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I.B.O.S. CamBoss User Manual

Monitoring system
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I.B.O.S. EU a.s.
CamBoss Monitoring
System
User´s manual
v2.5 (10/2014)
Manual for safe operation of the CamBoss monitoring system and its maintenance to ensure
trouble-free operation. All registered marks and trademarks mentioned in the guide are owned by
the corresponding owners.

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Summary of Contents for I.B.O.S. CamBoss

  • Page 1 I.B.O.S. EU a.s. CamBoss Monitoring System User´s manual v2.5 (10/2014) Manual for safe operation of the CamBoss monitoring system and its maintenance to ensure trouble-free operation. All registered marks and trademarks mentioned in the guide are owned by the corresponding owners.

  • Page 2: Table Of Contents

    Description of the product ......................11 General features ........................11 Application and equipment ....................11 3.2.1 Control unit ........................12 3.2.2 KZ90 CamBoss camera head..................12 3.2.3 Pan and rotate camera head KZ75CB ................12 3.2.4 BOSS150 Crawler ......................13 3.2.5 BOSS100 Crawler ......................
  • Page 3 CamBoss User´s Manual Supplies and connectors ....................... 22 4.2.1 Control unit side panel ....................23 4.2.2 Control unit connections ....................24 4.2.3 Connection of the NAVI cable drums ................24 4.2.4 Connectors of the crawlers ................... 25 Putting into operation ......................25 Inserting the crawler into the shaft ..................
  • Page 4 CamBoss User´s Manual Figure 1 CamBoss system component tree...
  • Page 5 CamBoss User´s Manual Document history v1.2 Actualization: LCD menu, 12/13 v1.3 Actualization: photo, added BOSS100, lights and its holder for BOSS100, 1/14 v1.5 Edit & Actualization: NAVIX00, 2/14 v1.8 Actualization: MN200, 3/14 v1.9 Actualization: REVI100, 4/14 v2.0 Actualization: REVI350, sonde REVI250, 5/14 v2.1 Actualization: added LCD Menu –...

  • Page 6: Introduction

    But, bear in mind that even the best product can do its job only if it is correctly maintained and operated. Guide purpose This guide serves as a manual for commissioning, using and maintaining the CamBoss inspection system produced by our company I.B.O.S. EU a.s. and includes safety instructions as well.

  • Page 7: Usage Of The System According To The Application

    CamBoss User´s Manual Usage of the system according to the application The CamBoss sewer and inspection system is intended only for piping inspections. Different usage or usage beyond this scope is not considered as the corresponding application. Never use the CamBoss inspection system for different purposes.

  • Page 8: Type Labels

    CamBoss User´s Manual Type labels You can find the type labels with the corresponding serial number on the individual components. You will need this information when contacting the I.B.O.S. EU a.s. customer service, for example if you wish to order accessories or spare parts. You should write the corresponding serial number for each component, Table 1, so that it is available if necessary.

  • Page 9: Used Symbols

    CamBoss User´s Manual Used symbols This guide uses the following symbols DANGER! This safety instruction warns against hazards connected with injury or damage to property. DANGER! This safety instruction warns against hazards connected with death or very serious injury caused by electric current.
  • Page 10 CamBoss User´s Manual DANGER! This symbol warns against danger connected with injuries caused by movable parts of the machine. DANGER! This symbol warns against danger connected with injuries caused by non-rotational movable parts of the machine. DANGER! This symbol warns against danger connected with injuries caused by rotational parts of the machine.

  • Page 11: Safety Measures

    2. Safety measures 2.1 Organizational measures The CamBoss inspection system has been designed according to the current condition of the technology and valid technical regulations. Nevertheless, its usage can cause damage to the health or even death of the user, a third person, animals or damage to the inspection system or other material values.

  • Page 12: Prevention Of Material Damage

    CamBoss User´s Manual 2.3 Prevention of material damage As an operator of the CamBoss inspection system, you are responsible for the following aspects:  observe the specified maintenance intervals  use the inspection system only in operations for which it has been designed ...
  • Page 13 CamBoss User´s Manual Danger of serious injury caused by a falling the crawler! When starting the system, make sure that the crawler does not stand too close to an open shaft and the joystick is in the zero position! When testing the travel functions, the crawler can fall into the shaft.
  • Page 14 CamBoss User´s Manual Danger of injury by non-rotational parts of the machine! The crawler and the cable drum include components that can be dangerous for the limbs. This especially concerns the crawler pantograph. Never put your fingers in the pantograph mechanism.
  • Page 15 CamBoss User´s Manual Warning! Operator of the equipment is responsible for proper waste disposal! When assembling components containing threads use silicon vaseline and appropriate seal to ensure the best possible sealing. Be careful when tightening threads and don´t use excessive force to...

