Mini?Cam Proteus CRP150 Operation instructions

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Mini‐CamProteus
OriginalInstructionManual
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ThisdocumentisapplicabletotheProteus™system.
Astandardsystemandavailableoptionsarecoveredbythisdocument.Dependingonyour
systemconfigurationyoumaylacksomeofthefeaturesmentionedinthisdocument.
Disclaimer
Hardwareandsoftwarementionedinthisdocumentaresubjecttocontinuousdevelopment
andimprovement.Consequently,theremaybeminordifferencebetweentheinformation
inthedocumentandtheperformanceordesignoftheproduct.Specifications,dimensions
andotherstatementsinthisdocumentaresubjecttochangewithoutpriornotice.
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Mini‐CamLtdanditssuppliersshallnotbeliableforanydamagesrelatedtothissoftwareor
hardware,orforanyotherdamageswhatsoevercausedbytheuseoforinabilitytouseany
Mini‐Camproduct.ThisisapplicableevenifMini‐Camhasbeenadvisedofthedamagerisk.
Underanycircumstances,Mini‐Cam’sentireliabilityshallbelimitedtoreplacesuch
defectivesoftwareorhardwarethatwasoriginallypurchasedfromMini‐Cam.
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Mini‐CamLtd,Unit4YewTreeWay,Golborne,Warrington,Cheshire,WA33JD.
Phone:+441942270524–Fax:+441942273735

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TableofContents
TextConventions....................................................................................................................................6
Danger,CautionandNote..................................................................................................................6
BoldFont.............................................................................................................................................7
Lists.....................................................................................................................................................7
MenuSelections..................................................................................................................................7
Productdescription.................................................................................................................................8
ECDeclarationofConformity.................................................................................................................9
SystemOverview..................................................................................................................................10
Warnings,safetymeasures&care.......................................................................................................11
Beforefirstuse..................................................................................................................................13
Safetymeasures................................................................................................................................15
Maintenance.....................................................................................................................................16
Cleaning.........................................................................................................................................17
Generalcleaningwork..................................................................................................................17
Removalandfittingofthecablereeldirttray..............................................................................18
Checkingplugandsocketconnections.........................................................................................19
ConnectingthePROTEUS™system.......................................................................................................20
Fittingandremovalofcrawlerwheels.............................................................................................20
Connectioncablingbetweencontrolunitandcablereel.................................................................21
Connectioncablingbetweencablereelandcrawler........................................................................22
Connectionofcameratocrawler.....................................................................................................24
Connectionofauxiliarymoduletocrawler.......................................................................................25
PressurisingthePROTEUS™system..................................................................................................26
Checklistforadjustinginternalpressureofmodules..................................................................26
Pressurisingthecrawler................................................................................................................27
Pressurisingthecamera................................................................................................................28
Testingthesystem............................................................................................................................29
Loweringthecrawlerintothemanhole...........................................................................................30
CrawlerCRP150.....................................................................................................................................31
Connectionsanddescriptions...........................................................................................................32
Informationandcare.......................................................................................................................33
Pressurisation................................................................................................................................33
Cleaning.........................................................................................................................................33

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Crawlerwheels..............................................................................................................................33
Maintenance.................................................................................................................................33
Technicaldetails............................................................................................................................33
CameramoduleCAM028......................................................................................................................34
Connectionsanddescriptions...........................................................................................................35
Informationandcare.......................................................................................................................36
Pressurisation................................................................................................................................36
Cleaning.........................................................................................................................................36
Maintenance.................................................................................................................................36
Technicaldetails............................................................................................................................36
CameramoduleCAM027......................................................................................................................37
Connectionsanddescriptions...........................................................................................................38
Informationandcare.......................................................................................................................39
Pressurisation................................................................................................................................39
Cleaning.........................................................................................................................................39
Maintenance.................................................................................................................................39
Technicaldetails............................................................................................................................39
AuxiliarymoduleALB300......................................................................................................................40
Connectionsanddescriptions...........................................................................................................41
Informationandcare.......................................................................................................................42
Pressurisation................................................................................................................................42
Cleaning.........................................................................................................................................42
Maintenance.................................................................................................................................42
Technicaldetails............................................................................................................................42
CablereelRMP150................................................................................................................................43
Connectionsanddescriptions...........................................................................................................44
Informationandcare.......................................................................................................................45
Cleaning.........................................................................................................................................45
Maintenance.................................................................................................................................45
Technicaldetails............................................................................................................................45
ControlunitCCU208.............................................................................................................................46
CCU208overview..............................................................................................................................47
ON/OFFbutton.............................................................................................................................48
ALLSTOPbutton...........................................................................................................................48

