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Table of Contents

• Introduction
  • Copyright
  • Language Support
    
  • Table of Contents
  • About this Document
    • Customize this Document
  • How to Get Help
    • Before Contacting Support
• Pro 4 Operator's Manual
• Maintenance Best Practices
  • Well Equipped Shop
  • Basic Equipment Care
  • Special Handling
    • Connectors
    • O-Rings
    • Cartridge Seals
      • Example Cartridge Seals
    • Electronics Components
  • Hull Materials
• Periodic Maintenance
• Diagnostics
  • Start Up
  • Power
  • Communications
  • Control
  • Hand Controller
  • Video
• Reference Documents
  • ROV Schematics
    • Main Hull Assembly
    • Vertical Thruster
    • Termination Block
    • Pressure Sensor
    • Horizontal Thrusters
    • Wire Harness
  • Control Panel Schematics
    • OverView
    • AC Input
    • AC Output
    • 75 V DC LIM
    • 12 V DC LIM
    • 12 V DC Fan
    • Communication
    • Video
    • Spare Pair
    • IP 65 Control Panel
  • Hand Controller Schematics
    • Hand Controller Schematic
  • Quality Control Documents
    • Pre QC
    • Basic Functions QC
    • In-water QC
    • Final QC
  • Accessory Integration
    • Accessory Port
    • Accessories Table
    • PAM
• Removal and Replacement
  • Main Hull
    • Float Block
    • Strain Relief
    • Skid Kit
    • Dome Retaining Rings
    • Front Dome
    • Rear Dome
    • Desiccant Pack
    • Front Hull Ring
    • Rear Hull Ring
    • Pressure Sensor
    • Termination Block
    • Wire Harness
    • Main Hull Tube
  • Horizontal Thrusters
    • Horizontal Propeller
    • Horizontal Cartridge Seal
    • Horizontal Nozzle
    • Horizontal Cone
    • Horizontal Bearing
    • Horizontal Drive Train
    • Horizontal Motor Mount
    • Horizontal Motor
    • Horizontal Thrust Tube
  • Vertical Thruster
    • Vertical Propeller
    • Vertical Thrust Splitter
    • Vertical Cartridge Seal
    • Vertical Thruster Kit
    • Vertical Motor Mount
    • Vertical Motor Adapter
    • Vertical Motor Shield
    • Vertical Motor
  • Lights
    • Light Dome
    • LED Light Module
    • LED Light Reflector Set
    • LED Light Board
    • LED Light Mount
  • Camera
    • Camera Assembly
    • Camera Lens-Focus
    • Camera Interface
    • Camera Tilt Servo
    • Camera Mount Base
    • Camera Focus Servo
    • Camera
    • Camera Mount Cover
    • Camera Ribbon Cable
  • Electronics
    • ROV Board Set
    • Compass-Nav Module
    • ROV CPU Board
    • ROV Power Board
    • ROV Heat Sink

About this Document

Document Navigation

You can navigate through the documentation to specific topics using the menu, or step through sequentially using the Next and Previous arrowhead buttons. The Next button will step you from the current topic to the next topic at the same level unless the current topic has a sub-topic. If the current topic has a sub-topic, the Next button will step you into the first sub-topic. The Previous button works similarly, but in reverse sequence. Your current location within the document is shown as a "breadcrumb" trail at the top of each page under the document title. You can click on any level of the breadcrumb hierarchy to go that location. You can also use the following keyboard shortcuts:

ACTION	KEYSTROKE or BUTTON
Previous Page	Alt-p or
Next Page	Alt-n or
Up one level of the breadcrumb hierarchy	Alt-u

Links are shown in brown font.

Finding Information

This document includes a Table of Contents, Glossary / Index and Google search on each page. You must be connected to the Internet in order to be able to use the Google search, and you can select whether to search VideoRay's online document library only (the default) or the Internet.

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.

The Highlight icon is used to indicate that a section of text can be highlighted. Clicking on the icon will reload the page with the text highlighted. This may be useful for printing a page with highlights or to send someone a link to a page with specific text highlighted when they open the page. Try it here - click on this highlight icon.

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.
	The Manual Cross Reference icon is used to link to reference material elsewhere in this document or in an external resource. To view the reference, click on the Manual Cross Reference icon.
	The Play Video icon is used to link to a video about the topic. To view the video, click on the Play Video icon.
	The Hand icon is used to indicate an interactive element of the page. When you hover your mouse over the Hand icon, an image on the page will change to reflect the information in the text immediately prior to the hand icon. Try it here - hover your mouse over the following text and Hand icon to turn the Hand icon to the left blue: Interactive Text .

Document Customization - My_Notes

This document has been developed to allow local online versions to be customized using the My_Notes feature. Users can add their own notes to each page. See the Customizing this Document page for more information about how to customize this document.

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.

Alternate Formats

Single HTML Page Format
This document is available as a single HTML page that can be viewed and/or printed by the viewer.

