsement by CUES Inc or SPX Corporation.
CUES Inc does not accept any liability for loss of data or damage to equipment when using any third-party
products.

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Compliance
EU Compliance
This equipment complies with the following EU Directives:
EMC Directive: 2014/30/EU
EMF Directive: 2013/35/EU
Low Voltage Directive: 2014/35/EU
RoHS Directive: 2011/65/EU
WEEE Directive: 2012/19/EU
Industry Canada Compliance
ICES-003 Class A Notice:
This Class A digital apparatus complies with Canadian ICES-003.
Avis NMB-003, Classe A:
Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada
Ingress Protection Marking
This system complies with this rating for IEC standard 60529, solid particle and liquid ingress protection:
IP55: Controller covers and connection panels open or closed.

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FCC 15 Compliance
This equipment complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
The equipment may not cause harmful interference.
The equipment must accept any interference received, including interference that may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the manufacturer’s instruction manual,
may cause harmful interference with radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference, in which case you will be required to correct the interference at your own
expense.
Any modifications made to this equipment not approved by CUES may void the authority granted to the user by
the FCC to operate this equipment.

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Warnings, Cautions and Notes
Please observe all warnings, cautions and notes in this manual before operating any CUES product.
Warning! Warnings alert you to possible personal injury.
Caution: Cautions alert you to possible equipment damage.
Note: Notes contain useful information.
Warning symbols
General Warning: Refer to the manual for specific instruction or advice.
Electrical Hazard: Observe safe practices and exercise extreme caution.
Biohazard: Disinfect after use. Wear appropriate personal protective equipment (PPE).
Hot Surface: Allow to cool or use appropriate protection when handling.
Heavy object: Take additional care when lifting.

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Perform a risk assessment
Warning: Always carry out a risk assessment of the site to be inspected. This equipment is NOT
approved for use in areas where potentially explosive (or otherwise hazardous) gases, vapors, liquids
or solids may be present.
CUES has taken care to provide the necessary information in this manual for the safe installation,
operation, maintenance and disposal of this equipment. However, you must carry out a risk
assessment before starting work as it may identify other safety issues.
Always follow standard safety precautions for working in hostile environments, including precautions
for manual handling, biological hazards and personal injury.
The C550c PSU has a number of ventilation slots around the casing that are designed to maximize air
circulation and reduce heat. There is a potential fire risk if the build-up of heat is prevented from
escaping. Under no circumstances are these ventilation slots to be covered or blocked.
Warning: Use the camera distance counter as an estimation only. CUES recommends that you use a
sonde and CUES cable locator to accurately locate positions of interest, especially before starting
construction works.

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Safety precautions
Electrical precautions
Warning: If the system connects to mains operated equipment, the external equipment must be
earthed in accordance with the manufacturer’s instructions. Failure to comply with this may cause the
system to become live and a lethal hazard.
Warning: System components must not be connected or disconnected when the power is on. Do not
touch any connectors while the system is live
Warning! Always remove the fuse when the controller is transported by air!
Always ensure that cabling is properly connected.
Always switch the system on and off using the controller power button and the on/off switch on the
Power Supply Unit (PSU). The PSU is integrated within the Powered Drum (see page 37) and
separate from the Manual Drum (see page 38).
Make sure that video and power cables are not entangled in the drum or reel. Cable ties are
recommended and will not impede system performance.
The C550c system requires a connection to a protective earth; if in doubt, consult a qualified
electrician. Electrical equipment is factory-tested for electrical safety. Routine inspection is
recommended (and may be required by law) to maintain this level of protection. If you are unsure,
contact your local safety authority for advice.

