I.B.O.S. CamBoss User manual

I.B.O.S. EU a.s.
CamBoss Monitoring
System
User´s manual
v2.5 (10/2014)
Manual for safe operation of the CamBoss monitoring system and its maintenance to ensure
trouble-free operation. All registered marks and trademarks mentioned in the guide are owned by
the corresponding owners.

CamBoss User´s Manual
Content
1. Introduction..................................................................................................................................... 1
1.1 Guide purpose ......................................................................................................................... 1
1.2 Usage of the system according to the application .................................................................. 2
1.3 Type labels............................................................................................................................... 3
1.4 Used symbols........................................................................................................................... 4
2. Safety measures .............................................................................................................................. 6
2.1 Organizational measures......................................................................................................... 6
2.2 Personal safety ........................................................................................................................ 6
2.3 Prevention of material damage............................................................................................... 7
2.4 Safety instructions................................................................................................................... 7
3. Description of the product ............................................................................................................ 11
3.1 General features.................................................................................................................... 11
3.2 Application and equipment................................................................................................... 11
3.2.1 Control unit.................................................................................................................... 12
3.2.2 KZ90 CamBoss camera head.......................................................................................... 12
3.2.3 Pan and rotate camera head KZ75CB............................................................................ 12
3.2.4 BOSS150 Crawler........................................................................................................... 13
3.2.5 BOSS100 Crawler........................................................................................................... 13
3.2.6 Automatic cable drum NAVI300 / NAVI500 .................................................................. 13
3.2.7 Automatic cable drum HANDCONTROL ........................................................................ 14
3.2.8 MN200 manual cable drum........................................................................................... 14
3.2.9 Pantograph GNTR200E .................................................................................................. 14
3.2.10 Module for ovality measurement OVLTC200A.............................................................. 15
3.2.11 DN400 chassis for BOSS150 crawler.............................................................................. 15
3.2.12 Localising transmitter (sonde)....................................................................................... 16
3.2.13 R250 push (axial) camera .............................................................................................. 16
3.2.14 REVI100 push camera.................................................................................................... 16
3.2.15 Localizing transmitter for push rod cable (sonde) ........................................................ 16
3.2.16 REVI250 Push rod reel ................................................................................................... 17
3.2.17 REVI350 push rod reel ................................................................................................... 17
4. Installation and Commissioning .................................................................................................... 18
4.1 Preparation of the system..................................................................................................... 18

CamBoss User´s Manual
4.2 Supplies and connectors ....................................................................................................... 22
4.2.1 Control unit side panel .................................................................................................. 23
4.2.2 Control unit connections ............................................................................................... 24
4.2.3 Connection of the NAVI cable drums ............................................................................ 24
4.2.4 Connectors of the crawlers ........................................................................................... 25
4.3 Putting into operation........................................................................................................... 25
4.4 Inserting the crawler into the shaft....................................................................................... 26
4.5 Protectioning the drum cable................................................................................................ 27
4.6 Crawler wheels ...................................................................................................................... 27
5. Operating the system.................................................................................................................... 31
5.1 Introduction........................................................................................................................... 31
5.2 Control of the camera head .................................................................................................. 34
5.3 Operating crawlers ................................................................................................................ 35
5.4 Operating the GNTR200E pantograph .................................................................................. 35
5.5 Setting the system up by menu............................................................................................. 36
5.5.1 Selecting appropriate wheels according to piping ........................................................ 36
5.5.2 Advanced system settings ............................................................................................. 37
5.6 Other system features........................................................................................................... 41
5.7 PC control .............................................................................................................................. 42
6. Maintenance of the System .......................................................................................................... 43
6.1 Maintenance of the pressurized components ...................................................................... 43
6.2 Maintenance of the cable drum............................................................................................ 43
6.3 Removal of defects................................................................................................................ 44
6.4 Replacement of the camera's front glass.............................................................................. 45
6.5 Cleaning ................................................................................................................................. 46
6.6 Sending defected components.............................................................................................. 46
6.7 Decommissioning and disposal ............................................................................................. 46
7. Technical data ............................................................................................................................... 47
8. Warranty ....................................................................................................................................... 52
8.1 Scope of warranty ................................................................................................................. 52
8.2 Warranty conditions.............................................................................................................. 52
8.3 Limitation of warranty........................................................................................................... 52
9. Declaration of conformity and RoHS2........................................................................................... 53

