Schilling Robotics

HD™ ROV System

Operations, Maintenance & Repair

Training Course Student Guide
Copyright
Copyright © 2012 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.

Revision
022-0002 Rev 01

Trademarks
FMC Schilling Robotics gives notice that it reserves the rights to the following
trademarks and their use is not authorized without the express written
permission of FMC Schilling Robotics.

Product Line Full Name Abbreviation

Corporate.......................FMC Schilling Robotics™..............................SR™
Manipulator...................TITAN 4™.........................................................T4™
Manipulator...................RigMaster™
Manipulator...................ORION 4™
Manipulator...................ORION 7R/RE™
Manipulator...................ORION 7P/PE™
Manipulator...................CONAN 7R™
Manipulator...................CONAN 7P™
Manipulator...................ATLAS 7R™
Manipulator...................ATLAS 7P™
Controls..........................Digital Telemetry System™..........................DTS™
Controls..........................Remote Systems Engine™............................RSE™
ROV.................................UltraHeavy-Duty™..........................................UHD™
ROV.................................Heavy-Duty™...................................................HD™
ROV.................................Electric Heavy-Duty™....................................EHD™
ROV.................................StationKeep™..................................................SK™
ROV.................................AutoTrack™
ROV.................................AutoDisplacement™
ROV.................................Mid-Water StationKeep™.............................MWSK™
TMS................................Heavy-Duty™ TMS.........................................HD™ TMS
TMS................................Extended-Excursion™ TMS..........................XE™ TMS
TMS................................Electric Extended-Excursion™ TMS...........EXE™ TMS

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 Definitions, Acronyms, and Abbreviations
AC................................. Alternating Current
AMP (A)....................... Unit of Electric Current
APU ............................. Auxiliary Power Unit
ASME........................... American Society of Mechanical Engineers
AWS............................. American Welding Society
CWDM........................ Coarse Wave Division Multiplexer
DAF............................... Dynamic Amplification Factor
DC................................. Direct Current
DMU............................. Dynamic Motion Unit
DNV ............................ Det Norske Veritas
DTS.............................. Digital Telemetry System
DVD.............................. Digital Video Disc
DVL ............................. Doppler Velocity Log
FAT............................... Factory Acceptance Test
FORJ............................. Fiber Optic Rotary Joints
FSE............................... Field Service Engineer
GFD.............................. Ground Fault Detection
GFI................................ Ground Fault Interrupter
GPM............................. Gallons per Minute
GUI............................... Graphical User Interface
HD................................. High Definition
HDD.............................. Hard Disc Drive
HP................................. Horsepower
HID .............................. High-Intensity Discharge
HMI.............................. Human Machine Interface
HPU ............................. Hydraulic Power Unit
HUD ............................ Heads-Up Display
HV................................ High Voltage
HVI............................... High Viscosity Index
HZ................................. Hertz
IEEE.............................. Institute of Electrical & Electronics Engineers
IM................................. Interface Module
IMD.............................. Insulation Monitoring Device
IMCA............................ International Marine Contractors Association
INS............................... Inertial Navigation System
IPDS............................. Instrument Power Distribution System
IRM............................... Inspection, Repair, and Maintenance
ISO............................... International Organization for Standardization
KGF............................... Kilograms of Force
KVA.............................. Kilo-Volt Ampere

4
LCD............................... Liquid Crystal Display
LCU.............................. Lighting Control Unit
LED............................... Light Emitting Diode
LPM.............................. Liters per Minute
LRU............................... Lowest Replaceable Unit
MWSK......................... Mid-Water StationKeep
NIM.............................. Network Interface Module
NTSC........................... National Television System Committee
OHM (Ω)..................... Unit of Electrical Resistance
ORFS ........................... O-Ring Face Seal
PAL............................... Phase Alternating Line
PBOF ........................... Pressure-Balanced, Oil-Filled
PCB............................... Printed Circuit Board
PDU.............................. Power Distribution Unit
PLC............................... Programmable Logic Computer
PSA............................... Position Sensor Array
PSU............................... Power Supply Unit
QD................................ Quick Disconnect
QMS............................. Quality Management System
ROV ............................. Remotely Operated Vehicle
RPM.............................. Revolutions per Minute
RS-232/ 485................ Recommended Standard 232/485 Serial Communications
RSTP............................ Rapid Spanning Tree Protocol
RTC............................... Real-Time Computer
Rx.................................. Receive (Incoming Communications)
SeaNet ........................ Subsea cabling and connector system
SFP............................... Small Form-Factor Pluggable
SHP............................... Shaft Horsepower
SIM............................... Serial Interface Module
SK................................. StationKeep
SWL ............................ Safe Working Load
Te.................................. Tonne
TCU.............................. Thruster Control Unit
TFL............................... Through Frame Lift
TMS............................. Tether Management System
TPR............................... Thermoplastic Rubber
TTL .............................. Transistor-Transistor Logic
Tx.................................. Transmit (Outgoing Communications)
UHD.............................. Ultra Heavy-Duty
UPS............................... Uninterrupted Power Supply
USB.............................. Universal Serial Bus
VFD.............................. Variable-Frequency Drives
VIM.............................. Video Interface Module
V................................... Volts

5
 Using this Student Guide
The objective of this course is to provide training for basic operation,
maintenance, and repair of FMC Technologies Schilling Robotics’ Heavy-Duty
(HD) remotely operated vehicle (ROV). Training includes both classroom and
hands-on learning. This Student Guide is intended for use in the classroom
environment under the guidance of an experienced instructor.

Course Objectives
Upon successful completion of this course, students will be able to demonstrate
a comprehensive understanding of all the main components and subcomponents
which combine to form the Heavy-Duty (HD) ROV system including:

System Overview
 Heavy-Duty (HD) ROV
 Tether management system (TMS)
 Digital Telemetry System (DTS)
 Topside controls
 Power distribution
 Work and control vans
 Technical manuals

Heavy-Duty (HD) ROV

 Compensation system components and operation
 Hydraulic system components
 Hydraulic system filling, bleeding and draining
 ROV system devices, sensors, and flight modes

Tether Management System (TMS)

 Identify components, subcomponents, and their operation

Digital Telemetry System (DTS)

 Identify components within the DTS
 Remove and replace modules within the system
 Carry out practical applications such as tunneling, node swap out and
control configuration
 Understand the theory of operation of fiber optic communications

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Topside Controls
 Layout and operation of the control console
 Rack mounted equipment
 System computers including the real-time computer(RTC), server and clients
 Start-up and shut-down procedures
 Graphical user interface (GUI)

Power Distribution
 Safe operating procedures and lock-out, tag-out system
 Safe operation of the power distribution unit (PDU)
 Input power configuration and control power
 Ground switches and ground fault monitoring (GFM)

Course Certification
Certification will be based on continuous assessment throughout the course and
successful completion of a written test at the end of the course.

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8
 We put you first.
And keep you ahead.

Schilling Robotics
Heavy-Duty (HD™) ROV System
Operations, Maintenance & Repair
Training Course Student Guide

Table of Contents

System Overview.................................................................................................. 11
Heavy-Duty (HD) ROV....................................................................................... 67
Tether Management System (TMS)............................................................. 127
Digital Telemetry System (DTS).................................................................... 147
Topside Controls................................................................................................ 185
Power Distribution............................................................................................ 221

9
Schilling Robotics
System Overview
Training Course Student Guide

The Heavy-Duty (HD) ROV system provides industry leading

performance, combined with ease of use and the lowest total cost of
ownership consisting of the remotely operated vehicle (ROV), tether
management system (TMS), launch and recovery system (LARS), and
vans (control and workshop).

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12
 We put you first.
And keep you ahead.

System Overview
Training Course Student Guide

Table of Contents

Heavy-Duty (HD) ROV System..........................................................................15

HD ROV..................................................................................................................18
Manipulators........................................................................................................ 25
Tether Management System (TMS)............................................................... 28
Digital Telemetry System (DTS)...................................................................... 32
Topside Controls................................................................................................. 35
Power Distribution.............................................................................................. 36
Vans....................................................................................................................... 38
Technical Manuals & Elementool.....................................................................41
Bulletins & Service Instructions....................................................................... 43
Part Numbers, BOMs, & Assembly Drawings............................................... 45
Shop Standards & Torque Table...................................................................... 47
Technical Support & Contacts......................................................................... 57
Local Support & Spares..................................................................................... 60

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14
Heavy-Duty (HD) ROV System
The HD ROV System is a compact 150 shp system capable of the most
demanding construction tasks. The system can be utilized for drill support,
inspection, maintenance and repair (IMR), and construction markets, providing
customers with the flexibility of extensive configuration options based on their
operational needs.

FMC Schilling Robotics also provides a comprehensive range of system options

including manipulators, controls, and auxiliary tooling. Each customer’s
unique requirements can be accommodated by configuring the system to suit
their specific needs, while providing a high degree of commonality with core
components and subsystems.

15
 System Layout

16
HD ROV & TMS Stackup

17
 HD ROV
The FMC Schilling Robotics HD ROV is designed for performance, reliability, and
maintainability. Innovative features in the frame design and modular subsystems
combine to produce a high performance vehicle suitable for inspection,
maintenance, and repair (IMR), drill support, and medium-duty construction
operations, while maintaining a compact system footprint ideal for rapid
transportation and mobilization.

Features include the following:

 StationKeep
 Compact footprint
 High thrust performance
 150 shp HPU
 3 Te through-frame lift
 250 kgf payload
 3,000 msw standard (4,000 msw option)
 72 LPM auxiliary hydraulic system option
 Extensive tooling installation space

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HD ROV Specifications
Structural
Safe Working Load 6,700kg 14,771lb
Through-Frame Lift 3,000kg 6,614lb
Weight in Air 3,500kg 7,716lb
Payload 250kgf 551lbf
Dynamic Amplification Factor 3.0 Vertical
Dynamic Amplification Factor 1.0 Horizontal

Performance, Peak Thrust

Forward 900kgf 1,984lbf
Aft 900kgf 1,984lbf
Lateral 900kgf 1,984lbf
Vertical - Up 850kgf 1,874lbf
Vertical - Down 850kgf 1,874lbf

Equipment Fit
Port/Starboard Manipulators Any Schilling Model
Cameras NTSC/ PAL
Depth Sensor Digiquartz 8000B - I
Heading Sensor Schilling Digital Compass
Dynamic Motion Unit Schilling VG700 DMU
Doppler RDI Navigator 1200kHz
Strobe Novatech ST400 AR
Sonar Tritech DST
Lights (8) ROS MVLED 26VDC
Pan and Tilt (1) Schilling Electric Programmable
Valve Pack 2 8 function

Propulsion
HPU 150shp 112kW
Main Pump Linde 135cc
Nominal Operating Pressure 207Bar 3,000psi
Thrusters Sub Atlantic SA380-40 x 7
System Flow [at 3,000psi] 216LPM 57GPM

Hydraulics - Auxiliary Circuit

Auxiliary Pump Rexroth A10VSO 45cc
Nominal Operating Pressure 207Bar 3,000psi
Maximum Flow [at 3,000psi] 72LPM 19 US GPM
Spare Functions 4-11
[Depending on Manipulator Fit]

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 Performance Features
The HD features substantial space for equipment payload at the side and forward
areas of the vehicle, with payload capacity biased towards the forward area. It
can be fitted with any of the FMC Schilling Robotics range of high capability
manipulators.

Key performance features include StationKeep dynamic positioning capability

as standard, tightly integrated with active power management and thruster
feedback. FMC Schilling Robotics’ integrated modular design philosophy enables
rapid maintenance in the field, with changeout of key modules of the HPU and
power supplies possible in under one hour.

The vehicle is pre-installed with attachment points for typical IMR and survey
tooling, including an underslung four-point skid attachment interface, aft tooling
attachment interface for workpacks, and a forward attachment interface for
interchangeable equipment mounting racks or bumper bars.

The HD is fully protected by impact resistant polypropylene fendering. Areas of

the fendering can be removed by quick release catches, providing quick access
for equipment installation or maintenance activities.

Frame
The HD incorporates high strength-to-weight ratio frame design that enables a
very high specification within a compact footprint.

Payload
The HD has a substantial payload capability of 250 kgf when including the
standard equipment and auxiliary hydraulics system option. Without the
auxiliary hydraulic system, HD payload is increased by approximately 40 kgf.

Control System
The HD utilizes FMC Schilling Robotics’ innovative Digital Telemetry System
(DTS) for control telemetry. Two DTS nodes are installed as standard. A
maximum of 48 channels are available for vehicle equipment and customer
interfaces, including five video and eight data modules that can be configured
for customer equipment requiring power and telemetry. The control system is
expandable by additional DTS nodes in 16 port configurations. Instrument power
of 5 kVA, 120 VAC, and 26 VDC is available.

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Flight Modes

Ease of Operation
FMC Schilling Robotics’ ROVs feature advanced auto-piloting modes that enable
ROV pilots to perform subsea intervention with unmatched levels of accuracy
and stability. StationKeep allows the pilot to offset the effect of poor visibility
and currents that can make it difficult to maintain position. With the touch of
a single button, the ROV automatically senses movement and compensates by
precisely controlling each thruster. AutoTrack leverages the same technology
to greatly improve the speed and accuracy of seafloor surveys, while
AutoDisplacement offers the capability to move the ROV in any given direction
with pinpoint accuracy. Other flight modes include Auto Heading, Auto Depth,
and Auto Altitude.

Power Management
The HD features FMC Schilling Robotics’ power management system technology,
which ensures that the system will maintain optimal efficiency under high
demand loads. This is particularly important when performing heavy-duty tasks
that require high performance of the thrusters and significant demand of any
tooling systems. To achieve optimal performance, the hydraulic power system on
the HD is software-controlled for the management of hydraulic pump pressure to
ensure the optimum use of available HPU power under a wide range of system
demands.

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 Devices & Equipment
FMC Schilling Robotics’ ROVs are supplied with a comprehensive array of
auxiliary sensors and devices. Any third party supplied equipment can be easily
interfaced to the ROV, leveraging the versatile DTS control system that can
be quickly configured to accept any industry standard device. The modular
expansion capabilities of the DTS allows customers to continually upgrade the
ROV capacity based upon project needs.

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Tooling Integration
The HD has been designed to readily accommodate auxiliary tooling systems.
Every aspect of tooling integration is simplified through the implementation
of standard mechanical interfaces, hydraulic connections and control system
interfaces. The HD provides the most onboard space available to mount tooling
for vehicles in its class. This key design feature enables customers to configure
the ROV for most subsea operations without the need for additional skids or
frameworks to accommodate the equipment.

Mechanical interfaces designed for both rapid and safe mounting of tooling are
provided for underslung work packages, and forward/aft mounted equipment.
The hydraulic system is designed to provide spare tooling capacity, including
the option of an auxiliary hydraulic circuit and additional valves/manifolds as
required for custom tooling. Similarly, FMC Schilling Robotics’ DTS provides
the most flexible control interface in the industry, utilizing Ethernet to interface
electronics to the ROV.

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24
Manipulators
FMC Schilling Robotics has over 2,000 manipulator systems delivered and
are operating on virtually every work-class ROV in the world as the industry
standard. Manipulators perform a variety of intervention tasks and are the
primary tool used by ROV operators. These systems are all controlled remotely
from the surface and range from the rugged 5-function RigMaster to the
7-function, position-controlled TITAN 4, which provides the highest degree
of precision and articulation. Additional manipulators include the CONAN,
ORION, and ATLAS manipulator systems, all of which serve different industry
requirements.

As subsea intervention tasks continue to increase in complexity, our manipulator

systems will continue to be at the forefront, providing the dexterity, strength, and
reliability to perform the task at hand.

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 Manipulator Specifications

Model TITAN 4 ATLAS 7R RigMaster

Category Heavy Work Heavy Work Heavy Work
Power Source Hydraulic Hydraulic Hydraulic
Rate/Position
Position Rate Rate
Control
Number of
7 7 5
Functions
Anodized Aluminum,
Primarily Anodized Aluminum
Materials Stainless Steel &
Titanium & Stainless Steel
Titanium
1,067mm/42.0in.
(retracted);
Maximum Reach 1,922mm/75.7in. 1,664mm/65.5in.
1,372mm/54.0in.
(extended)
Replica Master Rate Hand
Input Device Rate Hand Controller
Arm Controller
Depth Rating, 4,000msw/ 6,500msw/ 6,500msw/
Standard 13,124fsw 21,000fsw 21,000fsw
Depth Rating, 7,000msw/
N/A N/A
Optional 23,000fsw
270kg/595lb (retracted);
Lift at Full Reach 122kg/270lb 250kg/550lb
181kg/400lb (extended)
Weight in Air 100kg/221lb 73kg/160lb 64kg/142lb
Weight in
78kg/174lb 50kg/109lb 48kg/105lb
Seawater
**
Specifications shown are for the standard-reach ORION 7P.

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 Manipulator Specifications

CONAN 7P ORION 7P/7R** ORION 4R

Category Heavy Work Medium Work Medium Work
Power Source Hydraulic Hydraulic Hydraulic
Rate/Position
Position Position or Rate Rate
Control
Number of
7 7 4
Functions
Anodized
Anodized Aluminum & Anodized Aluminum &
Materials Aluminum &
Stainless Steel Stainless Steel
Stainless Steel
1,532mm/60.3in.
(7P/R)
Maximum Reach 1,806mm/71.1in. 682mm/26.9in.
1,850mm/72.8in.
(7PE/RE)
Replica Master Replica Master Arm or
Input Device Rate Hand Controller
Arm Rate Hand Controller
Depth Rating, 3,000msw/ 6,500msw/ 6,500msw/
Standard 9,800fsw 21,000fsw 21,000fsw
Depth Rating,
N/A N/A N/A
Optional
136kg/300lb
Lift at Full Reach 159kg/350lb 68kg/150lb

Weight in Air 107kg/235lb 54kg/120lb 30kg/67lb

Weight in
73kg/161lb 38kg/83lb 21kg/46lb
Seawater

27
 Tether Management System
(TMS)
FMC Schilling Robotics’ ROVs can be operated with or without a tether
management system (TMS). A TMS is generally required for operations where
the ROV is required to perform long-distance excursions, as seen in field
construction. In other applications where the ROV can be deployed in close
proximity to the work site, such as drill support, it may be possible to operate
without a TMS.

