VideoRay Explorer User manual

August, 2014 http://www.videoray.com Version 1.0, Rev. C
Explorer
S UBMERSIBLE R EMOTELY
O PERATED V EHICLE
V

VideoRay Explorer
August, 2014 http://www.videoray.com Version 1.0, Rev. C
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1 INTRODUCTION ...............................................................................................................................................4
1.1 ABOUT THIS MANUAL ...............................................................................................................................4
1.2 ABOUT YOUR VIDEORAY .........................................................................................................................4
1.3 FRIENDLY ADVICE .....................................................................................................................................4
2 GENERAL INFORMATION.............................................................................................................................5
2.1 DESCRIPTION...............................................................................................................................................5
2.2 OPERATING ENVIRONMENT ....................................................................................................................5
2.3 EXPLORER SPECIFICATIONS....................................................................................................................6
3 SAFETY FIRST! .................................................................................................................................................7
3.1 USE COMMON SENSE .................................................................................................................................7
3.2 ELECTRICAL AND VIDEORAY SAFETY..................................................................................................7
3.3 PERSONAL SAFETY ....................................................................................................................................7
4 GETTING FAMILIAR WITH YOUR VIDEORAY .......................................................................................8
4.1 UNPACKING YOUR VIDEORAY................................................................................................................8
4.2 INSPECTING YOUR VIDEORAY ................................................................................................................8
4.3 PREPARING TO OPERATE YOUR VIDEORAY ........................................................................................8
5 YOUR FIRST DIVE............................................................................................................................................9
5.1 DIVE CONDITIONS ......................................................................................................................................9
5.2 SETTING UP YOUR VIDEORAY.................................................................................................................9
5.3 PRE-DIVE INSPECTION.............................................................................................................................10
5.4 LAUNCHING THE VIDEORAY .................................................................................................................10
5.5 MANEUVERING THE VIDEORAY ...........................................................................................................11
5.6 RETRIEVING THE VIDEORAY.................................................................................................................12
5.7 POST-DIVE INSPECTION ..........................................................................................................................12
6 VIDEORAY CONTROLLER FEATURES AND FUNCTIONS ..................................................................13
6.1 CONNECTORS ............................................................................................................................................13
6.1.1 TETHER CONNECTION.....................................................................................................................13
6.1.2 VIDEO .................................................................................................................................................13
6.1.3 100/240 VAC 50-60 Hz........................................................................................................................13
6.2 SWITCHES...................................................................................................................................................13
6.2.1 MAIN POWER (On | Off) ....................................................................................................................13
6.2.2 DEPTH CONTROL (Up | Down) ........................................................................................................13
6.2.3 TILT (Down | Up) ................................................................................................................................14
6.2.4 FOCUS (Out | In) ................................................................................................................................14
6.2.5 LIGHTS (Dim | Bright) ........................................................................................................................14
6.2.6 AUXILIARY (On | Off).........................................................................................................................14
6.3 LCD DISPLAY .............................................................................................................................................14
6.3.1 DEPTH GAUGE..................................................................................................................................14
6.3.2 COMPASS............................................................................................................................................14
6.4 JOYSTICK (FORWARD |LEFT |RIGHT |REVERSE) ........................................................................................15
6.4.1 JOYSTICK THIRD AXIS CONTROL...................................................................................................15
6.4.2 JOYSTICK SENSITIVITY ....................................................................................................................16
6.5 MONITOR CONTROL.................................................................................................................................16
6.5.1 POWER................................................................................................................................................16
6.5.2 SYSTEM ...............................................................................................................................................16
6.5.3 Additional non-labeled buttons on the display monitor.......................................................................16
7 “BEST” PRACTICES AND DIVING TIPS....................................................................................................17
7.1 NAVIGATION..............................................................................................................................................17

