Schilling Robotics TITAN 3 Manipulator System Position-Controlled, 3 Km Submersible

Transcription

1 Schilling Robotics TITAN 3 Manipulator System Position-Controlled, 3 Km Submersible Document No Models: (Gamma)

2 Copyright 2013 by Schilling Robotics, LLC. All rights reserved. Schilling Robotics, the FMC Technologies logo, and their frameworks are trademarks and service trademark applications of FMC Technologies. No part of this document may be reproduced or used in any form without the express written permission of FMC Technologies. Descriptions and specifications are subject to change without notice. FMC Technologies Schilling Robotics 260 Cousteau Place, Suite 200, Davis, CA Ph: (530) Fax: (530) Sales Tech Support Customer Service Web Site Chap/Sec. Page Description Rev. Date Existing per last field update and interim revisions (8)A N/A , p. 11 Add comments: Securing slave cable to prevent conductor failures B Unk P.37-38, Drawing rev: Drawing & part list rev: /25/ Drawing, part list: Pitch/Yaw actuator replaced by p Work Instruction: Pitch/Yaw actuator replaced by /18/04 03/18/ p 4-5 Modify value ranges in table C 09/30/ misc. Add gamma versions, part lists & drawings: , , /22/ p 3 Add gamma specification 11/22/ p 33 Work instruction , rev D to E D 01/12/ p 50 Dwg , rev D to E, part list , rev C to D p 21 Add section Recovery from Water Intrusion 04/07/05 N/A N/A Replaced Teflon with polytetrafluoroethylene (PTFE) E 11/04/13

3 Table of Contents Specifications 1 Electrical Specifications Hydraulic Specifications Slave Arm Specifications Environmental Specifications Component Dimensions Customer-Supplied Equipment Password Information Installation 1 Installation Overview Hydraulic and Electrical Requirements Installation Overview Slave Arm Installation Parameters Slave Arm Installation Installing the Compensator Installing the Slave Controller Tips & Care: Slave Arm Cable & Connectors Installing the Master Controller Installing the Junction Box Page 3

4 Table of Contents 7 Deck-Test Connections Long-Line Connections Options Master Controller Junction Box Slave Controller Completing the Installation First-Time Installations Repeat Installations Host Computer Control Charging the Compensation System First Startup Tutorial Using the Master Controller First Startup The Startup Process The STOW OUT Menu The MAIN Menu The OPERATE Menu Configuring the SET STOW and SET LIMITS Menus System Shutdown Operation 1 The Master Controller Master Controller Features Using the Master Controller Master Arm Slave Arm Status Controlling Slave Arm Hydraulics Page

5 Table of Contents 2.4 Controlling Auxiliary Hydraulic Equipment Menu Structure Menu Security Avoiding Slave Arm Damage Operation Pre-Start Checks Startup Using the STOW OUT Menu Using the MAIN Menu Using the OPERATE Menu Using OPERATE Menu Options Using the SHUTDOWN Menu Shutdown Maintenance Setting Performance Options Using the OPTIONS Menu Using the SETUP Menu System Errors and Warnings Startup with System Warnings Startup with System Errors ERR (Error) Message During Operation Using the SHOW ERRORS Menu Enabling and Disabling System Error Checking Diagnosing Master/Slave Problems Fatal Telemetry Errors Troubleshooting 1 Preliminary Fault Isolation Procedures Definitions DRAFT Page 5

6 Table of Contents 2 Diagnosing Master/Slave Joint Problems The STOW IN/STOW OUT Test Diagnosis with the MASTER TEST Screen Diagnosis with the Slave Test Screen Diagnosing Key and Freeze Button Failures Troubleshooting Tables Screen-Displayed Symptoms Master Arm Symptoms Slave Arm Symptoms (Entire Arm) Slave Arm Symptoms (Individual Joints) Jaw Symptoms System Errors Fatal Telemetry Errors Maintenance & Service 1 Service Alerts Maintenance Daily Maintenance Long Term Periodic Maintenance Hydraulic Power Unit System Maintenance Important Service Practices and Procedures Junction Box Service Fuse Replacement Master Controller Service Accessing Internal Components Fuse Replacement Adjusting the LCD Screen Viewing Angle Master Controller EPROM Chip Replacement Page

7 Table of Contents 6 Slave Controller Slave Controller EPROM Chip Replacement Slave Arm Service Slave Arm Filter Replacement and Cleaning Emergency Manual Slave Arm Manipulation Recovery from Water Intrusion System Adjustments Setting Servo Valve Voltage Offsets Changing the Communication Protocol Work Instructions for Serviceable Components Using the Work Instructions Startup Following Maintenance or Service Drawings & Part Lists 1 Organization Index Manipulator System Spares Kits (Reference) Slave Arm Master Controller w/jaw Switch Slave Controller Junction Box Hydraulic Compensator DRAFT Page 7

8 Table of Contents Page

9 Safety & Service Summary Precautionary Notices Table of Contents This manual provides precautionary notices which carry important information about safety risks to personnel and damage to equipment while installing, operating, servicing, or maintaining this equipment. The form and significance of the notices are shown below.! WARNING A WARNING alerts you to a risk of injury or loss of life. It may also include instructions to help minimize or eliminate the risk.! Caution A CAUTION alerts you to a risk of equipment damage or loss. It may also include instructions to help minimize or eliminate the risk. NOTE: The absence of WARNING and CAUTION notices does not mean that risk is absent. Always use appropriate safety procedures, equipment, and personal protective equipment (PPE) when operating and servicing this equipment. Service Assumption This manual assumes that service personnel are familiar with the general operating principles, safety guidelines, and service practices associated with the types of equipment represented in this manual DRAFT Page 9

10 Table of Contents Safety & Service Summary Precautionary Notices This manual provides precautionary notices which carry important information about safety risks to personnel and damage to equipment while operating or maintaining this equipment. The form and significance of the notices are shown below.! WARNING A WARNING alerts you to a condition, situation, procedure, or action where there is a risk of severe injury or loss of life. It may also include instructions to help minimize or eliminate the risk.! Caution A CAUTION alerts you to a condition, situation, procedure, or action where there is a risk of minor to moderate injury to personnel and/or damage or destruction of equipment. It may also include instructions to help minimize or eliminate the risk. NOTE: The absence of WARNING and CAUTION notices does not mean that risk is absent. Always use appropriate safety procedures and equipment when operating and servicing this equipment. Service Assumption This manual assumes that service personnel are familiar with the general operating principles, safety guidelines, and service practices associated with the types of equipment represented in this manual. Page

11 Specifications In This Chapter: 1 Electrical Specificationspage 11 2 Hydraulic Specificationspage 11 3 Slave Arm Specificationspage 13 4 Environmental Specificationspage 13 5 Component Dimensionspage 14 6 Customer-Supplied Equipmentpage 14 7 Password Informationpage 14 1 Electrical Specifications System Supply (at junction box)90 to 260 VAC, Hz, single-phase Independent: Master controller voltage90 to 260 VAC, Hz, single-phase Slave Controller90 to 260 VAC, Hz, single-phase Power Consumptionsee Table 1 Table 1 Component Inrush Watts Run Master controller Slave controller + solenoid Hydraulic Specifications Motive (Active) System Fluid typesee Table Page 11

12 Specifications Table 2 Fluid Type Temperature Range 50 F to 140 F Petroleum-based Shell Tellus 32 Mobil DTE 24 Chevron AW Hydraulic 32 Texaco Rando 32 Castrol Hyspin AWS 32 Synthetic Royal Purple Marine Hydraulic Oil 32 (see Reference/Hydraulic folder on CD) Glycol-based Houghto-Safe 620 Vegetable-based Hydro-Safe ISO VG 32 NOTE: Use lower viscosity fluids as water temperature decreases. Viscosity cst to 200 cst Flow to 5.0 gpm ( l/min) Pressure (min.) to 3000 psi (max.) ( bar)* Internal slave arm filter microns (25 microns absolute) System return pressure, nominal psi (3.45 bar) Return relief valve cracking pressure, nom., slave arm psi (34.5 bar) Wireway relief valve cracking pressure, nom psi (1.726 bar) *Slave arm performance is reduced at less than 3000 psi. Recommended Hydraulic Filtration Filtration, supply microns (10 microns absolute) NOTE: Use of the recommended filtration will reduce the need to clean or replace the slave arm s internal hydraulic filter (10 microns, 25 microns absolute). Slave Arm Connection Requirements Supply hose psi working pressure, 1/4-in min. I.D.* Supply hose fitting JIC female swivel, 37 flare Return hose psi working pressure, 3/8-in min. I.D.* Page 12 2 Hydraulic Specifications

13 Specifications Return hose fitting JIC female swivel, 37 flare *If hose exceeds 20 feet, contact Schilling Robotics about increasing the hose diameters to maintain adequate pressure and flow. Wireway Compensation System Fluid requirement non-conductive Fluid capacity gal (2.2 l) Fluid pressure (above ambient) to 10 psi (0.48 to 0.69 bar) 3 Slave Arm Specifications See Table 3. Specifications are nominal, referenced to a standard Titan 3 slave arm. Refer to sheet 1 of the slave arm drawing for specifications of your Titan 3 slave arm (see the Drawings and Part Lists chapter). Table 3 Function Slave Arm Functions Actuator Mechanical Range 4 Environmental Specifications Position Sensor Azimuth Rotary 240 Resolver Shoulder Linear 120 Resolver pitch Elbow pitch Rotary 270 Resolver Wrist pitch Rotary 180 Resolver Wrist yaw Rotary 180 Resolver Wrist rotate Gerotor 360 continuous, Resolver 8-35 rpm Jaw Linear 3.8 in.± 0.1 (9.7cm ± 0.25) LVDT Operating temperature F to 130 F (-2 C to 54 C) Storage temperature F to 160 F (-15 C to 71 C) Humidity % to 100% condensing Depth rating ,843 fsw (3,000 msw) Exceptions Titan 3, M/N : Radiation hardened rad gamma Titan 3, M/N : Depth rating ,000 fsw (6,500 msw) Slave Arm Specifications Page 13

14 Specifications 5 Component Dimensions Slave Controller, Submersible, Standard Length in (41.9 cm) Diameter in (18.0 cm) Weight lb (15 kg) Weight in water lb (6 kg) Master Controller Length in (48.5 cm) Width in (15.25 cm) Height in (6.9 cm) Weight lb (4.3 kg) 6 Customer-Supplied Equipment The following equipment and/or services, if not ordered as options from Schilling Robotics, are needed to install and operate the this system: Electrical power source(s) Hydraulic power source All hardware, hoses, and fittings for connecting your hydraulic supply and return lines to the slave arm Mounting fasteners for the slave controller and compensator (if supplied) NOTE: Six 1/2-20 x 2-in screws (P/N ) are provided for mounting the slave arm azimuth spindle to your mounting platform. (Subsea operation) ROV power/telemetry connector 7 Password Information Some control and configuration menus for this manipulator system are password protected. A sheet listing factory-set passwords is located at the end of the Table of Contents. Page 14 5 Component Dimensions

15 Installation In This Chapter: 1 Installation Overview... page 15 2 Slave Arm Installation... page 19 3 Installing the Compensator... page 21 4 Installing the Slave Controller... page 22 5 Installing the Master Controller... page 24 7 Deck-Test Connections... page 24 8 Long-Line Connections... page 26 9 Completing the Installation... page Charging the Compensation System... page First Startup Tutorial... page 33 1 Installation Overview 1.1 Hydraulic and Electrical Requirements For information on hydraulic and electrical requirements of the system, see the Specifications chapter. 1.2 Installation Overview The general arrangement and connection of components are shown in Figure 1, Decktest configuration, on page 16, and Figure 2, long-line configuration options, on page 17. NOTE: Compensator is not supplied with Titan 3 model Page 15

16 Installation Figure 1 Deck-test configuration Page 16 1 Installation Overview

17 Installation Figure 2 long-line configuration options 1.3 Slave Arm Installation Parameters Use the following diagrams to help determine a mounting location for your slave arm: Range-of-motion diagrams: Figure 3 and Figure 4 NOTE: The range-of-motion drawings show the maximum mechanical limits. You can limit the range-of-motion by setting software limits for the travel of individual joints. Slave arm extended dimensions: Figure 5 Slave arm stow dimensions: Figure 6 Mounting dimensions: Figure Installation Overview Page 17

18 Installation Figure 3 Horizontal range of motion Figure 4 Vertical range of motion Page 18 1 Installation Overview

19 Installation Figure 5 Extended dimension Figure 6 Stow dimensions 2 Slave Arm Installation 1. Create a sturdy mounting platform with a flat surface and six through-holes (Figure 7). NOTE: A 1:1 drilling template, drawing , can be found under the Oversize Drawings tab Slave Arm Installation Page 19

20 Installation Figure 7 Azimuth mounting holes 2. Lower the slave arm onto the mounting platform while supporting the elbow and jaw. Orient the small arrow on the side of the azimuth base to the center of the desired azimuth travel. Align the mounting holes and verify that the azimuth sits flat on the mounting surface. Lubricate the screws with Aqua Lube (or equivalent), install, and torque to 80 ft/lb (108 Nm). NOTE: Six 1/2-20 x 1.5 in. screws (P/N ) are provided for mounting the slave arm azimuth spindle to your mounting platform. Minimum screw engagement into the spindle is 0.5-in (12.7 mm) 3. Cconnect the slave arm cable (Figure 8). Provide enough cable slack to allow full slave arm movement without stressing cable or connector. To avoid damage to the cable, observe the following minimum bend radius dimensions: Minimum bend radius, static in (100mm) Minimum bend radius, dynamic in (150 mm) Glenair Connector Slave Arm Cable Figure 8 Slave arm cable connection Page 20 2 Slave Arm Installation

21 Installation 4. Connect the hydraulic supply and return hoses to the slave arm (Figure 9). The ports are identified as follows: P = Pressure/Supply R = Return 5. Connect the compensator hose to the fitting on the slave arm azimuth (Figure 9). Compensation Port -6 JIC Return -4 JIC Pressure Figure 9 Hydraulic and compensation connections 3 Installing the Compensator Compensator is supplied only with Titan 3 model Select a mounting location for the compensator within hose-length of the base module. The compensator may be mounted horizontally or vertically (fitting end up). If the compensator must be sidewall mounted, a 1/2-in NPT port will be highest, and a bushing will be required to relocate the bleed/relief valve. Figure 10 Compensator mounting dimension Installing the Compensator Page 21

22 Installation 2. Drill the mounting surface to mate with the mounting bracket bolt pattern shown in Figure 10. NOTE: Do not use Loctite or similar compounds containing bisphenol A fumarate on fittings or hardware contacting the polyurethane compensator housings. They can cause brittleness and micro-cracking. The use of Nylock or patch hardware and polytetrafluoroethylene (PT- FE) tape for fittings is recommended. 3. Mount the compensator using 6mm or 1/4-in stainless-steel hardware. Relocate the bleed valve to the highest port as needed (see Figure 11). Compensator Supply Ports Bleed/Relief Valve (at highest point) Figure 11 Compensator ports 4. Connect the compensator hose to either of the two ports on the compensator body. 5. If you want to dry-test the compensation system, charge the compensator half-full with air (the spring-loaded diaphragm will produce a pressure of about 1 atmosphere, 15 psi). Check for leaks by spraying all connections and compensated components with a mild detergent or window cleaner. Active bubbles or foam indicate a leak. Or, install a pressure gauge on the compensation system and check the pressure gauge over a minimum of 2 hours. If a pressure drop occurs, check for leaks using the method described above. 6. For information on charging the compensator, see Charging the Compensation System on page 31. Although the compensation system can be charged now, the slave arm must be moved to several positions to bleed it. This is best accomplished when the Titan 3 system is completely installed, tested, and safe movement limits and stow/deploy positions have been set. 4 Installing the Slave Controller Mount the slave controller using the four 7/16-14 threaded holes in its base. Refer to Figure Determine a mounting location where the slave arm cable can reach the slave controller without snagging on other equipment, and the slave controller is safely located inside the vehicle s framework. Page 22 4 Installing the Slave Controller

23 Installation 2. Prepare the mounting location with four through-holes. 3. Lubricate the threads of four 7/16-14 stainless steel screws (not supplied) with Aqua Lube (or equivalent) and install into the mounting bracket. Minimum screw engagement = 0.5-in (13 mm) Figure 12 Slave controller mounting 4. Connect the slave arm cable to the slave controller (see Deck-Test Connections on page 24 or Long-Line Connections on page 26). 4.1 Tips & Care: Slave Arm Cable & Connectors The following recommendations can help to get the best performance and longest life from the standard slave arm cable ( ) and the bulkhead connectors on the slave arm and slave controller, particularly after the initial installation. 1. Clean the connectors on the cable prior to installation. a. Remove the flat seal (face seal), clean, inspect, and replace if required (P/N ). Do not lubricate the flat seal, as this can cause debris to collect and could lead to problems in the future. b. Clean the connector and locking ring to remove any debris and re-install the flat seal. NOTE: A cleaner and connector lubricant, such as Pro-Gold G5 ( ), is recommended for use on the connector pins and socket. Allow any moisture that may condense on the mating surfaces of the connector from the aerosol spray to evaporate before mating the connector 2. Before installing the cable, especially after prior use, remove the o-ring from the mating flanged connector on the slave arm and slave controller. Clean the o-ring groove with a cotton bud or Q-tip. Clean and inspect the o-ring and replace if Installing the Slave Controller Page 23

24 Installation damaged ( ). Lightly lubricate the o-ring with Dow Corning 55, Dow Corning 4, Moly-kote M55, or petroleum jelly, and install into the 0-ring groove. 3. Be sure that you are mating the male connector to the female connector.! Caution Mating the connectors male to male can damage the cable and/or slave wiring harness beyond repair. 4. Tighten the coupling nut to 6-8 Nm (50-70-in./lb). 5. Periodically, the flanged bulkhead connectors should be removed from the slave controller and slave arm to clean the o-ring groove and replace the o-ring ( ). Corrosion can be a problem on aluminum slave controllers. Therefore apply a film of o-ring grease or Aqualube beneath the flange to retard corrosion. 5 Installing the Master Controller The master controller (Figure 13), has no mounting hardware, and can be placed on any flat, dry surface. Master arm NOTE: The master arm is a precision instrument. Never use it to lift or carry the master controller. Always support the master arm, or rest it on the faceplate, when you carry the master controller. Do not force the master arm joints byond their mechanical limits. Figure 13 The master controller 6 Installing the Junction Box The junction box uses no mounting hardware and can be placed on any flat, dry surface. Its connections depend on whether it is used for deck-testing or is incorproated into a long-line system. These options are covered in Deck-Test Connections on page 24 and Long-Line Connections on page Deck-Test Connections The Titan 3 Manipulator System includes all components needed for deck-testing or local operation (see Figure 14). Page 24 5 Installing the Master Controller

