Eddyfi Technologies Magg 480 User manual

Eddyfi Robotics Inc.
2569 Kenworth Road, Suite C
Nanaimo, BC, V9T 3M4
CANADA
+1.250.729.8080
[e-mail]
www.eddyfitechnologies.com
Magg™480
Magnetic Inspection Crawler

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
Source Location: C:\ePDM\ISLEng\Products\DU-MiniMag\Manuals\UMDU011367.docm
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User Manual
Table of Contents
About this Manual .........................................................................................................................................5
Description ....................................................................................................................................................5
Specifications............................................................................................................................................6
Certification...............................................................................................................................................6
Safety........................................................................................................................................................7
System Setup..............................................................................................................................................11
Personnel Requirements........................................................................................................................11
Working and Storage Environment.........................................................................................................11
System Power.........................................................................................................................................12
Power Requirements ...........................................................................................................................12
Set the Line Voltage.............................................................................................................................12
Generators / Inverters..........................................................................................................................12
Connections............................................................................................................................................13
Pre-Configured Control Rack...............................................................................................................13
Control System Connections –SD Video............................................................................................14
Control System Connections –HD Video............................................................................................14
Vehicle and Tether...............................................................................................................................16
Winch Installation....................................................................................................................................17
Portable Reel Setup................................................................................................................................17
Mini-Reel Setup ......................................................................................................................................18
Tether Handling ......................................................................................................................................18
Connector Handling................................................................................................................................19
Vehicle Configuration..................................................................................................................................21
Magnet Removal / Installation ................................................................................................................21
Magnet Spacing......................................................................................................................................23
Peripheral Devices..................................................................................................................................24
Minitrac™ Mounting .............................................................................................................................24

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
Minitrac™ Control ................................................................................................................................24
Camera / Light Installation...................................................................................................................25
Payload Calculations ...........................................................................................................................26
Fall Arrest.............................................................................................................................................27
Shipping...............................................................................................................................................27
Operation.....................................................................................................................................................28
Pre-Operations Check ............................................................................................................................28
Post-Operations Check...........................................................................................................................29
ICON™ Software ....................................................................................................................................29
Power-Up Sequence...............................................................................................................................29
Ground Fault Detection & Alarms...........................................................................................................30
Driving the Vehicle..................................................................................................................................31
Inspection Guidelines .............................................................................................................................31
Powered Winch Operation......................................................................................................................31
Vehicle Recovery....................................................................................................................................32
Troubleshooting......................................................................................................................................32
Camera Control Problems ...................................................................................................................32
Video Problems....................................................................................................................................33
Vehicle Problems.................................................................................................................................33
Winch Problems...................................................................................................................................34
Maintenance................................................................................................................................................34
Galvanic Corrosion Control.....................................................................................................................34
Rinsing and Cleaning..............................................................................................................................35
Fuse Replacement..................................................................................................................................36
Minitrac™ Maintenance ..........................................................................................................................36
Camera Maintenance .............................................................................................................................36
Tether Re-termination.............................................................................................................................36
Parts and Repairs .......................................................................................................................................37

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
Source Location: C:\ePDM\ISLEng\Products\DU-MiniMag\Manuals\UMDU011367.docm
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User Manual
Ordering Parts/Customer Service...........................................................................................................37
Warranty Repairs....................................................................................................................................37
Factory Returns to Canada.....................................................................................................................38
Product/System Drawing Package Availability.......................................................................................38
Limited Warranty Policy ..............................................................................................................................38

