IBOS CamBoss User manual

CamBoss
;
Original operating instructions
revision 1.3 02/2020
Instructions for the safe and economic operation of CamBoss monitoring system and
its maintenance to ensure trouble-free operation. All trademarks mentioned in this
document are the property of their respective owners.
Equipment manufacturer:

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IMPORTANT
READ CAREFULLY PRIOR TO USING
SAVE FOR FUTURE USAGE
TABLE OF CONTENTS
1. Machinery identification
2. Product identification
3. General description of the machinery
4. Description of operator positions
5. Intended usage and presumed usage of the system
6. Instructions for assembly, installation and connection
7. Commissioning and usage instructions
8. Safety precautions
9. Conditions under which the device meets requirements for stability
10. Safety guidelines
11. System operation
12. Centring elements
13. System maintenance
14. Troubleshooting
15. Cleaning
1. Machinery designation: CamBoss
2. Product identification: CamBossIV model
The weight of the device depends on the configuration of the device. The noise emission
level does not exceed 70 dB.
The EC declaration of conformity is part of this manual.
3. General description of machinery:
The CamBoss inspection system is used for inspections of sewerages and piping. The system
consists of the following main components:

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CamBoss flow chart

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Control unit
The control panel is equipped with joysticks and push buttons for
head, trolley and winch control. Another part of the control unit is a
computer with installed software for recording, editing and saving of
video. This software is provided with its own manual included with
your product. The protocol on inspection, inclination or piping can be
produced according to software equipment installed in PC. The
computer also includes a DVD-burning unit that lets you save your
output to a CD or DVD disks immediately. If necessary, a USB flash /
hard disk can also be used for export. The device is either fixed to the
vehicle, or transportable in carrying case.
Automatic cable winches NAVI200,NAVI300,NAVI500
Automatic powered cable winches. The guide pulley on the cable drum
enables supported trolley loading without special load of the camera
cable. Measuring sensor for the unwound cable. For max. 200 m of
cable (NAVI200), max. 300 m (NAVI300), max. 500 m (NAVI500). The
winches are splash-proof. An auxiliary arm with an electric winch and
working light can be fitted for a fixed vehicle installation.
BOSS150 IV trolley
The BOSS150 camera trolley is designed for pipe diameters from
DN150, and with appropriate expansion modules up to DN1200. The
trolley allows turning. The internal sensors check the inclination and
tilt towards the longitudinal axis, as well as the internal trolley
pressure. The accessories include DN400 chassis to increase the
luminance and stability of the camera trolley in large pipe diameters,
as well as the set of wheels according to diameters and surface type.
The maximum speed of the trolley is 20 m/min. MAXON brushless
motors are intended for harsh working conditions. The CamBoss
trolley is equipped with a rear-view camera with its own illumination
source, which enables to view the cable's behaviour when reversing.
Weight 8.7 kg (without wheels).
Rotary and camera head KZ95
Colour CCD camera with 2.13mil pixel resolution, 1080p Full-HD
luminous sensitivity 0.05 lux / F1.6, remote focus, 50° angle of view, 2x
120° swivel and 360° rotation (infinite), 24x Superlit LED, 650 lm,
5.5 W, 10x optical + 12x digital zoom
Control unit
Winch NAVI200, NAVI300
BOSS150 trolley 6x6
KZ95 head

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This head allows rotation and swivel, and is equipped with electronic
sensing of these movements. It allows manual focus using the control
panel and features LED lighting.
BOSS100 trolley
The BOSS150 camera trolley is designed for pipe diameters from
DN100, and with appropriate expansion modules up to DN300. The
trolley allows turning. Designed for the KZ60 camera.
Weight 4.4 kg (without wheels).
Rotary and camera head KZ60
This head allows rotation and swivel, and is equipped with electronic
sensing of these movements. It allows manual focus using the control
panel and features LED lighting. It is designed for pipe diameters from
100 mm and is used mounted on BOSS150 trolley. There is antenna
available, that, when using a winch, enables steering the camera head
into pipe turns and branches.
4. Description of operator positions
The operator monitors the piping with cameras using the control unit, and at the same directly
monitors the winch operation and the synchronization of winding and unwinding of the cable
according to the movement of the trolley.
5. Intended usage and presumed usage of the system
The CamBoss monitoring system is intended solely for inspection of pipes of all kinds. Other
use or use beyond this limitation is not considered to be an intended use. Never use the
CamBoss sewerage and inspection system for any other purpose. The system must not be
used in pipelines containing the fluid presenting the risk of explosion. For this purpose, only
specially manufactured equipment, which is marked in appendix , is approved.
ENVIRONMENT
Operating temperature 0 –40° C.
The trolleys and cameras are made mainly of aluminium, brass, stainless steel, and pressure-
tight to 1 bar, suitable for inspections at water depths up to 10 m.
6. Instructions for assembly, installation and connection
The components of the built-in system (except the BOSS150 IV trolley) are fixed to the TV
inspection trolleys. The trolley shall be stored in a designated place and secured during
transport.
Head KZ60
BOSS100 trolley 6x6

