Schilling Robotics CONAN 7P Manipulator Systems 24 VDC, Position-Controlled, 3 Km Submersible

Transcription

1 Schilling Robotics CONAN 7P Manipulator Systems 24 VDC, Position-Controlled, 3 Km Submersible Document No Models:

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 TECHNICAL MANUAL REVISION LOG Conan 7P Manipulator Systems, Model Nos , , TECHNICAL MANUAL: Description Date Rev. Prototype release 7/11/08 Ø Production release 08/13/08 A Production release 09/08/10 B Replaced Teflon with polytetrafluoroethylene (PTFE) 11/04/13 C

3 Table of Contents Specifications 1 General Description Manipulator Arm Specifications Master Controller Specifications Electrical & Telemetry Requirements Environmental Specifications Ranges of Motion/Dimensions Hydraulics Fluids Requirements Compensation Installation 1 User-Supplied Equipment Installation Overview Mechanical Installation Slave Arm Compensator Junction Box Master Controller Electrical Power & Telemetry Connections Telemetry Configuration Long-Line Connections Deck Test Connections Completing the Installation Operation 1 System Overview The Slave Arm Base Module Compensator The Master Controller Page 3

4 1.5 Security Levels The Control Process Menu Structure Controlling Slave Arm Hydraulics Slave Arm Operational Status Avoiding Slave Arm Damage Operation Pre-Start Checks Startup Sequence STOW OUT Menu Using the MAIN MENU Using the OPERATE Menu Using the SHUT DOWN Menu Performance Options OPTIONS Menu SETUP Menu System Fault & Error Diagnosis Diagnosing Problems Troubleshooting 1 Diagnostic Approaches Troubleshooting Tables Screen-Displayed Symptoms Master Arm Symptoms Slave Arm Behavior Defined Entire Slave Arm Symptoms Slave Arm Joint Symptoms System Fault & Error Diagnosis Control System Orientation Using the DIAGNOSTICS Menus Diagnosing Problems Electrical Component Diagnosis Fuses Wireway Short & Open Circuits Diagnosing Servo Valve Failures Diagnosing Solenoid Valve Failure Diagnosing Potentiometer Failure Master Controller PCB Status LEDs Master Controller Voltage Test Points Base Module & Slave Arm PC Board Diagnosis Factory Assistance Maintenance & Service 1 Safety First! Worksite Safety Page 4 Table of Contents

5 1.2 Electrical Safety Mechanical Safety Hydraulic Safety Deck Testing Service Guidelines Service Assumption Guidelines Maintenance Daily Maintenance Long Term Periodic Maintenance Important Service Practices & Procedures Protecting PC Boards Startup After Maintenance or Service Junction Box Service Master Controller Service & Configuration PCB Features and Functions Accessing Internal Components Adjusting the LCD Screen Viewing Angle Master Controller Software Selection Incompatibility Alert Screens Base Module Service Fuse Replacement Servicing the Hydraulic Filter Accessing Internal Base Module Components Replacing the Jaw/Wrist Actuator Controller PCB Servicing the Jaw or Wrist Servo Valve Removing the Jaw Bypass Valve Slave Arm Service Servicing Slave Arm Servo Valves Servicing Slave Arm Actuator Boards Wrist Pitch/Yaw Hose Fittings System Configuration Adjusting Servo Valve Offsets Changing the Communications Protocol Instructions for Serviceable Components Startup Following Maintenance or Service Work & Service Instruction List Drawings & Part Lists 1 Index Manipulator Systems Standard Spares Kit Spares Kits Standard Spares Kit Table of Contents Page 5

6 Safety & Service Summary Precautionary Notices 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. Page 6 Table of Contents

7 Security Password Model No. Serial No. Level 5 Password This is your level 5 password: 1357! WARNING Misuse of the menus accessible with this password can cause malfunctions of the manipulator system, injury to personnel, and/or damage to equipment. The password for security level 5 is set at the factory and cannot be changed. It provides access to all configurable system menus, including those for setting other security levels and passwords for other operators. See the OPERATION module in your technical manual for complete information on how to use the level 5 password. Temporary Password, Levels 1-4 The temporary password 0000 is provided for access to security levels 1 through 4 during installation and first startup. This password can be changed to meet your security level requirements. Security Level 0 Security level 0 is the default level, always available at system startup and requiring no password. While permitting operation, it restricts access to almost all system configuration menus and security features. An operator using a correctly configured manipulator should need no higher privilege level. Levels above 0 require passwords and allow access to specific manipulator system configuration menus. Table of Contents Page 7

8 Page 8 Table of Contents

9 Specifications In This Chapter: 1 General Description...page 9 2 Manipulator Arm Specifications...page 9 3 Master Controller Specifications... page 10 4 Electrical & Telemetry Requirements... page 10 5 Environmental Specifications... page 10 6 Ranges of Motion/Dimensions... page 10 7 Hydraulics... page 11 8 Compensation... page 11 1 General Description Conan is a 7-function, position-controlled hydraulic slave arm, depth rated to 3000 msw (9800 fsw). The slave arm is remotely directed by a master controller. Control method closed-loop position control (except wrist and jaw/gripper) Input device master controller Number of functions plus grip Materials of construction aluminum, stainless steel 2 Manipulator Arm Specifications All specifications are based on the standard system configuration using Shell Tellus Oil 32 hydraulic fluid, input pressure of 207 bar (3,000 psi), and available flow of 19 lpm (5 gpm). Depth rating ,000 msw (9,843 fsw) Maximum reach (azimuth pivot to T-bar slot) ,805 mm (71.1-in.) Weight in air kg (235 lb) Weight in sea water (submersible models kg (161 lb) Lift at full extension, nominal kg (350 lb) Maximum lift, nominal kg (600 lb) Maximum gripper opening (standard gripper), nominal mm (6.0-in.) Grip force, nominal ,448 N (1,000 lbf) Wrist torque, nominal Nm (150 ft/lb) Wrist rotate, continuous , 6-35 rpm Functions see table below Page 9

10 Specifications Slave Arm Actuator Functions Function Type Function Mechanical Range Azimuth Linear 120 Shoulder pitch Linear 120 Elbow pitch Linear 120 Wrist pitch Linear 120 Wrist yaw Linear 120 Wrist rotate Gerotor 360 Parallel acting jaw Linear 152 mm (6.0-in.) Intermeshing jaw Linear 198 mm (7.8-in.) 3 Master Controller Specifications Length mm (18.5 in.) Width mm (7.0 in.) Height mm (2.6 in.) Weight kg (8.2 lbs) 4 Electrical & Telemetry Requirements System supply to 260 VAC, 50/60 Hz Base module VDC Power Consumption: Master controller W start, 3 W run Base module plus solenoid W start, 30 W run Telemetry user selectable between RS-485 half-duplex and RS Environmental Specifications Operating temperature C to +54 C (28 F to 130 F) Storage temperature C to +71 C (5 F to 160 F) Humidity % to 100% condensing 6 Ranges of Motion/Dimensions See the slave arm drawing for your system in the Drawings & Part Lists chapter for: Ranges of motion Extended dimensions Stow dimensions See drawing for mounting dimensions Page 10 Master Controller Specifications

11 Specifications 7 Hydraulics 7.1 Fluids Select a hydraulic fluid based on its maximum temperature during normal operations. Lower than 54 C (130 F): Use 22 grade oil. Higher than54 C (130 F): Use 32 grade oil. For temperatures above 71 C (160 F), below 0 C (32 F), or when in doubt about which fluid to use, contact your regional technical support representative. Do not use water-based fluids. If a fluid has been specified for this system to meet special environmental or operational requirements, use it and disregard the parameters listed above. 7.2 Requirements Viscosity cst to 200 cst Available flow l/min ( gpm) Pressure bar (1,500 psi) minimum to 207 bar (3,000 psi) maximum Hydraulic fluid temperature, maximum C (130 F) Rotary actuator return pressure, maximum bar (350 psi) Filtration microns (10 microns absolute) Customer supplied mating fittings required: Supply hose fitting JIC female, ¼-in. Return hose fitting JIC female, 3/8-in. NOTE: If hose lengths exceed 20 feet, contact the factory for information about increasing the hose diameters to maintain adequate pressure and flow. 8 Compensation Fluid requirement Non-conductive, non-water based Compensator fluid capacity l (0.58 gal) Fluid pressure (above ambient) to 0.69 bar (8 to 10 psi) Relief valve cracking pressure, nominal bar (20 psi) NOTE: The compensator and hose are not supplied with system Hydraulics Page 11

12 Specifications This page not used. Page 12 Compensation

13 Installation In This Chapter: 1 User-Supplied Equipment... page 13 2 Installation Overview... page 13 3 Mechanical Installation... page 13 4 Electrical Power & Telemetry Connections... page 16 5 Completing the Installation... page 18 1 User-Supplied Equipment The following services and equipment are required to complete the installation of the slave arm: Electrical and hydraulic power sources. See the Specifications chapter for details. All hoses and fittings for connecting hydraulic power to the slave controller. Topside wiring as needed for integration into long-line system. On some systems, the subsea slave cable is supplied by the user. See the 199- part list for the supplied model. 2 Installation Overview Long-Line Installation See Figure 3 on page 16. Deck-Test Installation See Figure 7 on page Mechanical Installation 3.1 Slave Arm 1. Determine a mounting location (See the Specifications chapter for information on slave arm dimensions and ranges-of-motion). 2. Create a sturdy mounting platform that will provide a flat surface for the minimum mounting footprint and three mounting holes for the azimuth base shown in Figure 1 on page 14. Three 5/8-in., or M16, hex-head cap screws, flat washers, lock washers, and hex nuts (not supplied) are required to attach the azimuth base to the mounting platform. The platform mounting holes may be tapped to receive the fasteners if the platform material and thickness are determined to be adequate. The material should engage a minimum of one bolt diameter of the fastener threads Page 13

14 Installation Figure 1 Mounting dimensions 3. Move the slave arm to the mounting platform. 4. Lubricate the fasteners with Aqua Lube, install, and torque as specified below: 5/8-in. fasteners: 108 Nm (80 ft/lbs) M16 fasteners: 95 Nm (70 ft/lbs) 5. Connect the hydraulic supply hose to the base module using a female -4 JIC fitting, and connect the hydraulic return hose using a female -6 JIC fitting. The base module male fittings for supply and return are located to the right of the power/telemetry cable connector Jaw Configuration Option The base module contains a bypass valve that causes the jaw to relax its grip when hydraulic power is disabled, either by the operator-controlled solenoid valve (in the base module), or by a failure of the hydraulic power system. If you prefer that the jaw remain locked when hydraulic power is disabled, the bypass valve can removed. Refer to Removing the Jaw Bypass Valve in the Maintenance & Service chapter for details. 3.2 Compensator Installation Notes See the Specifications chapter for fluid requirements. Use stainless steel Nylock ( patch ) mounting fasteners. If a compensator fitting is moved or changed: Use polytetrafluoroethylene (PTFE) tape on the fitting threads. Do not use any form of liquid sealant or thread locker. Apply 1-1/2 to 2-1/2 wraps of PTFE tape to the male threads in a clockwise direction when viewed from the tapered thread end. Do not apply tape to the first one or two threads on the fitting to avoid fluid contamination. Install NPT Fittings finger tight, then tighten an additional 1.5 turns. Page 14 3 Mechanical Installation

15 Installation! Caution Do not use thread-locking compounds containing bisphenol A fumarate on fittings or hardware contacting the polyurethane compensator housings. This chemical can cause brittleness and micro-cracking. 1. Select a mounting location for the compensator within hose-length of the slave arm. The compensator may be mounted horizontally or vertically (fittings end up). If the compensator is sidewall-mounted horizontally, a 1/4 x 1/2-in. bushing will be required to relocate the bleed/relief valve. 2. Drill mounting holes for 1/4-inch or M6 hardware using the dimensions in Figure cm (12-in.) Bleed valve (1/4 NPT) -4 JIC 1/2 NPT) 7.6 cm (3-in.) Figure 2 3. Mount the compensator and connect the compensator hose to the -4 JIC male fitting on the compensator. 4. If you want to dry-test the compensation system for leaks, charge the compensator half-full with air (the spring-loaded diaphragm will produce a pressure of about 0.7 atmosphere (10 psi). Check for leaks by spraying all connections with a mild detergent solution or window cleaner. Active bubbles or foam indicate a leak. 3.3 Junction Box The junction box (below, left) is used for deck testing. It has no mounting hardware and can be placed on any flat, dry surface. Master Arm Mechanical Installation Page 15

16 Installation 3.4 Master Controller The master controller (above, right), has no mounting hardware, and can be placed on any flat, dry surface. It is usually located at or near the system control console for use by the pilot or copilot.! Caution Do not use the master arm to lift or carry the master controller. It is a precision instrument and can be damaged. 4 Electrical Power & Telemetry Connections 4.1 Telemetry Configuration The default, factory-set telemetry protocol is RS-232. The system can also be configured to RS- 485 telemetry. For detailed instructions see Changing the Communications Protocol in the Maintenance and Service chapter. 4.2 Long-Line Connections In typical ship-based applications, the slave arm and base module of the Conan Manipulator System are mounted to a remotely operated vehicle (ROV) andconnected as shown in Figure Complete the two sections listed below. Subsea Wiring and Connections See section on page 17 Topside/Surface Wiring and Connections See section on page 17 Figure 3 Long-line power and telemetry options (jaw varies) Page 16 4 Electrical Power & Telemetry Connections

17 Installation Subsea Wiring and Connections Reference: see the drawings and schematics for your system s deck cable, junction box, and base module. 1. Make a subsea cable for connecting the base module to ROV power and telemetry. See the sections below for system-specific schematics. Manipulator Systems & Figure 4 Systems & NOTE: If the slave arm is equipped with a video camera, the signal is supplied to pin4 of the Burton connector (see Figure 4). Manipulator System , Figure 5 Model & Topside/Surface Wiring and Connections 1. Mount the supplied bulkhead connector to your control panel where it is convenient to connect the master controller cable. 2. Use pins to wire bulkhead connector to system telemetry/comms and to VAC power as shown in Figure 6. Figure 6 Bulkhead connector wiring 3. Connect the master controller whip Electrical Power & Telemetry Connections Page 17

18 Installation 4.3 Deck Test Connections The Conan manipulator system includes components needed for deck-testing or local operation (see Figure 7). 1. Connect the junction box AC power cord P1 to a VAC power source. 2. Connect the cable from the master controller to connector P2 on the junction box. 3. Connect the deck test cable between connector P3 on the junction box and the Burton connector on the base module. 4. If the Conan manipulator is equipped with a video camera, the signal is available at the BNC connector on the junction box. 5. Provide a deck cart to power slave arm hydraulics. 6. Proceed to Completing the Installation section on page 18. Figure 7 Deck-test connection (jaw varies) 5 Completing the Installation After all the components are installed, the manipulator system is connected first in the deck-test configuration and started up to confirm operation, set the Stow In/Stow Out (deploy) and travel limits menus for safe operation, and charge/bleed the compensation system. Then the system is connected in the long-lines configuration for final testing. The process is described below. Refer to the Operation chapter, as needed, for additional information. Part 1: Start System & Test Functions! Caution NEW USERS ONLY! If you are unfamiliar with Conan manipulator systems, please review sections 1 through 3 of the Operation chapter before proceeding. Page 18 5 Completing the Installation

19 Installation 1. Set up the manipulator system for deck-testing (see section 4.3). Connect a deck cart to the slave arm to supply hydraulic power. 2. Complete the following checks before you start-up the manipulator system. All system fasteners, fittings, and connectors are correctly installed and properly tightened. All hoses and cables are safely routed to allow full travel of the slave arm and are without kinks, snagging, and contact with sharp edges or rough surfaces. 3. Move all personnel, equipment, and installation supports outside the range-of-motion of the slave arm. 4. Apply hydraulic power to the supply line (does not energize arm). Check the hydraulic lines for leaks. Turn on any other hydraulic equipment using the same return line. Confirm that the return pressure does not exceed 500 psi (34.5 bar). NOTE: Filters and other hydraulic equipment sharing the return line may cause the return circuit pressure to rise. If pressure exceeds 500 psi (34.5 bar), hydraulic fluid will be released from the return relief valve on the upper arm. 5. Turn on electrical power to the junction box and master controller. 6. Complete master controller startup. For startup details, see the Operation chapter, section 2.2, Startup Sequence, on page 29. NOTE: Air in hydraulic lines or components can cause very rapid or jerky slave arm movement upon start-up.! Caution As you proceed, if the response of the slave arm or the master controller does not appear normal, IMMEDIATELY disable slave arm hydraulics and refer to the appropriate section of the Operation chapter for guidance. Return to this procedure only when you have determined that the system is functioning safely and correctly. 7. From the master controller, turn on hydraulics to the slave arm. Carefully test basic slave arm functions.! WARNING When testing a slave arm on deck: Move all personnel outside the slave arm's range of motion when hydraulic pressure is applied and functions are tested. Direct the slave arm to point away from personnel and critical or sensitive areas while testing jaw functions. Part 3 Set Stow Positions and Travel Limits 8. Set a stow sequence that will allow the slave arm to be safely stowed within its environment. see the Operation chapter, section 3.2.5, Setting the Stow In/Stow Out Sequence, on page 44) Completing the Installation Page 19

20 Installation NOTE: The factory default stowed and deployed slave arm positions are the same: the position of the slave arm in the shipping container. 9. Set slave arm travel limits that allow safe operation of the slave arm within its environment. see the Operation chapter, section 3.2.4, Setting Slave Arm Movement Limits, on page 42). NOTE: The factory default allows full slave arm travel. Part 3: Charge the Compensation System Reference information: Fluid requirement Non-conductive, non-water based Compensator fluid capacity l (0.58 gal)! Caution Compensated components can be damaged if the compensation fluid is conductive or water-based, and if the slave arm is submerged with large amounts of air in the compensation system. 10. Pump hydraulic fluid into the compensator. Do not over-fill. Lift the tip of the bleed valve at the top of the compensator with a thumbnail and bleed off any air. 11. Loosen, but do not remove, the self-sealing bleed screw (Phillips head) on the yaw actuator control module. Let the compensator pressure provided by the piston spring fill the supply hose, base module, and yaw wireway hose. Add fluid to keep the compensator filled. When hydraulic fluid starts to run out of the yaw bleed screw, tighten it. 12. Loosen the bleed screws on the remaining actuator control modules to allow air to be bled from the wireways (except the elbow actuator module, 2which is not accessible). 13. After all compensated volumes are bled, 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. 14. Inspect compensation system for leaks and correct as needed. Part 4: Testing Long-Line Connections 15. After the compensation system has been charged, connect the manipulator system for long-line operation and confirm slave arm functions. 16. Refer to the Operation chapter for complete information about system functions, configuration, operation, and diagnostics. Page 20 5 Completing the Installation