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
Source Location: C:\ePDM\ISLEng\Products\DU-MiniMag\Manuals\UMDU011367.docm
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User Manual
About this Manual
This manual has been prepared to assist you in the operation and maintenance of your Eddyfi
Technologies equipment. Correct and prudent operation rests with the operator who must thoroughly
understand the operation, maintenance, service and job requirements. The specifications and
information in this manual are current at the time of printing.
This product is continually being updated and improved. Therefore, this manual endeavors to explain and
define the functionality of the product. Furthermore, schematics or pictorials and detailed functionality
may differ slightly from what is described in this manual.
Eddyfi Technologies reserves the right to change and/or amend these specifications at any time without
notice.
Information in this manual does not necessarily replace specific regulations, codes, standards, or
requirements of others such as government regulations.
This manual is copyright © 2020 by Eddyfi Robotics Inc. All rights reserved.
Description
The Magg™ 480 is a magnetic tracked crawler capable of driving vertically or horizontally inverted along
ferrous (iron based) surfaces. Additionally, the magnet modules allow the vehicle to pull longer lengths of
tether than what could normally be achieved without magnets when travelling in steel pipes or on steel
decks. The crawler comes equipped with a Spectrum 90™, two 901 lights and a rear facing Sapphire™
camera. The vehicle uses two Minitrac™8000 for motive power that are mounted underneath the main
chassis plate. The vehicle utilizes two powerful rare earth magnet modules that can be manually
adjusted to accommodate different pipe diameters and strength requirements.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
Source Location: C:\ePDM\ISLEng\Products\DU-MiniMag\Manuals\UMDU011367.docm
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User Manual
Specifications
1
Weights may vary depending on optional components
2Minimum surface radius is based on magnetic adhesion when driving vertically or inverted –see Magnet Spacing
3Maximum payload depends on payload locations –see Payload Calculations
4Actual travel distance may be decreased depending on inspection geometry (traction and number of bends)
5Maximum power requirements depend on tether reel options
Certification
The Magg 480 system is built in accordance with the Low Voltage Directive 2014/35/EU, Machinery
Directive 2006/42/EC, and Electromagnetic Compatibility Directive 2014/30/EU.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
Source Location: C:\ePDM\ISLEng\Products\DU-MiniMag\Manuals\UMDU011367.docm
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User Manual
Safety
In order to be able to use this product properly and safely, every user must first read these operating
instructions and observe the safety instructions contained therein. Take care of these operating
instructions and keep them in a place where they can be accessed by everyone. Untrained personnel
should not handle or operate this equipment.
CAUTION: Failure to follow these safety instructions may result in injury or
equipment damage.
This system includes some specific devices that have their own User Manuals. Instructions on those
manuals must be also read before using the system.
WARNING: High Voltage
The tether carries 400 VDC to the rear harness block, and the Minitrac™ whips
carry 400 VDC from the harness block to the tracks. Always Keep the tether
capped when not installed on the vehicle. Follow the guidelines for preventing
tether damage.
400 VDC can cause serious injury or death. Do not operate with a damaged
tether or Minitrac™ whip. Do not operate the system with damaged wires.
Damaged cabling poses a shock hazard. Repair damaged cabling before
operating the vehicle. A short circuit may also damage the controller, cameras, or
any attached equipment.
Disconnect the power source before servicing the product; otherwise, damage or
fatal injury may result.
The power supply is equipped with a ground fault interrupt circuit. Do not cheat or
bypass the ground fault interrupt circuit. Do not power the equipment from a
source other than the Eddyfi Technologies provided power supply.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
WARNING: Magnetic Pinch Hazard –The magnetic
chassis is fitted with rare earth magnets. These magnets
are very strong and create an immanent pinch hazard.
Use caution when handling the magnets or vehicle near
steel objects and tools, they may snap together
unexpectedly.
WARNING: Medical Hazard –Operators with
magnetically sensitive medical implants should be aware
of and follow appropriate practices.
WARNING: Electronic Device Interference –
Magnetically sensitive devices, including computer hard
drives, cell phones, watches and credit cards may be
disrupted or damaged by the magnetic field.
Note: Rare earth materials are mechanically weak, and
magnetically very strong. They must therefore be
handled very carefully to avoid damage.
Note: To reduce risk of injury and damage to equipment, always store the
Magg™ 480 magnetic vehicle in its magnetically shielded storage and
shipping box or store the magnets on a steel plate when not in use.
Note: We strongly recommend using gloves when handling the vehicle to
reduce magnetic pinching hazard.
Warning: Avoid Magnetic Slamming. Extreme care must be taken when
handling the vehicle, particularly when placing it onto a wall or into its storage
box. Without taking heed of the sudden pull of the magnetic field onto surface,
the Magg™ 480 can be slammed down hard causing damage to the vehicle.
Using a solid grip on the vehicle, we recommend touching down the vehicle by
one end first and then pivoting flat.
