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

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Inspection of piping connections
Connection left/right are the functions that perform rotation of head by 90° to the respective
side, then a 360° rotation around the axis. This function is used to check the pipe connections.
Laser measurement
Activates the lasers on the camera head that can be used to create a distance calibration
within the image in the DigiCAN software (pipe connection gap or crack width).
Illumination
The illumination of the space in front of the camera is provided via LEDs integrated directly
into the camera head or the pantograph. The intensity can be controlled continuously by a
LED1 or LED2 potentiometers.
Return the camera to the zero position
To set the camera to its zero position, press "0" POS button on the LCD panel. The zero camera
head position means that the head will look straight ahead, perpendicularly to the earth's axis.
Trolley and winch speed correction
When reversing the trolley, it is possible to use the function of fine corrections. The function
is used to gently change the speed of the cable winding, and this the speed the trolley, so that
the cable is wound as quickly as the trolley moves. The function is suitable for optimum cable
winding at long distances of reversing trolley. When the joystick is moved backwards
(reversing travel), the text JEMNÁ KOREKCE (Fine correction) and a two-digit readings +20 to
-20 appear on the bottom of the LCD display on the control panel. When reversing, [+] and [-]
buttons can be used to gently vary the speed, at which the cable and the trolley are wound. If
you press [-] button, the trolley speed will decrease, if you press [+] button, the trolley speed
will increase.
Reversing camera
When reversing/moving back, you can use the rear-view camera located in the body of
camera trolley.
Localizer probe
The following description of the controls is identical for the trolley's probe, as well as for the
probes of axial cameras. When the probe is active, the red LED on the probe body lights up.
You can determine the position of the probe and this of the camera (or trolley) using the probe
signal detector. The probe signal detector is available from IBOS a.s.
Distance travelled indication
The CamBoss is provided with an odometer indicating the travelled distance (cable unwound),
which is located on the winch cable. The measured value is displayed on the display of the
control panel. This indication can be changed using the buttons on the LCD panel.
The [0] button resets the counter, the [+] button adds 10 cm and [-] deducts 10 cm.

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Inspection reports, inspection records
Use the software installed on the computer of the control unit to create a video recording and
a log. To document the recorded damaged locations, you may view the corresponding
measured data on the current video image and use the keypad to enter additional comments.
Operation of this software is described in its respective manual.
12. Centring elements
From the nominal diameter of DN200, BOSS150 trolley can be used with the R250 or KZ60
cameras. For larger pipe diameters, select additional accessories according to the following
sections in this manual.
Centring elements for camera according to pipe diameter and type

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Trolley wheels
For different pipe diameters and surface materials, more sets of additional trolley wheels are
available. These wheels are either screwed onto the existing trolley wheels using the supplied
screws, or directly on the wheel axis. For plastic pipes, where rubber wheels may slip, try the
ceramic wheels.
13. System maintenance
The system maintenance is very important and leads to a significant prolongation of service
life and lower operating costs. Therefore it should not be neglected in any way.
The system components must be cleaned regularly. Do not wash system components with
pressurized water! After each inspection, remove any coarse dirt. After each day, wash the
components with water to remove coarse dirt such as sand, etc. and remove the wheels once
a week to remove the dirt underneath. Remove any tangled strings, hairs, etc. from the axles.
Such dirt and debris are very dangerous to the wheel axle seal. You can also perform cleaning
more frequently, at your discretion.
Maintenance of cable winch
It is essential to keep the entire winch mechanism clean. This particularly means the
trapezoidal screw that is used to align the cable onto the drum. It is recommended to remove
coarse dirt such as sand, papers, etc. from the cable. Check the entire winch mechanism
regularly to remove any debris. Lubricate the chain and the entire cable alignment mechanism
regularly with non-sagging grease. Only perform these operations with the equipment
switched off and the supply voltage disconnected! Secure the drum so that the cable cannot
be pulled during maintenance and cause the injury by rotating drum.
When installing threaded components, use petroleum jelly and related sealing elements to
ensure maximum sealing effectivity. Do not use excessive force when tightening the threads,
this will prevent them from being stripped or damaging components.
14. Troubleshooting
The camera system is protected by a number of fuses and protections. If the fuse is blown,
turn off the device and disconnect it from the power supply. Secure against turning back on.
You can try to replace a blown fuse. Never use different type of fuse, especially a different
current value than the original fuse has.
Try to correct the cause of the fault using the information provided herein below. If the cause
remains unclear or the suggestions for correction do not lead to successful correction of
problem, please contact IBOS a.s. customer service.