CamBoss User´s Manual
Figure 1 CamBoss system component tree

CamBoss User´s Manual
Document history
v1.2 Actualization: LCD menu, 12/13
v1.3 Actualization: photo, added BOSS100, lights and its holder for BOSS100, 1/14
v1.5 Edit & Actualization: NAVIX00, 2/14
v1.8 Actualization: MN200, 3/14
v1.9 Actualization: REVI100, 4/14
v2.0 Actualization: REVI350, sonde REVI250, 5/14
v2.1 Actualization: added LCD Menu –Gradient/tilt calibration, 6/14
v2.2 Actualization: edit component tree, 7/14
v2.3 Published 8/14
v2.5 Published 10/14

CamBoss User´s Manual
1
1. Introduction
Congratulations on purchasing the new TV inspection I.B.O.S. EU a.s. system. Our
instruments represent long-lasting experience and a constant development.
Careful processing and checking is an important feature of our company. If, however, a
defect will occur, because it cannot be completely eliminated, you will receive a high level of
guarantee thanks to our generous warranty service.
But, bear in mind that even the best product can do its job only if it is correctly maintained
and operated.
1.1 Guide purpose
This guide serves as a manual for commissioning, using and maintaining the CamBoss
inspection system produced by our company I.B.O.S. EU a.s. and includes safety instructions
as well.
Read this guide before any operation. Pay attention to articles on safety that protect your
health and prevent hazards connected with operation of the entire system or its components.
If you are in any doubt, need to order a spare part or service, contact the manufacturer:
I.B.O.S. EU a.s.
Hlinska 694/2b
370 01 Ceske Budejovice
Czech Republic
[email protected]
Where, on the website www.ibos.cz you can find contacts for servicemen and technical
support.

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1.2 Usage of the system according to the application
The CamBoss sewer and inspection system is intended only for piping
inspections. Different usage or usage beyond this scope is not
considered as the corresponding application. Never use the CamBoss
inspection system for different purposes. The system must not be used
in piping with media subject to explosion. For this purpose, special
equipment marked "EX" is specially produced and approved.
AMBIENT CLIMATE
Temperature 0 - 40°C.
Relative air humidity 20 - 80 % non-condensing.
HAZARDS
Danger of fatal injury caused by electric current!
Ensure that no liquid can enter the control unit and a cable drum body. Protect the control
unit and the cable drum against the rain.
If this happened, immediately disconnect the power supply, seal the outlet against re-
connection and inform trained specialists or the I.B.O.S. EU a.s. customer service.

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1.3 Type labels
You can find the type labels with the corresponding serial number on the individual
components. You will need this information when contacting the I.B.O.S. EU a.s. customer
service, for example if you wish to order accessories or spare parts. You should write the
corresponding serial number for each component, Table 1, so that it is available if necessary.
Table 1 Component S/N
Component
Serial num.

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1.4 Used symbols
This guide uses the following symbols
DANGER!
This safety instruction warns against hazards connected with injury or
damage to property.
DANGER!
This safety instruction warns against hazards connected with death or
very serious injury caused by electric current.
WARNING!
This warning instruction warns that it is mandatory to disconnect
apparatus from a power supply before any maintenance or service.
DANGER!
This safety instruction warns against hazards connected with heavy
injuries caused by touching hot surfaces of the system.
DANGER!
This symbol warns against laser radiation, which can damage the eyes
or skin.
DANGER!
This symbol warns against a source of light, which can be dangerous
to the eyes.
DANGER!
This symbol warns against danger connected with injuries or damage
to property caused by a fall from the height.
DANGER!
This symbol warns against danger connected with injuries caused by
rotational parts of the machine.

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DANGER!
This symbol warns against danger connected with injuries caused by
movable parts of the machine.
DANGER!
This symbol warns against danger connected with injuries caused by
non-rotational movable parts of the machine.
DANGER!
This symbol warns against danger connected with injuries caused by
rotational parts of the machine.
This symbol warns against danger connected with injuries caused by
non-rotational movable parts of the machine.
DANGER!
This symbol warns against danger of explosion.
DANGER!
This symbol warns against danger connected with water and
environmental pollution.
DANGER!
This symbol warns against danger connected with injuries or damage
to property caused by a fall of the system or a tool from the height.
DANGER!
This symbol warns against danger connected with loss of balance and
injuries due to hit caused by moving parts of apparatus.

