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Baker Hughes Waygate Everest Ca-Zoom HD Operating Instructions Manual

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Everest Ca-Zoom HD
Operating Instructions

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Summary of Contents for Baker Hughes Waygate Everest Ca-Zoom HD

  • Page 1 Everest Ca-Zoom HD Operating Instructions...
  • Page 2 Everest Ca-Zoom HD Page ii 3068-7-0001 Rev. d Version 1.0...
  • Page 3 Everest Ca-Zoom HD Document Information Document reference 1048660.docx Revision Version Item number 3068-7-0001 Created on: 2023-05-02 Last update 2023-08-16 Manufacturer Waygate Technologies Robotics AG (WTR) Technoparkstrasse 1 8005 Zürich Switzerland Telephone +41 44 275 25 75 waygaterobotics_information@bakerhughes.com www.inspection-robotics.com 3068-7-0001 Rev. d Version 1.0 Page iii...

  • Page 5: Table Of Contents

    Everest Ca-Zoom HD Table of contents Safety ........................1-1 Safety references ..................1-1 Symbols used ....................1-2 General safety instructions related to the present device ....1-3 Basic safety instructions ................1-6 Operator responsibilities ................1-6 Reasonably foreseeable misuse .............. 1-9 Limits of the machinery ................
  • Page 6 Everest Ca-Zoom HD Interconnection ......................6-1 Connectors and fittings ................6-1 Connection between camera controller and equipment ..... 6-3 Connection to the main power supply ............ 6-5 System start-up ......................7-1 Ca-Zoom HD software application – camera controls ........... 8-1 Main screen of the Ca-Zoom HD software ..........

  • Page 7: Safety

    Everest Ca-Zoom HD Safety This chapter provides an overview of all the important safety aspects for optimum protection of the personnel as well as safe and trouble-free operation. Failure to observe the operating and safety instructions contained in this operating manual can lead to accidents with damage of equipment or injuries with severe consequences.

  • Page 8: Symbols Used

    Everest Ca-Zoom HD Symbols used The following explanations are intended for personal safety and security against damage to the described system or connected devices. Safety instructions and warnings for the prevention of hazards to life and health of users or maintenance personnel or to prevent damage to property are highlighted in this manual according to the following categories: DANGER: means that death, serious personal injury or material damage will ...

  • Page 9: General Safety Instructions Related To The Present Device

    Everest Ca-Zoom HD General safety instructions related to the present device These operating instructions are intended for the safe operation of this device only. For operation of additional cameras or NDT instruments not described in this manual, please refer to the respective operating manuals. DANGER POTENTIAL EXPLOSIVE ATMOSPHERE Everest Ca-Zoom HD is NOT ATEX compliant or explosion...
  • Page 10 Everest Ca-Zoom HD CAUTION Tripping hazards. The operator must ensure there is enough space in the working area to manipulate and install the camera, the telescopic poles and cables. The operator must secure the equipment with safety lines if required. DANGER ELECTRICAL SHOCK (AC / 48V DC Power adapter to camera controller)
  • Page 11 Everest Ca-Zoom HD CAUTION Cameras comprise STRONG LIGHTS for illumination. Do not look directly into the lights when switched on: temporary blinding might occur. Check nobody can stare at the cameras when the lights are switched on. POWER LEDS It is only permitted to activate lights in an environment where no personnel can stay in the camera field of view.

  • Page 12: Basic Safety Instructions

    Everest Ca-Zoom HD Basic safety instructions Take the required measures before installing the equipment and during the  operation. Avoid any risk of cable interference with persons or objects that can  potentially move. Never tension the cable(s).  Roll up and attach cables with a binder when they are not used. ...
  • Page 13 Everest Ca-Zoom HD  ensures that the personnel handle the system properly, as defined in the manual (take care with magnets, use integrated handles) and apply ergonomic postures. defines the necessary behavioral requirements for the operation of the  system at the site of operation. regularly checks during the entire period of use of the system whether the ...
  • Page 14 Everest Ca-Zoom HD Exposure to hazardous materials such as radiation sources must be  disclosed to Waygate with each re-quest for maintenance, service or support.  Contaminated materials cannot be returned to the manufacturer for disposal. Operator is responsible to implement appropriate procedure to handle, ...