VideoRay Explorer
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7.2 HANDLING THE TETHER .........................................................................................................................17
7.3 AVOIDING TANGLES ................................................................................................................................19
7.4 FREEING ASNAGGED TETHER ..............................................................................................................19
7.5 BALLAST SETUP........................................................................................................................................19
7.6 INCREASING THRUSTER POWER...........................................................................................................20
7.7 LOSS OF THRUSTER POWER ...................................................................................................................20
7.8 FOGGED VIEW PORT AND/ OR LIGHT LENSES....................................................................................20
8 VIDEORAY MAINTENANCE ........................................................................................................................21
8.1 CLEANING VIDEORAY .............................................................................................................................21
8.2 INTERNAL MOISTURE DETECTION.......................................................................................................21
8.2.1 MOISTURE INDICATOR ....................................................................................................................21
8.3 MECHANICAL SERVICING ......................................................................................................................21
8.3.1 PRECAUTIONS ...................................................................................................................................21
8.3.2 REQUIRED TOOLS ............................................................................................................................21
8.4 CARING FOR SEALS AND O-RINGS........................................................................................................22
8.4.1 O-RiNG RULE OF THUMB ................................................................................................................22
8.4.2 INSPECTION.......................................................................................................................................22
8.4.3 CARE AND STORAGE ........................................................................................................................22
8.4.4 HANDLING SEALED COMPONENTS...............................................................................................22
8.5 SERVICING THE LIGHTS ..........................................................................................................................23
8.5.1 REPLACING A LIGHT BULB .............................................................................................................23
8.6 THRUSTER GUARD AND PROPELLER REMOVAL ..............................................................................23
8.6.1 VERTICAL THRUSTER GUARD ........................................................................................................23
8.6.2 PROPELLER REMOVAL / REPLACEMENT......................................................................................23
8.7 CARTRIDGE SEAL INSPECTION AND REPLACEMENT ......................................................................23
8.8 MAIN HOUSING .........................................................................................................................................24
8.8.1 OPENING VIDEORAY’S MAIN HOUSING........................................................................................24
8.8.2 REASSEMBLY OF MAIN HOUSING ..................................................................................................25
8.9 CALIBRATION............................................................................................................................................25
9 FIELD SERVICING .........................................................................................................................................27
9.1 TROUBLE SHOOTING ...............................................................................................................................27
9.1.1 LIGHTS DO NOT WORK ....................................................................................................................27
9.1.2 LOSS OF THRUST OR MANEUVERABILITY....................................................................................27
9.1.3 VIDEO MONITOR DOES NOT SHOW PICTURE .............................................................................27
9.1.4 POOR PICTURE QUALITY ................................................................................................................27
9.2 ORDERING PARTS .....................................................................................................................................28
9.3 WARRANTY REPAIRS...............................................................................................................................28
10 VIDEORAY TOOLS & SPARE PARTS KIT..........................................................................................29
11 APPENDIX A – LIMITED WARRANTY...............................................................................................30

VideoRay Explorer
August, 2014 http://www.videoray.com Version 1.0, Rev. C
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1INTRODUCTION
1.1 ABOUT THIS MANUAL
The purpose of this manual is to provide information only. It is subject to change without
notice and does not represent a commitment on the part of the VideoRay, or its agents.
1.2 ABOUT YOUR VIDEORAY
Prior to shipment, the VideoRay Scout was tested and found to comply with factory
standards.
The serial number of the VideoRay is labeled on the hull under the float block, and inside
the hull (visible through the rear dome). The serial number of the controller is engraved
on a plate that is attached to the front of the Controller case. Please provide your system
serial number(s) whenever corresponding with us.
1.3 FRIENDLY ADVICE
“Flying” the VideoRay can be somewhat addictive. If you are operating VideoRay and
have an important appointment later in the day, we strongly recommend you set an alarm
clock or arrange to have a friend remind you at the appointed time!
This manual Copyright © 2014VideoRay LLC All Rights Reserved.

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August, 2014 http://www.videoray.com Version 1.0, Rev. C
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2GENERAL INFORMATION
2.1 DESCRIPTION
VideoRay Explorer is a submersible, Remotely Operated Vehicle (ROV) designed to take
advantage of its portability and size. Set up and vehicle control are simple and intuitive,
enabling VideoRay to be easily carried, deployed, and operated by one person. VideoRay
can go anywhere, powered from AC, or battery pack and inverter. Operation of the
VideoRay is quickly mastered after only a few practice “flights.” Connection to a video
monitor provides the operator with a view of everything the VideoRay sees.
VideoRay’s pressure housings are machined from marine grade aluminum and protected by
an anodized finish. The vehicle is equipped with a forward camera, two lights, and three
thrusters.
VideoRay carries no batteries; it is completely powered and controlled from the surface
through a small diameter tether.
The VideoRay power supply plugs into any standard grounded 100/240 Volts AC 50/60
Hz power source. For operational safety, the joystick control, vehicle and tether carry a
maximum voltage of 48 Volts DC.
2.2 OPERATING ENVIRONMENT
VideoRay ROV
Medium: Fresh or Salt Water
Operating Temperature: 32-122º F (0-50ºC)
VideoRay Power Supply / Controller
Caution: While VideoRay is designed to be operated in water, the Power Supply /
Controller is splash-resistant and should not be subject to excessive water spray or rain
when opened. The Power Supply /Controller case is watertight only when closed.