21 Operation In This Chapter: 1 System Overview... page 21 2 Operation... page 29 3 Performance Options... page 37 4 System Fault & Error Diagnosis... page 47 1 System Overview Conan is a hydraulically powered, remotely controlled manipulator system, composed of the following parts: The hydraulically powered, seven function slave arm, tipped with a jaw tool to grasp and manipulate objects. The base module, which serves as a hub for the control and distribution of hydraulic fluid to the slave arm, the distribution of electrical power to slave arm electrical assemblies, and the routing and processing of control telemetry between the master controller and slave arm. The master controller, which controls the slave arm. This assembly contains: The master arm, a small replica of the slave arm, which the operator manipulates to direct the slave arm. An LCD (liquid crystal display) screen flanked by function and control keys. The operator uses the keys to select operating options, and uses the screen to view system information. Electronic assemblies and software that control telemetry between the master arm and base module. A junction box that connects to an electrical power source, and links the master controller with the base module and slave arm. Electrical cables and hydraulic hoses that connect system components. Submersible models are supplied with a compensator unit that provides compensated pressure for the base module, actuator control modules, and telemetry wireways Page 21

22 Operation 1.1 The Slave Arm The position-controlled Conan slave arm is a hydraulically powered, electrically controlled manipulator with azimuth yaw, shoulder pitch, elbow pitch, wrist pitch, wrist yaw, wrist rotate, and jaw open/close functions. The azimuth, upper arm, forearm, and wrist pitch/yaw assemblies are the major structural members of the slave arm, and are cast from aluminum. Linking these structural members are the shoulder, elbow, wrist pitch, and wrist yaw joints, which pivot on stainless steel shafts. Large hydraulic linear actuators control movement of the azimuth, shoulder, elbow, wrist pitch, and wrist yaw joints. Each of these actuators has a pressure relief valve, a position sensor, and an actuator control module containing microprocessor electronics and a servo valve. Lock valves in the azimuth, shoulder, and elbow actuators freeze these joints when the actuators are not active, or when hydraulic pressure is disabled. The wrist uses a rotary actuator and the jaw uses a small linear actuator. (A bypass valve in the base module causes the jaw to relax and open when hydraulic pressure is disabled.) The wrist and jaw actuators have no position sensors. 1.2 Base Module The base module is mounted to the azimuth base and serves as the hub for reception and transfer of hydraulic power, compensation (for submersible systems), electrical power, and control telemetry. Hydraulic supply and return lines from the user-supplied hydraulic power unit terminate at the base module, where the supply fluid is filtered. The base module contains servo valves for the wrist and jaw actuators, manifolds for the slave arm supply and return lines, and an operator-controlled solenoid valve for enabling and disabling hydraulic power to the slave arm. Wire way hoses, carrying DC power and control telemetry, connect the slave arm-mounted actuator control modules to the base module. AC power and master controller telemetry reach the base module through a cable from the junction box. A power supply mounted to the top of the base module converts the input ( VAC or 24 VDC) to +12 and -12 VDC (the base module can also be powered by a local +12 and -12 VDC source). 1.3 Compensator Submersible models are supplied with a compensator unit that provides compensated pressure for the base module, actuator control modules, and wire way hoses. 1.4 The Master Controller Use the master controller to operate, configure, and diagnose the manipulator system.to direct the slave arm, move the controller's master arm (Figure 1). Configure and diagnose manipulator system operation by accessing appropriate master controller menus and making changes through keystroke inputs. Master Controller features are described below Master Arm The master arm is a miniature replica of the slave arm (Figure 1). 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: Page 22 System Overview

23 Operation Slave arm joint movement joint. Moving a master arm joint moves the corresponding slave arm Slave arm freeze its current position. Pressing the button on the end of the master arm freezes the slave arm in Master Arm LCD Screen Control Keys Jaw Switch Power Switch Function Keys Figure 1 Master controller Wrist rotate Rotating the collar from its null point initiates continuous slave arm wrist rotation in the same direction, with speed (rate) increasing with the degree of collar rotation. 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. NOTE: When hydraulics are disabled, whether through operator control or hydraulic failure, a bypass valve in the slave controller causes the jaw to relax its grip. If you prefer that the jaw lock when hydraulic power is disabled, the bypass valve can be removed. Refer to Removing the Jaw Bypass Valve in the Maintenance & Service chapter System Overview Page 23

24 Operation 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 Power Switch The rocker switch at the left of the LCD screen controls electrical power for the master controller only. 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: 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. Adjusting the LCD Screen Viewing Angle The LCD screen is provided with a temperature sensor and compensation circuit that maintains the viewing angle over 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). Page 24 System Overview

25 Operation Function Keys Eight function keys flank the LCD screen as shown on Figure 1. 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 UP LEFT RIGHT DOWN The four control keys in the diamond pattern on the right side of the display have various uses, which are called out in the appropriate menus, startup, or warning screens, or in the applicable section of the Operation chapter. NOTE: While in most menus, the red UP key (arrow) can be pressed to disable hydraulic power to the slave arm. 1.5 Security Levels The master controller offers a default operation level and two security levels for accessing menus that allow configuration of sensitive or critical system functions (two of the levels are passwordprotected): Level 0 (zero) is the default level available at system startup. No password is required. Full system operation is available at level 0, including access to menus for error-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 require a password, and allow access to the SET LIMITS, SET STOW, and SET SV (servo valve) OFFSET menus. (Levels 2 through 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 through 4 (and to edit the master memory under factory supervision). 1.6 The Control Process Control processes are diagrammed in Figure 2. Conan control telemetry uses an RS-485 serial interface. All slave arm control functions connected on a common bus. Telemetry is bi-directional and the control of each slave arm function (except wrist and the jaw) utilizes a closed loop: position feedback from each slave arm joint is compared with position data from each master arm joint (as adjusted by the operator) and any differential initiates the application of hydraulic power to appropriate slave arm joints until position correspondence is achieved. Slave arm position data is also sent to the master controller for use in diagnostic menus where it can be compared with master arm data for troubleshooting the system System Overview Page 25

26 Operation Electrical Power Source Analog master arm joint position data Digitized slave arm command data Master Arm Master Controller Position data for diagnostics Junction Box Electrical power Electrical power Digitized slave arm command data Position data for diagnostics Electrical power Digitized slave arm position data Slave Controller Current to control valve Hydraulic Supply Solenoid Valve Digitized slave arm command data & electrical power Actuator Controller Board Actuator Controller Board Current to control valve Current to control valve Analog slave arm joint position data Servo Valve Hydraulic fluid Slave Arm Hydraulic Actuator Electrical power Servo Valve Hydraulic fluid Slave Arm Hydraulic Actuator Open-Loop Control (jaw) Slave Arm Joint Potentiometer Figure 2 Control system Operator inputs to the master controller are generated by moving master arm joints, pressing the master arm freeze button (to idle the slave arm in its current position), and squeezing the master arm jaw bands (to initiate the jaw functions). Each physical action is translated into a varying analog voltage by the potentiometer in each joint of the master arm (or by switches for the jaw function). The analog data from each joint is converted to a digital command value, given a digital address specific to its function, and all commands of a given instant are grouped into a packet. This packet is sent to the base module and distributed to all the actuator controller boards. A DIP switch on each board is configured to only accept a command with its address and disregard all others. Simultaneously, potentiometers in the slave arm are translating physical positions into varying analog voltages which are also converted into a digital value. The actuator controller board then Page 26 System Overview

27 Operation compares the joint's position data with the command position data sent by the master controller. If the data are the same, no slave arm joint movement results. If the data are not the same, the actuator controller board applies a voltage to that joint s servo valve, causing the servo valve to release fluid to the appropriate port of its hydraulic actuator. The resulting actuator movement drives the slave arm joint towards the commanded position. When the joint feedback data corresponds with the position data commanded by the master controller the servo is closed and slave arm stops moving. The jaw does not have a potentiometer to provide position feedback: instead, master controller commands can only move the jaw in a specific direction (toggle open or closed) or move the jaw as long as a jaw band (or auxiliary jaw switch) is squeezed (position mode). Opening or closing the jaw to a specific position is only possible with visual guidance. 1.7 Menu Structure The operator operates and configures the manipulator system by accessing appropriate master controller menus and making keystroke and master arm inputs. The menu structure and hierarchy is shown in Figure 3. Establishing Communications with Slave Arm Incompatible EPROM Warnings: Keys Error Stow In Error Startup Screen System Errors Deploy Menu Main Menu Deploy Stow Stop Operate Menu Options Menu Setup Menu Shutdown Menu Diagnostics Menu Hydraulics Scale toggle Jaw Mode Wrist Mode Freeze Speed (Dyn) Jaw Speed Scale Security Menu Set Limits Set Stow Set SV Offset Set ERR Checks Memory Security Master Slave Show Errors Deploy Stow Stop Hydraulics Figure 3 Set Password Set Level Block diagram of menus System Overview Page 27

28 Operation 1.8 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, OPERATE, 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 Emergency Disable Hydraulics can be disabled at any time, regardless of menu, by pressing UP the red UP control key (Figure left, arrow). LEFT RIGHT DOWN If you disable the hydraulics by pressing the UP key, use the OPER- ATE menu to re-enable (see Using the OPERATE Menu section on page 33) Automatic Disable Some system errors automatically disable the hydraulics. See Diagnosing & Resetting System Errors section on page 50 and Enabling & Disabling System Error Checking section on page Slave Arm Operational Status The operational status of the slave arm is shown in the upper right corner of most menus using the following designations: REIN (reindex) indicates the master arm control of the slave arm is enabled. FRZ (freeze) indicates that master arm control of the slave arm is disabled and the slave arm is idle (frozen). FRZ status occurs when opening certain menus or after pushing the freeze button at the tip of the master arm. Press the freeze button again to activate the master arm for control of the slave arm. LOCK indicates that the arm is frozen and cannot be unfrozen from the current menu. The manipulator control system automatically locks the slave arm for menus or states in which the slave arm should not be operated. To unfreeze the slave arm, you must move to another menu. Communications errors may also lock the system to prevent damage Avoiding Slave Arm Damage The Conan 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 Page 28 System Overview

29 Collisions while manipulating extreme loads Operation 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) that may trigger automatic system shutdown by errorchecking software. If necessary, error checking can be disabled in order to assure uninterrupted operation. However, disabled error checking puts the slave arm at greater risk. (For details see Enabling and Disabling System Error Checking on page 45.) 2 Operation NOTE: If wrist drain/return pressure exceeds 350 psi above ambient, the relief valve will crack and release hydraulic fluid into the environment. 2.1 Pre-Start Checks Each time you prepare to start up the manipulator system, make the following checks: 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. Air has been purged from the hydraulic system if any connections have been opened for service or maintenance. All electrical connections between the master controller, junction box, base module, and slave arm are secure; electrical cables are safely routed to avoid damage. 2.2 Startup Sequence To start up the system, follow the steps below. 1. Clear personnel and equipment from the slave arm s range of motion. Turn on electrical power to the system with the switch on the junction box. If your system has independent electrical power to the base module, enable base module power first; then turn on power at junction box and/or master controller. 2. Turn on power to the master controller with the switch on the left side of the controller front panel. The message Establishing Communications with slave arm will appear briefly and then default automatically to the next message screen. NOTE: If the master controller fails to establish communication with the base module, a fatal telemetry error message will appear. Refer to the Troubleshooting chapter for more information on correcting the cause of the malfunction Operation Page 29

30 Operation SCHILLING ROBOTIC SYSTEMS CONAN-7P 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 4 Startup procedure screen 3. If the slave arm is near the stow position, and all system equipment and communications are functioning correctly, the Startup Procedure screen (Figure 4) will follow the establishing communications message. If the system was shutdown without returning the slave arm to the stowed position or keyboard errors are present, a decriptive WARNINGS: screen will appear as an alert (see example, Figure 5) SCHILLING ROBOTIC SYSTEMS CONAN-7P MANIPULATOR SYSTEM WARNINGS: Arm not near STOW point (STOW OUT will be bypassed) Exit < Figure 5 WARNINGS screen a. Press the Exit <8 key to proceed to the Startup Procedure screen (Figure 4). b. Complete the startup steps. Press the DOWN key to exit. The STOW OUT menu will be bypassed and the MAIN menu will open. c. From the MAIN menu you can choose to diagnose errors or proceed to the OPERATE menu. NOTE: Keyboard errors need not be corrected if emergency operation of the slave arm is essential. To correct them, refer to the Troubleshooting chapter and/or System Fault & Error Diagnosis section on page 47 in this chapter to diagnose. The appearance of other warning screens or the system error screen indicates a communication or system problem. Refer to System Fault & Error Diagnosis section on page 47, and/or the Troubleshooting chapter. Page 30 Operation

31 Operation 4. Perform the steps listed in the Startup screen. NOTE: The pitch, yaw, wrist, and jaw are not equipped with lock valves. They may sag or drift during shutdown or when hydraulic power is disabled. It is normal for them to return to their last commanded or stow position when hydraulic power is enabled. The azimuth, shoulder, and elbow joints are equipped with lock valves to maintain their positions during shutdown and regardless of hydraulic or slave arm status. They should not move more than slightly when hydraulics are enabled (unless they have been manually repositioned while the system was shutdown). If they begin moving more than a slight distance, immediately press 8> HYDR again to disable hydraulic power to the slave arm until the cause can be determined. 5. Press the DOWN control key (exits to the STOW OUT menu). UP LEFT RIGHT DOWN 2.3 STOW OUT Menu Use the STOW OUT menu (Figure 6) to automatically move the slave arm to a deployed position or to a compact stowed position. Movement of the slave arm to either position follows a set of up to 16 points (positions) that are user programmed in the SET STOW menu (MAIN/SETUP/SET STOW), as described section on page 44. STOW OUT STOW OUT <5 STOW IN <6 pnt:in STOP <7 EXIT < After stowing out press exit KEY Figure 6 STOW OUT menu Command Options STOW OUT <5 (deploy): Press the STOW OUT <5 key to deploy the slave arm to the operational position. As the slave arm moves, the pnt: field displays the next point in the sequence to which the slave arm is moving. STOW IN <6 (stow): Press the STOW IN <6 key to move the slave arm to the stowed position Operation Page 31

32 Operation NOTE: The slave arm will move first to the Stow Out (deployed) position before beginning the Stow In sequence. To avoid major automatic movements, position the slave arm at or near the stow out position before pressing the STOW IN <6 key. pnt:... STOP <7: The next programmed point is displayed the pnt:... field. Press the pnt:... <7 key to stop the slave arm at the next programmed point. To immediately stop the slave arm in an emergency, press the UP control key to disable hydraulic power. EXIT <8: Press the EXIT <8 key to return to the MAIN menu. 2.4 Using the MAIN MENU MAIN MENU LOCK > OPERATE SHUT DOWN <5 2> OPTIONS 3> SETUP 4> DIAGNOSE UP key turns hydraulics OFF Figure 7 MAIN MENU The MAIN MENU provides access to the five submenus described below. Press the key adjacent to the menu to select it (Figure 7). 1> OPERATE: Select this menu to direct the slave arm with the master arm. Key controls toggle between jaw operation modes, different slave arm scaling values, and enable or disable slave arm hydraulics. Slave arm joints can be selectively frozen in the FREEZE submenu. All controls and menus are accessible at security level 0 (zero). 2> OPTIONS: Submenus are provided to configure slave arm speed and jaw speed, and to scale the degree of slave arm movement relative to master arm movement. All menus are accessible at security level 0 (zero). 3> SETUP: Submenus are provided to configure slave arm movement limits, program the stow in/stow out sequence, set system error checking, set security levels and passwords, and edit master controller memory locations. These submenus require a password or a security level higher than 0 (zero) to use. 4> DIAGNOSE: Used to view diagnostic information about the master arm, slave arm and master controller, and to view details of system error conditions. All menus are accessible at security level 0 (zero). SHUT DOWN <5: Used to stow the slave arm and disable slave arm hydraulics in preparation for shutting down the manipulator system. All menus are accessible at security level 0 (zero). Page 32 Operation

33 Operation 2.5 Using the OPERATE Menu Access path: MAIN/OPERATE OPERATE FRZ > FREEZE Jaw Md:TOG <5 2> Hydr:OFF 3> Scale Tog:100% EXIT < Turn on hydraulics Figure 8 OPERATE menu Normal operation of the manipulator system takes place in the OPERATE menu. Use the master arm for direct control of the slave arm. Use the master controller keys to select among function options, enter the FREEZE submenu, control hydraulic power, or exit back to the main menu. The slave arm is stowed and the manipulator system is disabled in the SHUT DOWN menu. To prevent unintended or unexpected movement, the OPERATE menu always opens with the slave arm in the freeze (FRZ) state (Figure 8). 1. From the MAIN MENU press the 1> OPERATE key to access the OPERATE menu (Figure 8). 2. Air in hydraulic lines or components may cause very rapid or jerky slave arm movements. Sagging joints may return to their original position when hydraulics are enabled. Clear personnel and equipment from the slave arm s range of motion before startup. 3. If hydraulic power is not enabled, press the 2> Hydr key Using the Master Arm 1. Verify that the status field (at upper right) reads FRZ (Figure 8). Grip the master arm, move it from its parked location, and position it for convenient operation of the slave arm. Then press the freeze button at the tip of the master arm (status field changes to LIVE): the slave arm will now move to match the movements of the master arm. NOTE: The freeze function is also useful when a manipulation task results in an awkward position for the master arm. Press the Freeze button, reposition the master arm for more comfortable operation, and press the Freeze button again (to resume operation). These actions re-index the new master arm position to the existing position of the slave arm. 2. Operate the slave arm as desired. To optimize the Conan for a specific task and/or work site, refer to Performance Options section on page 37, for information on system functions that can be selected, set, and/or reconfigured using the OPERATE, OPTIONS, and SETUP menus Operation Page 33

34 Operation NOTE: If the wrist continues to turn when frozen when the slave arm is frozen, the wrist s servo offset may need adjustment. The procedure is described in the Maintenance & Service chapter Selecting the Jaw Operating Mode (Toggle) Access path: MAIN/OPERATE/Jaw Md (see Figure 8) Press the Jaw Md: <5 key to toggle between the three jaw function modes (POS, TOG, and LOCK): TOG (toggle): Squeezing the forward band toggles the jaw between fully closed and fully opened. The rear band has no function. POS (position): Squeezing the forward band causes the jaw to close until the band is released. Squeezing the rear band causes the jaw to open until the band is released. NOTE: The POS (position) option is lost if the master controller software image is changed by adjusting the PCB mode switches, replacing the EPROM (if used), or loading a new image from an SD card. To re-enable the POS option after one of these events has occurred, see Re-enabling POS (Position) Jaw Control in section 6.4, Master Controller Software Selection, on page 88 in the Maintenance & Service chapter. LOCK: The jaw is frozen in its current position and operator inputs to the jaw bands are ignored until you select another mode Scaling Slave Arm Movement (Toggle) Access path: MAIN/OPERATE/SCALE TOG The 3> Scale Tog key toggles between the default scale value of 100% and a lesser pre-selected scale value. A scale value of 100% produces one-to-one travel correspondence between master arm and slave arm movement. (For example, rotating the master arm elbow joint 50 causes the slave arm elbow joint to move 50.) Toggling to a scale value of less than 100% reduces slave arm movement to that percentage of master arm movement, allowing finer slave arm control. The manipulator system offers position scaling from 10% to 100% in increments of 10%. At startup the selectable scale defaults to 100% and must be reset if lesser values are required. 1. Use the master arm tip to freeze the slave arm. 2. Press the 3> Scale Tog key to toggle between the standard 100% scale of slave arm movement and a pre-selected lesser scale. Scaling affects only the azimuth, shoulder, elbow, forearm roll, and wrist pitch functions (wrist roll and jaw functions always remain at 100%). You must freeze the slave arm before toggling between scales. The speed of slave arm movements is not affected by changes in scaling. Although the alternate scale value is retained when power to the master controller is interrupted, the OPERATE menu always reopens with the Scale Tog value at 100% Setting the Scale Value Access path: MAIN/OPTIONS/SCALE SEL To set the alternate scaling value, follow these steps: Page 34 Operation