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PowerONsequence......................................................................................................................48
PowerOFFsequence....................................................................................................................49
Crawlerfunctionkeys...................................................................................................................49
Surveyfunctionkeys.....................................................................................................................50
Mediafunctionkeys......................................................................................................................50
Camerafunctionkeys...................................................................................................................51
Snapshotkey.................................................................................................................................51
Recordingandplaybackkeys........................................................................................................51
QWERTYkeys................................................................................................................................51
Connectionsanddescriptions...........................................................................................................52
Frontview.....................................................................................................................................52
Rearview.......................................................................................................................................53
Informationandcare.......................................................................................................................54
Cleaning.........................................................................................................................................54
Maintenance.................................................................................................................................54
Technicaldetails............................................................................................................................54
ExternalPowerSupplyUnitPSP24.......................................................................................................55
PSUSpecifications.............................................................................................................................55
WEEEStatement...................................................................................................................................56
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TextConventions
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Danger,CautionandNote
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Inthisusermanualthefollowingsymbolsareused:
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Danger
DANGER!Dangermeansapotentiallydangeroussituationthat
cancausedeathorseverebodilyinjury.Theiconidentifiesthe
typeofrisk.
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Caution
CAUTION!Cautionmeansthatthesystemorequipmentcanbe
damagedordatalost.Theiconidentifiesthetypeofrisk.
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Note
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NOTE!Notesareusedtoconveythroughoutthismanual
importantinformationorguidanceforsystemuse.
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BoldFont
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Boldfontisusedforimportantwords(Forexample:Thismustnotbedoneinreverseorder).
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Lists
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Listsaremarkedasfollows:
•Item1
•Item2
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Proceduresthatmustbeperformedinaspecificorderappearinnumberedlistslikethis:
1. Performthisstepfirst.
2. Performthisstepsecond.
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MenuSelections
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Whendescribingcontrolunitoperation,sequentialmenuselectionsaredescribedinthefollowing
format:
Setup>Camera>EnableBackeyeCamera>OK
ThisexampledescribespressingtheSetupkeyandselectingtheCameraandBackeyeoptions,and
finallypressingtheOKkey.
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Productdescription
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TheinspectionsystemPROTEUS™isamodularsystemdesignedfor,butnotlimitedto,inspecting
pipelinesystems.Usingavarietyofcolourcameras,optionalmodulesandaccessories,the
PROTEUS™platformofferseverythingneededforprofessionalpipelineinspection.
Thecomprehensivelistofmodulesandaccessoriesallowinspectionofpipesequaltoandgreater
than150mmdiameter.Differentwheelsetsallowthecrawlertobecentredinpipesizesfrom
150mmto600mm.TheAuxiliaryLightwithBackeyecameraprovidesadditionalforwardillumination
andacolourrearviewcamerawithilluminationtoaidmanoeuvringthecrawlerinreverse.The
systemusesacontrolunitwithtwinjoysticks,QWERTYkeyboard,andreportingsoftwaredeveloped
in‐housebyMini‐Cam.
BuiltusinghighqualitymaterialsandstateofthearttechnologythePROTEUS™systemisarobust
andpowerfultoolforuseinharshenvironments.
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ECDeclarationofConformity
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CEDeclaration
WeMini‐CamLtd.Unit4YewTreeWay,StonecrossPark,Golborne,Warrington,WA33JDhereby
declarethattheproductPROTEUS™towhichthisdeclarationrefersisincompliancewiththe
followingstandardsorstandardizingdocuments:
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EN61000‐6‐2:2005Genericstandards–Immunityforindustrialenvironments
EN61000‐6‐4:2007Genericstandards–Emissionforindustrialenvironments
EN61010‐1:2010Safetyrequirementsforelectricalequipmentformeasurement,control,and
laboratoryuse.
EHSRMSD EssentialHealthandSafetyRequirementsofMachinerySafetyDirective
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Thefollowingarethestipulatedoperatingandenvironmentalconditionsforsaidcompliance:
Residential,business,commercial,small‐companyandlightindustrialenvironments.
Thisdeclarationisbasedontestreport(s)oftherelevantEMCtestinglaboratory.

