Outland Technology OTPS1KW-ASM-TOPSIDE-R2 User manual

1
User Manual
OTPS1KW-ASM-ROV-R1/OTPS1KW-ASM-TOPSIDE-R2
Outland Technology, Inc.
38190 Commercial Court, Slidell, LA 70458
985-847-1104
[email protected]om
www.outlandtech.com
Document Number: 46-0013 Rev 2
July 2020

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Contents
Safety at a Glance ........................................................................................................................... 3
System Overview ............................................................................................................................ 4
Power Supply Unit: OTPS1KW-ASM-TOPSIDE-R2 ....................................................................... 4
ROV Power Supply Enclosure: OTPS1KW-ASM-ROV-R1 ............................................................. 5
System Status Display.................................................................................................................. 5
User Access Area......................................................................................................................... 5
Installation ...................................................................................................................................... 5
Quick Start Guide............................................................................................................................ 6
Troubleshooting.............................................................................................................................. 6
Electrical Interface .......................................................................................................................... 7

3
Safety at a Glance
1. Environmental Considerations
•The power supply console is not IP rated for water or dust ingress. Be aware of the working
conditions. Do not operate in rain and protect console from spray.
•The connector on the tether is only IP rated when mated. Replace cap when storing in box
with wet tether.
2. Operation
•Test the Ground Fault Interrupter (GFI) prior to use. If the GFI fails return for service.
•Do not close the lid of the power supply or block fan inlets and outlets during operation.
The unit requires air flow for proper cooling.
•The power supply allows for continuous operation of the vehicle. Limit amount of time at
full throttle to avoid potential overheating of motor drive components.
3. Maintenance and Upkeep
•Do not use cracked, cut, or damaged tether. Discontinue use and replace if damaged.
•Inspect connectors and penetrations for any signs of wear or damage prior to use.
•Always grease wet mate connectors prior to use.
•There are no user serviceable parts in the OTPS1KW-ASM-ROV-R1 or OTPS1KW-ASM-
TOPSIDE-R2 except for the user access area. Do not attempt to open either the OTPS1KW-
ASM-ROV-R1 or OTPS1KW-ASM-TOPSIDE-R2.
Legend
Safety
Warning
The OTPS1KW-ASM-ROV-R1 system is supplied with 400VDC. Improper use may
result in electrical shock or electrocution. Only trained and experienced
personnel should operate the equipment.
Warning
The OTPS1KW-ASM-TOPSIDE-R2 system is supplied with 100-240VAC and
supplies 400VDC. Improper use may result in electrical shock or electrocution.
Only trained and experienced personnel should operate the equipment.
Warning
Troubleshooting described in this manual is to be done only by qualified
service personnel. To avoid electrical shock or equipment damage, do not
troubleshoot or service any components unless you are qualified to do so.
Caution
NEVER PLUG OR UNPLUG ELECTRONICS WITH POWER ON! Damage or
personal injury may result.
Warning/
Caution
High Voltage

4
System Overview
The battery replacement system package is a drop-in replacement for the BlueROV2 battery watertight
enclosure. The battery replacement system is comprised of three parts: the OTPS1KW-ASM-TOPSIDE-
R2, OTPS1KW-ASM-ROV-R1, and tether. The OTPS1KW-ASM-ROV-R1 ROV enclosure easily replaces the
Battery Enclosure utilizing the same dimensions and mounting. The OTPS1KW-ASM-ROV-R1 utilizes wet
mate connectors allowing the tether to be removed. The enclosure provides 1000W @ 15V to the
vehicle and as well as data pass through. Connections to the BlueROV2 Electronics Enclosure are
maintained utilizing Blue Robotics penetrators. Power connection uses the standard 3.5mm bullet
connector and 0.1” (2.54mm) crimp connector for Fathom-X communications and spare twisted wire
pair. The tether is comprised of two twisted pairs for data and 3 pairs for power. The power conductors
allow for operation out to 300m. The top side power supply, OTPS1KW-ASM-TOPSIDE-R2, provides
400VDC to the OTPS1KW-ASM-ROV-R1. The supply incorporates a GFI for user safety, and status
indicator which reports power supply output voltage, current and run time.
Power Supply Unit: OTPS1KW-ASM-TOPSIDE-R2
Specifications
Input Voltage: 100-240VAC 50/60Hz
Input Current(MAX): 15A
Input Power(MAX): 1800W
Output Voltage: 400VDC
Output Current(MAX): 4A
Output Power(MAX): 1600W
Efficiency(NOM): 90.5%
Operating Temperature: -30°C to +50°C
Humidity: 10-95% RH non-condensing
IP rating: IP20
1
2
3
4
5
6
7
9
10
11
12
1. Green wire GND
2. Tether Connection
3. Input Power (Uses IEC
320-C13 connector)
4. Laptop Power Outlet
5. Power Switch
6. GFI Test Switch
7. System Status Display
8. Laptop Tray
9. User Access Panel
10. USB FXTI Conn.
11. External FXTI Conn.
12. FXTI Link and Power
Indicators
8