  • Page 15: Reasonably Foreseeable Misuse

    Everest Ca-Zoom HD Reasonably foreseeable misuse Reasonably foreseeable misuse means: Failure to observe all information and directives in the Instruction Manual.  Use for components other than those specified in the contract.  Operating, maintaining and repairing of the machine by non-authorized and ...
  • Page 16 Everest Ca-Zoom HD o Manhole bracket If additional equipment is used, an extended risk analysis must be created.  Page 1-10 3068-7-0001 Rev. d Version 1.0...

  • Page 17: Personal Protective Equipment (Ppe)

    Everest Ca-Zoom HD Personal protective equipment (PPE) Personal protective equipment is used to protect persons from impairment of safety and health at work. During the various kinds of work on and with the system, the personnel must carry personal protective equipment: ...

  • Page 18: Environmental Aspects

    Everest Ca-Zoom HD Environmental aspects NOTICE Environmental hazard due to incorrect handling of environmentally hazardous substances! Incorrect handling of environmentally hazardous substance, especially incorrect waste disposal, can cause considerable environmental damages. The following information regarding the handling of  environmentally hazardous substances and the corresponding waste disposal shall always be observed.

  • Page 19: Product Overview And Functionalities

    Everest Ca-Zoom HD Product overview and functionalities Intended use The Everest Ca-Zoom HD System is used to perform indoor remote visual inspection of pressure vessels and other industrial assets, typically, confined spaces. The cameras are either mounted in a fixed location or manually handled with the use of a pole.

  • Page 20: Ptzhd30 Camera

    Everest Ca-Zoom HD 2.2.1 PTZHD30 Camera Figure 2. PTZHD30 Camera Light emitters Lens and image sensor Laser line emitters, class 1 Valve seal screw Light emitters (1): The integrated lighting ensures optimum illumination of the immediate surroundings. The current LED technology enables high light output with low heat generation.

  • Page 21: Tz1 Camera

    Everest Ca-Zoom HD 2.2.2 TZ1 Camera Figure 3. TZ1 Camera Light emitters Lens and image sensor Laser point emitters, class 1 Light emitters (1): The integrated lighting ensures optimum illumination of the immediate surroundings. The current LED technology enables high light output with low heat generation.

  • Page 22: Pendant

    Everest Ca-Zoom HD 2.2.3 Pendant Figure 4. Pendant Rocker switch to zoom Video record button in/out Pan & Tilt joystick Freeze image button Light buttons Pan & Tilt joystick Touchscreen Capture image button HDMI socket USB Ports Connection to camera controller Page 2-4 3068-7-0001 Rev.

  • Page 23: Manhole Bracket

    Everest Ca-Zoom HD 2.2.4 Manhole bracket Figure 5. Manhole bracket Manhole mounting bracket Pole clamp Ball joint Ball joint clamp 3068-7-0001 Rev. d Version 1.0 Page 2-5...

  • Page 24: Camera Controller

    Everest Ca-Zoom HD 2.2.5 Camera controller Figure 6. Camera controller Ethernet RJ45 jack PTZHD30 camera connector Power button DC power supply connector TZ1 camera connector Pendant connector Page 2-6 3068-7-0001 Rev. d Version 1.0...

  • Page 25: Principal Dimensions

    Everest Ca-Zoom HD Principal dimensions 2.3.1 Manhole bracket Figure 7. Dimensions manhole bracket 2.3.2 TZ1 Camera Figure 8. Dimensions TZ1 camera 3068-7-0001 Rev. d Version 1.0 Page 2-7...
  • Page 26 Everest Ca-Zoom HD 2.3.3 PTZHD30 Camera Figure 9. Dimensions PTZHD30 camera Page 2-8 3068-7-0001 Rev. d Version 1.0...

