Jireh NAVIC User manual

NAVIC
Automated Steerable Scanner
CX0540 Rev 00.1

PAGE i of x CX0540 Rev 00.1
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 42 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 43 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. The handheld controller
produces a strong magnetic eld 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.
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 134)contains magnetic
material.
People with pacemakers or ICD’s must stay at least 10 cm (4 in) away.
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).
WARNING! DO NOT DISASSEMBLE. No user-serviceable parts.
Disassembling any of the components in this product, beyond the instructions
in this user manual, could void the regulatory certications and/or effect the
safety of the product.

PAGE iii of x CX0540 Rev 00.1
CAUTION! Pinch points exist with this product. Keep ngers and
hands clear of pinch points.
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 183 for additional details)
EMERGENCY STOP. This symbol indicates emergency stop button.

PAGE iv of x
Chapter1 Identification 3
1.1. Product Brand 3
1.2. Manufacturer 3
1.3. Compliance Declarations 3
1.3.1. ISED Emissions Compliance (Canada) 3
1.3.2. FCC Suppliers Declaration of Conformity (United States) 3
1.3.3. European Union CE Declarations 4
Chapter2 Product Specifications 5
2.1. Base NAVIC System 5
2.1.1. Intended Use 5
2.1.1.1 Operating Limits 6
2.1.1.2 Operating Environment 7
2.1.1.3 User 7
2.1.2. Unintended Use 7
2.1.3. Dimensions and Weight 8
2.1.4. Power Requirements 10
2.1.5. Environmental Sealing 10
2.1.6. Performance Specifications 10
2.1.7. Encoder Interface Specifications 11
2.2. Compatible Components 12
2.2.1. Low Profile Probe Holder Frame 12
2.2.1.1 Intended Use 12
2.2.1.2 Operating Limits 12
2.2.2. Vertical Probe Holder Frame 12
2.2.2.1 Intended Use 12
2.2.2.2 Operating Limits 12
2.2.3. Pivoting Probe Holder Frame 13
2.2.3.1 Intended Use 13
2.2.3.2 Operating Limits 13
TABLE OF CONTENTS

PAGE v of x CX0540 Rev 00.1
2.2.4. Frame Bar 13
2.2.4.1 Intended Use 13
2.2.4.2 Operating Limits 13
2.2.5. Slip Joint Probe Holder 14
2.2.6. Vertical Probe Holder 14
2.2.7. Heavy Duty Vertical Probe Holder 14
2.2.8. Corrosion Thickness Probe Holder 14
2.2.9. HydroFORM Cart 14
2.2.10. Preamp Bracket 15
2.2.10.1 Intended Use 15
2.2.10.2 Operating Limits 15
2.2.11. NAVIC Backpack 15
2.2.11.1 Intended Use 15
2.2.11.2 Operating Limits 15
2.2.12. NAVIC Camera Mount 16
2.2.12.1 Intended Use 16
2.2.12.2 Operating Limits 16
2.2.13. Battery Powered Optical Guide 16
2.2.13.1 Intended Use 16
2.2.13.2 Operating Environment 16
2.2.13.3 Power Requirements 16
2.2.13.4 Environmental Sealing 16
2.2.14. Medium Temperature Add-On Kit 17
2.2.14.1 Intended Use 17
2.2.14.2 Operating Limits 17
2.2.15. Encoder Adapter 17
2.2.15.1 Intended Use 17
2.2.16. 3-Axis Nozzle Scanner Add-On Kit 17
2.3. Child Products 18
2.3.1. Motorized Couplant Pump 18
2.3.2. Motorized Raster Arm 18
2.3.3. Actuated Probe Lift 18
2.3.4. Preamp 18
2.3.5. Optical Guide 19
2.3.6. Tracker 19
2.3.7. Battery Kit 19
Chapter3 Definitions 20
3.1. Definition of Symbols 20
3.2. Definitions of Terms 20
3.3. Safety Symbols 21
3.4. Safety Signal Words 21