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Defect table
Defect
Possible cause
Corrective action
The system is shutting
itself down during the
operation.
The internal mains part for the
trolley and the light is
overheated.
Provide cooling. Check if
the vent holes are free.
Image disturbances
Poor contact in the camera
connection connector.
Check the secure
connector connection.
Broken cable wire.
Replace the camera cable
or call IBOS a.s. service.
Incorrect image
Dirty windshield.
Clean the windshield.
Scratched windshield.
Replace the windshield.
The device is not working.
No AC power.
Service to remove the
defect.
Defective power cable.
Replace the power cable.
The system shuts itself
down during the
operation.
The main fuse in the socket on
the side of the control unit is
damaged.
Replace fuse, or inform
customer service.
Humidity in the camera
head
Camera head does not seal
properly.
Open the camera head,
dry it, and install new O-
rings.
Rapid loss of pressure in a
pressurized component
The component has damaged
sealing element.
Contact IBOS a.s. service.
Camera head does not
respond to rotation and
oscillation commands, red
“Low Pressure” warning
light flashes on the unit
panel. Button auto
CCW/CW rotation of
connection works.
Camera head internal pressure
has fallen below safe limit
(0.18 bar)
The camera head must be
pressurized to the desired
value.

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Replacement of windshield of the camera
If the operating personnel have sufficient training, the damaged glass may be replaced,
otherwise contact the IBOS a.s. service centre for technical support. To replace the camera
windshield:
•Unscrew the front camera cover;
•Carefully remove the windshield or any glass residue from the camera head;
•Fit new O-ring seal;
•Insert the new windshield and install the front cover back;
15. Cleaning
•After inspection, spray the trolley, camera, sliding runners and roller runners
thoroughly with water before releasing. Never use pressurized water.
•Immediately close any retractable and screw connectors with the supplied
protective caps and allow the individual components to dry.
•Clean the camera cable by letting it to run through a damp cloth while winding.
•Clean parts only with a damp cloth (water, mild detergent).
•Clean the camera lens with a tissue for cleaning of spectacle, do not use paper-
type one, to avoid scratching the camera's windshield.
Shipping of damaged system components
If repairs to system components are necessary, in addition to the work described in these
operating instructions, send all equipment components to IBOS a.s. customer service, so that
all components can be tested during the troubleshooting and set and update the control unit,
when necessary. Observe the following points:
•Secure the connectors with the appropriate plug to prevent damage;
•Ship components in clean state, carefully wrapped and preferably in original
packaging;
•Add accurate defect description;
Device decommissioning and disposal
Follow national regulations for decommissioning, disposal and reuse of
device. Contact the appropriate authorities responsible for
environment protection (according to waste, special waste and residual
materials laws and regulations).

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Type plates
The type plates with the appropriate serial number are found on each component. You need
this information if you are contacting IBOS a.s. (like when ordering accessories or spare parts).
Within the table, record the serial number for each system component, so that it is available
if necessary.
Organizational measures
The CamBoss inspection system is designed as the state-of-the-art device and according to the
recognized safety and technical rules. However, its use may create some risks to the health
and life of the user, animals or third parties, as well as risk of damage to the inspection system
itself and other material.
Personnel responsible for the works with inspection system must fully read and understand
these operating instructions before commencing the works. This is especially true for
personnel who only work occasionally with the inspection system, e.g. for maintenance, repair
or expansion of equipment.
The operator of the inspection system shall ensure safe and no-risk operation. This can be achieved,
for example, by the following measures:
Keep the operating instructions in place at all times of the inspection system
deployment;
Provide regular training;
Execute the checklist instructions for system maintenance;
Regularly inspect the personnel to ensure that they are aware of safety and risks.
Prevention of material damage
As the operator of the CamBoss inspection system, you are responsible for the observance of
the following points:
Use the inspection system only for the works, for which it is intended;
Observe the deployment conditions for this inspection system, as described in
this user manual.

