Copyright Notice

This material is copyright protected. No material may be reproduced or transmitted in any form or by any means for any purpose without expressed written consent of VideoRay LLC.

Copyright © 2019, VideoRay LLC - The Global Leader in Micro-ROV Technology

Table of Contents

Copyright Table of Contents About this Document How to Get Help Before Contacting Support Welcome Meet Your Instructor Goal and Course Objectives Agenda Support Infrastructure Navy Repair Levels VideoRay Support Organization VideoRay Support Channels VideoRay Factory Service Before We Begin Diagnostics Overview Diagnostic Process Diagnostic Aids Diagnostic Method Typical Problem Categories Typical Problem Causes System Overview Theory of Operation Modules Power Module Communications Module Communications Module Ports Thruster Module AHRS Module Camera Module LED Light Module Vehicle Architecture Diagnostic Interfaces Control Panel Computer ROV Power Overlay Communications Overlay Primary Interface Vehicle Configuration Vehicle Network Vehicle Sensors Positioning Advanced Diagnostics Signal View Process View Alarm View Signal Mapper Tuning Configuration Files Log Files Other Software Tools Video Interface Video Control Video Configure Video Network Video Update DVL Settings DVL Measurement DVL Display Data Sonar Application Symptom Recognition and Evaluation Start Up Diagnostics Tether Diagnostics Hand Controller Diagnostics ROV Modules Diagnostics Control Diagnostics Accessories Diagnostics Sonar Diagnostics DVL Diagnostics GPS Diagnostics Manipulator Diagnostics Module Architecture Module Configuration Module Programming

About this Document

Online Manual

This Quick Start Guide is a subset of the full version of this manual, which is available on the MSS control panel and online in the following formats:

• Installed on the MSS control panel at: mss_diagnostics for viewing the HMTL locally.

• http://download.videoray.com/mss_diagnostics for viewing the HMTL online.

• http://download.videoray.com/documentation/mss_diagnostics/pdf/videoray_doc_mss_diagnostics.pdf for viewing the PDF online.

• http://download.videoray.com/documentation/mss_diagnostics/zip/videoray_doc_mss_diagnostics.exe for downloading the HTML and PDF files.

Document Conventions

Several symbols are used throughout this documentation to add emphasis and to assist in relocating important information. The following table describes these symbols and their uses.

SYMBOL	DESCRIPTION
	The Danger icon is used to indicate there is a potential risk of personal injury or death. Extra care should be taken to understand the risks, and all personnel should exercise caution. It may also be appropriate to warn others in the immediate vicinity.
	The Caution icon is used to indicate there is a potential risk of damage to the equipment or surrounding property. Personnel should receive training in the appropriate procedures before attempting to operate or maintain the equipment.
	The Do Not icon is used to indicate that an action or activity should NOT be performed.
	The Note icon is used to highlight a specific detail or point of information.
	The Tip icon is used to highlight a suggestion or recommendation.

Beyond this Document

There is no substitute for experience and/or training, especially with respect to the real purpose for which you plan to use this equipment. We encourage you to explore options beyond the scope of these materials to expand your knowledge and skills necessary to support your applications. In addition to this documentation, VideoRay offers training and technical support and hosts a general user discussion forum and user image gallery.

We also realize that collectively, users of our products spend considerably more time operating our systems than we do ourselves. Users also encounter more diverse operating environments across an extremely broad range of applications. We highly value this vast experience base, and invite and encourage you to share your experiences and suggestions with us. Please feel free to contact us by any of the methods listed below.

Quality Commitment

VideoRay strives to design, manufacture, deliver and support the highest quality products and services, including this documentation. We have made every effort to ensure that this documentation is accurate and provides you with the most up-to-date information.

If you find any errors in this documentation or have suggestions for improvements, each page contains a "Help us improve this document" feedback link in the left margin (you must be connected to the Internet to use this link).

