Jireh NAVIC User manual

Automated Steerable Scanner
CX0098 Rev 07.5

PAGE i of viii CX0098 Rev 07.5
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.
DANGER! 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.
DANGER! 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 No Entry Fall Zone on page 9 for additional details)
DANGER! 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 10 for additional details)
DANGER! 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 viii
WARNING! LIFTING HAZARD. The NAVIC case can be heavy.
Single person lift could cause injury. Two person lift recommended.
WARNING! LASER RADIATION. Do not view directly with
optical instruments. Class 1M laser product.
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 25 cm (10 in) away.
The magnetic base of the raster arm cable tray contains magnetic
material. People with pacemakers or ICD’s must stay at least 10 cm (4 in)
away.
WARNING! MAGNETIC MATERIAL. The installation/removal
mat (Fig. 28 on page 14) 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.
CAUTION! DO NOT operate the NAVIC crawler on an inspection
surface which is electrically connected to a component that is being welded.

PAGE iii of viii CX0098 Rev 07.5
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 111 for additional details).
CAUTION! Do not disconnect under load. Shut off power before
connection or disconnecting. Permanent damage to electronics could occur.
Emergency Stop. This symbol indicates emergency stop button.

PAGE iv of viii
Chapter
1
Introduction 2
1.1. Product information 2
1.1.1. Intended use 2
1.1.2. Unintended Use 3
1.2. Regulations 4
1.2.1. FCC 4
1.2.2. Industry Canada 4
1.3. Intended User 4
1.4. Dimensions and Weight 5
1.5. Scanner Operation Specifications 5
1.6. Performance specifications 6
1.7. Maintenance 6
1.8. Power Requirements 6
1.9. Operating Environment 7
1.10. Definition of symbols 7
1.11. Included Tools 8
1.11.1. Optional tools 8
Chapter
2
Preparation for Use 9
2.1. Transportation 9
2.2. No Entry Fall Zone 9
2.3. Tether Requirements and Attachment 10
2.3.1. Lifting Sling Setup 11
2.3.2. Lifting Sling Low Profile Setup 13
2.4. Preparation of Inspection Surface 13
2.5. Scanner Component Identification 14
Chapter
3
Configurations 16
3.1. Single Drive Module with Frame Bar 16
3.2. Dual Drive Module with Probe Holder Frame 18
3.3. Dual Drive Module with Raster Arm Module 20
Chapter
4
Operation 22
4.1. System Startup 22
4.2. Placement of Crawler on Inspection Surface 24
TABLE OF CONTENTS

PAGE v of viii CX0098 Rev 07.5
4.3. Operation 26
4.3.1. Controller Layout 26
4.3.1.1 Touchscreen 27
4.3.1.2 Click Wheel 27
4.3.1.3 Joysticks 27
4.3.2. Main Mode Selection Screen 27
4.3.3. Jog Mode 28
4.3.4. Latched Jog Mode 30
4.3.5. Two Axis Scan Mode 30
4.3.5.1 Two Axis Scan Setup Screen 31
4.3.5.2 Scan Speeds Screen 32
4.3.5.3 Two Axis Scan Screen 33
4.3.6. System Utilities Screen 35
4.3.6.1 User Settings Screen 35
4.3.6.2 Diagnostics Screens 37
4.3.6.2.1. Detected Modules 37
4.3.6.2.2. System 1 38
4.3.6.2.3. System 2 38
4.3.6.2.4. System 3 39
4.3.6.2.5. LeftDrv, Right Drv, Raster 39
4.3.6.3 Touch Calibration Screen 40
4.3.6.4 Joystick Calibration Screen 41
4.3.6.5 Draw 42
Chapter
5
System Components 43
5.1. Controller 43
5.2. Right Drive Module 44
5.2.1. Swivel Mount 44
5.2.2. Umbilical 45
5.2.3. Encoder 46
5.2.4. Handle 47
5.3. Left Drive Module 48
5.3.1. Swivel Mount 48
5.3.2. Encoder 49
5.3.3. Handle 49
5.3.4. Connecting/Disconnecting Left and Right Modules 50
5.4. Raster Arm Module 51
5.4.1. Mounting a Raster Arm 52
5.4.2. Attaching a Cable Tray 53
5.4.3. Using the Cable Tray 54
5.4.4. Raster Arm Cable Setup 56
5.4.5. Mounting Probe Holders 57
5.5. Probe Holder Attachments 58

