VideoRay Pro 4 User manual

Copyright
Pro4MaintenanceManual,Novice1.00.00
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©2015,VideoRayLLCTheGlobalLeaderinMicroROVTechnology

TableofContents
Pro4MaintenanceManual,Novice1.00.00
TableofContents
Copyright
TableofContents
AboutthisDocument
HowtoGetHelp
UserMaintenancePolicy
MaintenanceBestPractices
WellEquippedShop
BasicEquipmentCare
SpecialHandling
ORings
CartridgeSeals
ExampleCartridgeSeals
ElectronicsComponents
HullMaterials
PeriodicMaintenance
Diagnostics
StartUp
Power
Communications
Control
HandController
Video
RemovalandReplacement
MainHull
FloatBlock
StrainRelief
SkidKit
HorizontalThrusters
HorizontalPropeller
HorizontalCartridgeSeal
HorizontalNozzle
VerticalThruster
VerticalPropeller
VerticalThrustSplitter
VerticalCartridgeSeal

AboutthisDocument
Pro4MaintenanceManual,Novice1.00.00
AboutthisDocument
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 
[e-mail] GeneralInformationandSales
[e-mail]

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.
OnlineManual
Thefullversionofthismanualisavailableonlineinthefollowingformats:
http://download.videoray.com/documentation/_pro_4_mntmasterforviewingtheHMTLonline.
http://download.videoray.com/documentation/mnt/pdf/videoray_doc__pro_4_mntmaster.pdfforviewingthePDFonline.
http://download.videoray.com/documentation/mnt/zip/videoray_doc__pro_4_mntmaster.exefordownloadingtheHTMLandPDFfiles.

HowtoGetHelp
Pro4MaintenanceManual,Novice1.00.00
HowtoGetHelp
HelpforyourPro4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 [e-mail]
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ServiceCentersandDealers www.videoray.com/dealer.html
Training
OperatorTraining www.videoray.com/learnmore/training.html
AdvancedMaintenanceTraining www.videoray.com/learnmore/advancedmaintenancecourses.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.

UserMaintenancePolicy
Pro4MaintenanceManual,Novice1.00.00
UserMaintenancePolicy
User'sareultimatelyresponsibleforthesafeoperationandlongevityoftheirVideoRayequipmentbyminimallyfollowingbestpracticesoutlined
intheOperator's/MaintenanceManual,recognizedindustrystandardsandusingcommonsense.
VideoRaystronglyrecommendsthatallserviceandrepairofVideoRayequipmentownedbyusersbecarriedoutbyVideoRayCertified
TechniciansatVideoRayAuthorizedServiceCenters.EquipmentleasedfromVideoRayMUSTbereturnedtoaVideoRayAuthorizedService
Centerforserviceandrepair.
VideoRayalsounderstandsthatlogisticsandotherissuesmaymakeitdifficultandcostlytoreturntheequipmenttoaFactoryAuthorizedService
Centerforcompletionofsomeofthesimplerprocedures.Thefollowingproceduresareconsideredacceptablefortheownersandlesseesto
completewithoutimpactonthewarranty.Notethatcleaningcomponentsisarequiredconditionforcontinuedwarrantyprotectionandthatfailure
toexercisereasonablecareduringtheseproceduresmayresultinwarrantyclaimsbeingdenied.
Cleaningcomponents
Lubricatingconnectors
Removingandreplacing:
FrontDomeProtector
FloatBlock
Skid
Propellers
CartridgeSeals
VerticalThrusterSplitter
HorizontalThrusterNozzle
InstructionsforperformingtheseproceduresareincludedintheOperator's/MaintenanceManual.Userswhodonotfeelcomfortablecompleting
theseproceduresareinvitedtocontactVideoRayforassistance.
RemovingothercomponentsoftheROVoropeningthecontrolpanelmayvoidthewarranty.
Foruserswhowanttocompleteserviceandrepairproceduresbeyondthescopeoftheabovelistontheirown,VideoRayoffersAdvanced
MaintenancecoursesandFactoryServicemanualsforadditionalfees.Thesemaybevaluableforsituationswheretheequipmentwillbeusedfor
missioncriticalapplicationsorinremotelocations.However,thebestadviceinthesesituationsistomaintainspareequipmentonsiteforinstant
resumptionofoperationsintheeventoffailure.