Address
VideoRay LLC 212 East High Street Pottstown, PA 19464 USA
Email
info@videoray.com	General Information and Sales
support@videoray.com	Technical Support
Telephone
+1 610-458-3000	Office
+1 610-458-3010	Fax

Disclaimer

This document is deemed accurate at the time of its writing, however it is not a legal contract and the information contained herein should not be construed to represent any form of commitment. This document as well as the associated products and services are subject to change without notice.

How to Get Help

Help for your MSS is available through several channels.

All Hours Self-Service / Crowd-Source Tools

Operator's Manuals and Standard Operating Procedures	www.videoray.com/support/manuals.html
Software Downloads	www.videoray.com/support/downloads.html
Frequently Asked Questions	www.rovfaq.com
ROV User Forum	www.rovinfo.com

Global Support

Email	support@videoray.com
Phone	+1 610-458-3000 (select option 1)
Skype	videoray.support (by appointment )
Remote Sessions	www.videoray.com/support/remote-support.html (by appointment )

Regional Support

VideoRay Authorized Dealers and Service Centers

www.videoray.com/dealer.html

Training

Operator Training	www.videoray.com/learn-more/training.html
Advanced Maintenance Training	http://www.videoray.com/learn-more/training/advanced-maintenance-training.html

Operational Strategies and Tactics Support

If you need help understanding how to apply your system to a specific project, contact VideoRay or you local VideoRay dealer. We can provide guidance or help you find a certified consultant.

Before Contacting Support

Welcome

Meet Your Instructors

Tom Glebas

Mark Fleming

Goal

• Maximize operational up-time of the VideoRay Defender in the field.

Course Objectives

• Best practices for equipment longevity

• Recognize symptoms and identify component failures

• Perform repair procedures

Agenda

• Day 1
  • Support Infrastructure

  • Diagnostics and Repair Overview

  • ROV System Orientation

  • ROV System Theory of Operation

  • Built-in Diagnostic Aids

  • ROV Subsystems Diagnostics

  • Module Programming

• Day 2
  • Diagnostic Exercises

Support Infrastructure

• Your success is our success!
  • We make capable, dependable products

  • We strive to fix problems quickly

  • We organize and operate to achieve our goals

  • We adapt

Navy Repair Levels

• Field - Immediate demand / minimal tools and spares
  • Basic Operator Course

• Intermediate - Less urgent / better capabilities
  • Advanced Maintenance Course

• Manufacturer - Full service capabilities

VideoRay Support Organization

• Customer Care Umbrella

• Customer Service

• Technical Support

• Repairs

• VideoRay Authorized Service Centers

VideoRay Remote Support Channels

• Email

• Phone

• Skype, WhatsApp, etc.

• Remote login

How to Get Help

Remote Support and Factory Service

1. Identify yourself and your equipment

2. Describe the symptoms

3. Work together to remotely resolve the problem

4. Receive an RMA

5. Ship the equipment (with form)

6. $100 diagnosis (flat fee)

7. Receive a repair quote

8. Approve (or decline) the repair quote

9. Pay for and receive the repaired equipment

Before We Begin

• VideoRay warranty and user maintenance policy

• Best practices
  • RTFM

  • Equipment care standards

  • Well equipped shop

  • Special materials handling

Diagnostics Overview

"An ounce of prevention is worth a pound of cure."
    - Ben Franklin -

• Allow only trained operators and technicians

• Learn about and use available resources

• Follow pre- and post dive procedures using checklists

• Follow periodic maintenance schedule

• "Drive it like you stole own it"