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SystemOverview
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TheinspectionsystemPROTEUS™consistsofthefollowingmaincomponents:
•ControlUnit(1)
•CableReel(2)
•Crawler(3)
•Camera(4)
Atypicalconfigurationisshowninthisillustration:
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NOTTOSCALE
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34

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Warnings,safetymeasures&care
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Pleasereadthesafetymeasurescloselyandobservethem.Theypreserveyourownsafety,the
safetyofco‐workersaswellasthepreventionofdamagetothePROTEUS™inspectionsystemand
itscomponents.
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CAUTION!
TheoperatorofthePROTEUS™inspectionsystemmustbetrainedbyeither
Mini‐Camoroneofitsauthorisedrepresentativesbeforeusingthesystem.
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CAUTION!
Despiteallofthesafetyfunctionsbuiltintothesystem,theoperatorisnot
exoneratedinanywayfromhis/herdutyofcare.Thustheuseraloneis
responsibleforanydamagecausedasaresultofmisuse.
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CAUTION!
Iftheequipmentisusedinamannernotspecifiedbythemanufacturer,the
protectionprovidedbytheequipmentmaybeimpaired.
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DANGER!
Riskofdeadlyinjuriesfromelectricalcurrent!
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ThemainsplugandorIECconnectorofthePSUisthesupplyisolationdevice
andmustbeeasilyaccessible.
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DANGER!
Riskofdeadlyinjuriesfromelectricalcurrent!
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•Thepowersupplyforthecrawlerisnominally120voltsDCwhichcanbe
consideredhazardous,howeverthissupplycannotbeswitchedon
unlessthecontrolunitisconnectedtothecablereelandthecableis
connectedtothecrawler.Consequentlythissupplyisnotaccessable
andassoonasanyconnectionisexposedthepowersupplywillbe
automaticallyshutoff.
•Thishazardousvoltagemaybeexposedifthecontrolunit,cablereelor
crawlerisopenedwhilethesystemisoperational.Thereforethe
modulesofthesystemshouldonlybeopenedbyaMini‐CamService
Centre.
•Therearenouserserviceablecomponentswithinanymoduleinthe
system.
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DANGER!
Riskofdeadlyinjuriesfromelectricalcurrent!
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Onlyuseanappropriatelyratedandapprovedcordsetinaccordancewiththe
regulationofthecountryinwhichthissystemisused.
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DANGER!
Riskofdeadlyinjuriesfromelectricalcurrent!
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Althoughthecablereelandcrawlercouldbeusedinwetenvironmentsthe
externalPSUisforindooruseonly(asmarkedonitslabel)andmustnotbe
usedinwetareas.
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DANGER!
Riskofdeadlyinjuriesfromelectricalcurrent!
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OnlythepowersupplysuppliedaspartofthePROTEUS™systemcanbeused
andshouldNOTbereplacedbyanyother.
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Beforefirstuse
Pleasenoticethefollowingsourcesofriskforseriousordeadlyinjuries:
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CAUTION!
Riskofdeadlyinjuriesfromelectricalcurrent!

•Ensurethatnofluidscanenterthecontrolpanelorpenetratethe
housingofthecablereel.Incasethishappens,immediatelydisconnect
thepowersupplyandinformtheappropriatelytrainedstafforMini‐
CamServiceCentre.
•Ensurethattheelectricalconnectioncablesareintactandthatthey
cannotbebentorcrushed.Ifyoufindcabledamage,immediately
disconnectthepowersupplyandinformtheappropriatelytrainedstaff
orMini‐CamServiceCentre.
•Workontheelectronics,whicharenotcoveredinthisdocument,shall
onlybecarriedoutbytrainedspecialiststafforaMini‐CamService
Centre.
•Maintenanceandrepairwork,whichisnotcoveredinthisdocument,
shallonlybecarriedoutbytrainedspecialiststaffataMini‐CamService
Centre.




