Jireh NAVIC 2 User manual

NAVIC 2
Automated Steerable Scanner
CX0344 Rev 05.3

PAGE i of x CX0344 Rev 05.3
SAFETY WARNINGS / PRECAUTIONS
KEEP THIS MANUAL – DO NOT LOSE
THIS MANUAL IS PART OF THE NAVIC SYSTEM AND MUST BE RETAINED FOR THE
LIFE OF THE PRODUCT. PASS ON TO SUBSEQUENT OWNERS.
Ensure any amendments are incorporated with this document.
WARNING! The NAVIC is designed for a specic use. Using the
NAVIC outside of its intended use is dangerous. Failure to comply with the
warnings, instructions, and specications in this manual could result in
SEVERE INJURY or DEATH. Read and understand this manual before
using.
WARNING! FALLING OBJECT HAZARD. The area below a
crawler must be kept clear at all times. A clearly marked NO ENTRY ZONE
must be cordoned off directly below the area of crawler operation.
(see“Preparation for Safe Use”on page 39 for additional details)
WARNING! Do NOT operate or place crawler on a surface higher
than 2 m (6 ft) without a proper tether held taut at all times.
(see“Tether Requirements and Attachment”on page 40 for additional details)
WARNING! ELECTRICAL CORDS CAN BE HAZARDOUS.
Misuse can result in FIRE or DEATH by ELECTRICAL SHOCK. Inspect
thoroughly before each use. Do NOT use if damaged. Do NOT use when
wet. Keep away from water. Do NOT drive, drag or place objects over cord.
WARNING! Do NOT operate scanner in an explosive environment.
Do NOT operate scanner in the presence of volatile substances.

PAGE ii of x
WARNING! LASER RADIATION. The battery powered optical
guide contains a Class 1M laser. Do not view directly with optical
instruments.
WARNING! MAGNETIC MATERIAL. The wheels of the crawler
produce an extremely strong magnetic eld which may cause failure or
permanent damage to items such as watches, memory devices, CRT
monitors, medical devices or other electronics.
Tools, magnets and metal objects can cut, pinch or entrap hands and
ngers. HANDLE WITH CARE.
People with pacemakers or ICD’s must stay at least 75 cm (30 in) away.
WARNING! MAGNETIC MATERIAL. When the carrying case
contains the crawler, a magnetic eld exists outside the case which may
cause failure or permanent damage to items such as watches, memory
devices, CRT monitors, medical devices or other electronics.
People with pacemakers or ICD’s must stay at least 10 cm (4 in) away from
the carrying case when it contains the crawler.
WARNING! MAGNETIC MATERIAL. The installation/removal mat
(see“Scanner Installation/Removal Mat Use”on page 130)contains magnetic
material.
People with pacemakers or ICD’s must stay at least 10 cm (4 in) away.
CAUTION! Pinch points exist with this product. Keep ngers and
hands clear of pinch points.
WARNING! If this product is to be used with any Child Products
listed in (Chaper 2.3), be sure to read and comply with the warnings,
instructions, and specications in the Child Product’s User Manual(s).

PAGE iii of x CX0344 Rev 05.3
CAUTION! DO NOT DISCONNECT UNDER LOAD. Shut off power
before connecting or disconnecting. Permanent damage to electronics could
occur.
CAUTION! Do NOT operate the NAVIC crawler on an inspection
surface which is electrically connected to a component that is being welded.
The WEEE symbol indicates that the product must not be disposed of as
unsorted municipal waste, but should be collected separately.
(see“Disposal”on page 175 for additional details)
EMERGENCY STOP. This symbol indicates emergency stop button.