Diagnostic Process

1. Suspect a problem

2. Verify the problem

3. Compare the problem to known problems

4. Isolate the problem
   • Seek help if needed

5. Solve the problem
   • Seek help if needed

6. Verify the solution

Diagnostic Aids

• Knowledge and expertise

• Reference documents

• Hardware status indicators

• Software alarms

• Software displays

• Software tools

• Recordings and system log files

• Shop tools

• VideoRay Support

Diagnostic Method

• Understand the correct operation / behavior

• Use verified information

• Suspect the obvious first

• Reset to a known state

• "Listen" to the symptoms

• Talk it out

• Divide and conquer

• One step at a time

• Use diagnostic aids

• Take notes

Typical Problem Categories

• Power

• Communications / Telemetry

• Mechanical

• Software

• User expectations

Typical Problem Causes

• USER ERROR

• Mechanical failure

• Electrical component failure

• Short or open conductor

• Poor ground

• Environmental factors

System Overview

Theory of Operation

• Power
  • Universal input (100-200 V AC 50, 60 Hz)

  • 400 V DC to ROV

  • Internal Bus Voltages (24, 19 12, 5 V DC)

• Communications
  • Ethernet

  • RS-485

• Sensor Data
  • Video

  • Spatial data (Heading, Attitude, 3D Location*)

  • Temperature

  • Sonar

  • Other options available

• Control
  • Manual (joystick)

  • Pilot assist (dynamic positioning)

  • Full autonomy (course and orbit)

  • Manipulator

Modules Overview

• Power

• Communications

• AHRS (Attitude, Heading Reference System with Depth)

• Thrusters

• Camera(s)

• LED Lights

Power Module

Communications Module

Communications Module Ports

Thruster Module

AHRS Module

Camera Module

LED Light Module

Architecture - Module Connectivity

Diagnostic Interfaces

• Status indicator LEDs

• Operating system Level

• Application alarms and displays

• Browser and application interfaces

• Troubleshooting trees (this manual, interactive example)

Control Panel

• Power indicators LEDs
  • AC input power

  • ROV 400 V DC

• Line Insulation Monitor (Ohms)

• Line Insulation Monitor (Alarms)

• Monitor

Computer

• Boot Messages

• Software error messages

• Software diagnostic tools

ROV

• Modules with indicators LEDs
  • Power Module

  • Communications Module

  • LED Module

• Camera will center on startup

• Thrusters can be configured to play a startup tune

Power Module Overlay

Communications Module Overlay

Primary Software Interface

• Video

• Sonar

• Software alarms

• DVL lock loss

• Diagnostics views
  • Main Diagnostics

  • "Super secret" Alt-3 Diagnostics

Vehicle Configuration

Vehicle Network

Vehicle Sensors

Positioning

Advanced Diagnostics

Some of the settings in this area can result in making the system inoperable or even dangerous to operate!

Proceed with Caution!

Alt-3

Signal View

Process View

Alarm View

Signal Mapper

Tuning

Configuration Files

There is only one Greensea core codebase. Execution for a specific vehicle is controlled by configuration files.

• gss_config folder (link to one of the following)

• gss_defender

• gss_config-pro5

• gss_config-nextModel?

• Text files - gedit

Log Files

• Recorded only while Record (Logging) is active

• Stored in gss_logs (unless changed by user)

• Can be replayed

• CSV export is supported

• Generally reserved for Greensea to analyze

• Note - Sonar is a video, not raw data
  • Sonar application can be used to record raw data

Other Software Tools

• Browser Interface for Video

• Browser Interface for DVL

• Native Application for Sonar

Video Interface - View

http://192.168.1.11 (Stream B for view)

Video Interface - Control

http://192.168.1.11 (Stream A)

Video Interface - Configure

http://192.168.1.11 (Stream A)

Video Network

http://192.168.1.11

Video Update

http://192.168.1.11 (Stream A)

DVL Interface - Instrument Settings

http://192.168.1.50

DVL Interface - Measurement

http://192.168.1.50

DVL Interface - Display Data

http://192.168.1.50

Native Sonar Application

• Windows Only - run on a separate computer

• Must "Stop" sonar in GSS

• http://192.168.1.45

Symptom Recognition and Evaluation

The following sections are based on common sense application, logical analysis of system architecture and manufacturing processes, and historical data from technical support cases.