MaintenanceBestPractices
Pro4MaintenanceManual,Novice1.00.00
MaintenanceBestPractices
 ToavoidinjuryordamagetotheVideoRay,disconnectthesystempowerandtetherbeforecommencingany
maintenanceand/orrepairs.
Thebestmaintenanceprogramsbeginbeforetroubleoccurs,andpreventativemaintenanceshouldbeyourfirststepontheroadtoreliable
systemperformance.
Inspections
Inspectionsshouldbecarriedoutbeforeandaftereverydiveaspartofthepreandpostdiveprocedures.Beobservantforsignsoflooseparts,
wearorimpendingfailurecatchsmallproblemsbeforetheybecomebigproblems.A
Failuretoinspectandreplacethrustercartridgesealsregularlyisoneofthemostcommonreasonsforsystemstobereturnedto
VideoRayforrepair.Wateringressthroughthethrustercartridgesealstypicallyleadstomajorinternalcomponentdamage,whichisexpensiveto
repair.Viewexamplecartridgeseals.
TrainedOperators
Donotsubjectequipmenttoaccidentalorinadvertentabusebysomeonewhoisnottrainedinitsproperuse.
TrainedTechnicians
Maintenanceshouldbecompletedbytrainedandcertifiedtechnicians,andusingfactoryauthorizedparts.VideoRayrecommendsthatyoucreate
andmaintainasystemlogbook.Thelogbookentriescanincludedetailsofmissions(date,location,conditions,divetime,etc.)andmaintenance
performed(date,procedure,partsreplaced,etc.).Thelogbookmayhelpidentifypossiblecausesofproblemsandsystemicissuesthatshouldbe
reportedtoVideoRayforfurtherinvestigation.
Service
Followrecommendedperiodicmaintenanceschedules,documentedproceduresandusethepropertools.Workinacleanenvironment.Forany
serviceorrepairprocedurebeyondthescopeofthesimplerproceduresdefinedintheUserMaintenancePolicy,contactVideoRayforassistance.
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
1/4"and5/16"nutdrivers
Miscellaneousscrewsandmainhullrods
5/16"Openendwrench Mainhullrods
7/16"Openendwrench Propellerlockingnuts
Rubbertippedpipepliers* Thrustercones
11/16"Openendwrench* Terminationblock(tetherconnection)
13/16"Openendwrench* Terminationblock(tetherconnection)
3/4"Openendwrench* Pressuresensor
7/8"Openendwrench* Pressuresensor(requiredforoldstyleblackaluminumhousingpressuresensorsonly)
11/4"Openendwrench* Verticalthruster
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thePro4.
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.
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.