35 Operation 1. From the MAIN MENU press the 2> OPTIONS key to display the OPTIONS menu (Figure 9). 2. The number next to 3> Scale Sel shows the current alternate scaling value. Press the 3> Scale Sel key to increment this number by 10%. (At 100%, the value defaults to 10%.) 3. When the desired alternate scaling value is displayed, press the EXIT <8 key to save and return to the MAIN MENU. The Scale Sel setting is retained in memory even if power to the master controller is interrupted. OPTIONS FRZ > Dyn:FAST 2> Jaw Speed:2 3> Scale Sel:050% EXIT < Figure 9 OPTIONS menu Freezing Individual Slave Arm Joints (Toggle) Access path: MAIN/OPERATE/FREEZE FREEZE FRZ > Azi: REIN Yaw: FRZ <5 2> Sho: REIN Wrs: REIN <6 3> Elb: REIN REIN all <7 4> Pit: REIN EXIT < Figure 10 FREEZE menu 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. 1. From the OPERATE menu press the 1> FREEZE key. The FREEZE menu (Figure 10) allows individual slave arm joints to be frozen so that they will not respond to master arm movements. Select among 1> Azi (azimuth), 2> Sho (shoulder), 3> Elb (elbow), 4> Pit (wrist pitch), Yaw <5 (wrist yaw), and Wrs <6 (wrist). To unfreeze all joints, press the REIN all <7 key Operation Page 35

36 Operation 2. Press the key next to each joint to toggle the field between FRZ and REIN. 3. After making your selections, press the EXIT <8 key to return to the OPERATE menu. 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. All FREEZE menu joint settings return to the default value (REIN) when power to the master controller is interrupted. 2.6 Using the SHUT DOWN Menu Access path: MAIN/SHUT DOWN SHUT DOWN LOCK Stow Out <5 Stow In <6 Pnt:IN Stop <7 4> Hydr to OFF EXIT < After stow, turn off hydraulics Figure 11 SHUT DOWN menu To shut down the manipulator system, follow these steps:! Caution Be sure to release objects from the jaws before shutdown. The jaw relaxes after hydraulics are turned off, and a grasped object will be dropped. 1. Release any objects from the grasp of the jaw. 2. Move the slave arm to a position that approximates the final stow out position. Exit the operation menu. 3. From the MAIN MENU, press the SHUT DOWN <5 key to display the SHUT DOWN menu (Figure 11). The status field shows that the slave arm is locked, preventing operation by the master arm.! Caution When you press the Stow In <6 key, the slave arm will first return to the final STOW OUT position before beginning the stow in sequence. Be prepared for this movement. 4. Press the Stow In <6 key to move the slave arm to its stowed position. Note that: a. Before beginning the stow sequence, the slave arm will first return to the deployed position. Page 36 Operation

37 Operation b. As the slave arm moves towards stow, the PNT: field displays each successive point number in the sequence. The final point (01) is displayed as IN. c. 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. d. You can reverse the stow sequence at any time by pressing the Stow Out <5 key. 5. Press the 4> Hydr key to close the base module hydraulic isolation valve. 6. Turn off power to the hydraulic power unit. 7. Turn off power to the master controller with the switch on the left side of the faceplate. Turn off power to the base module (if independently supplied). 3 Performance Options The Conan can be optimized for a specific task and/or work site by selecting, setting, or configuring system functions using the OPTIONS and SETUP menus. 3.1 OPTIONS Menu Access path: MAIN/OPTIONS OPTIONS FRZ > Dyn:FAST 2> Jaw Speed:2 3> Scale Sel:050% EXIT < Figure 12 OPTIONS menu Dyn (slave arm speed) and Jaw Speed settings return to default values when power to the master controller in interrupted or turned off. The Scale Sel setting is retained Controlling Slave Arm Dynamics Access path: MAIN/OPTIONS/DYN Slave arm speed can be toggled between two dynamic modes: FAST and SLOW. In the FAST mode, the speed of slave arm movement matches all but the most rapid movements of the master controller. This speed is useful in operations where quick response and close correspondence to rapid movements of the master arm are useful, and in submersible operation where slave arm movements are slowed by water resistance. SLOW mode is intended for use where speed-limited movements are needed for specific tasks or equipment handling. 1. Press the 1> Dyn key to toggle between SLOW and FAST modes Performance Options Page 37

38 Operation 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: When the manipulator system is operating in SLOW mode, avoid rapid movements of the master arm. Slave arm response will lag and may make it difficult to avoid obstacles or direct the slave arm to an exact position. For exact slave arm movements or positioning, slow your movements of the master arm until the slave arm can match them Controlling Jaw Opening and Closing Speed Access path: MAIN/OPTIONS (Figure 12, OPTIONS menu on page 37) When the jaw is in POSITION mode, you can specify the speed of jaw movement with the Jaw Speed function. In the OPTIONS menu (Figure 12 on page 37), the number next to 2> Jaw Speed shows the current jaw speed. The higher the number, the greater the jaw speed. Possible jaw speeds range from 1 (slowest) to 4 (fastest). 1. Press the 2> Jaw Speed key to increment the speed by 1. After jaw speed 4 the value defaults to Press EXIT <8 to save setting and return to the MAIN MENU. Jaw speed defaults to 1 when power to the master controller is interrupted or turned off Slave Arm Scale Selection Access path: MAIN/OPTIONS The 3> Scale Tog key in the OPERATE menu toggles between the default scale value of 100% and a lesser pre-selected scale value. A scale value of 100% produces one-to-one correspondence between master arm and slave arm movement. A scale value of less than 100% reduces slave arm movement to that percentage of master arm movement, allowing finer slave arm control. Scaling is selectable in increments of 10% from 10% to 100%. Although the alternate scale value is retained when power to the master controller is interrupted, the OPERATE menu always reopens with the Scale Tog value at 100%. To set the alternate scaling value, follow these steps: 1. From the MAIN MENU press the 2> OPTIONS key to display the OPTIONS menu (Figure 12 on page 37). 2. The number next to 3> Scale Sel shows the current alternate scaling value. Press the 3> Scale Sel key to increment this number by 10%. (At 100%, the value defaults to 10%.) 3. When the desired alternate scaling value is displayed, press the EXIT <8 key to save and return to the MAIN MENU. 3.2 SETUP Menu Access path: MAIN/SETUP The SETUP menu contains the following sub-menus for configuring functions (Figure 13): 1> SET LIMITS (set slave arm movement limits). 2> SET STOW (program the stow and deploy sequences). Page 38 Performance Options

39 3> SET SV OFFSET (Set servo valve offsets). See the Maintenance & Service chapter for information about adjusting the servo valve offsets. 4> SET ERR CHECKS (set system error checking parameters). MEMORY <5 (edit master controller memory locations).! Caution Operation Edit memory locations only under direction from manufacturer service personnel. 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 13 SETUP menu 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 factory-assigned level 5) password in the SECURITY menu. Only the level 5, factory-assigned password will provide access for configuring the MEM- ORY <5 menu. Settings in all SETUP submenus are retained even if power to the master controller is interrupted or turned off SECURITY Menu Access path: MAIN/SETUP/SECURITY Security level: 1 or higher NOTE: A factory-assigned password can be found at the end of the Table of Contents Performance Options Page 39

40 Operation SECURITY LOCK > SET LEVEL 2> SET PASSWORD EXIT < Figure 14 SECURITY menu 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: 1. Level 0 (zero) 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. While level 0 does allow operator access to the SET ERR CHECKS menu, all other SETUP submenus are inaccessible. A level 0 operator using a fully configured manipulator system will usually need no higher security level. 2. Levels 1 through 4 require a password, and allow access to the SET LIMITS, SET STOW, and SET SV OFFSET menus. (Levels 2 through 4 are functionally equivalent to level 1 on this model and may be disregarded.) 3. 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 through 4. Table 1 lists configuration menus and the security level needed to make changes. Function Table 1 Entering or changing the passwords for each level is done via the SECURITY menu, which is accessed by pressing the 6> SECURITY key in the SETUP menu The SET LEVEL Menu: Entering Passwords Access path: MAIN/SETUP/SECURITY/SET LEVEL Required Security Levels Setting the stow in/stow out sequence 1-5 Setting joint movement limits 1-5 Setting servo offset 1-5 Setting new passwords for security levels Directly editing master controller memory locations 0-5 All other functions 0-5 Page 40 Performance Options

41 Operation Security level: 1 or higher SET LEVEL Level:1 Inc <5 Password:**** Dec <6 Select <7 Current user's Privilege Level:0 EXIT < Figure 15 SET LEVEL menu Menus requiring security levels above 0 (zero) are accessed using a local- or factory-assigned password. To enter a password, perform the following steps: 1. From the SETUP menu, press the SECURITY <6 key to access the SECURITY menu. 2. From the SECURITY menu, press the 1> SET LEVEL key to display the SET LEVEL menu (Figure 15). The cursor will appear in the Level: field (the current security level is displayed at the bottom of the screen). To change the current level, press the Inc <5 or Dec <6 keys until the desired level is displayed. Press the Select <7 key to enter the level. 3. After selecting a security level, the cursor will drop to the first digit of the Password: field, changing the asterisk (*) to a 0 (zero). 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 move on to the next password number. Repeat until all four numbers of the password have been entered. 4. Press the Select <7 key once more to enter the password. The Current User s Security Level: field will show the new level. 5. Press the EXIT <8 key until you exit to the desired menu Setting & Changing Passwords Access path: MAIN/SETUP/SECURITY/SET PASSWORD Security level: 1 or higher The SET PASSWORD menu allows an operator with the factory-assigned level 5 password to set or change passwords for security levels 1 through 4. If the SET PASSWORD menu is selected while in security level 4 or lower, the message INSUFFICIENT SECURITY LEVEL appears below the menu. The password for security level 5 cannot be changed. To set a password, follow these steps: 1. Ensure that the current security level is 5. (If you aren t sure what the current level is, access the SET LEVEL menu (MAIN/SETUP/SECURITY/SET LEVEL) and note the level displayed on the screen). Enter the level 5 password if necessary. 2. From the SETUP menu, press the 6> SECURITY key Performance Options Page 41

42 Operation 3. From the SECURITY menu, press the 2> SET PASSWORD key to display the SET PASSWORD menu (Figure 16). SET PASSWORD Level:1 Inc <5 Password:**** Dec <6 Select <7 Current user's Privilege Level:5 EXIT < Figure 16 SET PASSWORD menu 4. The cursor will appear next to the Level: field. Press the Inc <5 or Dec <6 key until the desired level is displayed. Press the Select <7 key to enter the level. 5. The cursor will then drop to the first digit of the Password: field. Press the 5> Inc or 6> Dec key to set the first number of the password. Press the 7> Select key to move on to the next password digit. Repeat until all numbers of the new password have been entered. 6. Press the EXIT <8 key until you exit to the desired menu Setting Slave Arm Movement Limits Access path: MAIN/SETUP/SET LIMITS Security level: 1 or higher Slave arm joint movements are ultimately limited by the mechanical range of each joint. For the protection of the slave arm or personnel and equipment within the operational envelope of the slave arm it is often necessary to software-limit the movement range of slave arm joints. The software set limits for each joint (excluding the wrist and jaw) are configured in the SET LIMITS menu (Figure 17). SET LIMITS FRZ COUNT:01 Last <5 LIMIT: Next <6 AZI LEFT Teach <7 EXIT < Figure 17 SET LIMITS menu Page 42 Performance Options

43 Operation Accessing the SET LIMITS menu requires a security level of 1 or higher. If the SET LIMITS menu is selected while in security level 0 (zero), the message INSUFFICIENT SECURITY LEVEL appears below the menu. To set movement limits for individual slave arm joints, follow these steps: 1. Ensure that the current security level is 1 or higher. If you aren t sure what the current level is, display the SET LEVEL menu (MAIN/SETUP/SECURITY/SET LEVEL) and note the level displayed on the screen. Enter a 1 or higher security level password if necessary. 2. From the SETUP menu, press the 1> SET LIMITS key to display the SET LIMITS menu.! Caution While the SET LIMITS menu is open, slave arm joints are capable of full mechanical travel. Previously set limits (if retained) or newly set limits will not engage until you have exited from the SET LIMITS menu. 3. The SET LIMITS menu will identify the joint function by a number (in the COUNT: field) and the function description (in the LIMIT: field) for the limit being set. The sequence of joint functions and their corresponding numbers are shown in Table 2. (There are no movement limits for the wrist and jaw.) As the table shows, the azimuth left limit is the first function in the sequence. The COUNT: field will display 1, while the LIMIT: field will display AZI LEFT. Table 2 SET LIMITS Sequence Joint Travel Limit Limit No. Azimuth Yaw LEFT 01 RIGHT 02 Shoulder Pitch DOWN 03 UP 04 Elbow Pitch DOWN 05 UP 06 Pitch DOWN 07 UP 08 Yaw LEFT 09 RIGHT Unfreeze the arm by pressing the master arm freeze button. Move the slave arm to the farthest left 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. 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 function appears on the screen. You Performance Options Page 43

44 Operation may skip functions by pressing the Next <6 key instead of Teach <7. If you do this, the existing limit setting for the skipped function 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, freeze the slave arm, 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. 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 Setting the Stow In/Stow Out Sequence Access path: MAIN/SETUP/SET STOW Security level: 1 or higher SET STOW FRZ POINT:03 Last <5 Next <6 Teach <7 Last Stow 4> Point:05 EXIT < Figure 18 SET STOW menu The stow in/stow out path is a sequence of up to 16 fixed slave arm points (or positions) that the operator selects in the SET STOW menu (Figure 18). The stow in/stow out sequence can be reset at any time to accommodate changes in operational needs or the operating environment. The stow in/stow out sequence is used in the STOW OUT menu (automatically displayed as part of the startup process) and the SHUT DOWN menu. In either menu, when the Stow Out <5 key is pressed, the slave arm moves from its stow in position to its stow out position; when the Stow In <6 key is pressed, the slave arm first moves to the stow out position and then moves to the stowed in position. In planning a stow in/stow out sequence for your manipulator system, the following factors should be considered: You can issue a command to stop the slave arm at any time during the sequence, but the slave arm will continue to move until it reaches the next programmed point in the sequence. A stow in/stow out sequence with more points can be stopped sooner. Be sure to program enough points into the sequence to guide the slave arm around obstacles and equipment. To set a new stow in/stow out sequence, follow these steps: Page 44 Performance Options

45 Operation 1. Set the security level to 1 or higher. 2. Access the SET STOW menu (Figure 18 on page 44): MAIN/SETUP/SET STOW. The POINT field opens to the 01 (Stow In) point. 3. Press the 4> Last Stow Point:... key to change the number of points you want to use for the path sequence. 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 will increment to the next point. NOTE: Slave arm travel limits set 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 this step 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 Enabling and Disabling System Error Checking Access path: MAIN/SETUP/SET ERR CHECKS Security level: 0 (zero) or higher SET ERR CHECKS LOCK [01]Contin Change <5 Check:ENA 2> Last Disable all <6 3> Next Enable all <7 4> Save as default EXIT < Figure 19 SET ERR CHECKS menu The set error checks function allows you to selectively enable and disable monitoring of Control, Continuity and Telemetry errors. (Timeout errors cannot be disabled.) Normally, all system error monitoring should be left enabled so that operational faults will shut down the slave arm and prevent damage to the arm or its surroundings. However, there may be circumstances where Performance Options Page 45

46 Operation uninterrupted operation of the arm is necessary despite a known fault (such as a faulty position sensor), to diagnose a fault, or because collisions or extreme loads are likely to cause repeated system shutdowns. Good judgment is a necessity: error monitoring exists to protect the slave arm (and its surroundings) from damage. An automatic shutdown due to error checking indicates the slave arm is at risk. Disabling error checking indicates the operator's awareness and acceptance of increased risk. See Diagnosing & Resetting System Errors section on page 50 for a detailed description of the four types of system errors. To enable and disable system error checks, follow these steps: 1. From the MAIN MENU, select 3> SETUP. The SETUP menu (Figure 13 on page 39) will appear. 2. From the SETUP menu, press the 4> SET ERR CHECKS key to display the SET ERR CHECKS menu (Figure 19). The system error type and its current status will appear in the upper left of the screen. The three error types that can appear are: [01] Contin (Continuity) [02] Control [03] Telem (Telemetry) The type 04 error, Timeout, cannot be disabled and thus does not appear in this menu. The flag in the Check: field specifies whether or not the selected error check is enabled (ENA) or disabled (DIS). Enabled, an occurrence of the error type will cause a system error condition and a resulting shutdown of the slave arm hydraulics. Disabled, errors of this type will not result in a shutdown and the system will continue operating. (The condition causing the error may result in limited or erratic performance of the slave arm, however.) 3. To view and set the other error types, press 2> Last and 3> Next until the desired error type is displayed. 4. To enable or disable checking for the displayed error type, press the Change <5 key to toggle the Check: flag 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. 5. If you wish the changes to error checking to be temporary (lasting for the current session only), you can exit the SET ERR CHECKS menu by pressing the EXIT <8 key. If you want the changes to be permanent (until changed again), press the 4> Save as default key. Press the EXIT <8 key to exit the SET ERR CHECKS menu Set SV Offset Use of this menu is described in Adjusting Servo Valve Offsets on page 19 in the Maintenance & Service chapter Memory This menu should only be used under direction from factory service personnel. Page 46 Performance Options