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Electrical precautions (continued)
The external connectors of the C550c Manual PSU unit and Powered Drum are required to be
properly sealed by the blanking caps provided or by using the correct leads to prevent water damage
to the units. Under no circumstances are these connectors to be left un-blanked.
Take care to ensure that video and power cables do not get entangled in the drum. Cable ties are
recommended and will not impede system performance. Always store the flexitrax C550c system in a
clean and dry environment.
If using a generator follow the manufacturer’s instructions on load connection and sequencing. In the
absence of these instructions the following guidelines should be used:
When starting the generator; ensure that all electrical loads, including the flexitrax C550c are switched
off before starting the generator. Allow the generator to stabilize before connecting any electrical loads
or switching on the flexitrax C550c.
When stopping the generator; ensure all electrical loads, including the flexitrax C550c are switched off
before stopping the generator.
Starting or stopping a generator whilst the flexitrax C550c system is connected and the main switch is in
the On position could lead to damage to the flexitrax C550c system or the generator.

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Electrical precautions (continued)
If using an inverter to power the system, a good quality full sine-wave model should be selected
Quasi-sine wave inverters are not recommended for use with this product.
Please observe your company, region and country’s Standard Code of Practice for surveying
underground utilities with CCTV equipment when using this equipment.
Biological precautions
Warning: Foul systems can be a source of serious biological hazards. Wear appropriate personal
protective equipment (PPE) when handling the C550c.
Always use heavy-duty industrial gloves when withdrawing a rod from a sewer.
Battery precautions
The controller contains a Li-Ion rechargeable battery. Only use charging equipment provided by
CUES. The use of alternative chargers may cause a safety hazard and/or reduce the life of the
battery.
The battery is designed to protect itself against over-discharge, overcharge and short circuit between
charge terminals. Other batteries may not provide these safety circuits.
Warning: Exposing the controller’s Li-Ion battery to high temperatures (over 140°F or 60°C) may
activate safety systems and cause a permanent battery failure.

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Caution: Do not tamper with, or attempt to disassemble, the battery.
Caution: If battery failure is suspected, return the entire system to an authorized repair center for
investigation and repair. Local, national or IATA transport regulations may restrict the shipment of
faulty batteries. Check with your courier for restrictions and best practice guidelines. Talk to a CUES
sales representative for authorized repair centers.
Caution: Waste Li-Ion batteries must be disposed of properly, use an approved recycling facility for
electronic waste.
Camera precautions
Warning: The camera will get hot with use. This is normal. To avoid risk of burns, do not touch the
camera when it is switched on or immediately after switching it off. Leave time for it to cool before
handling. Exercise care when handling the camera; consider using gloves.
Warning: The camera LEDs are very powerful. Do not look directly at the LEDs or point them at other
people.
Pushrod reel precautions
Warning: A coiled rod retains a large amount of energy when coiled and can cause injury if not
correctly handled. Only competent personnel should handle this product.

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CUES and CUES recommend that a risk assessment is undertaken before the rod is handled, the
bindings are cut or when using, loading, unloading, uncoiling or coiling rod.
CUES and CUES accept no liability for injury or damage to equipment incurred whilst using, loading,
unloading, uncoiling or coiling the rod.
Moving or transporting the system
Warning: Some components of the C550c system are heavy. If available, use the wheels to assist
transport. Observe heavy-lifting safety practices when lifting any component of this system. For the
system weight and dimensions, see the specifications on page 265.
Warning! Never lower crawlers or other heavy equipment into manholes while personnel work in the
manhole.
Warning! Always remove the fuse when the controller is transported by air!
Disposal
Do not dispose of this product in municipal waste facilities. Please check local regulations for disposal
of electronic products, batteries and hazardous waste.
C550c complies with the requirements of 2012/19/EU Waste Electrical and Electronic Equipment.