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ROV Power Supply Bottle: OTPS1KW-ASM-ROV-R1
Specifications
Output Voltage(NOM): 15VDC
Output Current(MAX): 66.8A
Output Power(MAX): 1000W
Efficiency(NOM): 92%
System Status Display
•System Status: Indicates Current System Status: “Good”or “Fault”.
•Output DC Voltage: Voltage supplied to tether. Measured at topside power supply output.
•Output Current: Tether cable current.
•Output Voltage Bias: Indicates leakage current from high voltage positive to chassis ground and high
voltage negative to chassis ground. HVBias >2% indicates potential water leak on the high voltage
between power supply and OTPS1KW-ASM-ROV-R1. See troubleshooting.
•Run Time: Cumulative run time of power supply console
•Fault History Log: Log of last 8 power cycles, newest results are on the right. A dot indicates normal
operation, + indicates Pos-Side Leak, and –indicates Neg-Side Leak.
User Access Area
Within the laptop tray resides a user access area. This area is isolated from the internal high voltage and
is available for users to mount custom interface electronics. The standard package is equipped with a
Fathom-X interface board and ethernet to USB adapter. In addition, a Binder 770 connector is supplied
with blue and orange data pairs connected. The Blue pair is connected in parallel with the internal
Fathom-X interface board. The orange pair is available to the user as an additional connection.
Installation
The OTPS1KW-ASM-ROV-R1 bottle is delivered ready for install. Follow the standard procedure for the
Blue ROV2 Assembly.
Outland Technology Power Supply BlueROV2 Integration Guide
System Status
Output Current
Run Time
Fault History Log
Output Voltage Bias
Output DC Voltage

6
Caution: Once the power cord is connected to an outlet, AC voltage is
present in the console and at the Laptop charging outlet.
Note: Voltage applied to power supply is also present at the laptop
port. Example: 220V input will result in 220V at laptop charging port.
Quick Start Guide
1. Ensure the power connection has a good ground.
2. Connect supplied Green Wire to earth ground for added protection. Refer to OTPS1KW-ASM-
TOPSIDE-R2 image above for mounting location.
3. Inspect tether and bottle connectors for damage and lubricate with waterproof silicone grease.
Grease procedure: Subconn Handling Instructions
4. Connect tether to OTPS1KW-ASM-ROV-R1 and OTPS1KW-ASM-TOPSIDE-R2. Be mindful of the of
the connector mating position when connecting.
5. Test GFI
a. Disconnect tether from power supply.
b. Turn on Power.
Caution: Once the power is switched on, High Voltage is present on the
tether output.
c. Move GFI Test switch to HV+. Power supply will shut off. Fans will stop and LCD will
indicate fault to HV+ side, if not see subsection 6F.
d. Cycle power to unit by turning main power switch to Off and then back On.
e. Move GFI Test switch to HV-. Power supply will shut off. Fans will stop and LCD will
indicate fault to HV- side, if not see subsection 6F.
f. If either test fails, stop all operation and disconnect main power, see troubleshooting
guide.
6. Turn off power
7. Connect tether to power supply
8. Connect USB data connection to computer. Follow the Blue Robotics Network Setup instructions
for proper setup.
9. Power unit and run standard preflight checks.
Caution: Once the power is switched on, High Voltage is present on the
tether output. If vehicle is connected to tether it will also be powered
at this time, stay clear of all propellers. Do not connect or disconnect
tether with the power supply turned on.
10. Commence mission.
Troubleshooting
1. HV bias > ±2% indicated on System Status Display, Vehicle still operational.
•The Vehicle will continue to operate but the High Voltage leak needs investigated.