  • Page 16: Description Of The Product

    8. Localizing sonde for crawlers / cameras 3.2 Application and equipment Thanks to extensive accessories and additional equipment, The CamBoss inspection system can be used in sewers and piping of an internal diameter from DN 50 to ca DN 1000. For a diameter up to DN 200, use the push camera with reinforced cable 10 - 80 meters long reeled on a push rod reel, which is designed especially for inspections of service pipes.

  • Page 17: Control Unit

    Figure 4 Head KZ75CB with antenna This head is designed for pipe diameters from (on right) 100 mm a can be used with push rod reel REVI250 or CamBoss types crawlers (BOSS100, BOSS150). Optionally you could mount a special antenna for cornering inside pipe turnings.

  • Page 18: Boss150 Crawler

    The maximum speed of the crawler is 20m/min. The crawler is driven by maintenance-free motors. The CamBoss crawler is equipped with a back camera with its own light source, which gives information on the cable's behavior during reversing.

  • Page 19: Automatic Cable Drum Handcontrol

    CamBoss User´s Manual 3.2.7 Automatic cable drum HANDCONTROL The crawler can be easily inserted in the piping by this controller. It enables travelling of the crawler, releasing and re-winding of the cable from a position close to the shaft. The display shows the covered distance.

  • Page 20: Module For Ovality Measurement Ovltc200A

    CamBoss User´s Manual Warning! Risk of injury. The pantograph and its components can be very hot during operation. Warning! Risk of injury. Never put your fingers in the pantograph mechanism (arms). They can be severed or seriously injured by the movement of the pantograph.

  • Page 21: Localising Transmitter (Sonde)

    (available in I.B.O.S. EU a.s.). The camera is compatible with Figure 14 R250 Axial camera CamBoss, ReBoss10(CB) and REVI control units and REVI250 or REVI350 push rod reels. 3.2.14 REVI100 push camera The camera has an image stabilization circuit, integrated LED light and operates in diameters from 40mm to 100mm.

  • Page 22: Revi250 Push Rod Reel

    Compatible with R250 axial or KZ75CB rotary camera head. Laminated cable up to 80 meters in length is wound manually. This reel is connected to the CamBoss control unit by a special interconnection cable. The reel incorporates an unwinded cable length counter. The distance is evaluated and displayed in the control unit as well as in a video record.

  • Page 23: Installation And Commissioning

    CamBoss User´s Manual 4. Installation and Commissioning 4.1 Preparation of the system The inspection system is first operated during a training by workers of the I.B.O.S. EU a.s. Company. In small diameters, the inspection is done by R250 axial camera or KZ75CB rotary camera.
  • Page 24 CamBoss User´s Manual Figure 19 R250 camera centering part selection and assembly When assembling components containing threads use silicon vaseline and appropriate seal to ensure the best possible sealing. Be careful when tightening threads and don´t use unnecessary force to avoid pulling-down its...
  • Page 25 CamBoss User´s Manual Table 3 R250 Ring type centering part assembly 1 – body 2 – fixing bolt Table 4 R250 Roller type centering part assembly 1 – body 2- fixing bolt 3, 4, 5 - cylinder 1 – body 2 - bolts...
  • Page 26 CamBoss User´s Manual Table 5 KZ75 camera centering parts, flexible spacer and antenna Flexible spacer DN100 DN150 Antenna (for turning) (bended pipes) When assembling components containing threads use silicon vaseline and appropriate seal to ensure the best possible sealing. Be careful when tightening threads and don´t use unnecessary force to avoid pulling-down its...

  • Page 27: Supplies And Connectors

    DN100 4.2 Supplies and connectors The CamBoss system is powered by AC voltage 110 to 240V 50/60 Hz. An electric generator can be used if necessary. In this case, only a generator designed for the electronics and computers can be used. This type of generator has a converter on the output, which ensures supply with filtered voltage and is protected against overvoltage.

  • Page 28: Control Unit Side Panel

    CamBoss User´s Manual 4.2.1 Control unit side panel Internet connection LAN connector Connector for interconnection cable (NAVI/REVI/MN200 cable drums) Control unit main power switch Mains connector (110 – 240 V AC / 50 – 60Hz) Figure 20 Connectors of the control unit The supply voltage is conducted to the cable drum and control unit by a power cable, which is included in the system.