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7. Commissioning and usage instructions
On request, the manufacturer will carry out training of operating personnel. The operating
personnel must have the knowledge of at least within the scope of this operating manual.
Check the following before putting the device in operation:
1. For the built-in variant: Apply the hand brake and secure the vehicle with wheel
chocks, to prevent it from rolling away. The vehicle must be positioned on flat surface,
to avoid the risk of tipping over.
2. For both mobile and built-in variants: Designate and secure the workplace against
unauthorized persons falling into an open shaft.
3. For both mobile and built-in variants: Check the winch cable before starting work. In
the event of damage to the electrical insulation, the system must be disconnected
from the supply voltage immediately, and repaired.
Always make sure that the trolley cannot fall into the shaft and injure someone. When
commencing and operating the device, you must always ensure that no part of the
system is not too close to the edge of the shaft and that the camera controls cannot
be inadvertently operated.
4. Lower the trolley into the shaft and start monitoring. If the winch is provided with an
auxiliary arm with electric crane, any other usage than for lowering and removing the
trolley from the shaft is prohibited.
5. Do not use the drum to haul the crawler up from the pipeline !
Lowering the camera into the shaft
A special bracket (bag) is used to lower the camera into the shaft. It hooks into the trolley's
eyes and enables its lowering into the shaft using a rope or electric winch. The cable is used
for trolley balancing. Prevent the trolley from falling into the shaft by removing it from the
eyes. Once the trolley is been placed on the bottom of the shaft, unhook the bracket simply
from the eyes by loosening the wire.
8. Safety precautions
The operator must wear working clothes not having any loose parts that could be caught by
the winch. The winch is equipped with an emergency stop button.
The operator must use SB-grade safety shoes to avoid injury in the event of accidental trolley
fall.
During transport, the trolley must be placed in the transport box and secured with a strap
with ratchet.

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The device must not be operated in the event of a lightning storm, where there is a risk of
lightning strikes or electrical shock!
Protection of winch cable
The cable must be protected from abrasion around sharp edges, at the top and
bottom of the shaft. This is done by specially designed “rollers”. The cable protection
accessory are available from IBOS a.s. If you do not have such a device, you must
ensure such protection in another way. This will significantly reduce the risk of cable
damage and increase its service life.
9. Conditions under which the device meets requirements for stability
ENVIRONMENT
Temperature 0 to 40°C. The device is pressurized to 0.45 bar.
The device must not be used in the event of a lightning storms, where there is a risk of
lightning strikes.
In the event of a fault, blockage or accident, the power must be switched off and the trolley
manually pulled out of the pipe. Do not use the drum to haul the crawler up from the pipeline.
The camera head and other components coming into contact with liquids are
protected against ingress of moisture and water by internal pressurization. The
pressure value is indicated on the LCD panel of the control unit. Before
commencing the work, you must check the pressure level of each component.
This should ideally be a 0.45 bar. If the pressure falls below 0.2 bar, it must be
increased. When the pressure is low, moisture can damage the camera body or
its components. Pressurize the components ideally with nitrogen or dry air
using a reducing valve. The pressure above 0.55 bar unnecessarily stresses the
Proper use of the “roller” – pulley to protect the cable