47 Operation 4 System Fault & Error Diagnosis Access path: MAIN/DIAGNOSE Security level: 0 (zero) or higher DIAGNOSTICS LOCK > MASTER 2> SLAVE 3> SHOW ERRORS EXIT < Figure 20 DIAGNOSTICS menu The DIAGNOSTICS menu (Figure 20) provides access to menus that display system diagnostic information. The options under this menu can be used to diagnose faults in the slave arm position sensors, master arm and master controller, and to display, reset, and configure system error checking. To enter the DIAGNOSTICS menu, press the 4> DIAGNOSE key from the MAIN menu (Figure 20 on page 47). 4.1 Diagnosing Problems If the master arm is not properly responding to control inputs, proceed to Diagnosing Master Arm Joint Problems section on page 47. If you suspect that one or more of the master controller keys, or the master arm freeze button is not working properly, proceed to Diagnosing Master Controller Key & Freeze Button Failures section on page 48. If you suspect that the slave arm is not properly positioning itself, or that the correspondence between the master arm and the slave arm is not accurate, proceed to Diagnosing Slave Arm Positioning Failures section on page 49. If the slave arm has frozen automatically and an ERR flag is appearing in the top line of the LCD display, proceed to Diagnosing & Resetting System Errors section on page Diagnosing Master Arm Joint Problems Access path: MAIN/DIAGNOSE/MASTER Security level: 0 (zero) or higher Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST screen (Figure 21). The slave arm is automatically locked in this menu, allowing the master arm to be safely moved for diagnostic purposes System Fault & Error Diagnosis Page 47

48 Operation MASTER TEST LOCK Position: Jaw Bands: Azi Sho Elb Pit Yaw Wrs Keys: EXIT < Figure 21 MASTER TEST menu For this procedure, you will be viewing the values displayed for each joint in the Position: column and the jaw bands in the Jaw Bands: column. A value of 0 (zero) indicates that the joint is at the approximate midpoint of its range of motion. Positive values indicate movement either up, to the right, or clockwise (when the master arm is viewed from behind); negative numbers indicate movement down, to the left, or counterclockwise. The two jaw band values will jump from a very low (near-zero) value to a very high (1000 or more) value when squeezed. If a master arm joint is not being moved, the position value should either not change or should fluctuate only slightly. A changing position value for an immobile joint probably indicates a failure in a master arm potentiometer or a master controller printed circuit board. Conversely, a position value that does not change or changes only slightly when the joint is moved also indicates a failure of this type. Apparent discontinuity in master arm data (for example, a slight movement of a master arm joint causes a large change in position data, or vice versa) may indicate a failed master arm joint potentiometer Diagnosing Master Controller Key & Freeze Button Failures Access path: MAIN/DIAGNOSE/MASTER Security level: 0 (zero) or higher Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST screen (Figure 21 on page 48). For this diagnostic procedure, you will be viewing the binary values (0 or 1) in the Keys: field. The digits in this field display the status of each key and the freeze button, which lets you diagnose problems with master controller keys or the master arm freeze button. Each digit in this field corresponds to one key or to the freeze button. If the key or button is operating correctly, the character for that key or button will be 0 (zero) when it is not being pressed and 1 when it is pressed. If a failure has occurred, the display will show the same value for the corresponding digit whether the key or button is pressed or not. Use Table 3 to identify the functions in the Keys: field. In this table, the character position column indicates how far from the left the character is. (For example, the eleventh character from the left shows the status of the down key.) Page 48 System Fault & Error Diagnosis

49 Operation Table 3 Keys & Freeze Button Guide Character Position Function (from left) 1 Function key 1 2 Function key 2 3 Function key 3 4 Function key 4 5 Up key (UP) 6 Left key (LF) 7 Left master arm freeze button (functional in dual-arm systems only) 8 Master arm freeze button (in dual-arm systems, for the right master arm only) 9 Function key 5 10 Function key 6 11 Down key (DN) 12 Right key (RT) 13 Function key Diagnosing Slave Arm Positioning Failures Access path: MAIN/DIAGNOSE/SLAVE Security level: 0 (zero) or higher Press the 2> SLAVE key in the DIAGNOSTICS menu to display the SLAVE TEST screen (Figure 22). The slave arm will be frozen when you enter this menu (while the slave arm is frozen, master arm position values are not read, so the display will not change as you move the master arm). Press the master arm freeze button to unfreeze it and evaluate the master arm to slave arm positioning correspondence: When the master arm is moved, the master arm position values in the Cmd: (command) column should change as rapidly as the arm is moved. (If they do not, you should evaluate the master arm s performance as described in Diagnosing Master Arm Joint Problems section on page 47) The values in the Fdbk: (feedback) column, representing the position sensor information from the slave arm, should catch up with the Cmd: values whenever the movement of the master arm is halted. Although the values in the Diff (difference) column may reach the high hundreds when the master arm is moved quickly, they should drop to single digits (indicating close correspondence between the master and slave arm positioners) whenever the master arm is not being moved. If a large difference between the command and feedback values persists (for example, a value greater than 25 in the difference column), check the servo offset value for that joint. (Refer to the System Fault & Error Diagnosis Page 49

50 Operation Maintenance & Service chapter for details.) If the servo offset is properly nulled, or cannot be nulled, a faulty slave arm position sensor is most likely at fault. Since the wrist and jaw have no position sensors, no feedback or difference values are displayed for these joints. SLAVE TEST FRZ Cmd: Fdbk: Diff: Azi: Sho: Elb: Pit: Yaw: Wrs: Jaw: EXIT < Figure 22 SLAVE TEST screen Diagnosing & Resetting System Errors Access path: MAIN/DIAGNOSE/SHOW ERRORS All menus are accessible at security level 0 (zero). Press the 3> SHOW ERRORS key in the DIAGNOSTICS menu to display the SHOW ERRORS screen (Figure 23). SHOW ERRORS ERR LOCK ERRORS: Clr Errs <5 CONTROL [S,P] Warnings: Update <6 Hydr OFF Hydr On <7 EXIT < Hydr OFF Figure 23 SHOW ERROR menu If the ERR flag has appeared in the top line of all menus, the system error information will appear on the left side of the display. If there is no system error, or if the Clr Errs <5 key has been pressed, No Errors will appear instead. There are four error types that may appear in this screen: Control errors indicate there is a large difference between the actual and commanded position. The Control flag will be followed by one or more letters in Page 50 System Fault & Error Diagnosis

51 Operation brackets, which indicate the joint or joints experiencing control errors (Azimuth, Shoulder, Elbow, Pitch, and Yaw). In addition to system errors, collision, driving the slave arm against an immovable object, or an extreme load may also trigger a control error. Continuity errors indicate that a joint position sensor reported an unexpectedly large position change in a short time. This error may indicate that the sensor has failed, or that an external force, such as a collision or an extreme or immovable load) has pushed the joint out of position. The Contin flag will be followed by one or more letters in brackets, indicating the joint or joints experiencing continuity errors (azimuth, shoulder, elbow, pitch, and yaw). Telemetry errors occur when the master controller loses contact with one or more actuator control modules. This error may be caused by faulty position sensor, by a faulty connection between the master controller and the slave arm, or by a failure of the slave arm base module. The Telem flag will be followed by one or more letters in brackets, indicating the source of the error (azimuth, shoulder, elbow, pitch, yaw, wrist, jaw, base module). Timeout errors occur when the slave arm base module receives no communications for 500 milliseconds (one-half second) or longer. This error may be caused by a failure of electrical power to the slave arm base module, or by a faulty connection between the master controller and the base module. To clear a system error condition, press the Clr Errs <5 key. New control, continuity, telemetry and timeout errors will not generate a new display. If the ERR flag reappears in the top line of the menu, press the Update <6 key to display the new errors. All except timeout errors may be disabled in the SET ERROR CHECKS menu. See Enabling & Disabling System Error Checking for details. Some errors may be followed by warnings. The most common warning is that slave arm hydraulics have been disabled (for safety reasons). When the error has been corrected, slave arm hydraulics may be re-enabled by pressing the Hydr On <7 key. Press the EXIT <8 key to exit the SHOW ERRORS menu Enabling & Disabling System Error Checking Access path: MAIN/SETUP/SET ERR CHECKS Security level: 0 (zero) or higher The Set Error Checks function allows you to selectively enable and disable monitoring of Control, Continuity and Telemetry errors. (Timeout errors cannot be disabled.) Normally, all system error monitoring should be left enabled so that operational faults will shut down the slave arm and prevent damage to the arm or its surroundings. However, there may be circumstances where uninterrupted operation of the arm is necessary despite a known fault (such as a faulty position sensor), to diagnose a fault, or because collisions or extreme loads are likely to cause repeated system shutdowns. Good judgment is a necessity: error monitoring exists to protect the slave arm (and its surroundings) from damage. An automatic shutdown due to error checking indicates the slave arm is at risk. Disabling error checking indicates the operator's awareness and acceptance of increased risk System Fault & Error Diagnosis Page 51

52 Operation See Diagnosing & Resetting System Errors section on page 50 for a detailed description of the four types of system errors. To enable and disable system error checks, follow these steps: 1. From the MAIN MENU, select 3> SETUP. The SETUP menu will appear. 2. From the SETUP menu, press the 4> SET ERR CHECKS key to display the SET ERR CHECKS menu (Figure 24). SET ERR CHECKS LOCK [01]Contin Change <5 Check:ENA 2> Last Disable all <6 3> Next Enable all <7 4> Save as default EXIT < Figure 24 SET ERR CHECKS menu The system error type and its current status will appear in the upper left of the screen. The three error types that can appear are: [01] Contin (Continuity) [02] Control [03] Telem (Telemetry) The type 04 error, Timeout, cannot be disabled and thus does not appear in this menu. The flag in the Check: field specifies whether or not the selected error check is enabled (ENA) or disabled (DIS). Enabled, an occurrence of the error type will cause a system error condition and a resulting shutdown of the slave arm hydraulics. Disabled, errors of this type will not result in a shutdown and the system will continue operating. (The condition causing the error may result in limited or erratic performance of the slave arm, however.) 3. To view and set the other error types, press 2> Last and 3> Next until the desired error type is displayed. 4. To enable or disable checking for the displayed error type, press the Change <5 key to toggle the Check: flag 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. 5. If you wish the changes to error checking to be temporary (lasting for the current session only), you can exit the SET ERR CHECKS menu by pressing the EXIT <8 key. If you want the changes to be permanent (until changed again), press the 4> Save as default key. Press the EXIT <8 key to exit the SET ERR CHECKS menu. Page 52 System Fault & Error Diagnosis

53 Troubleshooting In This Chapter: 1 Diagnostic Approaches... page 53 2 Troubleshooting Tables... page 54 3 System Fault & Error Diagnosis... page 60 4 Electrical Component Diagnosis... page 68 5 Factory Assistance... page 75 1 Diagnostic Approaches This chapter has three main troubleshooting sections, each with a different diagnostic format or method: Troubleshooting Tables: Use these tables to diagnose observable performance or the behavior of major slave arm or system components. System Fault and Error Diagnosis: Use the master controller s diagnostic menu to troubleshoot slave arm performance and control malfunctions. Electrical Component Diagnosis: Discusses symptoms and troubleshooting within the context of individual electrical and control components. The essential materials in each section are interrelated in many ways and it is worth becoming familiar all of them. Then, if a satisfactory diagnosis cannot be achieved using one format, another one is readily available. Since major manipulator system components are interactive, the component that displays a symptom may or may not be the cause of the malfunction. To narrow the field of possible causes, regardless of your diagnostic approach, first eliminate those that are the easiest to check or correct: 1. Thoroughly inspect all system components for obvious faults or damage (damaged or disconnected cables, hydraulic leaks, etc. 2. Make sure components are receiving the specified electrical power: a. The junction box is connected to an electrical power source, the power switch is on, and the fuse is intact. b. If you are not using the junction box, check that the master controller and base controller are connected to an appropriate power source Page 53

54 Troubleshooting c. If the base controller is powered by a separate or local source, make sure the power source is operational and that power is reaching the cable connector at the base controller. Correct electrical supply problems before continuing diagnostics. 3. Make sure the base controller is receiving the specified hydraulic power: a. Supply pressure/flow and return pressure are within the specified range. b. Isolation valve is working (sounds/hose twitch). c. The HPU reservoir is full and the filters are clean. Correct hydraulic supply and return problems before continuing diagnostics. 4. Test electrical cables for continuity, shorts, and insulation resistance, or substitute with known functional spare cables. 5. Use the master controller s DIAGNOSTICS menu to eliminate or isolate telemetry malfunctions. 6. Substitute new or known functional spares for easily accessible suspect components. Remedy or rule out each possible cause of the malfunction until the source is isolated. 2 Troubleshooting Tables The troubleshooting tables are organized by major component: Master controller screen Master arm Entire slave arm Individual slave arm joints References within each table may direct you to other sections in this chapter providing additional information or diagnostic tools for determining the cause and correction of a malfunction. 2.1 Screen-Displayed Symptoms The master controller displays present diagnostic data, warning, and error screens to help you diagnose symptoms, and alerts you to other abnormal conditions. Use Table 1 to troubleshoot screen-displayed symptoms. Table 1 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 faceplate assembly. Secure connection. LCD display screen failure. Replace display. Master processor PCB failure. Replace board. Master controller display Replace board. board failure. Page 54 Troubleshooting Tables

55 Troubleshooting Screen-Displayed Symptoms (cont.) Symptom Possible Cause Remedy Error flag appears on the screen. Message Fatal telemetry error appears on the screen. Pressing a key does not execute the appropriate function; master arm data screen confirms that key failure has occurred (see Diagnosing Master Controller Key & Freeze Button Failures section on page 64). On MASTER TEST screen, position data for one joint changes even though the joint is not moving (also see Diagnosing Problems section on page 62). On MASTER TEST screen, position data for multiple joints changes even though the joints are not moving (also see Diagnosing Problems section on page 62). On SLAVE TEST screen, position data for one or more joint changes even though the slave arm is frozen (also see Diagnosing Slave Arm Positioning Failures section on page 63). On SLAVE TEST screen, position data for all joints changes even though the slave arm is frozen (also see Diagnosing Slave Arm Positioning Failures section on page 63). On SLAVE TEST screen, position data for one joint at its hard stop is not within range of the corresponding value in Table 4 on page 58 (also see Diagnosing Slave Arm Positioning Failures section on page 63). On SLAVE TEST screen position data for multiple joints at their hard stops are not within ranges of the corresponding values in Table 4 on page 58 (also see Diagnosing Slave Arm Positioning Failures section on page 63). (see System Fault & Error Diagnosis section on page 60) (see Diagnosing & Resetting System Errors section on page 65) Contaminated key switch Clean key switch contacts. contacts. Master processor PCB failure. Replace board. Keypad gasket failure. Replace keypad gasket. Keypad switch board failure. Replace board. Master processor PCB failure. Replace board. Master arm potentiometer Replace master arm. failure. Loose connection to PC board. Secure connection. Master processor PCB failure. Replace board. Defective master arm. Replace master arm. Loose position sensor connection. Secure connection. Position sensor failure. Slave controller PC board failure. Slave controller PC board failure. Mechanical interference with joint. Loose position sensor connection. Position sensor failure. Slave controller PC board failure. Slave controller analog board failure. Slave controller PC board failure. Replace sensor. Replace board. Replace board. Inspect joint and remove debris. Secure connection. Replace sensor. Replace board. Replace board. Replace board. 2.2 Master Arm Symptoms If the problem affects one or more slave arm joints, see Using the DIAGNOSTICS Menus on page 62 for information on determining whether a master arm or slave joint is at fault. If you have identified a joint problem using the master arm data display, see Table 2 on page 56, for fault isolation information Troubleshooting Tables Page 55

56 Troubleshooting 2.3 Slave Arm Behavior Defined Table 2 The following tables use the terms below to describe slave arm behavior. Unresponsive: Does not respond to control input. Sluggish: Responds predictably but slowly to control input. Erratic: Responds unpredictably to control input. Sagging: Fails to remain in position in the absence of control input. Hard over: Locked firmly against limit of mechanical travel. 2.4 Entire Slave Arm Symptoms Master Arm Symptoms Symptom Possible Cause Remedy Master arm freeze button works intermittently or not at all. Wrist collar does not actuate slave arm wrist. Pressing jaw bands/jaw switch does not actuate slave arm jaw. Master arm wiring failure or freeze button failure. Master processor PCB failure. Master processor PCB failure. Wrist collar failure. Base controller analog board failure. Wrist potentiometer failure. Wrist servo valve failure. Actuator controller board failure. Master processor PCB failure. Jaw band failure. Jaw switch failure. Base controller analog board failure. Jaw servo valve failure. Actuator controller board failure. Replace master arm. Replace board. Replace board. Replace master arm. Replace board. Replace potentiometer. Replace servo valve. Replace board. Replace board. Replace master arm. Replace jaw switch. Replace board. Replace servo valve. Replace board. Use Table 3 to troubleshoot problems that affect all slave arm joints. If only one joint is affected, see Table 4 on page 58. Page 56 Troubleshooting Tables

57 Troubleshooting Table 3 Entire Slave Arm Symptoms Symptom Possible Cause Remedy Slave arm is unresponsive. Slave arm is receiving hydraulic power even though disabled by master controller. TURN OFF HPU IMMEDIATELY! Entire slave arm is erratic. Damaged wiring or loose connection in any cable between master controller and slave arm. Electrical power failure to master controller or base controller. Blown fuses in master controller, junction box, or base controller. Master arm or master processor PCB failure Supply solenoid valve failure. Very low or no hydraulic pressure and/or flow. Blocked, pinched, or kinked supply or control hoses. Load exceeds slave arm capacity. Supply solenoid valve failure. Base module analog board failure. Intermittent fault in cables, master controller, or base controller. Damaged slave arm wiring harness. Base module CPU board failure. Air in hydraulic lines. Low hydraulic fluid level (possibly intermittent). High HPU demand (steady or intermittent). Partially blocked, pinched, or kinked supply or control hoses. Intermittent electrical power to HPU, master controller, or base controller. Check cable/connectors for continuity and shorts. Check connections. Restore electrical power. Check cables and connectors for continuity. Determine and repair cause. Replace with new fuse (base controller fuses are autoresetting and non-replaceable). (see Table 2 on page 56) Replace solenoid valve. Restore electrical power to HPU. Adjust or repair HPU. Reservoir low. Add hydraulic fluid. Filters clogged. Clean or replace. Clear, reposition, or protect hoses to ensure free flow. Reduce load. Use shoulder joint to lift heavy loads. Replace/repair solenoid valve. Replace board. Substitute components. Replace wiring harness. Replace board. Bleed hydraulic system. Add hydraulic fluid. Increase HPU fluid capacity. Reduce or stage HPU demand, or increase HPU capacity. Clear, reposition, or protect hoses to ensure free flow. Check power supply, cables, and connectors Troubleshooting Tables Page 57