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2.3 EXPLORER SPECIFICATIONS
Depth Rating 91 m (300 feet)
Depth Gauge Calibrated in meters or feet (user selectable)
Resolution = 0.1 units (meters or feet)
Dimensions 35 cm (13 ¾ inches) long
22.2 cm (8-¾ inches) wide
21.6 cm (8-½ inches) high
Weight 3.6 kg (8 lb.)
Housing Material Anodized Aluminum (marine grade)
Input Voltage 100/240 Volts AC 50/60 Hz Power Source
Internal Voltage 48 Volts DC maximum
Lights 2 - 20 watts (1 port, 1 starboard)
Camera Tilt Angle +/- 75º Pitch (vertical rotation)
Camera Focus Range From the face of the housing dome to infinity
Tether 76 m (250 feet) Neutrally Buoyant
Minimum bend diameter = approximately 8 cm (3 inches)
Controller Integrated with power supply in Pelican Diver Case
Video Display Monitor 127mm (5 inch) LCD

VideoRay Explorer
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3SAFETY FIRST!
The following are some safety tips that may prevent injury to you as the operator and those
around you, or damage to the VideoRay submersible.
3.1 USE COMMON SENSE
These first instructions appeal to common sense:
1) Read the safety and operating instructions before operating the VideoRay.
2) Retain this manual and other safety and operating instructions for future reference.
3) Heed all warnings printed on the system components and in the manual.
4) Follow the operating and maintenance instructions.
5) Be aware of and alert to potential hazards in and around water, including weather
conditions, and follow standard water safety practices.
3.2 ELECTRICAL AND VIDEORAY SAFETY
1) Protect the Power Supply / Controller from splashes and immersion in water when
open. The controller is sealed when closed, and splash resistant when open.
2) Always plug the system into a grounded receptacle.
3) There are No User Serviceable Parts Inside the power supply. Only qualified
technicians or VideoRay personnel should perform electrical servicing.
4) Do not subject the VideoRay to impact. The camera, lights, and electronic components
may be damaged by an impact.
5) Never operate the lights for more than 60 seconds out of water. Never operate the
thrusters for more than 20 seconds out of water. Your VideoRay is designed for
submerged operation and requires water to cool the lights and thrusters.
6) Do not stress or kink the tether or bend it tighter than the minimum bend diameter,
which is about 3 inches. Do not allow the tether to be deployed over sharp edges or
rough surfaces.
3.3 PERSONAL SAFETY
Be aware of the safety of those around you!
1) Beware of swimmers or boaters. The VideoRay and tether can pose a hazard to
swimmers, divers, and small craft, as well as persons in and around the operating area.
Obtain the acknowledgment of those around you prior to launch. Make sure everyone
within VideoRay’s range of operation is aware the vehicle is being deployed.
2) Keep your operating area neat and free of accident causing clutter.
3) Keep fingers and objects clear of the thruster propellers.

VideoRay Explorer
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4GETTING FAMILIAR WITH YOUR VIDEORAY
4.1 UNPACKING YOUR VIDEORAY
Your VideoRay Remotely Operated Video Inspection Submersible is packaged and
shipped in two rugged Pelican Diver Cases. These cases have O-rings and are sealed
against water when closed. The smaller case integrates the power supply, controller, and
video display monitor. The larger wheeled case contains the VideoRay ROV and 76
meters (250 feet) of tether.
Upon receiving your VideoRay, check the containers and contents for any damage that may
have occurred during transport.
4.2 INSPECTING YOUR VIDEORAY
In the shipping crates you should find these components:
1) Fully assembled VideoRay ROV with 76 meters (250 feet) of tether
2) Integrated Power Supply / Controller
3) Maintenance Tools and Spare Parts Kit
4) Video Display Monitor (mounted in the cover of the controller case)
5) This Owner's Manual
Should any of these components be missing or damaged, please notify the selling agency.
4.3 PREPARING TO OPERATE YOUR VIDEORAY
Operating your VideoRay controller is like being in the driver’s seat of your car. The
joystick and switches are used to control your VideoRay ROV, similar to the way you use
the steering wheel, pedals and dashboard knobs to control your car’s operation. The
controller’s LCD display provides feedback like your dashboard gauges do.
Before setting up and operating your VideoRay, we ask that you read all safety precautions
in Section 3. The fundamentals of operation can be found in Section 5. Detailed
descriptions of all of the features and functions can be found in Section 6. Section 7
provides advanced handling instructions and tips. Sections 8 and 9 cover maintenance
and troubleshooting.
Take a moment now to familiarize yourself with the VideoRay ROV, the controller’s
layout and the feel of the controls. Proper operation, maintenance and safe handling of
your VideoRay will provide you with many hours of enjoyment of the underwater views.