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camera seals and increases its wear. The pressure over 1 bar is already critical
and sealing of the device can be compromised.
Stainless steel bolts are used for fixing the wheels. Make sure that you use a
screw of correct length before assembly. Usage of longer screws may damage
the trolley body and motors. The bolts should be fixed (bonded) with a suitable
adhesive to prevent them from being released while the trolley is moving. For
this purpose, e.g. Loctite 243, Loxeal 55-03 or their equivalents may be used.
When connecting the cable to the trolley or winch, check that the O-ring is
fitted to the connector and that it is not damaged. Replace with new
component, if necessary.
10. Safety instructions
Read the following safety precautions carefully and observe them. They are intended for
your own safety, your employees, as well as for preventing damage to the CamBoss system
and its components.
Ensure that no liquid can enter the control unit, control panel or cable drum
cover!
If this happens, immediately disconnect the power supply, secure the power
connection socket to prevent its re-connection, and inform the appropriately
trained specialist personnel or IBOS a.s. customer service.
Never use damaged power supply cable!
If the damage happens during the device operation, immediately disconnect
the power supply, secure the power connection socket to prevent its
re-connection, and inform the appropriately trained specialist personnel or
IBOS a.s. customer service.
Work on electrical equipment beyond the work described in the chapter on
cleaning, maintenance and repair, must only be carried out by trained,
specialist personnel. Only IBOS a.s. or personnel authorized by IBOS a.s. are
allowed to carry out extensive maintenance and repair works.
Before cleaning, maintenance and repairs turn off and disconnect the device
from the power outlet or power supply and follow the instructions in this
operating manual.

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Danger of injury due to contact with hot parts of the system!
When working with the system, be aware that individual components
(especially lighting, cameras and trolleys) can be very hot during operation.
Explosion hazard!
Never use this device in piping that contains explosive atmospheres. For this
purpose, only specially manufactured equipment, which is marked in appendix,
is approved.
Fall hazard injury due fall from heights!
Always be careful and follow the procedures when inserting the camera into a
shaft or piping.
Injury hazard due to contact with rotating components!
When working, maintaining or otherwise handling the cable winch, be aware
that these machines contain rotating parts that may present a significant
hazard to your limbs and clothing.
Eye or skin injury hazard!
If the camera head is equipped with laser diodes, which present a safety risk
for your eyes and skin: Never look into the laser emitters, even when they are
turned off, do not let the laser light irradiate your skin.
Injury hazard due to contact with non-rotating components!
When moving the trolley, take the weight of the equipment into account. There
is a risk of injury and injury if the device is dropped or turned over due to loss
of stability. Do not incline the device so it could turn over.
Infection hazard due to contaminated water!
Never use the inspection system alternately for inspections in wastewater and
drinkable water systems! Even thorough cleaning of the system does not
guarantee sufficient protection against its contamination.
Always use a special, separate systems for inspections in wastewater and
drinkable water systems.
The camera head and other components coming into contact with liquids are
protected against ingress of moisture and water by internal pressurization. The
pressure value is indicated on the LCD panel of the control unit. Before
commencing the work, you must check the pressure level of each component.
This should ideally be a 0.45 bar. If the pressure falls below 0.2 bar, it must be
increased. When the pressure is low, moisture can damage the camera body or
its components. Pressurize the components ideally with nitrogen or dry air
using a reducing valve. The pressure above 0.55 bar unnecessarily stresses the

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camera seals and increases its wear. The pressure over 1 bar is already critical
and sealing of the device can be compromised.
Caution!
The operator of the plant is responsible for the proper disposal of the waste!
11. Controlling the system
All necessary controls are located on the control unit panel. There are two joysticks controlling
the movements of the trolleys and camera. Two potentiometers controlling the illumination
intensity for the camera head and pantograph. When the control unit is switched on, the
connected components are loaded –winch, trolley, camera head, etc. If the control unit does
not load any active connected equipment, the display shows the axial camera connection.
Recording of video
Accessory operation
Joystick for
controlling the
camera
Joystick for trolley
operation
Pantograph up / down
Open main menu /
return to previous menu
Open submenu /
selection confirmation
Resetting the meter
counter
Automatic CCW/CW detection of
piping connection
Sensor on / off toggle
Menu operation -
increase/decrease the
value
Camera alternation
switching - front / rear
Laser on / off toggle
Set the camera to zero
position