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•Turn Off system power, disconnect ROV tether from the OTPS1KW-ASM-TOPSIDE-R2. Turn On
system power and observe the HV bias reading. If reading anything over ±2%, there is an issue
with the power supply. Return for repair.
•If the HV Bias is <±2% with tether disconnected, turn Off system power and reconnect tether to
the OTPS1KW-ASM-TOPSIDE-R2. Disconnect the tether from the vehicle, and attach 3pin male
and 8 pin male dummy plugs to the ROV end of the tether. Submerge as much of the tether as
possible, turn On power and observe the HV Bias reading. If >±2% return tether for repair. If a
spare tether is available, repeat test with second tether.
•If HV Bias is <±2% with dummy plugged tether, power down unit and reconnect to vehicle. Turn
on power and observe the HV bias reading. If HV Bias >±2% return OTPS1KW-ASM-ROV-R1 for
repair.
2. HV Bias Trips GFI
Repeat steps from bias condition above and return faulty components for repair.
3. Depth Sensor Dropouts and Erratic Reading/HUD Errors
•The high voltage step-down power supply can add additional noise into the system due to high
voltage switching. In addition, the nature of I2C communications make it susceptible to this
noise. The solution is to implement common mode noise suppression by adding a ferrite to the
I2C connection from the depth sensor to the Pixhawk. The standard-length depth senor cable
only allows for single pass. Therefore, it is recommended to add two ferrites cores.
•Installation:
•Disconnect the I2C Depth Sensor wire from the Pixhawk
•Feed the I2C wire through two ferrite cores
•Position one ferrite near the Pixhawk and position the other near the depth sensor
•Secure in place using cable tie, heat shrink, etc.
•Reconnect the I2C depth sensor wire to the Pixhawk I2C port
•Recommended part: Laird-Signal Integrity Products LFB143064-000
Electrical Interface
OTPS1KW-ASM-ROV-R1 Enclosure Connections
Input Power Connection
Connector: Subconn/Seacon MC-BH-3-M
Pin
Signal
Function
Description
1
HV +
Power
+200 VDC
2
HV -
Power
- 200 VDC
3
Chassis
Power
Chassis Ground
Input Data Connection
Connector: Subconn/Seacon MC-BH-8-M
Pin
Signal
Wire Color
Description
1
2
Spare
Spare
Orange
Orange/White
Spare twisted
pair
MC-BH-3-M
Face View

8
3
4
N.C. on tether1
N.C. on tether
Green
Green/White
Spare twisted
pair
5
6
N.C. on tether
N.C. on tether
Brown
Brown/White
Spare twisted
pair
7
8
Fathom-X -
Fathom-X +
Blue
Blue/White
Fathom-X pair
Output Low Voltage Connection to BlueRov2
Power Cable: 03-0161
Connector: 3.5mm Bullet, female
Pin
Signal
Function
Description
1
+15V
ROV
Power
15V, 1000W supply, Red
2
GND
GND
Ground Input, Black
Data Pass through to BlueRov2
Data Cable: 03-0162
Connector: 4 x 3 Position 0.1” Crimp Connector with Housing, female (center pin not populated)
Pin
Signal
Wire Color
Description
1
2
Spare
Spare
Orange
Orange/White
Spare twisted pair
3
4
Spare
Spare
Green
Green/White
Spare twisted pair2
5
6
Spare
Spare
Brown
Brown/White
Spare twisted pair2
7
8
Fathom-X -
Fathom-X +
Blue
Blue/White
Fathom-X pair
Note: All 4 pairs are wired up to the 8pin tether connector using a 1-1 connection by wire color.
OTPS1KW-ASM-TOPSIDE-R2 Power Supply Connections
Input Power
Connector: IEC 320-C13
Pin
Signal
Function
Description
1
Line
Power
AC Line
2
E
GND
Ground
3
Neutral
Power
AC Neutral
Tether Connection
Connector: Binder 09-6504-000-08
Pin
Signal
Function
Description
1
HV+
Power
+200 VDC
2
N.C.
N.C.
No Connection
3
HV-
Power
-200 VDC
4
Fathom-X-
Signal
Fathom-X pair
1
N.C. = No Connect
2
Green and Brown spare twisted pairs are connected in the OTPS1KW-ASM-ROV-R1 for possible future expansion.
MC-BH-8-M
Face View
Binder 09-6504-000-08
Face View
IEC 320-C13
Face View

9
Pin
Signal
Function
Description
5
Fathom-X+
6
7
Spare-
Spare+
Signal
Spare Twisted Pair
PE
Protective Earth
GND
Protective Earth GND
USB FXTI Connection
Connector: USB Type-B
Standard USB pinout
Pin
Signal
Function
Description
1
VCC
Power
+5V
2
D-
Signal
Data -
3
D+
Signal
Data +
4
GND
GND
Ground
External FXTI Connection
Connector: Binder 770
Pin
Signal
Wire Color
Description
1
2
Fathom-X -
Fathom-X +
Blue
Blue/White
Fathom-X pair
3
4
Spare
Spare
Orange
Orange/White
Spare twisted pair2
5
6
N.C.
N.C.
Green
Green/White
No Connection
7
8
N.C.
N.C.
Brown
Brown/White
No Connection
Binder 09-6504-000-08
Back View
Blue
Blue/
White
Orange
Orange/
White

10
Tether Wiring