PAGE iv of x
Chapter1 Identification 2
1.1. Product Brand 2
1.2. Manufacturer 2
1.3. Compliance Declarations 2
1.3.1. ISED Emissions Compliance (Canada) 2
1.3.2. FCC Suppliers Declaration of Conformity (United States) 2
1.3.3. European Union CE Declarations 3
Chapter2 Product Specifications 4
2.1. Base NAVIC System 4
2.1.1. Intended Use 4
2.1.1.1 Operating Limits 5
2.1.1.2 Operating Environment 6
2.1.1.3 User 6
2.1.2. Unintended Use 6
2.1.3. Dimensions and Weight 7
2.1.4. Power Requirements 8
2.1.5. Environmental Sealing 8
2.1.6. Performance Specifications 9
2.1.7. Encoder Interface Specifications 9
2.2. Compatible Components 10
2.2.1. Low Profile Probe Holder Frame 10
2.2.1.1 Intended Use 10
2.2.1.2 Operating Limits 10
2.2.2. Vertical Probe Holder Frame 10
2.2.2.1 Intended Use 10
2.2.3. Pivoting Probe Holder Frame 11
2.2.3.1 Operating Limits 11
2.2.4. Frame Bar 11
2.2.4.1 Intended Use 11
2.2.5. Slip Joint Probe Holder 11
2.2.6. Vertical Probe Holder 12
2.2.7. Heavy Duty Vertical Probe Holder 12
2.2.8. Corrosion Thickness Probe Holder 12
2.2.9. HydroFORM Cart with Wheels 12
2.2.10. Preamp Bracket 13
2.2.10.1 Intended Use 13
2.2.10.2 Operating Limits 13
TABLE OF CONTENTS

PAGE v of x CX0344 Rev 05.3
2.2.11. NAVIC Backpack 13
2.2.11.1 Intended Use 13
2.2.11.2 Operating Limits 13
2.2.12. NAVIC Camera Mount 14
2.2.12.1 Intended Use 14
2.2.12.2 Operating Limits 14
2.2.13. Battery Powered Optical Guide 14
2.2.13.1 Intended Use 14
2.2.13.2 Operating Environment 14
2.2.13.3 Power Requirements 14
2.2.13.4 Environmental Sealing 14
2.2.14. Medium Temperature Add-On Kit 15
2.2.14.1 Intended Use 15
2.2.14.2 Operating Limits 15
2.2.15. Encoder Adapter 15
2.2.15.1 Intended Use 15
2.2.16. 3-Axis Nozzle Scanner Add-On Kit 15
2.3. Child Products 16
2.3.1. Motorized Couplant Pump 16
2.3.2. Motorized Raster Arm 16
2.3.3. Actuated Probe Lift 16
2.3.4. Optical Guide 16
2.3.5. Tracker 16
2.3.6. Preamp 17
Chapter3 Definitions 18
3.1. Definition of Symbols 18
3.2. Definitions of Terms 18
3.3. Safety Symbols 19
3.4. Safety Signal Words 19
Chapter4 System Components 20
4.1. Component Identification 20
4.1.1. Base System 20
4.1.2. Compatible Components 22
4.1.3. Child Products 23
4.2. Tools 24
4.2.1. Included Tools 24
4.2.2. Optional Tools 24
4.3. Base System Components 25
4.3.1. Crawler 25
4.3.1.1 Right Drive Module 25

PAGE vi of x
4.3.1.1.1 Encoder 25
4.3.1.2 Left Drive Module 26
4.3.2. Power Controller 27
4.3.2.1 Power Connection 28
4.3.3. Umbilical 29
4.3.3.1 Umbilical Connections 29
4.3.3.2 Emergency Stop Button 30
4.3.3.3 Encoder Signal Isolation 31
4.3.4. Handheld Controller 31
4.3.5. Auxiliary Cable 32
4.3.6. Encoder Cable 32
4.3.7. Installation/Removal Mat 32
4.3.8. Lifting Sling 33
4.3.9. Irrigation Kit 33
4.3.10. Cable Management 33
4.3.11. Cap (x2) 33
4.3.12. Tools 33
4.3.13. Cases 33
4.4. Compatible Components 34
4.4.1. Low Profile Probe Holder Frame 34
4.4.2. Vertical Probe Holder Frame 34
4.4.3. Pivoting Probe Holder Frame 34
4.4.4. Frame Bar 34
4.4.5. Slip Joint Probe Holder 34
4.4.6. Vertical Probe Holder 35
4.4.7. Heavy Duty Vertical Probe Holder 35
4.4.8. Corrosion Thickness Probe Holder 35
4.4.9. HydroFORM Cart 35
4.4.10. Preamp Bracket 35
4.4.11. NAVIC Backpack 36
4.4.12. NAVIC Camera Mount 36
4.4.13. Battery Powered Optical Guide 36
4.4.14. Automated Crawler Medium Temperature Add-On Kit 36
4.4.15. Encoder Adapter 36
4.4.16. 3-Axis Nozzle Scanner Add-On Kit 37
4.5. Child Products 37
4.5.1. Motorized Couplant Pump 37
4.5.2. Motorized Raster Arm 37
4.5.3. Actuated Probe Lift 37
4.5.4. Optical Guide 37
4.5.5. Tracker 38
4.5.6. Preamp 38