WARNING: Intense Optical Radiation - The Spectrum 90™ camera lights and
901 auxiliary lights are extremely bright. Never look directly at the lights. Use a
welding filter (shade #8 or higher) if inspecting the LEDs.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
•CAUTION: Class II Laser: The optional Spectrum 90™
may be equipped with laser lines. Do not intentionally stare
into the beam. Typically, Class II relies on the blink reflex to
limit exposure to no more than ¼-second. Intentionally
staring into the beam can cause eye injury.
•When performing maintenance or functional checks of the
lasers and camera lights, take precautions to protect
nearby personnel from unintended exposure which could
be temporarily blinding.
•Observe safe lifting practices. For storage and shipping, the Magg™ 480 system is packed in
three parts: Controller, Vehicle, and Reel / Tether. Each of the three components is either built or
packed into a Pelican case with carrying handle. The heaviest case containing the tether and
mini-reel is equipped with wheels and extending handle like a suitcase.
•Do not operate the system with damaged wires. A short circuit may damage the power system,
telemetry system, cameras, or attached equipment. Exposed wires may also create a shock
hazard.
•Disconnect the power source before servicing the product; otherwise, damage may result.
•Although designed for durability, the vehicle and its components or attached devices may suffer
structural damage if dropped or impacted. A lifeline or fall arrest system should be used at all time
when the vehicle is navigating on a vertical or inverted horizontal position. In addition, stepping on
the tether may pull the vehicle off the wall causing it to fall and sustain physical damage.
•All personnel operating or maintaining this equipment must be trained and competent.
•Eddyfi Technologies equipment is used in many varied environments from hot/dry to confined
spaces to deep underwater. Such diverse environment risks must be addressed by the operators
who are trained to work in such surroundings. As such, the operator is responsible to determine
safe site setup and appropriate personal protective equipment (PPE) for operation and
maintenance of the equipment.
WARNING: Spark Hazard - Under no circumstances should this equipment be
used in a potentially explosive atmosphere
WARNING: Trip Hazard - Never stand on the tether. A snap load to the tether
may pull it out from underneath you and cause you to fall. Standing on the tether
may also damage its internal conductors, cause unnecessary wear, and decrease
its life. Stepping on the tether may also pull a magnetic vehicle off the wall.
WARNING: High Temperature - The camera head, auxiliary lights, and harness
block may become hot during operation. Allow a cool-down period before
handling.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
WARNING: Mechanical Pinch Hazard –Rotating or moving components can
draw fingers into a pinch position. Do not handle the vehicle while mobile parts are
running, turn off power or disconnect the tether while reconfiguring or maintaining
the vehicle.
WARNING: Falling Object - A lifeline or fall arrest system should be used at all
times when using the magnetic option and the vehicle is navigating on a vertical or
inverted surface. When the vehicle is climbing, never stand below the vehicle
operations area.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
System Setup
Personnel Requirements
Basic deployment of the Magg™ 480 system may be performed by one person. Operations at more
complex worksites may require two people, especially when the console location is removed from the
point of deployment.
•Console Operator: This person is responsible for driving the vehicle, watching the pipe and
making comments about the location and pipe condition. It is also the operator’s responsibility to
assess whether a pipe is in the appropriate condition for safe passage of the vehicle or if there is
a risk of getting stuck. The operator may also assist in general site setup (cones, warning signs,
etc.), vehicle maintenance and configuration.
•Deployment / Tether Handler / Field Maintenance: This person has several tasks including:
oConfiguring the vehicle for the current pipe
oLowering the vehicle in and out of the manhole
oWatching the tether as the vehicle enters and exits the pipe
oOperating the reel and winding the tether during recovery
Establish a good channel of communication between the operator and deployment personnel. Good
communication can avoid accidents, damage to the equipment, and promotes efficiency and productivity.
In particular, the person deploying the vehicle and watching the tether must be able to quickly tell the
operator to stop the vehicle if something goes wrong. The operator should never turn on power or initiate
movement without first communicating with the vehicle handler.
Working and Storage Environment
The control system (interface box, power supply, and Control computer) is to be used in a dry, covered
environment only. These components are not waterproof. Keep all cords and cables away from water.
The tether and vehicle are depth rated to 60 m (200 ft) of water. The tether connector is a wet-mate type
which may be wet when plugged in but cannot be plugged in underwater. Keep the tether connector
capped with a dummy plug when not connected to the vehicle to help keep out dirt. The tracks are
tolerant to sandy and muddy conditions, although this decreases seal life. The vehicle may also be
operated in dry or dusty environments.
The portable reel and winch are splash resistant only. Refer to the reel manual.
To maximize component life and minimize deployment time it is recommended that the vehicle and tether
be cleaned after use and the entire system stored in a dry, dust free, location.
System storage temperatures are between -20 ˚C –60 ˚C (-4 ˚F – 140 ˚F)