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2. Safety measures
2.1 Organizational measures
The CamBoss inspection system has been designed according to the current condition of the
technology and valid technical regulations. Nevertheless, its usage can cause damage to the
health or even death of the user, a third person, animals or damage to the inspection system
or other material values.
A personnel entrusted with operating the inspection system is obliged to read this user guide
and understand it before starting the work. This is especially important for people who only
work with the inspection system occasionally, e.g. during a maintenance, repairs or adding
accessories.
The operator of the inspection system is obliged to ensure safe and hazard-free operation.
He can achieve this by observing the following measures:
keeping this User´s Guide constantly in the application area of the inspection
system
holding regular training courses
keeping control sheets for maintenance and care
regular checking of the personnel for conscious work as regards safety and
hazards
2.2 Personal safety
The person responsible for an operation, maintenance and additional modifications of the
equipment must be specialists or trained by a specialist. The specialists must have adequate
knowledge in inspection systems through special training and experience. They are acquainted
with the corresponding regulations on safety at work and prevention of injury on a level
sufficient for evaluation of safe working condition of the inspection system
follow the service rules for your workplace
respect the corresponding anti-injury regulations
attend training in treating hazardous substances
respect safety instruction in this guide

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2.3 Prevention of material damage
As an operator of the CamBoss inspection system, you are responsible for the
following aspects:
observe the specified maintenance intervals
use the inspection system only in operations for which it has been designed
observe conditions for application of this inspection system described in this
User´s manual
2.4 Safety instructions
Read the following safety instructions carefully and respect them. They serve to your own
safety, safety of your employees, the CamBoss system and its components safety.
Ensure that no liquid can enter the control instrument, the control
unit or the cable drum cover!
If it happens, immediately disconnect the power supply, seal the
outlet against re-connection and inform trained specialists or the
I.B.O.S. EU a.s. customer service.
Ensure that electric cables are undamaged, cannot be broken or
squeezed!
If you detect a damage, immediately disconnect the power supply,
seal the outlet against re-connection and inform trained specialists
or the I.B.O.S. EU a.s. customer service.
Work on electrical equipment beyond operations described in the
cleaning, maintenance and repairs section can only be performed by
a specialized trained person. Larger maintenance or repairs can only
be performed by the I.B.O.S. EU a.s. service or persons authorized by
the I.B.O.S. EU a.s. Company.
Before any cleaning, maintenance and repairs unplug apparatus
from wall socket or power supply and follow this user´s maual.

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Danger of serious injury caused by a falling the crawler!
When starting the system, make sure that the crawler does not stand
too close to an open shaft and the joystick is in the zero position!
When testing the travel functions, the crawler can fall into the shaft.
A person in the shaft can suffer a serious injury. It is prohibited to
hang up other things on cable winch Arm than crawler.
Danger of injury by non-rotational parts of the machine!
Never use automated or manually-driven winch to release fixed or
stuck bodies. Never use automated or manually-driven winch to
raise /lower/pull people or animals, avoid short ON impulses to cable
drum motor and do not exceed the maximum capacity of it and/or
arm winch.
Danger caused by infection of pure water!
Never use the inspection system alternatively for inspections in
waste water and pure water!
Even thorough cleaning of the system cannot guarantee adequate
protection against contamination.
Use a special system for inspections in waste water and pure water.
Danger of serious injuries caused by a touch of hot surfaces of the
system!
When working with the system, keep in mind that the individual
components (especially the lighting, cameras and crawler) can be
very hot during the operation.
Touching hot components of the system can cause serious injury.
Risk of eye damage!
The camera head is equipped with laser diodes, which represent a
hazard for the eyes and skin. Never look into the laser sources, even
if they are not activated and do not aim the laser at your skin.
Danger to the eyes!
The camera head and the additional lights are equipped with a very
powerful light source, which can damage your eyes, eyes of people
and animals around. Ensure that the lights are always switched off
when they are away from the piping to prevent injury.
Danger of injury by rotational parts of the machine!
When operating, maintaining or otherwise manipulating the crawler
and the cable drum, keep in mind that these devices include
rotational components (toothed wheels, chains, etc.), which can
cause serious damage to your limbs or parts of your clothes. When
cleaning or maintaining them, disconnect them, ensure that they
cannot be re-connected and secure the equipment against
undesired movement (ensure the cable against pulling, the crawler
against travel, etc.). You can maintain and clean the equipment only
if it is secured.

