Installation In This Chapter: 1 User-supplied Equipment... page 15 2 Installing the Slave Arm... page 15 3 Installation Checkout & Test... page 19 4 Bleeding Air from Slave Arm Actuators... page 21 1 User-supplied Equipment The following equipment, if not ordered as options from Schilling Robotics, is required to complete the installation of the slave arm and provide for its control and operation: A hydraulic power source. Compensation, as needed to support user s hydraulic system in submersible operation. A hydraulic control manifold. Two relief valves for each slave arm function except wrist pitch (special relief valves are provided). All hardware, hoses, and fittings for connecting to the slave arm s hydraulic hose fittings. 2 Installing the Slave Arm 2.1 Preparing the Slave Arm Mounting Platform 1. Determine an appropriate mounting location for the slave arm using the range-of-motion and slave arm dimensions drawings in the Specifications chapter. 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 as shown in Figure 1. 3. Three 0.5-inch or M12 hex-head cap screws, flat washers, lockwashers, and hex nuts 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 1.2 cm (0.5-in.) or of the fastener threads. 011 0559 Page 15
Installation 2.2 Mounting the Slave Arm 1. Move the slave arm to the mounting platform, providing support at the elbow and jaw. Lower the azimuth base onto the platform and align the mounting holes in the azimuth base and mounting platform. 2. Lubricate the threads of the fasteners, add the flat washers, and install the fasteners through the azimuth base and into the mounting platform. Install the hex nuts and lockwashers, if required, and torque as specified below: 1/2-in fasteners: 81 Nm/60 ft-lb M12 fasteners: 68 Nm/50 ft-lbs Figure 1 Orion R & RE mounting dimensions 2.3 Installing the Control and Drain Hoses 2.3.1 Slave Arm Note: Slave arm 199-0280 is not supplied with control hoses. The slave arm hydraulic hoses are fitted with female -4 JIC fittings. Connect them to your hydraulic controls. Hose functions are shown in Table 1. When the Orion slave arm is used with a Schilling Robotics rate manifold, match up each slave arm function with the fitting designations shown on the manifold drawing in the manifold technical manual. The forearm and wrist roll actuators also have a common drain/return line and a pressure relief valve (located on the forearm roll actuator). Page 16 2 Installing the Slave Arm 011 0559
Installation! Caution The relief valve cracking range is 350 to 600 psi above ambient. If the wrist drain/return pressure exceeds the cracking pressure, the relief valve will release hydraulic fluid into the environment. If a Schilling rate hand controller (005-2909) is used with the manifold, the far right column in Table 1 matches each slave arm function and hose code with the appropriate hand controller switch and connector pin. Slave Arm Actuator/ Function Azimuth yaw Shoulder pitch Elbow pitch Joint Travel Table 1 Hose Code Actuator Movement Hand Controller Pin No. Right 0A Extend 2 Left 0B Retract 1 Up 1A Extend 4 Down 1B Retract 3 Up 2A Extend 6 Down 2B Retract 5 Forearm roll CW 3A Rotate CCW 10 Forearm roll CCW 3B Rotate CW 9 Wrist pitch Wrist roll Jaw Forearm and wrist roll drain/return a N/A (spares) b Up 4A Extend 7 Down 4B Retract 8 CCW 5A Rotate CCW 11 CW 5B Rotate CW 12 Open 6A Extend 14 Close 6B Retract 13 N/A C N/A N/A N/A 7A,7B N/A N/A a. The maximum forearm and wrist roll drain/return pressure is 350 psi or less. If the wrist drain/return line passes through a filter or is manifolded with other equipment returns, check the return pressure when all equipment is running to be sure it does not exceed the maximum. b. Auxiliary connections for equipment supplied by the customer are made at the forearm manifold. If unused, connect the auxiliary hoses to the valve pack or case drain (return). This will prevent collapse and damage when submerged Note: Forearm and wrist roll CW/CCW movements are referenced from behind the slave arm. 2.3.2 Auxiliary Function Hose Lines Two auxiliary hose lines, terminating at the forearm manifold, are provided for the operation of arm-mounted, user-supplied tools. If unused, connect them to the valve pack or case drain. 011 0559 2 Installing the Slave Arm Page 17
Installation Note: If unused, connect the auxiliary hoses to the valve pack or case drain/return (do not cap). This will prevent their collapse and damage when submerged. 2.4 Installing Relief Valves Pressure relief valves must be installed on all control lines to protect slave arm components from the abnormally high pressures generated by overloads or collisions. The fluid release relieves excessive pressure on seals, and reduces stress on mechanical and hydraulic components. When normal working pressures return, the affected relief valves close and allow normal operation to resume. Without relief valves, slave arm components and seals are forced to directly absorb pressures and stresses above their rated working capacity; the result can be damage or breakdown.! Caution Operating the slave arm without relief valves on all control lines can result in damage to components. 1. Adjust the cracking pressure of the A and B line relief valves to the figures shown on the slave arm hydraulic schematic (with 025- prefix) in the Drawings & Part Lists chapter. The cracking pressure may be set closer to the operating pressure of the system, if desired, but be sure the reseal pressure is also above the normal operating pressure range of the system. If it is not, the valve may not reseal during normal operation and the actuator will respond erratically. Note: Do not set the cracking pressure higher than 4500 psi. 2. Connect the relief valves at any point between the hydraulic control manifold and the slave arm hose connections. Note: If a circuit has a restrictor, throttle, or flow control valve, install the relief valve between the actuator and the flow control valve. 2.5 Factory Set Forearm Roll Index & Options Although the Orion range of motion is generally symmetrical, the forearm roll range of motion (270 ) is indexed at the factory for operation as the right-hand slave arm in a dual arm installation: as viewed from behind the slave arm and looking down the forearm rotational axis, travel starts approximately at the 4 o clock position and continues clockwise to approximately 1 o clock (see index option 2 in Figure 2). To accommodate left-hand installations and other custom installation requirements the forearm range of motion (270 ) can also be re-indexed to seven other orientations (in 45 increments). All eight index settings are shown in Figure 2. Index position No.2 is the setting as supplied from the factory. Instructions for re-indexing forearm roll are located in the Maintenance & Service chapter. Page 18 2 Installing the Slave Arm 011 0559