PAGE vi of x
Chapter4 System Components 22
4.1. Component Identification 22
4.1.1. Base System 22
4.1.2. Compatible Components 24
4.1.3. Child Products 26
4.2. Tools 27
4.2.1. Included Tools 27
4.2.2. Optional Tools 27
4.3. Base System Components 28
4.3.1. Crawler 28
4.3.1.1 Right Drive Module 28
4.3.1.1.1 Encoder 28
4.3.1.2 Left Drive Module 29
4.3.2. Power Controller 30
4.3.2.1 AC/DC Power Supply 31
4.3.3. Umbilical 32
4.3.3.1 Umbilical Connections 32
4.3.3.2 Emergency Stop Button 33
4.3.3.3 Encoder Signal Isolation 34
4.3.4. Handheld Controller 34
4.3.5. Auxiliary Cable 35
4.3.6. J300 Encoder Cable 35
4.3.7. Installation/Removal Mat 36
4.3.8. Lifting Sling 36
4.3.9. Irrigation Kit 36
4.3.10. Cable Management 36
4.3.11. Cap & Plug 37
4.3.12. Tools 37
4.3.13. Cases 37
4.4. Compatible Components 37
4.4.1. Low Profile Probe Holder Frame 37
4.4.2. Vertical Probe Holder Frame 37
4.4.3. Pivoting Probe Holder Frame 37
4.4.4. Frame Bar 38
4.4.5. Slip Joint Probe Holder 38
4.4.6. Vertical Probe Holder 38
4.4.7. Heavy Duty Vertical Probe Holder 38
4.4.8. Corrosion Thickness Probe Holder 38
4.4.9. HydroFORM Cart 39
4.4.10. Preamp Bracket 39
4.4.11. NAVIC Backpack 39
4.4.12. NAVIC Camera Mount 39

PAGE vii of x CX0540 Rev 00.1
4.4.13. Battery Powered Optical Guide 39
4.4.14. Automated Crawler Medium Temperature Add-On Kit 40
4.4.15. Encoder Adapter 40
4.4.16. 3-Axis Nozzle Scanner Add-On Kit 40
4.5. Child Products 40
4.5.1. Motorized Couplant Pump 40
4.5.2. Motorized Raster Arm 40
4.5.3. Actuated Probe Lift 41
4.5.4. Preamp 41
4.5.5. Optical Guide 41
4.5.6. Tracker 41
4.5.7. Battery Kit 41
Chapter5 Preparation for Use 42
5.1. Preparation for Transportation 42
5.2. Preparation for Safe Use 42
5.2.1. No Entry Fall Zone 42
5.2.2. Tether Requirements and Attachment 43
5.2.3. Lifting Sling Setup 44
5.2.4. Lifting Sling Low Profile Setup 46
5.3. Preparation of Inspection Surface 46
5.4. System Connectivity 47
5.5. Configurations 49
5.5.1. Single Drive Module with Frame Bar 49
5.5.2. Crawler with Actuated Probe Lift 51
5.5.3. Crawler with Multiple Probe Holders 53
5.5.3.1 Vertical Probe Holder Frame 53
5.5.3.2 Low Profile Probe Holder Frame 55
5.5.3.3 Pivoting Probe Holder Frame 57
5.5.3.4 Flange 59
5.5.4. 3-Axis Nozzle Scanning 61
5.6. Right Drive Module 63
5.6.1. Swivel Mount 63
5.6.2. Umbilical 64
5.6.3. Handle 66
5.6.4. Dovetail Accessory Mount 67
5.7. Left Drive Module 68
5.7.1. Swivel Mount 68
5.7.2. Umbilical Connection 69
5.7.3. Handle 69
5.7.4. Dovetail Accessory Mount 69