PAGE vi of viii
5.5.1. HydroFORM™ Probe Holder 58
5.5.2. Heavy Duty Vertical Probe Holder 58
5.5.2.1 Probe Holder Setup 59
5.5.2.2 Probe Holder Vertical Adjustment 60
5.5.2.3 Probe Holder Left/Right Conversion 61
5.5.2.4 Probe Holder 90° Adjustment 62
5.5.3. Corrosion Thickness Probe Holder 63
5.5.4. Two Probe Raster Arm 64
5.5.5. Pivoting the Raster Arm 65
5.5.6. Pivot Nose 65
5.5.7. Raster Arm Cable 66
5.6. Battery Powered Optical Guide 67
5.7. Power Supply 68
5.8. Power Supply Cable 69
5.9. Umbilical 70
5.10. Controller Cable 73
5.11. Encoder Cable 73
5.12. Vertical Probe Holder 74
5.12.1. Probe Holder Setup 74
5.12.2. Probe Holder Vertical Adjustment 75
5.12.3. Probe Holder Transverse Adjustment 76
5.12.4. Probe Holder Longitudinal Adjustment 77
5.12.5. Probe Holder Left/Right Conversion 78
5.13. Slip Joint Probe Holder 80
5.13.1. Probe Holder Setup 80
5.13.2. Probe Holder Adjustment 82
5.13.3. Probe Holder Force Adjustment 82
5.13.4. Slip Joint Probe Holder Left/Right Conversion 84
5.14. Low Profile Probe Holder Frame 86
5.14.1. Low Profile Probe Holder Frame Setup 86
5.15. Probe Holder Frame 89
5.15.1. Probe Holder Frame Setup 89
5.16. Pivoting Probe Holder Frame 92
5.16.1. Mounting a Pivoting Probe Holder Frame 93
5.16.2. Pivoting Probe Holder Frame Setup 94
5.16.2.1 Longitudinal Scanning 94
5.16.2.2 Circumferential Scanning 95
5.16.2.3 Flange Scanning 95
5.16.3. Optical Guide Pivot Mount 98
5.17. Cable Management 99
5.17.1. Mounting a Zipper Tube 99

PAGE vii of viii CX0098 Rev 07.5
5.17.2. Zipper Tube Setup 99
5.17.3. Clamp Setup 100
5.18. Backpack 101
5.19. Preamp Bracket 102
Chapter
6
Maintenance 103
6.1. Safety Precautions Before Maintenance 103
6.2. Maintenance Schedule 103
Chapter
7
Troubleshooting 105
7.1. Startup Issues 105
7.1.1. Joystick Off Center 105
7.1.2. Checking Network 105
7.2. Startup Override 106
7.2.1. Scan Devices 107
7.2.2. Reset Parameters 108
7.2.3. System Parameters 108
7.3. Additional Issues 109
7.4. Retrieval of a Stranded Crawler 110
Chapter
8
Service and Repair 111
8.1. Technical Support 111
8.2. Disposal 111
Chapter
9
Spare Parts 112
9.1. Crawler 112
9.2. Kit Components 113
9.3. Raster Arm Module 114
9.3.1. Mounting Rail 114
9.3.2. Base Raster Arm 115
9.3.3. Cable Tray 115
9.3.3.1 Cable Tray Parts 116
9.3.3.2 Cable carrier 116
9.4. Corrosion Thickness Probe Holder 117
9.5. HydroFORM™ Probe Holder 118
9.6. Probe Holder Frame 119
9.7. Low Profile Probe Holder Frame 120
9.8. Pivoting Probe Holder Frame 121
9.9. Slip Joint Probe Holder Parts 122

PAGE viii of viii
9.10. Vertical Probe Holder Parts 123
9.11. Heavy Duty Vertical Probe Holder 124
9.12. Probe Holder Components 125
9.12.1. Arm Style 125
9.12.2. Yoke Style 125
9.12.3. Heavy Duty Yoke Style 125
9.12.4. Pivot Button Style 125
9.13. Variable Components 126
9.13.1. Frame Bar 126
9.13.2. Cable Management 126
9.13.2.1 Cable Management Sleeving 126
9.14. Encoder Connector Type 127
9.15. Accessories 127
9.15.1. Battery Powered Optical Guide 127
9.15.2. Preamp Bracket 128
9.15.3. NAVIC Backpack 128
Chapter
10
Limited Warranty 129

PAGE 1 of 131 CX0098 Rev 07.5

PAGE 2 of 131
CHAPTER 1
INTRODUCTION
1.1. Product information
1.1.1. Intended use
The NAVIC is a remotely operated vehicle with magnetic wheels suitable
for driving on ferrous material. Its primary purpose is to move inspection
equipment over areas of structures, such as tanks or pipes, made from
ferrous materials.
The intended ferrous surface is to:
►be bare metal for up-side-down surfaces, or
►be coated to a thickness no greater than:
►0.5 mm (.02 in) for vertical surfaces
►1 mm (.04 in) for horizontal surfaces on which the crawler is
right-side-up
►be free of excess rust, scale, ferrous debris, ice, frost
►have a minimum thickness of 3 mm (0.12 in)
►have a minimum ID of 610 mm (24 in) for internal circumferential driving
►have a minimum OD of 70 mm (2.75 in) for external circumferential
driving
►have a minimum OD of 305 mm (12 in) for longitudinal driving
The NAVIC is intended to:
►be used by trained personnel (see “Intended User” on page 4).
►operate in an appropriate environment
(see “Operating Environment” on page 7)
►operate with a proper tether system (see “Tether Requirements and
Attachment” on page 10)
►The NAVIC backpack is intended to mount objects that:
►have a maximum weight of 1.36 kg (3 lb)
►are attached to the NAVIC via a tether or probe cables strong
enough to prevent the object from falling
►have smooth edges so as not to cut backpack strap

