Requirements

• A CrunchCam production image (naming convention: "CrunchCam_Production_v_[major version #]_[minor version #]_[revision #].img").
• A Windows 10 computer with a micro SD card port OR a USB micro SD card adapter.
• A new 16 gb micro SD card
• Raspberry Pi 4
• Raspberry Pi 4 PoE Hat
• Raspberry Pi 4 Camera
• Basler Dart Camera (optional)

Download Win32 Disk Imager Application

Download the Win32 Disk Imager application from sourceforge: https://sourceforge.net/projects/win32diskimager/

Run .exe file you just downloaded from sourceforge and follow the install wizard to install Win32 Disk Imager on your computer.

Flash the CrunchCam Production Image

Insert the micro SD card into the Windows computer.

Download the latest CrunchCam production image file from the CrunchFTP FTP server: \\PiCrunchFTP\CrunchFTP\Beam Cruncher Production\CrunchCam SD Card Images

Open the Win32 Disk Imager application and select the desired CrunchCam production image file (naming convention: "CrunchCam_Production_v_[major version #]_[minor version #]_[revision #].img").

Select the device letter that matches that of the micro SD card (be sure that you pick the correct drive letter or this could overwrite data on another disk!!!)

Click the "Write" button to begin the flashing process. This will take some time (~20 minutes).

When the flashing process is complete, you will be shown a success message. Close the Win32 Disk Imager Application.

Configure System Files for the New CrunchCam

To configure the system files for the new CrunchCam, navigate to the "Production" directory in the top-level of the CrunchCam github repository on your local machine (if these files are not on your computer yet, you can clone them with the following command: git clone https://github.com/crunchtec/CrunchCam). Note that git must be installed in order to use the previous command.

Right-click the "runSetup.ps1" file in the Production directory and select "Run with PowerShell" from the drop-down menu.

You will now be guided through the rest of the system files configuration by the above script. Be sure to carefully read the instructions!

If everything goes well, you will be presented with the following message: "CrunchCam setup complete. Press any key to exit."

Setup the Raspberry Pi 4 Hardware

First, feed the camera ribbon cable through the thin rectangular slot in the Raspberry Pi 4 PoE hat. Then, connect the camera ribbon cable to the CSI connector on the Raspberry Pi 4.

Next, seat the PoE hat onto the Raspberry Pi 4's pins, taking care not to break the camera cable.

Remove the micro SD card you just flashed from the computer and place it into the micro SD card slot on the bottom of the Raspberry Pi 4.

If included in this order, connect the Basler Dart camera via its USB 3.0 cable to the USB 3.0 port (one of the blue ones) on the Raspberry Pi 4.

The CrunchCam's First Run

Power the CrunchCam by connecting its Ethernet port to a PoE injector port of a PoE port switch. The Raspberry Pi 4 green and red LEDs should power-on and/or blink to indicate that the device is receiving power from the PoE injector.

Allow the CrunchCam to run for 5 minutes before disconnecting. During this first run, the CrunchCam will take care of setting-up all of the files that we configured earlier.

Finally, after the 5 minutes have passed, disconnect the Ethernet cable from the Raspberry Pi 4 and then reconnect the Ethernet cable after a few seconds.

The CrunchCam has now been assigned a unique hostname, static IP address and serial number. Test with the Beam Cruncher system before shipping.

End of procedure