25 Installation Figure 14 Deck-test connections Making the Deck-Test Connections Refer to Figure Connect the junction box AC power cord P1 to a VAC power source. 2. Connect the cable from the master controller to connector P2. 3. Connect the deck test cable ( ) to connector P3 and the bulkhead connector on the slave controller. Figure 15 Junction box connections 4. Proceed to Completing the Installation on page Deck-Test Connections Page 25

26 Installation 8 Long-Line Connections 8.1 Options In typical ship-based applications, where the slave arm and slave controller of the Titan 3 Manipulator System are mounted to a remotely operated vehicle (ROV), telemetry is routed through the long-line telemetry system. Electrical power must be available on the ROV for the slave controller and in the control station for the junction box/master controller. Long-line connection options are illustrated in Figure 16. Figure 16 Long-line power and telemetry connection options Integrating the Titan 3 Manipulator System into a long-line systems is usually done using the options below. Page 26 8 Long-Line Connections

27 Installation Option 1 The preferred integration option is to use the bulkhead connector ( ) to link the master controller telemetry with your long-line system and supply VAC power to the master controller. Use the subsea power/telemetry cable whip (item 14) for connecting the slave controller to ROV telemetry and power. This option leaves the junction box and deck test cable ( ) free for deck testing. Option 2 Plug the junction box AC cord into a VAC source to power the master controller. Use the spare plug connector ( ) to link telemetry from the junction box to your long-line system. Use the subsea power/telemetry cable whip (item 14) for connecting the slave controller to ROV telemetry and power. For deck testing, the junction box must be disconnected from control station electrical power and telemetry. NOTE: Bulkhead connector , plug connector , and a slave cable whip (see 199- part list for number) are supplied for making long-line connections. The specific component connections for both options are covered in the following sections. 8.2 Master Controller The master controller (Figure 13), has no mounting hardware, and can be placed on any flat, dry surface. NOTE: The master arm is a precision instrument. Never use it to lift or carry the master controller. Always support the master arm, or rest it on the faceplate, when you carry the master controller. Do not force the master arm joints byond their mechanical limits Option 1 Wire the bulkhead connector ( ) to connect the master controller into your long-line telemetry system and VAC power. Connector pin assignments are the same as shown for junction box connector P2 in Figure 17. Connect the master controller power/telemetry cable to the bulkhead connector Option 2 Connect the master controller power/telemetry cable to junction box connector P2 (see Figure 17) Long-Line Connections Page 27

28 Installation Figure 17 Junction box connector pin assignments 8.3 Junction Box The junction box (Figure 18) uses no mounting hardware, and can be placed on any flat, dry surface. If you are using an auxiliary computer for system control, connect its cable to the RS-232 port (P4). Option 1 Figure 18 Junction box connections No connections are necessary. The junction box is used only for deck testing. Option 2 1. Use the plug connector ( ) for linking Titan 3 telemetry from the junction box connector P3 (Figure 17) to your long-line telemetry. Pin assignments are shown in Figure 19. Page 28 8 Long-Line Connections

29 Installation P1 P1 AC LIVE AC LIVE AC GND AC GND AC NEUTRAL 422+ AC NEUTRAL FD FD- FD+ 422 FD- P P MATING SIDE VIEW 5 MATING SIDE VIEW WIRE SIDE VIEW 6 WIRE SIDE VIEW Figure 19 P3 Cable wiring, Titan 3 M/N Connect the master controller cable to connector P Slave Controller Options 1 and 2 Use the Burton cable whip ( ) for connecting the slave controller to ROV telemetry and power using a customer-supplied Burton connector. J1 P1 J1 P1 AC LIVE 1 1 AC GND 2 2 AC NEUTRAL FD FD MATING SIDE VIEW Figure 20 J1 (Slave controller) cable wiring MATING SIDE VIEW WIRE SIDE VIEW Also see Tips & Care: Slave Arm Cable & Connectors on page Completing the Installation After all the Titan 3 components are installed, the system is started to confirm operation, configure the stow/deploy and movement limits menus for safe operation, and charge/bleed the compensation system. The process is discussed below, based on whether this is a first time or repeat installation Completing the Installation Page 29

30 Installation 9.1 First-Time Installations If this is your first installation of a Titan 3 manipulator system, we recommend completing the First Startup Tutorial on page 33. The tutorial takes you step by step through the basics of operation, and explains how to configure slave arm stow points and movement limits. Once the slave arm has these menus configured for safe operation, return to section entitled Charging the Compensation System on page 31. Once the compensation is functional, the Titan 3 manipulator system will be ready for normal service. Refer to the Operation chapter for complete information about the startup, configuration, and operation of the manipulator system and the diagnostics for the control system. 9.2 Repeat Installations If you are already familiar with the installation and operation of the Titan 3 manipulator system, complete the steps outlined below. Refer to the Operation chapter, if necessary, for additional information. 1. Complete the following checks before you start-up the manipulator system. Personnel and objects cleared from the slave arm's range-of-motion. Installation is complete for all system components. The electrical power source(s) meets the power requirements. Power and telemetry cable or conductor connections are sound and correct. Slave arm hydraulic supply and return connections are secure and correct, and meet the pressure requirements. Compensator hoses and fittings are sound and connected. All hoses are routed and secured to reduce the risk of snagging and kinking during slave arm movement. Installation supports are removed from the slave arm. 2. Apply hydraulic power to the Titan 3 components. 3. Turn on electrical power to the Titan 3 components: Deck testing with the junction box: Turn on junction box, then the master controller. Long-line: Turn on power to slave controller, then master controller.! Caution Air in hydraulic lines or components can cause very rapid or jerky slave arm movement upon start-up. Arm segments that have sagged or been moved may return to their original positions. Clear personnel and equipment from the slave arm s range of motion BEFORE startup! Page 30 9 Completing the Installation

31 Installation NOTE: If the hydraulic return passes through a filter or is manifolded with other equipment returns before returning to the tank, check the return pressure does not exceeds 500 psi (3.45 bar). The slave arm is equipped with a return relief valve on the upper arm segment to protect components from excessive return pressure. If system return pressure exceeds 500 psi (3.45 bar) hydraulic fluid will be released from the relief valve. 4. Set a stow sequence that will allow the slave arm to be safely stowed within its environment. a. See Entering Passwords: the SET LEVEL Menu in the Operation chapter. b. See Setting the Stow Path on page 24 in the Operation chapter. 5. Set slave arm movement limits that allow safe operation of the slave arm within its environment (see Setting Slave Arm Movement Limits in the Operation chapter). 6. Operate the system to test all control, programming, and slave arm functions. 7. When you have confirmed the Titan 3 manipulator system is functioning correctly, proceed to the section on Charging the Compensation System below. 9.3 Host Computer Control Documentation for host computer operation varies with the configuration of your system. Information about the controls and functions of the system can be found in the chapters concerning custom features, functional descriptions, operation, and programming. Chapters are included as needed. General guidelines and suggestions for safe initial start-up and testing are outlined below. 1. Follow steps present in the Operation and Programming chapters for start-up of the system. 2. Set operating limits and stow sequences that will allow the slave arm to be safely deployed, moved, and stowed within the test area. 3. Operate the system to test all control, programming, and slave arm functions. 4. When you have confirmed the Titan 3 Manipulator System is functioning correctly, proceed to the section on Charging the Compensation System below. 10 Charging the Compensation System The charging procedure assumes the Titan 3 system is completely installed, tested, and safe movement limits and stow/deploy positions have been set. About 3 gallons (12 liters) of fluid are needed to fill the compensator, wireway hoses and internal cavities. Although the hydraulic and compensation systems are separate, it is preferable that the same fluid be used in both applications, with one important exception: the compensation fluid must be non-conductive Charging the Compensation System Page 31

32 Installation! Caution 1. Compensation fluid must be non-conductive. 2. Damage may occur to compensated components if the slave arm is submerged with large amounts of air in the compensation system. Be sure to bleed the air from the compensation system. Fluid Capacities: Compensator gal. (2.2 l) Compensated slave arm volumes gal (9.5 l) Refer to Figure Start the manipulator system and move the slave arm to a wrist-high position Open the purge port (see Figure 21 point 1). 1a. Wire Way Cover 2. Top Plate Fastener 1. Purge Port 3. Shoulder Cover Screw, 2x Position 2 4. Purge Port Position1 Figure 21 Bleed positions and bleed points 3. Begin charging the compensator through one of its unused fittings until the yellow band on the piston approaches the full band on the housing - do not overfill. Crack the fitting seal at the top of the compensator and bleed off any air in the accumulator. NOTE: Charging pressures above 20 psig (1.4 bar) will cause the discharge of compensation fluid or vapor from the relief valve. Page Charging the Compensation System

33 Installation 4. Allow the compensator pressure to fill the hose and slave arm cavities. NOTE: This will take some time as some passages are small and the compensation must travel all the way to the wrist before returning to the purge port near the elbow. You can speed up filling to the wrist by loosening the wrist wireway cover (Figure 21 point 1a). Tighten when fluid emerges. 5. Close the purge port when fluid emerges. (Continue adding fluid to the compensator as needed.) 6. Move the slave arm to position 2 and remove one top plate fastener (Figure 21 point 2). Replace when fluid emerges. 7. Remove the screw from each shoulder cover (Figure 21 point 3, 2x) and replace when fluid emerges. 8. Move the slave arm back to position 1 for a few minutes. Open the purge port for final bleed. 9. Verify tightness of all bleed point hardware, etc. 10. Bleed any remaining air from the compensator and charge until the yellow band on the piston approaches the full band on the housing. Do not completely fill. Leave about 6 mm (.25-in) of diaphragm travel to allow for thermal expansion. 11. Inspect compensation system components, hoses, and connections for leaks and correct all leaks. 11 First Startup Tutorial Use this tutorial to become familiar with the Titan 3 control system, the steps for the first startup of your Titan 3 Manipulator System, and configuring the stow/deploy and movement limits menus. You will then be prepared to safely maneuver the slave arm for bleeding the compensation system. Complete information about all of the Titan3 options, configuration menus, and diagnostics will be found in the Operation chapter.! Caution If, at any time, the response of the slave arm or the master controller differs from this tutorial, or you have unresolved questions about a procedure or step, STOP, disable slave arm hydraulics, and refer to the appropriate section in the Operation chapter for guidance and additional details. Return to this tutorial only when the system is functioning normally Using the Master Controller Use the master controller to operate, configure, and diagnose the manipulator system First Startup Tutorial Page 33

34 Installation To direct the slave arm, the operator moves the controller's master arm (Figure 22). The operator configures and diagnoses manipulator system operation by accessing appropriate master controller menus and making changes through keystroke inputs. The master controller provides the following control components: Master arm Liquid Crystal Display screen (LCD) Function and control keys Auxiliary jaw switch Electrical power switch Master Arm LCD Screen Control Keys Jaw Switch Power Switch Function Keys Figure 22 The master controller Master Arm The master arm is a miniature replica of the slave arm (Figure 22). Each master arm joint or function matches a similar joint or function on the slave arm. The small size of the master arm allows you to easily control all functions with the wrist and fingers. These functions include: Moving a master arm joint moves the corre- Slave arm joint movement sponding slave arm joint. Slave arm freeze Pressing the button on the end of the master arm freezes the slave arm in its current position. Wrist rotate Rotating the master arm wrist collar rotates the slave arm wrist. Page First Startup Tutorial

35 Installation Jaw grip Squeezing the textured jaw bands on the master arm wrist activates the grip function. The precise way in which the jaws will respond to this action depends on the current jaw mode setting. TOG (toggle). Squeezing the forward jaw band fully opens or closes the jaw. POS (position). The jaw moves as long as the jaw band is squeezed. Forward band = Jaw closes Rear band = Jaw opens LOCK. This menu selection disables master arm input, leaving the jaw in its current position. To escape from the LOCK mode, press the JAW MD: key and toggle to the TOG or POS mode Power Switch The rocker switch at the left of the LCD screen controls electrical power for the master controller only and is used mainly to reset the master controller when necessary. The master controller power switch is normally turned off only after the slave arm has been moved to a safe position (stowed), frozen, and slave arm have been hydraulics disabled Data Display Screen An LCD screen in the center of the master controller front panel provides you with information about system status and available operating options. Example screens are used throughout this section. In most menus, the operational state of the slave arm is shown in the upper right corner of each menu using one of the following signs: Slave Arm Operational Status The operational status of the slave arm is shown in the upper right hand corner of the MAIN menu screen. Three states are possible: REIN (reindex) = Master arm is enabled to control the slave arm, starting at their current positions. Pushing the freeze button (at the tip of the master arm) toggles between REIN and FRZ status (freeze). FRZ (freeze) = Master arm control of the slave arm is disabled (slave arm is frozen at its present position). Opening most menus automatically engages FRZ status. Pushing the freeze button (at the tip of the master arm) toggles between REIN and FRZ status (freeze). LOCK = Control system locked. LOCK status engages automatically First Startup Tutorial Page 35

36 Installation In certain menus or states in which the slave arm should not be operated. (To unlock the slave arm, move to another menu where REIN or FRZ is the default status.) When telemetry errors could cause erratic or uncontrolled slave arm movements Function Keys Eight function keys flank the LCD screen as shown on Figure 22. These keys are used to select menus, enter programming data, or to activate/deactivate functions. In each menu, the function of each active key is displayed on the screen beside the key. (If no key label appears on the screen, the corresponding key is not used in that menu.) Control Keys The four control keys in the diamond pattern on the right side of the display are identified in Figure 22. These keys have various uses, which are called out in the appropriate menus, startup or warning screens, or in the applicable section in the Operation chapter. NOTE: In most operational menus the UP key (at top) can be pressed to disable hydraulic power to the slave arm. Auxiliary Jaw Switch The auxiliary jaw switch is located opposite the master arm and provides the same functions as the jaw bands on the master arm. Move switch forward = Jaw closes Move switch rearward = Jaw opens 11.2 First Startup Complete the following checks before you start-up the manipulator system. No people or objects are within the slave arm's range-of-motion Installation is complete for all system components. The electrical power source(s) meets the power requirements (see the Specifications chapter). Power and telemetry cable or conductor connections are sound and correct. Slave arm hydraulic supply and return connections are secure and correct, and meet the pressure requirements (see the Specifications chapter). (Submersible systems) Compensator hoses and fittings are sound and connected. All hoses are routed and secured to reduce the risk of snagging and kinking during slave arm movement. Page First Startup Tutorial

37 Installation supports are removed from the slave arm.! Caution Installation Activating hydraulic power without having completed all steps in the pre-start checks and startup sequence can cause injury to personnel and damage to equipment The Startup Process To start up the manipulator system, follow the steps below: 1. Clear personnel and equipment from the slave arm's range of motion. 2. Turn on the HPU. 3. Turn on electrical power: (Using the Junction Box and deck-test cable) Turn on junction box, then turn on master controller. (Using long-line telemetry and power) Turn on power to the slave controller first. Then turn on power to the master controller. NOTE: If the slave controller is not turned on first, correct communications may not be established and the slave arm may move unpredictably when hydraulic power is enabled. 4. When you turn on the master controller, the message Establishing Communications with slave arm will appear briefly. NOTE: If the master controller fails to establish communication with the base module, a fatal telemetry error message will appear. Refer to Fatal Telemetry Errors in the Troubleshooting chapter for more information on correcting the cause of the malfunction. 5. If the slave arm is at or near the Stow In position (as shipped in case), the Startup screen (Figure 23) will follow the Establishing Communications message. If the slave arm is not at or near the stow-in position, a warning screen will follow the establishing communications message indicating that the Stow Out menu, which normally follows the Startup menu, will not be displayed as part of the startup sequence. Press EXIT <8 to access the Startup screen. NOTE: The appearance of other warning screens or the system error screen indicates a communication or system problem. Refer to System Errors and Warnings in the Operation chapter, and/or the Troubleshooting chapter as appropriate First Startup Tutorial Page 37

38 Installation SCHILLING ROBOTIC SYSTEMS TITAN MANIPULATOR SYSTEM Startup Procedure: 1.Verify arm position. 2.Turn on HPU power. 3.Enable arm hydraulics. 4.Turn hydraulics off if the slave arm moves from its current position. 5.Press DOWN key to exit. Hydr:OFF < Version Rev. C Figure 23 Startup screen 6. Proceed with the steps listed in the Startup screen. a. Verify arm position. The slave arm should be at or near the stow-in point. b. Turn on the HPU (hydraulic power unit) to provide pressure up to the solenoid valve. c. Enable hydraulic power to the slave arm by pressing the Hydr: <8 key. The display will change to Hydr:ON <8", indicating that the hydraulic isolation valve in the upper arm is open. NOTE: The slave arm should not move more than slightly when hydraulics are enabled. If it begins moving more than a slight distance, immediately press 8> HYDR or the UP control key to disable hydraulic power until the cause can be determined. d. Disable hydraulic power to the slave arm by again pressing the Hydr: <8 key. The display will change to Hydr:OFF <8." to indicate that the hydraulic isolation valve is closed. e. Press the DN key to exit the startup menu (The bottom key of the four in the diamond pattern to the right of the display and function keys). If the slave arm was at or near the Stow In position at startup, the STOW OUT menu will open (Figure 24). NOTE: If a warning screen appeared before the startup menu screen indicating the slave arm was not at or near the stow in position, the STOW OUT menu will be bypassed and exiting the startup menu will open the MAIN menu (Figure 25 on page 40). Page First Startup Tutorial

39 11.4 The STOW OUT Menu Installation The STOW OUT menu (Figure 24) allows the operator to automatically move the slave arm between a compact, protected position (Stow In <6) and an operational position (Stow Out <5). The operator may also stop (Stop <7) the stow out sequence, or bypass the STOW OUT menu altogether (EXIT <8). NOTE: Pressing STOP <7 does not stop the slave arm until it reaches the next programmed point in the stow path. To stop the slave arm immediately, press the UP control key to disable hydraulic pressure). STOW OUT Stow Out <5 Stow In <6 Pnt:IN Stop <7 EXIT < After stowing out press EXIT key Figure 24 STOW OUT menu screen 1. Do not use the STOW OUT menu at this time: a. If this is the initial installation, the Stow Out and Stow In positions have both been factory set to approximate the position of the slave arm in the shipping case, so the Stow-Out and Stow-In commands will have little effect. b. If the slave arm was previously installed elsewhere, the existing Stow Out and Stow In positions may be unsafe or unsuitable for its new environment. 2. New stow commands will be set later in this tutorial. Press EXIT <8 and proceed to the MAIN menu screen The MAIN Menu The MAIN menu provides access to five sub-menus for the operation, setup, configuration, diagnosis, and shutdown of the manipulator system (see Figure 25). The slave arm can not be operated in the MAIN menu so the status field (upper right) shows LOCK. Hydraulics in the MAIN menu are turned off by pressing the UP key (The top key of the four in the diamond pattern to the right of the display and function keys) First Startup Tutorial Page 39