PAGE vii of x CX0344 Rev 05.3
Chapter5 Preparation for Use 39
5.1. Preparation for Transportation 39
5.2. Preparation for Safe Use 39
5.2.1. No Entry Fall Zone 39
5.2.2. Tether Requirements and Attachment 40
5.2.3. Lifting Sling Setup 41
5.2.4. Lifting Sling Low Profile Setup 43
5.3. Preparation of Inspection Surface 43
5.4. System Connectivity 44
5.5. Configurations 46
5.5.1. Single Drive Module with Frame Bar 46
5.5.2. Crawler with Actuated Probe Lift 48
5.5.3. Crawler with Multiple Probe Holders 50
5.5.3.1 Probe Holder Frame 50
5.5.3.2 Low Profile Probe Holder Frame 52
5.5.3.3 Pivoting Probe Holder Frame 54
5.5.3.4 Flange 56
5.5.4. 3-Axis Nozzle Scanning 58
5.6. Right Drive Module 60
5.6.1. Swivel Mount 60
5.6.2. Umbilical 61
5.6.3. Handle 63
5.6.4. Dovetail Accessory Mount 64
5.7. Left Drive Module 65
5.7.1. Swivel Mount 65
5.7.2. Umbilical Connection 66
5.7.3. Handle 66
5.7.4. Dove-tail Accessory Mount 66
5.7.5. Connecting/Disconnecting Left and Right Modules 67
5.7.6. Probe Holders 69
5.7.7. Vertical Probe Holder 69
5.7.7.1 Probe Holder Setup 69
5.7.7.2 Probe Holder Vertical Adjustment 70
5.7.7.3 Probe Holder Transverse Adjustment 71
5.7.7.4 Probe Holder Longitudinal Adjustment 72
5.7.7.5 Probe Holder Left/Right Conversion 73
5.7.8. Slip Joint Probe Holder 75
5.7.8.1 Probe Holder Setup 75
5.7.8.2 Probe Holder Adjustment 77
5.7.8.3 Probe Holder Force Adjustment 78
5.7.8.4 Slip Joint Probe Holder Left/Right Conversion 80
5.7.9. Heavy Duty Vertical Probe Holder 82