There may be additional symptoms or root causes not listed here.

Start Up Diagnostics

Problems are most frequently found during start up. Your pre-dive check should catch these problems. Your post dive check will provide a baseline for the next dive and may catch problems that can be solved before the system is needed urgently.

If the system does not start or respond correctly, eliminate the tether from the set up and test again.

Issue	Items to Check	Status / Resolution
No Power	Is the AC power source working?	Fix or change the AC power source.
	Is the GFCI tripped?	Reset the GFCI.
	Check that all cables are plugged in.	Plug in any loose cables.
	Are the power switches on?	Turn on the power switch(es).
No Display	Monitor cable connected	Connect monitor c able
	Monitor cable damaged	Repair or replace cable
	Check brightness	Adjust brightness
	Check for Computer boot	restart the system
No Desktop	"GRUB" Menu visible	Select UBUNTU to boot
No ROV Power	Check ROV power switch and 400 V indicator	Turn on ROV power switch
	Check tether	Fix or replace tether
No ROV control/telemetry/etc.	Check tether	Fix or replace tether
	Run vr_enum	If vr_enum reports modules present, problem is in the Ethernet. If vr_enum does not report modules present, power, telemtry or ROV system failure suspected.

Tether Diagnostics

Tether problems include physical faults, which may be visual or not, and can occur in the connectors or midspan. Tether problems can cause a range of system symptoms including no power or communications, which can result in partial to complete system failure to operate.

The Tether is an easy component to remove from the system to isolate the source of the problem.

Isolate the problem to the tether before performing these actions.

Issue	Items to Check	Status / Resolution
Loss of power or telemetry, or LIM trip	Check connectors for damage, corrosion or wear.	Clean or repair connector.
	Use a meter to check for open on each pin end to end.	Repair tether.
	Use a meter to check for shorts on each pin to all other pints.	Repair tether.

Hand Controller Diagnostics

Hand controller consists of switches, analog knobs, an interface board and cables. Problems include complete or partial loss of function, and incorrect response.

Issue	Items to Check	Status / Resolution
No function	Check that the cable is plugged in.	Plug in the cable.
	Verify whether the controller works in a Windows computer.	If not, repair or replace the controller. If it does work, suspect an interface or application problem.
Partial function	Check the response in the Vehicle configuration diagnostics.	Isolate the problem and repair or replace the controller, or change the signal map to allow the function to be used.
Improper function	Verify it is being held correctly.	Hold the controller correctly.
	Check the Signal Mapper Interface	Correct the signal map.

ROV Modules Diagnostics

All modules include a cable and require power and telemetry

• Looks for signs of physical damage

• Check the status indicators

• Check the source of power

• Check the Vehicle Network diagnostics

• Use vr_debug to test

Control Diagnostics

Control problems are usually manifested as an inability to control the ROV in the desired motions. This can be due to system problems or environmental factors such as the ROV being stuck or running out of tether.

Control problems can also arise when a system component has been improperly installed or configured or fails during operations. Examples include:

• Improperly installed propeller
• Fouled thruster
• Faulty or improperly configured thruster
• Faulty or improperly configured hand controller
• faulty or improperly configured DVL

Control problems are divided into manual flight, auto pilot modes like Auto Heading or Auto Depth, or fully autonomous dynamic positioning, course following and orbiting.

For manual flight, check the hand controller and the thrusters.

For dynamic positioning, first verify manual flight then check the control interfaces are selected properly, the verify DVL lock.

Accessories Diagnostics

Accessories include the Sonar, DVL, GPS and Manipulator. Each of these devices is connected to the Communications Module. Problems with the communications module may affect any one of these devices or all of them.

Sonar Diagnostics

Sonar problems include loss of power, signal failure, or poor image quality that makes interpreting the issue difficult or impossible. Poor image quality can result from an intrinsic problem with the ROV, sonar, improper settings or environmental factors.