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5YOUR FIRST DIVE
Your VideoRay ROV has been designed with ease of use in mind. This section covers
only the most basic aspects of operating your VideoRay. It will walk you through the steps
required to make your first dive. Section 6 contains a complete reference to all of the
features and functions of your VideoRay.
Note: If the Safety Instructions have not been read, it is recommended you do so before
operating your VideoRay.
5.1 DIVE CONDITIONS
Your first dive should be made in conditions that are suitable for learning. The following
conditions are optimal:
•Slow water current
•Low wind speed
•Clear water
•No obstructions above or below the surface
While VideoRay can be used in less than optimal conditions, including some rather
extreme conditions, it is best to gain some experience before attempting such challenges. If
the conditions are too adverse, it may be wise to postpone your dive or find a more suitable
dive location.
Until you feel comfortable operating your VideoRay, you should try to operate it within a
close range.
5.2 SETTING UP YOUR VIDEORAY
The following procedures outline the steps required to prepare the VideoRay for operation.
1) Open the Power Supply / Controller box and make sure the Main Power switch is set to
the “Off” position.
2) Unpack the VideoRay and tether. Be careful not to kink the tether. See Section 7.2 for
proper tether handling techniques and cautions.
3) Connect the surface end of the tether directly to the controller. Connect the VideoRay
ROV end of the tether to the VideoRay ROV. The connectors are different and cannot
be accidentally reversed.
4) Plug the power cord into an appropriate Alternating Current (AC) power source.
5) You may need to adjust the ballast depending upon dive conditions and the activities
you intend to perform. See Section 7.5 for more information on adjusting the ballast.
Once the system is connected together, a Pre-Dive Inspection should be made.

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5.3 PRE-DIVE INSPECTION
A Pre-dive check should to be carried out prior to every dive.
1) Visually inspect the vehicle to ensure that the propellers are free of tangles and that the
vehicle is in operational condition. Check the propeller guards for damage and / or
misalignment.
2) Check the tether for scrapes, nicks or other visible damage.
3) Ensure that all fasteners are in place and secure.
4) Ensure that the VideoRay has been properly ballasted for the water conditions in which
you plan to dive, and that the ballast is secure. The VideoRay comes from the factory
ballasted for fresh water although water properties may vary locally and cause a need
for re-ballasting the VideoRay. See Section 7.5 for information on Ballast Setup.
5) Ensure that all cables are properly connected and the tether connectors are screwed
together to avoid separation and loss of the VideoRay ROV.
6) Power up the system by engaging the Main Power switch to the “On” position. The
monitor should automatically power up, but if it does not, there is a power button on the
monitor that may need to be pressed.
7) Using the joystick, displace it in all directions to test the port and starboard thrusters.
CAUTION! Do not operate the thrusters for more that 20 seconds when the VideoRay
ROV is out of the water. Prolonged operation in a dry environment will result in
damage to motor shaft seals.
8) Using the Depth Control knob, rotate it to test the vertical thruster. Return the knob to
the neutral position.
9) Verify that both lights are working by rotating the joystick toward “Bright”, and then
returning the knob to the “Dim” position.
CAUTION! Do not operate the lights for more than 60 seconds when the VideoRay
ROV is out of the water. Doing so may cause overheating and damage the unit.
10) Test the camera tilt and focus functions. The Tilt and Focus switches are spring-loaded
momentary contact type switches and will return to the neutral position when pressure
is released. All switches, except the Main Power switch, work in this way.
11) Check the camera and monitor operation. If you are using a VCR, check that the
recording and playback functions are operational.
12) Power down the system until you are ready to launch the VideoRay.
5.4 LAUNCHING THE VIDEORAY
CAUTION! Be certain that the tether connectors are securely connected and screwed
together to avoid separation and loss of the VideoRay ROV.
1) Power up the VideoRay.