The TMS essentially decouples the ROV from the main steel armored umbilical
which, due to length and overall weight, can restrict the capability of the ROV
when this has to be dragged around underwater. The TMS also decouples the
ROV from the heave-motion of the host vessel. This is beneficial in areas where
high sea-states are commonly encountered.

The purpose of the TMS is to manage the ROV tether which transfers power,
telemetry, and video information between the surface through the umbilical. The
tether is usually neutrally buoyant to negate the effects of drag on the ROV itself
and to keep the tether clear of seabed structures.

TMS systems are supplied as part of integrated ROV systems, or as stand-alone

units for use with other third-party ROV systems. Our electric Heavy-Duty (HD)
TMS is designed for medium-duty work-class ROV systems which require a
maximum excursion of 425 m. An optional electric extended-excursion (EXE)
TMS can accommodate up to 850 m of tether, enabling ultra-long excursions
for applications, such as pipeline touchdown monitoring and deepwater drill rig
anchor installation.

28
TMS Specifications

TMS
Safe Working Load 9,700kg 21,385lb
Through-Frame Load 6,700kg 14,771lb
Weight in Air 2,608kg 5,750lb
Weight in Water 1,580kg 3,549lb
Tether Capacity 425m 1,395ft
Haul in Speed 50mpm 164fpm
Height 2,209mm 87in
Diameter 1,853mm 73in

Tether
Manufacturer Nexans RT487
Length 425m 1,395ft
Depth Rating 4,000msw 13,123ft
Diameter 28mm 1,102in
Jacket TPR Yellow
Weight in Air 675kg/km 1,488lb/km
Weight in Water 45kg/km 99lb/km
Minimum Bend Diameter 425mm 16.73in
Safe Working Load 20kN 4,496lbf
Minimum Break Load 110kN 24,729lbf

29
 Specifications & Performance
FMC Schilling Robotics’ electric HD TMS systems provide optimal tether spooling
with highly responsive control for handling tether. They offer the additional
advantage of reducing umbilical diameter since it is not necessary to include
power conductors for running an onboard HPU. This alone is a significant
benefit, in addition to the requirement for a smaller winch which also helps
reduce overall deck footprint and system cost.

Features include:
 Electrically driven without hydraulics
 Duplex stainless steel construction
 425 m tether capacity (850 m option)
 28 mm neutrally buoyant tether
 Shock absorbing docking snubber unit
 9.7 Te safe working load
 6.7 Te lower latch capacity
 3,000 msw standard (4,000 msw option)

30
Electric Drive
The HD TMS is electrically operated. Powered by a single 4,160 VAC primary
branch circuit, AC motors provide the drum and pinch wheel drive motion, under
close control of AC variable-frequency drives (VFDs). An electrically operated fail-
safe latch system has two sets of pre-engaged latches.

Electrically operated drive and latch systems simplify operations and significantly
reduce the number of components. This provides increased reliability and ease
of maintenance. The AC VFD system provides exceptional tether handling
performance, with closed loop control of the drive sheave torque and speed
ensuring optimal handling of the tether under all operating conditions.

The HD TMS has been designed around a field-proven ‘shuttling drum’ concept
offering exceptionally simple tether routing. The complete tether drum moves on
a carriage system allowing the tether to exit the drum directly above and through
the payout sheave.

Tether
The 28 mm tether takes advantage of the reduced conductor size at 4,160 VAC to
enable a durable, neutrally buoyant jacket.

Quick Connect
Sliprings, tether, and umbilical connections are managed by a quick connect
system that eliminates the need for a rotary junction box. Connections are made
outside the drum for easy access.

31
 Digital Telemetry System (DTS)
FMC Schilling Robotics’ Digital Telemetry System (DTS) is the ideal control
platform, providing communications, control, and power distribution for virtually
any remotely operated system.
Features include:
 Superior reliability and lower operational costs
 Allows rapid system expansion and a wide range of physical configurations,
making it the most flexible subsea-ready controls system on the market for
evolving projects
 Node flexibility allows customization to suit any subsea application
 Ports can be individually configured for serial, video, or Ethernet
communications
 Digital video transmission supporting NTSC and PAL
 SeaNet cables provide power and telemetry to devices and components
 Utilizes fiber optic technology with a 1 Gbps backbone
 Supports RSTP protocol for redundancy with seamless fiber switching

32
Control System Specifications
DTS System
Maximum ports (per single optical fiber) 512
Communication Speed (per optical fiber) 1 Gbps

Subsea Node
Length 305cm (12.0in.)
Height 305cm (12.0in.)
Width (at port array with SeaNet cables installed) 165cm (6.5in.)
Weight in air 4.1kg (9.1lb)
Weight in seawater 2.7kg (6.0lb)
Depth rating, standard 4,000m (13,125ft)
Ports per node (any combination of serial, video, 16
and Ethernet)
Electrical input 26VDC
Maximum node power (all ports combined) 30 A (1,200 W DC)
Communication input/output Optical Fiber

Node Ports
Maximum power per port 360 W, 26 VDC @15 A continuous
Power protection
Fast fuse (10 µsec) 20 A
Slow fuse (200 µsec) 0 to 15 A (configurable)

Interface Modules
Serial interface module Supports RS-232/485
Ethernet interface module Supports 10/100 Ethernet,
including IP cameras
Video interface module Supports NTSC/PAL
USB 2.0 interfaces Optional
Port connector type, standard (others optional) SeaNet

Topside Node
Length 330mm (13in.)
Height 91mm (3.6in.)
Width 483mm (19in.)
Weight in air 3.2kg (7lb)

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34
Topside Controls
ROV systems are controlled from consoles located on the host vessel, or in a
dedicated, road-transportable van. The ROV pilot commands the system through
the console flight stations, while the main system computers interact with the
DTS network to provide real-time control over the entire system.

Control Console
The ROV system is operated from a control console with two side-by-side
operator control stations. Either station can be used to operate the ROV, TMS,
manipulators, and nearly all other subsystems.
Features include:
 Built-in touch screen LCDs for issuing commands on the graphical user
interface (GUI) and viewing system status
 Flight control pods with flight joystick and other flight controls
 Tool control pods with rate hand controller for operating a rate-controlled
slave arm or other rate-controlled equipment, pan and tilt joystick, camera
and light controls, and assignable switches
 Heads-up display (HUD) with nine 24-inch LCDs for displaying the Master
Executive, Dashboard, camera views, sonar, and other graphic information
 Optional stand-alone master controller for position-controlled manipulators
 Keyboard, video, mouse (KVM) switch with keyboard
 Foot pedal for each control station controlling TMS tether functions
 Sonar remote (if sonar is used with the system) for sonar operation
 Fully adjustable pilot chairs with built-in air conditioning

35
 Power Distribution
Vessel / Main Power Requirements
The HD uses vessel power or a dedicated generator set to run the ROV system.
• Input Power 380 -480 VAC, 3 Phase, 50-60 Hz

Power Distribution Unit (PDU)

The power distribution unit (PDU) takes incoming vessel power to transform and
distribute the various voltages required for operation of the HD hydraulic and
control systems.

PDU Features
Protection
The PDU protects from over-voltage, under-voltage, phase loss and ground fault
detection. HPU power circuits can be disabled by software-detected conditions,
such as high motor temperature, high oil temperature, or low hydraulic fluid
reservoir level.

Transmission
The PDU steps up the incoming voltage to 4,160 VAC for delivery through the
umbilical to the HD ROV system.

Control and Monitoring

The PDU provides a local control panel with individual on/off controls, along with
current, voltage, and ground fault monitoring.

Emergency Stop Circuit

All doors and removable panels contain interlock switches that operate the
emergency stop circuit. If any door is opened or panel removed, all circuit
breakers will trip, cutting all instrument and HPU power. A phase sequence
monitor activates the emergency stop circuit in case of out of sequence three
phase power, phase failure or drop out, or phase imbalance.

36
Power System Remote Monitoring
In addition to the local controls on the PDU, there are power pages for remote
control and monitoring of the power system at the control console operator
stations. These GUI power pages include start/stop control buttons for the TMS
and ROV branch circuits and voltage, current and frequency displays.

Ground Switches
The PDU incorporates a high voltage grounding facility for safely isolating both
the ROV and TMS high voltage power during on-deck operations.

Ground Fault Detection (GFD) System

A Megacon GFD system is mounted within the PDU to monitor the three 4160
VAC power circuits for line-to-ground resistance.

37
 Vans
FMC Schilling Robotics can supply integrated control van and workshop systems
as required. Custom vessel installations can also be supported with FMC
Schilling Robotics personnel conducting on-site integrations. Standard design
configurations offer ergonomic and spacious layouts for the operators, with ease
of access to equipment also being a primary consideration. Work vans are also
fully outfitted with efficient storage space for spare parts and maintenance tools,
providing an effective environment for conducting system maintenance.

The compact PDU and optimized control console allow use of ISO
16ft x 8ft control and workshop vans as a system option. These vans can be
stacked offering an ultra compact format ideal for drill rig installations.

Workshop Van

38
Van Specifications
General Description
Dimensions L x W x H, Standard 6,058mm x 2,438mm x 2,519mm
Dimensions L x W x H, Option 4,876mm x 2,438mm x 2,519mm
Structural DnV CN 2.7-1 and BS EN 12079
Fire Rating - SOLAS Compliant A60
Electrical Installation IEE Compliant
Power Supply 480VAC 50/60Hz
Zone, Standard Safe Area
Zone, Option ATEX IEC Zone II
Control Van Standard Option
TARE Weight 12,000kg 10,000kg
Payload 2,000kg 2,000kg
Gross Weight 14,000kg 12,000kg
Air Conditioning (2) 9.8kW 9.8kW
Control Van Features
• Compliant Flooring Material in Control Van
• Emergency and Variable Task Lighting
• Fluorescent Lighting
• Shelving and Office Desk
• Multiple 110VAC / 240VAC Power Points
• Fire Extinguisher, Fire and Smoke Detection

Workshop Van Standard Option

TARE Weight 12,000kg 10,000kg
Payload 2,000kg 2,000kg
Gross Weight 14,000kg 12,000kg
Air Conditioning (2) 9.8kW 9.8kW
Workshop Features
• (2) Full-size A60 Doors
• Electrical Workbench Area with Power Sockets, Hydraulics Work Area
• (2) Multi-drawer Storage with Additional Cupboard under Workbench
• Compressed Air Points with External Connection
• (6) Double wall Cupboards, Large COSHH Cupboard
• (3) Heavy-Duty Multi-drawer Storage Units, (3) Heavy-Duty Cupboards
• Fire Extinguishers, Fire and Smoke Detection
• Emergency Lighting, General Fluorescent Lighting

39
 Launch and Recovery System
(LARS)
ROV systems are deployed from a variety of surface vessels, such as drill rigs,
ROV support vessels, and platforms. In each case, a launch and recovery system
(LARS) is required to lift the ROV and TMS to deploy it over the side of the
vessel or through the vessel moonpool. The LARS incorporates a hydraulically
powered umbilical winch, an armored umbilical, an A-frame (or similar), a
hydraulic power supply, and operator control station. The HD System is supplied
as standard with a LARS system. The winch can be used with either the standard
A-frame or optional telescoping A-frame.

LARS Specifications
 Compact installation footprint
 European Union (EU) road transportation compliant
 Designed to DnV 2.22 lift appliance code
 Combined LARS control station
 9.5 Te safe working load
 Supports up to 4,000 msw deployment

40
Technical Manuals &
Elementool
The Technical Manuals for FMC Schilling Robotics’ ROV systems include
information about the following:
 System operation and maintenance
 System power, telemetry, compensation, and hydraulics
 Topside and subsea components and devices
 Original equipment manufacturer (OEM) documents
 System and test software
 Other supporting documentation
Technical Manuals are provided in both print volumes and digital formats. CDs
and a USB flash drive with all digital files are supplied with each hard copy. The
digital manual files are also available online.

Access Online (http://elementool.com)

The manual files and other useful information are posted to the Elementool web
site in a password-protected directory assigned to each customer’s account.
 Enter the user name and password for your account. If you can’t remember
your login, contact technical support at [email protected]
 Press the drop-down arrow next to Issue Tracking and select File Sharing
Accessible files include:
 Technical Manuals, manual updates, bulletins, and support documents

41
 Manual Volumes

Volume 1 - System Information and Mobilization

 System Specifications, Customer Service, Safety Guidelines, Service
Guidelines, Maintenance & Inspection, Spares & Tool Kits, Mobilization

Volume 2 - Controls, Operations & Diagnostics

 System Software & Controls, Operational Procedures, System Diagnostics

Volume 3 - Telemetry, Power, & Compensation Systems

 Digital Telemetry System & Components, Electrical Power Systems &
Components, Cable & Slip Ring Terminations, Compensation Systems &
Components, System Schematics & Interconnect Diagrams

Volume 4 - ROV & ROV Hydraulic System and Components

 Information on the function, configuration, troubleshooting, maintenance,
and service of ROV-specific components, Main/Aux Hydraulic Systems,
Thruster & Thruster Control Unit (TCU), Valve Packs & Manifolds

Volume 5 - TMS & TMS Subsystems

• Information on the function, configuration, troubleshooting, maintenance,
and service of TMS-specific components.

Volume 6 - System Hardware & Components

 Topside Equipment, AC Junction Box, Lighting, Pan & Tilts, Sensors, Survey
Junction Box, Universal Control Modules (UCM)

Manual Revisions
New print volumes may be issued if there are major updates or revisions to their
content. Minor updates may be supplied in support of service, upgrade, or safety
bulletins.

Original Equipment Manufacturer (OEM) Documents

Most OEM documents are collected as digital files on the technical manual USB
flash drive for each system. Original OEM print manuals or copies are provided
as available.

42
Bulletins & Service Instructions
Bulletins
Service Bulletins and Service Alerts are issued by Customer Service when field
action:
 Is required to ensure personnel safety, equipment functionality, and/or
continuation of warranty coverage
 Will result in significantly increased levels of personnel safety and/or
equipment functionality
 May be useful under certain circumstances
Service Bulletin compliance is mandatory to maintain equipment functionality,
warranty, and safe working conditions. Service Alerts are optional and serve to
enhance operations and equipment. Bulletins can be accessed online through
http://elementool.com. Information developed for service bulletins is included in
the technical manual where appropriate.

Service Bulletins
Service Bulletins inform the client of a change to drawings or parts, to request
inspection of components, or to advise them of any other changes. Compliance
will vary depending on the severity of the issue. These are denoted by the 011-
XXXX part number (P/N) series.

Upgrade Bulletins
Upgrade Bulletins inform the client of parts or software changes that require the
exchange of parts. This may be free and covered under warranty or optional and
available for purchase. For example, a defect is noted in the Thruster Control
Board so an Upgrade Bulletin is created to inform the client of this and the action
needed to exchange this part. Compliance will vary depending on the severity of
the issue. These are denoted by the 012-XXXX P/N series.

Safety Critical Bulletins

Safety Critical Bulletins inform the client of a safety hazard in the system that
presents a serious risk of injury or death to personnel. Compliance with this type
of bulletin is always Safety Critical and requires immediate action by the client.
These are numbered depending on the nature of the issue. For an inspection
only, the 011-XXXX P/N series will be used. For exchanging or sending parts, the
012-XXXX P/N series will be used. This type of bulletin can be easily identified
by a red border and status box.

43
 Service Instructions
Service instructions detail all the information needed for completing the task of
replacing or servicing systems and subsystem components down to the lowest
replaceable unit (LRU). Reference all Service Instructions within the Technical
Manual.

44
Part Numbers, BOMs &
Assembly Drawings
Part Numbers
All FMC Schilling Robotics’ released parts, drawings, and documentations are
categorized by part numbers. Some important part numbers that are frequently
referenced include the following:

 001-xxxx Machined Parts

 002-xxxx Store Bought Hardware
 007-xxxx Welded Assemblies
 025-xxxx Hydraulic Schematics
 035-xxxx Electrical Schematics
 101-xxxx Assembly Drawings
 130-xxxx Procedural Documentations
 300-xxxx Custom Systems

Bill of Materials (BOMs)

FMC Schilling Robotics develop a bill of materials (BOM) for each assembly
manufactured internally. A BOM is a list of raw materials, sub-assemblies, parts
and the quantities of each that are needed to manufacture the end product. Item
numbers on the BOM are referenced with the associated assembly drawing to aid
assembly or repair of a part.

45
 8

4
Assembly Drawings 4 C

8 7 6

NOTES:
1. ITEMS LISTED BELOW TO BE TORQUED AS INDICATED:
ITEMS: TORQUE:
3 30 FOOT LBS.
Item #
2. BAG AND TAG ITEMS 4 AND 5 QTY 14 EACH PER SHOP STANDARD.
5
3. CHARGE ACCUMULATOR TO 1900PSI. 2
Quantity #
D

8 7 6 5 4 3 2 1
PCO REV ZONE DESCRIPTION DATE BY APPR
NOTES: 1582 0 - RELEASED FOR PROTOTYPE 9/17/10 RDJ DF
1930 1 - UPDATED TO REFLECT BOM REVISION; 1/06/11 SWR DF
1. ITEMS LISTED BELOW TO BE TORQUED AS INDICATED: DELETED NOTE 2
ITEMS: TORQUE: 2826 2 D8 ADDED NOTE 2 5/24/11 SWR DF
3183 3 - ADDED NOTE 3 7/28/11 NLH DF
3 30 FOOT LBS.