CAUTION!
Riskofseriousinjuriesbyfallingcrawler!

Whenpreparingthesystemforoperationpayattentiontothecrawlerposition,
thatitisnottooclosetothemanhole.Whentestingthedrivingfunction,the
crawlermightfallintothemanhole.Anypersoninthemanholemaysuffer
seriousinjuries.





CAUTION!
Hazardofinfectionandcontaminationoffreshwater!

Neveralternatetheuseoftheinspectionsystemforinspectionsinwastewater
andfreshwater!Evenathoroughcleaningofthesystemwillnotensure
sufficientprotectionagainstcontamination.Forinspectionsinwastewaterand
freshwateruseaseparateinspectionsystemforeach.Bacteriacanleadtoan
infection.Allindividualsemployedfortheworkmustbeadvisedofthehazards
andmustbeinstructedintherequiredsafetymeasures.




Page|14


CAUTION!
Explosionhazard!

Donotusetheinspectionsysteminpipelineswhichmighthavecontained
explosivesubstances,suchasgasorsolvents.Ifthiskindofapplicationshould
berequired,contactMini‐CamLtdtoobtaininformationonsystemcomponents
destinedforthispurpose.





CAUTION!
Suffocationhazard!

Beforeandwhileloweringthecrawlerintothepipesystemitisnecessaryto
performasafetytestwithacertifiedgasdetector.



Page|15

Safetymeasures

ThestaffassignedtotasksinvolvingthePROTEUS™inspectionsystemmusthavereadand
understoodthisusermanualcompletelybeforethestartofthework.Thisappliesequallytothe
staffwhoonlyworkontheinspectionsysteminfrequently,e.g.formaintenance,repairor
retrofittingwork.


NOTE!

Theoperatorofthisinspectionsystemisobligedtoensureasafeand
hazard‐freeoperation.Thismaybeachievedbythefollowingmeasures:
•Makingtheusermanualavailableonthesiteoftheuseofthe
inspectionsystematalltimes.
•Checklistsformaintenanceandcare.
•Regularreviewsofthesafetyandhazardconditions



NOTE!
Safetyofpersons!

Thestaffforoperation,maintenanceandupgradingmusthavespecialist
expertiseorbeinstructedbycompetentindividuals.Competentindividuals
musthaveadequateknowledgeofthePROTEUS™inspectionsystembased
ontechnicaltrainingandexperience.Theymustbefamiliarwiththe
relevantworksafetyregulationsandaccidentpreventionrulestoanextent
thattheyarecapableofjudgingtheinspectionsystem’soperationalsafety.

Theymust:
•Observetheoperatingmanualfortheworkplace.
•Observetherelevantworksafetyregulationsandaccident
preventionrules.
•Seekinstructionforthehandlingofhazardoussubstances.
•Adheretothesafetyinformationdescribedinthisusermanual.
•Theoperatormustwearsafetyequipmentthatisappropriateto
thesurveybeingperformed(suchasgoggles,gloves,safetyshoes,
etc).



NOTE!
Avoidphysicaldamage!

TheoperatorofthePROTEUS™inspectionsystemisresponsibleforthe
followingaspects:
•Onlyusetheinspectionsystemforworkthatisappropriatetothe
specifications
•Observetheoperationalrequirementsforthisinspectionsystemas

Page|16

describedinthisusermanual.
•Keepthesystemclean.Observetheindividualcleaninginstructions
forthispurpose.
Maintenance

ToensurethemaximumservicelifeofthePROTEUS™systemtheindividualmodulesandaccessories
belongingtothesystemhavetobeindependentlymaintainedandkeptclean.Movingparts,in
particular,canhaveimprovedoperationallifebyfrequentprofessionalcleaningafterinspections.
Also,therisktotheoperatorofinfectioncanbesignificantlyreducedbyusingacleanedsystem.
Takenoticeofthefollowingcommentsongeneralmaintenance:
•Keeptheentiresystemcleanandcleanthesystemdirectlyaftereachinspection.
•Thoroughlywashdownthepartsofthesystemthathavecomeintocontactwithmoisture
andthendrythemwithacleananddrycloth.
•Keepallelectricalconnectionsandcontactsfreeofdirt,greaseandmoistureatalltimes.
•Neverbendthecableofthesystemandavoidknots.
•Cleanthecablewitharagwhenretracting.
•RegularlygreaseallexposedO‐ringsusingO‐ringlubricantasrequiredinthemaintenance
instruction.
•Useonlysuitabledisplaycleanersforcleaningthedisplayasrequiredinthemaintenance
instruction.
•Useonlycleananddustfreeclothsforcleaningthedisplay.
•Usewaterforcleaningwithouttheadditionofcleaningagentsorsolvents.
Fordetailedmaintenanceinstructionsforindividualmodulesandaccessoriespleasereadthe
commentsinthedescriptionforeachmodule.Thespecificmaintenanceworkstepswillalsobe
explained.