40 Installation MAIN MENU LOCK > ROBOTICS SET UP <5 2> OPTIONS DIAGNOSE <6 3> OPERATE SHUT DOWN < UP key turns hydraulics OFF Figure 25 MAIN menu screen 1> ROBOTICS If your system has optional robotic software, use the ROBOT- ICS menu to record and play back slave arm movements (see the Robotic Operation tab in this manual). On systems without robotic software the message NOT AVAILABLE will appear on the screen if you select the ROBOTICS menu. 2> OPTIONS Use the OPTIONS menu to: configure slave arm and jaw speed. set an alternate scale for slave arm movement relative to master arm movement (toggle-select in the OPERATE menu). All OPTIONS menus are accessible at security level 0. 3> OPERATE Use the OPERATE menu to: control normal slave arm operation with the master arm. toggle through jaw and wrist operation modes, and toggle between alternate slave arm scaling values. enter the menu for freezing selected slave arm functions. enter the DRIVER menu to enable/disable hydraulics or operate auxiliary hydraulic equipment. All OPERATE menus are accessible at security level 0. SETUP >5 Use the SETUP menu to set slave arm movement limits, program stow sequence, set security levels and new passwords, enable/disable error checking functions, adjust servo valve offsets, and edit master controller memory locations. These sub-menus require a password or a security level higher than 0 to use. DIAGNOSE >6 Use the DIAGNOSE menu to: Page First Startup Tutorial

41 Installation diagnose faults in the slave arm position sensors, master arm and master controller. display, reset, and configure system error checking. All DIAGNOSE menus are accessible at security level 0. SHUT DOWN <7 Use the SHUT DOWN menu to: activate the pre-recorded automatic stow in (or stow out) sequence for the slave arm and to disable slave arm hydraulics in preparation for shutting down the manipulator system. All menus are accessible at security level The OPERATE Menu OPERATE FRZ > FREEZE Jaw Md:TOG <5 2> Hydr:OFF 3> Scale Tog:100% EXIT < Turn on hydraulics Figure 26 OPERATE menu screen The OPERATE menu (Figure 26) is used when directing the slave arm with the master arm. For safety, the OPERATE menu always opens with the slave arm in the freeze (FRZ) state. The OPERATE menu offers the following sub-menus for configuring slave arm performance: 1> FREEZE: Displays a menu for freezing and unfreezing individual slave arm joints. 2> Hydr:(OFF/ON field): Toggles the state of the base module hydraulic isolation valve between OFF and ON. 2> Hydr: must be ON to provide hydraulic power to the slave arm. 3> Scale Tog: (% field): Toggles between different movement scales (scaling of master arm movement to slave arm movement). The Freeze and Scale Tog menus are fully explained in the Operation chapter. They will not be configured in this tutorial. JAW MD: (TOG, POS, LOCK jaw mode field) <5: Toggles between the three jaw operating modes: First Startup Tutorial Page 41

42 Installation POS (position): In this mode squeezing the forward band causes the jaws to close until the band is released. Squeezing the aft band causes the jaws to open until the band is released TOG (toggle): In this mode squeezing the forward jaw band toggles the jaw between fully closed and fully opened. Squeezing the aft jaw band has no effect LOCK: In this mode, master controller jaw input is disabled, leaving the jaw seeking the last commanded position. If the jaw control has not been used, the jaw remains in its current position; if the jaw control has been used to grip an object, and the command exceeds the travel allowed by the object, the jaw will continue to exert force, trying to reach the commanded position EXIT <8: Exits to the MAIN Menu Operating the Slave Arm! Caution Air in hydraulic lines or components may cause very rapid or jerky slave arm movement upon startup. Sagging or physically moved joints may return to their original positions. Clear personnel and equipment from the slave arm's range of motion BEFORE startup. 1. Enable slave arm hydraulic power. Press the 2> Hydr: key (field changes to ON). 2. Verify that the status field (at upper right) reads FRZ (master arm not enabled). Grip the master arm and position it for comfortable operation of the slave arm. Press the freeze button at the tip of the master arm (status field changes to REIN): the slave arm will now move to match the movements of the master arm. 3. Keep master arm movements small and slow until you develop a feel for the response of the slave arm. Remember, you can use the freeze button at the tip of the master arm to immobilize the slave arm, reposition the master arm to a more comfortable position, and push the tip button again to resume operation. During initial operation of the slave arm: Use caution when approaching the mechanical travel limits of each joint and any equipment within the range of motion. Do not use the slave arm to lift heavy objects. Toggle to each of the jaw modes (Jaw MD <5) and test their operation Configuring the SET STOW and SET LIMITS Menus Now is a good time to set the slave arm's stow in/stow out sequence and movement limits. Setting a stow in/stow out sequence allows you to safely deploy and stow the slave arm automatically. Movement limits protect fixed objects and equipment within Page First Startup Tutorial

43 Installation the slave arm's range of motion and prevent running joints into their mechanical stops. NOTE: The SET STOW and SET LIMIT menus are interrelated: 1. Current movement limits (set in the SET LIMITS menu) will also apply to new changes in the SET STOW menu. 2. The current stow sequence cannot be limited or affected by new changes in the SET LIMIT menu. The SET LIMITS and SET STOW menus are accessible from the SETUP menu (Figure 27). SETUP LOCK > SET LIMITS MEMORY <5 2> SET STOW SECURITY <6 3> SET SV OFFSET DISPLAY <7 4> SET ERR CHECKS EXIT < Figure 27 SETUP menu screen 1. While in the OPERATION menu press the 2> Hydr: key to disable hydraulic power. 2. Press the EXIT <8 key to return to the MAIN menu. 3. Press the 3> SETUP key to display the SETUP menu. 4. Before making changes within the SET LIMITS and SET STOW menus you must first access security level 1 or higher by entering a locally or factory assigned password in the SECURITY menu. NOTE: A factory-assigned password sheet is located at the end of the Table of Contents Entering the Password The master controller offers a default operation level and two password-protected security levels for accessing menus that allow configuration of sensitive or critical system functions (Figure 28). Level 0 is the default level available at system startup. No password is required. Full system operation is available at level 0, including access to error-checking First Startup Tutorial Page 43

44 Installation and diagnostic menus. A level 0 operator using a fully configured manipulator system will usually need no higher security level. Levels 1 through 4 require a locally-set password, and allow access to the SET LIMITS, SET STOW, and SET SV OFFSET menus. (Levels 2-4 are functionally equivalent to level 1 on this model and may be disregarded). Level 5 requires the factory-assigned password, and allows access to all configuration and security menus. Level 5 access is required to set or change passwords for security levels 1-4. SET LEVEL Level:1 Inc <5 Password:**** Dec <6 Select <7 Current user's Privilege Level:0 EXIT < Figure 28 SET LEVEL menu screen To enter the password: 1. From the SETUP menu, select 6> SECURITY to display the SECURITY menu. 2. From the SECURITY menu, press the 1> SET LEVEL key to display the SET LEVEL menu (Figure 28). The cursor will appear in the Level: field, while the current security level is displayed at the bottom of the screen). To change the current level, press the Inc <5 or Dec <6 until the level for which you have a password is displayed in the Level: field. Press the Select <7 key to select (enter) that level. 3. The cursor will then drop to the first digit of the Password: field, changing the asterisk (*) to 0 (zero). Press the Inc <5 or Dec <6 key until the first number of the four-digit password appears. Press the Select <7 key to enter the number and move on to the next password number. Repeat until all four numbers of the password have been entered. 4. When all four numbers are entered, press the 7> Select key again. The Current User's Security Level: field will now show the new level. 5. Exit back to the SECURITY menu by pressing the EXIT <8 key. Exit from the SECURITY menu to return to the SETUP menu. Page First Startup Tutorial

45 Installation Setting the Stow-in and Stow-Out (Deploy) Path The SET STOW menu is used only to program a repeatable path for safely stowing and deploying the slave arm. Use the SET LIMITS menu for defining the travel limits of the slave arm during normal operation. SET STOW FRZ POINT:03 Last <5 Next <6 Teach <7 Last Stow 4> Point:05 EXIT < Figure 29 SET STOW menu screen How It Works The stow in and stow out commands are available in the STOW OUT menu (automatically displayed as part of the startup process) and the SHUTDOWN menu. In either menu, when the Stow Out <5 key is pressed, the slave arm moves automatically from the Stow In position to the Stow Out (deployed) position; when the Stow In <6 key is pressed, the slave arm automatically first moves to the stow out position and then to the stowed in position. The stow in/stow out path is a sequence of 2 to 16 fixed slave arm positions (or points) that the operator selects in the SET STOW menu (Figure 29). The manipulator control system calculates how to move the slave arm most efficiently from one point to the next. The stow in/stow out sequence can be reset at any time to accommodate changes in operational needs or the operating environment. NOTE: The SET STOW and SET LIMIT menus are interrelated: 1. Current movement limits (set in the SET LIMITS menu) will also apply to new changes in the SET STOW menu. 2. The current stow sequence cannot be limited or affected by new changes in the SET LIMIT menu Setting a New Stow Sequence You can program from 2 to 16 points between the stow in and stow out positions. In planning a stow in/stow out sequence, consider the following factors: First Startup Tutorial Page 45

46 Installation You can press the STOP <7 button at any time during the sequence, but the slave arm will continue to move until it reaches the next point in the sequence. A stow in/stow out sequence with more points can be stopped sooner. NOTE: To stop the slave arm immediately, press the UP control key to disable hydraulic pressure). The control system calculates how to move the slave arm smoothly from one point to the next in the sequence, without regard for its environment. If the slave arm will encounter obstacles or equipment, you must program enough points into the sequence so it can avoid striking them. The stow/deploy sequence is changed in the SET STOW menu. To set a new stow/ deploy sequence, follow these steps: 1. From the SETUP menu, press the 2> SET STOW button. 2. Press the 4> Last Stow Point key to increment to the desired number of total stow points. Select any number between 02 and 16 (After 16 the number defaults to 02). 3. Unfreeze the slave arm by pressing the master arm freeze button. 4. With the POINT: field at 01 move the slave arm to the desired STOW IN position. Press the TEACH <7 key to save the position (only the position of the arm is entered, not the time or number of motions needed to get it there). The POINT: field will automatically increment to 02. NOTE: With the factory default movement limits, you have full travel of all slave arm functions from which to select the new stow path. This path will not be affected by any future changes to movement limits made in the SET LIMITS menu. 5. Move the slave arm to the next point in the stow/deploy sequence and press the TEACH <7 key to save it. To reteach previous points, press the Last <5 key. Skip taught points by pressing the NEXT <6 key instead of TEACH <7. The last (highest) point taught will be the Stow Out (deployed) point, after which the field will not increment. 6. Press the EXIT <8 key to save the settings (returns to SETUP menu) Setting Slave Arm Movement Limits The limits of motion for each slave arm joint (excluding the wrist and jaw) are configured in the SET LIMITS menu (Figure 30). To set movement limits for individual slave arm joints, follow these steps: 1. From the SETUP menu, press the 1> SET LIMITS key to display the SET LIMITS menu. Page First Startup Tutorial

47 Installation NOTE: While the SET LIMITS menu is open, slave arm joints are capable of full mechanical travel. Previously set movement limits or newly set limits will not engage until you have exited from the SET LIMITS menu. SET LIMITS FRZ COUNT:01 Last <5 LIMIT: Next <6 AZI LEFT Teach <7 EXIT < Figure 30 SET LIMITS menu screen 2. Unfreeze the arm by pressing the master arm freeze button. 3. This menu will display both the function count (in the COUNT: field) and the function name (in the LIMIT: field) for the limit being set. The sequence of limits and their corresponding limit numbers are shown in Table 1. (There are no movement limits for the wrist and jaw.) As the table shows, the azimuth left limit is the first function to be limited. The counter will display 1, while the LIMIT: field will display AZI LEFT. NOTE: Changes to the movement limits made now will not affect or limit the stow path already set. Table 1 Sequence limits and numbers Joint Travel Limit Limit No. Azimuth Yaw LEFT 01 RIGHT 02 Shoulder Pitch DOWN 03 UP 04 Elbow Pitch DOWN 05 UP 06 Forearm Roll CCW 07 CW First Startup Tutorial Page 47

48 Installation Table 1 Sequence limits and numbers (cont.) Wrist Pitch RETRACT 09 EXTEND Unfreeze the arm by pressing the master arm freeze button. Move the slave arm to the farthest left position desired position for the azimuth function. To set this limit close to the mechanical limit, move the azimuth gently to the limit, then slightly back. NOTE: All movement limits should be at least slightly less than the mechanical limits. 5. Press the Teach <7 key to enter that position as the limit. The counter will automatically increment to the next function number. 6. Repeat steps 4 and 5 to set limits for the remaining joints. You may return to and reteach a previous limit by pressing the Last <5 key until the desired limit appears on the screen. You may skip ahead by pressing the Next <6 key instead of Teach <7. If you skip or do not teach a joint limit, its existing limit setting will be retained when you exit the SET LIMITS menu. 7. When all limits have been set, move the arm to any position inside the new limits and press the EXIT <8 key. The new or retained movement limits will be saved. (If you have positioned any joint outside these limits, the arm will move to a position within the limits the next time the arm is unfrozen.) 8. Press the EXIT <8 key to return to the MAIN menu Testing the Movement Limits and Stow Sequence 1. From the MAIN menu, press the 3> OPERATE key to access the OPERATE menu. Enable hydraulics and move the master arm into correspondence with the slave arm. Press the freeze button at the tip of the master arm (status REIN) and operate the slave arm. Carefully test the movement limits you have set. Approach the mechanical limits, objects, and equipment slowly and with caution until you are sure the limits you set will prevent collisions. 2. If you are satisfied that the manipulator system can be safely operated, charge and bleed the compensation system (see Charging the Compensation System on page 31). Then return to this section. 3. Move the slave arm to approximate the stow out point you have set. Freeze the slave arm and park the master arm on the faceplate of the master controller. NOTE: (STOW OUT and SHUTDOWN menus) When you press the Stow In <6 key, the slave arm will first move to the Stow-Out position and then begin the Stow In sequence. To avoid major Page First Startup Tutorial

49 Installation unplanned movements like this at shutdown, direct the slave arm to the approximate Stow Out point before entering the SHUTDOWN menu and using the Stow In command. 4. Exit to the MAIN menu and access the SHUT DOWN menu (Figure 31). SHUT DOWN LOCK Stow Out <5 Stow In <6 Pnt:IN Stop <7 4> Hydr to OFF EXIT < After stow, turn off hydraulics Figure 31 SHUTDOWN menu screen 5. From the SHUT DOWN menu test the Stow In and Stow Out commands. Test the Stop command. Note that: The POINT field counts each point in the Stow In and Stow Out sequence. You can stop the sequence by pressing the Stop <7 key. The slave arm will halt when it reaches the next point in the sequence. You can reverse the stow sequence at any time by pressing the other stow key. Submersible systems: If you have installed a compensator with this manipulator system for submersible operation, return to OPERATION menu and proceed to the Installation section entitled Charging the Compensation System on page 31. If you will not complete the compensation setup at this time, proceed to System Shutdown on page 50. Terrestrial systems: Proceed to System Shutdown on page First Startup Tutorial Page 49

50 Installation 11.8 System Shutdown SHUT DOWN LOCK Stow Out <5 Stow In <6 Pnt:IN Stop <7 4> Hydr to OFF EXIT < After stow, turn off hydraulics Figure 32 SHUTDOWN menu screen To shut down the manipulator system, follow these steps: 1. Direct the slave arm to a position that approximates the STOW-OUT position. Exit the OPERATION menu. 2. From the MAIN menu, Select 5> SHUT DOWN menu (Figure 32). NOTE: (STOW OUT and SHUTDOWN menus) When you press the Stow In <6 key, the slave arm will first return to its Stow-Out position before beginning the Stow In sequence. Be prepared for this movement. To avoid unplanned, automatic movements like this at shutdown, direct the slave arm to the approximate Stow Out point before entering the SHUTDOWN menu and using the Stow In command. 3. Press 6> STOW IN to move the slave arm to its stowed position. 4. Press 4> Hydr to close the base module hydraulic isolation valve. 5. Turn off power to the hydraulic power unit. 6. Turn off the master controller with the switch on the left side of the faceplate. 7. Turn off power to the slave controller (junction box or long-line power). 8. Refer to the Operation chapter for complete information on system startup, configuration, operation, performance options, error checking, and control diagnostics. Page First Startup Tutorial

51 Operation In This Chapter: 1 The Master Controller... page 51 2 Using the Master Controller... page 53 3 Avoiding Slave Arm Damage... page 57 4 Operation... page 57 5 Setting Performance Options... page 69 6 System Errors and Warnings... page 78 1 The Master Controller Operation of the slave arm is controlled, configured, and diagnosed using the master controller. Slave arm movements are initiated by moving the master arm (see Figure 1) and observing the slave arm s response, either directly or through a video system. Performance options and system functions are selected and configured using master controller keys and menus shown on the LCD (liquid crystal display) screen. The LCD screen also displays system status and diagnostic information. Master Arm Jaw Switch LCD Screen Control Keys Control Keys Function Keys Power Switch LCD Screen Figure 1 Master controller features, single arm and dual arm systems Page 51

52 Operation 1.1 Master Controller Features LCD Display Screen The LCD screen in the center of the master controller front panel provides you with information about system status and configuration, operating options, and diagnostic information. Example screens are used throughout this chapter. The LCD screen has a temperature sensor and compensator circuit to automatically stabilize the viewing angle across a broad temperature range. However, if the viewing angle is not acceptable, the compensation range can be shifted to suit local viewing or temperature conditions by adjusting a trimmer potentiometer inside the master controller (see Adjusting the LCD Screen Viewing Angle in the "Maintenance & Service" chapter. Function Keys Use the four function keys to each side of the LCD screen to select menus or to control functions. The function of each key is displayed on the LCD screen next to the key. Control Keys The control keys are located to the right of function keys 5-8 and have various uses which are identified in the appropriate menus and the startup or warning screens. Power Switch The power switch, at the left of the LCD display screen, controls electrical power to the master controller. NOTE: Turn off the master controller power switch only after the slave arm has been moved to a safe position, frozen, and slave arm hydraulics have been disabled. Auxiliary Jaw Switch The auxiliary jaw switch is located opposite the master arm and provides the same functions as the jaw bands on the master arm (see Jaw Bands on page 53): Move switch forward = Jaw closes Move switch rearward = Jaw opens The jaw switch is not present on the dual-arm master controller. The Master Arm The master arm (Figure 4) is a small replica of the slave arm, with equivalent joints, functions, and relative ranges of motion. The small size of the master arm allows you to easily control all functions with your fingers, wrist and forearm. Page 52 1 The Master Controller