B
2. BAG AND TAG ITEMS 4 AND 5 QTY 14 EACH PER SHOP STANDARD.
3. CHARGE ACCUMULATOR TO 1900PSI.

D D

3 1
B
2 2

3 1
2 2
C C

4
4

5
2 6

3
2

B B

5
2

4
4

C
1
A 2
A
GENERAL NOTES
UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION
INTERPRET DIMENSIONING AND TOLERANCING
PER ASME Y14.5M-1994. IN ADDITION, S
DENOTES REGARDLESS OF FEATURE SIZE.
9 DIMENSIONS APPLY AFTER ALL PROCESSES
HAVE BEEN COMPLETED.
REMOVE ALL BURRS AND BREAK ALL SHARP
EDGES.
PROJECT HD

8
ALL MACHINED SURFACES TO BE 63 RMS FINISH.
HYDRAULIC POWER UNIT,
SIGNATURE DATE
TITLE
DIMENSIONS ARE IN INCHES. DRAWN
R. JONES 9/17/10
150 HP, HD
CONCENTRIC FEATURES ARE TO BE CONCENTRIC
PROPRIETARY WITHIN .005 REGARDLESS OF FEATURE SIZE DESIGNED

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO

RELEASED FOR DECIMALS
TOLERANCES
FRACTIONS ANGLES CHECKED
D. FURMIDGE 8/02/10
SCALE: DRAWING NUMBER SIZE SHEET REV
SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR .X ±.1 X. ±1 0'
USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT
AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING. PROTOTYPE .XX ±.02
.XXX ±.005
±1/16 X.X ±30'
X.XX ±15'
LEAD
D. FURMIDGE 1:5 101-7331 D 1 OF 1 3

8 7 6 5 4 3 2 1

4
4
A

A
GENERAL NOTES
UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION
INTERPRET DIMENSIONING AND TOLERANCING
PER ASME Y14.5M-1994. IN ADDITION, S
DENOTES REGARDLESS OF FEATURE SIZE.
DIMENSIONS APPLY AFTER ALL PROCESSES
HAVE BEEN COMPLETED.
REMOVE ALL BURRS AND BREAK ALL SHARP
EDGES.
PROJECT HD
ALL MACHINED SURFACES TO BE 63 RMS FINISH.
HYDRAULIC POWER UNIT,
SIGNATURE DATE
TITLE
DIMENSIONS ARE IN INCHES. DRAWN
R. JONES 9/17/10
150 HP, HD
CONCENTRIC FEATURES ARE TO BE CONCENTRIC
WITHIN .005 REGARDLESS OF FEATURE SIZE DESIGNED

RELEASED FOR TOLERANCES

CHECKED
D. FURMIDGE
5 8/02/10
DECIMALS FRACTIONS ANGLES SCALE: DRAWING NUMBER SIZE SHEET REV
.X ±.1 X. ±1 0'
2
PROTOTYPE .XX ±.02
.XXX ±.005
±1/16 X.X ±30'
X.XX ±15'
LEAD
D. FURMIDGE 1:5 101-7331 D 1 OF 1 3

3 PROPRIETARY 2 1
THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO
SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR
USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT
AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING.

B 8 7

46
Shop Standards & Torque Table
NOTE: This information defines standard practices, settings, and assembly techniques
that are commonly used with the FMC Schilling Robotics supplied equipment. In all cases,
the information supplied in the Technical Manual, service/upgrade/safety bulletins, or
engineering drawings supersedes the information below.

Safety
Personal Protective Equipment (PPE)
 Be aware of your surroundings and the work being performed in your
vicinity. Observe posted PPE requirements for the area you are working in.
Each team member has the obligation to uphold safety for himself/herself
and others in the company.
 Approved safety glasses and steel toe shoes must be worn at all times when
working or passing through the shop floor.
 Goggles, hard hats, fall-arrest equipment, gloves, high-voltage foot
protection and personal floatation devices (PFD) shall be utilized when and
where required.

Material Safety and Data Sheet (MSDS)

 Information about the hazard and safety of the chemicals used in a
process is listed in the MSDS. Consult your area supervisor or EHS
representative for more information about MSDS. Use chemicals,
adhesives and lubricants in accordance with the work instruction and/or the
manufacturer’s recommendations.
 Caution: Chemicals containing solvents, including Loctite and acetone, must
never come in contact with any acrylic, polycarbonate or Isoplast materials.
Assume that any component that is made of clear plastic can be damaged
by solvent-based chemicals. Consult your area supervisor or engineer if you
are unsure of the materials you are working with.

Handling Lead
 Always use leather or rubber gloves when handling lead. Refer to the
MSDS to learn about the specific health hazards associated with lead.
Always wash your hands with soap and water after performing operations
that involve the handling of lead.

47
 Lifting
 Always use your legs and not your back when lifting heavy objects. If
an object is too heavy for one person to lift, ask for help and/or use the
appropriate device.

Fork Lift and Crane Operation

 Only team members with the appropriate training or certification on file
can operate a fork lift or crane. Hard hats are required for all overhead
lifting operations.

Trip Hazards
 Many manufacturing areas have electrical, air or hydraulic lines lying on the
floor. Be extremely watchful of these trip hazards when traveling through
all manufacturing areas.

Electrical Hazards
 Do not step on or kick cables or wires on the floor; or drive over cables and
wires with carts, dollies, pallet jacks, etc.; they could be energized with high
voltage and might injure you.

Electro Static Discharge (ESD)

 ESD may be hazardous when working in proximity of volatile substances.
ESD may also damage electronic devices. Refer to 130-0033 for more
information.

First Aid
 First aid for minor injuries or over-the-counter medication shall be used
only for self-medication. (Do not administer first aid to others).
 Fill out injury report for all incidents regardless of how minor the injury
may be.

Emergencies
 Summon the emergency response team (ERT) to the emergency location
using the paging system as follows: (ext 7000 + listen for “Beep” + dial “0”
+ speak message). When in doubt, call 911 by dialing 9 + 911.

Injury and Illness Prevention Program

 Refer to IPP 130-0359 to review all company procedures.

48
Documentation

Documentation Package
 Shop Standards, forms and templates are on the Schilling Network at O:\
Systems Mfg.
 The technician shall print copies of all the assembly documents: BOM, test
data sheet (TDS), work instruction (WI), and/or drawing.
 The assembly documents shall be organized and processed in accordance
with the Build Book Shop Standard/Template.
 Forward doc package (all redlines and production audit) to the Production
Coordinator upon completion of the build process. Discard drawing, BOM
and/or WI if no red-lines were generated.
 BOM Items/Zero QuantityThe BOM shall list any documents, tools and/or
consumables that are required for assembly and/or inspection. These items
shall be listed at the end of the BOM and stated as quantity zero.

Interpreting Indented Item Numbers

 Indented items are represented with brackets and hyphens to separate item
numbers from there corresponding BOM. The hyphens used within the
brackets of an item number are not dash numbers.
 Item numbers may display several sub-assemblies before arriving at the
indicated or subject component. The component will always be the last
number in the bracket. All of the preceding numbers within the bracket are
assemblies.
 Referring to the illustration below, items (2), (3) and (4) are indented items
of item (1). The indented item brackets typically contain two or three
levels.

49
 Serialization and Part Identification
 Work Order serial number is the job number without the “80” prefix
(normally six digits). The serial number may contain alpha and numeric
characters.
 Cell Build serial number with Kwikbuild is the date code, YYMMDD.
Example: January 5, 2010 is 100105
 Serial number (S/N) extensions give each assembly a unique identifier that
is used to provide traceability with other assemblies. S/N extensions shall
always be used when identifying assemblies.
–– Part identification is made up of the following: Part number, BOM
revision, job number and serial number extension.
 Conversion Jobs: Keep original serial number – Change part number and
revision.
 Rework Jobs: Keep original serial number – Change revision letter only if
rework fully upgrades assembly to the next revision. Exception: Use new
job/serial number if original serial number is missing or no longer visible.
 Permanently identify all parts and assemblies as shown in the examples
below:

 Example 1 (Two Lines, Preferred):

–– 101-XXXX X
–– XXXXXX-X
 Example 2 (All on One Line):
–– 101-XXXX X XXXXXX-X

50
Workmanship

Quality
 Documentation hierarchy for over ruling specifications: Drawing/BOM,
work instruction (WI) and Shop Standard.
 Focus on quality is our number one responsibility.
 The top assembly and all subassemblies shall have a test data sheet (TDS)
to accompany either a drawing or work instruction. All of the specified
quality control (QC) points shall be performed by an authorized inspector
per 130-0365.
 All specified QC points on the TDS must pass inspection for the assembly
to be complete.
 The assembly technician shall record inspection and/or test results on the
TDS. The QC points and tests listed on the TDS shall be confirmed, signed,
and dated by an authorized QC inspector.
 Issues, changes or corrective measures taken during the assembly process
shall be recorded in the “remarks” section of the TDS.
 Issues may also be addressed using Elementool (at www.elementool.com/)
per 130-0332. Check with your supervisor for training on how to use the
Elementool program.

Accuracy of Documentation
 REVIEW ALL DOCUMENTATION ENTRIES FOR ACCURACY AND
COMPLETENESS!
 Redlines may be generated by the assembly technician but must be
approved before implementing the change in production.
 All red-lines must be approved by a design or manufacturing engineer to be
valid.
 Discrepancies in BOMs, drawings or work instructions must be addressed
by Manufacturing Engineering at the time they are discovered.

51
 Accuracy of Assembly
 Physically verify that all components listed on the BOM(s) have been
properly incorporated into the assembly as specified in the drawing and/or
work instruction.
 It is expected that the finished assembly “look like” the drawing.
 Verify that soft lines, hoses, high pressure tubes and/or cables are identified
with their corresponding part numbers (where applicable). Lines with long
runs need to have a label at each end of the line to aid in inspection and
maintenance.

Keeping Track of Material

 All unassembled parts, including subassemblies, must be identified.
 Transient materials are items that will ship with a system but are not
incorporated in the assembly. These items shall be identified by their UHD
Number and part number then stored in a pre-assigned location.
 Materials needed at the next assembly must be bagged and tagged using
the appropriate tag template and attached to the subassembly. When bag
and tag is called out on the drawing; bag each item individually and label
the bag with BOM item number, part number, quantity and description.
Secure the individual bags together into a larger bag or box. Label this
box or bag with the assembly part number, quantity and serial number.
Attach packaging to the assembly. Alternatively, items needed at the
next assembly may be installed on the subassembly in a loose yet secure
manner. Identification of loose items is not needed in this case.

Discrepancies
 Visually inspect the assembly for quality defects such as dents, cuts, deep
scratches, leaks, loose hardware, and/or sharp or protruding objects.
 Submit an “Inspection Request” e-mail to notify supervision and quality
assurance when discrepant materials or damaged components are
discovered during assembly.
 Contact Manufacturing Engineering for issues that require root cause
analysis and preventative measures to prevent future occurrences.

Status White Board

 The white boards shall be used to schedule daily activity and record issues.

52
Mechanical

Installation of Fasteners
 All fasteners shall have a retaining mechanism to prevent loosening. (i.e.
patch bolts, nylock nuts, lock washers, etc.). Note patch bolts alone do
not work in mechanisms where Loctite is required. Use Loctite instead of
lubrication.
 Apply Primer N to threads of mating components.
 NEVER use Loctite with patch or nylon insert fasteners.
 NEVER use any Loctite products on Isoplast material (compensator
housings).
 ALWAYS use Loctite sparingly.

Sealant Application
 Teflon tape 002-0798 on pipe threads into compensator housings.
 ORFS fitting shall be lubricated with EP on the threads and o-ring.
 Use PST sealant 002-1618 on CV plugs into anodized aluminum per 130-
0098.
 Use PST sealant 002-1618 on stainless steel pipe threads.

53
 Adhesives
 All adhesives require clean, close-fitting surfaces. Do not fill large gaps with
extra adhesive. Always follow the manufacturer’s instructions for mixing
and application.

Dissimilar Metals
 Assemblies of dissimilar metals (such as aluminum to stainless steel)
shall be isolated with non-metallic spacers. These spacers are normally
incorporated in the design or installation kit.
 Mating surfaces made of untreated steel (for example, pump faces) shall be
coated with a thin layer of Aqua Lube before installation.
 Mating surfaces near o-ring grooves made of stainless steel and aluminum
(untreated or anodized) shall be coated with a thin layer of Desitin (zinc
oxide) before installation.
 Consult the manufacturing engineer if further assistance is needed.

Cable Ties
 All cable ties shall be trimmed after installation. Excess cable tie material
shall be trimmed flush with the clinching head of the tie using flush cutters.
Ensure that no sharp edges remain after trimming.

Hose Clamps
 Hose clamps shall be positioned near the end of the hose and installed over
a barbed fitting. Leave a small gap between the edge of the clamp and the
end of the hose. Tighten the clamp until the surface of the hose begins to
bulge around the edges of the clamp. Do not over-tighten clamp; add a
second clamp if required.
 The protruding band is an obstruction and safety hazard. The extra band
material can be tucked underneath the assembly to prevent snagging or
injury by the sharp edges at the end of the band. Alternatively, the extra
band material may be secured with cable ties to keep the band flat against
the rest of the assembly.
 Hose clamps used to mount devices shall be covered with shrink wrap
around the perimeter of the device, except in the area that is required to
tighten the clamp.
 Install Oetiker clamp per 130-0073.

54
Routing Flexible Lines
 “Flexible line” is a generic term for hoses, electrical wires, fiber optics, etc.
 Flexible lines shall be routed by layering each system in small bundles that
can be easily traced.
 Do not weave lines; keep lines routed in unidirectional bundles.
 Make sure lines connected to articulating devices have just enough slack to
allow proper range of motion.
 Each installation needs to have proper identification to facilitate inspection
and maintenance.
 All flexible lines shall be securely fastened with cable ties approximately
every 4” on straight runs.
 NEVER route lines in the path of the thruster wash (jet stream). Lines on
the edge of the thruster wash must be secured with heavy cable ties
 Excess material shall be coiled and secured to immovable objects in an
area where it will not be affected by or caught in a thruster or articulating
devices.

Installation of Seals
Proper installation of o-rings is vital to the devices we create at FMC Schilling
Robotics. The following information points are essential when installing o-rings:
 Inspect the o-ring and gland assembly for abrasions, nicks, scratches, dents,
etc. Do not assemble damaged materials.
 NEVER use cotton tipped swab to apply lube to an o-ring or gland. Swabs
will contaminate lube supply and application with lint debris.
 ALWAYS use o-ring lube sparingly.
 Use DC111 for large o-rings and face seal applications requiring “sticky”
 Apply 002-0799 silicon grease on all pin-to-sock connections and PCB
instillations.
 Lubricate Burton connectors prior to installation.

Soldering
 Soldering shall be performed in accordance with the following
requirements: IPC-A-610 Class 3 for PCB and IPC-A-620 Class 3 for cables
and wires.
 Soldering performed by systems manufacturing shall be limited to tinning
of wires.

55
 Torque Table

56
Technical Support & Contacts
[email protected]
24-hour support U.S.A: +1 866-342-2562
Outside U.S.A.: +44 (0) 1224-215-319

 24-hour telephone support with qualified technical staff

 Detailed manipulator system Technical Manuals with full part lists,
engineering drawings, and schematics
 Download our Technical Support Flyer from www.schilling.com and visit the
Pr​oduct FAQs page​for additional support​​

For urgent issues, FMC Schilling Robotics offers a 24 hour, 7 days a week help
line. This help line is staffed by qualified FMC Schilling Robotics technicians and
engineers. Support staff have extensive knowledge and experience on all FMC
Schilling Robotics products and related offshore operations.

57
 Installation and Mobilization
After completion of the ROV system factory acceptance test (FAT) and delivery
to the work site, two FMC Schilling Robotics field service engineers (FSEs) are
deployed to assist the customer with the installation and mobilization of the
equipment onto the vessel, upon request.

Field Service
FMC Schilling Robotics’ factory-trained FSEs are available to service customer’s
manipulators, ROVs, and control systems. FSEs can provide service offshore and
on land anywhere in the world. The regional service teams can provide multiple
services.

 On-site technical support & training

 Site installation & testing (SIT) management & support
 OEM integration / interface testing
 Offshore operational support, troubleshooting, preventative maintenance
and repair

FSE personnel are thoroughly trained on:

 Hydraulic Systems
 Mechanical Systems
 Electrical Systems
 Fiber Optic Systems
 Software Systems

58
Customer Service Contacts

Headquarters
[email protected]
+1 530 753 6718

Gulf of Mexico Regional Office

+1 281 598 4100

North Sea Regional Office

[email protected]
+44 (0) 1224 215300

Asia Pacific | FMC Technologies

149 Gul Circle, Singapore
[email protected]
+65 6861 3011

Brazil | FMC Technologies

Rodovia Amaral Peixoto s/n KM187
Lote 1, Quadra 1, Cabiunas
Macaé - CEP 27913-350 Brazil
[email protected]
+55 22 2773 0718

Japan | Nishiyama Corporation

1-17-14 Ohyodo-Naka, Kita-Ku, Osaka City,
Japan
+81 (0) 6 6453 0627
Contact: Kazuhiko Shigeno

Norway | Innova A/S

Lagerveien 12 C 4033, Stavanger, Norway
+47 51 96 17 00

59
 Local Support & Spares
Global Presence, Local Support
The subsea oil and gas market is a global enterprise, and we maintain a global
presence to support it, with facilities in all major offshore regions. FMC Schilling
Robotics is a wholly owned business unit with FMC Technologies, which
has strengthened our capacity for worldwide sales and managing complex
international logistics for the oil and gas industry. Our regional support centers
provide training, technical support, and an inventory of spare parts. Our support
staff members are fluent in local languages with proven experience in managing
complex international logistics. When help is needed on-site, our highly trained
FSEs are experienced in assisting customers.​

Spare Part Sales

FMC Schilling Robotics maintains comprehensive spares inventory for all
products in regional facilities that are available 24/ 7 for supporting customer
operations. FMC Schilling Robotics stores spares for installation, commissioning,
operations, maintenance, and repair. Our spares philosophy is to store any
part that could make the equipment inoperable were it to fail during normal
operations. Regional facilities stock all genuine FMC Schilling Robotics parts.