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5. Technical data
CamBoss control unit
Control panel, PC or DVD-recorder (optional)
Interface
3 x USB
1 x cable winch / push camera
1 x power supply 110 –240 V AC
1 x RJ45 (Internet)
Control panel
CamBoss trolley and cameras control unit, two joysticks, micro-buttons,
alphanumeric keyboard
Current draw [A]
3.5 (110 V AC, 60 Hz)
1.7 (230 V AC, 50 Hz –60 Hz)
Power consumption [W]
385 max.
Temperature [°C]
From 0 to 40
Relative air humidity
20 - 80% non-condensing
Size H x W x D [mm]
500 x 340 x 120
Weight [kg]
10
Axial camera KA46/R250
¼ inch CCD image sensor, automatic white level stabilization, 317,612 pixels / 400 horizontal TV
lines, LED lighting, approximate 68° angle of view, optional centring with accessories, waterproof
Luminance sensitivity
[lux]
1
Maximum surrounding
pressure [bar]
<1
Dimensions [mm]
190.5 x 46
Temperature [°C]
From 0 to 40
Weight [kg]
0.5

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Rotary camera head KZ60
¼" CCD image sensor, automatic white level stabilization, 317,612 pixel / 400 horizontal TV lines, LED
illumination, swivelling 115° to both sides, 68° angle of view, “slip-ring” connector, pressure sensor,
optional centring with accessories
Luminance sensitivity
[lux]
0.3
Maximum
surrounding/internal
pressure [bar]
<1
Dimensions [mm]
length 113, average 59
Temperature [°C]
From 0 to 40
Weight [kg]
0.65
Cable winch NAVI200
Equipment
meter counter, guide roller, water spray-
resistant
Cable length [m]
200 m
Power consumption [W]
1000 max.
Size H x W x D [mm]
600 x 650 x 400
Weight [kg]
40 (not including cable)
BOSS150 trolley
Drive
2 x EC-MAX Maxon motor
Equipment
localizer transmitter –probe (optional)
gradient and tilt sensor
Piping nominal
diameter
DN 150 - DN 1000
Max. ambient/internal
pressure
< 1 bar max. / inspection depth, up to 10 m water column
Possible extension
Wheel sets, chassis
Dimensions L x H x W
[mm]
834 x 145 x 123
Weight [kg]
13

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Warranty
What is covered
The IBOS a.s. product, designed and tested according to current product safety and quality
guidelines, is protected by 12-month warranty.
Defects manifested due to material defects or workmanship, will be eliminated at no charge
during the warranty period. However, we reserve the right, at our sole discretion, to choose
whether to repair, replace product completely, replace only defective parts, or pay off residual
value, if repair or replacement is not possible.
Warranty terms
Removal of components without the manufacturer approval is prohibited. Failure to comply
with this instruction will void all warranty claims.
The date of delivery is the beginning of the warranty period. Damages resulting from
inappropriate use of the equipment, lack of maintenance, normal wear and tear, and natural
events caused by force majeure, are excluded from the warranty.
Furthermore, the warranty does not cover rapidly worn parts such as windshields, trolley
wheels, shaft seals, bulbs, cables, etc., or any damage that does not adversely affect the
usability of the device.
If you wish to claim your warranty, please contact your nearest dealership or service centre,
submitting the original invoice.
Liability limitation
The liability we accept under the above conditions, is limited solely to repairs, compensation
or refunds.
IBOS a.s. shall not be liable for any consequential or incidental damages which may arise in
connection with the sale or operation of the product. This also applies to consequential
damages that can be classified as commercial losses, for example loss of profits, downtimes,
damage to reputation, and damage to other instruments or assets.

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We wish you every success and joy in working with your new CamBoss TV inspection
system. We are happy to answer any questions you have. We will be grateful for the
suggestions for improvement and other feedback!
IBOS a.s. České Budějovice, 2020
Entrance to admin mode of the control unit
Admin code: 1452
How to enter the code:
Press the [Menu] button.
Use [+] or [-] buttons to select Nastavení item.
Press [MOD] button
Press [+] or [-] buttons to set “1”, then confirm with [MOD] button.
Press [+] or [-] buttons to set “4”, then confirm with [MOD] button.
Press [+] or [-] buttons to set “5”, then confirm with [MOD] button.
Press [+] or [-] buttons to set “2”, then confirm with [MOD] button.
Admin mode ON