  • Page 27: Tz1 Camera

    Everest Ca-Zoom HD List of parts and accessories Depending on the needs of the customer the following items can be implemented in the Ca-Zoom HD System: Part # Description PTZ-ACC-PNDNT Ca-Zoom HD pendant PTZ-ACC-CASE Ca-Zoom HD system case PTZ-ACC-HD30-HEAD PTZHD30 - inspection camera head PTZ-ACC-POLEMNT PTZHD30 - pole mount for V4010 pole PTZ-ACC-C30M...
  • Page 28 Everest Ca-Zoom HD PTZ-ACC-CORD-UK Mains power cord C13 UK PTZ-ACC-CORD-US Mains power cord C13 US PTZ-ACC-CORD-AUS Mains power cord C13 AUS A typical Ca-Zoom HD Kit comprises these items: Quantity Item Ca-Zoom HD system case Ca-Zoom HD pendant TZ1 inspection camera TZ1 - pole mount for V4010 pole PTZHD30 - inspection camera head PTZHD30 - pole mount for V4010 pole...
  • Page 29 Everest Ca-Zoom HD Figure 10. Typical Ca-Zoom HD System 3068-7-0001 Rev. d Version 1.0 Page 3-3...

  • Page 31: Handling

    Everest Ca-Zoom HD Handling Packing / unpacking WARNING Squeezing hands while manipulating the mounting bracket and the clamps. Sharp edges causing hand injuries. Ensure there is enough room to manipulate the telescopic pole, the camera and the cables. Use suitable protective gloves for mounting bracket and telescopic pole manipulation.

  • Page 33: Assembly

    Everest Ca-Zoom HD Assembly General safety instructions Take the required measures before installing the equipment and during the  operation. Avoid any risk of cable interference with persons or objects that can  potentially move. Never tension the cable(s).  Roll and attach cables with a binder when they are not used.

  • Page 34: Unfold Manhole Bracket

    Everest Ca-Zoom HD Unfold manhole bracket Figure 11. Unfold manhole bracket Unfold the three fastening arms of the manhole bracket one after the other 2. Secure each arm of the manhole bracket with a cotter pin. Page 5-2 3068-7-0001 Rev. d Version 1.0...

  • Page 35: Mount Manhole Bracket

    Everest Ca-Zoom HD Mount manhole bracket Figure 12. Mount manhole bracket Attach the manhole bracket to the manhole using suitable fastening material. Make sure that the mounting is able to support the weight of the camera and the pole. Assemble pole on manhole bracket Figure 13.

  • Page 36: Assemble Pole Adapter On Ptzhd30 Camera

    Everest Ca-Zoom HD Assemble pole adapter on PTZHD30 camera Figure 14. Assemble pole adapter on PTZHD30 camera Slide the pole adapter over the cable of the camera. 2. Place the pole adapter over the corresponding holes in the connector socket of the camera.

  • Page 37: Assemble Ptzhd30 Camera (A) Or Tz1 Camera (B) On Pole

    Everest Ca-Zoom HD Assemble PTZHD30 camera (A) or TZ1 camera (B) on pole Figure 15. Assemble cameras on pole Place the thread of the pole in the corresponding opening of the pole adapter. 2. Screw the pole to the pole adapter. 3068-7-0001 Rev.

  • Page 38: Use Ball Joint To Rotate Pole

    Everest Ca-Zoom HD Use ball joint to rotate pole Figure 16. Use ball joint to rotate pole Loosen the ball joint clamp by slightly loosening the hand screw. Make sure that the pole does not accidentally slip out of the ball joint. 2.

  • Page 39: Interconnection

    Everest Ca-Zoom HD Interconnection Connectors and fittings Push-pull connectors The cylindrical push-pull connectors include a self-latching system to ease the mate and unmate of the connectors. To connect the cylindrical push-pull connectors:  Line up the red dot on the connector shell with the red index mark on the socket Push the connector in axial direction to engage the latches.
  • Page 40 Everest Ca-Zoom HD CAUTION Plugged connectors and sockets can be progressively damaged if mechanically stressed. Do not pull the cables when connectors are plugged.   Do not put any load (axial or lateral) on the plugged connectors. Do not let long cables hang with their own weight. ...