60
Repair
FMC Schilling Robotics’ regional facilities have technicians and equipment to
locally repair products. All items sent back to FMC Schilling Robotics for repair
are given a returned material authorization (RMA) number for traceability from
the time the part is received, until it is returned to the client. All repairs are
completed by qualified FMC Schilling Robotics trained technicians.

61
Notes
Notes
Notes
Notes
Schilling Robotics
Heavy-Duty (HD™) ROV
Training Course Student Guide

The Heavy-Duty (HD) ROV employs innovative technology to bring a

high performance 150 shp work-class ROV system to the market that
has a compact deck footprint, while providing design features and
performance normally reserved for larger systems.

67
 We put you first.
And keep you ahead.

Heavy-Duty (HD) ROV

Training Course Student Guide

Table of Contents

Heavy-Duty (HD) ROV........................................................................................ 70

Buoyancy & Protection...................................................................................... 73
ROV Compensation............................................................................................ 78
Hydraulics ............................................................................................................ 80
Manipulator Systems......................................................................................... 94
Devices & Equipment......................................................................................... 98
Sensors................................................................................................................ 107
Flight Modes ......................................................................................................117

69
 Heavy-Duty (HD) ROV
At 150 horsepower and a standard depth rating of 3,000 meters (4,000 meters
optional), the key to the Heavy-Duty (HD) ROVs overall performance success is in
the development of subsystems, and how easily they interface with each other. A
number of unique features that dramatically improve the system reliability and
productivity set the HD apart from other similar systems in the market. Several
of these key features are detailed below and include:
 High voltage power system (4,160 VAC)
 Hydraulic propulsion and tooling control
 Integrated HPU (motor, pumps, reservoirs and filters)
 Vehicle control (StationKeep throughout the entire water column)
 Open deck space for tooling
 Removable full buoyancy protection
 Automated operator controls
The HD is classified as a Class III B (>100 hp) work-class ROV system, in
accordance with the definition provided by the NORSOK U-102 standards for
Remotely Operated Vehicle (ROV) services.

NOTE: NORSOK standards are developed by the Norwegian

petroleum industry to ensure adequate safety, value adding and cost effectiveness
for petroleum industry developments and operations.

70
Weight and Dimensions
The HD is optimized for a compact overall system, yet provides a stable platform
with sufficient space for additional tooling. Core vehicle dimensions are
illustrated below.

Frame
The vehicle frame supports a wide range of inspection, maintenance, repair
(IMR) construction tasks, as well as typical drilling and field development support
tasks. Frame features include the following:
 DNV certified
 Adjustable lift points
 Load-tested emergency lifting sling
 Multiple pan and tilt attachment points
 Forward, aft, and underslung tooling interfaces
 Manipulator mounting pads
 Sensor-mounting area
 Hydraulic quick-disconnect (QD) points for deck cart
 Frames and bumpers for protecting vehicle buoyancy and peripheral
equipment
 Lightweight, removable grating providing a modular deck for equipment
installation
 Integrated payload storage areas providing for easy adjustment, installation
and removal of lead blocks

71
 Tooling Capabilities
The ROV has forward, aft, and underslung tooling interfaces for installing
additional equipment with a combined load up to 3000 kg TFL (maximum). The
attachment locations and dimensions include the following:

Under-Slung
The frame bottom has a 4-point mechanical interface for underslung loads up to
3000 kg. The four-point interface allows the insertion and extraction of locking
pins and enables straightforward docking of skids on deck.

Aft
A universal interface frame allows the connection of various work packages
such as the tooling deployment unit (TDU), dirty work pack, and suction anchor
system, to the aft frame docking points. Up to 600 kg of equipment can be
attached, as a part of the 3000 kg TFL total.

Fore
The forward interface for structural tooling/equipment attachments meets survey
task requirements such as multibeam/pipetracker installation.

72
Buoyancy & Protection
Buoyancy Overview
The buoyancy modules are syntactic foam structures designed for maximum lift
efficiency. Vertical thruster tunnels are located near the front of the blocks for
optimal pitch/roll control. Characteristics of the buoyancy modules include the
following:
 Each flotation block contains lift points recessed within the blocks to
facilitate safe installation and removal
 Flotation blocks are installed with threaded rod and bellville washers to
accommodate for buoyancy size changes at depth
 Three buoyancy modules are installed (one forward/two aft)
 Buoyancy edges protected with plastic guards
 Non-skid and non-reflective surfacing is applied to the top of the buoyancy
modules

Vehicle Protection
Protective guards surround the vehicle to protect buoyancy and peripheral
equipment. The guards are manufactured from highly impact resistant
polypropylene. The material is also neutrally buoyant, rather than aluminum and
heavy bumper rubber sections currently being used on conventional equipment.
They are lightweight and can be easily removed for maintenance by quick-release
fasteners in convenient locations.

Quick Release Fasteners

73
 Compensation & Water
Detection
Theory
The HD system is subject to immense pressures at depth. In order to combat
component failure due to crushing forces and water intrusion, numerous
components and devices utilize active compensation to remain functional while
submerged. Any component with an open cavity is filled with hydraulic fluid that
is maintained at 8-10 psi above the ambient water pressure. For components that
may be sensitive to hydraulic fluid, special one-atmosphere housings are used to
maintain the same internal pressure as the surface. Additionally, components are
equipped with water detection circuitry that will alarm the pilot if water intrusion
is detected.

The ROV and TMS have several compensation circuits. Each circuit is
independent, has one or more compensators, a fill point, a volume sensor,
and one or more connected devices. Each circuit will have one or more QD
for isolating devices and allowing them to be drained without affecting the
total circuit. Individual circuits are shown on the ROV and TMS compensation
schematics for each system.

74
Hydraulic Compensator
 2.2 liter volume
 20 psi relief valve
 Filled with a non-compressible fluid, such as hydraulic oil
 Oil filled housing and water side housing separated by diaphragm
 Spring applies 8 to 10 PSI on end of piston.

Upon submersion, water enters through holes in water side housing. Water
pressure plus spring pressure acts on end of piston, increasing pressure on the
oil side, therefore compensated cavities are always 8 to 10 PSI above ambient

! WARNING !
Spring pressure inside the compensator is extremely dangerous. Never remove the
v-band clamp connecting the oil side housing to the water side housing without first
consulting the SI 011-5041 in the Technical Manual.

75
 How Compensation Works

76
Compensation Cart
The compensation cart uses air pressure to quickly vacuum air from
compensated lines and components and fill them with fluid. The vacuum
produces a more complete fill by removing about 90% of the air from the
component before it is filled. This is also useful prior to service or maintenance.

Specifications
 Compressed air input 5.52 to 8.62 bar (80 to 125 psi) @ 3.2 cfm (1.51 l/s)
 Input regulated to 1 bar (15 psi) @ no flow
 Output fluid pressure @ <1 bar (15 psi)
 Tank capacity 37.85 L (10 gal) with fluid level indicator
 Particulate/water filter element
 An in-line air filter and input regulator
 A three-way control valve: (1) charge (fill) (2) off (3) vacuum (drain)
 A fill/vacuum pressure gauge
 Male and female quick disconnect (QD) fittings

Servicing a Compensation Circuit

Refer to the manual volume on “Compensation System & Components” for
procedures to fill and drain ROV & TMS compensation circuits.

NOTE: Never mix ROV main or auxiliary reservoir hydraulic fluid

with compensation circuit fluids.

77
 ROV Compensation

Compensation Circuits

78
Devices & Cables
The vehicle compensation system consists of individually isolated circuits for
subsea devices that require pressure compensation. Subsea devices are grouped
together to allow the minimum number of circuits, but not cause unnecessary
single failure points of critical components. All compensator circuits are fitted to
provide feedback for monitoring fluid levels.

Each circuit is sized to account for fluctuations in fluid volume due to changes
in depth, and all volumes are displayed by the system software in the form
of histographs, providing operators the ability to display circuit volumes over
periods of 2, 6, 12, or 24 hours.

QD’s are utilized throughout each circuit to facilitate easier servicing and trouble-
shooting.

79
 Hydraulics
Theory
Hydraulic systems use a non-compressible fluid to transfer power. Pumps are
used to create flow in a hydraulic circuit, and valves can be used to direct that
flow to different devices. When opposition or restriction to flow is introduced,
system pressure (PSI) increases and movement in the hydraulic system will
occur.

All HD ROV propulsion and tooling systems are hydraulically driven in order to
provide the highest performance possible. The vehicle uses an electric motor to
drive the pumps for both the main and auxiliary HPU circuits. These pumps are
load compensated, variable displacement pumps. The amount of displacement is
varied automatically to keep a constant pressure.

80
Integrated Hydraulic Power Unit (HPU)
The vehicle is supplied with a 150 shp double-ended hydraulic power unit (HPU).
The entire HPU can be removed as a module from the vehicle with minimal
effort. The hydraulic connections mate to the vehicle supply and return pipe-
work on a quick disconnect type arrangement.

HPU Motor
The motor is designed to integrate seamlessly with the hydraulic pump modules
through the distribution manifolds which form the motor end caps as well as
provide the pump interfaces. The motor includes integrated water detect and
winding temperature sensors.

Type.............................................................................................AC Induction motor 4 Pole

Motor rating.................................................................................................150 shp [112kW]
Operating RPM...................................................................................................1740 at 60Hz
Motor operating voltage...................................................................... 4,160 VAC at 60 Hz

81
 HPU Motor Distribution Manifolds (“Head Plates”)
An important feature of the HD is the integration of a large portion of the main
and auxiliary hydraulic circuitry within the HPU motor distribution manifolds,
also known as head plates. The head plates incorporate the high and low
pressure filters, control, instrumentation electronics and sensors, as well as
providing the physical installation points for the pump modules and HPU motor
itself. A SeaNet connection from the main and auxiliary head plate carry serial
control and instrumentation data to and from the DTS.

82
Main Hydraulics
The main hydraulic system includes the thruster case drain circuit, which flows
into the main circuit return.

NOTE: Reference the Technical Manual and Service Instructions

for fill, bleed and drain procedures.

83
 Main Pump
A 135 cc pump provides pressure and flow for operation of the vehicle’s main
hydraulic circuit. The main circuit operates the ROV propulsion system, as well
as a tooling valve pack for manipulators. The pump is housed within its own
reservoir can and submerged in oil, providing a quick mating facility to the HPU
motor head plate. An accumulator is installed in the main circuit and is located
inside of the main pump/reservoir can. The purpose of the accumulator is to
smooth the flow of fluid to the pump control block to prevent oscillations in
pressure. The accumulator is charged to 1900 psi with nitrogen.

Main Pump Specifications

Pump Manufacturer.......................................................................................Linde HPR 135
Displacement.................................................................................................................. 135 cc
Operating Pressure (max)...................................................................... 275 Bar [4000 psi]
Operating Flow (max)..............................................................................242 lpm [64 gpm]

84
Thruster Control Unit (TCU)
The thruster control unit (TCU) is used to house the proportional pressure
reducing valves for controlling the vehicle thruster operations, an over-pressure
relief valve, and the control printed circuit board (PCB). The TCU is designed
to ensure redundancy by separating the manifold into two control areas that
allows limited thruster operation in the event a single control area is lost. The
TCU relief valve on the supply circuit prevents over-pressure of the system and
vents to the return circuit. Red, amber, and green LEDs on the TCU PCB provide
diagnostic information. The manifold is compensated and equipped with a
water detection circuit.

Each TCU can control up to four thrusters. Two TCUs are used on the ROV to
control the forward and aft thruster groups.

85
 Sub-Atlantic Thrusters
Seven SA-380 hydraulic thrusters are installed on the HD ROV. Each thruster
is fitted with a speed sensor in order to provide “closed-loop” feedback on
thruster shaft speed. The control system processes the feedback and adjusts
pressures accordingly, enabling precise ROV control as well as advanced auto-
functions such as StationKeep, AutoDisplacement, Auto Depth, Auto Altitude,
Auto Heading, Auto Pitch and Auto Roll. Thruster speed sensors are connected
directly to the TCU PCB.

Thruster Case Drain & Bearing Compensation

Each thruster bearing housing is actively compensated through the case drain
and bearing compensation manifold located above its respective TCU. The
bearing housing has five ports to allow purging of air in any thruster orientation
on the vehicle.

86
Auxiliary Hydraulics
NOTE: Reference the Technical Manual and Service Instruction
for fill, bleed and drain procedures.

87
 Auxiliary Pump
The auxiliary pump provides pressure and flow to operate auxiliary equipment,
such as hydraulic tools, on a separate hydraulic circuit that is isolated from the
main propulsion circuit. The pump can produce 36 hp [27kW] at its nominal
pressure and maximum flow. A flow meter mounted in the auxiliary circuit
head plate provides feedback of hydraulic flow to the operator GUI. The pump
is housed within its own reservoir can and submerged in oil, providing a quick
mating facility to the HPU motor head plate identical to the main pump can.

Auxiliary Pump Specifications

Pump Manufacturer........................................ Rexroth A10VO 45 DRG/31L PSC62N00
Displacement......................................................................................................................45cc
Circuit Pressure (max)............................................................................ 207 Bar [3000 psi]
Operating Flow (max)................................................................................ 72 lpm [19 gpm]

Distribution Manifold
The auxiliary circuit distribution manifold provides hydraulic pressure, return,
and relief for connecting tooling and other types of hydraulic equipment.

88
3-Function (3F) Manifold [optional]
The 3-function (3F) manifold is used for controlling customer-supplied tooling,
providing two bi-directional, proportional pressure/flow control valves and one
proportional high flow control valve. Valve operation is typically controlled
from the TOOLS/VALVE 3 page on the GUI, which also displays aux hydraulic
pressure, manifold pressure, and flow. This component is compensated and
equipped with a water detection sensor.

3F Manifold Specifications
Operating Pressure................................................................................ 207 BAR [3000 psi]
Circuits A & B (max)................................................................................32 LPM [8.5 gpm]
High Flow Valve (max).............................................................................. 72 LPM [19 gpm]

89
 Hydraulic Components
Pressure Gauges
Compensated gauges are installed at the front end of the HD ROV within clear
viewing range of the pan & tilt camera. Gauges are provided as a backup for
monitoring main and auxiliary system pressure.

Cardev Filter
The main and auxiliary hydraulic circuits are equipped with Cardev filters. The
main purpose of the filter is to remove water contamination from the hydraulic
system, ensuring maximum life of hydraulic components.

90
Sub-Atlantic 8-Function (8F) Valvepack
The system is fitted with two eight-function valve packs, one connected to the
main hydraulic circuit and one connected to the auxiliary hydraulics circuit.

SA 8F Specifications
 8 station proportional pack fitted with 7 ea. solenoid and 1 ea. proportional
valves [optional configurations available]
 Variable input pressure 145 psi (10 Bar) – 3,000 psi (210 Bar)
 Variable remote flow control (proportional valves)
 Proportional valves - 8 lpm max at 3,000 psi (200 Bar)
 Solenoid valves - 14 lpm max at 3,000 psi (200 Bar)
 Externally adjustable and removable pressure relief/pilot-operated check
valves and flow metering valves on each station
 Valve packs have integrated software control through the operator GUI
 Each valve pack is actively compensated

91
 Hydraulic System Filling & Draining

Fluids
The vehicle is tested using Tellus® 32 hydraulic oil. Reference the Technical
Manual for fluid selection and system servicing guidelines.

Fill & Drain Connections

The HD hydraulic circuits include easily-accessible fill and drain ports to facilitate
fluid removal or replacement. Quick-disconnect type fittings are used for each
circuit.

Hydraulic Hammer Effect

The effect caused when high pressure is suddenly applied to the hydraulic
circuits from an external source is known as “hydraulic hammer.” The rapid flow
of oil and high pressure may cause damage and fatigue to components. Only
open a ball valve on a high pressure line below 1000 psi and open the valve
slowly.

NOTE: Never run the main or auxiliary pump if the oil level is below 75% in the sight
glass on either pump.

75%

92
Deck Hydraulics, Auxiliary Power Unit (APU)
An auxiliary power unit (APU) or “Deck Cart” is included with the system to allow
for system testing, filling, and draining without having to use high power or the
vehicle’s HPU.

The APU has fully adjustable flow and pressure settings, with max pressure
reaching 3000 psi. Pressure and flow gauges built into the control panel allow
for easy monitoring while in operation. The reservoir has a capacity of 60 US
gallons. An optional water separator can filter out moisture from the APUs
reservoir or the vehicle itself. 120 VAC is available from a plug directly below
the main power junction box. To run the vehicles hydraulic system on deck using
the APU, refer to the “Using the APU” document, 130-1581, of the ROV Technical
Manual.

The APU has three circuits:

 System Pressure Circuit: Allows you run all vehicle functions
 System Fill/Return Circuit: Used to fill or drain the vehicle hydraulic
systems
 Tooling Circuit: Uses a simple A-B circuit to operate other equipment

93
 Manipulator Systems
Each ROV is outfitted with two manipulators that provide a high degree of
dexterity and lifting capability. These manipulators offer multiple degrees of
freedom (or range of motion), ranging from a simple 5-function arm that is
typically used to hold or lift objects up to a 7-function arm with position control
that can perform highly accurate operations.