Sonar problems usually do not affect the system, with the exception of sonar relative orbiting. Sonar problems may prevent the operator from being able to navigate easily or locate and identify targets of interest from a distance.

Sonar diagnostic tools include the Greensea Advanced Diagnostics Panel (Process View tab) and using the native sonar application* to connect to the sonar directly (192.168.1.45) and a multimeter.
* - Windows computer with Oculus software required.

Diagnostic Table

If unable to resolve a problem, contact VideoRay Support and report efforts and results.

Issue	Items to Check	Status / Resolution
Lack of power	Check Sonar cable.	Reconnect or replace cable.
	Check power from communications module port.	See communications port connector pinout.
No Image	Try to ping the sonar IP (192.168.1.45)	Sonar should respond to pings
	Check Greensea Advanced Diagnostics panel Process View, openfls_oculus.	Verify operation indicated by the green Running indicator.
Inability to locate targets	Too close or too far from target.	Move the ROV to within specified range (0.5 m to 100 m).
	Target outside of range setting.	Adjust the sonar range to include the target.
Poor Image quality	Check for physical obstructions.	Clear obstruction.
	Check for cavitation bubbles.	Dive the ROV and move forward to clear bubbles Reduce thruster action while on the surface to reduce cavitation.
	Check image quality settings.	Adjust settings to improve image quality.
	Check the native sonar application.	How does the image compare with Greensea's display?
	Check for environmental interference.	Some target types, particularly heavy vegetation may reduce signal quality.
	Check for environmental interference.	Make sure there are no acoustic sources nearby.

DVL Diagnostics

DVL problems include loss of power, signal failure, or poor data quality that prevents a DVL from achieving an altitude and bottom lock. Poor data quality can result from an intrinsic problem with the ROV, DVL, improper settings or environmental factors.

DVL problems can lead to other system issues such as the inability to use Auto Depth or Navigation for tracking or dynamic positioning.

DVL diagnostic tools include the HDVL hardware LED status indicator, Greensea Altitude display, DVL Lock Indicator and Alarm, Diagnostics Panel (Vehicle Sensors tab), Advanced Diagnostics Panel (Process View tab) and the browser interface (192.168.1.50), flighthack tools and a multimeter.

Diagnostic Table

If unable to resolve a problem, contact VideoRay Support and report efforts and results.

Issue	Items to Check	Status / Resolution
Lack of power	Check DVL cable.	Reconnect or replace cable.
	Check Hardware status LED.	Reconnect or replace cable.
	Check power from communications module port.	See communications port connector pinout.
No signal input	Check Greensea diagnostics panel.	Timestamp should be incrementing. If not, stop Greensea, turn off the ROV, turn on the ROV and restart Greensea.
	Check DVL browser interface.	Interface should open and live data appear.
	Check Greensea Advanced Diagnostics panel Process View, nortek_socat_bridge.	Click on checkbox for nortek_socat_bridge and check data stream.
Navigation Alarm or No Altitude or Bottom Lock	Too low or two high.	Move the ROV to within specified range (0.2 m to 75* m). * Currently limited to about 30 m.
	Check for physical obstructions.	Clear obstruction.
	Check for cavitation bubbles.	Dive the ROV and move forward to clear bubbles Reduce thruster action while on the surface to reduce cavitation.
	Check browser interface (data view).	Verify good data on all four beams.
	Check browser interface (Bottom Track Data).	Set Bottom Track Data to "DF21 DVL BT Binary".
	Check for environmental interference.	Some bottom types, particularly heavy vegetation may reduce signal quality. Move the ROV to a new location.
	Check for environmental interference.	Make sure there are no acoustic sources nearby.
Incorrect tracking direction	Check DVL orientation setting in the DVL browser interface.	Set DVL orientation to 180 degrees.