  • Page 41: Connection Between Camera Controller And Equipment

    Everest Ca-Zoom HD Connection between camera controller and equipment WARNING Squeezing fingers, hands or arms. Secure boxes with safety rope.  3068-7-0001 Rev. d Version 1.0 Page 6-3...
  • Page 42 Everest Ca-Zoom HD Figure 17. Connection of the equipment Pendant PTZHD30 camera To optional display (HDMI) Camera controller TZ1 Camera To DC power supply Page 6-4 3068-7-0001 Rev. d Version 1.0...

  • Page 43: Connection To The Main Power Supply

    Everest Ca-Zoom HD Connection to the main power supply Use the power cord with latched C13 connector provided with the Everest Ca-Zoom HD System to ensure a reasonable protection against dust. If another power cord is used, it must comply with national and international regulations.

  • Page 45: System Start-Up

    Everest Ca-Zoom HD System start-up WARNING Risk of damage to eyes. Do not look directly into the lights when switched on.  Temporary blinding might occur. WARNING Risk of damage to skin. The housing of PTZ or TZ1 cameras becomes hot during operation, in particular, if lights are switched on.

  • Page 47: Ca-Zoom Hd Software Application - Camera Controls

    Everest Ca-Zoom HD Ca-Zoom HD software application – camera controls The Ca-Zoom HD software is explained using PTZHD30 camera as an example. The functionality of the software changes only slightly when switching to TZ1 camera. All important differences are described in (see chapter 8.7). Main screen of the Ca-Zoom HD software Figure 18.
  • Page 48 Everest Ca-Zoom HD No. Button Function Focus Enable or disable the auto focus of the camera with the button “Auto”. Adjust the camera focus manually with the buttons “N / F”. Light intensity Adjust the intensity of the lighting with the buttons “- / +”.
  • Page 49 Everest Ca-Zoom HD No. Button Function Measure Open the measure mode with a set of tools to measure distances and/or areas. Leave the measure mode by tapping the button again. For more details see chapter (8.4). Rotate image Rotate the camera image counterclockwise or clockwise.

  • Page 50: Position

    Everest Ca-Zoom HD No. Button Function Information bar The information bar displays:  the current pan, tilt and zoom of the camera.  the intensity of the lighting. whether the camera picture is rotated or  mirrored. the pressure inside the camera. ...

  • Page 51: Annotation Mode

    Everest Ca-Zoom HD No. Button Function Export Export current position settings to a json file. Position 1-6 Set up to 6 individual camera positions. Zero Return to default camera values:  Pan = 0°/360° Tilt = 0°  Zoom = 1.0 ...
  • Page 52 Everest Ca-Zoom HD No. Button Function Contour Add a contour to the image. To edit the contour:  Tap, hold and drag the contour to move it.  Drag the moving-point-indicator to move the edges of the contour.  Add points to create an n-sided polygon. ...

  • Page 53: Measure

    Everest Ca-Zoom HD Measure No. Button Function Rectangle Add a rectangle to the image.  Edit the rectangle as described in annotation  mode (see chapter 8.3).  Length, width and area of the rectangle will be displayed. Ellipse  Add an ellipse to the image.
  • Page 54 Everest Ca-Zoom HD No. Button Function Textbox Add a textbox to the image.   Edit the textbox as described in annotation mode (see chapter 8.3). Measuring tape Toggle display of measurements on or off. Units Select measurement unit from the dropdown menu. Delete Delete a measurement annotation.