58 Troubleshooting Entire Slave Arm Symptoms (cont.) Symptom Possible Cause Remedy Entire slave arm is sluggish. Low hydraulic pressure/flow. Partially blocked, pinched, or kinked supply or control hoses. Excessive demand on HPU Control or supply hoses not sized for distance from manifold. Hydraulic fluid dirty, contaminated or incorrect type or viscosity, temperature too high or too low to maintain viscosity. Load at or near slave arm capacity. Severe hydraulic leak. Adjust or repair HPU. Fluid level low. Add hydraulic fluid. Filters clogged. Clean or replace. Clear, reposition, or protect hoses to ensure free flow. Turn off other hydraulic equipment, reduce or stage HPU demand, or increase HPU capacity. Increase hose diameter to provide adequate pressure and flow to slave arm. Replace fluid if dirty, contaminated, or incorrect type or viscosity. Install heater or cooler to keep viscosity within specification. Reduce load. Use shoulder joint to lift heavy loads. Repair leak source. 2.5 Slave Arm Joint Symptoms Use Table 4 to troubleshoot problems that affect one or more joints. If all joints are affected, see Table 3 on page 57. See Diagnosing Master Arm Joint Problems on page 62 for information on determining whether a slave arm joint symptom is actually being caused by the master arm. Table 4 Slave Arm Joint Symptoms Symptom Possible Cause Remedy Joint leaks hydraulic fluid. One or more joints are hard over. Actuator/hose leak (from any slave arm actuator). Master arm potentiometer or master controller board problem Servo valve failure. Actuator potentiometer failure. Actuator controller board failure Faulty actuator seal or component. Replace actuator seals. Tighten or replace hose. (see Table 2 on page 56) Replace servo valve. Replace potentiometer. Replace board. Repair or replace actuator seal or component. Page 58 Troubleshooting Tables

59 Troubleshooting Slave Arm Joint Symptoms (cont.) Symptom Possible Cause Remedy One joint is unresponsive. One joint is erratic. Master arm potentiometer or master controller board failure. Servo valve failure. Joint potentiometer failure. Actuator controller board failure. Incorrect actuator controller board address. Master arm joint or master controller board failure. Servo valve failure. Joint potentiometer failure. Actuator controller board failure. Incorrect actuator controller board address. (see Table 2 on page 56 and Diagnosing Master Arm Joint Problems section on page 62) Replace servo valve. Replace potentiometer. Replace board. Set correct address. (see Table 2 on page 56) Replace servo valve. Replace potentiometer. Replace board. Set correct address. One joint is sluggish. Servo valve failure. Replace servo valve. Master arm joint or master processor (see Table 2 on page 56) PCB failure Multiple joints are unresponsive. Azimuth, shoulder, or elbow sags or moves freely when hydraulics are off. A joint moves when there is no command to move. Load at or near joint s capacity near limit. Control hose clogged, pinched, kinked, or leaking. Partial failure of actuator seal or component. Stuck or faulty relief valve. (Wrist only) Incorrect wrist motor preload. (Wrist only) Excessive return/drain pressure. Master processor PCB failure. Lock valve failure. Actuator controller board failure. Master arm potentiometer or master processor PCB failure. Servo valve failure. Slave arm joint potentiometer failure. Incorrect actuator controller board address. Reduce load. Use shoulder for heavy loads. Clear, reposition, protect, or replace hose to ensure full flow. Repair or replace seal or component. Repair or replace relief valve. Service wrist joint and set correct motor preload. Clear return line. Check for internal leak in wrist. Adjust return manifold. Replace board. Replace lock valve. Replace board. (see Master Arm Symptoms section on page 55) Replace servo valve. Replace potentiometer. Set correct address (see Special Service and Configuration of the Maintenance and Service chapter Troubleshooting Tables Page 59

60 Troubleshooting Slave Arm Joint Symptoms (cont.) Symptom Possible Cause Remedy Single joint/actuator sagging or drifting. Faulty actuator seal or component. Faulty relief valve. Hydraulic leak. Extreme load on linear actuator or unbalanced load on roll actuator. 3 System Fault & Error Diagnosis 3.1 Control System Orientation Repair or replace actuator seal or component. Repair or replace relief valve. Repair leak. Reduce or balance load. Sagging linear actuators or drifting roll joints are normal with extreme or unbalanced loads. The control of each slave arm function (except the wrist and jaw) utilizes a closed loop, in which control software compares position feedback from each slave arm joint with operator inputs to the master controller and directs hydraulic power to the slave arm as needed to achieve correspondence. Control functions are diagrammed in Figure 1 on page 61. Standard Conan control telemetry is bi-directional and uses an RS-485 serial interface. All slave arm control functions are connected on a common bus. Operator inputs to the master controller are generated by moving master arm joints, pressing the master arm freeze button (to freeze the slave arm in its current position), and squeezing the master arm jaw bands or pressing the auxiliary jaw switch (to operate the jaw functions). Each physical action is translated into a varying analog voltage by the potentiometer in each joint of the master arm (or by switches for the jaw function). An A-D (analog to digital) converter in the master controller converts the analog data into a digital value (or command ). Then, a digital address for the corresponding slave arm joint is added to each command and all commands of a given instant are grouped into a packet. This packet is sent to the base controller and distributed to all the actuator controller boards. Each board is configured to accept commands with its address and to disregard all others. Simultaneously with the creation and distribution of digital command values, potentiometers in each slave arm joint are translating physical positions into varying analog voltages. An analogto-digital converter on each actuator controller board converts each joint s analog data into a digital value. The actuator controller board then compares the joint's position data with the command position data sent by the master controller. If the data are the same, no slave arm joint movement results. If the data are not the same, the actuator controller board applies a voltage to that joint s servo valve, causing the servo valve to release fluid to the appropriate port of its hydraulic actuator. The resulting actuator movement drives the slave arm joint towards the commanded position. When the joint feedback data corresponds with the position data commanded by the master controller the servo is closed and slave arm stops moving. The wrist and jaw do not have a potentiometer to provide position feedback. For the jaw, master controller commands can only move the jaw in a specific direction (toggle open or closed), move Page 60 System Fault & Error Diagnosis

61 Troubleshooting the jaw as long as a jaw band is squeezed, or the auxiliary jaw switch is pressed (position mode), or switch the jaw to a software initiated function (clamp mode). Directing the jaw to a specific position is only possible with visual guidance. Control of the wrist is limited to direction of rotation and speed of rotation. Diagnostic Feedback Data Master arm and slave arm digital position data are also provided to diagnostic menus within the master controller. This information can be displayed on the master controller screen for evaluating master controller and slave arm problems. Electrical Power Source Analog master arm joint position data Digitized slave arm command data Master Arm Electrical power Master Controller Position data for diagnostics Electrical power Junction Box Digitized slave arm command data Digitized slave arm position data Electrical power Digitized slave arm position data Slave Controller Current to control valve Hydraulic Supply Solenoid Valve Digitized slave arm command data & electrical power Actuator Controller Board Actuator Controller Board Current to control valve Current to control valve Analog slave arm joint position data Servo Valve Slave Arm Hydraulic Actuator Hydraulic fluid Electrical power Servo Valve Hydraulic fluid Slave Arm Hydraulic Actuator Open-Loop Control (jaw) Slave Arm Joint Potentiometer Closed-Loop Control (azimuth, shoulder, elbow, wrist yaw, wrist pitch & wrist roll) Figure 1 Control system System Fault & Error Diagnosis Page 61

62 Troubleshooting 3.2 Using the DIAGNOSTICS Menus Access path: MAIN/DIAGNOSE Security level: 0 (zero) or higher DIAGNOSTICS LOCK > MASTER 2> SLAVE 3> SHOW ERRORS EXIT < Figure 2 DIAGNOSTICS menu The DIAGNOSTICS menu (Figure 2) provides access to menus that display system diagnostic information. The options under this menu can be used to diagnose faults in the slave arm position-sensing potentiometers, master arm, and master controller, and to display, reset, and configure system error checking. To enter the DIAGNOSTICS menu, press the 4> DIAGNOSE key from the MAIN MENU. 3.3 Diagnosing Problems If the master arm or slave arm is not properly responding to operator inputs, proceed to Diagnosing Master Arm Joint Problems section on page 62. If you suspect that the slave arm is not properly positioning itself, or that the correspondence between the master arm and the slave arm is not accurate, proceed to Diagnosing Slave Arm Positioning Failures section on page 63. If you suspect that one or more of the master controller keys, or the master arm freeze button is not working properly, proceed to Diagnosing Master Controller Key & Freeze Button Failures section on page 64. If the slave arm has frozen automatically and an ERR flag is appearing in the top line of the LCD display, proceed to Diagnosing & Resetting System Errors section on page Diagnosing Master Arm Joint Problems Access path: MAIN/DIAGNOSE/MASTER TEST Security level: 0 (zero) or higher Page 62 System Fault & Error Diagnosis

63 Troubleshooting MASTER TEST LOCK Position: Jaw Bands: Azi Sho Elb Pit Yaw Wrs Keys: EXIT < Figure 3 MASTER TEST screen Principal control components in the master arm are the potentiometers measuring joint positions and the jaw band switch. Failure of these components is likely to be exhibited as problem with the corresponding joint on the slave arm. NOTE: Since other system component failures can also affect single slave arm joints, the problem can be isolated by using the stow or deploy command to move the slave arm. If the slave arm joint exhibiting a problem moves properly while following the stow or deploy command, the cause is probably in the corresponding master arm joint. Use the MASTER TEST display to check the data output of each master arm joint for problems or inconsistencies. Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST screen (see Figure 3). The slave arm is automatically locked in this menu, allowing the master arm to be safely moved for diagnostic purposes. The screen displays the values for each joint in the Position: column and the jaw bands in the Jaw Bands: column. A value of zero indicates that the joint is at the approximate midpoint of its range of motion. Positive values indicate movement either up, to the right, or clockwise (when the master arm is viewed from behind); negative numbers indicate movement down, to the left, or counterclockwise. The two jaw band values will jump from a very low (near-zero) value to a very high (1000 or more) value when squeezed. Carefully observe the position values while the master arm is moving and while it is at rest. A highly varying position value for an immobile joint or an unvarying position value for a moving joint indicates a failure in a master arm potentiometer or a master controller printed circuit board. Other inconsistencies in master arm data (for example, a slight movement of a master arm joint causes a large change in position data, or vice versa) indicate a failed master arm joint potentiometer Diagnosing Slave Arm Positioning Failures Access path: MAIN/DIAGNOSE/SLAVE Security level: 0 (zero) or higher System Fault & Error Diagnosis Page 63

64 Troubleshooting SLAVE TEST FRZ Cmd: Fdbk: Diff: Azi: Sho: Elb: Pit: Yaw: Wrs: Jaw: EXIT < Figure 4 SLAVE TEST screen Press the 2> SLAVE key in the DIAGNOSTICS menu to display the SLAVE TEST screen (see Figure 4). The slave arm is frozen when this menu opens. Pressing the master arm freeze button allows the master arm position Cmd (command) data to be read and displayed, allows the master arm to direct the slave arm, and displays position Fdbk (feedback) from the potentiometers in the slave arm actuators. The difference between the position commanded by the master arm and the actual position of the slave arm is shown in the Diff (difference) column of the display. The values in the Cmd: column should change as rapidly as the master arm is moved. (If they do not, you should evaluate the master arm s performance as described in Diagnosing Master Arm Joint Problems on page 62) The values in the Fdbk: column should catch up with the Cmd: values whenever the movement of the master arm is halted. The values in the Diff (difference) column may reach the high hundreds when the master arm is moved quickly, but should drop to single digits (indicating close correspondence between the master and slave arm positioners) whenever the master arm is not being moved. A changing feedback value when the slave arm is frozen indicates a failure of a slave arm potentiometer or actuator control board. If a large difference between the command and feedback values persists (greater than 25 in the Diff column) when the master arm is at rest, the servo offset value for that joint may need adjustment. (Refer to the Maintenance & Service chapter for details.) If the servo offset is properly nulled (and the high Diff values remain) or the offset cannot be nulled, a faulty slave arm position sensor is most likely at fault. The jaw has no position sensor, so no Fdbk or Diff values can be displayed for this function Diagnosing Master Controller Key & Freeze Button Failures Access path: MAIN/DIAGNOSE/MASTER All menus are accessible at security level 0 (zero). Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST screen (see Figure 3 on page 63). For this diagnostic procedure, you will be viewing the binary values (0 or 1) in the Keys: field. Page 64 System Fault & Error Diagnosis

65 Troubleshooting The status of each key and the freeze button is shown at the bottom of the display. Each character on the display corresponds to a key or to the freeze button. If the key or button is operating correctly, the character for that key or button will be 0 when it is not being pressed and 1 when it is pressed. If a failure has occurred, the display will show either 0 or 1 both when the key or button is pressed and when it is not. Use Table 5 to identify the functions in the Keys: field. In this table, the character position column indicates how far from the left the character is. (For example, the eleventh character from the left shows the status of the down key.) Table 5 Keys & Freeze Button Identification Character Position Function (from left) 1 Function key 1 2 Function key 2 3 Function key 3 4 Function key 4 5 Up key (UP) 6 Left key (LF) 7 Left master arm freeze button (functional in dual-arm systems only) 8 Master arm freeze button (in dual-arm systems, for the right master arm only) 9 Function key 5 10 Function key 6 11 Down key (DN) 12 Right key (RT) 13 Function key Diagnosing & Resetting System Errors Access path: MAIN/DIAGNOSE/SHOW ERRORS Security level: 0 (zero) or higher System errors are announced with an ERR flag in the top line of all menus. Press the 3> SHOW ERRORS key in the DIAGNOSTICS menu to access the SHOW ERRORS menu (see Figure 5) and display system error information (left side of screen). Control, continuity, and telemetry errors are identified by joint or function using the following letter code: A = Azimuth S = Shoulder E = Elbow P = Pitch Y = Yaw W = Wrist System Fault & Error Diagnosis Page 65

66 Troubleshooting J = Jaw B = Base module SHOW ERRORS ERR LOCK ERRORS: Clr Errs <5 Telem [A,S,E,P,Y,W,J,B] Timeout Warnings: Update <6 Hydr OFF Hydr On <7 EXIT < Hydr OFF Figure 5 SHOW ERROR menu If no system error exists, or if the Clr Errs <5 (clear errors) key has been pressed, No Errors will appear instead. There are four system error types that may appear in this screen: Control errors indicate that the system is unable to accurately control one or more joints. The Control flag will be followed by one or more letters in brackets indicating the joints with control errors. Control errors may be triggered by conditions within the manipulator control system or by collision, driving the slave arm against an immovable object, or an extreme load. Contin (continuity) errors indicate that a joint potentiometer reported an unexpectedly large position change in a short time. This error may indicate that the sensor has failed, or that an external force, such as a collision or an extreme or immovable load) has pushed the joint away from its commanded position. The Contin flag will be followed by one or more letters in brackets, indicating the joints experiencing continuity errors. Telem (telemetry) errors occur when the master controller loses contact with one or more joint potentiometers. This error may be caused by faulty potentiometer, actuator control board, a faulty connection or cable anywhere between the master controller and the slave arm, or by a failure of other base controller circuitry. The Telem flag will be followed by one or more letters in brackets, indicating the source of the error. Timeout errors occur when the slave arm base controller receives no communications for 500 milliseconds (one-half second) or longer. This error may be caused by a failure of electrical power to the base controller, or by a faulty connection somewhere between the master controller and the base controller. To clear a system error condition, press the Clr Errs <5 key. New or continuing control, continuity, telemetry and timeout errors will cause to ERR flag to be displayed in the top line of the menu but won t automatically generate a new display in the SHOW ERRORS menu. Press the Update <6 key to display any new errors. All except timeout errors may be disabled in the SET ERROR CHECKS menu. See Diagnosing & Resetting System Errors section on page 65 for details. Page 66 System Fault & Error Diagnosis

67 Troubleshooting Some errors may be followed by warnings. The most common warning is that slave arm hydraulics have been disabled (for safety reasons). Slave arm hydraulics may be re-enabled by pressing the Hydr On <7 key. Press the EXIT <8 key to exit the SHOW ERRORS menu Enabling and Disabling System Error Checking Access path: MAIN/SETUP/SET ERR CHECKS All menus are accessible at security level 0 (zero) The SET ERR CHECKS menu allows you to selectively enable and disable monitoring of control, continuity and telemetry errors. (Timeout errors cannot be disabled.) Normally, all system error monitoring should be left enabled so that operational faults will shut down the slave arm and prevent damage to the arm or its surroundings.! Caution Error checking may be disabled when uninterrupted operation of the arm is necessary despite a known fault (such as a faulty potentiometer), to diagnose a fault, or because collisions or extreme loads are likely to cause repeated system error shutdowns. Good judgment is a necessity: error monitoring exists to protect the slave arm and its surroundings from damage. An automatic shutdown because of a system error indicates the slave arm is at risk. In disabling error checking the operator accepts responsibility for increased risk. To enable and disable system error checks, follow these steps: 1. From the MAIN MENU, press the 3> SETUP key. From the SETUP menu press the 4> SET ERR CHECKS key to display the SET ERR CHECKS menu (see Figure 6). SET ERR CHECKS LOCK [01]Contin Change <5 Check:ENA 2> Last Disable all <6 3> Next Enable all <7 4> Save as default EXIT < Figure 6 SET ERR CHECKS menu 2. The system error type and its current status will appear in the upper left of the screen. The three error types that can appear are: [01] Contin (Continuity) [02] Control [03] Telem (Telemetry) System Fault & Error Diagnosis Page 67

68 Troubleshooting The type 04 error, timeout, cannot be disabled and thus does not appear in this menu. See Diagnosing & Resetting System Errors section on page 65 for a detailed description of the four types of system errors. The flag in the Check: field specifies whether or not the selected error check is enabled (ENA) or disabled (DIS). Enabled, an occurrence of the error causes a system error condition and a shutdown of the slave arm hydraulics. Disabled, errors do not result in a shutdown and the system can continue to be operated. (The condition causing the error remains, however, and the operator should anticipate limited or erratic performance of the slave arm.) To view and set the other error types, press 2> Last and 3> Next until the desired error type is displayed. To enable or disable checking for the displayed error type, press the Change <5 key to toggle the Check: flag 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. If you want the changes to error checking to be temporary (lasting for the current session only), exit the SET ERR CHECKS menu by pressing the EXIT <8 key. If you want the changes to be permanent (until changed again), press the 4> Save as default key. Press the EXIT <8 key to exit the SET ERR CHECKS menu. 4 Electrical Component Diagnosis 4.1 Fuses A single-use, replaceable fuse is present in the junction box. The base module is protected by auto resetting, non-replaceable fuses. A blown or tripped fuse in any of these components may be caused by a surge or spike in the supplied power or an internal malfunction. The result is a nonoperational manipulator system until the cause is corrected and the fuse replaced. If the base controller fuse has tripped, operation may resume when it resets. If the cause hasn t been corrected, it will trip again. If a fuse has tripped, first verify that power supplied to the junction box (and base controller, if independently supplied) is stable and within the specified voltage and Her (see Specifications and Installation chapters). Check cables for visible damage. Test cable power conductors for continuity, internal shorts, and shorts to ground. Correct any problems. To rule out a supply surge or spike as the cause, replace any blown fuses and turn on power to the system. If the fuse blows again, look for internal failures. See Master Controller Voltage Test Points section on page 72 for information on diagnosing circuit board problems. 4.2 Wireway Short & Open Circuits Wireways are the transparent tubing and wires that run between the position-sensing potentiometers in the slave arm joints and the base controller. An individual wireway that gets pinched or damaged could produce an intermittent, short, or open circuit to the enclosed wires. The wires are also susceptible to damage or faulty termination at the potentiometer and the controller board within the base controller. Page 68 Electrical Component Diagnosis

