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.