Schilling manipulators are used on virtually every work-class ROV in the world
and are recognized as an industry standard. The TITAN 4 manipulator is
specifically designed to provide the optimum range of motion, strength, and
reliability. Other manipulators in the product range include the RigMaster,
ORION, CONAN, and ATLAS, which can be provided in a variety of
configurations to best suit specific applications and different types of ROVs.

The standard HD ROV includes the TITAN 4 and the RigMaster Manipuator.

94
TITAN 4

7 Function Position Controlled arm

 Powerful & dextrous
 Reliable
 4000 msw depth rating

ATLAS 7R

7 Function Rate Controlled

 High lift capacity & rugged design
 Economical
 Ease of maintenance

RIGMASTER

5 Function Rate Controlled Arm

 Strong, rugged and reliable
 High lift-to-weight ratio
 6,500msw depth rating
 Interchangeable jaw configurations
 Boom function extends arm length by 305 mm (12 inches)

95
 CONAN

7 Function Rate/Position Controlled Arm

 High lift capacity & rugged design
 Economical
 Ease of maintenance

ORION 4R

4 Function Rate Controlled Arm

 Weighs only 21 kg (46 lb) in seawater
 Depth rating of 6,500 msw
 Suitable for small vehicles

ORION 7P/7R

7 Function Rate or Position Controlled

 Economical & compact
 Short or extended reach options
 6,500msw depth rating
 Suitable for medium to lightweight vehicles
 Unique forearm roll function

96
Manipulator Arm Joints

Master Controller
The Master Controller includes a six-degree-of-freedom replica master arm that
ensures comfortable, intuitive manipulator operation. Its movements are just as
sharp when it’s moving a 5 lb object as when it is moving a 250 lb object.

The controller also contains function keys for selecting menu options and a
display for viewing diagnostic and status information. The controller’s advanced
operational features are individual joint freeze, position scaling (altering the
ratio of master arm movement to manipulator arm movement), password
security, programmable stow/deploy routines, individual joint movement limits,
incremental gripper movement, individual joint diagnostics, and automatic error
checking.

97
 Devices & Equipment
IPDS
The ROV is fitted with an electric power system that supplies power for
operation of the ROV main circuit.

IPDS Features:
 T-Box: Two QD landing ports, INPUT and OUTPUT
 Transformer: PDU power is routed to the transformer, and two internal
windings supply 120 VAC to the IPDS Backbone
 IPDS Backbone: Features include 4x 120 VAC stations for connecting power
adapters, 4x 26 VDC stations for supplying power to vehicle nodes, a 26
VDC deck power input port, and replaceable fuses for the 120 VAC supplies
 Monitor Module: Provides water-detect reporting, transformer temperature
reporting, and communications to attached power adapters

98
Nodes
Subsea nodes interface between the topside nodes and the subsea sensors,
controls, lights, cameras, and other devices. The nodes control, evaluate, and route
telemetry and 26 VDC power for attached devices through 16 individual node
ports.

Node Features:
 Nodes can be added in a daisy chain structure to provide additional ports
as needed
 A line-isolation monitor measures the resistance from both sides of the DC
bus to the vehicle frame
 LED indicators for 26V power and node “health” are visible through the
transparent connector of the 26V power cable
 Nodes are actively compensated and can provide compensation fluid to
attached SeaNet cables and devices
 Water detection sensing

99
 AC Junction Box (AC J-Box)

An AC J-Box is available to support customer equipment requiring 120 VAC

power and communications. Typically, this may include equipment such as a
cable or pipe tracker, or power input for some tooling control pods such as tie-
in skids. The AC J-Box is actively compensated and includes a water detection
sensor.

Incoming Power
Power to the AC J-Box is provided by one of the 120 VAC ports on the IPDS multi
pack through a Burton connector, and is switched on and off from the POWER
page on the operator GUI.

100
120 VAC Output
The AC J-box provides power for up to four 120 VAC devices:
 Three ports supply 120 VAC @ 3A/250W
 One high power port rated for 120 VAC @ 17A

Each port uses a Burton connection for 120 VAC output and a SeaNet connection
for switching the output voltage on and off. The SeaNet connects to a node port
which, when turned on, supplies 26 VDC power and telemetry to the port relay
on the AC J-Box. The node ports are powered from the NODE page or the AUX
POWER panel on the ROV page of the operator GUI.

Circuit Protection
Two 20A fuses protect ports 1-4 and the AC J-Box itself, and current draw is
monitored internally for each of the four device ports. If an over current state is
detected for a device, that port is turned off by the controller in the AC J-Box and
the control system initiates an over current alarm and directs the associated node
port to turn off.

120 VAC line-isolation is monitored through a SeaNet connection next to the

Burton connectors on the AC J-Box. GFD reporting may be routed through a
lighting control unit (LCU).

Software Configuration
To add, delete, or relocate AC J-Box devices, use the Configuration Application
available on the Master Executive page.

101
 Survey Junction Box (Survey J-Box)

The Survey J-Box enables the use of devices that require 48 VDC power,
large amounts of bandwidth, or have specific data requirements that are not
compatible with conversion to Ethernet within the Digital Telemetry System
(DTS). It provides 26 & 48 VDC power, several kinds of signal conversion,
and up to 8 fiber optic channels. Each of these fiber channels may be used for
upstream or downstream communication, and are multiplexed onto a single
fiber optic cable. The J-Box incorporates 8-pin Burton, 13-pin Burton, and SeaNet
connectors, allowing the user to make connections to a variety of devices.

The Survey J-Box is actively compensated and equipped with a water detection
sensor.

Power Output
The Survey J-Box is powered by the IPDS multi pack 48 VDC supply which can
also be routed to power devices on ports 6-11 requiring 48 VDC. Power is enabled
by configuring a jumper on the J-Box PCB and connecting the associated SeaNet
cable to a node port on the ROV. When the node port is turned on, a relay is
energized by 26 VDC SeaNet power and 48 VDC is supplied to the device.

26 VDC power is available at all eight Burton ports through their associated
SeaNet cable. If 26VDC is required for the device, the switching relay for 48V
can be disabled by moving a jumper on the PCB. Telemetry for these devices can
either be through the associated SeaNet or through one of the other input types
of the Survey J-Box.

Survey J-Box Specifications

Maximum Depth.................................................................................................4000 meters
48 VDC switching........................4 ports (Energized by 26 VDC from SeaNet cables)
Power rating ports 1-5.......................26 VDC @ 15 A (max) (max. 30A on the Node)
Power rating ports 8-11...................................48 VDC @ 5A & 26 VDC @ 15 A (Max)
Fiber telemetry............................ Coarse Wavelength Division Multiplexing (CWDM)
Fiber channels............................................................... 8 @ 1.5 Gbps each—multiplexed
Fiber penetrator....................................................................................................................... 1
-4 compensation ports............................................................................................................2
-8 compensation ports............................................................................................................2
Input power (from IPDS)...........................................................................................48 VDC

102
Fiber Optic Communication

The Survey J-Box, in conjunction with the topside de-multiplexer located in the
computer rack, supports the use of additional customer installed equipment
such as high-resolution sonar or high-definition video. Broadband data from
these devices is routed to an 8-channel coarse wavelength division multiplexor
(CWDM) in the submersible J-Box and sent topside through a dedicated fiber
optic cable in the umbilical and tether path. Data is de-multiplexed in the topside
J-Box and ported to connectors on its rear panel. The surface and submersible
Survey J-Boxes contain an 8-channel coarse wavelength division multiplexer
(CWDM) that creates eight broadband channels for carrying simultaneous,
independent transmissions through a single fiber. The 8 different wavelengths,
or colors, used in a CWDM are spaced 20 nm apart, from 1470 nm to 1610 nm.
Small Form-factor Pluggable (SFP) modules interfacing with a CWDM system
will transmit on one of these wavelengths.

The 8-channels can multiplex up to 8 standard or 4 Y/C video signals onto the
fiber. High Definition-Serial Digital Interface (HD-SDI) and Gigabit Ethernet
(GbE)

Small Form-factor Pluggable (SFP) modules are designed to convert an electrical

signal on a coaxial cable into an optical signal that is transmitted by laser at a
specific wavelength over the fiber. The optical receiver on an SFP module can
accept any wavelength.

103
 Lighting
Vehicle lights may be powered directly from the subsea nodes or by a lighting
control unit (LCU).

Lighting Control Unit (LCU)

The LCU controls up to twelve dimmable lights on the vehicle. The unit is
powered from one of the two 120 VAC ports on the IPDS multi pack, and is
controlled through a single SeaNet cable connected to a subsea node port. The
ROV pilot controls the lights from the LIGHTS panel on the ROV page. The LCU
is compensated and equipped with a water detect sensor.

LCU Features:
 Twelve ports with 3 pin Burton connectors that can handle up to 250W
each
 Each port is individually switchable, dimmable, and has software fuse
protection
 Two SeaNet connectors on the unit:
–– The CONTROL SeaNet connects to the subsea node and is used for
port switching, software fuse detection, and GFD/WD reporting
–– The second SeaNet connection is used for software fuse detection
and GFD/WD reporting for the optional AC J-Box

NOTE: Ports supply full-wave, rectified power suitable only for dimmable lights. This
form of power is not suitable for other devices requiring standard 120 VAC power.

104
ROS Lighting
Special dual-penetrator SIM modules available for the subsea nodes allow for
controlling two ROS MV-LED lights through a single node port. The lights operate
on node 26 VDC power and communicate using the RS-485 serial protocol. The
lights are programmed with a specific ID number through the supplied ROS
software application, allowing the control system to address each light separately.

105
 Cameras
The HD offers significant configuration and expansion options to support standard
video equipment and high-definition capability through the optional survey
junction box.

Camera options include:

 Color focus & zoom camera (Pegasus, Insite Pacific Inc.)
 Low light monochrome camera (Mercury, Insite Pacific Inc.)
 Mini color camera (Aurora, Insite Pacific Inc.)
 TITAN 4 wrist camera
 Mini monochrome camera (Mini-Probe, Insite Pacific Inc.)
 HD color focus & zoom

Pan & Tilt

Electric pan & tilt units installed at the forward end of the vehicle allow various
combinations of lights and cameras to be easily viewed and controlled from the
console.

Pan and tilts use two electric rotary actuators and rigid bracketry to provide stable
and accurate positioning for a variety of cameras, lights, and other tools. The rotary
actuator features a compact and powerful electric motor and efficient harmonic
drive gearbox in a titanium, actively compensated housing. Position, velocity, and
torque at the tool interface are controlled from the GUI in the control station.
Control telemetry, 26 VDC power, and active compensation are supplied through
a standard SeaNet cable.

106
Sensors
Sensors are an integral part of the HD ROV system and are used for everything
from hydraulic control to subsea navigation. This section will cover the various
forms and functions of subsea sensors.

There are three general categories of sensors, as follows:

 Position & Feedback Sensors: Indicates latch position, hydraulic pressure,
reservoir levels, etc.
 Flight Control Sensors: Affects vehicle stability, motion feedback, and
auto functions
 Navigation Sensors: Detects vehicle depth, position, and subsea
obstructions

All sensors are linked by three common factors: power, communications, and
DTS connection.

Devices accepting 12 or 26 VDC that use RS-232 or RS-485 protocol connect to a

DTS node using a Serial Interface Module (SIM).

Devices accepting 26 VDC and communicate via Ethernet connect to a DTS node
network interface module (NIM). An example of this is a high-resolution sonar.

107
108
Universal Control Module (UCM)
The universal control module (UCM) passes serial communications, converts
signals between digital and analog, and detects position and speed using two
Hall Effect Sensors. Certain models are also fitted with a temperature sensor.
Connection to the DTS is provided through either a feed or flow through
penetrator (depending on the application).

The UCM PCB, powered by 26 VDC, is often mounted in a housing with a

connector for mating to a standard SeaNet cable. When used with onboard Hall
Effect Sensors, a back cover is installed to permit external mounting to other
devices. The back cover is not used when the UCM is mounted to a compensated
device or interface bottle where board connections are required. The sensors are
controlled by an onboard micro-controller that communicates using the RS-232
protocol.

Connections on the UCM PCB consist of:

 Two analog-to-digital (A/D) converters
 Three digital-to-analog (D/A) converters
 Four general-purpose input/output (GPIO) lines

The UCM contains the following Hall Effect Sensors:

 One rotational, speed and direction
 One ratiometric, linear

109
 Hall Effect Sensors
A Hall Effect Sensor is a transducer that varies its output voltage in response
to changes in a magnetic field. As a magnet is moved closer to the sensor it
changes the properties of a semi-conductive element allowing more voltage to
pass across the sensor. This voltage is then sent to the UCM micro controller and
interpreted as a reading. There are two types of Hall Effect Sensors used in the
UC: Rotational and Ratiometric.

 Rotational (Speed and Direction)

–– As two magnets of opposite polarity pass in front of the sensor,
its voltage output changes polarity which is interpreted by the
UCM control board as a count. When the direction of a wheel is
reversed, the same magnet polarity passes the sensor twice and the
voltage output remains the same. This is interpreted as a change in
rotational direction and the counts will decrease. The frequency of
the polarity switch is used to determine speed.
 Ratiometric (Linear)
–– As with the rotation type, this Hall Effect Sensor provides a voltage
output that is proportional to the applied magnetic field. However,
polarity affects this sensor differently. A magnet oriented with its
south pole facing the sensor will result in an output starting at 12
VDC and increasing to 24 VDC. If the magnet were flipped with its
north pole facing the sensor then the same sensor would result in an
output starting at 12 VDC and decreasing to 0 VDC. This sensor is
used to detect the volume of compensators and reservoirs.

Rotational (Speed and Direction)

110
Motion Reference Unit (MRU)
The HD ROV system displays and tracks the vehicles movement using the
Crossbow motion reference unit (MRU). This device uses three micro electro-
mechanical system (MEMS) accelerometers and three fiber optic gyro (FOG)
angular rate sensors.

The three accelerometers are surface micro-machined silicon devices that use
differential capacitance to sense acceleration along the lateral (X and Y) and
vertical (Z) axis. These values represent the vehicles inertial speed and is used by
the system to calculate the thruster commands needed for various auto functions
as well as pilot commands.

The FOG sensors provide measurements along the rotational axis (yaw) of the
vehicle as well as pitch and roll. The vehicle’s heading relative to the Earth’s
magnetic field is tracked using the compass while the MRU uses the FOG to
track vehicle heading to its last know position. In this way the system is able to
overcome compass lag and update heading changes faster. The FOG is susceptible
to gyro drift, so this reading is compared to the compass for long term accuracy.
This function can be disabled when working in and around areas of magnetic
interference such as subsea platforms. Pitch and roll are taken solely from the
MRU.

The MRU is housed inside of an aluminum, one atmosphere subsea bottle and
communicates through a single SeaNet penetrator. It is mounted as close to the
exact center of the vehicle as possible and should not be moved from its factory
installed location. As with the DVL, this device is calibrated to reside in a specific
location and deviation from this will result in inaccurate readings. If the unit
must be removed, refer to the installation placard on the top to ensure that it is
reinstalled in the correct orientation or vehicle operation will be degraded.

111
 MRU Servicing

The Crossbow MRU inside the aluminum housing is not field serviceable and
should never be opened due to the extremely sensitive nature of the internal
components. Field calibration of this unit is not possible and if its accuracy is
suspect then it should be replaced. To test the device, use the Crossbow MRU
test software supplied with the ROV technical manuals.

112
Doppler Velocity Log (DVL)
ROV movement across the seabed is tracked by the doppler velocity log (DVL). This
device consists of four acoustic transducers enclosed in a single, one atmosphere
housing mounted on the bottom of the ROV, and communicates through a single
SeaNet penetrator. The transducers are capable of detecting small changes in the
seabed topography, allowing the DVL to detect motion on the X, Y, and Z axes.
The DVL may be used as an altimeter as well.

Many of the auto features of the HD ROV system rely upon the DVL, including:
 StationKeep
 X-Y measurement and displacement
 Auto Altitude
The standard Workhorse 1200 DVL is accurate from 0.25 m to 30 m (1 ft to 100
ft) from the seabed. Beyond this range, the acoustic signal becomes too degraded
to be accurate. The signal quality can also be affected by poor water conditions,
extremely uneven terrain or structures, or dense populations of marine life.

113
 DVL Testing & Calibration
Calibration of the DVL is done at the factory and cannot be performed in the field.
To test the DVL for proper operation and communications, use the test software
provided with the Schilling technical manuals.

DVL Mounting
The HD system software is calibrated to control vehicle movement from a specific
frame reference point. The system software will become increasingly disoriented
the further the DVL is moved from this location and performance of the auto
functions will be greatly degraded. If the DVL must be moved, the new location
can be input in the “UserConfig” menu from the Master Executive. Consult FMC
Schilling Robotics technical support for the proper procedure.

Alignment mark on DVL head (to front of ROV)

NOTE: Ensure the DVL is correctly oriented with the alignment mark
toward the front of the ROV.

114
Depth Sensor
The Paroscientific Digiquartz depth sensor tracks changes in vehicle depth. It
accomplishes this by using a quartz crystal whose vibration frequency varies as the
pressure increases with depth. This resonance is detected by the sensor, translated
into a depth reading and communicated through a single SeaNet penetrator.

Mounting may be either vertical or horizontal. Avoid placing the depth sensor in
the path of thrusters as turbulent water can cause fluctuations within the sensor
and result in inaccurate readings. A small coil of tubing on the inlet pipe serves to
dampen water flow into the sensor but cannot eliminate the full force of a thruster.