PeriodicMaintenance
Pro4MaintenanceManual,Novice1.00.00
PeriodicMaintenance
Thefollowingtablesprovideinformationforperiodicinspectionandmaintenance.Allusersshouldfollowtheseguidelines,however,somerepair
/replacementproceduresrequireadvancedtraining.
Action Frequency
SkillLevel
forRepair/
Replacement
Reference/Notes
External
Visual
Inspection
Beforeandaftereverydive. AllUsers SeetheQuickStartGuideinthe
Operator'sManual.
FreshWater
Soak
Aftereverydive. AllUsers SeetheQuickStartGuideinthe
Operator'sManual.
Cartridge
Seal
Replacement
Whenthecartridgesealoillevelislessthan1/2thevolumeofthe
cartridge.
Whenthecartridgesealoillookscloudyorcontaminated.
Whenyounoticeasignificantchangeinthecartridgesealoillevelover
ashortperiodoftimeoruse.
AllUsers Seethehorizontalorverticalcartridge
sealremovalandreplacement
instructionsintheMaintenanceManual.
Propeller
Replacement
Whenthepropellerbladeiscracked,chippedorexcessivelyworn. AllUsers Seethehorizontalorverticalpropeller
removalandreplacementinstructionsin
theMaintenanceManual.
FloatBlock
Replacement
IftheROVisusedinenvironmentswherethefloatblockisroutinely
scraped,suchasinshiphullinspections,thefloatblockshouldbe
replacediftheoutershellissignificantlyworn.Thefloatblockshouldbe
replacedbeforetheoutershelliswornthroughtothecorematerial.
AllUsers Seethefloatblockremovaland
replacementinstructionsinthe
MaintenanceManual.
MainDome
Replacement
Whenthedomeisscratchedormarredwithinthecamera'sview.
Whenthedomehasdeepscratchesorcracks.
Advanced
Training
Required
Seethefrontorreardomeremovaland
replacementinstructionsinthe
MaintenanceManual.
Note:Themaindomesare
interchangeableandthereardomecan
beusedonthefrontoftheROVto
replaceamildlyscratchedormarred
domethataffectscameraimagequality.
LightDome
Replacement
Whenthedomehasdeepscratchesorcracks. Advanced
Training
Required
Seethelightdomeremovaland
replacementinstructionsinthe
MaintenanceManual.
Desiccant
Pack
Replacement
Whencondensationappearsontheinsideofthedomesandaleakhas
beenruledout.
Advanced
Training
Required
Seethedesiccantpackremovaland
replacementinstructionsinthe
MaintenanceManual.
Note:Thedesiccantpackcanbedried
andreused.Todrythedesiccantpack,
removeitandheatitinalow
temperatureoven(150200For6595
C)forabout1/2hour.
Oring
Replacement
Annually.
WhenanOringlookscrackedorsufferingfromdryrot.
Advanced
Training
Required
Seethespecificinstructionsforeach
componentintheremovaland
replacementsectionoftheMaintenance
Manual.
Hull
Component
Replacement
Withpropermaintenanceandcleaning,mosthullcomponentshavelife
expectancyofmanyyears.Ifyounoticecorrosionordeeppitting,you
mayneedtoreplacethatcomponent.
Advanced
Training
Required
Seethespecificinstructionsforeach
componentintheremovaland
replacementsectionoftheMaintenance
Manual.
Procedureswithaskilllevelof"AdvancedTrainingRequired"requireknowledgeandskilllevelsbeyondwhatispresentedinthisuser
manual.VideoRayofferstrainingcoursesforoperatorsandtechnicianstoaddresstheseneeds.ContactVideoRayformoreinformation.
ProceduresforremovingandreplacingcommonwearitemscanbefoundintheRemovalandReplacementsectionoftheMaintenanceManual.