Portable / Printable Format
An abbreviated print version of this document is also available in HTML and PDF formats in Letter and A4 sizes for viewing and/or printing. A free PDF Reader is available from Adobe. Printed versions of this document are available from VideoRay.

HTML File Set
This document set is also available for download as a self extracting zip archive for installation on your local device.

Customize this Documentation - My_Notes

My_Notes are easy to incorporate directly into the pages of this manual. They can be used to clarify content, add additional information, or document your custom settings, operational tactics or procedures. My_Notes are page specific and display at the bottom of the desired page under the "My_Notes" heading. No programming is required - it is as simple as saving a file with your notes.

Creating My_Notes

My_Notes can be written in HTML or plain text. HTML allows for more flexible formatting and inclusion of images or links to other web pages.

To add a My_Note, create an HTML or text file containing the note and save it in the VideoRay\My_Notes\ folder, which can be found in the computer account user's documents folder (Documents\ for Windows 7, or My Documents\ for Windows XP).

The file should be named the same as the page in which you want the note to appear, with a "my_" prefix (without the quotes). For example, if you want a My_Note to appear at the bottom of this page, the name of the file to create is: my_custom_my_notes.html. The name of the page being viewed can be found in the address bar of the browser being used to display this documentation.

Even if you are using a text file, the file name must end with the ".html" extension.

All My_Notes files are processed as HTML, so if you are using a plain text file, you will need to add "<pre>" (without the quotes) at the beginning of the file and "</pre>" (without the quotes) at the end of the file if you want to preserve the layout. The "<pre>" and "</pre>" will not show up in the display.

When using HTML, the My_Notes folder serves as the root for relative links. An images folder is included for you to store images. You may add other folders or files as desired.

Viewing My_Notes

When you reload the page, your My_Note will appear - there is nothing else to install or configure. A sample My_Note file has been included to display the My_Note below. You can use this file as a model for creating your own My_Notes.

Updating My_Notes

To update a My_Note, simply edit and re-save the My_Note file.

Removing My_Notes

My_Notes can be removed by deleting or renaming the My_Note file.

Sizing My_Notes Display (Optional)

The default vertical size for My_Notes is set to 200 pixels, which is used for the sample My_Note below. Due to browser limitations, My-Notes do not size dynamically. This means that a long My_Note may display a scroll bar in order to view the whole My-Note. You can adjust the size to eliminate the need for the scroll bar. To set the size of a My_Note, you need to edit the file named "my_notes_size_table.js" in the My_Notes\ folder (location defined above). The file contains one line for each page of this document using the following format:

    window.page_name = size_in_pixels;

Find the line for the page that includes the My_Note you want to resize and replace the value of size_in_pixels with the desired size in pixels. The page names are listed alphabetically. Example line from the "my_notes_size_table.js" file for this page:

    window.custom_my_notes = 200;

Note that ".html" in not included in the page name, and the line must end with a ";" Also, the optimum size required is dependent upon the size and aspect ratio of the browser window.

Before Contacting Support

Please make sure to consider the following information before contacting VideoRay's Technical Support to report a problem. The following information should available:

• User name and contact information
• Name of the owner if not the same as the user
• System model
• Serial Number of the affected component(s)
• Accessories in use
• Detailed information about the issue:
  • Symptoms
  • Operating conditions that create the symptoms
  • Anything new or unusually about the system or operations

In addition, please review VideoRay's Support website for additional information about:

• Principles of Customer Interactions
• Customer Care Philosophy
• Technical Support Policy
• Third Party Accessory Support Statement
• Use of Non-VideoRay Supplied Computers

Well Equipped Shop

A well equipped shop is organized, clean, and well lit. Ideally all work can be conducted in such an environment, however there may be times when maintenance or repairs must be completed in the field. For those occasions,

Maintenance Tools Required

VideoRay is designed with ease of maintenance in mind, and only a few tools are required to service the system. In fact, many maintenance procedures, such as changing light modules can be done without tools. VideoRay also includes a small tool and spares kit with each system delivered that contains most of the required tools. The following list of tools is recommended:

TOOL	TYPICAL USE
O-ring lubricator	Lubricating O-rings and O-ring grooves and landings.
Multi-tip screwdriver with Phillips and straight blades	Miscellaneous screws
7/16" Open end wrench	Propeller locking nuts
Multi-meter*	Electrical circuit testing
Soldering iron*	Electrical circuit repair
Flashlight*	Internal inspections

* - These items are not included in the standard tool kit that comes with .

Additionally, small trays to hold parts and fasteners are recommended.

Field Tool Kit

Ideally all work can be conducted in a workshop environment, however there may be times when maintenance or repairs must be completed in the field. For those occasions, it is recommended that you carry a well stocked tool kit, and a clean mat that can be used as a clean workspace for maintenance.

Basic Equipment Care

Do not abuse the VideoRay and be careful not to damage the system's components through normal use. For example, avoid letting the tether connectors come in contact with the ground where rough surfaces or dirt can damage the contacts.