Calibration of this device is accomplished through the operator GUI by using the
ZERO DEPTH SENSOR button on either the TMS or SETUP pages and should be
performed as soon as the vehicle enters the water at the start of every dive.

The depth sensor is not considered field serviceable. Faulty units should be
returned to FMC Schilling Robotics.

115
 Sonar
The sonar head is a subsea device that sends and receives acoustic pulses to scan
for obstacles and structures in front of the ROV. The topside sonar computer
receives the signal data from the sonar head, and the resulting image is used
to navigate the ROV during subsea operations. The sonar head is mounted in
a sealed housing on the light rack of the HD ROV and connects to the system
through a single SeaNet connection for communication and 26 VDC power.

The sonar is typically installed with the SeaNet penetrator at the top and the beam
transmitter pointing downwards. The sonar head must have a clear, unobstructed
view forward of the vehicle, and some units will have markings on the head
indicating orientation. Consult the supplied OEM manual and software for further
details.

116
Flight Modes
Auto Control Modes
The HD features the following automatic control modes to assist piloting the
system:

Auto Heading........................................................................................... ± 2°, 360° Range

Auto Pitch.............................................................................................± 2°, +12/-5° Range
Auto Roll.................................................................................................... ± 2°, ± 6° Range
Auto Depth..................................................................................................±15 cm (6.0 in)
Auto Altitude...............................................................................................±15 cm (6.0 in)
StationKeep............................................................................ 10 cm (3.9 in) watch circle

117
 StationKeep
The StationKeep (SK) function provides the ROV pilot with the subsea equivalent
of vessel dynamic positioning. While in SK the vehicle control system takes
command of the vehicle and automatically maintains position relative to a
point on the seafloor. The control system also maintains the vehicle position
while external forces such as current are applied (up to the vehicle’s capability).
When SK is selected the pilot is able to release manual vehicle control and focus
completely on manipulator or tooling tasks.

SK mode is able to maintain vehicle position within a 100 mm watch circle in

currents in excess of 2 knots. Thruster speed feedback to the control system
allows for almost unperceivable movement of the ROV system relevant to its
surroundings. This allows the operator to perform tasks requiring high-precision
operations, such as hot stab insertions and extended inspections without needing
to stabilize the vehicle using subsea structures.

Benefits of SK include:
 Safety of ROV in low/nil visibility
 Lower wear and tear on ROV
 Significant reduction of crew fatigue associated with continuous flying for
long periods
 Accurate focus of camera on specific task
 Ability to perform manipulator tasks adjacent to a subsea structure without
the need to grab on
 Accurate deployment of transponder arrays and other subsea hardware
 Ability to assist with engagement of tooling packages with subsea
structures
 Accurate grid searches and surveys
 Improved interception of down-lines and loads by holding relative position
and ascending
 Maintaining position whilst seabed disturbance clears during deployment
of heaving loads
 Maintaining accurate position during lengthy observation tasks, with
current present

118
Mid-Water StationKeep [Optional Hardware Required]
FMC Schilling Robotics has further enhanced the StationKeep function and is
now able to provide Mid-Water StationKeep (MWSK) automatic control mode.
With the aid of an inertial navigation system (INS), SK is no longer limited to the
range of the DVL.

The benefits of MWSK include the following:

 Enhanced station keeping performance using position estimates rather than
integrated velocity
 Greater immunity to intermittent loss of bottom lock
 Ability to operate unaided automatically outside of DVL range
 Improved auto-depth performance

119
 AutoDisplacement
While in StationKeep mode, the operator can choose a desired vehicle
displacement in fore/aft and port/starboard directions for accurate vehicle
movements in low-visibility or survey operations. AutoDisplacement can also be
used to measure distances between two objects. The speed of displacement can
be adjusted, as desired.

120
AutoTrack
In AutoTrack mode, the vehicle control system can accept coordinate inputs from
an external source, such as a survey computer, to allow automatic flight over a
pre-planned route at a speed controlled by the ROV operator.

The ROV control system and position sensors keep the ROV on the designated
survey line, closing the control loop with feedback from the survey system that
reports the vehicle’s variance (cross-track error or lateral offset) from the survey
line. AutoTrack moves the ROV in the forward flight direction only (not aft) along
the survey line.

*Dependent on survey company equipment accuracy.

121
Notes
Notes
Notes
Notes
Schilling Robotics
Tether Management System (TMS)
Training Course Student Guide

The HD Tether Management System (TMS) has been designed

around a field-proven ‘shuttling drum’ concept that provides
exceptionally simple tether routing. The complete tether drum
moves on a carriage system allowing the tether to exit the drum
directly above and through the payout sheave.

127
 We put you first.
And keep you ahead.

Tether Management System (TMS)

Training Course Student Guide

Table of Contents
Tether Management System (TMS)............................................................. 130
Variable-Frequency Drive (VFD).................................................................... 132
Pinch Wheel....................................................................................................... 134
Latches................................................................................................................. 135
Position Sensor Array (PSA)........................................................................... 137
Instrument Power Distribution System (IPDS).......................................... 138
Devices & Sensors............................................................................................. 139
Compensation.................................................................................................... 140

129
 Tether Management System
(TMS)
The function of the tether management system (TMS) is to manage the ROV
tether which transfers power and fiber optic information to the surface through
the umbilical. The tether is usually neutrally buoyant to negate the effects of drag
on the ROV itself and to keep the tether clear of seabed structures. A kellums
grip provides tether strain relief inside of the drum and on the frame of the ROV.

The HD TMS is designed around a field-proven ‘shuttling drum’ concept that

provides simple tether routing. The complete tether drum moves on a carriage
system so the tether can exit off the drum directly above and through the fixed
pinch wheel sheave. This concept promotes reliable multi-layer spooling and
longer tether lifespan.

Performance
The HD TMS has the following performance characteristics:
 Tether Capacity: 425 m / 28 mm diameter standard
 Optional: 850 m

130
Frame
The standard TMS frame is an uncoated, 2205 duplex stainless steel, welded
structural element that houses and protects the main TMS system components.
The frame forms a rigid load path between the TMS lift point and the latch
mechanism, where the ROV is docked during system launch and recovery
operations.
 The lift point SWL is rated for 9,500 kg (system in air weight; TMS and ROV
including through-frame lift)
 Through-frame lift (TFL) is rated 6,500 kg
 Frame incorporates anodes for components mounted to the frame

Tether Rendering “Drum & Carriage”

The drum and carriage assembly is powered by a 5 hp variable-frequency drive
(VFD) motor which rotates the drum and the diamond screw drive. This drive
shuttles the drum carriage from side to side so the tether can always maintain
a zero degree fleet angle with the pinch wheel. Sensors on the diamond screw,
pinch wheel, and drive motors provide constant data to the control system, which
uses it to coordinate their functions and provide information to the operator
on the TMS page in the form of sensor status lights, tether speed, and payout
lengths. As a result, the operator can render tether with a high degree of control
and reliability. Tether rendering functions are commanded from the control
console using controls on the TMS page, flight joy stick, or the foot pedals.

The shuttling drum accommodates a maximum of 425 m of 28 mm tether, with

an 850 m option. It incorporates a grooved cable shell to maintain accurate
control of tether wraps. The interior of the drum houses a slip ring unit with
adequate support provided to ensure no axial or radial load of the unit. The drum
design allows for ease of installation and removal of the slip ring and access to
the termination points.

Drum & Carriage Operation:

 The drive motor rotates the drum and diamond screw drive
 A pawl tang rides in the diamond screw threads and mechanically translates
diamond screw rotation into lateral drum motion
 Drum carriage rides on rollers that support the full weight of the drum

131
 Variable-Frequency Drive (VFD)
Two 5 hp, variable-frequency drive (VFD) motor/gear reduction assemblies and
controller bottles power TMS tether rendering functions. One motor rotates the
drum and shuttles the drum carriage, the other motor drives the pinch wheel.
Power (240 VAC single-phase) is supplied by the IPDS to the control bottle, which
directs calculated power requirements to the drive motor for precision control.
The controller receives command through an Ethernet connection (NIM) to the
subsea node. Each controller is also responsible for operation of one of the two
sets of latch assemblies.

VFD Motor VFD Motor Controller

VFD Motors
 Motor rating: 5 hp
 Motor operating voltage: 240 VAC @ 60Hz
 Motor temperature and water detects
 Rotary position sensing
 Compensated
 70:1 Gear Reduction Output

132
VFD Motor Controllers
 Controls one VFD motor and one set of latche assemblies
 One atmosphere housing

133
 Pinch Wheel
The pinch wheel assembly grasps and renders tether cable in and out. Power is
supplied by one of the 5 hp VFD motor and controller systems. A quick-release
mechanism disengages the pinch rollers to make on-deck spooling operations
easier.

134
Latches

The ROV is secured to the TMS with a simple two-stage, primary/secondary

latching assembly. A set of four electric solenoid actuators control the latches:
two for the primary latches and two for the secondary latches. When a pair of
solenoid actuators are energized, the solenoid plungers pull the latches open. De-
energized, the solenoid springs push the latches closed.

135
 TMS Latch Solenoid
 Spring return (pushes pin out)
 26 VDC power open (pulls pin in)
 Compensated
 Quickly replaced without disassembly of the whole latching system
 Serviced with seal replacement cartridge kit

Powered by the VFD Motor Controllers

Latch Chute

Energized = Open De-energized = Closed

NOTE: A notch etched into the top of the secondary latches allows for easy identification.

136
Position Sensor Array (PSA)
The position sensor array (PSA) is an oil compensated control box with eight
magnetic rotary encoder sensor heads. Each sensor monitors the absolute
rotational position of a magnet. Six heads are typically used for TMS functions:
 One for drum movement
 One for pinch wheel movement
 Two for primary latch status
 Two for secondary latch status
 Two for spares

Other features:
 A “heartbeat” LED in each sensor head indicates the presence of power and
active telemetry
 Faults in a single sensor head do not affect the operation of the others
 The two spare sensor heads can replace damaged or malfunctioning heads
 Functions are assigned using the “Device Configuration Application”

137
 Instrument Power Distribution
System (IPDS)
The TMS is fitted with an electric power system that supplies power for
operation of the TMS main circuit. The power system consists of the instrument
power distribution system (IPDS), tether, sliprings and the electric drive units for
the TMS drum and power sheave.

NOTE: The IPDS is the same unit utilized on the ROV but with a power module
configuration suited to the TMS. Please refer to the relevant ROV section for details.

240 VAC Adapter

The 240 VAC adapter connects with two IPDS 120 VAC ports to produce 240
VAC for the TMS VFDs.

138
Devices & Sensors
Node
One node is installed on the TMS which controls all VFD, device, and sensor
communications on the vehicle.

Cameras & Lighting

Two cameras and two 24 VDC ROS LED lights are used for monitoring drum and
pinch wheel operations.

Electric Pan & Tilt Unit

One electric pan & tilt mounts one camera and one light for operator control.

Depth Sensor
One depth sensor is standard on the TMS. Optional equipment may include an
altimeter or a compass.

Depth Sensor

139
 Compensation
The vehicle compensation system consists of individually isolated circuits for
subsea devices and cables that require pressure compensation. All compensator
circuits are fitted to provide feedback for monitoring fluid levels.

Circuits
 Circuit 1: Drive Motors
 Circuit 2: Latches & Nodes
 Circuit 3: IPDS

140
Safety
All TMS components are mounted within the confines of the TMS frame.
Protective doors are provided to enclose the entire TMS assembly, while still
providing quick access to components. The doors are mounted on spring-release
hinges, so it does not require unfastening bolts to access the TMS.

Work platforms are integrated into the protection doors and the TMS frame
includes fall arrestor attachment points for working on the TMS.

141
Notes
Notes
Notes
Notes
Schilling Robotics
Digital Telemetry System (DTS™)
Training Course Student Guide

The Digital Telemetry System (DTS) is the perfect control platform

for a variety of subsea systems, by providing communications,
control, and power distribution for virtually any remotely operated
system.

147
148
 We put you first.
And keep you ahead.

Digital Telemetry System (DTS™)

Training Course Student Guide

Table of Contents
Introduction....................................................................................................... 150
Nodes................................................................................................................... 153
Interface Modules............................................................................................. 157
SeaNet Cables & Connectors......................................................................... 165
Node Line-Isolation........................................................................................... 169
Fiber Optic Communications...........................................................................171
Tunneling & DTS Viewer................................................................................. 179

149
 Introduction
All HD system communications and data are transmitted through FMC
Schilling Robotic’s Digital Telemetry System (DTS). The DTS consists of a set
of components that process, evaluate, route, send, and receive digital signals
between the topside control station and the subsea TMS, ROV, and devices
providing sensing, control and navigation data.

The DTS also supports multiple low-latency video streams from subsea cameras
to the surface. With standard interface modules, the communications hub can
be configured with communication protocols, such as RS232, RS485, Ethernet,
and video, to monitor and control virtually any number of devices.

150
Benefits
The benefits of DTS include the following:
 Superior reliability and flexibility
 Rapid system expansion and a wide range of physical configurations
 Digital video transmission supporting NTSC or PAL
 Fiber optic communications with a gigabit Ethernet backbone
• Rapid spanning tree protocol (RSTP) for redundancy with seamless fiber
switching

DTS Core Components

The DTS core components include the following:
 Nodes (Topside and Subsea)
–– Topside nodes interface between the control station computer
network and the subsea nodes
–– Subsea nodes interface between the topside nodes and the subsea
devices (sensors, controls, lights, cameras, etc.)
 Interface Modules (VIM, SIM, NIM and Specialty)
–– Interface Modules allow the system to support composite video
(NTSC/PAL), serial (RS232/RS485) and Ethernet (10/100MB)
 SeaNet
–– SeaNet cables provide power and telemetry between the subsea
devices and the node interface modules
 Fiber Optics
–– Fiber optics provide communication between the topside computers
and the subsea system

151
 Network Map

152
Nodes
There are two types of nodes: topside and subsea. All communications and data
are transmitted through these nodes to the connected devices. Each node has a
total of 17 ports. Ports 1 thru 16 are for video, serial or network communications,
and port 17 is the node motherboard. All inter-node communications are made
through fiber optics, while node-to-device communications are made through
SeaNet and Burton cable connections. Compensation and air-bleeding is
provided through oil passages located in the corner assembly bolts.

Topside Node

Subsea Node

153
 Node Power
Power to the subsea nodes is provided by the 26 VDC power bus on the vehicle
mounted instrument power distribution system (IPDS). Topside node power is
provided by a 120/220 VAC to 26 VDC converter mounted in the topside node case.

Each node has two LED indicator lights. These are inside the power connector
on the subsea nodes and on the front panel labeled “Power and Health” on the
topside nodes.
 Red “Power” LED indicates when the unit is powered on
 Green “Health” LED indicates the Ethernet activity and flashes the node ID
number (i.e. two flashes = node 2, three flashes = node 3, and so on) and
becomes solid so long as that node is communicating

154
 Each node port power is independently switched and will provide a 26 VDC
supply to the interface module
 Power rating of a node is 30 A maximum
–– Each port can output 15 A maximum
–– Cumulative port power cannot exceed the node limit, so a device
requiring high current must be placed on a node to where the total
power draw does not exceed 30 A
 Software fuses
–– Slow-Blow Fuse: A device that has an inrush current of greater than
15.25 A tolerated for about 200 ms before tripping
–– Fast Fuse: set to trip instantly at 19 A
 Hard fuses
–– Sacrificial hard fuses are inside the node (15 A slow burn)
–– “Last-chance” fuses that are soldered to the motherboard to protect
it (not designed to be field serviceable)

155
156
Interface Modules
Each subsea node controls and routes telemetry and 26 VDC power to
16 individual node ports. Port configuration for serial, video, or Ethernet
communication is handled through “interface modules.” Node modules that
interface with the topside computers and subsea devices include the following:
 Serial interface modules (SIM) for (RS-232 or RS-485) communications
 Video interface modules (VIM) for (PAL/NTSC digital or analog)
 Network interface modules (NIM) for Ethernet communications
• Specialty modules including Burton, Dual SIM/VIM, and Dual Penetrator

Topside “Clients”
Topside node modules have no housing and their connections are made through
a whip with a connector accessible at the back of the topside node case. These
topside modules are referred to as “clients”.

Subsea “Servers”
Subsea node modules have a color-coded aluminum or plastic housing to seal
against the node housing. These subsea modules are referred to as “servers”.
Each subsea node module can provide compensation fluid to cables and devices.

NOTE: When removing a module, the affected node should be powered off. Hot
swapping these items can lead to device, module, or node failure.

157
 Serial Interface Module (SIM)
Subsea SIMs (servers) are used for devices that require serial communication
with the system, such as rotary actuators, universal control modules (UCMs),
thruster control units (TCUs). Subsea SIMs may be equipped with a SeaNet
penetrator or a Burton connector.

Topside SIMs (clients) used in the topside nodes have no housing and the PCB
simply plugs onto the node motherboard. These modules have a whip with an
RJ11 connector on the end.

Most subsea devices connect through SIMs to the DTS communicate directly
with the RTC and are known as “system devices.” These do not require a topside
SIM. To tunnel directly to a subsea SIM with a stand-alone computer or control
device, a topside SIM must be used.

The SIM translates RS-232 and RS-485 serial data into an Ethernet format
suitable for delivery over the DTS. The SIM can be configured for baud rates
(from 1200 to 230k baud), data bits, parity, and number of stop bits using the
control system Configuration Application (Config App).

SIMs are the only module that can be setup to output either 26 VDC @ 15A
(max) or 12 VDC @ 750 mA (max). SIMs can work in a “unicast” mode, sending
data to a single destination, or in a “bicast / mirror” mode, sending data to two
destinations simultaneously (SIM Rev. 13 and newer for bicast / mirror port
operations). SIMs can timestamp serial data, providing the ability to synchronize
data very accurately for surveyors or other users.