53 2 Using the Master Controller Operation This section describes the function and use of master controller features. See Operation on page 57 for details on how they are used to direct the slave arm during normal operations. 2.1 Master Arm Major Master Arm Joints Moving a master arm joint (azimuth, shoulder, elbow, wrist pitch, wrist yaw) produces an equivalent movement in degree (and speed, subject to hydraulic limitations) of the slave arm joint. When finer control is required, slave arm movements can be scaled down from 100% in the Options menu (see Scaling Slave Arm Movement (Toggle) on page 65). Figure 2 Master arm (box) and wrist/jaw controls Wrist Rotate The wrist has two operation modes. POSITION MODE Rotate the wrist collar = slave arm wrist rotates to the position of the collar RATE MODE Rotate the wrist collar = slave arm wrist rotates continuously, the speed increasing with the rotation of the collar Jaw Bands Squeezing the textured jaw bands on the master arm wrist activates the jaw. The jaw has three operation modes. TOG (toggle) Using the Master Controller Page 53

54 Operation Squeezing the forward jaw band fully opens or closes the jaw. POS (position) Moves the jaw in either direction for as long as the appropriate jaw band is squeezed. Forward band = Jaw closes Rear band = Jaw opens LOCK Locks the jaw in its current position and prevents the jaw from being operated with the master arm. Escape from the LOCK mode by using the JAW MD: key to select the TOG or POS mode. NOTE: The jaw relaxes its grip when hydraulics are disabled, whether through operator control or interruption of hydraulic pressure. Objects held by the jaw may be released or dropped Freeze Button The freeze button is located at the tip of the master arm. Pressing it toggles between enabling and disabling master arm control of the slave arm. 2.2 Slave Arm Status Slave arm operational status is displayed in the upper right corner of the LCD screen. Three states are possible: REIN (reindex) indicates the master arm is enabled to control the slave arm, starting at their current positions. Pushing the freeze button (at the tip of the master arm) toggles between REIN and FRZ status (freeze). FRZ (freeze) indicates that master arm control of the slave arm is disabled and the slave arm is idled. FRZ status occurs when opening certain menus or after pushing the freeze button at the tip of the master arm (pressing the freeze button toggles between FRZ and REIN status. LOCK indicates that master arm control of the slave arm is disabled and cannot enabled in the current menu or state. LOCK status engages automatically: when opening certain menus or in states where the slave arm should not be operated. (To unlock the slave arm, move to another menu where REIN or FRZ is the default status.) Page 54 2 Using the Master Controller

55 Operation when telemetry errors could cause erratic or uncontrolled slave arm movements. 2.3 Controlling Slave Arm Hydraulics Use the master controller to control hydraulic power to the slave arm. Hydraulic (supply) pressure to all slave arm functions is controlled with a single isolation valve located in the upper arm. The Startup, DRIVERS, and SHOW ERRORS menu screens designate keys for controlling the isolation valve and show hydraulics status: Hydr: ON = Hydraulics enabled Hydr: OFF = Hydraulics disabled NOTE: To avoid unexpected movements, always enable slave arm hydraulics before you unfreeze the slave arm. If the hydraulics are disabled while in the slave arm is in REIN (active) status and the master arm is moved to a new position, the slave arm will move automatically to the new master arm position when the hydraulics are enabled Emergency Disable UP LEFT RIGHT DOWN Figure 3 Control keys You can disable hydraulics any time, regardless of menu, by pressing the UP control key (Figure 3, arrow). If you disable the hydraulics by pressing the UP key, use the DRIVERS menu to re-enable (see Using the DRIVERS Menu on page 64) Automatic Disable Some system errors automatically disable the hydraulics. See Using the SHOW ERRORS Menu on page 80 and Enabling and Disabling System Error Checking on page Controlling Auxiliary Hydraulic Equipment Five additional channels are available in the DRIVERS Menu for controlling auxiliary hydraulic equipment or tools. Contact Schilling Robotics for more information Using the Master Controller Page 55

56 Operation 2.5 Menu Structure The slave arm is controlled and configured through menus displayed on the master controller LCD screen. The menu structure and hierarchy is shown in Figure 4, The menu structure on page 56. Establishing Communications with Slave Arm Incompatible EPROM Warnings: Keys Error Stow In Error Startup Screen System Errors Stow Out Menu Main Menu Stow Out Stow In Stop Operate Menu Options Menu Setup Menu Shutdown Menu Diagnostics Menu Freeze Drivers Scale toggle Wrist Mode Jaw Mode Dynamics Jaw Speed Scale Set Security Menu Set Limits Set Stow Set SV Offset Set ERR Checks Memory Set Password Set Level Master Slave Show Errors Stow Out Stow In Stop Hydraulics Figure 4 The menu structure 2.6 Menu Security The master controller has three security levels for accessing menus. Two of the levels are password-protected and restrict access to menus that control sensitive or critical system functions. Level 0 (default level) is available at system startup. No password is required. Full system operation is available at level 0, including access to menus for error- Page 56 2 Using the Master Controller

57 Operation checking, diagnostics, and configuration of some functions. A level 0 operator using a fully configured manipulator system will usually need no higher security level. Levels 1 Through 4 allow access to the SET LIMITS, SET STOW, SET SV (servo valve) OFFSET, and MEMORY menus, and require a password. (Levels 1 through 4 are functionally equivalent.) Level 5 requires the factory-assigned password, and allows access to all configuration and security menus. Level 5 access is required to set or change passwords for security levels Avoiding Slave Arm Damage Your Titan 3 is designed with safety factors well in excess of its rated capacities. However, situations can occur in operation where safety factors may be exceeded, placing the slave arm and surrounding equipment/personnel at risk. These situations include: Collisions Collisions while manipulating extreme loads Collisions and/or extreme loads while at the slave arm s mechanical limits The best protection is anticipating risky situations and planning slave arm operations to avoid or minimize them. NOTE: Collisions and extreme loads can cause unusual joint movements (reversed, overly slow or accelerated, etc.) that may trigger automatic system shutdown by error-checking software. If necessary, error checking can be disabled in order to assure uninterrupted operation. However, you should be aware that disabled error checking puts the slave arm at greater risk. (For details see Enabling and Disabling System Error Checking on page 83.) 4 Operation! Caution Activating hydraulic power without having completed all steps in the pre-start checks and startup sequence can cause injury to personnel and damage to equipment. 4.1 Pre-Start Checks Each time you prepare to start up the manipulator system, make the following checks: Avoiding Slave Arm Damage Page 57

58 Operation All fasteners and fittings are properly tightened and in good condition. All hoses are safely routed to avoid kinks, snagging, and contact with sharp edges or rough surfaces. Hydraulic components, hoses, and fittings are sound and free of leaking. All electrical connections between the master controller, junction box, slave controller, and slave arm are secure; electrical cables are safely routed to avoid damage. Compensation system is full and bled. 4.2 Startup To start up the system, follow the steps below. 1. Clear personnel and equipment from the slave arm s range of motion. 2. (Deck test) Turn on electrical power to the manipulator system with the switch on the junction box. (Long-line) Turn on power to the slave controller.! Caution (Long-line systems) The slave arm may behave erratically if the master controller is turned on before the slave controller. 3. Turn on the master controller power switch. The message Establishing Communications with slave arm will appear briefly and, if all system conditions are normal, then default to the Startup screen (Figure 5). SCHILLING ROBOTIC SYSTEMS TITAN MANIPULATOR SYSTEM Startup Procedure: 1.Verify arm position. 2.Turn on HPU power. 3.Enable arm hydraulics. 4.Turn hydraulics off if the slave arm moves from its current position. 5.Press DOWN key to exit. Hydr:OFF < Figure 5 Startup screen 4. Abnormal system conditions at startup may result in other message screens: A WARNINGS: screen appears if the slave arm is not near the stow position or if there is a keyboard error. Keyboard errors are rare. This condition typically occurs when the system is turned off without returning the slave Page 58 4 Operation

59 Operation arm to the stow-in position, or if the slave arm is physically moved while the system is turned off. The message Slave arm is not near the stow position is advisory and does not prevent operation (screen exits to MAIN menu; the STOW OUT menu is bypassed. Keyboard errors need not be corrected if emergency operation of the slave arm is necessary. Refer to Startup with System Warnings on page 78. Other warning screens or the system error screen appear if a communication or system malfunction is present. Refer to Startup with System Errors on page 80 before proceeding. A fatal telemetry error message indicates the master controller and slave controller are unable to communicate. Refer to 'Fatal Telemetry Errors in the Troubleshooting chapter for causes and remedies. If no warning or error screens are present, proceed to the next step. 5. Proceed with the steps listed in the Startup Procedure: screen. a. Verify the slave arm position (at or near the stow point). b. Turn on the HPU (hydraulic power unit) to provide pressure up to the slave arm solenoid valve. 6. Enable hydraulic power to the slave arm by pressing the Hydr: <8 key. The status will change to Hydr: ON <8. NOTE: The slave arm should move very little when you enable hydraulics. Disable hydraulics immediately (press the Hydr >8 key or the UP key) If the slave arm moves unpredictably or in a way that endangers itself or other equipment. 7. Press the DOWN control key (see Figure 3 on page 55) to exit the startup screen and go to the STOW OUT menu. 4.3 Using the STOW OUT Menu Use the STOW OUT (Figure 6) menu to automatically move the slave arm along a user-designated path between a compact, protected position (STOW IN <6) and an operational position (STOW OUT <5). You can also press the STOP <7 key to stop the stow out sequence at the next point, or bypass the STOW OUT menu altogether (EXIT <8) Operation Page 59

60 Operation STOW OUT STOW OUT <5 STOW IN <6 pnt:in STOP <7 EXIT < After stowing out press exit KEY Figure 6 STOW OUT menu screen 1. Press the STOW OUT <5 key to Stow Out (deploy) the slave arm (There s a slight delay before the process begins). Note that: as the slave arm moves, the PNT: field displays each successive point number in the sequence. pressing the STOP <7 key stops the slave arm at the next stow point. NOTE: Pressing the STOP <7 key does not stop the slave arm until it reaches the next point on the stow path. To IMMEDIATELY stop the slave arm, press the UP control key (disables hydraulic power). Pressing the STOW IN <6 key reverses the STOW OUT sequence. NOTE: When you press the Stow In <6 key, the slave arm will first move to the Stow Out position before beginning the Stow In sequence. Be prepared for this movement. 2. Press the EXIT <8 key to go to the MAIN menu. The stow out/stow in sequence can be changed using the SET STOW menu (see Setting the Stow Path on page 74). 4.4 Using the MAIN Menu Password level: 0 or higher Page 60 4 Operation

61 Operation MAIN MENU LOCK > ROBOTICS SET UP <5 2> OPTIONS DIAGNOSE <6 3> OPERATE SHUT DOWN < UP key turns hydraulics OFF Figure 7 MAIN menu screen Use the MAIN menu (Figure 7) to access the OPERATE menu and five other menus described below: 1> ROBOTICS If your system has optional robotic software, use the ROBOT- ICS menu to record and play back slave arm movements (see the Robotic Operation tab in this manual). On systems without robotic software the message NOT AVAIL- ABLE will appear on the screen if you select the ROBOTICS menu. 2> OPTIONS Use the OPTIONS menu to: configure slave arm and jaw speed. set an alternate scale for slave arm movement relative to master arm movement (toggle-select in the OPERATE menu). All OPTIONS menus are accessible at security level 0. 3> OPERATE Use the OPERATE menu to: control normal slave arm operation with the master arm. toggle through jaw and wrist operation modes, and toggle between alternate slave arm scaling values. enter the menu for freezing selected slave arm functions. enter the DRIVER menu to enable/disable hydraulics or operate auxiliary hydraulic equipment. All OPERATE menus are accessible at security level 0. SETUP >5 Use the SETUP menu to set slave arm movement limits, program stow sequence, set security levels and new passwords, enable/disable error checking functions, adjust servo valve offsets, and edit master controller memory locations. These sub-menus require a password or a security level higher than 0 to use. DIAGNOSE >6 Use the DIAGNOSE menu to: Operation Page 61

62 Operation diagnose faults in the slave arm position sensors, master arm and master controller. display, reset, and configure system error checking. All DIAGNOSE menus are accessible at security level 0. SHUT DOWN <7 Use the SHUT DOWN menu to activate the pre-recorded automatic stow in (or stow out) sequence for the slave arm and to disable slave arm hydraulics in preparation for shutting down the manipulator system. All SHUT DOWN menus are accessible at security level Using the OPERATE Menu Access path: MAIN/OPERATE Password level: 0 or higher OPERATE FRZ > FREEZE Wrs Md:POS <5 2> Drivers Jaw Md:POS <6 3> Scale Tog:100% EXIT < Figure 8 OPERATE menu screen Use the OPERATE menu for normal operation of the slave arm with the master controller. 1. In the MAIN menu press the 1> OPERATE key to access the Operate menu (Figure 8). To prevent unintended operation, the OPERATE menu always opens with the slave arm in the freeze (FRZ) state. 2. Grip the master arm, move it from its parked location, and position it for convenient operation of the slave arm. 3. Press the freeze button at the tip of the master arm (status field changes to REIN) and use the master arm to direct the slave arm. NOTE: The freeze function is also useful when a slave arm task results in an awkward position for holding the master arm. Press the Freeze button and move the master arm to a more comfortable position. The, press again to resume operation. Page 62 4 Operation

63 4. Move the master arm to operate the slave arm as desired. Operation 5. Use the SHUTDOWN menu to stow the slave armand disable hydraulics. (See Using the SHUTDOWN Menu on page 68.) Important Steps after Initial Installation Avoiding Damage Avoid damage to the slave arm and surrounding equipment. Program travel limits and the stow in/stow out path as soon as possible after installation. To program travel limits, see Setting Slave Arm Movement Limits on page 76. To program the Stow In/Stow Out path, see Setting the Stow Path on page 74. Bleeding the Compensator (Subsea only) When your system is operational and before submersion, the slave arm can be positioned for bleeding the compensator system. Refer to Charging the Compensation System in the Installation chapter ERR (Error) messages An ERR (Error) message appearing any time during operation (top line, to the left of status field) indicates a system error has been detected and hydraulics are disabled. See Using the SHOW ERRORS Menu on page 80 and Enabling and Disabling System Error Checking on page 83 for causes and remedies. 4.6 Using OPERATE Menu Options Freezing Individual Slave Arm Joints Access path: MAIN/OPERATE/FREEZE Password level: 0 or higher Freezing individual joints is useful for tasks where only some joints are required to move and/or where greater stability of specific individual slave arm joints is desired. The FREEZE menu (Figure 9) allows the following slave arm joints to be frozen so that they will not respond to master arm movements: 1> Azi (azimuth) 2> Sho (shoulder) 3> Elb (elbow) 4> Pit (wrist pitch) Yaw <5 (wrist yaw) Wrs <6 (wrist rotate) Operation Page 63

64 Operation FREEZE FRZ > Azi: FRZ Yaw: FRZ <5 2> Sho: REIN Wrs: REIN <6 3> Elb: FRZ REIN All <7 4> Pit: FRZ EXIT < Figure 9 FREEZE menu screen To freeze individual joints, follow the steps below: 1. From the OPERATE menu press the 1> FREEZE key. 2. In the FREEZE menu (Figure 9), unfreeze the slave arm (using the master arm freeze button) and position each joint where you ant it frozen. 3. Press the key next to the joint to toggle the field between FRZ and REIN. 4. After making your selections, press the 8> EXIT key to return to the OPERATE menu. 5. Press the master arm freeze button to unfreeze the slave arm. Joints set to FRZ in the FREEZE menu will remain frozen. Joints set to REIN can be directed with the master arm. 6. To unfreeze all joints, return to the FREEZE menu and press the REINALL <7 key. All FREEZE menu joint settings return to REIN (active) when power to the master controller is interrupted Using the DRIVERS Menu Access path: MAIN/OPERATE/DRIVERS Password level: 0 or higher The DRIVERS menu (Figure 10) has two main functions: Enabling hydraulics if you disabled the hydraulics by pressing the UP key For controlling auxiliary hydraulic equipment or tools using the five driver channels. Contact Schilling Robotics for more information Page 64 4 Operation

65 Operation DRIVERS LOCK > #1: OFF #5:FRZ <5 2> #2: OFF Hydr:ON <6 3> #3: OFF 4> #4: OFF EXIT < Figure 10 DRIVERS menu screen To enable hydraulics, follow the steps below: 1. From the OPERATE menu, press the 2> DRIVERS key. 2. In the DRIVERS menu (Figure 10), press the Hydr <6 to toggle between ON (enabled) and OFF (disabled). 3. Press the EXIT<8 key to return to the OPERATE menu. NOTE: If the hydraulics are disabled while in REIN (active) status and the master arm is moved to a new position, the slave arm will move automatically to the new master arm position when the hydraulics are enabled Scaling Slave Arm Movement (Toggle) Access path: MAIN/OPERATE/OPTIONS Password level: 0 or higher Scaling controls the travel relationship between the master arm and slave arm. The default scale is 100%: slave arm travel matches master arm travel. To select an alternate scale while in the OPERATE menu: 1. Use the master arm tip to freeze the slave arm. 2. Press the 3> Scale Tog key to toggle between 100% and a pre-selected lesser scale. At each startup the selectable scale defaults to 100%. To reset if lesser values are required: 1. From the MAIN menu press the 2> OPTIONS key to display the OPTIONS menu (Figure 11) Operation Page 65

66 Operation OPTIONS FRZ > Dyn: FAST 2> Jaw Speed:16 3> Scale Set:050% EXIT < Figure 11 OPTIONS menu screen 2. Press the 3> Scale Sel key to change the alternate scale value in 10% increments. (At 100%, the value defaults to 10%.) 100% = the default value producing one-to-one correspondence. For example, rotating the master arm elbow joint 50 degrees causes the slave arm elbow joint to rotate 50 degrees. Less than 100% = reduces slave arm movement to a percentage of master arm movement, allowing finer slave arm control. For example, at 50% scale, rotating the master arm elbow joint 90 degrees causes the slave arm elbow joint to rotate 45 degrees. Scaling affects only the azimuth, shoulder, elbow, wrist yaw, and wrist pitch functions (wrist roll and jaw functions always remain at 100%). 3. When the desired alternate scaling value is displayed, press the EXIT <8 key to save and return to the MAIN menu Selecting the Wrist Mode (Toggle) Access path: MAIN/OPERATE Password level: 0 or higher Press the Wrist Md: <5 key to toggle between POS (position) and RATE modes of control (described below). RATE Rotating the collar from its null point (center of travel) initiates continuous slave arm wrist rotation in the same direction, with its speed (rate) increasing with the degree of collar rotation. To stop wrist rotation, you can either freeze the master arm or rotate the master arm wrist collar back to its null point (center of travel). NOTE: When you unfreeze the master arm, the wrist will not rotate until master collar is near the null point (center of travel). Page 66 4 Operation