PAGE viii of x
5.8. Handheld Controller 70
5.8.1. Magnetic Mounts 70
5.8.2. Connecting/Disconnecting Left and Right Modules 71
5.8.3. Probe Holders 73
5.8.4. Vertical Probe Holder 73
5.8.4.1 Probe Holder Setup 73
5.8.4.2 Probe Holder Vertical Adjustment 74
5.8.4.3 Probe Holder Transverse Adjustment 75
5.8.4.4 Probe Holder Longitudinal Adjustment 76
5.8.4.5 Probe Holder Left/Right Conversion 77
5.8.5. Slip Joint Probe Holder 79
5.8.5.1 Probe Holder Setup 79
5.8.5.2 Probe Holder Adjustment 81
5.8.5.3 Probe Holder Force Adjustment 82
5.8.5.4 Slip Joint Probe Holder Left/Right Conversion 84
5.8.6. Heavy Duty Vertical Probe Holder 86
5.8.6.1 Probe Holder Setup 86
5.8.6.2 Probe Holder Vertical Adjustment 88
5.8.6.3 Probe Holder Left/Right Conversion 88
5.8.6.4 Probe Holder 90° Adjustment 90
5.9. 3-Axis Nozzle Scanning 91
5.9.1. Scanner Preparation 91
5.9.2. 3-Axis Nozzle Operation 96
5.9.3. Encoded Skew Vertical Probe Holder 100
5.9.4. Probe Holder Setup 100
5.9.5. Skew Encoder Cable 102
5.9.6. Encoded Skew Vertical Probe Holder Adjustment 102
5.9.6.1 Latch Pin 103
5.9.7. Skew Angle Adjustment 104
5.9.7.1 Ratchet Lever 105
5.9.8. Pivot Buttons 105
5.9.9. Cable Clips 106
5.10. Slider PPS 107
5.10.1. Slider PPS Encoder 109
5.11. Probe Holder Frames 110
5.11.1. Vertical Probe Holder Frame - Flat or Circumferential Only 110
5.11.2. Low Profile Probe Holder Frame - Flat or Circumferential Only 114
5.11.3. Pivoting Probe Holder Frame 118
5.11.3.1 Mounting a Pivoting Probe Holder Frame 119
5.11.3.2 Pivoting Probe Holder Frame Setup - Longitudinal Scanning 120
5.11.3.3 Pivoting Probe Holder Frame - Circumferential Scanning 121
5.11.3.4 Pivoting Probe Holder Frame - Flange Scanning 122
5.11.3.5 Optical Guide Pivot Mount 124

PAGE ix of x CX0540 Rev 00.1
5.12. Accessories 125
5.12.1. Battery Powered Optical Guide 125
5.12.2. Cable Management 126
5.12.2.1 Mounting Cable Management 126
5.12.2.2 Cable Management Setup 126
5.12.2.3 Clamp Setup 127
5.12.3. NAVIC Backpack 128
5.12.4. Preamp Bracket 129
5.12.4.1 Mounting Preamp Bracket 129
5.12.4.2 Attaching Preamp with Screws 129
5.12.4.3 Attaching Preamp with Velcro Straps 130
Chapter6 Operation 131
6.1. System Startup 131
6.2. Placement of Crawler on Inspection Surface 133
6.2.1. Scanner Installation/Removal Mat Use 134
6.3. Operation 136
6.3.1. Handheld Controller Layout 136
6.3.1.1 Touchscreen 137
6.3.1.2 D-pad 137
6.3.1.3 Joysticks 137
6.3.2. Mode Select Screen 138
6.3.3. Jog Mode 138
6.3.4. Latched Jog Mode 140
6.3.5. 1 Axis Scan Mode 141
6.3.5.1 1 Axis Scan Screen 142
6.3.6. System Utilities Screen 144
6.3.6.1 User Settings Screen 145
6.3.6.2 Diagnostics Screens 146
6.3.6.2.1 Detected Modules 146
6.3.6.2.2 System 1 147
6.3.6.2.3 System 2 147
6.3.6.2.4 System 3 148
6.3.6.2.5 LeftDrv, Right Drv, 148
6.3.6.3 Touch Calibration Screen 149
6.3.6.4 Joystick Calibration Screen 150
6.3.6.5 Draw 151
6.3.7. High Internal Temperature Screen 151
Chapter7 Maintenance 153
7.1. Safety Precautions Before Maintenance 153
7.2. Cleaning 153
7.3. Maintenance Schedule 154