69 Troubleshooting The symptoms of an intermittent connection are erratic or jerky operation of the affected joint. A shorted or open connection usually results in an unresponsive or hard-over joint (see Table 4 on page 58). Diagnosis using the SLAVE TEST diagnostic screen would show unchanging or erratic data in the feedback column, similar to the feedback from a faulty potentiometer (also see Diagnosing Slave Arm Positioning Failures section on page 63 and Actuator Controller Board section on page 72). NOTE: Always inspect and test wireway wires and terminations before troubleshooting or replacing a potentiometer or any control board. 4.3 Diagnosing Servo Valve Failures In the most common failure mode, the servo valve opens wide in one direction and remains open. This is called a hard-over condition, because the faulty servo valve drives the corresponding slave arm joint hard to its mechanical limit. The joint remains in this position and does not respond to master controller inputs. A servo valve can also fail by only partially opening, causing the corresponding joint to respond sluggishly to control inputs. If joint travel velocity is faster in one direction than the other, the servo valve offset voltage may require adjustment (see the Maintenance & Service chapter). This condition does not necessarily indicate servo valve failure and most commonly occurs after a servo valve or other control software or hardware has been replaced without resetting the offset voltage. You can conclusively diagnose a faulty servo valve by replacing the suspect valve with a spare, but first eliminate master controller and base controller telemetry errors using the master controller diagnostics menu described in System Fault & Error Diagnosis section on page Diagnosing Solenoid Valve Failure The solenoid valve in the base module controls the slave arm hydraulic supply. This valve can malfunction by failing to open (resulting in an unresponsive slave arm), partially opening (resulting in sluggish slave arm movement), or failing to close (resulting in slave arm movement even when the master controller display says hydraulics are off). To determine if an unresponsive slave arm is being caused by solenoid valve failure, enable slave arm hydraulics and listen for the valve to click as it opens. If this test is inconclusive, disable slave arm hydraulics at the master controller. Open the base module to expose the base controller board, and then enable slave arm hydraulics. If the LED 6 indicator light on the board lights up, current is being sent to the solenoid valve. Listen for the valve to click as it goes on. If it does not, either the solenoid valve or its cartridge may need to be replaced (see Base Module/SCU Board LED Diagnostics section on page 73 for more information). 4.5 Diagnosing Potentiometer Failure For each slave arm or master arm joint except the jaw, the degree of extension or rotation is measured with a potentiometer. A 5VDC reference voltage is applied across the resistor element. Actuator travel moves a wiper along the element and produces a voltage that varies with the wiper position. This analog voltage is converted to a digital value in the master controller or actuator controller board for use by control software Electrical Component Diagnosis Page 69

70 Troubleshooting Potentiometer failures in both the master arm or slave arm typically produce either a hard-over condition in the associated joint or in jerky or erratic joint movement. Potentiometer outputs (after conversion from analog voltages to digital position data) should be checked in the MAS- TER TEST and SLAVE TEST diagnostic screens (access path: MAIN/DIAGNOSE) on the master controller before disassembling or servicing any hardware (see Using the DIAGNOSTICS Menus section on page 62 for additional information about interpreting this data for troubleshooting purposes). Hard-over or unresponsive conditions can result under the following conditions: The wiper is broken or stuck. Potentiometer conductors are open or shorted. Potentiometer signals are prevented from reaching the actuator controller board by an open connection or broken wire between the potentiometer (slave arm) and the actuator controller board (base controller or actuator module). The actuator controller board is not producing the proper reference voltage (5v). Jerky or erratic movement can result from: A wiper contact or ribbon that is worn or contaminated. A wiper that does not move smoothly. An intermittent connection between the potentiometer and the controller board. See the slave arm wiring diagram in the Drawings & Part Lists chapter for information necessary to check potentiometer reference and output voltages. connector for proper voltages. A functional potentiometer should show a varying voltage from the wiper that changes proportionally with movement of the joint. Disconnected from its controller module, a faulty potentiometer will show infinite resistance between any two potentiometer leads (also see Actuator Controller Board section on page 72). Slave arm potentiometers and the complete master arm assembly are not considered to be user serviceable. You can conclusively diagnose a faulty slave arm potentiometer by replacing the suspect unit with a spare. A suspect master arm potentiometer can be checked by either replacing the master arm assembly or the complete master controller unit. NOTE: Newer master controllers (with the curved case) and older controllers fitted with the single PCB upgrade can be reconfigured for testing with Conan systems. See Master Controller Software Selection, in the Service & Maintenance chapter of this manual.! Caution Confirm that a replacement master controller has a compatible operating voltage. Older models use 110 VAC only. Newer models are rated for VAC. 4.6 Master Controller PCB Status LEDs The master controller processor board has seven diagnostic LEDs. Page 70 Electrical Component Diagnosis

71 Troubleshooting NOTE: There are no user-serviceable parts on the master controller processor board. If the board fails to function, replace it with a spare Power Pwr When the master processor is turned on, the Pwr (power) LED will illuminate and the program image will load according to the position of the hex switches. Vref LF and RF LEDs Vref RF and Vref LF, adjacent to master arm connectors P4 and P5, illuminate when the 4VDC reference is present. Failure of either LED to light could indicate a short circuit in the master arm (disconnect the master arm connector to check) or a failure of the A/D converter. 4V Reference voltage LEDs for left and right master arms Pwr, Proc, TX, and RX LEDs Communications Figure 7 Done LED Done The Done LED lights when the program successfully loads. Observing the operation on the LCD while turning on power to the master controller, the LCD will indicate which image is being loaded ( Loading master.001 for example additional LCD text will be dependent on the type of manipulator being operated). Proc The Proc (processor) LED ( heartbeat ) will blink at 1 Hz to indicate the master processor is functioning correctly. If no software image is installed, the LED is continuously lit. If the LED does not illuminate, the board is either damaged or has not been programmed. TX The TX LED will blink each time a packet is sent to the slave controller. RX If a response is received from the slave controller, the RX LED will illuminate. Check all connections between master controller and slave controller, mux/demux configuration, and so on Electrical Component Diagnosis Page 71

72 Troubleshooting 4.7 Master Controller Voltage Test Points The first step in troubleshooting is to ensure that the correct voltages are present at all test points. There are test-points on the master processor board for -16V, +12V, +5V, +3.3V, +2.5V, +1.2V, and ground (Figure 8). The power LED should be illuminated whenever +5V is available to the board from the AC-DC or DC-DC converter. NOTE: There are no user-serviceable parts on the master controller PCB. If the board fails to function, replace it with a spare. Ground 2.5V 1.2V +12V 3.3V 5V -16V Ground Figure 8 Voltage and ground test points 4.8 Base Module & Slave Arm PC Board Diagnosis If you suspect that a printed circuit board has failed, the easiest way to confirm a failure is to replace the suspect board with a spare Actuator Controller Board Each actuator control module on the base controller motherboard board provides the 5V reference voltage to its position-sensing potentiometer and the A-D (analog to digital) conversion of the potentiometer s feedback voltage. If SLAVE TEST feedback data for a joint indicates a problem (see Diagnosing Slave Arm Positioning Failures section on page 63) check the reference voltage (+5V) and feedback voltage (0-5V) at the terminal strip of the appropriate actuator controller board. If the reference and feedback voltages appear normal, the actuator controller board s A-D converter may be at fault. If the reference voltage is OK, but the feedback voltage is erratic or absent, the potentiometer or its wiring may be at fault. If the reference voltage is erratic or absent, the actuator board s voltage regulator may be at fault. Each actuator control module is configured with a specific address for the joint/actuator its servo will control. When the master controller generates a command packet to the slave arm, each individual command is encoded with its unique address. Every actuator controller board receives the complete packet, but accepts only the command encoded with its address. Commands with other address are disregarded. Page 72 Electrical Component Diagnosis

73 Troubleshooting If a replacement board is not configured, or configured with the wrong address, the actuator it controls will not function as intended. Wrong addresses can have two consequences: If the board is configured with an address the control system does not recognize, the board will disregard all master controller movement commands and the joint will remain unresponsive. If the board is configured with the address of a different joint, it will respond to commands for that joint. For example, if the actuator controller board for the shoulder is configured with the azimuth s address, the shoulder will attempt to comply with azimuth movement commands. An incorrect address can be diagnosed using the FREEZE menu (access path: MAIN/OPERATE/ FREEZE). Freeze the malfunctioning joint. If the joint continues to respond to general master arm movements, its address may be incorrect. Careful manipulation of the master arm and observation of slave arm responses may indicate the other joint with which it shares an address. Another approach is to continue freezing joints until it becomes inactive. Instructions for setting actuator board addresses can be found in the Maintenance & Service chapter Base Module Board The base module s LED indicator lights can be used to diagnose some manipulator system communication failures and failure of the solenoid valve that controls slave arm hydraulic supply. See Base Module/SCU Board LED Diagnostics for more information. Two components on the base module board (U4 and U5) contain software programs that must be compatible with software in the master controller. Before you replace a base module board with a spare, verify that these parts on the spare are marked with the same part and revision number as those on the original board. Contact the manufacturer if you need assistance with this verification Base Module/SCU Board LED Diagnostics You can use the diagnostic LEDs on the base module board to diagnose some manipulator system communication problems and failure of the solenoid valve that controls slave arm hydraulic supply. Figure 9 shows the location of each LED on the board. The LEDs function as described in Table 6. Some LEDs are used only if your system uses the RS- 485 communication protocol; others are used only for the RS-232 communication protocol Electrical Component Diagnosis Page 73

74 Troubleshooting Figure 9 Base module LED indicator lights Table 6 Base Module Board LED Indicators LED Protocol State Explanation LED 1 LED 2 LED 3 LED 4 RS-232 RS-232 RS-485 RS-485 On Off On Off On Off On Off Data is being transmitted from the master controller to the base module board. In your system, this light should always be on. No data is being transmitted from the master controller to the base module board. Data is being transmitted from the base module board or an actuator controller board to the master controller. No data is being transmitted from the base module board or an actuator controller board to the master controller. The base module board is receiving data from the master controller. In your system, this light should always be on. The base module board is not receiving data from the master controller. An actuator controller board or the base module board is transmitting data to the master controller. No transmissions are taking place from an actuator controller board or the base module board to the master controller. Page 74 Electrical Component Diagnosis

75 Troubleshooting LED 5 LED 6 LED 7 LED 8 RS-485 N/A On Off 5 Factory Assistance Base Module Board LED Indicators (cont.) LED Protocol State Explanation On Off The base module board is set to receive a data transmission from the master controller. This light should always be on. The base module board is set to send a data transmission to the master controller. The transmitted data could be from the base module board or an actuator controller board. Not in use. Not in use. Current is being sent to the solenoid valve that controls slave arm hydraulic supply (enabling the slave arm hydraulic supply). Current is not being sent to the solenoid valve that controls slave arm hydraulic supply (disabling the slave arm hydraulic supply). To help speed diagnosis and problem resolution, please have the following information available when you contact Customer Service. 1. What are the symptoms of the problem? 2. Are the symptoms intermittent or constant? 3. If the problem is intermittent, under what conditions does it occur? 4. Was the affected part of the manipulator system subjected to excessive loads or adverse conditions (such as vibration, heat, or shock)? 5. Did the problem occur suddenly or gradually? 6. Does the problem appear to affect other functions? 7. What system functions are still operable? 8. Has anyone tried to fix the problem? If so, have actuators and/or actuator control modules been interchanged with those from another Conan slave arm or from spares? 9. What is the system serial number? (You can find the serial number on the slave arm base segment.) If the problem is appears to be electrical or software-related, what is the part number of the master controller? 10. Are there other relevant details? Factory Assistance Page 75

76 Troubleshooting This page not used. Page 76 Factory Assistance

77 Maintenance & Service In This Chapter: 1 Safety First!... page 77 2 Service Guidelines... page 79 3 Maintenance... page 81 4 Important Service Practices & Procedures... page 83 5 Junction Box Service... page 84 6 Master Controller Service & Configuration... page 85 7 Base Module Service... page 93 8 Slave Arm Service... page 96 9 System Configuration... page Instructions for Serviceable Components... page Safety First! These guidelines, warning, and cautions are a reminder of the safety issues present when maintaining or servicing a slave arm or manipulator system. They do not cover every possible safety risk and are not meant to supersede or replace existing vessel/operator safety policies, standards, processes, and practices. Please Note: This slave arm or manipulator system is not an isolated piece of equipment. Be sure to know and use the safety and service guidelines provided in the technical manual for the system or vehicle on which it is used. 1.1 Worksite Safety! WARNING ELECTRICAL, HYDRAULIC, AND MECHANICAL HAZARDS! Before any contact with this equipment: Notify the appropriate personnel of your activities. Be sure you have a safe electrical, hydraulic, and mechanical working environment. Turn off, lock out/tag out, and/or isolate surrounding equipment that could be a safety hazard to you. Observe all safety regulations and procedures in effect at the worksite. Wear personal protective equipment (PPE) appropriate for the task Page 77

78 Maintenance & Service 1.2 Electrical Safety! WARNING SHOCK HAZARD! Lethal voltages can be present in the manipulator system (see the Specification chapter for specific voltages). Before any contact with this equipment, CONFIRM that it is electrically isolated, locked-out and tagged-out as directed by applicable electrical safety regulations and procedures. Wear personal protective equipment (PPE) appropriate for the task. 1.3 Mechanical Safety! WARNING Slave arm components are heavy and can move, drop, shift, or collapse suddenly when hydraulic pressure is removed or relieved. Support the slave arm at the elbow and jaw when relieving hydraulic pressure or opening any hydraulic connection. Wear personal protective equipment (PPE) appropriate for the task. 1.4 Hydraulic Safety! WARNING Slave arm components are heavy and can move, drop, shift, or collapse when hydraulic pressure is removed or relieved. Support the slave arm at the elbow and jaw when relieving hydraulic pressure or opening any hydraulic connection. Wear personal protective equipment (PPE) appropriate for the task.! WARNING Failure to follow safety procedures for working with high-pressure hydraulic equipment can result in serious injury or death. ALWAYS assume that hydraulic equipment is energized until you have CON- FIRMED that it is isolated, locked out, and tagged out as directed by applicable hydraulic safety regulations and procedures, that all pressure gauges indicate zero pressure, and that all stored and residual pressures have been isolated or relieved. Common causes of serious injury and death from high-pressure hydraulic equipment include: Injection of pressurized hydraulic fluid into the body. Blunt force trauma to the body from flailing, pressurized hoses and forcefully ejected fittings. Bodily contact with hot hydraulic fluids and sprays or ignited fluids, sprays, or mists. Falls caused by slipping on spilled fluids. Page 78 Safety First!

79 Maintenance & Service To prevent injury or death while working with high-pressure hydraulic equipment, always follow all applicable hydraulic safety regulations and procedures. The instructions listed below provide general guidelines and are not meant to replace or modify existing safety regulations and procedures. Always lock out and tag out hydraulic equipment before it is serviced so that it cannot be accidentally energized. Provide support for equipment and components that can move, drop, shift, or collapse when hydraulic pressure is removed or relieved. Always wear safety glasses and other required personal protective equipment (PPE). Confirm that equipment pressure gauges indicate zero pressure. Before loosening any fittings, isolate or relieve any stored or residual pressure that remains in components even when the hydraulic system is de-energized. Never use any part of your hand or body to check for hydraulic fluid leaks, even if you are wearing personal protective equipment. High-pressure hydraulic fluid injects easily into any body part, and an injection wound, regardless of size, must be evaluated immediately by a physician as a surgical emergency. Service hydraulic equipment away from sparks or open flame. Immediately clean up spilled hydraulic fluid from floors or other surfaces. Before returning the equipment to service, tighten all fittings and connections as specified by the equipment manufacturer. Move all personnel away from serviced hydraulic equipment before pressurizing it and testing for safe operation. Only qualified and authorized personnel should perform hydraulic work on this equipment. A qualified person is one who has the required skills and knowledge to perform hydraulic work safely, even under adverse environmental conditions, and who knows the hazards associated with hydraulic work and the methods for reducing the risk of accidents from those hazards. 1.5 Deck Testing! WARNING Use extreme caution when testing a slave arm on deck: Move all personnel outside the slave arm's range of motion when hydraulic pressure is applied and functions are tested. Direct the slave arm to point away from personnel and critical or sensitive areas while testing jaw functions. 2 Service Guidelines 2.1 Service Assumption Instructions in this manual assume that service personnel are familiar with the general operating principles, safety guidelines, and service practices associated with the types of equipment described in this manual Service Guidelines Page 79

80 Maintenance & Service 2.2 Guidelines ESD-Sensitive Devices! Caution Electrostatic discharge (ESD) can permanently damage sensitive electrical components like printed circuit boards (PCBs), integrated circuits (ICs), and other ESD-sensitive components. To prevent damage, always handle these components according to ESD prevention guidelines. Microelectronic devices are very susceptible to ESD. Careless handling may cause immediate component failure. It may also make a component more vulnerable to future damage, which can be difficult to detect and often results in faulty performance and intermittent failures. When you handle PCBs, ICs, and other ESD-sensitive components, follow the basic ESD prevention guidelines below. Prepare an ESD workstation by grounding all items in the work area (work surfaces, people, equipment, etc.) to the same electrical ground point (called the common point ground). Keep the work area free of nonessential insulators (such as plastic cups, bags, and envelopes). If possible, disconnect all power sources, signal sources, and loads connected to the component before you begin maintenance or service. Always ground yourself before you touch ESD-sensitive equipment. Discharge any static electricity by touching ground on the workstation each time that you approach and sit at the workbench. Ground all tools that may come into contact with the ESD-sensitive equipment. Before you handle PCBs, ICs, and other ESD-sensitive components, attach a grounding wrist strap and confirm that the strap is connected to the grounding pad. Handle PCBs by the base or edges; always avoid contact with pins. Do not unnecessarily pick up, hold, or carry ESD-sensitive devices that are not in shielded packaging. Always store and seal ESD-sensitive components in the anti-static packaging in which they were shipped, or in equivalent storage material Torque Specifications See the Maintenance & Service section, service or work instructions, and/or drawings in the Drawings & Part Lists sections for torque specifications. When a torque specification differs between manual text and engineering drawing, use the specification on the drawing. When no torque specification is present, use prevailing industry standards and common sense. Page 80 Service Guidelines