  • Page 29: Control Unit Connections

    CamBoss User´s Manual 4.2.2 Control unit connections REVI100 REVI250 REVI350 MN200 CamBoss NAVI Figure 21 Connectors of the control unit diagram The control unit has input CINCH connector for connecting external camera and another output CINCH connector to plug external TV monitor or recording device. Figure 21 shows how cable drums or push rod reels can be connected to control unit.

  • Page 30: Connectors Of The Crawlers

    CamBoss User´s Manual 110-240V/50-60Hz Figure 22 NAVI cable drum component connection 4.2.4 Connectors of the crawlers This crawlers have two connectors. The back one is for the cable drum cable. It is waterproof only if the cable is connected. The front side of the crawler has a connector for a camera head or a pantograph (only BOSS150 type).

  • Page 31: Inserting The Crawler Into The Shaft

    CamBoss User´s Manual Always be sure that the crawler and the cable drum can´t fall to the shaft and hurt anybody. When turning the system ON and operating do not let the system parts stand too close to a shaft edge and prevent unintentional controls.

  • Page 32: Protectioning The Drum Cable

    CamBoss User´s Manual 4.5 Protectioning the drum cable It is necessary to protect the cable against rubbing on sharp edged on the top and the bottom of the shaft by specially designed fairleads - Figure 26 (available at I.B.O.S. EU a.s.). If such equipment is unavailable, provide this protection in another way.
  • Page 33 CamBoss User´s Manual Table 8 BOSS150 wheels overview BOSS150 DN120 DN150 DN225 DN300 DN400 Gum (d90) Gum (d100) d120 d150 d200* Main Middle Main Middle Ceramic d90 Ceramic d100 Spacing shims HARD SOFT HARD SOFT Ceramic + gum (d100) *mounted on DN400 chassis...
  • Page 34 CamBoss User´s Manual Table 9 Crawler Boss150 wheel size selection according to pipe diameter small wheels 100mm small wheels 100mm + pantograph medium wheels 150mm + pantograph + medium wheels 150mm + pantograph spacing shims DN400 chassis + wheels 200mm +...
  • Page 35 CamBoss User´s Manual Table 10 BOSS100 wheels overview BOSS100 DN150 DN100 (d65) DN150 (d100) DN200 (d120) Ceramic + gum (d100) Main MIddle...

  • Page 36: Operating The System

    CamBoss User´s Manual 5. Operating the system 5.1 Introduction All essential control elements are located on the control unit´s panel. There are two joysticks for camera and crawler movement, two potentiometers, which control camera and pantagraph lighting intensity. When the system is started, the connected components are immediately detected.
  • Page 37 CamBoss User´s Manual Table 11 LCD panel buttons description Function Function Pantograph - up Menu items list / decrease value Reset camera position to zero Pantograph - down position Enter main menu / return to previous Automatic clockwise piping joint...
  • Page 38 CamBoss User´s Manual Table 12 Control unit buttons description Function Function 22,23,24 No user function Permit / forbid crawler movement Speed / Power LED bargraph Cruise control Increase crawler speed Permit / forbid cable movement Decrease crawler speed Table 13 Control unit joysticks and sockets...

  • Page 39: Control Of The Camera Head

    CamBoss User´s Manual 5.2 Control of the camera head Rotation, pan, zoom, focus Use the right joystick, part 20, Table 13 , to control the camera head. It controls the pan and rotation. Rotation is active while moving the joystick up / down. Pan is active while moving the joystick to left / right.

  • Page 40: Operating Crawlers

    CamBoss User´s Manual 5.3 Operating crawlers Move the left joystick up / down to move the crawler forward / backward. The cable is wound and unwound according to the speed of the crawler. To turn the joystick button must be pressed down.

  • Page 41: Setting The System Up By Menu

    CamBoss User´s Manual 5.5 Setting the system up by menu Main menu is entered by pressing the [MENU] button. To list menu items use following buttons: [MENU] – enter main menu / return to previous menu [MOD] – enter submenu / confirm selection [+] –...

  • Page 42: Advanced System Settings

    CamBoss User´s Manual 5.5.2 Advanced system settings Turning off the protection on low pressure This protection is factory set as active and serves to block the operation of the components when inside pressures levels do not prevent moisture / water passing inside related components.
  • Page 43 CamBoss User´s Manual Calibration of crawler gradient / camber Crawler gradient and camber are factory set to optimum. In the sub-menu of respective crawler: e.g. BOSS150 → Re-calibrate → Gradient (to calibrate gradient) or Camber (to calibrate camber). The calibration is recommended to perform on a completely narrow surface.
  • Page 44 CamBoss User´s Manual b) Set light parameters for optimal image visibilty Camera White balance Auto Indoor Outdoor Custom To red Down Reset To blue Down Reset c) Adjust the camera chip exposition parameters: Kamera Exposure Auto Brightness Down Reset Iris...
  • Page 45 CamBoss User´s Manual d) Save actual settings to memory: Head KZ90CB Camera Memory Current Save Load Reset Mode 0 Save Load Reset Mode 1 Save Load Reset Two settings are are possible to save – Mode 0, Mode 1. Use reset to empty the memory and revert to factory setting.