  • Page 55: Camera Setup

    Everest Ca-Zoom HD Camera setup Designation Function Set Pan Zero Angle Add an offset to the pan or tilt value. This can be used Reference to give the camera a new zero point within the object to Set Tilt Zero Angle be examined.
  • Page 56 Everest Ca-Zoom HD Designation Function Toggle on to use the built-in image stabilization of the Image Stabilization camera. Select the white balance settings to correct colors in White Balance correlation to the light source. Select a picture effect to make certain defects more Picture Effect visible.

  • Page 57: Settings

    Everest Ca-Zoom HD Settings Designation Function Use Auto Filenaming Toggle on to use automatic naming of the saved files. Default Save location Select a folder for the default location of the saved files. Show Logo Toggle on to show the logo in the lower left side of the image.

  • Page 58: Differences Using Tz1 Camera

    Everest Ca-Zoom HD Differences using TZ1 camera Figure 19. Differences in the TZ1 screen No. Button Function Spot Adjust the intensity of the spot lighting with the buttons “- / +”. Flood Adjust the intensity of the flood lighting with the buttons “- / +”.
  • Page 59 Everest Ca-Zoom HD No. Button Function Laser Activate two laser points. The two laser points have a fixed distance of 27,5 mm and are used as reference for measurements. Deactivate the laser points by tapping the button again. 3068-7-0001 Rev. d Version 1.0 Page 8-13...

  • Page 61: Measure And Document

    Everest Ca-Zoom HD Measure and document Measure and make annotations With the measurement function, points in the observation environment can be marked, documented and measured. Therefor the Everest Ca-Zoom HD System uses lasers with a fixed distance as reference. PTZHD30 camera: two laser lines with a fixed distance of 22,0 mm. ...

  • Page 62: Take A Screenshots

    Everest Ca-Zoom HD To mark, measure and document use the measure tools as described in (8.4) Take a screenshots There are two ways to take a screenshot: a) Press the “capture image button” (10) on pendant (see chapter 2.2.3). b) Tap “save image” (10) on the touchscreen of the pendant (see chapter 8.1).

  • Page 63: Shutdown

    Everest Ca-Zoom HD Shutdown Do not turn off the camera controller while the operating system is still running. To shut down the system: Tap “close” (7) to exit the software application (see chapter 8.1). 2. Shut down Microsoft Windows. 3. Turn off camera controller (see chapter 2.2.5) with power button (2). 3068-7-0001 Rev.

  • Page 65: Packing

    Everest Ca-Zoom HD Packing 11.1 Disconnection / Disassembly CAUTION Attention to equipment handling (electrical shock or short- circuits) and manipulation (dropping or tipping over). Personnel can be injured, and equipment can be seriously damaged. Disconnect the power supply before disassembly. Use safety gloves.

  • Page 67: Maintenance

    Everest Ca-Zoom HD Maintenance 12.1 Safety instructions DANGER Risk of electric shock in case of damage to cables and equipment. Do not open the sealed board panels of the Control Station, no inside parts require maintenance. DANGER Risk of injury from nuclear radiation Equipment cannot be returned for service once it has been used in a nuclear facility due to contamination.

  • Page 68: 12.2 Maintenance Work And Functional Test

    Everest Ca-Zoom HD 12.2 Maintenance work and functional test NOTICE Regular cleaning, care and maintenance within the intervals described below will ensure efficient operational readiness. All maintenance work must be performed by trained and authorized staff in compliance with the instruction manual, taking all safety instructions into consideration.
  • Page 69 Everest Ca-Zoom HD Figure 21. Accessories Pushbutton cartridge Allen keys Valve adapter Pump with manometer Cartridge housing 3068-7-0001 Rev. d Version 1.0 Page 12-3...
  • Page 70 Everest Ca-Zoom HD Changing the CO cartridge WARNING Danger of icing. If the cartridge is screwed in too slowly, CO gas can escape. Never remove the cartridge with pressure inside Danger of icing in this area. Wear protective gloves and goggles. ...
  • Page 71 Everest Ca-Zoom HD Camera pressurization procedure: Unscrew the black cartridge housing (6), remove the emptied cartridge if necessary and insert a new CO cartridge into the housing. 2. Screw in the cartridge housing including the cartridge until a small resistance is felt. Tighten it in one go, without changing your grip, so that no gas escapes unnecessarily.
  • Page 72 Everest Ca-Zoom HD Figure 24. Pushbutton 6. Press the pushbutton into the pump housing. At best, take the pump in both hands and grasp the cartridge housing with one hand and press the pushbutton with the other palm of your hand. The CO gas flows into the device.
  • Page 73 Everest Ca-Zoom HD Before retightening the valve sealing screw, make sure that the O-ring is clean and lightly greased. The area around the O-ring must not be contaminated. CAUTION Danger of icing in this area. If the cartridge is screwed in too slowly, CO gas can escape.