Diagnostics
Pro4MaintenanceManual,Novice1.00.00
DiagnosticsandRepair
AreyouhavingabaddaywithyourPro4?Youhavecometotherightplace.
Solvingproblemsrequireseitheramethodicaldiagnosticsapproach,orlotsofluck.Ifyoudon'tliketogamble,thefollowingmayhelpyou
overcomechallengesthatinevitablypresentthemselvesfromtimetotime.
BeforeprovidingthespecificdetailsofdiagnosingandrepairingthePro4,somebasictroubleshootingguidelinesareinorder.Followingthese
practicesshouldmakeyoureffortsmuchmoreefficientandsuccessful.
SuspectandchecktheobviousfirstIt'seasytogetdistractedandoverlooksomethingobvious.
RechecktheobviousHavesomeoneverifyyourwork.Ifyou'rehelpingsomeone,verifywhatyou'vebeentold.Sometimes,justtalking
throughthedetailscanhelpyourealizedyoumissedasteporfact.
UnderstandcorrectoperationandexpectedresultsHowshoulditworkandwhatshouldhappen?Doesit?
LearnandrecognizesymptomsWhataretheresultstellingyou?Whatarethemostlikelysuspectsandwhatcanberuledout?
Isolate,DivideandConquerClassifytheproblemtosubsystems,removewhatyoucanandsubstituteknownworkingpartsifpossible.
Or,trysuspectpartswithaknownworkingsystem.
OnestepatatimeBelogicalandmakeeachtestprovideresultsyoucanusetonarrowdowntheproblem.
ThePro4isacollectionofrelativelysimplecomponents,butwhensomethinggoeswrong,it'seasytogetoverwhelmed.Thefollowingsteps
shouldbeyourfirstresponsetoageneralsystemmalfunction,especiallyifthepowerandcommunicationswarningindicatorsintheROVHealth
instrumentarelit.
1. Powerdownthesystem,checktheconnectionsandrestartusingtherecommendedprocedures.
2. USBproblemscanbetherootofseveralbasicsystemmalfunctions.DisconnecttheUSBcablefromthebackofthecomputer,waitafew
secondsandthenreconnectit.SometimestheUSBcontrollercanbelockedup.TryconnectingtheUSBcabletoadifferentportonthe
computerorrebootingthecomputer.
3. Toidentifywhetherthetetherisapossiblesourceoftheproblem,connecttheROVdirectlytothecontrolpaneltoseeifthesymptoms
persist.
4. Removeallattachedaccessoriestoeliminatethepossibilitythatanaccessoryisthesourceoftheproblem.
Iftheproblemismoreisolatedtoaspecificfunction,orthesestepsfailtoresolveageneralproblem,it'stimeforacloserlookatthesymptomsand
subsystems.
SubSystemDiagnostics
Power
Communications
Control
Controller
Video
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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

RemovalandReplacement
Pro4MaintenanceManual,Novice1.00.00
ComponentRemovalandReplacement
ThisdocumentationguidesusersthroughremovalandreplacementoftheprimarycomponentsoftheROV.Thesecomponentsarecategorized
asrequiringNovice,IntermediateorAdvancedknowledgeandskills,andversionsofthisdocumenthavebeencreatedtoincludeonlyuptoone
oftheselevels.AttheAdvancedlevel,allIntermediateandNovicecomponentsareincluded,soallthreeversionsarenotneededtohavethefull
set.ThisNoviceversionisincludedwithproductdocumentation.TheIntermediateandAdvancedversionsareincludedwiththeappropriate
trainingcourses.
Theinstructionsforeachcomponentconsistoftwosections:
1. Removal
2. Replacement
Eachsectionconsistsof:
1. Aonepageoverviewthatincludes
a. Skilllevelrequirement
b. Estimatedtimetocompletetheoverallremovalorreplacementprocess
c. Alistofthetoolsrequired
d. Alistoftheothercomponentsthatneedtoberemoved/replaced
2. Pagesthatoutlinethestepsforeachcomponentthatneedstoberemovedorreplacedthatinclude
a. Skilllevelrequirementforthespecificcomponent
b. Estimatedtimetocompletethestepsforthespecificcomponent
c. Alistofthetoolsrequiredforthespecificcomponent
d. Adetailedlistofpartsthatareconsideredpartofthespecificcomponent,suchasscrews,washers,and/orothermiscellaneous
hardwareitems.
Inaddition,thereisa"ComprehensivePartsList,"pagethatlistsallofthepartsthathavetoberemovedorreplacedforthespecificcomponent
andalloftheassociatedcomponentsthatmustberemovedorreplaced.
MainHull
TheMainHullsectionincludesremovalandreplacementstepsforthefollowingcomponents:
1. FloatBlockKit
2. StrainReliefCableKit
3. SkidKit
HorizontalThrusters
TheHorizontalThrusterssectionincludesremovalandreplacementstepsforthefollowingcomponents:
1. HorizontalThrusterPropellerKit(LeftandRight)
2. HorizontalThrusterCartridgeSeal
3. HorizontalThrusterNozzleKit
VerticalThruster
TheVerticalThrustersectionincludesremovalandreplacementstepsforthefollowingcomponents:
1. VerticalThrusterPropellerKit
2. VerticalThrusterSplitter
3. VerticalThrusterCartridgeSeal