67 Operation POS (position) The slave arm wrist rotates to the same degree (position) the collar is rotated. If one of the collar s mechanical stops prevents achieving the desired wrist position, freeze the slave arm, and rotate the wrist collar away from the mechanical stop until there is adequate travel to direct the wrist as desired. Then unfreeze the slave arm and continue the task. NOTE: If the collar is at or near its mechanical limit in position (POS) mode, and you freeze the slave arm and switch to RATE wrist mode, the wrist will not rotate until you first rotate the collar back to the rate mode null point (this prevents immediate full-speed rate rotation when you change modes) Selecting and Using the Jaw Operating Modes Access path: MAIN/OPERATE Password level: 0 or higher Press the Jaw Md: <5 key to toggle between the three jaw function modes (POS, TOG, LOCK). TOG (toggle) Squeezing the forward jaw band fully opens or closes the jaw. POS (position) The jaw moves as long as the jaw band is squeezed. Forward band = Jaw closes Rear band = Jaw opens LOCK This menu selection disables master arm input, leaving the jaw in its current position. To escape from the LOCK mode, press the JAW MD: key and toggle to the TOG or POS mode. NOTE: The jaw relaxes its grip when hydraulics are disabled, either through operator control or hydraulic failure. Objects held by the jaw may be released or dropped Auxiliary Jaw Switch The auxiliary jaw switch is located on the left side of the master controller faceplate and provides the same functions as the jaw bands on the master arm (see Selecting and Using the Jaw Operating Modes on page 67). Move switch forward = Jaw closes Move switch to rear = Jaw opens Operation Page 67

68 Operation 4.7 Using the SHUTDOWN Menu Access path: MAIN/SHUTDOWN Password level: 0 or higher SHUT DOWN FRZ Stow Out <5 Stow In <6 Pnt:OUT Stop <7 4> Hydr to OFF EXIT < After stow,turn off hydraulics Figure 12 SHUT DOWN menu screen To shut down the manipulator system: 1. Release any objects from the grasp of the jaw. NOTE: Release objects from the jaws before shutdown. The jaw relaxes when hydraulics are disabled, and a grasped object will be dropped. 2. Move the slave arm to a position that approximates the STOW OUT position. Exit the OPERATION menu. 3. From the MAIN menu, press the SHUT DOWN <5 key to display the SHUTDOWN menu (Figure 12). 4. Press the Stow In <6 key to move the slave arm to its stowed position. Note that: before beginning the Stow In sequence, the slave arm will first move to the Stow Out position. as the slave arm moves towards Stow In, the PNT: field displays each successive point number in the sequence. The final point (01) is displayed as IN. to stop the sequence, press the Stop <7 key. NOTE: Pressing the STOP <7 key does not stop the slave arm until it reaches the next point in the stow path. To immediately stop the slave arm, press the UP control key (disables hydraulic power). to reverse the stow sequence at any time, press the Stow Out <5 key. 5. Press the 4> Hydr key to disable hydraulics. 6. Turn off power to the hydraulic power unit. Page 68 4 Operation

69 Operation 7. Turn off power to the master controller with the switch on the left side of the faceplate. Turn off power to the slave controller (if independently supplied). 4.8 Shutdown Maintenance You can keep your system in good operating condition by performing the following post-operation steps. All Models 1. Park the master arm on the faceplate, above the LCD screen, and stow the master controller in a protected location. 2. Check slave arm and hydraulic lines for: Damage Loose or missing fasteners Trapped debris Hydraulic leaks Submersible Models 1. Hose down the slave arm and slave controller with clean, fresh water. 2. Check a sample of hydraulic fluid for water or other contamination. If either are found, flush and refill the system with clean hydraulic fluid 3. Apply a spray lubricant to the slave arm jaw assembly and actuator rods to displace any water. 5 Setting Performance Options The Titan 3 can be optimized for a specific task and/or worksite by selecting, setting, or configuring system functions using the OPTIONS and SETUP menus. 5.1 Using the OPTIONS Menu Access path: MAIN/OPTIONS Password level: 0 or higher Use the OPTIONS menu (Figure 13) to set slave arm speed and alternate scaling, and set the jaw speed Setting Slave Arm Speed (Dynamics) Access path: MAIN/OPTIONS Password level: 0 or higher Slave arm speed (compared to the speed of master arm movements) can be toggled between FAST and SLOW in the 1> Dyn menu Setting Performance Options Page 69

70 Operation FAST Mode Slave arm speed attempts to match movements of the master arm. Use when quick response and close correspondence to rapid movements of the master arm are needed, and in submersible operation where slave arm movements are slowed by water resistance SLOW mode Slave arm speed is limited regardless of master arm movement speed. Use when hydraulic flow is limited to prevent pressure from dropping due to high demand. OPTIONS FRZ > Dyn: FAST 2> Jaw Speed:16 3> Scale Set:050% EXIT < Figure 13 OPTIONS menu screen To change the slave arm speed: 1. Press the 1> Dyn key to toggle between SLOW and FAST modes. 2. Press EXIT <8 to save setting and return to the MAIN menu. Slave arm speed defaults to FAST when power to the master controller is interrupted. NOTE: Avoid rapid movements of the master arm in the SLOW mode. Slave arm response lags and may make it difficult to avoid obstacles or direct the slave arm to an exact position. Slow master arm movements until the slave arm can match them Controlling Jaw Opening and Closing Speed Access path: MAIN/OPTIONS Password level: 0 or higher Jaw speed is functional in POSITION mode only. Jaw speeds range from 04 to 32 (slow to fast) in increments of 4. Jaw speed defaults to 16 when power to the master controller is interrupted. To change the jaw speed: Page 70 5 Setting Performance Options

71 Operation 1. Press the 2> Jaw Speed key to increase the speed in increments of 4. After 32, the jaw speed value defaults to 04 (Figure 13, OPTIONS menu screen on page 70). 2. Press EXIT <8 to save setting and return to the MAIN menu Setting an Alternate Slave Arm Scale Access path: MAIN/OPTIONS Password level: 0 or higher You can set an alternate scale of slave arm movement to master arm movement in the OPTIONS menu (Figure 13) and use the 3> Scale Tog key in the OPERATE menu to toggle between it and 100% (the default scale value). 100% = 1:1 correspondence (For example, 50 degree master arm elbow joint rotation results in 50 degree slave arm elbow joint rotation.) Less than 100% = slave arm movement is a percentage of master arm movement (For example, at 50% scale, a 90 degree rotation of the master arm elbow joint results in 45 degree slave arm elbow joint rotation.) Scaling affects the azimuth, shoulder, elbow, wrist yaw, and wrist pitch functions Wrist roll and jaw functions always remain at 100% To set the alternate scaling value, follow these steps: 1. From the MAIN menu press the 2> OPTIONS key. 2. In the OPTIONS menu, press the 3> Scale Sel key to select the scaling you want (in 10% increments). 3. Press the EXIT <8 key to save the setting and return to the MAIN menu. The alternate scale value default to 100% when power to the master controller is interrupted. 5.2 Using the SETUP Menu Access path: MAIN/SETUP Password level: 1 or higher (level 5 required for MEMORY and SECURITY/SET PASSWORD) The SETUP menu (Figure 14) is used for configuring the following functions: 1> SET LIMITS (set slave arm movement limits). 2> SET STOW (record the stow in/stow out path). 3> SET SV OFFSET (Set servo valve offsets). See Setting Servo Valve Voltage Offsets in the "Maintenance & Service" chapter. 4> SET ERR CHECKS (enable/disable system error checking). MEMORY <5 (edit master controller memory locations only under direction from Schilling service personnel) Setting Performance Options Page 71

72 Operation SECURITY <6 (set and access security levels, set passwords). SETUP LOCK > SET LIMITS MEMORY <5 2> SET STOW SECURITY <6 3> SET SV OFFSET 4> SET ERR CHECKS EXIT < Figure 14 SETUP menu screen To configure the menus within the Setup menu, except MEMORY<5, you must first access security level 1 or higher by entering a local- (or the factory-assigned level 5) password in the SECURITY menu. Only the level 5, factory-assigned password will provide access for configuring the MEMORY <5 menu. Settings in all SETUP submenus are retained even if power to the master controller is interrupted. NOTE: A factory-assigned password sheet is located at the end of the Table of Contents The SECURITY Menu Access path: MAIN/SETUP/SECURITY SECURITY LOCK > SET LEVEL 2> SET PASSWORD EXIT < Figure 15 SECURITY menu screen The master controller has one unprotected, default access/operation level. Two additional password-protected security levels allow you to access menus and configure sensitive or critical system functions. Entering or changing the passwords for each Page 72 5 Setting Performance Options

73 Operation level is done via the SECURITY menu (Figure 15), which is accessed by pressing the 6> SECURITY key in the SETUP menu. Level 0 is the default level available at system startup. No password is required. Full system operation is available at level 0, including access to error-checking and diagnostic menus. The level 0 operator can access only the SET ERR CHECKS in the SETUP menu. A level 0 operator using a fully configured manipulator system will usually need no higher security level. Levels 1 through 4 require a password, and allow access to the SET LIM- ITS, SET STOW, SET SV OFFSET, and MEMORY menus. (Levels 1-4 are functionally equivalent.) Level 5 requires the factory-assigned password, and allows access to all configuration and security menus. Level 5 access is required to set or change passwords Entering Passwords: the SET LEVEL Menu Access path: MAIN/SETUP/SECURITY/SET LEVEL Password level: 1 or higher SET LEVEL Level:0 Inc <5 Password:#### Dec <6 Select <7 Current user's Privilege Level:0 EXIT < Figure 16 SET LEVEL menu screen To enter a password for a higher security level, perform the following steps: 1. From the SETUP menu, press the SECURITY <6 key. 2. From the SECURITY menu, press the 1> SET LEVEL key to display the SET LEVEL menu (Figure 16). (The current security level is displayed at the bottom of the screen.) 3. The cursor appears in the Level: field. Press the Inc <5 or Dec <6 keys until the desired level (number) is displayed. Press the Select <7 key to enter the setting. 4. The cursor drops to the first digit of the Password: field, changing the first asterisk (*) to a zero (0). Press the 5> Inc or 6> Dec keys until the first number of the four-digit password appears. Press the Select <7 key to enter the number and repeat until all four numbers of the password have been entered Setting Performance Options Page 73

74 Operation 5. When the level and password have been correctly entered, DONE will appear at the bottom of the screen. 6. Press the EXIT <8 key to exit Setting and Changing Passwords Access path: MAIN/SETUP/SECURITY/SET PASSWORD Password level: 5 Use the SET PASSWORD menu (Figure 17) to set or change passwords for security levels 1 through 4 (The password for security level 5 cannot be changed). SET PASSWORD LOCK Level:0 Inc <5 Password:#### Dec <6 Select <7 Current user's Privilege Level:5 EXIT < Figure 17 SET PASSWORD menu screen To set or change a password: 1. Set the security level to 5 (see Entering Passwords: the SET LEVEL Menu on page 73). 2. From the SETUP menu, press the 6> SECURITY key. 3. From the SECURITY menu, press the 2> SET PASSWORD key. 4. In the SET PASSWORD menu, the cursor appears in the Level: field. Press the Inc <5 or Dec <6 key until the desired level is displayed. Press the Select <7 key to enter. 5. The cursor drops to the first digit of the Password: field. Press the 5> Inc or 6> Dec key to set the first number of the new password. Press the 7> Select key to enter the number. Repeat until all numbers of the new password have been entered. 6. When the level and password have been correctly entered, the message DONE will appear at the bottom of the screen. 7. Press the EXIT <8 key to exit Setting the Stow Path Access path: MAIN/SETUP/SET STOW Password level: 1 or higher Page 74 5 Setting Performance Options

75 Operation The stow path is a pre-recorded sequence of 2 to 16 points the slave arm automatically travels through when the Stow In or Stow Out (deploy) key is pressed in the STOW OUT or SHUT DOWN menus. Use the SET STOW menu (Figure 18) to change the stow sequence for your slave arm. SET STOW FRZ POINT:01 Last <5 Next <6 Teach <7 Last Stow 4> Point:08 EXIT < Figure 18 SET STOW menu screen Note that the SET STOW and SET LIMIT menus are interrelated: Current movement limits (set in the SET LIMITS menu) also apply while you are in the SET STOW menu. The current stow sequence cannot be limited or affected by new changes in the SET LIMIT menu. If you want to set new stow points outside the current movement limits, you must first extend the limits in the SET LIMITS menu. Then return to the SET STOW menu to set the stow points. If desired, restore the original movement limits using the SET LIMITS menu (the stow sequence, including the points outside the limits, will not be affected). Some other considerations: Pressing the Stop >7 key while the slave arm is performing a Stow In or Stow Out action will not halt the slave arm until it reaches the next point on the stow path. A Stow In/Stow Out path with more points allows the slave arm to be stopped sooner in an emergency. The control system calculates how to move the slave arm between points, so using just a few points leaves much of the slave arm movement up to the control system. Use more points if the slave arm must avoid obstacles or equipment. To change the stow path for your slave arm, following these steps: 1. Set that the security level to 1 or higher. 2. Access the SET STOW menu (Figure 18): MAIN/SETUP/SET STOW. The POINT field opens to the 01 (Stow In) point. 3. Press the 4> Last Stow Point key and increment to the number of points you want to use for the path sequence Setting Performance Options Page 75

76 Operation Point 01 = The Stow-In position Last Stow Point = The final Stow Out position Select any number of points between 2 and 16 to reach the Stow Out point. 4. Unfreeze the arm. 5. Move the arm to the desired Stow In point (01). Press TEACH<7 to record the position (the POINT: field increments to the next point). NOTE: Slave arm travel limits set now in the SET LIMITS menu will apply to and limit future changes to settings in the SET STOW menu. Existing stow settings are not affected. 6. Move the slave arm to the next position and press TEACH<7. Repeat to record each point in the stow sequence. LAST<5 key = Return to a previous point and reteach NEXT<6 key = Skip ahead (skipped points retain existing settings) The last point taught = The final Stow-Out point 7. After recording the last point, press the EXIT <8 key to save the recorded path Setting Slave Arm Movement Limits Access path: MAIN/SETUP/SETLIMITS Password level: 1 or higher SET LIMITS FRZ COUNT:01 Last <5 LIMIT: Next <6 AZI LEFT Teach <7 EXIT < Figure 19 SET LIMITS menu screen Limit the range of motion of each slave arm joint (except wrist and jaw) by entering travel limits in the SET LIMITS menu (Figure 19). Note that the SET STOW and SET LIMIT menus are interrelated: Current movement limits (set in the SET LIMITS menu) also apply while you are in the SET STOW menu. Page 76 5 Setting Performance Options

77 Operation The current stow sequence cannot be limited or affected by new changes in the SET LIMIT menu. If you want to set new stow points outside the current movement limits, you must first extend the limits in the SET LIMITS menu. Then return to the SET STOW menu to set the stow points. If desired, restore the original movement limits using the SET LIMITS menu (the stow sequence, including the points outside the limits, will not be affected). To set movement limits for individual slave arm joints, follow these steps: 1. Set the security level to 1 or higher (MAIN/SETUP/SECURITY/SET LEVEL). 2. Access the SET LIMITS menu (MAIN/SETUP/SETLIMITS). NOTE: While the SET LIMITS menu is open, slave arm joints are capable of full mechanical travel. Limits will NOT engage until you have exited from the SET LIMITS menu. 3. The COUNT: field and LIMIT: field identify each slave arm function (Table 1). Table 1 Joint limit numbers (Menu) COUNT: (Menu) LIMIT: Joint Function 01 AZI LEFT Azimuth Yaw 02 AZI RIGHT 03 SHO DOWN Shoulder Pitch 04 SHO UP 05 ELB DOWN Elbow Pitch 06 ELB UP 07 PIT DOWN Wrist Pitch 08 PIT UP 09 YAW LEFT Wrist Yaw 10 YAW RIGHT 4. The menu opens at COUNT: 01 and LIMIT: AZI LEFT. 5. Unfreeze the arm by pressing the master arm freeze button. 6. Move the slave arm to the desired left azimuth travel limit. 7. Press the Teach <7 key to enter the position as the limit. The COUNT: field will automatically increment to 02, for setting the AZI RIGHT limit. 8. Repeat steps 6 and 7 to set limits for the remaining joints. Press the Last <5 key to return to a previous function. Press the Next <6 key to skip a function (keeps existing setting) Setting Performance Options Page 77

78 Operation 9. To save all settings, move the arm to any position inside the new limits, freeze the slave arm, and press the EXIT <8 key. NOTE: If you have positioned any joint outside its limits, the arm will move to a position within the new limits the next time the arm is unfrozen.) 10. You should immediately test the new limits to ensure that the slave arm s range of movement is acceptable. Use caution near equipment until you are certain that the new limits prevent collisions. NOTE: The slave arm will not respond normally to master arm input if contradictory movement limits have been set (for example: a right azimuth limit that is set to the left of the left azimuth limit). If the slave arm does not respond as expected after setting movement limits, re-enter the menu and set new limits, paying careful attention to the function and direction being set Set ERR Checks Menu For configuring system error-checking and emergency operation when a system error cannot be cleared, see Enabling and Disabling System Error Checking on page 83 of this chapter Set SV Offset Menu Use of this menu is described in the Setting Servo Valve Voltage Offsets on page 16 in the Maintenance & Service chapter Memory Menu! Caution The MEMORY menu should only be used under direction from Schilling Robotics service personnel. 6 System Errors and Warnings 6.1 Startup with System Warnings The Startup with Warnings screen (Figure 20) appears under the conditions described below Arm not near STOW (In) point For this condition follow the steps below: 1. Press the EXIT <8 key (exits to Startup Procedure screen). Page 78 6 System Errors and Warnings

79 Operation 2. Clear people from the slave arm s range of motion. Follow the steps in Startup on page 58 of this chapter and exit to MAIN menu. 3. Access the OPERATE menu and test operation of the slave arm. SCHILLING ROBOTIC SYSTEMS TITAN MANIPULATOR SYSTEM WARNINGS: Arm not near STOW point (STOW OUT will be bypassed) Keys Error( ) Exit < Version Rev. A Figure 20 Startup with Warnings screen Keys Error A 1 in the Keys Error field indicates a depressed or malfunctioning key (or freeze button). In many cases, an object or the master arm is depressing a key, the key itself is stuck, or the master arm is resting on the freeze button (freeze button depressed). 1. If a key or the freeze button is depressed: a. Remove the pressure from the key or freeze button. b. Turn power to master controller off and on. Watch for the warning screen. c. If there are no keys errors, proceed to step 4. If the key error remains, refer to Diagnosing Key and Freeze Button Failures in the Troubleshooting chapter. d. Press the EXIT<8 key (exits to the startup screen). e. Proceed with normal startup (see Startup on page 58 of this chapter, beginning with step 5). 2. If a key or the freeze button is not depressed: a. Note the position of any 1 numbers in the Keys Error field. b. DO NOT proceed with startup. Refer to Diagnosing Key and Freeze Button Failures in the Troubleshooting chapter. NOTE: In an emergency, the slave arm may be operated with keys errors. Exit the warning screen and proceed with the startup. Use caution until safe operation of the slave arm is verified System Errors and Warnings Page 79