The circuit board used for both the server and client SIM are the same part
number. A SIM module may be wired to receive a transistor-to-transistor logic
(TTL) signal ranging from 5-30 VDC @ 2 mA for triggering devices such as
acoustic beacons.

Topside “Client” SIM Subsea “Server” SIM

158
SIM Configuration
 SIMs are configured at the subsea server side for baud rate(b), data bits(d),
parity(p), and stop bits(s)
 SIMs are independently configured for RS 232/485, and for straight or
crossover communication (as a result, it is possible to have different serial
protocols for the client and server sides)

159
 Video Interface Module (VIM)
Subsea VIMs (servers) convert standard composite video to Ethernet packets for
transmission over the DTS. The topside VIM (client) converts the Ethernet stream
back to composite video for display on the HUD monitors.

The VIM supports both NTSC and PAL, and is specially designed to provide
less than 100 ms latency from capture to display in order to facilitate real-time
control of subsea tasks. The VIM also supports RS-232 communications at up to
38,400 baud for cameras with zoom and focus controls.

Topside VIMs (clients) are equipped with a BNC connector that is accessible at
the back of the topside node. Maximum current output is 2 A @ 26 VDC. VIMs
use “multi-cast” to transmit data over the DTS, meaning several client VIMs can
receive video data from one server VIM.

Topside “Client” VIM Subsea “Server” VIM

160
VIM Configuration
 VIMs are configured for video standard at the subsea server side
 VIM servers multi-cast video data onto the network, not to a specific client
 Client VIMs are configured to the server VIM to receive data

 Multi-casting makes it possible for two client VIMs to display the same
camera image

161
 Network Interface Module (NIM)
The NIM allows connection of a device directly to the Ethernet backbone of the
system through a 10/100 Mbps port. Topside NIMs (clients) are equipped with a
cable whip with an RJ45 connector, while subsea NIMs (servers) are fitted with a
SeaNet penetrator.

Maximum current output for a NIM is 15 A at 26 VDC. These modules are the
simplest and most affordable module and therefore are good for devices that
require a 26 VDC power source only. An example of this would be the ROS LED
lights on the TMS.

Topside “Client” NIM Subsea “Server” NIM

162
NIM Configuration
 NIMs do not require configuration as it is a simple plug-and-play module
 Network devices must be set with static IP addresses and set to “monocast,”
not “braodcast,” to prevent excessive traffic on the DTS network
 Third party network based devices may require additional setup to work on
the DTS

163
 Specialty Modules
Certain subsea devices and applications may require custom modules in order to
communicate effectively with the DTS.

Dual SIM/VIM: Used for the T4 manipulator when fitted with an optional wrist
camera. This module has a single housing spanning two node ports, one for
serial communication and the other for video. The video and serial data from the
manipulator is transmitted through a single SeaNet cable to the module, where
the signals are split and converted to Ethernet packets for delivery over the DTS.
The serial data is sent to the client SIM connected to the Master Controller, and
the video data is sent to the client VIM for display on the HUD monitors.

Burton: For power and communications, a special purpose module utilizing a

SIM PCB in a plastic housing is used. The SIM circuit board terminal strip allows
simple re-configuration to the Burton connector pin out, and fits into any node
port like a regular module.

Dual-penetrator module: Used for controlling two LED lights through one
node port. RS-485 serial communication allows each light to be “addressed” and
switched on or off independently.

164
SeaNet Cables & Connectors
SeaNet cables connect the subsea sensors, controls, lights, cameras, and
other devices to the node interface modules. Electrical power and data
communications, as well as device compensation, are provided to each device
through a single cable.

SeaNet components include the following:

 SeaNet-to-SeaNet Cables
–– For connecting devices fitted with SeaNet penetrators to DTS node
ports. The cables come in several standard lengths, from 1m (3 ft) to
7.5m (24.5 ft)
 SeaNet Adapter Cables (SeaNet-to-Burton, impulse, and other OEM
connector types)
–– For connecting a DTS node port to a device fitted with an OEM
penetrator, or for connecting a device fitted with a SeaNet
penetrator to an OEM penetrator. Adapter cables are also supplied
as kits to allow custom wiring of the proprietary plug
 SeaNet Penetrators (feed-through and flow-through)
–– For adapting devices for SeaNet cables
 SeaNet Caps and Plugs
–– For protecting unused or disconnected cables and penetrators

165
 SeaNet cables provide 26 VDC electrical power and data connections between
remotely operated devices and the DTS node ports through seven conductors:
 Two power conductors (26 VDC and return)
 One chassis ground (line-isolation monitoring)
 Four signal (serial, video, and Ethernet)

SeaNet cables are field serviceable. All components of the SeaNet can be
replaced in the field. Components may also be swapped between SeaNets
allowing usable spares from two or more damaged cables.

NOTE: Due to the special connectors used on them, the coaxial

cables are not able to be re-terminated.

166
SeaNet Indicator LEDs
SeaNet power, data, and video lines can be monitored by using status indicator
LEDs visible inside the connnector heads on every SeaNet cable.
 All LEDs flash briefly as a self-test when the node port is turned on
 The spare data line has no status LED

SeaNet Removal & Installation

NOTE: When removing a SeaNet or other cable, the affected module should always be
powered off. Hot swapping these items can lead to device, module, or node failure.

167
 SeaNet Penetrators
A penetrator is the interface between a device and the SeaNet cable. This inter-
face is fitted to all FMC Schilling Robotics supplied components. There are seven
gold plated, conductive rings on the face of the penetrator that mate with the
seven conductors of the SeaNet cable.

The SeaNet penetrators on modules may be one of two types:

 Flow Through: These penetrators allow oil to pass through the face of the
connector to compensate a cable and device such as a rotary actuator. This
is the most common type and can be readily identified by their face which
is raised slightly from the housing and can be depressed
 Feed Through: These penetrators do not allow oil to pass through the
face of the connector and is slightly recessed or flush with the top of the
housing. These are used on circuits where the device already has its own
compensation circuit such as the T4, or on devices that are sealed in one
atmosphere housings such as the MRU or DVL.

Penetrators are not considered to be field serviceable and rarely require service.
The most common fault in these parts is corrosion due to water intrusion and
damage due to arcing.

Penetrator Burns Adapter Burns

168
Node Line-Isolation
Node line-isolation is the resistance from the positive and negative sides of the
26 VDC power bus to the vehicle frame, or “chassis.” Bus power originates in the
IPDS and is distributed to the nodes and their connected devices.

Node 4 on the ROV is responsible for measuring this value and reporting it
back to the RTC. The line-isolation monitor circuit applies an isolated voltage
alternately between the chassis and the +26 VDC bus or the 26 VDC RET bus. If a
leakage resistance exists, the isolation monitor measures current flow and reports
it to the control system. The reported values are displayed in the LINE ISO bar
on the NODE page of the console GUI.

NOTE: Line-isolation is not measured for the topside nodes.

There are two types of faults reported by the system:

 High Side Faults: Resistance between the +26 VDC (positive) side of the
device and the vehicle chassis
 Low Side Faults: Resistance between the 26 VDC RET (negative) side of
the device and the vehicle chassis

There are three values that the LINE ISO bar will display:
 Green Bar: 500 kΩ to 1 MΩ
 Yellow Bar: 100 to 500 kΩ
 Red Bar: Less than 100 kΩ

169
 26 VDC Line-Isolation Fault Troubleshooting
Common causes for a line-isolation fault are:
 Water intrusion during subsea operation
 Water intrusion into a SeaNet connector or penetrator interface
 Incorrect power connections in a device connected to a node port (at
startup or when turning on a node port)
 Internal capacitors on a device between the chassis and the +26 VDC or 26
VDC RET line
 A short or leakage between 26 RET and the chassis

NOTE: Refer to the Technical Manual for information on

High Side and Low Side Fault Troubleshooting

170
Fiber Optic Communications
FMC Schilling Robotics’ DTS utilizes fiber optic technology to provide accurate,
real-time control and feedback at all times. By using light signals to transmit
data, fiber optics provide an extremely high bandwidth communications platform
perfect for subsea controls.

All data communications are multiplexed onto a single fiber that both sends
and receives data between the surface and subsea. Commands from the
control computers are converted to fiber optic signals by the topside nodes and
broadcast the length of the umbilical and tether cables to the subsea nodes.

Data Transmission
 SFP Modules convert fiber optic data to Ethernet data
 Interface modules convert Ethernet data to serial or video data

171
 Fiber Path
Nodes are numbered in series downstream, as follows:
 #1, 2 Topside nodes
 #3 TMS node
 #4,5,6 ROV nodes

172
Fiber Cables
There are typically three fiber cables used with the HD (F1, F2, F3):
 F1: Primary fiber used for both transmit (Tx) and receive (Rx)
 F2: Secondary fiber used for RSTP and acts as a backup in case F1 fails
 F3: Dedicated to the Survey J-Box and the rack de-multiplexor (de-mux)

NOTE: There are three additional fibers which are left unterminated as spares.

173
 Rapid Spanning Tree Protocol (RSTP)
Benefits of rapid spanning tree protocol (RSTP) includes the following:
 Maximizes the quality and reliability of communications
 Uses two fiber optic cables to connect the topside and subsea nodes
providing redundancy to network communication paths
 Evaluates paths F1 and F2 for signals, fewest pass-through connections, and
recent availability, and then directs communication to the best path
 Disables communications on the other path to eliminate duplicate data
traffic to the topside computer
 Changes fiber paths instantly to maintain communications with the surface
node(s) and ensures continued system operation, if a fiber cable or an
internal component of a node becomes damaged or nonfunctional during
operations

174
Small Form-factor, Pluggable (SFP) Modules
Each node has two 1 Gbps fiber ports for communications. Each port utilizes a
small form-factor, pluggable (SFP) module which is a compact optical transceiver
used in the telecom industry for data transmission. These modules convert data
from electrical signal to an optical signal for transmission via fiber cable. There
are two types of SFP modules used on each node:
 Port A (blue) transmits upstream at 1310 nm and receives at 1550 nm
 Port B (green) transmits downstream at 1550 nm and receives at 1310 nm

Signal strength for fiber optics is measured in dBm, or the power ratio in decibels
(dB) of the measured power referenced to one milliwatt (m). Typical signal
strength for the HD system is -5 dbm to -20 dbm. At each node the fiber signal
is amplified by the SFP modules and rebroadcast to the next node in the chain
ensuring maximum signal strength.

175
 Node Fiber Domes
The subsea nodes are fitted with a titanium dome encasing the SFP modules.
These modules would be distorted by the pressure at depth so it is critical that
they are isolated in a one atmosphere environment.

The domes have been cross drilled between the fiber connectors to allow oil to
pass from one whip to the next, while maintaining the atmospheric integrity of
the dome.

The small fibers inside of the dome that link the fiber whips to the SFP modules
are very delicate. If the dome must be removed then extra caution should be
used upon reassembly to not pinch these fibers. If they are damaged then the
fiber whip must be replaced as an assembly.

176
Fiber Connections
There are four types of fiber optic connectors used in the HD system, as follows:

 Straight Tip (ST) Connectors: ST Connectors are the most common type
and are used in several applications such as the interconnect between the
topside nodes and the umbilical and tether terminations. These connectors
may be readily terminated in the field by trained personnel.

 Little Connectors (LC): LCs are used to connect to the SFP Modules used
on the node motherboard and inside of the Survey J-Box. These connectors
are not typically considered field serviceable.

 Modified ST Connectors: The fiber connections used for connecting from

the IPDS to the node and between the nodes have a modified ST connector
inside of a machined housing that is designed to plug in to the node dome.
These connectors are factory built and are not field serviceable.

 Penetration Fiber Connectors: The connection made on the inside of the

node fiber dome is accomplished using a custom built, one atmosphere
housing penetration fiber connector. These connectors are factory built and
are not field serviceable.

177
 Fiber Cables
 Fiber dome to SFP module whips have an LC (Little Connector) at one end
and a specialized connector at the other that is designed specifically for the
node dome. This whip is not field serviceable.

 Node to Node, QD to QD, and node to QD connections are made by a whip

with a compensated tubing and modified ST connectors on both ends. This
whip is not field serviceable.

Bleeding Fiber Optic Cables

Step 1 Step 2 Step 3

Install a fiber cap over Depress cap with your NEVER insert screw-
the fiber in the end of thumb to bleed. Hold drivers, picks, or
the whip. until all air is purged. other objects into the
connector as this will
damage it.

178
Tunneling & DTS Viewer
DTS Viewer (DTS_Viewer.exe) is a proprietary software application that can run
on any stand-alone computer connected to the DTS via Ethernet link. Sending
data from one location to another on the DTS is referred to as “Tunneling.”

Tunneling is a key feature of DTS Viewer. A stand-alone PC running the applica-

tion can create temporary tunnels between two serial interface modules (SIMs)
and between video interface modules (VIMs). Tunnels connect interface modules
in a client-server relationship. Once the tunnel is created, the same standalone PC
can run diagnostic applications on the device at the other end of the tunnel.

Common uses of DTS_Viewer.exe are:

 Create temporary tunnels between two SIMs
 Create temporary tunnels between VIMs
 Inspect the DTS configuration and status
 Temporarily modify serial port parameters
 Test and configure new serial or video devices (bench-testing)
 Troubleshoot faults within the HD node network and attached devices
 Diagnose video issues
 Create configuration and serialization reports

NOTE: Ensure the computer IP address is set to the subsea network to run DTS Viewer.

179
 Example: As illustrated above, a subsea device is connected to a SIM on Node
5 and the stand-alone PC is connected to a SIM on Node 2. If a tunnel is created
between the SIM on Node 5 and the SIM on Node 2, the stand-alone PC can
communicate directly with the subsea device.

180
Notes
Notes
Notes
Schilling Robotics
Topside Controls
Training Course Student Guide

The topside controls include a control console with two side-by-

side operator stations. Either station can be used to operate the
ROV, TMS, manipulator arms, and nearly all other subsystems. The
topside controls consists of the server computer, left and right
client computers, and the real-time computer (RTC).

185
186
 We put you first.
And keep you ahead.

Topside Controls
Training Course Student Guide

Table of Contents

Control Console................................................................................................. 188

System Computers........................................................................................... 197
Server Computer............................................................................................... 198
Real-Time Computer (RTC)............................................................................. 207
Client Computers.............................................................................................. 208
Graphical User Interface (GUI)....................................................................... 209

187
 Control Console
Dual Flight Stations
The ROV system is operated from a control console with two side-by-side
operator control stations. Either station can be used to operate the ROV, TMS,
manipulator arms, and nearly all other subsystems.

System Controls
Each flight station consists of two control pods, a foot pedal, a touch screen
display for viewing and navigating the control system graphical user interface
(GUI), and a power-adjustable, air conditioned pilot chair. Pods are modular,
easily serviced, and are connected to the system through Ethernet cabling.

188
Flight Control Pod
The flight control pod consists of the flight joystick and auto function controls.
By strategically locating auto function buttons and wheels near the armrest, the
pilot can switch between modes without use of the touch screen.

The flight joystick controls vehicle movement along the x, y, and z axes, and also
has controls for pan and tilt movement and tether rendering.

Trim/Displacement Wheels
 With auto function turned OFF, each control will act as a trim adjust with a
push-in reset
 With auto function turned ON, each control will act as a displacement
function

189
 Tool Control Pod
The tool control pod controls pan and tilts, lights, cameras, and valve packs
and puts commonly used system controls at the finger tips of the operator.
A rate-hand controller is standard and is used to operate any 5- or 7-function
FMC Schilling Robotics’ rate controlled manipulator. Assignable switches for
controlling tooling and other items are included and can be configured in the
TOOLS page.

190
Foot Pedal
Each operator station has a foot pedal to control tether pay in and pay out. The
further that you press the pedal toward the floor, the faster the tether moves.
Only one pedal in the control station can be active at a time. You can also
disable both control console pedals and switch tether control to the touch screen
or joystick. Pedal functions are configured in the SETUP/JOYSTICK & PEDAL
page.

Touch Screens
Touch screen liquid crystal display (LCD) monitors are mounted in the console at
each pilot station. The left touch screen is connected to the left client computer,
and the right touch screen is connected to the right client computer. The GUIs
displayed on each touch screen are completely redundant and provide controls
and system feedback for the operator. In addition, the touch screens can be
locked to provide a work surface.

Manipulator Master Controller

A stand-alone master controller is also present when the ROV is equipped with a
position-controlled manipulator. It is a free-standing unit independent of control
console touch screens and joysticks, connecting directly to the topside node
through a serial connection.

191
 Heads-Up Display (HUD)
Situated in front of the control console is the heads-up display (HUD). The HUD
consists of nine 24-inch LCDs on which camera views, sonar, and other graphic
information can be displayed and arranged using controls on the console touch
screens. The center monitor displays the Master Executive menu and Dashboard
running on the server computer. The outer top monitors are connected to
Avitech video tilers configured for quad displays. The remaining monitors are
for camera input directly from the video switcher or other devices, such as a
sonar. Each row of monitors folds down for easy servicing access.

192
Rack Mounted Equipment
ROV systems are equipped with 19-inch rack mount(s) to hold system computer
and network components, video processing and recording equipment, the sonar
computer, deck power supply, uninterruptible power supply and other optional
equipment.

193
 System Computers for Data Processing, Communication, and Control
The four main system computers are mounted in the equipment rack and include
the server computer, real-time computer (RTC), and two client computers.