  • Page 75: Troubleshooting

    Everest Ca-Zoom HD Troubleshooting Problem Cause Remedy The application cannot One or more connectors Check that the find devices on the are not plugged correctly connectors are correctly network latched. A connector does not A pin can be damaged Try another cable, call latch correctly or the connector guiding the Technical Support.

  • Page 77: Disposal

    Everest Ca-Zoom HD Disposal DANGER Risk of injury from nuclear radiation Equipment cannot be returned for service once it has been used in a nuclear facility due to contamination. DANGER Risk of injury by toxic vapors or chemicals Equipment cannot be returned for service once used in a contaminated environment.
  • Page 78 Everest Ca-Zoom HD CAUTION Incorrect or faulty disposal can damage environment! Electronic waste, electronic components, lubricants and other auxiliaries are: Subject to special waste treatment and may only be  disposed of by authorized specialist companies for waste treatment!  Liable to treatment of special refuse and must only be disposed of by authorized specialist companies! Local authorities and waste disposal companies provide information on...

  • Page 79: Technical Support

    Phone: +1-866-243-2638 Customer Support Centers Waygate Technologies China LP 721 Visions Drive Baker Hughes Sensing & Inspection Co., Ltd. Skaneateles, NY 13152 No. 8 Xi hu Road, Wu jin high-tech zone Tel: +1 832-325-4368 Changzhou, Jiang Su 213164 E-mail: China waygate.usa@bakerhughes.com...

  • Page 81: Appendix A Specifications

    Everest Ca-Zoom HD Appendix A Specifications Camera heads PTZ HD30 TZ1 HD Resolution 1920 x 1080 1920 x 1080 Image sensor size 2.38 MP 4.08 MP Zoom 30 x optical (12 x digital) 10 x optical Focal length range 4.3 mm..129 mm 3.3 mm..33 mm Field of view (in air) tele: 2.3°...
  • Page 82 Everest Ca-Zoom HD Camera heads PTZ HD30 TZ1 HD Operating pressure IP68, Waterproof to 50 m IP65 Pressurization max 2.5 bar internal Camera controller & Pendant Weight  Camera controller 1.64 kg  Pendant 2.01 kg Input rating to AC/48V DC power adapter, 100-240 VAC (47-63Hz), 150W Power Processor...

  • Page 83: Appendix B Regulatory Compliance

    Everest Ca-Zoom HD Appendix B Regulatory Compliance European Equipment Classification Group 1, Class A mark on this product indicates it has been tested to and conforms with the provisions noted within the 2014/30/EU Electromagnetic Compatibility Directive. The Everest Ca-Zoom HD system is in conformance with the following standard: EN61326-1.
  • Page 84 Everest Ca-Zoom HD 2) This device must accept any interferences, including interferences that may cause undesired operation of the device. Cet appareil est conforme avec Industrie Canada exempts de licence standard RSS (s). L‘utilisation de ce dispositif est autorisée seulement aux conditions suivantes: 1) il ne doit pas produire de brouillage et 2) l’utilisateur du dispositif doit être prêt à...
  • Page 85 Everest Ca-Zoom HD Legal Note © 2023 Baker Hughes This document may not be copied, redistributed or republished for any reason whatsoever, without the written permission of Waygate Technologies Robotics. 3068-7-0001 Rev. d Version 1.0...

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