GPS Diagnostics

GPS problems include loss of power or signal failure or poor GPS data reception that prevents the GPS from acquiring a fix. Signal failure can result from an intrinsic problem with the ROV, GPS or connecting it to the wrong port on the communications module. Poor reception can result from being submerged or having overhead obstructions.

GPS problems can lead to other system issues such as the inability to achieve a starting location for navigation purposes.

GPS diagnostic tools include the the GPS hardware LED status indicators, Greensea Diagnostics Panel (Positioning), Greensea Advanced Diagnostics Panel (Process View tab), flighthack tools and a multimeter.

Diagnostic Table

If unable to resolve a problem, contact VideoRay Support and report efforts and results.

Issue	Items to Check	Status / Resolution
Lack of power	Check GPS cable.	Reconnect or replace cable.
	Check power from communications module port.	See communications port connector pinout.
No GPS Data	Check that the Greensea Diagnostics Panel (Position)	Check the timestamp for connectivity
	Check that the GPS is connected to the correct port on the communications module.	Connect the GPS to the correct port or change the port configuration on the communications module.
	Check Greensea Advanced Diagnostics panel Process View, rov_gps.	Click on checkbox for rov_gps and check data stream.
No GPS Lock or wandering position	If data streaming is functioning, allow ample time for the GPS to resolve the position.	Wait for the GPS signal to stabilize. This may take several minutes for the GPS to download the satellite ephemeris data.
	Check Greensea Advanced Diagnostics panel Process View, rov_gps.	Click on checkbox for rov_gps and check data stream for the GLL string.
	Check the location of the GPS - it cannot be submerged (even on the surface can result in reduced performance). Additionally, overhead obstructions can interfere with getting a GPS lock.	Move the GPS to a position above the water surface and free from overhead obstructions.

Manipulator Diagnostics

Manipulator problems include loss of power or control signal failure. Control signal failure can result from an intrinsic problem with the ROV, hand controller, manipulator or connecting it to the wrong port on the communications module.

Manipulator problems usually do not affect the system. Sonar problems may prevent the operator from being able to place, manipulate or retrieve objects.

Manipulator diagnostic tools include the Greensea Diagnostics Panel (Vehicle Configuration), Greensea Advanced Diagnostics Panel (Process View tab) and using the native manipulator application to connect to the manipulator, flighthack tools and a multimeter.

Diagnostic Table

If unable to resolve a problem, contact VideoRay Support and report efforts and results.

Issue	Items to Check	Status / Resolution
Lack of power	Check Manipulator cable.	Reconnect or replace cable.
	Check power from communications module port.	See communications port connector pinout.
No Manipulator response	Check that the Manipulator is connected to the correct port on the communications module.	Connect the manipulator to the correct port or change the port configuration on the communications module.
	Check the manipulator response in Greensea Diagnostics Panel (Vehicle Configuration tab).	Ensure the button and know response to input is as expected.
	Check Greensea Advanced Diagnostics panel Process View, manip.	Click on checkbox for manip and check data stream.
	Check the native manipulator application (~/flighthack/vr_engage_manip_rotating.py.	If the native application works the problem may be the Greensea software. If it does not work, the problem may be the manipulator.
Reduced manipulator response	Check if the jaws are fully opened or closed.	A fully open or closed manipulator puts axial stress and may reduce rotation rate or stop rotation. If this is the case, slightly open or close the manipulator jaws to avoid fully open or closed position The manipulator orientation should be set while the jaws are empty and not fully open or closed.

Module Architecture

• Cable Pinout

• Firmware

• Configuration
  • Flighthack Programming / Debugging Tools

Module Configuration

Module Programming

• vr_refresh - Refresh the firmware for a module

• vr_enum - Enumerate (list) the connected modules

• vr_setid - Set the Node ID and Group ID for a module

• vr_debug_putty.py - Debug and/or configure a module

• vr_create_virtport_all.sh - Create virtual ports for modules connected to the Communications module

Automated and visually oriented interface improvements are pending.