80 Operation 6.2 Startup with System Errors The Startup with System Errors screen (Figure 21) when error checking software detects a problem. SCHILLING ROBOTIC SYSTEMS TITAN MANIPULATOR SYSTEM System errors were detected! Diagnose errors before starting hydraulics. Press EXIT key to view the next menu. EXIT < Figure 21 System Errors screen Follow these steps: 1. Press the EXIT <8 key (exits to the MAIN menu). DO NOT proceed with startup. 2. Press the DIAGNOSE <6 key to access the DIAGNOSTICS menu. 3. See Using the SHOW ERRORS Menu on page 80 of this chapter and System Errors in the "Troubleshooting" chapter, to diagnose system errors. 6.3 ERR (Error) Message During Operation An ERR (error) message in the top line (left of the status field) during operation indicates a system error has been detected and hydraulics have been disabled. See Using the SHOW ERRORS Menu on page 80 and Enabling and Disabling System Error Checking on page 83 of this chapter. 6.4 Using the SHOW ERRORS Menu Access path: MAIN/DIAGNOSE/SHOW ERRORS Password level: 0 or higher You are alerted to system errors by: a System Errors screen during startup. an ERR message in the top line of a menu at any time during operation. Use the SHOW ERRORS menu (Figure 22) to: View a list of errors detected by the system. Identify which joint caused the error. Reset error conditions that have been corrected. After correcting the error, re-enable slave arm hydraulics. Page 80 6 System Errors and Warnings

81 Operation System Errors The system errors are described in Table 2. Table 2 System errors Error No. Error Name System Errors Description 01 Slave range Feedback information from the slave arm indicates that the slave arm is outside of its factory set movement limits. This means that the system is reporting that the arm is in a position that it cannot actually attain. 02 Slave continuity Feedback information from the slave arm indicates that the slave arm position is changing at a faster rate than is actually possible. 03 Slave control Feedback information from the slave arm indicates that a control problem may exist for one or more joints. 04 Slave telemetry Indicates that communications from the master controller to the slave controller have been halted, interrupted, or fatally corrupted. 05 Slave CPU reset Indicates that the slave controller has reset. This occurs if the slave controller loses power or the slave controller CPU board fails. 06 Master range Feedback information from the master arm indicates that the master arm is in a position that it cannot actually attain. 07 Master telemetry Indicates that communications from the slave controller to the master controller have been halted, interrupted, or fatally corrupted. See System Errors in the Troubleshooting chapter for a description of error types and a list of causes and remedies Show and Clear System Errors To show and clear system errors: 1. Access the SHOW ERRORS menu: MAIN/ DIAGNOSTICS/SHOW ERRORS (Figure 22). 2. Detected errors or warnings will appear In the upper left corner of the display in the ERRORS: and Warnings: fields. 3. See Table 2 for error descriptions and System Errors in the Troubleshooting chapter for more information on diagnosing and correcting errors System Errors and Warnings Page 81

82 Operation SHOW ERRORS LOCK ERRORS: Master Range Clr Errs <5 Warnings: Hydr OFF Hydr OFF <6 EXIT < Figure 22 SHOW ERRORS menu screen Intermittent or Transient Errors Some conditions causing error messages can be corrected and cleared immediately, allowing normal operation to resume. For example: Pushing the slave arm against an immovable object or lifting too heavy an object. Transient or intermittent cable/connector malfunction. 1. Correct these conditions and press the Clr Errs <5 key to clear the ERRORS: field. Note that: The ERRORS: field is completely updated when you press the Clr Errs <5 key. Uncorrected error conditions will again be displayed. An error disabling hydraulics must be corrected and cleared before hydraulics can be enabled. 2. When ALL errors have been corrected and cleared, press the Hydr On <6 key to enable the hydraulics. 3. Press the EXIT<8 key and return to the OPERATE menu. Uncleared Errors Requiring Service 1. Shut down system and correct error conditions. See Table 2 on page 81 of this chapter for error descriptions and System Errors in the Troubleshooting chapter for more information on diagnosing and correcting errors. 2. Restart the system. Verify that no error messages are present. Proceed with normal startup and operation. Emergency Operation For emergency operation when an error cannot be cleared or reoccurs frequently during operation, see Enabling and Disabling System Error Checking on page 83, below. Page 82 6 System Errors and Warnings

83 Operation 6.5 Enabling and Disabling System Error Checking Access path: MAIN/SETUP/SET ERR CHECKS Password level: 1 or higher Error checking detects malfunctions or dangerous conditions and automatically disables hydraulics to prevent damage. You can use the Set Error Checks menu (Figure 23) to selectively disable error checking: when collisions or extreme loads are likely to cause repeated error messages. for emergency operation. for diagnosing a fault or malfunction. SET ERR CHECKS LOCK [01] Slave Range Change <5 Check ENA State:OFF 2> Last Disable all <6 3> Next Enable all <7 4> Save as default EXIT < Figure 23 SET ERR CHECKS menu screen! Caution An automatic shutdown due to a system error protects the slave arm and its surroundings from risk of damage. Disabling error checking to resume operation indicates the operator s awareness and acceptance of increased risk. The safety features that result from error-checking (such as automatically disabling hydraulics) will no longer be in effect. The condition causing the error may result in limited or erratic operation of the slave arm To enable and disable system error checks: 1. Review system errors or determine error status (see Using the SHOW ERRORS Menu on page 80 of this chapter. 2. Access the SET ERR CHECKS menu: MAIN/SETUP/SET ERR CHECKS System Errors and Warnings Page 83

84 Operation 3. In the SET ERR CHECKS menu (Figure 23), the error type and its current status will appear in the upper left of the screen. For example: [01] = Error number Slave Range = Error type Check ENA = error checking enabled (DIS = error checking disabled) State: OFF = no error detected (ON = error detected) 4. Press the 2> Last and 3> Next keys to review the other error types and their status. 5. Press the Change <5 key to toggle the Check: field between ENA and DIS. To disable checking for all error types, press the Disable all <6 key. To enable checking for all error types, press the Enable all <7 key. 6. Your settings can be saved two ways: Temporary (until the master controller is turned off): press the EXIT <8 key. Default (until changed again): press the 4> Save as default key. Then press the EXIT <8 key. 6.6 Diagnosing Master/Slave Problems See Diagnosing Master/Slave Joint Problems in the Troubleshooting chapter for information about using the DIAGNOSTICS menu to view to screens that display joint position data for the master arm or slave arm. 6.7 Fatal Telemetry Errors A fatal telemetry error occurs when communication between the master controller and slave controller is interrupted for more than several seconds. See Fatal Telemetry Errors in the Troubleshooting chapter for causes and remedies. Page 84 6 System Errors and Warnings

85 Troubleshooting In This Chapter: 1 Preliminary Fault Isolation Procedures... page 85 2 Diagnosing Master/Slave Joint Problems... page 86 3 Diagnosing Key and Freeze Button Failures... page 90 4 Troubleshooting Tables... page 90 1 Preliminary Fault Isolation Procedures Eliminate the obvious causes of a fault or malfunction. Check the following: The master controller is receiving electrical power. The slave controller is receiving electrical power. The junction box (if used) is receiving electrical power and the fuse is intact. The electrical power and hydraulic inputs are correct as described in the Specifications and Installation chapters. All telemetry conductors between the master controller and slave controller show continuity and connectors are secure. Isolate cable malfunctions by testing the cables for continuity and insulation resistance, or by substituting spare cables. If the fault or malfunction persist, use the following sections and troubleshooting tables to isolate the fault. 1.1 Definitions The following terms are used to describe slave arm performance: Unresponsive = No response to commands Sluggish = Responds predictably, but slowly, to commands Erratic = Responds unpredictably to commands Sagging = Joint that should be rigid sags instead Hard over = A slave arm joint moves abruptly to its hardware limit Page 85

86 Troubleshooting 2 Diagnosing Master/Slave Joint Problems Although a malfunction of the slave arm is often the first sign of a problem, the cause may be elsewhere in the manipulator system. This section explains how you can use the STOW IN or STOW OUT menu and the MASTER TEST and SLAVE TEST screens to help isolate the cause. 2.1 The STOW IN/STOW OUT Test When the slave arm malfunctions during operation with the master arm, using the Stow Out or Stow In command in the STOW OUT or SHUT DOWN menu can help isolate the cause: If a single slave arm joint was malfunctioning but accurately follows the stow path, the fault is most probably in the corresponding master arm joint potentiometer. To test it, see Diagnosis with the MASTER TEST Screen below. If the entire slave arm was malfunctioning but accurately follows the stow path, the cause is most probably in the master controller PC boards. See Slave Arm Symptoms (Entire Arm) on page 93. If the single joint still malfunctions following the stow path, the cause is most probably in the joint s slave arm wiring, resolver, or servo valve. See Diagnosis with the Slave Test Screen on page 87 and Slave Arm Symptoms (Individual Joints) on page 94. If the entire slave arm still malfunctions following the stow path, other diagnostic test may be more helpful. See Diagnosis with the Slave Test Screen on page 87 and Slave Arm Symptoms (Entire Arm) on page Diagnosis with the MASTER TEST Screen The MASTER TEST screen displays joint position output values from position-sensing potentiometers in the master arm. These output values are helpful in diagnosing problems exhibited by the slave arm and isolating the cause to the master arm or slave arm. Note the following: Displaying the MASTER TEST screen locks the slave arm. The MASTER TEST screen displays position values for: each master arm joint. jaw bands/auxiliary jaw rocker switch. Moving the master arm changes the output values. A 1 in the Keys: field indicates a key or freeze button error. See Diagnosing Key and Freeze Button Failures on page Diagnosing with Master Arm Position Values 1. Access the MASTER TEST screen (Figure 1): MAIN/ DIAGNOSTICS/MASTER TEST. Page 86 2 Diagnosing Master/Slave Joint Problems

87 Troubleshooting MASTER TEST LOCK Command: Jaw Bands: Azi: Sho: Elb: Yaw: Pit: Wrs: Keys: EXIT < Figure 1 MASTER TEST screen 2. Move the master arm and observe the position values from each joint: If a specific slave arm joint is malfunctioning, check the matching master arm joint: a. If the joint is stable, the position value should be stable (an unstable value for a stable joint indicates a possible failure of its potentiometer or a master controller analog PC board). b. If a small movement of the master arm joint causes a large or erratic change in its position value, this may indicate a failure to that joint s master arm potentiometer. If the values for all joints are unresponsive or erratic, a master controller board failure may be the problem. 3. If all values, and value changes in response to master arm movement, appear normal, proceed to Diagnosis with the Slave Test Screen on page Diagnosis with the Slave Test Screen The SLAVE TEST screen displays joint position output values from position-sensing resolvers in the slave arm. These position values are helpful in diagnosing problems exhibited by the slave arm and isolating the cause. Note: In the SLAVE TEST menu, you can unfreeze the slave arm and control it with the master arm while observing the command and position values. Command: values = Generated by computer, based on movement of master arm MASTER TEST Command: values = generated by movements of the master arm Position: values = position values sensed by slave arm joint resolvers ~0 values = Approximate middle of range of motion + values = Movement up or right - values = Movement down or left Diagnosing Master/Slave Joint Problems Page 87

88 Troubleshooting Diagnosing SLAVE TEST Position Values 1. Access the MASTER TEST screen (Figure 2): MAIN/ DIAGNOSTICS/SLAVE TEST. SLAVE TEST FRZ Command: Position: Azi: Sho: Elb: Yaw: Pit: Wrs: Jaw: EXIT < Figure 2 SLAVE TEST screen 2. While in FRZ status, with master arm and slave arm at rest, observe the Command: and Position: values. If Command: values are unstable refer to Diagnosing with Master Arm Position Values on page 86. Correct any malfunction before proceeding. If a specific slave arm joint is malfunctioning, check its Position: value. If the Position: value is unstable, the most probable cause is its resolver, followed by resolver to slave controller wiring, or a slave controller PC board.) 3. Unfreeze the slave arm and move the master arm as directed: If a small movement of the master arm joint causes a large or erratic change in its Command: value, refer to Diagnosing with Master Arm Position Values on page 86. Correct any malfunction before proceeding. Use the master arm to move each slave arm joint to its travel limits. The Position: values noted at the limits should fall within the ranges shown in Table 1. Table 1 Joint hardware limit values Joint Limit Value Range (±400 Counts) Azimuth Left Right Shoulder Down Up Elbow Down Up Page 88 2 Diagnosing Master/Slave Joint Problems

89 Troubleshooting Table 1 Joint hardware limit values (cont.) Joint Limit Value Range (±400 Counts) Pitch Down Up Yaw Left Right Jaw Completely open Completely closed A value range that is skewed higher or lower may be caused by an incorrect SV (servo valve) offset (see Setting Servo Valve Voltage Offsets in the Maintenance & Service chapter). An erratic or widely varying value range may be caused by the joint s resolver. If a specific slave arm joint is malfunctioning, check its Position: value. If slight movement of the master arm joint causes erratic slave arm movement and a large change in the slave arm joint s position value, the cause may be the joint s resolver. If movement of the master arm joint produces no change in the slave arm joint or its Position: value, the cause may be a slave controller board, resolver to slave controller wiring, or the joint s servo valve. If general movement of all master arm joints produces either erratic slave arm movement and Position: values for all joints or no slave arm movement and no change in Position: values for all joints, the cause may be the slave arm to slave controller cabling/connector, a slave controller board, or the slave controller to slave arm cabling/connector. If general movement of all master arm joints produces sluggish slave arm movement and normal Position: value responses for all joints, the cause may be the solenoid valve, blockage of hydraulic supply/return lines, or inadequate hydraulic pressure. 4. For transient and intermittent slave arm malfunctions, unfreeze the slave arm and use the master arm to produce movement in all slave arm joints: Observe each pair of Command: and Position: values. Watch for unusual or abnormal jumps in values and lack of change in values that might allow you to isolate the cause to either a single joint (resolver, potentiometer, servo valve) or a more global malfunction (cabling, PC board, solenoid valve Diagnosing Master/Slave Joint Problems Page 89

90 Troubleshooting 3 Diagnosing Key and Freeze Button Failures The status of each key and the freeze button is shown in a specific character in the Keys: field at the bottom of the MASTER TEST screen (see Figure 1, MASTER TEST screen on page 87). The status characters are: 1 = Key/button pressed 0 = Key/button not pressed Each character represents a specific key or the freeze button as shown in Table 2. Table 2 Function key diagnosis Keys: Field Character (from left) Function 1 Function key 1 2 Function key 2 3 Function key 3 4 Function key 4 5 Up key 6 Left key 7 Left master arm freeze button (dual-arm systems only) 8 Master arm freeze button (std. and right in dual-arm systems) 9 Function key 5 10 Function key 6 11 Down key 12 Up key 13 Function key 8 14 Function key 7 When no keys or the freeze button are pressed, all characters in the Keys: field should show 0 status: Key/button failure = A 1 is present in the field (identify using Table 2.) Key/button failure = The number does not change when key/button is pressed (identify using Table 2.) If a key/button failure is confirmed, replace the faulty component. 4 Troubleshooting Tables Since manipulator system components are interactive, the component that displays a fault (typically the slave arm) may not be the cause of it. Page 90 3 Diagnosing Key and Freeze Button Failures

91 Troubleshooting To isolate and correct the cause of a fault: 1. Go to the table for the component that displays the fault or symptom that alerts you to the problem. 2. Remedy the most likely cause first and continue until you have eliminated the fault. The troubleshooting tables are organized as follows: Table 3, Screen-displayed symptoms, on page 91 Table 4, Master arm symptoms, on page 93 Table 5, Slave arm symptoms (entire arm), on page 93 Table 6, Slave arm joint symptoms, on page 94 Table 7, Jaw symptoms, on page 95 Other tables explain how to diagnose and troubleshoot: System errors Table 8, System error descriptions, on page 96 Table 9, System error symptoms, on page 97) Fatal telemetry errors Table 10, Fatal telemetry errors, on page Screen-Displayed Symptoms The master controller display presents diagnostic data, warning, and error screens to help you diagnose symptoms, and alerts you to other abnormal conditions. Use Table 3 to troubleshoot screen-displayed symptoms. Table 3 Screen-displayed symptoms Symptom Possible Cause Remedy Master controller power is on, but the screen display is blank. Transient electrical problem. Turn master controller power switch off, then on. Loose connection to the Secure connection. faceplate assembly. LCD display screen failure. Replace display. Master controller CPU board Replace board. failure. Master controller display Replace board. board failure. Error flag appears on the screen. (see System Errors on page 96) Message Fatal telemetry error appears (see Fatal Telemetry Errors on page 98) on the screen Troubleshooting Tables Page 91

92 Troubleshooting Table 3 Screen-displayed symptoms (cont.) Symptom Possible Cause Remedy Pressing a key does not execute the appropriate function; master arm data screen confirms that key failure has occurred (see Diagnosing Key and Freeze Button Failures on page 90). On MASTER TEST screen, position data for one joint changes even though the joint is not moving (also see Diagnosis with the MASTER TEST Screen on page 86). On MASTER TEST screen, position data for multiple joints changes even though the joints are not moving (also see Diagnosis with the MASTER TEST Screen on page 86). On SLAVE TEST screen, position data for one or more joint changes even though the slave arm is frozen (also see Diagnosis with the Slave Test Screen on page 87). On SLAVE TEST screen, position data for all joints changes even though the slave arm is frozen (also see Diagnosis with the Slave Test Screen on page 87). On SLAVE TEST screen, position data for one joint at its hard stop is not within range of the corresponding value in Table 1, Joint hardware limit values, on page 88 (also see Diagnosis with the Slave Test Screen on page 87). On SLAVE TEST screen position data for multiple joints at their hard stops are not within ranges of the corresponding values in Table 1, Joint hardware limit values, on page 88 (also see Diagnosis with the Slave Test Screen on page 87). Contaminated key switch contacts. Master controller CPU board failure. Keypad gasket failure. Keypad switch board failure. Master controller analog board failure. Master arm potentiometer failure. Loose connection between CPU board and analog board. Master controller analog board failure. Master controller CPU board failure. Defective master arm. Loose resolver connection. Resolver failure. Slave controller analog board failure. Slave controller analog board failure. Slave controller reference generator board failure. Mechanical interference with joint. Loose resolver connection. Resolver failure. Slave controller analog board failure. Slave controller analog board failure. Slave controller reference generator board failure. Clean key switch contacts. Replace board. Replace keypad gasket. Replace board. Replace board. Replace master arm. Secure connection. Replace board. Replace board. Replace master arm. Secure connection. Replace resolver. Replace board. Replace board. Replace board. Inspect joint and remove debris. Secure connection. Replace resolver. Replace board. Replace board. Replace board. 4.2 Master Arm Symptoms Use Table 4 to troubleshoot master arm problems. Page 92 4 Troubleshooting Tables