Cleaning

VideoRay systems should always be cleaned after use. When used in salt water or contaminated environments, make sure to thoroughly rinse and then soak all wet components. It is especially important that you rinse the pressure sensor and allow it to drain. You must remove the float block to do this.

Use care when cleaning the pressure sensor to avoid damaging the sensor. Do not insert anything into the pressure sensor cavity, and do not apply high pressure spray to the sensor.

Storage and Transport

Always pack the system securely to make sure it is not damaged in transport.

Special Handling

VideoRay ROVs and their components can be damaged by improper care and handling. The following sections provide guidelines and procedures for working with these components.

Connector Care and Handling

Connectors should be handled with care and inspected and cleaned regularly. Always follow any specific instructions provided by the manufacturer for connector care. The following general guidelines are provided to help extend the life of the connectors.

1. Do not allow dirt or debris to get into the female sockets.

2. Do not allow the male pins to suffer from abrasion.

3. Make sure the connector is clean before mating. Do not use an abrasive cleaner.

4. Make sure the connector is dry before mating unless the connector is designed to be wet mate-able or rated to be connected underwater.

5. Apply a light coating of silicone lubricant before connecting to its mate (unless the connector has explicit instructions to the contrary).

6. Make sure to align the pins with sockets carefully to prevent damage while mating.

7. Make sure any sealing O-rings are in good condition and installed properly.

8. Make sure the connection is completely sealed when connected.

9. Use the connector locking devices when they are supplied for the connector.

10. Use the appropriate strain relief if applicable for the connection and make sure the strain relief is connected properly to ensure there is no strain on the connector.

11. For underwater connectors, rinse the connector in fresh water any time is has been disconnected from its mate.

12. Periodically, disconnect the connector and inspect each side for corrosion or damage and inspect the sealing surfaces or O-rings.

Specific Instructions from the Manufacturer for IE55 Connectors (used on the BluePrint Sonar, Manipulators, USBL)

1. Lubricate mating surfaces with 3M Silicone Lubricant or equivalent.
2. DO NOT GREASE! Connectors must be lubricated on a regular basis.
3. Lubricate o-rings with Dow Corning #111 Valve Lubricant or equivalent
4. Use dust caps and keep connectors clean to prevent damage in storage and service.
5. Keep o-ring grooves clean and avoid cuts, nicks and tears on rubber surfaces
6. Elastomers can be seriously degraded if exposed to direct sunlight or high ozone levels for extended periods of time.
7. Clean plugs and receptacles with soap and fresh water.
8. Rinse out with alcohol, allowing connector to air dry.
9. Replace o-rings when re-using connectors.

O-Ring Care and Handling

O-Ring Rule of Thumb - If in doubt, throw it out! Generally, when compared to the equipment they are protecting, O-rings are very inexpensive. Should an incorrectly sized or damaged O-ring be installed, the result can be catastrophic. If there is any doubt as to the suitability or condition of an O-ring it should be replaced.

O-rings and other components with sealing surfaces should never be handled with dirty or gritty hands. A small amount of dirt trapped next to an O-ring will cause leakage, which could result in serious damage to the ROV's internal components. The most common situation is a single strand of hair or lint, so care should be taken to ensure a clean work area. Should an O-ring or sealing surface become dirty, wash it with mild soap and water, and then rinse it with clean water. Avoid scratching the surfaces of the O-ring grooves and landings. Do not use sharp objects such as a knife or screwdriver to pry apart sealed assemblies or remove O-rings. Serious damage to the O-ring or the seat may result.

O-ring Lubrication - VideoRay recommends the use of pure silicone spray or the O-ring lube kit that comes in the standard tool kit. Other lubricants can lead to deterioration and failure of the O-rings and components. Do not use other lubricants! Other lubricants may cause deterioration or attract dirt and lead to leaks or premature failure.

O-ring Inspection - O-rings wear out over time. Inspect all O-rings whenever a sealed assembly is apart. "Healthy" O-rings are soft, flexible and have not been pinched or nicked. Should an O-ring appear brittle, or have apparent cracks, nicks, or evidence of being pinched or permanently compressed, it should be replaced. Sealing surfaces should also be inspected while an assembly is apart. The surfaces should be examined to determine that they are free of dirt, nicks, scratches, or damage, which may result in seal failure once reassembled.

O-ring Storage - O-rings should be stored in clean plastic bags to protect them from dust when not in use. Avoid prolonged storage in direct sunlight as this may result in deterioration of the O-ring material. Stored O-rings should be sorted with regard to type and size with that information noted on the storage bag. Use of an incorrect O-ring can result in an ineffective seal.

Cartridge Seals

View example cartridge seals.