PAGE 3 of 131 CX0098 Rev 07.5
1.1.2. Unintended Use
The NAVIC is NOT intended for:
►operation on surfaces that are not clean (e.g. excess rust, scale, ferrous
debris, ice, frost)
►lifting / lowering objects or people (i.e. using the crawler as a crane / elevator)
►driving into obstructions
►operating in ambient temperatures below -20° C (-4° F) or above
50° C (122° F)
►In addition to the preceding points, operating at a height greater than 2 m
(6 ft), 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
upwards (front of the NAVIC is lower than the umbilical connection)
►operating with objects mounted in backpack that have a weight greater
than 1.36 kg (3 lb) or objects that are not attached to the NAVIC via a
tether or probe cables, or objects with sharp edges
DANGER! FALLING OBJECT HAZARD.
Failure to comply with the warnings, instructions
and specications in this manual could result in
SEVERE INJURY or DEATH.

PAGE 4 of 131
1.2. Regulations
1.2.1. FCC
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.
1.2.2. Industry Canada
CAN ICES-3 (A)/NMB-3(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. Intended User
The NAVIC is intended to be used by persons who have read and understood this
user manual.
For operating at a height greater than 2 m (6 ft), the NAVIC is intended to be used
by two people:
►a person who is trained in rigging and fall protection as well as able to e󰀨ectively
apply the same safety principals to the crawler
►a person who is trained to control the crawler
The NAVIC is intended to be used by persons without limitations in the physical
abilities of the upper and lower limbs, sight and hearing. The NAVIC should not be
used by anyone with a pacemaker or ICD.

PAGE 5 of 131 CX0098 Rev 07.5
1.4. Dimensions and Weight
Crawler weight* 7.7 kg 17 lb
Crawler dimensions** 21 x 25 x 8 cm 8.3 x 10 x 3.2 in
Shipping weight, crawler case 30 kg 100 lb
Shipping dimensions, crawler case 52 x 32 x 81 cm 20.5 x 12.5 x 32 in
Raster arm 300 mm (12 in) 2.45 kg 5.4 lb
Raster arm 600 mm (24 in) 3.36 kg 7.4 lb
Raster arm 900 mm (35 in) 4.04 kg 8.9 lb
Raster arm 1160 mm (45 in) 4.54 kg 10.0 lb
* Dual Module Conguration excluding case, attachments, umbilical, power supply and
controller.
** Crawler height is 12.45 cm (4.9 in) with handles attached.
1.5. Scanner Operation Specications
Scanner
diameter range
External, circumferential scans: 70 mm (2.75 in) OD to Flat.
Internal, circumferential scans: 610 mm (24 in) ID to Flat.
External, longitudinal scans: 305 mm (12 in) OD to Flat.
Right module
(Idler encoder)
13.78 counts/mm (349.9 counts/inch)
Left module
(Motor encoder)
872.5 counts/mm (22162.8 counts/inch)
Raster arm
module encoder
240.2 counts/mm (6100.9 counts/inch)
Environmental
sealing
Dust tight, water tight (not submersible)
Required radial
clearance*
70 mm (2.75 in) on pipes under 200 mm (8 in) OD and
81.5 mm (3.2 in) on pipes over 200 mm (8 in) OD
* With handles removed, using slip joint probe holders only.
WARNING! LIFTING HAZARD. The NAVIC
can be heavy. Single person lift could cause injury.
Two person lift recommended.

PAGE 6 of 131
1.6. Performance specications
Crawler vertical payload:* 10 kg 22 lb
Drive module speed 0 - 25 cm/sec 0 - 10 in/sec
Raster arm module speed 0.5 - 76.2 cm/sec 0.2 - 30 in/sec
* Performance may vary with surface type.
**Heavy payloads may require reduced speeds.
1.7. Maintenance
General cleaning of components is important to keep your system working well. All
components that have no wiring or cables are completely waterproof. Components
can be washed with warm water, dish soap and a medium bristle brush.
Before using the scanner, ensure all connectors are free of water and moisture.
NOTE: All components with wiring, cables or electrical connections are splash
proof. However, these components are NOT submersible.
NOTE: Never use strong solvents or abrasive materials to clean your scanner
components.
1.8. Power Requirements
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).