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Danger of injury by non-rotational parts of the machine!
The crawler and the cable drum include components that can be
dangerous for the limbs. This especially concerns the crawler
pantograph. Never put your fingers in the pantograph mechanism.
The fingers or parts of the limbs can be severed.
Danger of injury by rotational parts of the machine!
Unprotected covers of the cable drum or the cable aligning
mechanism with trapezoidal screw could cause injury. Do not touch
or step on movable parts of cable drum or string electric winder
placed on cable drum arm. Pay attention to your clothes or their
parts to be at safe distance from this movable parts of apparatus.
Danger of injury by non-rotational parts of the machine!
Cable drum should cause injury during moving by user or unattended
self-moving on tilted plane. Pay attention to avoid your hands and
legs when transporting cable drum to avoid pushing. Check cable
drum to be secured to self-moving and positioned at narrow
horizontal plane.
Danger of injury by non-rotational parts of the machine!
During moving any part of machine consider its weight. When
dropped or turned over by loss of stability a danger of injury or hurt
may arise. Do not tilt the machine to point of turn over.
Danger of injury caused by a fall from the height!
Always be careful and use the specified work processes and aids
when inserting the crawler or the camera in the shaft or pipe.
Danger of explosion!
Never use the inspection system in piping that contains or contained
explosive medium, e.g. gas or thinner.
In this situation, contact the I.B.O.S. EU a.s. Company to find
information on systems that are equipped and certified for these
purposes.
Danger of injury due to hit and consequent lost of balance and fall!
Be aware when the crawler is accelerating or moving. Accelerating
or moving crawler could hit and cause loosening of your body
balance, your fall and consequent injuries.

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Warning!
Operator of the equipment is responsible for proper waste disposal!
When assembling components containing threads use silicon
vaseline and appropriate seal to ensure the best possible sealing. Be
careful when tightening threads and don´t use excessive force to
avoid pulling-down its thread or component damage.

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3. Description of the product
3.1 General features
The CamBoss inspection system intended to inspect sewers and piping.
The system contains the following main components:
1. Control unit with a color 15" LCD monitor, PC and control elements
2. Automatic cable drum (a gantry with winch option)
3. Crawler (wheel chassis and wheel sets optionally)
4. Pantograph with additional lighting
5. Camera head(s) (and its centering parts, rollers)
6. Module for ovality measurement
7. Automatic cable drum hand control
8. Localizing sonde for crawlers / cameras
3.2 Application and equipment
Thanks to extensive accessories and additional equipment, The CamBoss inspection system
can be used in sewers and piping of an internal diameter from DN 50 to ca DN 1000. For a
diameter up to DN 200, use the push camera with reinforced cable 10 - 80 meters long reeled
on a push rod reel, which is designed especially for inspections of service pipes. Sliding guides
(from 80 mm) or wheeled guides (from 150 mm) are selectable according to the nominal
diameter.
From the diameter of 150mm (ie 100mm for BOSS100 type), you can use the crawler with
camera. For diameters larger than DN 200, we deliver a remote-controlled pantograph for
lifting the camera head. According to the application, special sets of wheels for various
diameters and surfaces are available and additional lighting provides better illumination of
large diameters pipes.
The components are supplied as a mobile boxed version or they can be permanently installed
in the TV-inspection van on demand. To document the recorded damaged areas, you can
display the corresponding measured data on a video and input additional comments by a
keyboard.
The crawler and cameras are made of aluminum, brass and stainless steel; they are
waterproof to 1 bar, thus being suitable for inspections in the depth of 10 meters.

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3.2.1 Control unit
The control unit exists in two variants. The first is built in the
TV-inspection van, next, a boxed portable system is available.
Both versions have identical functions. The control panel has
joysticks and buttons for controlling the camera head, the
crawler and the cable drum. The control panel also incorporates
a computer with software (SW) for recording, editing and
storing the video. According to the SW, it is possible to produce
a protocol on the inspection and a protocol on the gradient or
ovality of the pipe. The computer also includes a DVD burner,
which immediately exports the data to CD or DVD. It is also
possible to use a USB Flash Disk or USB Hard Disk.
3.2.2 KZ90 CamBoss camera head
The standard design of the KZ90 head with 10x optical zoom is
able to pan in both directions by ca 135° and rotate 360° axially
(endlessly). This camera incorporates extra-luminous LEDs and
Information about rotation is measured against the earth's axis,
thus providing accurate data on the position of the head.
A special equipment such as lasers for measuring cracks and
distances between joints is built-in on demand.
3.2.3 Pan and rotate camera head KZ75CB
This head is able to rotate and pan with an
electronic position sensoring of mentioned
movements, just like the KZ90 head. It can be
manually focused from the control unit. The
lighting comes from LEDs (8 LEDs - total 4 Watts).
This head is designed for pipe diameters from
100 mm a can be used with push rod reel
REVI250 or CamBoss types crawlers (BOSS100, BOSS150). Optionally you could mount a
special antenna for cornering inside pipe turnings.
Figure 2 Portable control unit
Figure 3 KZ90 CamBoss camera
head
Figure 4 Head KZ75CB with antenna
(on right)