PAGE viii of x
5.7.9.1 Probe Holder Setup 82
5.7.9.2 Probe Holder Vertical Adjustment 84
5.7.9.3 Probe Holder Left/Right Conversion 84
5.7.9.4 Probe Holder 90° Adjustment 86
5.8. 3-Axis Nozzle Scanning 87
5.8.1. Scanner Preparation 87
5.8.2. 3-Axis Nozzle Operation 92
5.8.3. Encoded Skew Vertical Probe Holder 96
5.8.4. Probe Holder Setup 96
5.8.5. Skew Encoder Cable 98
5.8.6. Encoded Skew Vertical Probe Holder Adjustment 98
5.8.6.1 Latch Pin 99
5.8.7. Skew Angle Adjustment 100
5.8.7.1 Ratchet Lever 101
5.8.8. Pivot Buttons 101
5.8.9. Cable Clips 102
5.9. Slider PPS 103
5.9.1. Slider PPS Encoder 105
5.10. Probe Holder Frames 106
5.10.1. Vertical Probe Holder Frame - Flat or Circumferential Only 106
5.10.2. Low Profile Probe Holder Frame - Flat or Circumferential Only 110
5.10.3. Pivoting Probe Holder Frame 114
5.10.3.1 Mounting a Pivoting Probe Holder Frame 115
5.10.3.2 Pivoting Probe Holder Frame Setup - Longitudinal Scanning 116
5.10.3.3 Pivoting Probe Holder Frame - Circumferential Scanning 117
5.10.3.4 Pivoting Probe Holder Frame - Flange Scanning 118
5.10.3.5 Optical Guide Pivot Mount 120
5.11. Accessories 121
5.11.1. Battery Powered Optical Guide 121
5.11.2. Cable Management 122
5.11.2.1 Mounting Cable Management 122
5.11.2.2 Cable Management Setup 122
5.11.2.3 Clamp Setup 123
5.11.3. NAVIC Backpack 124
5.11.4. Preamp Bracket 125
5.11.4.1 Mounting Preamp Bracket 125
5.11.4.2 Attaching Preamp with Screws 125
5.11.4.3 Attaching Preamp with Velcro Straps 126
Chapter6 Operation 127
6.1. System Startup 127
6.2. Placement of Crawler on Inspection Surface 129

PAGE ix of x CX0344 Rev 05.3
6.2.1. Scanner Installation/Removal Mat Use 130
6.2.2. Handheld Controller Layout 132
6.2.2.1 Touchscreen 133
6.2.2.2 Click Wheel 133
6.2.3. Mode Select Screen 133
6.2.4. Jog Mode 134
6.2.4.1 Joysticks 134
6.2.5. Latched Jog Mode 136
6.2.6. System Utilities Screen 137
6.2.6.1 User Settings Screen 137
6.2.6.2 Diagnostics Screens 138
6.2.6.2.1 Detected Modules 139
6.2.6.2.2 System 1 140
6.2.6.2.3 System 2 140
6.2.6.2.4 System 3 141
6.2.6.2.5 LeftDrv, Right Drv, 141
6.2.6.3 Touch Calibration Screen 143
6.2.6.4 Joystick Calibration Screen 144
6.2.6.5 Draw 145
6.2.7. High Internal Temperature Screen 145
Chapter7 Maintenance 146
7.1. Safety Precautions Before Maintenance 146
7.2. Cleaning 146
7.3. Maintenance Schedule 147
Chapter8 Troubleshooting 148
8.1. Startup Issues 148
8.1.1. Joystick O Center 148
8.1.2. Checking Network 148
8.2. Startup Override 149
8.2.1. Scan Devices 150
8.2.2. Reset Parameters 151
8.2.3. System Parameters 151
8.2.4. Device Address 151
8.3. Encoder Failure 152
8.4. Umbilical Troubleshooting 153
8.5. Additional Issues 153
8.6. Retrieval of a Stranded Crawler 154
Chapter9 Service and Repair 155

PAGE x of x
9.1. Technical Support 155
Chapter10 Spare Parts 156
10.1. Crawler 156
10.2. Kit Components 157
10.2.1. Encoder Connector Type 158
10.2.2. Power Cord Type 158
10.3. Probe Holder Frame 159
10.4. Low Profile Probe Holder Frame 160
10.5. Pivoting Probe Holder Frame 161
10.6. Slip Joint Probe Holder Parts 162
10.7. Vertical Probe Holder Parts 163
10.8. Heavy Duty Vertical Probe Holder 164
10.9. Corrosion Thickness Probe Holder 165
10.10. Encoded Skew Vertical Probe Holder 166
10.11. 3-Axis Nozzle Scanner Add-On Kit 167
10.11.1. Slider PPS Encoded Leadscrew 168
10.12. Probe Holder Components 168
10.12.1. Arm Style 168
10.12.2. Yoke Style 168
10.12.3. Swing Arm Style 168
10.12.4. Heavy Duty Yoke Style 168
10.12.5. Pivot Button Style 169
10.13. Probe Holder Receptacle and Wear Plate 169
10.14. Variable Components 170
10.14.1. Frame Bar 170
10.14.2. Cable Management 170
10.14.2.1 Cable Management Sleeving 170
10.14.3. Automated Crawler Medium Temperature Add-On Kit 171
10.15. Accessories 172
10.15.1. Preamp Bracket 172
10.15.2. NAVIC Backpack 172
10.15.3. Battery Powered Optical Guide 173
10.16. Cases 174
Chapter11 Disposal 175
Chapter12 Limited Warranty 176