PAGE 7 of 131 CX0098 Rev 07.5
Power Requirements: 90-270VAC, 45-65Hz, 5 Amps
NOTE: The NAVIC power supply automatically adjusts to the supplied
voltage.
1.9. Operating Environment
The NAVIC is designed for use in an industrial environment that is between
-20° C (-4° F) and 50° C (122° F).
1.10. Denition of symbols
Instructions to ‘look here’ or to ‘see this part’
Denotes movement. Instructing user to carry out
action in a specied direction.
Indicates alignment axis
Alerts user that view has changed to a reverse angle
CAUTION! Do not disconnect under load.
Shut off power before connection or disconnecting.
Permanent damage to electronics could occur.

PAGE 8 of 131
1.11. Included Tools
The included 3 mm hex driver (Fig. 1) is
suitable for most typical adjustments of
the NAVIC modules.
Also included in this kit is a 3/8 in wrench
(Fig. 2) which is used to remove and install
probe holder buttons.
The included 3 mm at driver (Fig. 3) is
useful for releasing the aps of the raster
arm’s cable tray.
1.11.1. Optional tools
Some specialized adjustments require tools that are not included with this kit.
Fig. 1 - 3 mm hex driver Fig. 2 - 3/8 in wrench
Fig. 3 - 3 mm at driver
Fig. 4 - 1.5 mm hex
wrench
Fig. 5 - 2 mm
hex wrench
Fig. 6 - 2.5 mm
hex wrench
Fig. 7 - 3 mm
hex wrench

PAGE 9 of 131 CX0098 Rev 07.5
CHAPTER 2
PREPARATION FOR USE
2.1. Transportation
2.2. No Entry Fall Zone
The area below a crawler must be kept clear at all times. A clearly marked
NO ENTRY FALL ZONE must be cordoned o󰀨 directly below the area of crawler
operation, according to the dimensions shown in (Fig. 8).
Example: If inspecting a tank that is 6 m (20 ft) tall, the No Entry Fall Zone radii
CAUTION! PINCH / CRUSH HAZARD. BE
CAREFUL when passing the NAVIC crawler through
narrow ferrous (magnetic) openings, such as man-holes.
The magnetic drive wheels can cause bodily harm if
allowed to slam onto the walls of the opening.
DANGER! FALLING OBJECT HAZARD. The
area below a crawler must be kept clear at all times. A
clearly marked NO ENTRY FALL ZONE must be
cordoned off directly below the area of crawler
operation.
Area of crawler
operation
No Entry
Fall Zone
H
Radius = H/2
(minimum)
Radius = H/2
(minimum)
Fig. 8 - No entry fall zone

PAGE 10 of 131
must be no smaller than 3 m (10 ft) from the area below the area of crawler
operation.
2.3. Tether Requirements and Attachment
When used at a height greater than 2 m (6 ft), the NAVIC crawler MUST be
tethered with a proper tether system to prevent the crawler from falling. The tether
system must:
►be capable of safely suspending the crawler from above in case the crawler
detaches from the inspection surface;
►have su󰀩cient capacity to catch and hold a 70 kg (150 lb) load;
►include a mechanism (i.e. self retracting inertia reel fall arrester) or person to
continuously take up slack in the tether as the crawler moves;
►include a lifting hook with a safety latch to prevent accidental disconnection. The
hook must be free of sharp edges that may cut or abrade the provided lifting
sling.
Before placing the crawler on the surface to be inspected (e.g. tank), attach the
provided lifting sling to the NAVIC and then hook the tether hook to the lifting sling.
DANGER! FALLING OBJECT HAZARD.
Failure to comply with the warnings, instructions,
and specications in this manual could result in
SEVERE INJURY or DEATH.
DANGER! Do NOT operate or place
crawler on a surface higher than 2 m (6 ft) without a
proper tether held taut at all times.
DANGER! Hook the tether hook to
the provided lifting sling BEFORE placing the
crawler on the surface to be inspected (e.g. tank).
IMPORTANT: Tether hook must have a safety latch
to prevent accidental disconnection.
CAUTION! The overhead attachment point for
the tether must be located as close as possible to a
location directly above the crawler to minimize
dangerous swinging of the crawler should it detach from
the inspection surface.

PAGE 11 of 131 CX0098 Rev 07.5
2.3.1. Lifting Sling Setup
Secure the lifting sling to the NAVIC as indicated here:
1. Lift the two tether attachment points (Fig. 9).
IMPORTANT! Carefully inspect the lifting
sling for damage prior to each use. Ensure the tether
hook does not have sharp edges that may cut the lifting
sling.
Fig. 9 - Lift tether attachment points
Fig. 10 - Press release button Fig. 11 - Pull pin from