81 Maintenance & Service Nylock ( Patch ) Fasteners Under ideal conditions, Nylock ( patch ) fasteners can be reused up to 5 times. Because tracking their use is difficult and operating conditions are always less than ideal, Nylock fasteners should be replaced whenever they are removed.! Caution DO NOT replace Nylock fasteners with standard fasteners. Standard fasteners may loosen and cause component failure or loss Fastener Lubrication Stainless steel to stainless steel or titanium: Apply nickel or molybdenum-based anti-seize compound (Bostik Never-Seez, or equivalent) when assembling stainless steel fasteners or threading them into stainless steel or titanium components (including nylon-patch/nylock fasteners). Stainless steel to aluminum: Apply waterproof grease (Aqua Lube, or equivalent) when assembling stainless steel fasteners to aluminum IF they are exposed to seawater. Do NOT use Aqua Lube on fasteners penetrating hydraulic or compensated areas, unless directed otherwise in a service instruction or engineering drawing O-rings Inspect o-rings for damage during routine maintenance. Replace o-rings that are broken, damaged, or hardened. Lubricate o-rings prior to installation (Dow Corning 55 O-ring lube, petroleum jelly, or equivalent) Connection Identification Before disconnecting any hose, cable, or conductor, make sure the item and its matching fitting, connector, or terminal are adequately labeled for correct re-assembly Drawings & Part Lists Engineering drawings and part lists are supplied to assist in servicing and maintaining the equipment. They can be a valuable source for determining torque values and the part numbers for serviceable components. Most are located in the Drawings & Part Lists section. 3 Maintenance 3.1 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 Maintenance Page 81

82 Maintenance & Service All Models Inspect slave arm for: 1. Damage: If the slave arm has had severe service or a collision, inspect slave arm components, inspect all joints, actuator shaft pivot pins, and joint 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 inspect for damage. 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. 3.2 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. Page 82 Maintenance

83 Maintenance & Service Table 1 contains a minimum schedule for performing regular long-term maintenance. Table 1 Recommended Long Term Maintenance Schedule Schedule Period Every 100 operating hours Every 2000 operating hours Every 2000 operating hours or every 3 years (whichever comes first) 4 Important Service Practices & Procedures Key practices and procedures for successful manipulator system service: 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). NOTE: 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, EXCEPT: when threads are exposed to the hydraulic system. when 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. 4.1 Protecting PC Boards Maintenance Task Tighten all external slave arm fasteners to the specified torque. Check a sample of hydraulic fluid for water and particulates. Replace if contaminated. Apply anti-corrosion paint wherever an anodized surface is damaged and aluminum is exposed. Submersible: Recoat pivot pins and pivot pin bores with silicone grease such as DC-5. Replace worn or damaged actuator pins and bushings. Replace all actuator o-rings and seals. Lubricate with Dow Corning DC-4. Clean all o-ring grooves and surfaces.! Caution Electrostatic discharge (ESD) can permanently damage sensitive electrical components like printed circuit boards (PCBs), integrated circuits (ICs), and other ESD-sensitive components. To prevent damage, always handle these components according to ESD prevention guidelines. Microelectronic devices are very susceptible to ESD. Careless handling may cause immediate component failure. It may also make a component more vulnerable to future damage, which can be difficult to detect and often results in faulty performance and intermittent failures. When you Important Service Practices & Procedures Page 83

84 Maintenance & Service handle PCBs, ICs, and other ESD-sensitive components, follow the basic ESD prevention guidelines below. Prepare an ESD workstation by grounding all items in the work area (work surfaces, people, equipment, etc.) to the same electrical ground point (called the common point ground). Keep the work area free of nonessential insulators (such as plastic cups, bags, and envelopes). If possible, disconnect all power sources, signal sources, and loads connected to the component before you begin maintenance or service. Always ground yourself before you touch ESD-sensitive equipment. Discharge any static electricity by touching ground on the workstation each time that you approach and sit at the workbench. Ground all tools that may come into contact with the ESD-sensitive equipment. Before you handle PCBs, ICs, and other ESD-sensitive components, attach a grounding wrist strap and confirm that the strap is connected to the grounding pad. Handle PCBs by the base or edges; always avoid contact with pins. Do not unnecessarily pick up, hold, or carry ESD-sensitive devices that are not in shielded packaging. Always store and seal ESD-sensitive components in the anti-static packaging in which they were shipped, or in equivalent storage material. 4.2 Startup After Maintenance or Service 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 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. 5 Junction Box Service This section contains special maintenance and service procedures not covered in the Work Instructions. For additional details, refer to the junction box drawing and part list in the Drawings & Part Lists chapter. Fuse Replacement Littlefuse T 6.3AL 250V (SRS P/N ) The fuse is located under the fuse symbol, between the power switch and the power-in socket. Use the tab on the fuse cover to pry out the fuse for replacement or inspection. Page 84 Junction Box Service

85 6 Master Controller Service & Configuration Maintenance & Service This section contains special maintenance and service procedures not covered in the Work Instructions. For additional details, refer to master controller, in the Drawings & Part Lists chapter. This section contains special maintenance, service, and configuration procedures not covered in the Work Instructions. PCB Features and Functions... page 85 Accessing Internal Components... page 87 Adjusting the LCD Screen Viewing Angle... page 87 Master Controller Software Selection... page 88 Incompatibility Alert Screens... page PCB Features and Functions The master processor board performs the following functions: Communicates with the slave controller. Reads master arm potentiometer positions for use by the control algorithm. Detects front panel switch inputs for use by the control algorithm. Displays operation information on the LCD display. Contains the program information for each system. Stores system parameters in non-volatile memory for use by the control algorithm. Illuminates status LED's to assist troubleshooting and diagnostics. The master processor board operates on VAC (standard) or 18-36VDC (optional). Power is supplied by either the supplied AC junction box, or by a user installed CPC connector mounted near the operating station. A 4 pin power connector (P7) plugs into the board. An adjacent 4 pin plug (P2) connects to a SPST on/off switch mounted in the controller faceplate. An in-line fuse (F1) provides over-current protection to the PCB. Communication between the master processor board and the slave controller board is via RS- 232 or RS-485. A 9 pin connector is plugged into the appropriate receptacle (Either P1A or P1B) depending on system requirements. An auxiliary RS-232 connection is also present on both connectors for applications that require an additional serial port connection. (The auxiliary RS-232 is not used for connection to the slave controller board) A telemetry daughter (inductive isolation) board is plugged into connectors J1 and J2. The purpose of the telemetry board is to provide electrical isolation and protection from over-voltage or voltage spikes between the telemetry conductors and the PCB electronics. Two hex switches marked Mode H (high bit) and Mode L (low bit)' are used to select which program to load during startup. This allows the PCB to be pre-loaded with all standard product program software and allows the user to reconfigure the PCB for other systems without the need for additional ICs or programming. A table provides the switch position options. The master arm connects to 12-pin circular connector P4 (Standard). In a dual arm system, the additional master arm connects to P5. The master processor board sends a 4VDC reference volt Master Controller Service & Configuration Page 85

86 Maintenance & Service age to each of the potentiometers in the master arm. An analog to digital converter interprets the voltage as a numerical value that is used by the control algorithm. The USB port (J6) can be used in place of the auxiliary RS-232 connector for applications that require serial port connection. (The USB port cannot be used for connection to the slave controller board) The 20 pin DIP connector (J7) can be used to run legacy LCD displays that have a ribbon cable interconnection. Current displays connect via spring loaded pins onto contacts (J4) on the back side of the PCB. Two additional SIP receptacles marked LCD backlight are also used with legacy LCD displays and provide ~80VAC to power the backlight via two wires coming from the legacy display. Two spring loaded pins are used on current displays Adjusting the LCD A potentiometer (VR1) is used to set the optimal contrast between the black text and the bluegray background at the desired viewing angle. Once the potentiometer is adjusted, it will automatically compensate for changes in temperature so the display remains viewable throughout the operating temperature range. See Adjusting the LCD Screen Viewing Angle section on page Changing the Software Image Changing software image (Titan to Conan, Orion to Titan, etc.) is accomplished by selecting the appropriate hex switch settings on the PCB and then cycling power to the master processor. See Selecting Pre-Loaded Software Images section on page 88. The master processor can also be run from a legacy EPROM installed in the 28 pin DIP socket (U11). This connector was installed to ensure the master processor board is fully backwards compatible with existing master controllers. See Installing an EPROM section on page 89. The Secure Digital card slot (J5) allows new software, when available, to be loaded into memory on the PCB. See Installing Images from an SD Card section on page 89. For more information on changing the software image, see Master Controller Software Selection section on page Troubleshooting the PCB Communications The master controller PCB has seven LEDS to indicate the status of PCB power, master arm reference voltage, image loading, processor function, and communication with the slave controller (TX and RX). See the Troubleshooting chapter for details. Power There are test-points on the master controller PCB for -16V, +12V, +5V, +3.3V, +2.5V, +1.2V, and ground. See the Troubleshooting chapter for details. NOTE: There are no user-serviceable parts on the master controller PCB. If the board fails to function, replace it with a spare. Page 86 Master Controller Service & Configuration

87 Maintenance & Service 6.2 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, right). 3. Lift the faceplate assembly out of the enclosure. Turn it over to expose the face of the PC board. Take care to immobilize the master arm(s) 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. 6.3 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:! WARNING Remove screws (4X) SHOCK HAZARD! Be aware that potentially lethal voltages are present while adjusting the LCD viewing angle potentiometer. Always observe appropriate safety procedures. 1. While keeping power supplied to the master controller, open the assembly as described in Removing the Faceplate section on page Identify the LCD adjustment potentiometer (labeled VR1 on the PC board), located at the bottom right of the board (Figure 1). Figure 1 LCD Adjustment potentiometer 3. Using a small flat blade screwdriver, adjust this potentiometer for the desired viewing angle. 4. Close the master controller as described in Installing the Faceplate section on page Master Controller Service & Configuration Page 87

88 Maintenance & Service 6.4 Master Controller Software Selection The master processor board is shipped with several pre-loaded software images, allowing the master controller to be used with different Schilling Robotics slave arms. The software is userselectable by configuring two Mode switches located on the main PC board. Software can also be loaded from: an existing EPROM using the 28-pin connector on the PC board a Secure Digital card using slot (J5). The three methods are described in the following sections. NOTE: The jaw mode POS (position) option is lost when the software image is changed. To re-enable it after a software change, see section 6.4, Master Controller Software Selection, on page Preparation 1. Turn off the master controller and disconnect the whip from its power source. 2. Open the master controller as described in Removing the Faceplate on page 87.! Caution PC board components can be damaged by static electricity. Wear a grounded anti-static wrist band handling PC boards or chips Selecting Pre-Loaded Software Images The two hexadecimal Mode switches (H and L) are located at the top center of the processor board (Figure 3, left). The available software is listed in a table at the right of Figure 3, and the switch settings for the H and L switches are shown as well. Figure 3 H L Description 0 0 Titan 4, Titan 3, Titan Orion 7P 0 2 Conan 7P 0 3 Dual T3 0 4 Dual Orion 0 5 Dual Conan 0 6 T3 Spaceball FLX 0 7 T3 Robotics 0 8 Titan 4, Enhanced 0 9 Titan 4, Dual F F EPROM F 0 SD Card Read 0 F SD Card Write 4 0 Buzzer Test Hexadecimal switch orientation and software values 1. Using a small, flat head screwdriver, adjust each switch so the H and L values match those shown for the software you want to use. 2. Close the master controller as described in Installing the Faceplate on page 87 and reconnect the whip. Page 88 Master Controller Service & Configuration

89 Maintenance & Service 3. Power up the master controller and view the LCD display. If a compatibility issue occurs between the new system parameters and the old software image, a message will appear on the screen asking you to Ignore, Overwrite, or Update the version number only. If in doubt, overwrite; there are no irreparable consequences due to overwriting the image. (Overwriting loads the factory default values for system parameters, gains, limits, and stow positions.) Installing an EPROM To install an EPROM chip on the master controller processor board, perform the following steps (also refer to the master controller drawing in the Drawings & Part Lists chapter). The 28-pin connector is located at the lower left corner of the processor board (see Figure 4). 1. Confirm that all pins on the EPROM are aligned and straight. Orient the EPROM with its notch towards the edge of the PCB and press it gently into the socket until the locking clips snap into place. Figure 4! EPROM 28-pin connector Caution EPROM notch to this end Installing the chip backwards will damage system electronic assemblies. Locate the notch on the chip to the edge of master processor board. 2. Set each hexadecimal switch to F (see Figure 3 on page 88 for an example of the hexadecimal switches and the EPROM switch settings). 3. Close the master controller as described in Installing the Faceplate on page Power on the master controller to load the new software. NOTE: You can also load the EPROM image into the master processor board memory by moving the hex switch to F 0, and then switch to 0 F while the processor board is powered. The EPROM can then be removed from the board and the EPROM image will be available for loading by selecting the hex switch position 0 F. A different EPROM can be installed and the image loaded by selecting hex switch position F F, however if you overwrite the image by selecting F 0 then 0 F, the image from the first EPROM is lost Installing Images from an SD Card The Secure Digital card slot (J5) allows new software, when available, to be loaded into memory on the PCB. Binary images containing the manipulator programs can be loaded onto the SD cards root directory. When the card in inserted into the slot, changing the hex switch settings Master Controller Service & Configuration Page 89

90 Maintenance & Service from F 0 then to 0 F while the processor is running loads the images into memory. The program can then be loaded by selecting the appropriate hex switch positions. After loading into memory, the SD card can be removed Re-enabling POS (Position) Jaw Control The jaw mode POS (position) option is lost when the master controller software image is changed by: adjusting the PCB mode switches. replacing the EPROM (if used). loading a new image from an SD card. To re-enable position jaw control when one of these events has occurred, edit the MEMORY menu as described below. 1. Reconnect the master controller to the manipulator system. Do not provide hydraulic power to the slave controller. 2. Turn on electrical power at the junction box and/or master controller, and the base module. 3. Cycle through the startup menus to the MAIN MENU. Press the 3>SETUP key. Press the SECURITY <6 menu and set the security level to 1 or higher. 4. Press the MEMORY <5 key to enter the MEMORY menu. Use the RT and LF control keys to move the cursor (^) along the address line. Using the UP and DN control keys to select numerals and letters, change the address line from [0:0000-FFFF] to [5:00F0-0000] (FFFF changes to 0000 automatically) as shown in Figure 5. MEMORY EDIT LOCK > Edit:OFF 2> View:OFF LF & RT keys control the cursor. UP & DN keys control the numeral. [5:00F0-0000] ^ EXIT < <CAUTION>-CONSULT MANUAL BEFORE USING THIS MENU Figure 5 MEMORY EDIT menu with new address 5. Press the 1> Edit key to display 1> Edit:0000 (+0000). Use the control keys to change the fourth zero (0) to 1, and the line reads 1> Edit: 0001 (+0001). 6. Press the 1> Edit key to turn the edit function to OFF. The address line now reflects your editing as shown in Figure 6. Page 90 Master Controller Service & Configuration

91 Maintenance & Service MEMORY EDIT LOCK > Edit:OFF 2> View:OFF LF & RT keys control the cursor. UP & DN keys control the numeral. [5:00F0-0001] ^ EXIT < <CAUTION>-CONSULT MANUAL BEFORE USING THIS MENU Figure 6 Address line after editing 7. Press the EXIT <8 key to return to the SETUP menu. Exit the SETUP menu and shut down the system. The editing changes will not take affect until the master controller has been turned off and restarted. 6.5 Incompatibility Alert Screens Incompatibility alert screens may occur during startup when (1) a master controller is used as-is to operate a slave arm other than the one it was supplied with, or (2) when the master controller software configuration has been changed to operate a slave arm other than the one it was supplied with, and (3) the software encounters a setting, ID code, or other condition that differs from what it is expecting. This difference may range from unimportant to critical. The alert screen typically offers an option and the user may have other options for proceeding. These are described in the following sections. No matter which option is chosen, proceed with extreme caution during the startup and operation of the slave arm.! Caution When an incompatibility alert screen appears, use extreme caution if you continue operation. Be prepared to quickly disable hydraulics if the slave arm behaves erratically. NOTE: A Fatal Telemetry Error message at startup is NOT an incompatibility alert screen. It indicates a communications failure caused by component or connection problems, or that the master controller and slave controller/slave arm are completely different models (that is, a master controller configured with Conan software has been connected to an Orion slave controller/slave arm, etc.) Incompatible User-Configurable Settings The user-configurable settings (such as joint travel limits, stow sequence, etc.) remain in nonvolatile memory even after the master controller has been configured with new software. If they are not compatible with the software currently loaded, the alert screen in Figure 7 will be displayed. You have three options Master Controller Service & Configuration Page 91

92 Maintenance & Service a. Press the 4> Overwrite EEPROM button to install the default system non-volatile user-settings. b. Press 3> Ignore to operate the slave arm with the current user-settings. Use extreme caution when testing the slave arm for safe and successful operation. Note that the alert screen will reappear each time the master controller is turned on. c. Press the <7 Update EEPROM Version # only button to operate the slave arm with the current user-settings on a continuing basis the version number is updated to prevent the alert screen from appearing each time the master controller is turned on. Use this option only if you have successfully tried option b. SCHILLING ROBOTICS, INC XXXXX MANIPULATOR SYSTEM Non-volatile memory (EEPROM) is not compatible with this ROM version. Danger exists if the system is operated without the correct memory value. 3> Ignore Update EEPROM <7 Version # only 4> Overwrite EEPROM Figure 7 Non-volatile memory (EEPROM)... warning screen Incompatible Slave Arms/Controllers If the master controller is configured for a standard manipulator system and is connected to an incompatible or custom slave arm and slave controller, you may see the alert screen shown in Figure 8. SCHILLING ROBOTICS, LLC XXXXX MANIPULATOR SYSTEM The Master Controller software is not compatible with the slave arm. Further operation may risk damage to equipment. Select [Yes] only if you would like to proceed anyway. 4> Yes Figure 8 Incompatibility screen You have three options. a. Recommended: Do not use the master controller with this slave arm. Connect a compatible model instead. Page 92 Master Controller Service & Configuration

93 Maintenance & Service b. Operate the slave arm with the software on its original EPROM: if the original EPROM ( PROM ) used with the slave arm is available, install it in the master controller as described in section 6.4.3, Installing an EPROM, on page 89. c. Pressing the 4> Yes key updates the user-configurable memory with the factory default settings for the currently loaded software. Use extreme caution when testing the slave arm for safe and successful operation Incompatible Systems A master controller configured for use with one type of manipulator system (Titan, Conan, or Orion) cannot communicate with a slave arm of a different type system, and if connected, will display a Fatal Telemetry Error screen at startup. 7 Base Module Service This section contains special maintenance and service procedures not covered in the Work Instructions. For additional details, refer to the drawing and part list in the Drawings & Part Lists chapter. 7.1 Fuse Replacement Base module circuits are protected by self-resetting, non-replaceable fuses. 7.2 Servicing the Hydraulic Filter The base module contains a tubular, mesh-screen hydraulic filter which can be removed for cleaning. The most common symptom of a clogged filter is sluggish operation of all slave arm functions despite adequate hydraulic pressure and flow from the HPU. Refer to drawing and the parts list for for this procedure.! WARNING Bleed off all pressure to all slave arm hydraulic lines before continuing. Hydraulic fluid is under high pressure and may cause injury. 1. Disable electrical power and hydraulic power to the base controller. 2. Remove the hydraulic pressure hose from the -4 hydraulic fitting (34). 3. Remove the reducer fitting (35) from the manifold block (1). Pull the filter from the manifold block. 4. Remove the filter (11) from the filter base (12). You may install a new filter or replace the original filter after cleaning it with ultrasound. Remove the two o-rings (14 & 15) from the filter base. 5. Lubricate two new o-rings with o-ring lube and install onto the filter base. Insert the filter into the manifold block. 6. Install the reducer fitting, with the -4 hydraulic fitting, onto the manifold block. 7. Install the hydraulic pressure hose. 7.3 Accessing Internal Base Module Components The base module must be opened to perform the following procedures: Base Module Service Page 93