PAGE 1 of 177 CX0344 Rev 05.3

PAGE 2 of 177
Chapter 1
IDENTIFICATION
1.1. Product Brand
This user manual describes the proper safety precautions, setup and use of the
NAVIC system.
1.2. Manufacturer
1.3. Compliance Declarations
1.3.1. ISED Emissions Compliance (Canada)
CAN ICES-003(A) / NMB-003(A)
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.
1.3.2. FCC Suppliers Declaration of Conformity (United States)
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) this device may not cause harmful interference, and (2)
this device must accept any interference received, including interference that may
cause undesired operation.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to
cause harmful interference in which case the user will be required to correct the
interference at his own expense.
Distributor:
Jireh Industries Ltd.
53158 Range Road 224
Ardrossan, Alberta, Canada
T8E 2K4
Phone: [phone]
jireh.com
Manufacturer:

PAGE 3 of 177 CX0344 Rev 05.3
RESPONSIBLE PARTY NAME: Jireh Industries
ADDRESS: 2955 S Sam Houston Pkwy E
Suite 300
Houston, Texas
United States 77047
TELEPHONE: [phone]
1.3.3. European Union CE Declarations
Jireh Industries hereby declares that the NAVIC product complies
with the essential requirements and other relevant provisions of
the following European Union directives:
2014/30/EU EMC Directive
2014/35/EU Low Voltage Directive
2012/19/EU Directive on Waste Electrical and Electronic Equipment
2011/65/EU Directive on Restriction of Hazardous Substances (RoHS)

PAGE 4 of 177
Chapter 2
PRODUCT SPECIFICATIONS
2.1. Base NAVIC System
This section outlines the product specifications of the base system. When the base
system is used together with compatible components (Chaper 2.2) or child products
(Chaper 2.3), the product specifications of the base system may be superseded. See
(see “Compatible Components” on page 10) and (see “Child Products” on page 16).
2.1.1. Intended Use
The NAVIC’s primary purpose is to perform inspections of ferrous assets such
as pipes, vessels, or storage tanks by moving an inspection tool over a ferrous
surface. It is intended for industrial use only.
WARNING! FALLING OBJECT HAZARD.
The NAVIC is intended for a specic use. Read and
understand the intended and unintended use limits
below. Using the NAVIC outside of its intended use
is dangerous and could result in SEVERE INJURY
or DEATH.

PAGE 5 of 177 CX0344 Rev 05.3
2.1.1.1 Operating Limits
Category Parameter Specification
Inspection
Surface
Maximum coating thickness:
Up-side-down orientation Bare metal only
Vertical orientation 0.5 mm (0.020 in)
Horizontal, Right-side-up
orientation
1 mm (0.040 in)
Condition Clean, free of excess rust, scale, debris
(i.e. dirt, sand, etc.), ice, frost
Minimum thickness 3 mm (0.120 in)
Minimum ID, internal
circumferential driving
610 mm (24 in)
Minimum OD, external
Circumferential driving
70 mm (2.75 in)
Minimum OD, longitudinal
driving
305 mm (12 in)
Maximum surface temperature 50°C (122°F)
Category Parameter Specification
Scanner Maximum umbilical length 30 m (100 ft)
Maximum payload
(performance may vary with
surface condition)
10 kg (23 lb)
(Umbilical and attachments are considered
payload)
Attachments Restricted to those listed in compatible
components or child products
Orientation while driving at
height >2 m (6 ft) on vertical
surface
Umbilical strain relief to point downwards,
or at worst, horizontal. It is not to point
upwards
Required radial clearance
(handles removed, circumferential
driving)
70 mm (2.75 in) on outer diameters
<200 mm (8 in)
81.5 mm (3.2 in) on outer diameters
>200 mm (8 in)