PAGE x of x
Chapter8 Troubleshooting 155
8.1. Startup Issues 155
8.1.1. Joystick O Center 155
8.1.2. Checking Network 155
8.2. Startup Override 156
8.2.1. Scan Devices 157
8.2.2. Reset Parameters 158
8.2.3. System Parameters 158
8.2.4. Device Address 158
8.3. Encoder Failure 159
8.4. Umbilical Troubleshooting 160
8.5. Additional Issues 160
8.6. Retrieval of a Stranded Crawler 161
Chapter9 Service and Repair 162
9.1. Technical Support 162
Chapter10 Spare Parts 163
10.1. Crawler 163
10.2. Kit Components 164
10.2.1. Encoder Connector Type 166
10.2.2. Power Cord Type 166
10.3. Probe Holder Frame 167
10.4. Low Profile Probe Holder Frame 168
10.5. Pivoting Probe Holder Frame 169
10.6. Slip Joint Probe Holder Parts 170
10.7. Vertical Probe Holder Parts 171
10.8. Heavy Duty Vertical Probe Holder 172
10.9. Corrosion Thickness Probe Holder 173
10.10. Encoded Skew Vertical Probe Holder 174
10.11. 3-Axis Nozzle Scanner Add-On Kit 175
10.11.1. Slider PPS Encoded Leadscrew 176
10.12. Probe Holder Components 176
10.12.1. Arm Style 176
10.12.2. Yoke Style 176
10.12.3. Swing Arm Style 176
10.12.4. Heavy Duty Yoke Style 176
10.12.5. Pivot Button Style 177
10.13. Probe Holder Receptacle and Wear Plate 177

PAGE 1 of 185 CX0540 Rev 00.1
10.14. Variable Components 178
10.14.1. Frame Bar 178
10.14.2. Cable Management 178
10.14.2.1 Cable Management Sleeving 178
10.14.3. Automated Crawler Medium Temperature Add-On Kit 179
10.15. Accessories 180
10.15.1. Preamp Bracket 180
10.15.2. NAVIC Backpack 180
10.15.3. Battery Powered Optical Guide 181
10.16. Cases 182
Chapter11 Disposal 183
Chapter12 Limited Warranty 184

PAGE 2 of 185

PAGE 3 of 185 CX0540 Rev 00.1
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 2K
Phone: [phone]
jireh.com
Manufacturer:

PAGE 4 of 185
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 5 of 185 CX0540 Rev 00.1
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 12) and (see “Child Products” on page 18).
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 6 of 185
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 7 of 185 CX0540 Rev 00.1
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)*
* CAUTION! In some high temperature conditions, the surface temperatures
may become too hot for prolonged touch. When operating with the maximum
payload of 10 kg (23 lb) and at an ambient temperature of 50°C (122°F), reduce
the operation to a 25% duty cycle with a maximum on time of 30 minutes to
ensure safe surface temperatures. It is important that the operator be aware
of the possibility of hot surfaces and utilize gloves when necessary.
The NAVIC has built in temperature protections for its electronics and will
warn the operator and shutdown before temperatures are reached which
might damage the system (see “High Internal Temperature Screen” on page 151).
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

PAGE 8 of 185
►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).
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): 8.1 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

PAGE 9 of 185 CX0540 Rev 00.1
* Dual module configuration excluding case, attachments, umbilical, power controller and handheld
controller.
28.2 cm (11.1 in)
12.5
cm
(4.9 in)
8.1 cm
(3.2 in)
Fig. 2 - Dual module dimensions
16.1
cm
(6.3
in
)
8.1 cm
(3.2 in)
Fig. 3 - Single module dimensions