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3.2.4 BOSS150 Crawler
The crawler BOSS150 is designed for pipe diameters
from DN150 and, with corresponding extending modules,
up to DN1200. It is produced in 4x4 or 6x6 wheel versions
and is able to turn. Internal sensors monitor the gradient
against the longitudinal axis, tilt value and internal
pressure in the crawler. There is also DN400 chassis that
increase the diameter and stability of the crawler in large diameter pipes and additional sets
of wheels.
The maximum speed of the crawler is 20m/min. The crawler is driven by maintenance-free
motors. The CamBoss crawler is equipped with a back camera with its own light source, which
gives information on the cable's behavior during reversing.
3.2.5 BOSS100 Crawler
The crawler BOSS100 is designed for pipe diameters
from DN100 and depending on extensensions up to
DN300. Crawler is all-wheel drive and able to turn.
Internal sensors monitor the gradient against the
longitudinal axis and a pressure inside the crawler.
You can find detailed information on your model in
the technical data section. There are also additional
crawler wheels for larger diameter pipes and various surface materials. The maximum speed
of the crawler is 10m/min.
3.2.6 Automatic cable drum NAVI300 / NAVI500
The cable drum is available in built-in (inspection TV-vans) or
portable variant. Portable drum has cable length capacity up to
300m. Built-in version has cable length ability up to 500 meters.
The winding is fully synchronized with movement of the
crawler by the "Smart Feed" technology.
Figure 5 BOSS150 crawler
Figure 6 BOSS100 crawler
Figure 7 Automatic cable drum

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3.2.7 Automatic cable drum HANDCONTROL
The crawler can be easily inserted in the piping by this controller. It
enables travelling of the crawler, releasing and re-winding of the cable
from a position close to the shaft. The display shows the covered
distance. It is equipped by emergency STOP button to cut the power
supply to the crawler and cancel the movement of the cable drum.
The HANDCONTROL is connected to NAVI cable drum.
3.2.8 MN200 manual cable drum
This drum has special light-weighted cable up to 200m capacity,
is water-splash proofed and contain a cable leading roll to ensure
appropriate cable alignment. This drum is designed for BOSS type
crawlers and powered by standard 110-230V/50-60Hz. Use water-
proof power supply cable only with lenght up to 10m.
3.2.9 Pantograph GNTR200E
This component is for operation inside DN200 pipes and
larger. It contains integrated 20 Watt LED light. The light and
the movement of the pantograph are controlled
electronically from the operator's control panel. The
pantograph is a separately sealed component with its own
pressure sensor and is inserted between BOSS150 crawler
and KZ90CB camera head.
Figure 8 Hand controller
Figure 9 MN200 cable drum
Figure 10 Pantograph

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Warning! Risk of injury.
The pantograph and its components can be very hot during
operation.
Warning! Risk of injury.
Never put your fingers in the pantograph mechanism (arms). They
can be severed or seriously injured by the movement of the
pantograph. Never carry the camera by the pantograph.
Warning!
Never carry the camera system by the pantograph. The
pantograph mechanism can be damaged by excessive stress.
3.2.10 Module for ovality measurement OVLTC200A
This module is designed to continuously measure pipe ovality
during inspection. A light beam measures the vertical and
horizontal diameter of the pipe and the data are sent to the control
unit where they are processed and evaluated. The measured
values are displayed online and stored for further processing
(creating charts).
3.2.11 DN400 chassis for BOSS150 crawler
This chassis is to increase the height of the crawler in
DN400 pipes and larger. It increases stability of the
complete system. Together with the electronic pantograph,
this chassis can keep the camera in the center of the pipe
even in diameters up to DN 800.
Warning!
Remember that if you use the chassis, you must set the wheel size to 200mm
in the control unit menu. This chassis reverses the direction of the travel -
the crawler can fall into the shaft or cause another damage by moving in the
opposite direction.
Figure 11 Ovality module
Figure 12 Boss150 crawler additional
chassis