NOTE!

Theoperatorofthesystemisresponsiblefortheproperdisposal!See
informationonpage56onthereturnofequipmentattheendoftheuseful
life.




Page|17

Cleaning

TominimisedowntimeandsubsequentrepairsitisnecessarytokeepyourPROTEUS™systemclean.
Pleasefollowtheinstructionsbelowtohelpavoiddisruption.


CAUTION!
Riskoffatalinjuriescausedbyelectricalcurrent!

Ensurethatnofluidscanenterthecontrolpanelorpenetratethehousingofthe
cablereel.Incasethishappens,immediatelydisconnectthepowersupplyand
informtheMini‐CamServiceCentre.



CAUTION!
Riskoffatalinjuriescausedbyelectricalcurrent!

Forallcleaningandmaintenanceworkdisconnectthesystemfromthepower
supply.


Generalcleaningwork


CAUTION!
High‐pressurecleanersmustnotbeused.Itcancauseconsiderabledamageto
thecrawler,cameraandothersystemcomponents.

Cleaningagentsorsolventsmustnotbeused.Thesecandamagethesealsand
othermaterialsonthesystem.

Onlycleanwatershouldbeused.


•Cleanthecrawlerandcamerawithwaterafterthefirstinspection.Onlyafterthisshouldyou
loosenelectricalconnections.
•Immediatelyfittheprotectivecapsafterremovingelectricalconnections.
•Keepallelectricalconnectionsclean.
•CheckO‐ringsfordamageandreplaceifnecessaryandgreaseregularlywithO‐ringlubricant.
•Cleanthecablereelandcontrolunitwithadampcloth.
•Onlycleanthecameraandlightlenseswithaspecificlenscleaningclothtoprevent
scratches.

Page|18

Removalandfittingofthecablereeldirttray

Afteruse,dirtandwaterwillhavecollectedinthecablereel.Atrayisbuiltintothebottomofthe
cablereeltocollectthis,whichcanberemovedforcleaning.


1. Pulloutthetray.
2. Removedirt,wateranddebris.
3. Pushthetraybackintoposition.


Page|19

Checkingplugandsocketconnections

Toensurereliableoperationitisimportantthattheelectricalconnectionsarenotdamagedandkept
cleananddry.Itisimportanttocheckbeforeandaftereachuseoftheinspectionsystem.
•Checkthecontactsonthecamerabackplate.
•Checkthecontactsonthecrawlercameraconnector(withcare).
•Checkthecontactsonthecrawlercableconnector.
•Checkthecontactsonthecablereelconnector.
•Checkthecontactsonthecontrolunit.
•Checkthecontactsontheauxiliarymodule.
Cleanthepinsandconnectorsfromdirtandmoistureusinganelectroniccontactcleaneraerosol.


NOTE!
•Disconnectthepowersupplyfromthesystem.
•ChecktheO‐ringsfordamageandreplaceifnecessary.
•GreasetheO‐ringsifnecessaryusingO‐ringlubricant.






Page|20

ConnectingthePROTEUS™system

Fittingandremovalofcrawlerwheels


1. Ensurethequickreleasewheelretainerisalignedwiththeaxle(1).
2. Slidewheel(2)ontothecrawleraxle(3).


1. Turnthewheelretainerboltclockwisetolockthewheelontotheaxle.

NOTE!
Toremovethewheelturntheretainersboltanticlockwise,ensurethatthe
retainerisalignedwiththewheelaxle,andslidethewheeloffthecrawler
axle.

1
2
3