Cartridge seals must be checked before every dive and must be replaced with new ones before the air bubble reaches 1/2 of the volume of the seal. Cartridge seals must also be replaced with new ones if they contain contamination or look milky instead of clear. On long duration dives, the cartridge seals should be checked at hourly intervals during the dive unless this is impossible (for example, continuous extended video is required). Any cartridge seal that shows a high rate of air bubble growth or increasing contamination should be replaced (if unable to be replaced on-site, it must be checked more frequently until it is replaced). When replacing seals that are worn, the shaft must be checked for scoring or other signs of wear that could lead to premature seal failure. The shaft must also be checked for wobble (bent), which could also lead to premature seal failure. Thrusters should not be run for more than a minute in air, which could also result in premature seal failure. Cartridge seals must be replaced in a clean environment to ensure a good water tight fit of the O-ring and seals.

If these recommendations are followed, the ROV should NEVER experience a flood through the cartridge seal unless the seal itself suffers a catastrophic failure. VideoRay's warranty does not cover damage due to flooding of the ROV through a cartridge seal unless the customer can demonstrate that they have followed the above recommendations and there is reasonable evidence that the seal failed catastrophically due to a manufacturing defect.

Cartridge Seal Storage Recommendations:

• Cartridge seals should be stored in a sealed plastic bag so they do not attract dirt.

• Recommended storage temperature is between 2 to 15 degrees C (35 to 60 degrees F) to keep the storage gel from softening and allowing the oil to drain.

• Storage or transport at low air pressure (checked baggage in an unpressurized cabin) is not recommended.

Example Cartridge Seals

	New cartridge seal.
	Cartridge seal with an acceptable bubble - this seal is okay to use.
	Nearly empty cartridge seal - this seal should have been replaced when the oil level reached 1/2 of the original volume. Cartridge seals like this should not be used.
	Cartridge seal with contamination - this seal should be replaced. Cartridge seals like this should not be used.

Electronics Components Care and Handling

Electronic components (circuit boards) are susceptible to damage from ESD (Electro-Static Discharge). Numerous sources are available that provide background information and recommend procedures for handling these components. These procedures should be followed when directly handling VideoRay's electronic components.

ESD is caused by the build up of static electricity. Steps to reduce the build up of static electricity or drain off any static build up are encouraged in order to prevent ESD damage.

General Guidelines for handling electronic components include:

• Avoid static build up in the work area

  • Avoid carpet in work areas

  • Maintain proper humidity levels: 40 - 60%

• Implement practices to prevent static build up

  • Provide ground points in the work area

  • Wear a grounded wrist strap

  • Provide grounded static dissipative mats on work surfaces and floors

  • Wear static dissipative outer clothing

  • Work standing rather than sitting

• Use ESD protective packaging

If you cannot work in a properly equipped ESD safe area, there are some general precautions you can follow in addition to the above.

• Always touch a metal ground to dissipate any static charge build up before handling circuit boards.

• When transferring a circuit board to another person or work surface, touch the person or surface with your free hand to dissipate and static charge build up.

Hull Materials Care and Handling

Aluminum Hull Components

VideoRay's aluminum parts are protected by anodizing and/or ceramic coatings. The use of metal tools can scratch these coatings leading to corrosion. Be careful when working with with metal tools near hull parts. Use only wood or plastic tools when the tool must contact an aluminum hull component.

Main Dome and Light Dome

The domes should be cleaned with mild soap and water. They are acrylic and small scratches can be buffed out.

Do not use cleaners that contain alcohol or other solvents. Solvents can make the domes brittle.

Galvanic Corrosion

Galvanic corrosion results from dissimilar metals being in contact when exposed to a conductive medium like salt water. Make sure all stainless steel fasteners are not in direct contact with aluminum hull parts. VideoRay uses nylon spacers for these contact points to keep the materials separated. Always make sure to use these spacers when reassembling parts after routine maintenance or a repair.

Diagnostics and Repair - System Start Up

When VideoRay Cockpit starts up, it checks the hardware configuration to detect three required items:

• Video Interface
• Communications Interface
• Hand Controller

If any of these items are not detected, VideoRay Cockpit will display an error message and will not operator correctly until the configuration issues are corrected.

In each case, the first thing to check is that the appropriate cable is plugged in. For the first two, the USB cable from the computer to the control panel must be plugged in. For the hand controller, its USB cable must be plugged into the computer or one of the ports at the rear of the control panel.

Additional details about diagnosing each one of these items are provided in the following sections.

Diagnostics and Repair - Power

When the ROV powers up, you will hear a series of tones, the lights will flash, and you should be able to see some internal LEDs light up. If none of these occur a power problem is possible. Power problems can occur on the AC side or DC side. If some, but not all of the start-up indicators work, a power problem is less likely, and a communications or other ROV internal problem is possible.

AC Power Problems

If the control panel will not turn on, the first place to check is the power cord and power source. Press the GFCI test button. The GFCI will not trip without power being applied to it. If the system does not trip, either there is no power (more likely) or the GFCI has malfunctioned (less likely). If you confirm there is power and the power cord is plugged in, but the GFCI will not trip, a faulty GFCI is possible.