Installation Figure 2 Forearm roll index options 1-8 3 Installation Checkout & Test This section describes procedures for initially checking, starting up, and testing the slave arm after all system components have been installed and interconnected. 3.1 Checks Before First Startup Before you operate the slave arm, confirm the following: Installation instructions have been completed for the slave arm and all other system components. Individual control valves and hoses are securely connected to the appropriate slave arm hoses for each actuator function. Control hoses are routed and supported/secured to eliminate snagging, kinking, and damage during slave arm operation. A relief valve is installed on each control hose line. The wrist drain hose is connected to the hydraulic system return. Hydraulic supply and return hoses/fittings are correctly connected and securely tightened to the user s control manifold. (Submersible models) Compensator hoses/fittings for user s hydraulic system are correctly connected and securely tightened. (The slave arm does not require compensation.) 011 0559 3 Installation Checkout & Test Page 19
Installation 3.2 First Startup! WARNING Air in hydraulic lines or components may cause very rapid or jerky slave arm movement. Clear personnel and equipment from the slave arm s range of motion before you turn on hydraulic power. Note: If system pressure on the wrist drain/return exceeds 1500 psi above ambient, hydraulic fluid will be released into the environment from the relief valve. 1. Clear all personnel or equipment from within the slave arm s range of motion. 2. Remove any installation supports from the slave arm. 3. Activate the hydraulic power unit (HPU). 4. Check and confirm: Hydraulic supply pressure is within the range listed in the System Specifications chapter. Hydraulic return or tank pressure is 350 psi or less. If the hydraulic return passes through a filter or is manifolded with other equipment returns before returning to the tank, check the return pressure when all equipment is running to be sure it does not exceed the maximum. No leaks from hoses, fittings, components, etc. 5. Following the manufacturers recommendations, bleed air from the HPU and manifold components. 3.3 Testing Functions! Caution The following steps are for testing slave arm functions and controls only. Until correct operation of all controls is verified and the actuators have been bled, do not use the slave arm to manipulate any loads. 1. Briefly operate control valves and verify that they are correctly matched to slave arm functions. Correct any misconnected hoses. Label the hydraulic controls to match the slave arm s functions and movements. 2. Adjust the restrictor valves, if present, to produce the maximum rate of travel desired for each slave arm function. Page 20 3 Installation Checkout & Test 011 0559
Installation 4 Bleeding Air from Slave Arm Actuators! WARNING Air in hydraulic lines or components may cause very rapid or jerky slave arm movement. Clear personnel and equipment from the slave arm s range of motion before operation. Bleed screws for all linear actuators except the jaw are located on the side of the actuator body, directly opposite the hose connections for the same extend or retract function. (See the slave arm drawing for specific hose positions and designations.) Note that for linear actuators, A hose markings always indicate an extend function, while B markings indicate a retract function. Bleed screws for the forearm roll function are located on the upper roll actuator housing, while the jaw actuator bleed screws are located on the right hand side of the wrist base. Note: Extra bleedscrew/o-ring assemblies and bleedscrew o-rings are provided in the optional Orion spares kit 008-0100. Specific bleed instructions are outlined below: Note: Activate/energize only one function control at a time during the bleed process. Enter the slave arm s range of motion to loosen or retighten bleed screws only when ALL function controls are returned to their OFF positions 1. Extend the azimuth actuator until it is against its full right mechanical stop. Return control to OFF position. Loosen the 0A/extend bleed screw directly opposite the 0A/ extend hose fitting until the o-ring seal is broken. 2. Retract the azimuth actuator until it is against the full left mechanical stop and all air has stopped coming out of the 0A bleed port. Return control to OFF position. Note: To avoid extruding the o-ring when tightening a bleed screw, make sure the joint is unloaded or supported. 3. Retighten the 0A/extend bleed screw and loosen the 0B/retract bleed screw (opposite the 0B/retract hose fitting) until the o-ring seal is broken. 4. Extend the actuator once again until it is at its full right mechanical stop and all air has stopped coming out of the 0B bleed port. Return control to OFF position. Retighten the 0B/retract bleed screw. The azimuth actuator is now fully bled. 5. Repeat steps 1 through 3 for bleeding the remaining linear actuators, including the jaw. Bleed in the following order: shoulder, elbow, roll, pitch, jaw. Note: The jaw bleed screws are located on the right side of the wrist base. The lower screw, 6A, bleeds the extend/open function. The upper screw, 6B, bleeds the retract/close function. 6. There are four bleed screws on the top of the forearm roll actuator housing. Use the two bleed screws closest to the forearm to bleed the actuator. Rotate the actuator to its full CW stop. Loosen the bleed screw on the right side (as viewed from behind the slave arm) of the housing. Rotate the actuator towards its full CCW stop until all air bubbles have 011 0559 4 Bleeding Air from Slave Arm Actuators Page 21
Installation stopped coming out of the bleed port. Retighten the right hand bleed screw and loosen the left one. Once again rotate the actuator towards its full CW stop until all air bubbles have stopped coming out of the bleed port. Retighten the left hand bleed screw. 7. Test all functions for smooth operation. Check for leaks at all bleed screws. Installation of your Orion slave arm is now complete. Proceed to the Operation chapter. Page 22 4 Bleeding Air from Slave Arm Actuators 011 0559