93 Troubleshooting If the problem affects one or more master arm joints, see Diagnosing Master/ Slave Joint Problems on page 86 to determine whether a master arm or slave joint is at fault. If you identified a joint problem using the MASTER TEST screen, also see Screen-Displayed Symptoms on page 91 to isolate the fault. Table 4 Master arm symptoms Symptom Possible Cause Remedy Master arm freeze button works intermittently or not at all (also see Diagnosing Key and Freeze Button Failures on page 90). Wrist collar does not actuate slave arm wrist (also see Diagnosis with the MASTER TEST Screen on page 86). Pressing jaw bands/jaw switch does not actuate slave arm jaw (also see Diagnosis with the MASTER TEST Screen on page 86). Master arm wiring failure or freeze button failure. Master controller CPU board failure. Master controller motherboard failure. Master controller analog board failure. Wrist collar failure. Slave controller analog board failure. Slave arm wrist resolver failure. Slave arm wrist servo valve failure. Master controller analog board failure. Jaw band failure. Jaw switch failure. Slave controller analog board failure. Jaw LVDT failure. Jaw servo valve failure. 4.3 Slave Arm Symptoms (Entire Arm) Replace master arm. Replace board. Replace board. Replace board. Replace master arm. Replace board. Replace resolver. Replace servo valve. Replace board. Replace master arm. Replace jaw switch. Replace board. Replace jaw LVDT assembly. Replace servo valve. Use Table 5 to troubleshoot symptoms affecting all slave arm joints/functions. If not all joints are affected, see Slave Arm Symptoms (Individual Joints) on page 94. Table 5 Slave arm symptoms (entire arm) Symptom Possible Cause Remedy Slave arm is unresponsive. Loose connection in any cable section between master controller and slave arm. Secure connection. Damaged cable in any section between master controller and slave arm. Master arm or master controller board failure. Slave controller analog board failure. Slave controller CPU board failure. Slave arm hydraulics solenoid valve failure. Replace cable. (see Table on page 91) Replace board. Replace board. Replace solenoid valve Troubleshooting Tables Page 93

94 Troubleshooting Table 5 Slave arm symptoms (entire arm) (cont.) Symptom Possible Cause Remedy Slave arm is receiving hydraulic power even though power is disabled; immediately turn off user s hydraulic power. Slave arm is erratic (also see Diagnosis with the Slave Test Screen on page 87). Slave arm hydraulics solenoid valve failure. Slave controller analog board failure. Master arm or master controller board failure. Damaged slave arm wiring harness. Slave controller analog board failure. Slave controller CPU board failure. Replace solenoid valve. Replace board. (see Table on page 91) Replace wiring harness. Replace board. Replace board. Slave arm is sluggish. Low hydraulic pressure. Repair hydraulic power unit. Replace slave arm hydraulic fluid filter. Clear clogged hydraulic lines. Repair solenoid valve. Master arm or master controller (see Table on page 91) board failure. Dynamics option set to SLOW. Toggle to FAST. 4.4 Slave Arm Symptoms (Individual Joints) Use Table 6 to troubleshoot slave arm joint symptoms. Also see Diagnosing Master/Slave Joint Problems on page 86 for some simple tests to determine causes. See Master Arm Symptoms on page 92 and Diagnosis with the MASTER TEST Screen on page 86 to determine whether a slave arm joint symptom is actually being caused by the master arm. If you have identified a joint problem using the SLAVE TEST screen ( Diagnosis with the Slave Test Screen on page 87), also see Screen-Displayed Symptoms on page 91 to isolate the fault. For jaw problems, see Jaw Symptoms on page 95. Table 6 Slave arm joint symptoms Symptom Possible Cause Remedy Joint leaks hydraulic fluid. One or more joints are hard over. Actuator leak (from any slave arm actuator). Joint slip ring leak. Replace actuator seals. Replace slip ring seals. Servo valve failure. Replace servo valve. Master arm problem. Replace master arm. Slave controller analog board failure. Replace board. Joint resolver failure. Replace resolver. Page 94 4 Troubleshooting Tables

95 Troubleshooting Table 6 Slave arm joint symptoms (cont.) Symptom Possible Cause Remedy One joint is unresponsive. Slave controller analog board failure. Replace board. Master arm joint potentiometer or master controller board problem. Replace potentiometer or controller board. Servo valve failure. Replace servo valve. Joint resolver failure. Replace resolver. Joint is frozen in FREEZE menu. Toggle to REIN. One joint is erratic. Slave controller analog board failure. Replace board. Servo valve failure. Replace servo valve. Contaminated hydraulic fluid. Replace fluid. Joint resolver failure. Replace resolver. Master arm problem. Replace master arm. One joint is sluggish. Servo valve failure. Replace servo valve. Low hydraulic pressure. Repair hydraulic power unit. Replace slave arm hydraulic fluid filter. Clear clogged hydraulic lines. Slave controller analog board failure. Replace board. Master arm problem. Replace master arm. Multiple joints are unresponsive. Slave controller analog board failure. Replace board. Master controller CPU board failure. Replace board. Shoulder moves freely when hydraulics are off. Lock valve failure. Replace lock valve. 4.5 Jaw Symptoms Use Table 7 to troubleshoot jaw problems. Also see Diagnosing Master/Slave Joint Problems on page 86.. Table 7 Jaw symptoms Jaw Symptoms Symptom Possible Cause Remedy Jaw is erratic. Slave controller analog board failure. Replace board. Jaw servo valve failure. Replace servo valve. Jaw LVDT* failure. Replace LVDT Troubleshooting Tables Page 95

96 Troubleshooting Table 7 Jaw symptoms (cont.) Jaw Symptoms (cont.) Jaw is sluggish or unresponsive. Jaw servo valve failure. Replace servo valve. Slave controller analog board failure. Replace board. Master controller CPU board failure. Replace board. Jaw LVDT failure. Replace LVDT assembly. * LVDT is the jaw s position sensor 4.6 System Errors Use Table 8 and Table 9 to troubleshoot system errors. Errors can originate in any system component handling or processing telemetry. Causes are described in Table 8. When the software detects an error, the display may show a Startup with System Errors screen (at startup) or an ERR message (during operation). Use Table 8 to isolate the fault. Use Table 9 to determine the cause and remedy. NOTE: All system errors disable the hydraulics. Table 8 System error descriptions Error Error Name Description 01 Slave range Feedback information from the slave arm indicates that the slave arm is outside of its factory set movement limits. This means that the system is reporting that the arm is in a position that it cannot actually attain. 02 Slave continuity Feedback information from the slave arm indicates that the slave arm position is changing at a faster rate than is actually possible. 03 Slave control Feedback information from the slave arm indicates that a control problem may exist for one or more slave arm joints. 04 Slave telemetry Indicates that communications from the master controller to the slave controller have been halted, interrupted, or fatally corrupted. 05 Slave CPU reset Indicates that the slave controller has reset. This occurs if the slave controller loses power or the slave controller CPU board fails. 06 Master range Feedback information from the master arm indicates that the master arm is in a position that it cannot actually attain. 07 Master telemetry Indicates that communications from the slave controller to the master controller have been halted, interrupted, or fatally corrupted. Use the SHOW ERRORS menu to identify the error (see Using the SHOW ERRORS Menu in the Operation chapter). Page 96 4 Troubleshooting Tables

97 Troubleshooting You can disable error-checking for any of the system errors in order to keep the slave arm operational for emergencies and diagnostic testing (see Enabling and Disabling System Error Checking in the Operation chapter).! Caution 1. An automatic shutdown due to a system error protects the slave arm and its surroundings from the risk of damage. Disabling error checking to resume operation indicates the operator's awareness and acceptance of increased risk. 2. The safety features that result from error-checking (such as automatically disabling hydraulics) will no longer be in effect. 3. The condition causing the error may result in limited or erratic operation of the slave arm. Table 9 System error symptoms Listed Error Possible Cause Remedy Slave range Slave arm resolver failure. Replace resolver. Loose resolver connection. Secure connection. Slave controller analog board failure. Replace board. Slave controller CPU board failure. Replace board. Slave controller reference generator board failure. Replace board. Slave continuity Slave arm resolver failure. Replace resolver. Loose resolver connection. Secure connection. Slave controller analog board failure. Replace analog board. Slave controller CPU board failure. Replace board. Slave controller reference generator board failure. Replace board. Slave control During operations, pushing hard against an immovable Cease activity. object. During operations, lifting too heavy an object. Cease activity. Slave arm actuator failure. Replace actuator. Slave controller reference generator board failure. Replace board. Slave telemetry Slave controller CPU board failure. Replace board. Loose connection at any point between slave arm Secure connection. and master controller. Damaged cable at any point between slave arm and master controller. Replace cable Troubleshooting Tables Page 97

98 Troubleshooting Table 9 System error symptoms (cont.) Listed Error Possible Cause Remedy Slave CPU reset Loose connection at any point between the slave controller and the user s electrical power source. Interruption of user s electrical power. Secure connection. Restore continuous power. Voltage outside of specified range, or noise in the Supply correct power. supplied power. Damaged cable at any point between the slave controller Replace cable. and the user s electrical power source. Slave controller CPU board failure. Replace board. Master range Master arm potentiometer failure. Replace master arm. Master controller analog board failure. Replace board. Master controller CPU board failure. Replace board. Master telemetry Loose connection at any point between the master Secure connection. controller and slave controller. Master controller CPU board failure. Replace board. 4.7 Fatal Telemetry Errors A fatal telemetry error occurs when communication between the master controller and slave controller cannot be enabled or is interrupted for more than several seconds. When this occurs, a fatal telemetry error message appears on the screen. A fatal telemetry error can appear at start up or during operation. If a fatal telemetry error occurs during operation, hydraulic power is disabled and the master controller command loop is idled. To resume operation after a fatal telemetry error: 1. Turn off power to the master controller. 2. Diagnose and correct the problem that caused the error. 3. Restart the system. Use Table 10 to troubleshoot fatal telemetry errors. Table 10 Fatal telemetry errors Possible Cause Faulty telemetry connection or cable at any point between the master controller and slave controller. Master controller opto or CPU board failure. Slave controller opto or CPU board failure. Remedy Secure connection / Replace cable. Replace board. Replace board. Page 98 4 Troubleshooting Tables

99 Maintenance & Service In This Chapter: 1 Service Alerts... page 99 2 Maintenance... page Important Service Practices and Procedures... page Junction Box Service... page Master Controller Service... page Slave Controller... page Slave Arm Service... page System Adjustments... page Work Instructions for Serviceable Components... page 122 Work instructions for user-serviceable assemblies include: Slave arm azimuth, upper arm, elbow, forearm, pitch assembly, yaw assembly, wrist, jaw, and linear actuators Slave controller Master controller Compensator Drawings and part lists to support the work instructions can be found in the Drawings & Part Lists chapter. To troubleshoot a problem, see the Troubleshooting chapter. 1 Service Alerts Observe the following WARNING and CAUTION notices.! WARNING SHOCK, PRESSURE, AND MECHANICAL HAZARDS! Before you service the manipulator system, turn off hydraulic and electrical power Page 99

100 Maintenance & Service! Caution Even when the slave arm has been hydraulically isolated, high pressure may remain in some components. Wear safety goggles, bleed system pressure where possible, and open hydraulic components and fittings slowly to allow safe release of pressure. PC board components can be damaged by static electricity. Wear a grounded anti-static wrist band while handling PC boards, chips, etc. Do not use lubicants containing molybdenum or graphite on o- rings. The suspended particles can plug hydraulic filters. 2 Maintenance 2.1 Daily Maintenance Perform the following steps daily, or after every duty cycle: Submersible Models 1. Thoroughly rinse the slave arm and slave controller with clean, fresh water. 2. Apply a spray lubricant to the slave arm jaw assembly and actuator rods to displace any water. All Models Inspect slave arm for: 1. Damage: If the slave arm has had severe service or a collision, inspect slave arm components, check all joints, actuator shaft pivot pins, and shoulder pivot pins. inspect the linear actuator body and shaft for dents, bends, or damaged components. check all hoses, fittings, and electrical cables. repair or replace damaged components. 2. Loose or missing fasteners Replace or retighten fasteners, as needed. Vibration and temperature cycles may cause fasteners to loosen. 3. Loose or dirty electrical connectors. Re-tighten as needed. Clean and lubricate o-rings prior to mating. Vibration and temperature cycles may cause electrical connectors to loosen. 4. Trapped debris Remove debris and nspect for damage. Page Maintenance

101 Maintenance & Service 5. Hydraulic leaks Repair any leaks, replace lost fluid, and bleed air, as needed. 6. Damaged hydraulic hoses Repair or replace hoses, as necessary. If possible, install protection or reroute hoses to prevent future damage. 7. Anode consumption Inspect all anodes and replace when 2/3 or more is consumed. 2.2 Long Term Periodic Maintenance Efficient and reliable long-term operation depends on the following three steps: 1. Inspect components and observe performance frequently. Do this starting with the first use. You will then be able to develop a schedule of inspection, maintenance, and service for hydraulic and mechanical components that meet the needs of the slave arm s operating environment and duty cycles. 2. Perform the inspections, maintenance, or service as scheduled. Staying with the schedule below will help keep the slave arm in good working condition. 3. Keep a log of all inspection, maintenance, and service actions. Keeping a log will help you understand when and why problems are occurring. Then you can modify your schedule based on this knowledge. Table 1 contains a minimum schedule for performing regular long-term maintenance. Use it along with the documentation for your Hydraulic Power Unit (HPU). Table 1 Long term maintenance schedule Period Every 100 operating hours Every 500 operating hours or per HPU documentation Every 2000 operating hours Every 2000 operating hours or per HPU documentation Every 2000 operating hours or every 3 years (whichever comes first) Task Retorque all external slave arm fasteners. Check a sample of hydraulic fluid for water and particulates. Replace if contaminated. Check hydraulic tank fluid level. Clean/replace HPU suction strainers. Replace worn or damaged actuator pins and bushings. Drain and replace hydraulic fluid. Replace all actuator o-rings and seals. Replace all slave arm o-rings and seals. Clean all o-ring grooves and surfaces Maintenance Page 101

102 Maintenance & Service 2.3 Hydraulic Power Unit System Maintenance Your hydraulic power unit (HPU) requires consistent maintenance to maintain the performance, efficiency, and service life of your manipulator system. The following is the basis for an effective maintenance schedule. Read and understand the documentation supplied with your HPU. Maintain a clean, sufficient quantity of hydraulic fluid of the proper type and viscosity. Keep air out of the system by keeping all connections tight and purging connections that have been opened. Clean/replace the HPU fluid filters, breather filters, and suction strainers as recommended in your HPU documentation. Inspect the HPU during operation for excessive heat or noise, which can indicate hydraulic, mechanical, or electrical problems. HPU failures can allow contaminates into the hydraulic fluid. Always flush the hydraulic system after major HPU repairs. Regularly inspect hoses for damage. Repair or replace damaged hoses. If possible, install protection or reroute hoses to prevent future damage. 3 Important Service Practices and Procedures You need to follow these practices and procedures when you service the manipulator system: Always turn off hydraulic and electrical power to the manipulator system. Wear a grounded anti-static wrist band when you work on PC boards or components. Support the slave arm at the elbow and jaw before opening any hydraulic connection. Clean, degrease, and inspect disassembled parts before reassembling. Replace o-rings that are broken, damaged, or shows signs of wear. Lubricate all o-rings with o-ring lubricant (Dow Corning 55 or petroleum jelly). Do not use lubricants that contain suspended particles such as molybdenum or graphite the particles can be drawn into the hydraulic system and clog filters. Apply Aqua Lube (or equivalent) to all fastener threads unless they are exposed to the hydraulic system or you are directed otherwise by the work instruction or engineering drawing. Torque all fasteners as specified. Torque specifications on engineering drawings take precedence over all other text references. Page Important Service Practices and Procedures

103 Maintenance & Service Startup After Minor Maintenance or Service 1. Follow steps in the Pre-Start Check and Startup sections of the Operation chapter. 2. Be sure to replace hydraulic and compensation fluids lost during maintenance or service. Startup After Major Service 1. Follow the procedures in Completing the Installation in the Installation chapter before resuming normal operation. 2. If the hydraulic or compensation fluid has been contaminated, flush the system and refill with fresh fluid. 4 Junction Box Service This section contains special maintenance and service procedures not covered in the Work Instructions. 4.1 Fuse Replacement The fuse is located under the fuse symbol, between the power switch and the powerin socket. Use the tab on the fuse cover to remove the fuse for replacement or inspection. Replacement fuse Littlefuse T 6.3AL 250V (SRS P/N ) 5 Master Controller Service This section contains special maintenance and service procedures not covered in the Work Instructions. 5.1 Accessing Internal Components Removing the Faceplate 1. Turn off the master controller and disconnect the whip from its power source. 2. Remove the four screws holding the master controller faceplate to the enclosure (Figure 1) Junction Box Service Page 103

104 Maintenance & Service Remove Screws (4X) Swing Faceplate Up To Left Figure 1 Removing the faceplate 3. Lift the faceplate assembly out of the enclosure. Swing it up and over to the left until it is upside down (Figure 1). This will expose the face of the CPU PC board. Take care to immobilize the master arm and avoid stressing the cables connected to the boards in the enclosure Installing the Faceplate 4. Carefully swing the faceplate assembly back over and seat it on the enclosure. Reinstall the four mounting screws. Check that no wires or cables are pinched between the faceplate and the enclosure. 5.2 Fuse Replacement Replacement fuse Littlefuse microfuse 5ALF 125V (SRS P/N ). To check or replace the fuse follow these steps: 1. Open the master controller as described in Removing the Faceplate on page Check or replace the fuse. The fuse (F1) and a spare fuse (F1A) are located at the corner of the master controller PC board (Figure 2). F1 F1A Figure 2 Master controller fuse (F1) and spare fuse (F1A) 3. Close the master controller as described in Installing the Faceplate on page 104. Page Master Controller Service

105 Maintenance & Service 5.3 Adjusting the LCD Screen Viewing Angle The LCD screen comes with a temperature sensor and compensation circuit that keeps the viewing angle stable over a broad temperature range. If you find the viewing angle is not acceptable for your work environment, adjust it as follows: 1. Before changing the LCD screen angle, check the current angle: a. Turn on power to the master controller under work environment conditions. The slave controller and slave arm need do not need to be powered up for this test. b. Allow the master controller to reach its normal operating temperature (5-10 minutes). It is not unusual for the viewing angle to be unacceptable for the first few minutes of operation. To adjust the LCD screen viewing angle follow these steps: 1. Open the master controller as described in Removing the Faceplate on page Locate the LCD adjustment potentiometer (labeled R1 on the PC board) (Figure 3). Figure 3 LCD Adjustment potentiometer 3. Use a small flat blade screwdriver, adjust this potentiometer: Move viewing angle toward top of the LCD: Turn screw CW 1/8 turn. Move viewing angle toward the side of the LCD: Turn screw CCW 1/8 turn. 4. Put the master controller faceplate back on its enclosure. Connect power and turn on the master controller. Allow the master controller to reach its normal operating temperature (5-10 minutes). Check the viewing angle. If the angle is good, replace the four screws. If the viewing angle requires further adjustment, repeat steps 1-5 until the viewing angle is acceptable. 5. Close the master controller as described in Installing the Faceplate on page Master Controller Service Page 105