If the system passes the GFCI test, then the 2 IEC outlets on the rear of the panel should have power when the GFCI is turned on - the computer should show it is operating on AC power and not its battery. If the GFCI is on, and there is no power at the IEC outlets, a faulty GFCI switch or wire fault in the panel is possible.

DC Power Problems

When you turn on the power switch, you should hear the fans turn on, and the green power LED should light. You should also be able to measure 75 Volts DC in the tether connector between pins 3 and 5. If any of these do not work, it could be a faulty power switch, power supply failure or wiring problem (loose or disconnected connector).

If you measure 75 Volts DC in the tether connector, but the ROV still does not have power, it could be a fault in the tether or ROV. Connect the ROV directly to the panel without the tether. If the ROV works, it could be a problem in the tether or its connectors. If the ROV does not work, it could be a problem in its tether connector, or it could be a board failure in the ROV.

The Pro 4 includes a DC LIM (Line Insulation Monitor) protection circuit that is similar to a GFCI. If the LIM is tripped, a yellow LED alarm light on the control panel will illuminate. The LIM can be tested and reset using the buttons on the control panel. If the LIM alarm does not clear after pressing the reset button for at least 30 seconds, eliminate the tether and try again. If the LIM alarm still does not clear, the ROV or control panel must be serviced. See the LIM section of the Operator's manual for more information.

Test Points

Test	Procedure / Location	Expected Result
Measure tether Ohms for continuity	Tether pin 3 male to pin 3 female	Continuity
Measure tether Ohms for continuity	Tether pin 5 male pin 5 female	Continuity
Test tether for a short	Tether pin 3 male/female to any other pin	No short
Test tether for a short	Tether pin 5 male/female to any other pin	No short
Measure control panel voltage	With the control panel on, measure 74 V DC on control panel tether pin 3 female (+) to tether pin 5 (- ground)	74 V DC +/-
Measure ROV accessory port voltage	With the ROV connected and the system on, measure 24 V DC on ROV accessory port pin 3 female (+) to accessory port pin 5 female (- ground)	24 V DC +/-
Measure ROV accessory port voltage	With the ROV connected and the system on, measure 12 V DC on ROV accessory port pin 9 female (+) to accessory port pin 5 female (- ground)	12 V DC +/-

Diagnostics and Repair - Communications

Communications problems can result in loss of control of the ROV. Communications in the Pro 4 occurs at several levels.

The computer has to communicate with the control panel via the USB cable. First verify that the cable is connected. The computer must also recognize the control panel devices, specifically the RS-485 interface. The RS-485 device will only be recognized while the control panel is turned on. To check the status of the communications with the RS-485 device, the control panel must be turned on. The RS-485 interface can be confirmed by checking the Ports in Device Manager. To access device manager, open the Windows Control Panel, and in the Classic View, click on System. Next, click on the Hardware tab, and then the Device Manager button. Click on the plus sign (+) next to Ports and confirm that the SeaLevel RS-485 port is listed as one of the ports. If the RS-485 device is not listed, unplug the USB cable, wait a few seconds and plug it back in. If the RS-485 device is still not listed, power down the control panel and reboot the computer. If the RS-485 device is not listed after a shut down, restart and reboot, a problem with the USB cable, RS-485 device, or internal USB hub or controller is possible.

The control panel must communicate with the ROV through the tether. Communications occur via pins 7 and 8. verify the continuity of the tether to ensure all conductors are intact. The tether conductors are straight through - pin 1 to pin 1, pin 2 to pin 2, etc. You can also connect the ROV directly to the control panel without the tether to either rule out or confirm whether the tether is the problem.

Test Points

Test	Procedure / Location	Expected Result
Communications device present	Verify "SeaLINK +485Isolated USB to RS-422/485 Converter (COMx)" is visible in Device Manager under "Ports"	Device recognized and no warnings
Measure tether Ohms for continuity	Tether pin 7 male to pin 7 female	Continuity
Measure tether Ohms for continuity	Tether pin 8 male pin 8 female	Continuity
Test tether for a short	Tether pin 7 male/female to any other pin	No short
Test tether for a short	Tether pin 8 male/female to any other pin	No short
Measure control panel Ohms	Control panel tether pin 7 female to control panel tether pin 8 female	120 kOhm +/-
Measure ROV Ohms	ROV tether pin 7 male to ROV tether pin 8 male	120 Ohm +/-
Measure ROV Ohms	ROV tether pin 7 male to ROV accessory port pin 7 female	120 Ohm +/-
Measure ROV Ohms	ROV tether pin 8 male to ROV accessory port pin 8 female	120 Ohm +/-
Measure ROV Ohms for continuity	ROV tether pin 7 male to ROV accessory port pin 8 female	Continuity
Measure ROV Ohms for continuity	ROV tether pin 8 male to ROV accessory port pin 7 female	Continuity

Diagnostics and Repair - Control

Control problems can occur due to a communications problem, a hand controller problem, a problem with an ROV subsystem, poorly adjusted buoyancy, or a physical problem like a stuck tether or fouled propeller.