  • Page 46: Other System Features

    You can use special detector (available at I.B.O.S. EU a.s.) to localize the axial camera / crawler. Measuring the travelled distance CamBoss system is equipped with a counter of covered distance / unwinded rod located on the cable drum. The measured value is displayed on the control panel display. You can change this value by buttons [+], [-] and [0], buttons 5, 9 and 10, Table 11.

  • Page 47: Pc Control

    CamBoss User´s Manual LED display – meters counter /crawler speed Slow down / speed up Crawler movement On/Off Crawler movement front / back Cable drum On/Off Winch up/down (wind / unwind arm Emergency reel) STOP Figure 27 Hand control buttons description 5.7 PC control...

  • Page 48: Maintenance Of The System

    CamBoss User´s Manual 6. Maintenance of the System Maintenance of the system is very important, because it increases service life and reduces operating costs. Do not neglect or underestimate it. 6.1 Maintenance of the pressurized components All parts should be cleaned regularly. Remove potential coarse dirt after each inspection.

  • Page 49: Removal Of Defects

    CamBoss User´s Manual 6.3 Removal of defects The system is protected by many fuses. If any fuse blow turn the system off, unplug from supply and secure against plug-in. You could try to change broken fuse. Never use other type of fuse than was the original value.

  • Page 50: Replacement Of The Camera's Front Glass

    CamBoss User´s Manual Table 14 Faults table Defect Possible cause Remedy The internal power section for The system turns off Provide cooling. Check that the spontaneously during crawler and lighting is venting holes are unobstructed. operation overheated Bad contact in the camera...

  • Page 51: Cleaning

     send the components carefully packed in the original packaging if possible  add an accurate description of the defect 6.7 Decommissioning and disposal For decommissioning, disposal and reuse of the CamBoss system the applicable national regulations must be followed. Please contact the relevant environmental protection office or authorized department for more information (Laws and regulations concerning waste, special refuse and residual materials).

  • Page 52: Technical Data

    CamBoss User´s Manual 7. Technical data Control unit specifications Mobile integrated 15" LCD color monitor, PC or Features DVD-recorder (optional) 3 x USB 1 x cable drum / push rod reel Interface 1 x supply 110 – 240 V AC...
  • Page 53 CamBoss User´s Manual KZ75 rotary camera head ¼" color CCD image sensor, 317.612 pix resolution / 400 horizontal screen lines, LED lights, 68° view angle, “slip-ring“ connector, pressure sensing, additional centering for larger pipes Sensitivity [lux] Max. ambient <1 pressure [bar] 110 ×...
  • Page 54 • laminated rod with 10 to 20m length home piping up to DN100. It is • interconnection cable to control unit with compatible with CamBoss, ReBoss10 3m length and REVI control units. • for DN40 up to DN100 •...
  • Page 55 CamBoss User´s Manual MN200 cable drum For BOSS type crawler, light-weighted cable up to 200m 750 × 550 × 350 mm Dimensions [mm] 29.53 × 21.65 × 13.78" 0 to 40 °C Temperature 32 to 104 °F 23 kg Weight 50.7 lbs.
  • Page 56 CamBoss User´s Manual BOSS100 crawler Drive 2 x EC-MAX motor – MaxonMotor pan & gradient sensor Features localizing transmitter - sonde (optional) Nominal diameter of the piping DN 100 - DN 300 Ambient pressure [bar] < 1 max. / inspection depth to 10 m of water column...

  • Page 57: Warranty

    CamBoss User´s Manual 8. Warranty Scope of warranty We provide a 12 month warranty for the I.B.O.S. EU a.s. product, which has been produced and tested according to our manufacturing and quality standards. We will remove defects provably caused by a flaw of material or manufacture free of charge during the warranty period.

  • Page 58: Declaration Of Conformity And Rohs2

    CamBoss User´s Manual 9. Declaration of conformity and RoHS2...
  • Page 59 CamBoss User´s Manual We wish you much success and pleasure in working with your new I.B.O.S. EU a.s. inspection system. We will gladly answer any potential questions. We will also appreciate any suggestions for improvement or other responses. I.B.O.S. EU a.s.

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