106 Maintenance & Service 5.4 Master Controller EPROM Chip Replacement! Caution PC board components can be damaged by static electricity. Wear a grounded anti-static wrist band handling PC boards or chips. To replace the EPROM chip on the master controller CPU board, perform the following steps (also refer to the master controller drawing in the Drawings & Part Lists chapter). 1. Open the master controller as described in Removing the Faceplate on page Remove the elastic band (if present) from the locking clips securing the EPROM. Pull the clips away from the EPROM and extract it from the socket (see Figure 4). 3. Confirm that all pins on the new EPROM ( ) are aligned and straight. Orient the EPROM with its notch towards the edge of the CPU board and press it gently into the socket until the locking clips snap into place. Install the elastic band over the locking clips. Locking clips Notch Band Edge of CPU board EPROM Figure 4 EPROM chip and associated hardware! Caution Installing the chip backwards will damage system electronic assemblies. Locate notch on chip to edge of CPU board. 4. Close the master controller as described in Installing the Faceplate on page Slave Controller This section contains special maintenance and service procedures not covered in the Work Instructions. Page Slave Controller

107 Maintenance & Service 6.1 Slave Controller EPROM Chip Replacement! Caution PC board components can be damaged by static electricity. Wear a grounded anti-static wrist band when handling PC boards, chips, etc. To replace the EPROM chip on the submersible slave controller, perform the following steps: Refer to the master controller drawing in the Drawings & Part Lists chapter. 1. Turn off hydraulic power to the slave arm. 2. Turn off power to the slave controller by turning off the power switch on the junction box or disconnecting the local power source. 3. Disconnect all cables from the cover plate. 4. Remove the 1/4-inch screws securing the bottle mounting brackets to the mounting surface. 5. Remove the eight 1/4-20 SHCS securing the cover plate. To remove the cover plate mechanically, insert a 3/8-16 UNC screw fastener into the threaded center hole. Pull the fastener straight out with even pressure. Pressurizing the bottle with 10 to 15 psi of air can also help loosen the cover plate. To do this, remove the plug from the -4JIC threaded port on the cover plate. Screw a fitting (-4, straight thread) into the port and attach the hose from an air pump or compressor. Pad the cover plate with a blanket or large towel. Pressurize the bottle with 10 to 15 psi.! Caution The cover plate can suddenly release from the bottle with explosive force. DO NOT pressurize the bottle to more than 15 psi. 6. Carefully remove the assembly containing the cover plate, backbone (board support), and the PC boards from the bottle. Lay the assembly on a clean surface. 7. Remove the small optical-isolation board from its standoffs to expose the EPROM (located on the CPU board). 8. Remove the EPROM by pulling aside the plastic locking clips located at each end of the EPROM socket. 9. Install the replacement EPROM into the socket Slave Controller Page 107

108 Maintenance & Service NOTE: When you install the EPROM chip, be sure that the small notch in the edge of the chip is toward the edge of the CPU board. Installing the chip in the wrong orientation will damage system electronic assemblies. Press the EPROM gently into the socket until the locking clips snap into place. 10. Reinstall the optical-isolation board. 11. Carefully install the assembly containing the cover plate, backbone (board support), and the PC boards from the bottle. Lubricate the o-rings with o-ring lube (Dow Corning 55 or petroleum jelly). Torque all screws to 10 ft/lb.! Caution Do not submerge the slave controller until you have tested for it for leaks. To leak test the slave controller, follow these steps: 1. Remove the plug from the port on the cover plate. 2. Screw a fitting (-4, straight thread) into the port and attach a vacuum pump or air compressor. Provide this test assembly with an appropriate gauge and isolation valve. 3. Evacuate air from the slave controller or pressurize the slave controller to psi. Allow the system to stabilize and then monitor the gauge to see if the gauge reading remains constant. If you are testing by gauge only, allow at least 2 hours to monitor for changes. If there is no pressure change, the seals are good. Remove the test assembly and reinstall the hydraulic plug to the port. If you are pressure-testing, cover plate seals can also be checked immediately by spraying the cover assembly with soapy water. Active, foaming bubbles indicate a leak. If the gauge reading changes or foaming bubbles are present, inspect the two cover plate o-rings, the o-rings on the electrical connectors, and the fittings of the test assembly. Correct any problems. Then reassemble the slave controller and repeat the test. 4. Connect all cables to the cover plate. 7 Slave Arm Service This section contains special maintenance and service procedures not covered in the Work Instructions. Page Slave Arm Service

109 Maintenance & Service 7.1 Slave Arm Filter Replacement and Cleaning The slave arm supply filter (pleated, microweave 304 stainless steel) is located in the upper arm (see Figure 5). Filter information is shown below. Filtration microns (25 microns absolute) Replacement filter part number: Schilling P/N OEM P/N G-10VL (Norman Filter Co.) NOTE: To avoid frequent replacement or cleaning of this filter, the supply line to the slave arm should be filtered to 3 microns (10 microns absolute). Recommended Service Clean and inspect the filter when performance of all slave arm functions is reduced or sluggish, and/or when filter is accessible due to other service. Replace a damaged filter. Inspect the filter for damage if other components under repair show evidence of media contamination (media accumulation, abnormal wear, scoring, etc.). Follow the steps below to clean or replace the hydraulic filter. NOTE: Replace all o-rings that have been disturbed. 1. Disconnect the compensator and drain the upper arm volume. 2. Remove the two cover plates on the topside of the upper arm. 3. Disconnect the three fittings shown in Figure 5 and remove the upper tubing assembly. Disconnect Upper Arm Cover Port Cover Port Filter Assembly Remove: 1/4-28 SHCS & Washers, 2x Figure 5 Removing the filter assembly Slave Arm Service Page 109

110 Maintenance & Service 4. Remove the two SHCS and washers shown in Figure 5 and extract the filter, tubing, and mounting assembly from the upper arm. 5. Remove the nose nut and filter from the filter housing as shown in Figure Clean or replace filter, as needed. 7. Return filter assembly into upper arm, install the SHCS and washers (2 ea.), install and connect tubing and fittings. Nose Nut Filter Element Filter Housing Figure 6 Filter assembly 8. Pressurize the supply line and check all filter connections for leaks. 9. Replace the two upper arm covers. Connect compensation. Charge and bleed the slave arm s compensated volumes. 7.2 Emergency Manual Slave Arm Manipulation Collision, hydraulic or electrical power failure, or component malfunction may leave the slave arm joints frozen in a position where it is difficult to withdraw the slave arm from its work site, or remove the work from the slave arm. Under these circumstances, the azimuth, shoulder, and/or elbow actuators and their related joints can be manually moved by opening their bleed ports. This is considered an emergency procedure for several reasons: When a joint is manually moved, the actuator draws in air (or water, if submerged) through one of its bleed ports, and forces hydraulic fluid out of the other port into the environment. The joint will lose all rigidity. For example, opening the shoulder bleed ports will cause the slave arm to drop suddenly. Temporary support must be provided to avoid injury to people or damage to equipment.! Caution Opening the bleed ports will cause the affected joints to suddenly lose rigidity. Provide support for the joints to be bled. Page Slave Arm Service

111 Maintenance & Service There are two bleed ports each for the azimuth, shoulder, and elbow actuators and all are located on the forearm, just below the elbow. See the slave arm drawings for port locations. Azimuth = Port 0 Shoulder = Port 1 Elbow = Port 2 To use the bleed functions, follow these steps: 1. Turn off the hydraulics and electrical power to the manipulator system. 2. Remove the two bleed screws for the actuator you want to move. Plan this step carefully. Support the slave arm joints as necessary to prevent injury to personnel and damage to the equipment. 3. Manually move the related joint. Note that movement causes the actuator to draw in air (or water, if submerged) through one of its bleed ports, and forces hydraulic fluid out of the other port into the environment. 4. When you have the slave arm in the position you need, bleed the hydraulic system of all air and reinstall the bleed port screws. If the bleed ports were opened while submerged, return the slave arm to the surface. Manually move the affected joints back and forth to the full extent of their travel to force the water from the actuator cavities and journals. Bleed the air and any residual water from the hydraulic system and reinstall the bleed port screws. 5. Inspect the slave arm as outlined in Maintenance on page Recovery from Water Intrusion If you suspect that water has entered the Titan slave arm compensation system, or if WATER* appears in the top dashed line of the display (Titan 4 only), take quick action as described below to minimize damage. This procedure applies to Titan 2, 3, and 4 Manipulator Systems. 1. Turn power off to the manipulator system as quickly as possible to minimize damage to electrical assemblies. 2. When the Titan slave arm can be serviced, turn off/lock out the hydraulic power. Place a receptacle to catch oil under the slave arm. 3. Remove all resolver covers, upper arm cover plates, forearm manifold cover, and wireway covers, shoulder pivot covers, azimuth lid. NOTE: Do not disconnect any electrical connectors at this point Slave Arm Service Page 111

112 Maintenance & Service 4. Fill a squirt bottle with alcohol and wash out the entire inside of the slave arm. Pay special attention to the difficult to clean areas under the resolvers. 5. The wrist requires some additional attention as it is not easy to reach the voids around the wrist and jaw resolver. By hand, position the wrist pointing down. Fill the wireway leading to the wrist with alcohol. Point the wrist back towards the azimuth to allow the alcohol to drain. Perform this step 2-3 times; more if the system was severely flooded. 6. Remove the drain screw on the upper arm (Figure 7, arrow) to drain the fluid that accumulates in the low points near the filter. Figure 7 Upper arm drain screw 7. At the shoulder pivots, there will likely be grease on the bearings that was applied in the manufacturing process. Since this area will be filled with comp oil, it is not necessary to re-grease the bearings; the comp oil will act as the lubricant. Pay particular attention to rinsing the right side of the slave arm as this is where the shoulder resolver sits. 8. Wipe the entire inside of the slave arm as dry as possible with clean cloths or paper towels. 9. Disconnect each electrical connector (resolvers, servos, solenoid) and spray with Contact Cleaner. If the system was severely flooded, remove each connector backshell and spray with contact cleaner. The backshells have been filled with DC5 silicone grease at the factory as a water barrier. If the grease is removed in the cleaning process, it should be replaced. DC5 is a very stiff grease that does not wash away easily. DC4 or other silicone grease can be used if DC5 is not available, but will not be as effective. 10. When all electrical connections have been cleaned, put a small (pea sized) drop of DC5 in each connector interface. Slowly mate each connector to allow the grease to displace and create a water barrier. 11. (Titan 4 and Titan 3 with in-arm slave controller) Remove the back cover from the main circuit board. Clean the board with contact cleaner paying special attention to connectors. Carefully inspect the board for any corrosion damage. If any conformal coating has come off, re-spray the board with a Urethane protective coating (TechSpray UR or MIL-I-46058C, Type UR equivalent). Page Slave Arm Service

113 Maintenance & Service 12. Perform an electrical test before replacing the cover plates. Turn on electrical power to the slave controller and master controller. When communications are established, go to the SLAVE TEST screen (Figure 8) (path: MAIN/ DIAGNOSTICS/. (Titan 4 and Titan 3 with in-arm slave controller) If you are unable to establish communications, replace the circuit board in the slave arm. SLAVE TEST FRZ Command: Position: Azi: Sho: Elb: Yaw: Pit: Wrs: Jaw: EXIT < Figure 8 Titan SLAVE TEST screen 13. The Position values should be stable (within 2 or 3 digits) while the arm is motionless. If any joint shows excessive noise (unstable values), disconnect and clean it's resolver connector again. Swap functions to ensure the noise is coming from the connector wiring and not the circuit board. NOTE: Resolvers are resistant to short-term contact with water and not usually a noise source unless corroded from long-term exposure to water. 14. Move each slave arm function by hand and ensure that the values go up when the arm is moving right or up, and down when the arm is moved left or down. 15. When all functions report stable position values (less than 2-3 digit change) while the arm is motionless, enable hydraulic power and test all functions.! Caution Do not enable hydraulics to the slave arm if position values are not stable. Unstable values produce uncontrolled slave arm movements. 16. When all functions are confirmed, turn off the slave arm and replace all resolver covers, upper arm cover plates, forearm manifold cover, and wireway covers, shoulder pivot covers, azimuth lid, etc. Make sure all o-rings are in place; replace all damaged o-rings Slave Arm Service Page 113

114 Maintenance & Service 17. Charge and bleed the slave arm compensation system as described in the technical manual. The slave arm takes about 10 liters (2.5 gal) of comp oil, so make sure you completely fill the arm and remove all air. 18. Once the arm is filled and bled of air, operate it throughout it's range of motion and look for any errors. Before submerging the arm, bleed all high points again and top off the compensator. 8 System Adjustments 8.1 Setting Servo Valve Voltage Offsets Servo valves control the hydraulics to the actuators in your salve arm. Individual servo valves vary slightly in their response to a given voltage and work environment. You may need to set voltage offsets so that voltage sent to the servo valves provides the proper slave arm action. Correct adjustment keeps the actuators without lock valves (all except the shoulder) immobile when the servo valve is inactive (no control input pending) and reduces sag and/or drift when hydraulics are disabled. Once voltage offsets have been set, you should not need to change the offsets. If you replace a servo valve, you will need to reset the voltage offsets. The key symptoms indicating the need for adjustment are: A joint that moves faster in one direction than the other (given similar control inputs). This is most noticeable following a high speed movement of the master arm, when the servo valve is fully driven. Small movements of a joint at the moment when the slave arm is frozen and unfrozen. To set the servo valve voltage offset: 1. Start up the manipulator system. 2. Enable slave arm hydraulics. 3. From the MAIN menu, select 3>OPERATE. Set jaw and wrist to POS mode. 4. Move slave arm joints to the positions shown in Figure 9. Page System Adjustments

115 Maintenance & Service Figure 9 Slave arm position for setting offsets 5. Press EXIT<8. 6. From the MAIN menu, select SETUP<5, then select SET SV OFFSET<7 (Figure 10). SET SV OFFSET FRZ OFFSETS: Azi: Set <5 Sho: Elb: Pit: Clear <6 Yaw: Wrs: Jaw: EXIT < Figure 10 SET SERVO OFFSET screen! Caution Clear slave arm range of motion of personnel and equipment. Pressing SET<5 or CLEAR<6 on the SET SV OFFSET menu may cause slave arm joints to move a small amount. Be prepared to immediately disable slave arm hydraulics (UP key) if there are greater movements. 7. Press CLEAR<6 to reset all servo valve offsets to zero. The numbers next to each joint should change to zero. Be prepared for the slave arm to move slightly. 8. Press SET<5. The proper servo valve offsets will be calculated for your slave arm System Adjustments Page 115

116 Maintenance & Service Be prepared for the slave arm to move slightly. 9. Press SET<5. The joints should move only one or two degrees. NOTE: If the joints move more than a small amount, contact the Schilling Robotics. Wait 5-10 second before moving to the next step. 10. To exit, press EXIT<8. The servo valve offset values are automatically saved for your next slave arm use. 8.2 Changing the Communication Protocol Three communications protocols are available on the Titan 3 manipulator system: RS-232 (factory default for replacement opto-iso boards) RS-422 half duplex RS-422 full duplex Each protocol is selected by: a. Configuring seven jumpers on the optical-isolation boards (P/N only) located in the master controller and slave controller (see Figure 11 and Figure 12). b. Configuring how the telemetry lines in the master controller whip are connected to the motherboard. BOTH boards and the master controller whip connection must be configured for the same communication protocol. Inconsistent configuration will result in NO communications. NOTE: Current factory replacement optical-isolation boards are configured for RS-232. Older spares may be configured for RS-422. DO NOT install an opto-iso board without confirming it has been correctly set to match your existing communication protocol. Page System Adjustments

117 Maintenance & Service Master Controller Slave Controller Figure 11 Opto-iso board locations! Caution PC board components can be damaged by static electricity. Wear a grounded anti-static wrist band handling PC boards or components How to Change the Jumpers Settings The opto-iso board has seven jumpers for configuring the desired communication protocol. Each jumper selects two of three board-mounted pins. To configure the PC board for a specific protocol, move the jumpers to connect the desired pin numbers. Figure 12 shows the jumper locations and protocol options. Table 2 shows the jumper settings for each protocol. Table 2 Jumper Settings by Protocol Switch Number RS-422 Half Duplex Jumper Settings RS-422 Full Duplex RS-232 (factory default) Switch 1 Pin 1 to pin 2 Pin 1 to pin 2 Pin 2 to pin 3 Switch 2 Pin 1 to pin 2 Pin 1 to pin 2 Pin 2 to pin 3 Switch 3 Pin 1 to pin 2 Pin 2 to pin 3 Pin 1 to pin 2 Switch 4 Pin 1 to pin 2 Pin 2 to pin 3 Pin 1 to pin 2 Switch 5 Pin 1 to pin 2 Pin 1 to pin 2 Pin 2 to pin 3 Switch 6 Pin 1 to pin 2 Pin 1 to pin 2 Pin 2 to pin 3 Switch 7 Pin 1 to pin 2 Pin 1 to pin 2 Pin 2 to pin System Adjustments Page 117

118 Maintenance & Service = RS232 HD (FACTORY DEFAULT) = Reset for RS422 FULL DUPLEX = Reset for RS422 HD Figure 12 Jumper Settings on Opto-Iso PC Board To change a jumper setting, follow the steps below.! Caution When you remove and insert jumpers, be careful not to bend or damage the board-mounted pins. 1. Grasp the jumper with a pair of needle-nosed pliers. Carefully lift the jumper straight up until it is clear of the pins. 2. Still holding the jumper with the needle-nosed pliers, carefully lower the jumper so that it connects the desired pins. 3. The configuration steps for specific manipulator systems are described in the following sections. Page System Adjustments

119 Maintenance & Service Master Controller Opto-Iso Board & Whip To access the master controller opto-iso board, perform the following steps (also refer to the master controller drawing in the Drawing & Part Lists chapter in this manual): 1. Open the master controller as described in Accessing Internal Components on page Configure the opto-iso board (see Figure 11 for location). Figure 12 shows the jumper locations and protocol options. Table 2 shows the jumper settings for each protocol. 3. To configure the whip, disconnect connector J1 from the master controller motherboard (see Figure 13) and rearrange lead connections for the desired protocol as shown in Figure 14, below. To release and re-install a specific whip lead, press a small slot screwdriver into the slot on the side of the connector. Confirm J1 connector lead identification with an ohmmeter between the lead on J1 and socket on the P1 whip connector). For reference, the pin 1 end of connector J1 is marked on the PC board, and pin 9 is marked on the board-face of the connector. For an overview of the telemetry lines, see drawing , T3 Telemetry & Power Long Line Schematic, in the Drawings & Part Lists chapter of your technical manual. NOTE: Telemetry changes at connector J1 apply whether the system is operated using your long lines (for subsea operation) or the junction box and decktest cable (for deck testing). Whip connector P1 4 5 Master Controller Whip Leads J1 2 1 Figure 13 Connector J1 on Motherboard System Adjustments Page 119