VideoRay Cockpit instruments can confirm that a hand controller input is being received. If the instrument does not indicate a controller input, such as the camera indicator does not move when you press the camera tilt button, then check to make sure the hand controller is plugged in. You can also check whether the hand controller is recognized by Windows. You can check if the hand controller is recognized by Windows using the Game Controller application in the Windows Control Panel.

If the hand controller is working, but you cannot pilot the ROV, check for a loose or fouled propeller. If the propellers are clear, the problem could be a thruster motor or motor controller. If the problem is vertical control, then you might need to adjust the ballast.

If the problem is horizontal control, check to make sure the propellers are installed in the correct orientation.

If the ROV can be piloted, but another subsystem, like camera tilt, is not functioning, verify the hand controller function as listed above, and then suspect the subsystem.

See the Control Sensitivity and Systems Tuning section of the VideoRay Cockpit Guide for more information about adjusting the responsiveness and power settings of the thrusters.

Diagnostics and Repair - Hand Controller

Directional control and other ROV functions result from a series of operations, configuration settings, wiring and functions. Normally, pressing forward on the joystick results in the ROV moving forward, pulling the joystick in reverse reverses the ROV, and left and right joystick inputs result in the ROV turning left and right respectively. If the behavior is not as expected, one of the following can be the problem. It is important to correct the situation in the right place, otherwise it may compound the problem and make components (controller, computer, ROV) incompatible with other systems.

Holding the joystick inverted

The VideoRay hand controller should be held so that the joystick and the wire to the control panel are to the right.

Broken joystick

If the joystick does not "feel" right, it might be broken. If there is no response (as opposed to an incorrect response) the joystick might be broken. This may also result from a wire failure in the hand controller or between the hand controller and the computer. The joystick can be checked using the Windows game controller properties found in the Windows Control Panel. Also, when you move the joystick, you should see the corresponding thruster indicator(s) moving in VideoRay Cockpit.

Mis-wired joystick

If the joystick is mis-wired it may not operate as expected. The joystick wiring can be checked using the Windows game controller properties found in the Windows Control Panel.

The default joystick and knob response for the VideoRay Industrial Hand Controller is shown in the following image:

Move joystick to the right (J1 +X) = The crosshair should move to the right

Move joystick away (forward) (J1 +Y) = The crosshair should move down

Rotate the joystick clockwise (J1 CW) = the bar size should decrease

Rotate controller knob on upper left clockwise (RX CW) = the bar size should decrease

Rotate controller knob on lower left clockwise (RY CW) = the bar size should decrease

Rotate controller knob on the side clockwise (RZ CW) = the bar size should decrease

Default Button Mapping

1. Manipulator Close
2. Manipulator Open
3. Focus Out
4. Tilt Up
5. Help
6. Snapshot
7. Lights Bright
8. Lights Dim
9. Tilt Down
10. Focus In
11. Camera Select
12. Record/Stop

Error in the joystick configuration file

The configuration file maps joystick inputs to specific ROV functions. If these are not mapped correctly, a different response can be expected. This is not always a problem - changing the configuration file is required in order to create a custom configuration. Configuration files are XML. They require manual edit, but a future version of VideoRay Cockpit will include a joystick mapping user interface.

Modified Thruster Direction Setting in the main configuration file

There is a setting in the main VideoRay Cockpit configuration file to change the port thruster direction. <InvertPortThrusterDirection>. If this value is set to true, the port thruster direction will operate in the reverse direction from normal operation. This setting is for legacy support and should not normally be changed.

Mis-wired thruster motors

If the thruster motor wires are incorrect, the thruster motor may rotate in the wrong direction. Swapping any two of the three thruster motor wires should correct this problem.

Improper propeller installation

The propellers on a Pro 4 are counter rotating (reverse pitch) and should be installed so that the top blade curves towards the center when viewed from behind. Do not install the propellers on the wrong shaft, and do not install two propellers with the same directional pitch.

Diagnostics and Repair - Video

Understanding the video circuit can help in diagnosing and solving video problems. Typical video problems include complete loss of video, video noise, image quality (focus, color, inverted image) and video frame rate (stutter).

Overview

Composite video (in NTSC or PAL format depending upon country standards) originates in the primary, or external, camera and passes through a switching circuit in the ROV. The switching circuit determines which camera source signal is displayed, and is controlled by VideoRay Cockpit software on the topside. From the ROV, the video is passed via the tether to the control panel. Within the control panel the video is either passed through a Lyyn visual enhancement system, if one is installed, or directly to a video splitter. The video splitter provides video feeds to both a digital and analog display circuits.

Digital Circuit

The digital circuit includes a USB video capture device, which is connected to a USB hub within the control panel and then to a computer via a USB cable. Within the computer, VideoRay Cockpit software can display the video, in real time with or without video overlay text or graphics. If a second monitor is attached to the computer, the video window can be displayed on either or both display devices. VideoRay Cockpit software can also record the video to disk. Other software can also use the digital video source, and this can be helpful for diagnostic purposes.