PAGE 6 of 177
2.1.1.2 Operating Environment
The NAVIC is for use in dry industrial environments having ambient
temperatures shown below. It is NOT intended for use in explosive
environments.
Category Parameter Specification
Environment Minimum ambient temperature -20°C (-4°F)
Maximum ambient temperature 50°C (122°F)
2.1.1.3 User
The NAVIC is intended to be used by persons who have read and understand
the user manual. The intended user is to be a person without limitations in the
physical abilities of the upper and lower limbs, sight, hearing, or anyone with
a pacemaker.
For operating at a height greater than 2 m (6 ft), the Navic is intended to be
used by two people:
1. a person who is trained in rigging and fall protection and is able to
eectively apply the same safety principles to the crawler, and
2. a person who is trained to operate the Navic
2.1.2. Unintended Use
The NAVIC is NOT intended for:
►use outside of its intended use
►lifting / lowering objects or people (i.e. using the Navic as a crane / elevator)
►driving into / over obstructions, excluding standard weld caps
►installation on a surface on which welding is actively occurring
In addition to the above points, for operating at a height greater than 2 m (6 in),
the crawler is NOT intended for:
►operation without a proper tether system
►operating up-side-down
►operating while oriented such that the umbilical strain relief points upward
(front for the Navic is lower than the umbilical connection).

PAGE 7 of 177 CX0344 Rev 05.3
2.1.3. Dimensions and Weight
Crawler height: 12.5 cm 4.9 in
Crawler width: 28.2 cm 11.1 in
Crawler depth: 30.8 cm 12.1 in
Crawler height (handles removed): 81. cm 3.2 in
Crawler width (right drive module): 16.1 cm 6.3 in
Crawler weight: * 7.7 kg 17 lb
Crawler weight (right drive module): 4.2 kg 9.3 lb
30.8 cm (12.1 in)
Fig. 1 - Crawler dimensions
28.2 cm (11.1 in)
12.5
cm
(4.9 in)
8.1 cm
(3.2 in)
Fig. 2 - Dual module dimensions

PAGE 8 of 177
* Dual module configuration excluding case, attachments, umbilical, power controller and handheld
controller.
2.1.4. Power Requirements
Power Requirements: 100-240 VAC, 50/60 Hz, 3.5A
2.1.5. Environmental Sealing
Dust-tight, watertight (not submersible).
16.1
cm
(6.3
in
)
8.1 cm
(3.2 in)
Fig. 3 - Single module dimensions
WARNING! A reliable power source must be
used to power the crawler. Connections must be
secured to prevent accidental disconnection. Power
failure may cause the crawler to freewheel down when
operating in a vertical orientation. Portable generator
usage is not recommended unless accompanied by
the use of an uninterruptible power supply.
WARNING! Proper grounding of the power
supply is important for safe operation. When a
generator is used to supply power to the system (not
recommended), the generator must be properly
grounded (refer to generator manual).
CAUTION! Do not disconnect under load.
Shut off power before connection or disconnecting.
Permanent damage to electronics could occur.

PAGE 9 of 177 CX0344 Rev 05.3
2.1.6. Performance Specifications
Category Parameter Specification
Crawler Maximum speed 25 cm/sec (10 in/sec)
Encoder resolution, right module
(idler encoder)
13.78 counts/mm
(349.9 counts/in)
Encoder resolution, left module
(motor encoder)
872.5 counts/mm
(22161.8 counts/in)
2.1.7. Encoder Interface Specifications
Output type: 4 channel quadrature 5VDC RS422 compatible.
Power: Power must be supplied to the interface.
5VDC +/-10% power limited to < 15w.
9Enc +5V
Enc A
Enc A’
Enc B
Enc B’
Enc Com
Aux Enc A’
Aux Enc B
Aux Enc B’
Shield
Aux Enc A
3
4
1
2
10
6
5
8
7
H
9
4
3
1
7
2
5
6
10
Fig. 4 - JIREH Industries pin out configuration