94 Maintenance & Service Replacing the Jaw/Wrist Actuator Controller PCB... page 94 Servicing the Jaw or Wrist Servo Valve... page 95 Removing the Jaw Bypass Valve... page Opening the Base Module Refer to drawing and the parts list for for this procedure. To access internal base controller components, follow the procedure below: 1. Disable hydraulic power to the manipulator system. 2. Disable power by turning off the power switch on the junction box or disconnecting local power to the base module. 3. Isolate the compensation system and drain the compensation fluid from the base module. 4. Remove the four HHCS (13) and washers (17) and separate the power supply cover (4) and manifold cover (power supply atmospheric container) (2) from the base module case. Disconnect the wiring harness coming from the power supply (21).! Caution When you handle the PC boards or other electronic components, wear an anti-static wrist band attached to earth ground or a large metal object Closing the Base Module To reinstall the power supply cover (4) and manifold cover (2) follow the procedure below: 1. Check that all wire harnesses are connected and that no wires will be pinched when the covers are reinstalled. 2. Lubricate two new o-rings (26) with o-ring lube and install onto the power supply cover and the manifold block. 3. As you lower the manifold cover into place, connect the wiring harness to the power supply. 4. Install the power supply cover. Install the four HHCS and washers. Torque to 9 ft/lb (12Nm). 7.4 Replacing the Jaw/Wrist Actuator Controller PCB Refer to drawing and the parts list for for this procedure. 1. Open the base module as described in Opening the Base Module section on page At the controller board (3), remove the wire harness coming from the servo valve (7). Remove the five wires going to J4 from the base module board (36). 3. Remove the three SHCS (37) and washers (38) that hold the actuator control board in place.! Caution When any actuator controller board is replaced, the new board s DIP switch must be set with the address of the actuator it will control. If the controller board has the wrong address, the actuator may not respond to commands or may respond to commands intended for a different actuator. 4. Set the DIP switches on the replacement controller board as outlined below: Page 94 Base Module Service

95 Maintenance & Service The DIP switch unit is shown in Figure 9 on page 95. The individual switches are labeled, left to right, with numbers from 1 through 8 across the bottom of the switch unit. Each switch contains a sliding tab. The switch is in the ON position when the sliding tab is moved towards the ON label. The switch is in the OFF position when the sliding tab is moved closest to its number. Figure 9 Setting controller board address switches Switch settings for each joint are shown in Table 2 and Table 3. Use a non-conducting tool for moving switches. Joint No. Table 2 DIP Switch Settings, Right-Hand Slave Arm Joint Name SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 5 Wrist Off On Off On On On On Off 6 Jaw On Off Off On On On On Off Table 3 Left-hand Slave Arm DIP Switch Settings Joint No. DIP Switch Settings, Left-Hand Slave Arm Joint Name SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 5 Wrist Off On Off Off On On On Off 6 Jaw On Off Off Off On On On Off 5. Install the replacement controller board. While installing the board, be careful not to damage the pins that the boards seats on. 6. Install the three SHCS (37) and washers (38) that hold the actuator control board in place. 7. Install the five wires going to J4 from the base module board and secure them with a harness tie. Install the wire harness coming from the servo valve. 8. Close the base module as described in Closing the Base Module on page Servicing the Jaw or Wrist Servo Valve Refer to drawing and the parts list for for this procedure. 1. Open the base module as described in Opening the Base Module on page At the controller board (3), remove the wire harness coming from the servo valve (7). 3. Remove the four SHCS (8) from the servo valve Base Module Service Page 95

96 Maintenance & Service 4. Remove the four o-rings (49) from beneath the servo valve. 5. Lube four new o-rings (49) with o-ring lube and install to the underside of the servo valve. 6. Place the new servo valve in position and install with four SHCS. Torque to 9 ft/lb (12Nm). 7. Connect the wire harness to the controller board. 8. Close the base module as described in Closing the Base Module section on page Removing the Jaw Bypass Valve When hydraulics are disabled, because of operator control or hydraulic failure, a bypass valve in the base module causes the jaw to relax its grip. Objects held by the jaw may be released or dropped. If you prefer that the jaw lock when hydraulic power is disabled, the bypass valve must be removed. To service the jaw bypass valve, complete the steps in Accessing Internal Base Module Components section on page 93. Then proceed to the steps below: Refer to drawing and the parts list for for this procedure.! Caution This procedure requires four new SHCS, x 1-1/2-in (manufacturer P/N , and cannot be completed without them (see Conan Spares Kit , item 7-37). NOTE: It is not necessary to separate the servo valve from the lock valve for this procedure. 1. Open the base module as described in Opening the Base Module section on page Locate the jaw servo valve. 3. Remove the four SHCS (46) that secure the servo valve/lock valve assembly (7 & 31) and the jaw bypass valve to the manifold block (1). 4. Carefully lift the servo valve/lock valve assembly and remove the bypass valve block (81) and four o-rings (47). 5. Lubricate four new o-rings with o-ring lube and install to the bottom of the servo valve/lock valve assembly. Place the servo valve/lock valve assembly onto the base controller manifold and align the mounting holes. 6. Install the four new SHCS x 1-1/2-in (P/N ) and torque to 45 in/lb (5.1Nm). 7. Close the base module as described in Closing the Base Module section on page Slave Arm Service This section contains special maintenance and service procedures not covered in the Work Instructions. For additional details, refer to the slave arm drawing and part list in the Drawings & Part Lists chapter. Servicing Slave Arm Servo Valves... page 97 Servicing Slave Arm Actuator Boards... page 97 Wrist Pitch/Yaw Hose Fittings... page 99 Page 96 Slave Arm Service

97 8.1 Servicing Slave Arm Servo Valves Maintenance & Service To replace the azimuth, shoulder, elbow, pitch, or yaw actuator servo valve, you will need to gain access to the control module (containing the servo valve). 1. Position the slave arm or disconnect slave arm components as needed to allow the control module cover to be removed. 2. Remove the four SHCS (5) from the cover (2). 3. Gently remove the cover. Try to leave the base of the control module attached to the actuator. This will retain the o-rings located between the control module and the actuator. As you remove the cover, disconnect the five wires from J4 on the controller board (9). Remove the o-ring (12) from the cover (2). 4. Disconnect the wire harness that leads from the servo valve (4) to the controller board at J5. 5. Remove the four nuts (8) holding the servo valve in place. Lift the servo valve off the manifold (1). 6. Lubricate four new o-rings ( ) with o-ring lube and install to the bottom of the replacement valve. 7. Install the valve. Install the four nuts that hold the valve in place. 8. Install the wire harness from the valve to the controller board (J5). 9. Lubricate a new o-ring with o-ring lube and install into the cover. As you install the cover, connect the five wires to J4 on the controller board. Note that the wires are color coded to the J4 connector. 10. Install the four SHCS to hold the cover in place. 11. Reconnect slave arm components disconnected to gain control module access. 8.2 Servicing Slave Arm Actuator Boards To service the azimuth, shoulder, elbow, pitch, or yaw actuator board, you will need to gain access to the control module (containing the actuator board).! Caution When you handle the PC boards or other electronic components, wear an anti-static wrist band attached to earth ground or a large metal object. 1. Position the slave arm or disconnect slave arm components so the control module cover can be removed. 2. Remove the four SHCS (5) from the cover (2). 3. Gently remove the cover. Try to leave the base of the control module attached to the actuator. This will retain the o-rings located between the control module and the actuator. As you remove the cover, disconnect the five wires from J4 on the controller board (9). Remove the o-ring (12) from the cover (2). 4. Disconnect the wire harness that leads from the servo valve (4) to the controller board at J5. 5. Remove the three SHCS (14) and washers (15) that hold the controller board in place. Remove the controller board. NOTE: When an actuator controller board is replaced, the new board s DIP switch must be set with the address of the actuator/function it will control. If the controller board has Slave Arm Service Page 97

98 Maintenance & Service the wrong address, the actuator may not respond to commands or may respond to commands intended for a different actuator. 6. Set the address on the replacement controller board as outlined below: The DIP switch unit is shown Figure 10. The individual switches are labeled, left to right, with numbers from 1 through 8 across the bottom of the switch unit. Each switch contains a sliding tab. The switch is in the ON position when the sliding tab is moved towards the ON label. The switch is in the OFF position when the sliding tab is moved closest to its number. Figure 10 Setting controller board address switches Switch settings for each joint are shown in Table 4 and Table 5. Use a non-conducting tool for moving switches. Joint No. Joint Name Table 4 Switch Settings, Right-Hand Slave Arm SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 0 Azimuth On On On On On On On On 1 Shoulder Off On On On On On On On 2 Elbow On Off On On On On On On 3 Pitch Off Off On On On On On On 4 Yaw On On Off On On On On On Joint No. Joint Name Table 5 Switch Settings, Left-Hand Slave Arm SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 0 Azimuth On On On Off On On On On 1 Shoulder Off On On Off On On On On 2 Elbow On Off On Off On On On On 3 Pitch Off Off On Off On On On On 4 Yaw On On Off Off On On On On 7. Install the controller board using the three SHCS and washers. 8. Install the wire harness from the valve to the controller board (J5). Page 98 Slave Arm Service

99 Maintenance & Service 9. Lubricate a new o-ring with o-ring lube and install into the cover. As you install the cover, connect the five wires to J4 on the controller board. Note that the wires are color coded to the J4 connector. 10. Install the four SHCS to hold the cover in place. 11. Reconnect slave arm components that were disconnected to gain control module access. 8.3 Wrist Pitch/Yaw Hose Fittings Wrist pitch and yaw hoses are supplied with reusable fittings at the ends connected to the base module. These fittings must be removed to extract the hoses from the slave arm. Replacement wrist pitch and wrist yaw hydraulic hoses are supplied without the fittings installed so they can be installed through the pitch and yaw structural segments. See the fitting installation instructions below. Installing Reusable Fitting The following instructions describes how to shorten a hydraulic hose and/or terminate it with reusable fitting (OEM Aeroquip ). 1. Determine the required hose length and mark the hose at the cut-off point. Disconnect both ends of the hose from components. 1-1/2 2. Wrap the hose with masking tape at the cutoff point and cut square through the taped area using a cut-off saw fitted with an abrasive blade (you can also use a fine-tooth hacksaw, as shownin figure, left). Remove the tape and trim any loose wires flush with the tube stock. Remove any burrs on the bore of the tube stock with a knife. 3. Trim the hose jacket back about 1-1/2 in. from the end, exposing the braid, as shown at left. 4. Install the socket onto the hose end. Push the new sleeve over the end of the tube and under the wire braid by hand ( figure left, arrow). Complete positioning of the sleeve by pushing the hose end against a flat surface. It is critical that the tube stock butts against the inside shoulder of the sleeve (nearly flush with the flat end-face of the sleeve). Visually confirm this orientation Slave Arm Service Page 99

100 Maintenance & Service 5. Clamp the hex of the nipple in a vise (male fitting shown). Push the hose and sleeve over nipple as shown in Figure, left. Work the hose with twisting motion until it is seated against the nipple chamfer (at the base of the nipple). 6. As shown in Figure A, below, push the socket forward on the hose and thread onto the nipple. 7. As shown in Figure B, below, use a wrench to tighten the nipple hex until it bottoms on the socket hex and the corners of nipple and socket hexes align. A Installing Reusable Fitting (cont.) B 8. Clean interior of hose assembly with compressed air or flush with mineral spirits or hot water (65 C/150 F max.). If the hose will not be reconnected immediately, cap or plug end fittings. 9. Inspect the fitting assembly. The gap between the nipple hex and the socket should be 1/32-in. or less. The nut on a female fitting should swivel freely. 10. Proof testing:! Caution Conduct hose tests with adequate safeguards to protect personnel in the test area. Test the hose assembly at 6000 psi (twice the recommended working pressure of the hose). Hold the test pressure for not more than one minute and not less than 30 seconds. When test pressure is reached, visually inspect hose assembly for any leaks, bulges, or any movement of the hose in relation to the hose fitting. Correct any defects before placing the hose into service.\ 11. Install the hose between the slave arm and base module, matching the hose and fitting codes. 12. When hose installation is completed, apply hydraulic pressure to the slave arm, operate the affected slave arm joint, and inspect the new fitting for leaks or any movement of hose within the hose fitting. Page 100 Slave Arm Service

101 9 System Configuration Maintenance & Service Adjusting Servo Valve Offsets... page 101 Changing the Communications Protocol... page Adjusting Servo Valve Offsets Access path: MAIN/SETUP/SET SV OFFSET Security level: 1 or higher The servo offset adjustment balances the response of a servo valve to control input so the speed of actuator movements is consistent in both directions of travel. Correct adjustment also keeps the actuators without lock valves (wrist pitch/yaw, wrist, jaw) immobile when the servo valve is inactive (no control input pending) and reduces sag and/or drift when hydraulics are disabled. The key physical 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. Spontaneous joint drift in the wrist pitch/yaw, wrist, or jaw functions An increase in the sag or drift of the wrist pitch/yaw, wrist, or jaw functions when hydraulics are disabled. The servo valve offset for each function is set at the factory but should be checked and adjusted when a servo valve, control module, actuator, or other control software or hardware within the master controller, base module, or control module has been serviced or replaced. Component wear, temperature, and other environmental factors may also affect the servo valve response and initiate the need for offset adjustment. The servo offset for each joint (including the wrist and jaw) is set independently, and does not affect the offset for any other joint. The goal is to equalize the servo valve's null position so that when it is activated the servo can provide an equivalent hydraulic flow to either port of the actuator. This will ensure balanced travel rates and minimize sagging and drift in the functions without lock valve. To set the slave arm servo offsets, follow these steps: 1. Set the current privilege level to 1 or higher. (If you aren't sure what the current level is, display the SET LEVEL menu, as described in the Operation chapter, and note the level displayed on the screen). Enter the password and change to a higher privilege level if necessary. 2. From the OPERATE menu toggle the jaw mode to POS. Make sure hydraulics are enabled (ON). 3. From the MAIN menu, select the 3> SETUP menu. From the SETUP menu, select the SET SV OFFSET <7 menu (Figure 11) System Configuration Page 101

102 Maintenance & Service SET SV OFFSET FRZ > Joint:Azimuth Inc Offset <5 Pos Error:+0004 Dec Offset <6 SV Offset:-050 EXIT < Figure 11 Setting servo offsets 4. The slave arm should be positioned so that all joints are near the centers of their ranges of motion. If any of the joints are at or near their limits, unfreeze the arm and reposition it, then freeze it again. 5. The joint for which servo offset is being set will appear in the 1> Joint: field. You can cycle through the joints by pressing 1> Joint. 6. For each joint, a value will appear in the Pos Error: field. The goal is to get this value as close to zero as possible. (In practice, the lowest absolute value between and is acceptable.) If the displayed value is not near-zero, press the 5> Inc Offset and 6> Dec Offset keys to adjust the value in the SV Offset: field until the Pos Error: field value is lowest. NOTE: The slave arm will move slightly after each increment or decrement of the servo offset. You should wait a few seconds after each change for the arm, and the values, to stabilize. 7. Press 1> Joint: to move to the next joint. Repeat steps 6 and 7 until the servo offsets for all joints except the wrist and jaw (azimuth, shoulder, elbow, pitch and yaw) have been nulled. 8. Wrist offset adjustment: If necessary, reposition the arm so that you can see the wrist, and freeze the arm again. The wrist does not have position feedback, so adjustment of its servo offset is less precise. Normally, you will need to adjust the wrist servo offset only if the servo valve has been serviced, or if the wrist rotates spontaneously. To null the wrist servo offset, perform the following adjustment procedure: a. Press 1> Joint until the adjacent field reads WRI. b. Press 5> Inc Offset until the wrist begins rotating slowly. Note the SV Offset value (it may be relatively large). c. Press 6> Dec Offset until the wrist begins rotating slowly in the opposite direction. Again note the SV Offset value. d. Add the two offset values algebraically (that is., include the plus or minus signs). If, for example, the positive offset value was +260 and the negative offset value was -60, their algebraic sum is Divide this value by 2. Increment or decrement the SV offset to match this result (+100, in the example). Page 102 System Configuration

103 Maintenance & Service 9. Jaw offset adjustment: If necessary, reposition the arm so that you can see the jaw, and freeze the arm again. The jaw mode must be set, in the OPERATE menu, to POS for this step. The jaw does not have position feedback, so adjustment of its servo offset is less precise. Normally, you will need to adjust the jaw servo offset only if the servo valve has been serviced, or if the jaw slowly opens or closes spontaneously. To null the jaw servo offset, perform the following adjustment procedure: a. Press 1> Joint until the adjacent field reads JAW. b. Press 5> Inc Offset until the jaw begins closing slowly. Note the SV Offset value (it may be relatively large). (Allow the jaw to close all or most of the way.) c. Press 6> Dec Offset until the jaw begins opening slowly. Again note the SV Offset value. d. Add the two offset values algebraically (that is, include the plus or minus signs). If, for example, the positive offset value was +500 and the negative offset value was -240, their algebraic sum is Divide this value by 2. Increment or decrement the SV offset to match this result (+130, in the example). 10. Press 8> EXIT to exit the SET SV OFFSET menu and save the new settings.! Caution Changes to the servo offsets can change the positioning response of the slave arm joints. Reset the slave arm movement limits and/or stow sequence immediately if their settings are needed to prevent damage to the slave arm or work area (see Setting Slave Arm Movement Limits and Setting the Stow In/Stow Out Sequence in the Operation chapter for details). 9.2 Changing the Communications Protocol This manipulator system can be operated using RS-232 (factory default) or RS-485 protocol. To change the telemetry configuration you must move a connector on the master controller master processor PC board and change jumper settings on the Base Module PC board Configuring the Master Processor Board 1. Open the master controller as described in Removing the Faceplate section on page 87. The RS-232 (P1A) connector (default) and the RS-485 (P1B) connector are located at the upper right side of the processor board (Figure 12). Figure 12 RS-232 / RS-485 connection points System Configuration Page 103