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Contents
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Contents
flexitrax™ C550c Operation Manual .....................1
Preface.................................................................2
Before you begin.............................................2
Copyright © 2020 CUES Ltd. All rights
reserved.................................................3
Compliance.....................................................4
Warnings, Cautions and Notes........................6
Perform a risk assessment..............................7
Safety precautions..........................................8
Disposal........................................................12
Contents.............................................................13
1 Introduction .....................................................20
1.1 C550c features........................................21
1.2 Definitions...............................................22
1.3 Safety notices......................................... 22
1.4 Training.................................................. 23
1.5 Updates and latest information............... 23
1.6 CUES technical support.......................... 23
2 Quick Start...................................................... 24
3 System overview............................................. 26
3.1 Controller................................................ 26
3.2 Controller home screen .......................... 34
3.3 Controller battery.................................... 36

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3.4 Cable drums............................................37
3.5 Pushrod reels..........................................44
4 System assembly............................................49
4.1 Crawler, Camera and accessories ..........49
4.2 Drums & External PSU............................69
4.3 Command module...................................70
4.4 Controller................................................ 73
4.5 Pushrod reels......................................... 76
4.6 Cameras and accessories...................... 78
4.7 Battery.................................................... 87

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5 System setup...................................................93
5.1 Insert the fuse.........................................93
5.2 Power on the controller...........................94
5.3 Setup wizard: Set controller preferences
and company details............................95
5.4 Calibrate the equipment..........................99
5.5 Status icons ..........................................100
5.6 Configure the system settings...............101
5.7 Import a company logo......................... 128
5.8 Set up a video title page....................... 129
6 Operating the system.................................... 135
6.1 Before you begin.................................. 135
6.2 Confirming the system equipment ........ 136
6.3 Emergency stop ................................... 137
6.4 Crawler Deployment............................. 137

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6.5 System stop..........................................149
6.6 Driving the crawlers...............................150
6.7 Camera control (lights, focus, pan, rotate,
zoom).................................................160
6.8 Pushrod reels........................................165
6.9 Deploy pushrods...................................168
6.10 Zero the camera distance....................169
6.11 Streaming images to a nearby device .171
6.12 Record a video ................................... 174
6.13 Video tools.......................................... 182

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6.14 Replay a video....................................191
6.15 Take a photo directly...........................193
6.16 Turn off the camera.............................196
6.17 Retrieve the crawler............................197
7 Surveys.........................................................198
7.1 Create a new survey.............................198
7.2 Edit survey screen.................................201
7.3 Manage existing surveys.......................202
7.4 Export a survey.....................................207
7.5 Observations........................................ 224
7.6 Reports................................................. 233

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7.7 Video streaming....................................236
7.8 Menu shortcuts .....................................238
7.9 Supported survey standards .................239
8 WinCan PC connections................................242
8.1 Ethernet connection –no router............243
8.2 Ethernet connection –via router............250
9 Status icons...................................................257
10 Maintenance and cleaning...........................258
10.1 Maintenance .......................................258
10.2 Cleaning the system........................... 261
10.3 Factory reset ...................................... 262
11 Software updates........................................ 263
12 Specifications.............................................. 265
12.1 Controller specifications...................... 265
12.2 Drums and PSU.................................. 267
12.3 Crawlers............................................. 268
12.4 Elevators............................................ 269
12.5 Lighthead ........................................... 270
12.6 Crawler cameras ................................ 270
12.7 Crawler wheels and spacers............... 271
12.8 Controller to drum/PSU link cables..... 272
12.9 Crawler-wheel-elevator configurations 273
12.10 Crawler configuration examples........ 275
12.11 Pushrod reel and rod specifications.. 276
12.12 Pushrod camera specifications......... 277

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13 Open Source Software ................................278
14 Index ...........................................................279
Contact us........................................................286

C550c Operation Manual
1 Introduction
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1 Introduction
The C550c is an advanced pipeline video inspection
system that is ideal for a broad range of applications. It
allows operators to precisely identify and document
pipeline faults using digital video recording.
Rugged and weatherproofed, the system is designed
for use in harsh conditions. It is easy to transport and
deploy, enabling quick and successful inspections.
The C550c controller can drive any combination of
compatible pushrod reels and cameras. Its 12.1”
(307mm) screen displays the camera’s video feed,
stored videos and photos, and configuration settings.
You operate the controller using its built-in buttons and
keyboard.
If required, you can connect the controller to external
video equipment (input and output), to a headset with
microphone, and to an external keyboard.
Fig. 1.1: flexitrax C550c system with
Powered Drum and selected crawler
options