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
System Power
Power Requirements
The power requirements given below are maximums for a fully configured system with cable reel. For
use with 115 VAC source, a fully configured Magg™ 480 system requires three independent standard 15
A circuits for power, or one 20 A and one 15 A circuits as follows.
Set the Line Voltage
Before powering on the Magg™ 480 system, it is important to check that the input voltage settings are
correct - an incorrect voltage setting will damage the system power supply and the winch controller.
When installing the system in a new location always check the line voltage.
•Monitor: Universal - no action required.
•Computer: Universal - no action required.
•Interface Box: Universal - no action required.
•Power Supply: Set the line voltage switch to 115/230VAC and change fuse.
oFor 115 VAC use 15 A MDA type fuse.
oFor 230 VAC use 10 A MDA type fuse.
•Winch: Jumpers must be set inside the hand-held controller to switch between 115 VAC and
230 VAC. Refer to the winch manual for instructions.
WARNING: Line Voltage Select –Failing to select the proper line voltage on the
power supply and winch will result in equipment damage.
Generators / Inverters
If powering the system from a generator or inverter, refer to that unit’s operating manual for
recommendations on continuous and peak load ratings. These power sources may apply a reduced
output rating based on electrical load and environmental temperature. Remember to include the power
needs of other connected devices (external monitors, recording devices, lighting, etc.) when selecting a
generator or inverter.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
Connections
Pre-Configured Control Rack
The monitor, computer, interface box and power supply are typically installed and connected in a shock-
mount portable 19 in rack case. Systems pre-configured in a control rack will only need the tether, winch
and vehicle connections to be made before operations.
See the Controller and Winch / Reel user manuals for detailed operation and interconnects.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
Control System Connections –SD Video
The ability to receive standard definition or high definition video depends on the interface box used with
the system. A standard definition interface box is depicted below which would be connected to the high
voltage power supply.
1. Connect the power supply to the interface box using the supplied interface cable. Ensure the
locking collars are screwed on all the way.
2. Connect the USB comms to the control computer.
3. Using equipment power cords connect the power supply and interface box to the 20-Amp power
bar supplied with the equipment rack. Note that the power bar will only accept equipment power
cords. The input cord on the power bar can be changed depending on the input voltage and
location.
4. Connect the tether (or deck cable from the winch or reel) to the interface box as illustrated below.
5. Connect the front monitor or video capture to channels A, B or C (three-way splitter) and the rear
monitor or video capture to channel D, E or F. These are the default output, but the connector
assignments are also software configurable.
Control System Connections –HD Video
A high definition interface box is depicted below which would be connected to the high voltage power
supply. For an HD system make the following connections:
1. Connect the power supply to the interface box using the supplied interface cable. Ensure the
locking collars are screwed on all the way.
2. Connect the USB2 comms to the control computer.
3. Using equipment power cords connect the power supply and interface box to the 20-Amp power
bar supplied with the equipment rack. Note that the power bar will only accept equipment power
cords. The input cord on the power bar can be changed depending on the input voltage and
location.
4. Connect the tether (or deck cable from the winch or reel) to the interface box as illustrated below.
5. Different options may be present for SD video, depending on interface box model. If the interface
box has an internal video capture card there will be two USB2 ports labelled Video A and Video
B. These will be the front and rear standard definition cameras on the vehicle. Analog SD video
is available as normal through the RCA connectors. Use A,B or C for front video (if this is an SD