Analog Circuit

The analog circuit passes from the splitter directly to a Video Out RCA style connector on the rear of the control panel. From this connection, a cable can be connected to a monitor or video recording device. If the video is split at this point to two or more devices, a video amplifier/splitter is recommended. Splitting the video without an active amplifier is likely to result in poor video quality.

Note: Video overlay text and graphics are supported on the digital circuit, but not the analog circuit.

Summary of Video Circuit Components

• Camera
• Switching circuit within the ROV
• Wiring within the ROV, tether or control panel
• Video capture device
• USB system
• Software
• Display component
• Power

When diagnosing video problems, the divide and conquer method is recommended. See the other FAQs about video problems for more specific instructions.

Video problems are widely variable. It could be a faulty cable, signal problem, video noise, improper camera setting for the conditions, or even lighting.

If there is no video signal, first verify that rest of the system is functional. If the rest of the system is functional, verify that the video circuit in the control panel is recognized by the computer. The video circuit can be verified by checking the Sound, video and game controllers section in Device Manager. To access device manager, open the Windows Control Panel, and in the Classic View, click on System. Next, click on the Hardware tab, and then the Device Manager button. Click on the plus sign (+) next to Sound, video and game controllers and confirm that the DVD Maker 2 (or USB 2861 Device) is listed. If the DVD Maker 2 device is not listed, unplug the USB cable, wait a few seconds and plug it back in. If the DVD Maker 2 is still not listed, power down the control panel and reboot the computer. If the DVD Maker 2 is not listed after a shut down, restart and reboot, a problem with the USB cable, DVD Maker 2 device, or internal USB hub or controller is possible.

If video noise seems to be a problem, it could be local interference, a mismatched ground, or a poor connection somewhere in the system. If you are operating off a local power source such as a generator, make sure the ground is the same as the water in which the ROV is being used. Also, check that each connection in the tether is clean and well seated.

If you do not have video on the second monitor, make sure the monitor is powered on, the cable connected and computer configured to display on two screens.

If the video image is poor, check the camera focus and the camera settings. You may also need to adjust the lights.

Test Points

Test	Procedure / Location	Expected Result
Video capture device present	Verify "DVD Maker" or "USB 2861 Device" is visible in Device Manager under "Sound video and game controllers"	Device recognized and no warnings
Verify video presence on analog video out	Connect a monitor to the analog video out connector	Video displayed on external monitor
Measure tether Ohms for continuity	Tether pin 1 male to pin 1 female	Continuity
Measure tether Ohms for continuity	Tether pin 2 male pin 2 female	Continuity
Test tether for a short	Tether pin 1 male/female to any other pin	No short
Test tether for a short	Tether pin 2 male/female to any other pin	No short
Measure control panel Ohms for continuity	Control panel tether pin 1 female to Video Out RCA ground	Continuity
Measure control panel Ohms for continuity	Control panel tether pin 2 female to Video Out RCA signal	Continuity
Measure ROV Ohms for continuity	ROV Tether pin 2 male to ROV accessory port pin 2 female	No continuity

ROV Schematics

ROV schematics include the following documents:

• Main Hull Assembly
• Vertical Thruster
• Termination Block / Cable Whip
• Pressure Sensor
• Horizontal Thrusters
• Wire Harness

Main Hull Assembly

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Vertical Thruster

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Termination Block

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Pressure Sensor

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Horizontal Thrusters

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Wire Harness

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Control Panel Schematics

ROV schematics include the following documents:

• OverView
• AC Input
• AC Output
• 75 V DC LIM
• 12 V DC LIM
• 12 V DC Fan
• Communication
• Video
• Spare Pair

OverView

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AC Input

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AC Output

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75 V DC LIM

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12 V DC LIM

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12 V DC Fan

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Communication

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Video

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Spare Pair

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IP 65 OverView

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Hand Controller Schematics

Hand Controller schematics include the following documents:

• Hand Controller Schematic

Hand Controller Schematic

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Quality Control Documents

ROV schematics include the following documents:

• Pre QC
• Basic Functions QC
• In-water QC
• Final QC

Pre QC

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Basic Functions QC

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In-water QC

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Final QC

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ROV Connections

The ROV includes the following connections:

CONNECTION	TYPE	FUNCTION
Tether Whip (View Specifications)	8 pin round male	Used to connect the ROV to the tether for power, communications, video and accessory support.
Accessory Port (Specifications listed below)	9 pin rectangular female	Provides power, communications and video. Can be used to connect accessories electrically to the ROV.

Accessory Port

The ROV accessory port provides power, access to the ROV communications bus and the APIC (Auxiliary Pair of Independent Conductors) to the surface. Most accessories, with the exception of the manipulator and cutter, use a stackable pass through connector that allows multiple accessories to be connected to the accessory port in parallel.

The accessory port must be sealed with a terminated accessory connector or the accessory port terminator dummy plug. Failure to seal the accessory port may lead to loss of control of the ROV or damage to the components.