Magg™ 480 User Manual
Document: UMDU011367.docm
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Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
video system) and D, E or F for rear video. There are spare front and rear video outputs which
can be connected to external monitors.
6. Options for HD video out include HD-SDI, USB3 (internal capture device) and component Pr-Y-
Pb. These connectors are for the front High Definition Camera. Spare connectors are active and
may be connected to external monitors, capture cards or recording devices.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
Vehicle and Tether
It is important that the tether be properly connected to the vehicle –otherwise damage to the system may
result.
1. Connect the vehicle end of tether to the back of the integrated harness block. Visually line up the
key in the connector before mating. Fully screw down and hand-tighten the locking collar.
2. Secure the tow cable to the cable grip on the tether using the quick-link. Adjust the cable grip
position to maintain a small amount of slack tether regardless the direction the tether is pulled, as
illustrated below.
3. Verify all device whips from the harness block to their respective components are securely
connected, and the whips are free from damage.
4. Ensure any unused connectors are capped with dummy plugs to insulate and protect their
electrical contacts.

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
IPN: 3063241-A06
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User Manual
Winch Installation
If your system includes an AC powered winch refer to the winch manual for setup and installation
instructions.
Portable Reel Setup
If your system includes a portable reel, follow these steps to operate:
1. Remove the shipping cap from the front of the case and insert the crank handle.
2. Connect the deck cable from the reel to the controller.
3. Disengage the packing brake (pull back and turn on the locking pin).
4. Make sure the friction brake is engaged - disengaging the friction brake can result in slack tether
resulting in potentially jamming the reel.
5. Unwind some tether and connect the tether to the vehicle.
6. Run the tether through the level wind as follows:
a. There is an access slot which must be opened by lifting up on the two exposed screw
heads to raise the tether support shafts.
b. Pull up on both sides of the axle on the top wheel and slide the tether beneath it - failing
to lift up on the wheel can scuff and damage the tether.
c. Make sure that the two wheels that sandwich the tether top and bottom in the level wind
are tracking properly as the tether is paid out - this tells the controller how much tether
the reel has unwound and how far your vehicle has travelled.

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Date: 13 Apr 2021
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User Manual
Mini-Reel Setup
If your system includes a Mini-Reel, follow these steps to operate:
1. Remove the Mini-Reel from the shipping case.
2. Connect the deck cable from the reel to the Video Interface and Power Supply.
3. Connect the encoder deck cable from the reel to the Video Interface and Power Supply (if
provided with Mini-Reel).
4. Disengage the shipping brake.
5. Make sure the friction brake is engaged –disengaging the friction brake can result in slack tether
resulting in potentially jamming the reel.
6. Unwind some tether and connect the tether to the vehicle.
Tether Handling
The tether is one of the most important parts of the system. It feeds power and control signals to the
system and returns data to the controller. If the tether is damaged from improper use, poor handling or an
accident, the system may become inoperable. This could lead to significant downtime, loss of production,
and avoidable costly repairs. It is encouraged to stress the importance of the tether and its use to anyone
operating or maintaining the system. For maximum tether life and reliability, we recommend the following
tether handling tips.
•Do not step on the tether
•Do not drive over the tether
•Do not bend the tether beyond its minimum bend radius

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User Manual
•Do not kink the tether
•Do not snap load the tether
•Avoid loading the tether whenever possible
•Always use the cable grip strain relief if applicable to your system
•Regularly inspect the tether for damage
•Regularly clean the tether
Note:
Protecting the conductors inside the tether is critical to the life and operation of the tether.
Proper tether handling and care will result in extended tether life and system reliability.
Connector Handling
Connectors are an essential part of system reliability. They should be properly maintained and cared for
to ensure long life and reliability. It is recommended to follow these steps to help prevent damage and
increase the life of connectors.
•Always put the cap back on the tether bulkhead when the tether is disconnected
•Always inspect the end of the connector prior to engaging
•Never plug in a dirty or damaged connector
•Visually align keyways or locating pins prior to engaging the connector
•Always fully engage or tighten the connector
•Secure locking collars finger tight
•Install dummy plugs on unused connectors
•Disconnect by pulling straight, not on an angle
•Do not pull on the cable to disengage the connector
IMPORTANT: Never “Hot Plug” any connector, this will result in internal damage to the
electronics. Power down the system prior to connecting the inspection system tether.
Note:
Never use WD-40 or similar solvent-based fluids on connectors or crawlers. These will cause
the rubber parts of the connector or crawler to soften and swell rendering them inoperable.
SubConn Connector: Lubrication and Cleaning
•Periodically apply Molykote 111 silicone grease or equivalent before mating connectors
•For dry mate connections, a layer of grease corresponding to 1/10 the socket depth should
be applied to the female connector
•After greasing, fully mate the male and female connector and remove excess grease from the
connector joint
•General cleaning and removal of sand or mud on a connector should be performed using a
spray-based contact cleaner like isopropyl alcohol

Magg™ 480 User Manual
Document: UMDU011367.docm
Revision: A06
Created by: JS
Date: 13 Apr 2021
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User Manual