Accessory Port Specifications

PIN	FUNCTION
1	Video -
2	Video +
3	24 VDC + (30 Watts)
4	Aux + (APIC) Connects to tether pin 4 and control panel AUX port pin 7
5	Power Common (Ground)
6	Aux - (APIC) Connects to tether pin 6 and control panel AUX port pin 8
7	RS-485 -/A
8	RS-485 +/B
9	12 VDC + (30 Watts)

Accessory Port pin numbering is as follows. When looking at the mating end of the connector with the row of 5 sockets or pins on top - For female connectors, pin 1 socket is at the right end of the row of 5 sockets, and pins 2-5 sockets proceed from right to left. Pins 6-9 sockets are in the lower row and proceed from left to right. For male connectors, pin 1 is at the left end of the row of 5 pins and pins 2-5 sockets proceed from left to right. Pins 6-9 are in the lower row and proceed from right to left.

Accessories Table

Accessory	Power	Data
Auxiliary Camera with Dimmable Lights	12 V DC	Analog Video / PAM
GoPro Camera Mount	N/A	N/A
HD Camera	12 V DC	Digital Fiber
BlueView Multibeam Sonar	24 VDC	Ethernet (DSL)
Gemini Multibeam Sonar	24 V DC	Ethernet (DSL)
Micron Scanning Sonar	12 V DC	RS-485
MicronNav USBL	12 V DC	N/A
Smart Tether	74 V DC	RS-485 (Communications Bus)
Hull Crawler	N/A	N/A
Manipulator	24 V DC	RS-485 (Communications Bus)
Rotating Manipulator	24 V DC	RS-485 (PAM)
Laser Scaling Tool	12 V DC (PAM)	N/A
Ultrasonic Thickness Gauge	12 V DC	RS-485 (PAM)
Radiation Sensor	12 V DC	Modified RS-232 (PAM)
CP Probe	N/A	Analog
METS Methane Sensor	12 V DC	RS-485 (PAM)
Turner C3	12 V DC	RS-485 (PAM)
YSI EXO (Series)	12 V DC	RS-232 PAM
WFS Modem	12 V DC	RS-485 (PAM)
Retrieval Kit	N/A	N/A

Main Hull

The Main Hull section includes removal and replacement steps for the following components:

1. Float Block Kit ^N
2. Strain Relief Cable Kit ^N
3. Skid Kit ^N
4. Dome Retaining Rings and Main Hull Rods ^I
5. Front Dome ^I
6. Rear Dome ^I
7. Desiccant Pack ^I
8. Front Hull Ring Assembly with Camera ^I
9. Rear Hull Ring Assembly ^I
10. Pressure Sensor Kit ^A
11. Termination Block and Accessory Port ^A
12. ROV Wire Harness ^A
13. Main Hull Tube ^A

Horizontal Thrusters

The Horizontal Thrusters section includes removal and replacement steps for the following components:

1. Horizontal Thruster Propeller Kit (Left and Right) ^N
2. Horizontal Thruster Cartridge Seal ^N
3. Horizontal Thruster Nozzle Kit ^N
4. Horizontal Thruster Cone Assembly ^I
5. Horizontal Thruster Bearing ^I
6. Horizontal Thruster Drive Train Assembly ^I
7. Horizontal Thruster Motor Mount ^A
8. Horizontal Thruster Motor Assembly ^A
9. Horizontal Thruster Tube ^A

Vertical Thruster

The Vertical Thruster section includes removal and replacement steps for the following components:

1. Vertical Thruster Propeller Kit ^N
2. Vertical Thruster Splitter ^N
3. Vertical Thruster Cartridge Seal ^N
4. Vertical Thruster Kit ^A
5. Vertical Thruster Motor Mount ^A
6. Vertical Thruster Motor Adapter ^A
7. Vertical Thruster Motor Shield ^A
8. Vertical Thruster Motor Assembly ^A

Lights

The Lights section includes removal and replacement steps for the following components:

1. Light Dome ^I
2. LED Light Module Assembly ^I
3. LED Light Reflector Set ^A
4. LED Light Printed Circuit Board ^A
5. LED Light Mount ^A

Camera

The Camera section includes removal and replacement steps for the following components:

1. Camera Assembly ^A
2. Camera Lens-Focus Cam Gear ^A
3. Camera Interface Printed Circuit Board ^A
4. Camera Tilt Servo Motor Assembly ^A
5. Camera Mount Base Assembly ^A
6. Camera Focus Servo Motor Assembly ^A
7. Camera ^A
8. Camera Mount Cover ^A
9. Camera Ribbon Cable ^A

Electronics

The Electronics section includes removal and replacement steps for the following components:

1. ROV Board Set ^A
2. Compass - Navigation Module ^A
3. ROV CPU Printed Circuit Board ^A
4. ROV Power Control Printed Circuit Board ^A
5. ROV Heat Sink ^A