Keyboard, Video, Mouse (KVM) Switcher

The KVM switcher is used to switch the keyboard, video, and mouse between
the system computers. Selecting a computer is done by pressing the following
keyboard commands:
 Ctrl > Ctrl > [Enter Computer Switch #]
 Computer Switch # [typical]: Server = 1, Real-Time = 2, Sonar = 3, VIGRA
Annotator = 4, Left Client = 5, Right Client = 6, Remote Diagnostics = 7

Video Processing
The control system uses video processors that enable video to be recorded,
annotated, and switched between monitors in order to create the HUD.
Composite video from the ROV system is fed to the video router, which in turn,
directs the selected video to the LCD monitors.

The video router also supplies composite video to the annotator where graphics
can be overlaid onto the image, such as a company logo, along with pertinent
operational information such as date and time, heading, and depth. The
annotated video is then looped back to the router for distribution to the monitors
and two video tilers. Video tilers produce a quad display on the upper left and
upper right monitors.

194
Sonar Processor [Optional]

The sonar is controlled by a stand-alone computer that controls all functions

of the sonar head and displays feedback on the monitor. This system will vary
in appearance and features depending upon the manufacturer. Software for
controlling the sonar is provided by the original equipment manufacturer and is
independent from the FMC Schilling Robotics software.

A cable between the computer and a topside node SIM provides a direct serial
link to the subsea head through the DTS. Some controllers utilize the control
system keyboard while others utilize a remote access terminal (RAT) that mounts
to the top of the console.

The video output of the sonar is run through the video router for display on
the HUD. This image may also route to the video tiler for multiple outputs or
recording, however, this typically results in a much lower video quality due to
conversion to composite video.

Remote Access Terminal (RAT)

Topside Sonar Computer

195
 Communications Processor [Optional]
Communications to the bridge or other ship locations is done through a
processor located in the computer rack.

Communication System [Optional]

The system includes an eight-station communications system for conducting
ROV operations, a speaker with two push-to-talk microphones for pilot and
co-pilot communications at the control console, and wireless headsets for use
outside the control van.

Remote Diagnostics Panel [Optional]

Remote access allows the ROV operator to receive real-time, remote technical
support over the internet from FMC Schilling Robotics customer service.

Uninterrupted Power Supply (UPS)

A UPS is provided on the main power input to facilitate proper control system
shutdown in the event of power loss or failure. The UPS does not support the
operation of any subsea equipment.

Deck Power Supply

Deck diagnosis and testing is available by connecting the 26 VDC deck power
supply directly into the ROV IPDS or TMS IPDS through a Burton cable.

196
System Computers
As mentioned earlier, the control system consists of four main computers:
 Server computer: The “brain” of the system
 Real-time computer (RTC): Interface between the control station and the
DTS
 Left & right client computer: Operates the left & right pilot stations
The server computer and two client computers run on Windows XP, while the
real-time computer (RTC) operates on VxWorks.

Network Settings

197
 Server Computer
Overview
This high level control computer uses several sub programs to break the software
into control blocks. Programs running on the server include the Master Executive
menu and agents. The server computer performs the following:
 Accepts user input
–– Switch panel
–– Joysticks
–– Survey
–– Touch screen commands from client computers
 Outputs system data
–– Information on touch screens
–– Survey/annotation strings
–– Dashboard
 Controls topside equipment
–– PDU
–– Video switcher
–– Avitechs
After system startup, the Dashboard screen replaces the Master Executive menu.

NOTE: Pressing F1 on the server keyboard toggles the display

between Dashboard and Master Executive programs.

198
Dashboard
During system operation, the Dashboard displays important information such as
heading, depth, AutoMode status, alarm states, and system status.

Agents
Agents act as the interface between the control hardware and the HD program.
Each agent is a separate application that runs on the server computer. The agents
take data from a device or from another agent, normalizes it, and publishes it for
use by other applications.

Examples:
• Event Agent: Publishes significant events and alarms to the event log. The
log can be viewed or saved as a file and e-mailed to aid in troubleshooting.
The event log uses the same format as the built-in event viewer in Windows
XP, so the file can be read on any Windows NT, 2000, or XP machine.
• BG Stick Agent: Takes serial data from the joystick controller board,
applies any offsets due to “joystick zeroing,” and publishes the data in a
range and format that can be used by other applications such as the motion
control, pan and tilt, and valve pack agents (for running the RigMaster), etc.
Agents are activated by the system at startup and continue to run in the
background of the server computer (minimized). If the agent stops running for
any reason, the system generates an alarm and display in the status window that
an agent has unexpectedly terminated. The system will then attempt to restart
the agent and records the successful restart in the event log. The agents’ screens
can be displayed for fault-finding purposes by using a series of keystrokes on the
server computer.

199
 Additional agents include the following:
 Alarm
 Pan and Tilt
 Setup
 Instrumentation
 TMS
 Motion Control
 Node
 Valvepack
 Switcher
• VIGRA Annotator

Agent Screen

! Caution !
The parameters of some agents can be edited from the agent window. Do not
change or edit any settings unless directed by FMC Schilling Robotics service
personnel, or system malfunctions may result.

200
Common Keyboard Commands
Server computer commands include the following:
 Ctrl + Shift + Insert (CSI): Enables and disables the keyboard hook
 F1: Toggles between the Master Executive and the Dashboard
 F4: Populates the DOS window
 Alt + F11 (x5): Enables and disables Control + Alt + Delete
Window’s commands include the following:
 Control + Shift + Esc: Populates the task manager
 Alt + Tab: Toggles between running programs (agents)
 Alt + Print Screen: Captures a screen image

201
 Master Executive
The Master Executive menu not only manages system STARTUP and
SHUTDOWN, but also installation and configuration of new control software.
Navigate to this screen at anytime by pressing the F1 key on the server keyboard.
The Master Executive does the following:
 Controls the entire normal software install process
 Responsible for launching and stopping the Configuration Application
 Shows the status of the clients and the RTC
 Monitors the status of the individual computers
 Handles the start, stop, and re-starts of agents
• Handles the shutdown of the Windows system computers
The Master Executive displays a computer icon with status indicator for each
client and the RTC. A green check mark indicates the computer is operating
normally, while a yellow question mark or red x mean the server has not received
a from one of the computers, indicating there is a problem with communications
and the system should be restarted. A “heartbeat” is a short message sent by a
computer when it has finished initializing. When all three computer icons show
a green check mark, the system is ready for startup.

202
Startup, Shutdown & Install Buttons
Turning on the console control power switch powers up the system computers
and launches the Master Executive program. Within a few moments, the Master
Executive screen is displayed on the HUD. The console touch screens display an
initialization screen until all computers are functional and the STARTUP button is
pushed.

STARTUP Button
 Initiates system operation
 When pushed, the initialization screen is replaced with the ROV page, and
the Master Executive screen is replaced by the Dashboard
 Enabled when initialization is complete and disabled during initialization of
the server, RTC, and client computer control software

SHUTDOWN Button
 Terminates system operation
 When pushed, the control software on the system computers is stopped and
the server and clients are powered down (the RTC must be powered down
manually)
 Enabled always, except during installation of new software, or while running
the Configuration Application (Config App)

INSTALL Button
 Installs new control software on the system computers
 When pushed, the control software on the system computers is stopped,
and new control software is copied from the installation CD that has been
inserted into the server computer CD drive (after new software has been
installed, all computers are automatically restarted)
 Enabled only if the RTC and client control software is operational

NOTE: The INSTALL button is only available if the STARTUP button is available
and has NOT been clicked. If you find that the INSTALL button is grayed out, simply shut
down the system and restart. Once the Master Executive is
running, assure that the MMI/RTC build disk is in the server’s CD drive and click the
INSTALL button that should now be available.

203
 Configuration Application (Config App)
The Config App is the program used for configuring persistent tunnels between
subsea devices and surface monitoring / controls. Config App is used to
configure “port to port” or “port to RTC” tunnels.

Config App modifies the Flat File used by the RTC. When the nodes boot up,
the RTC will broadcast the system configuration as stored in the Flat File and
listen for responses from the appropriate port. The RTC will respond by setting
up the tunnels for SIM / SIM , VIM / VIM or SIM / RTC. The SIMs will setup the
serial configuration and VIMs will set up video configurations as well as serial
communications where required. Network devices do not require additional
configuration from the RTC.

Use Config App to perform the following:

 Add, delete, and move devices attached to topside and subsea nodes
NOTE: You cannot add or delete devices that are essential to
ROV system operation, including some sensors, thruster controllers,
compensators, and reservoirs.

 Customize communication parameters for devices

 Assign cameras to pan & tilts

204
Access the Config App
Click the CONFIGURE button at startup while the Master Executive screen is
present on the HUD screen. When the “Select Configuration App” pop-up box
appears, select “Device (Node/Port) Configuration Application.”

System-Critical Devices
System-critical devices are permanent and cannot be added or deleted
 Compensators
 Reservoirs
 Thruster Control Units
 ROV/TMS hydraulic control manifolds
 TMS latch manifold
 Tether speed sensor
 Lighting Control Unit
 Valve packs (12-function, 8-function, and 3-function)

Common System Devices

Common system devices have stored configuration settings.
 Pan and Tilts
 ROV / TMS Altimeter
 ROV / TMS Compass
 Doppler Velocity Log (DVL)
 Cameras
 Gyro, Crossbow, CDL, IXSEA
 Depth Sensor

205
 User Settings Configuration Application (User Config App)
The User Config App allows you to change settings for RTC applications, GUI
pages, and control software (such as TMS tether control parameters and over-
temperature thresholds). Some items in User Config App may not apply to
your ROV system. You can access User Config App only if the control system is
operating in supervisor mode.

! Caution!
Changing a factory-set option can cause control system malfunctions, damage to
equipment, and injury or death to personnel. Use the User Config App only as directed by
Service/Upgrade Bulletins or FSEs..

206
Real-Time Computer (RTC)
The real-time computer (RTC) interfaces between the server and the DTS, and
performs the following functions:
 Accepts input commands from the server computer
 Controls command status
 Accepts input data from system devices
 Calculates flight information, such as thruster RPM
 Performs unit value conversions
 Issues commands to system devices
 Sets up node tunneling
 Monitors data channels for valid data

Specific Settings
The RTC runs VxWorks, a Unix-like operating system designed for real-time
control applications. The ROV program operating on VxWorks is called the
device control supervisor (DCS).

Flat File
The Flat File “flatfile1.txt” is a text file that contains all the node and port
assignments for all devices installed on the HD. It includes information on serial
settings, tunneling, frequency of device information, and any specific device
information such as data string type. The Flat File is stored on the RTC and
is read at boot up. If the Flat File is damaged or missing, the RTC will fail to
complete the boot up process.

Config App is the application used to modify the Flat File. It is recommended to
perform a backup of the Flat File prior to modifying settings in Config App.

! Warning !
Do not modify the Flat File inside the .txt document. This document should not be
altered unless instructed to do so by FMC Schilling Robotics Customer Support.

207
 Client Computers
The two client computers control the touch screen monitors at each pilot station.
The programs running on the client computers are bbPage and bbDeus:
 The bbPage program runs the button bar at the bottom of the screen.
When you press a button on the button bar, it performs the action, such
as changing to another page (the button bar remains) or scrolling through
additional button bar controls
• The bbDeus starts up and shuts down pages, including auto restart if a
page is terminated for some reason. The program also handles commands
from the Master Executive, produces the “heartbeat” for the client, and
handles new software installation

Client Specific Settings:

 Touch screen driver
 Video output is set for 180 degree rotation to accommodate mounting the
screen upside down for an improved viewing angle

208
Graphical User Interface (GUI)

Screenshot Examples

209
 GUI Buttons

Safety-Protected Button
Buttons are safety-protected if they could cause harm to the ROV system, crew,
or the mission when accidentally pressed. They are identified by the red circle
and slash symbol. Pressing a safety-protected button has no effect unless the
SAFETY button is pressed first.

NOTE: Pressing the SAFETY button removes safety-protection from all

safety-protected buttons on the current page for ten seconds or until one of
them is pressed (whichever comes first).

Password Protected Button

Buttons with functions that could negatively affect operation or cause equipment
damage if improperly used are password-protected (locked out) and accessible
only while in the “Supervisor Mode.” These buttons have a small green or black
triangle in the upper, right-hand corner of the button when they are locked. The
corner triangle disappears when Supervisor Mode is entered, indicating the button
is functional.

Active / Inactive Button

Buttons are active/inactive if they initiate an action or condition that persists until
the button is pushed again. The color green means it is active and grey means it
is inactive.

210
Trying Button
If the action initiated by a button takes more than a fraction of a second
to complete, the button’s status bar is barred, indicating the “trying” state.
This may also occur if the client computer has not received an update of the
requested functions status.
 Example: If a node port is turned on but the client missed the feedback
confirming the port came on it will remain in the “trying state” with green
bars until updated

Unavailable Button
Buttons become unavailable at times because they are dependent on the state of
other buttons or system conditions, or have not been implemented in this software
release.

Toggle Button
Some buttons toggle between two active states. An example is the “Normal/
Reverse” button on the ROV page.

211
 Momentary / Instant Button
• A momentary button is pushed briefly to initiate a self-completing action. It
reverts to an inactive state when:
• It is released (momentary/instant)
• The time for an action expires (momentary/time-out)
• The action is completed (momentary/feedback)
• Example: Momentary valve controls

Repeating Button
A repeating button sustains an action until released. Among repeating buttons
in the system are those for tethering in or out, operating hydraulic tools, and
for adjusting zoom and focus, pan and tilt position, hydraulic pressure and flow,
cruise, trim, and displacement set points.

212
Radio Button
A radio button belongs to a set of buttons, where only one at a time can be active
or selected. When you press an inactive radio button, it becomes active, and the
formerly active button becomes inactive. Examples of radio buttons are those on
the Main Menu bar, tab buttons for opening pages, profile and layout buttons,
router input buttons, operating VCR buttons, and those for selecting among pan
and tilt devices, nodes, or valve packs.

Scroll / Control Button

Scroll/control buttons are identified by the white triangle on a black or colored
field. Press the scroll button once to display the next option available on an
adjacent button or display panel or to initiate an action. Press and hold to cycle
through all options or continue an action.

Labeling Button
Buttons labels that can be changed are identified with a boxed “A”.

213
 To label a button:

 Press the LABEL button, located on the right side of the main menu bar
 Press the button to be labeled. A dialog box will appear for entering the
name for the button
 Type in the new label
 Press the OK button

NOTE: The user must be in supervisor mode to modify labels.

Supervisor Mode
Supervisor mode enables password protected buttons and allows for editing labels
and buttons. At the SETUP page, press ENTER under supervisor mode and type
“Schilling” as the password.

214
Notes
Notes
Notes
Notes
Schilling Robotics
Power Distribution
Training Course Student Guide

Power is supplied from the ship’s main generator source or a deck

generator set for the remotely operated vehicle (ROV), tether
management system (TMS), launch and recovery system (LARS),
and other system equipment. The power distribution unit (PDU)
transforms, distributes, and monitors ship power used by the ROV
system.

221
222
 We put you first.
And keep you ahead.

Power Distribution
Training Course Student Guide

Table of Contents
High Voltage Safety.......................................................................................... 224
Electrical Power................................................................................................. 225
Power Distribution Unit (PDU)....................................................................... 226
Human Machine Interface (HMI).................................................................. 236
Programmable Logic Computer (PLC)......................................................... 237
PQube.................................................................................................................. 238
Tether & Slipring............................................................................................... 241
Instrument Power Distribution System (IPDS).......................................... 244
Future Training.................................................................................................. 254
Customer Satisfaction...................................................................................... 255

223
 High Voltage Safety
! WARNING !
HIGH VOLTAGE SHOCK HAZARD! Lethal voltages are present inside the PDU even when
the PDU Main circuit breaker is open. Before performing any service, open and lock out/tag
out ALL EXTERNAL circuit breakers controlling power to the PDU.

Only qualified and authorized individuals should perform electrical work on the PDU.
Incoming power may still be live even when the PDU is completely shut down and must be
cut-off at the source(s).

224
Electrical Power
Main Power Supply

Power is supplied from the ship’s main generator source or a deck generator
set for the remotely operated vehicle (ROV), tether management system (TMS),
launch and recovery system (LARS), and other system equipment. The power
distribution unit (PDU) accepts 380, 400, 440, 460, or 480 VAC at 50-60 Hz (50
Hz will lower system performance) for use by the HD system.

225
 Power Distribution Unit (PDU)
The PDU transforms, distributes, and monitors ship power used by the ROV
system. PDU features include the following:
 Converts shipboard 380-480 VAC to 4160 VAC - 4400 VAC single and three
phase for use by the system
 Controlled by a programmable logic controller (PLC)
 Power quality is measured by a device called the PQube
 Completely self contained (all transformer, contactors, breakers, etc. the
system uses are inside one cabinet)
 Safety interlocks that shut off the unit if a door or access panel is opened
 Ground fault detection (GFD) system and at least one remote E-stop

PDU Input Power

 Main Power: Power used to run the ROV HPU, ROV and TMS instrument
power
 Clean Power [optional]: Power supplied from a dedicated or filtered power
source used for ROV instrument power (IPDS) and TMS power (IPDS). This
is optional but is most commonly used when the main power supply is
unstable

PDU Output Power

 ROV
–– IPDS: Powers the instruments and telemetry for the ROV
–– HPU: Powers the hydraulic systems on the ROV
 TMS
–– IPDS: Powers all components on the TMS

NOTE: Meeting the HD system power requirements is critical to achieving

optimum system performance and protecting topside and subsea electrical
components from damage and failure. Refer to the Technical Manual
for electrical power requirements and setup procedures.

226
PDU Power Flow Overview
Outgoing 4,160 VAC PDU power is routed to the LARS winch through a deck
cable with metal braiding inside for reinforcement. The deck cable is terminated
at the winch slip ring where the power is transferred to the umbilical cable. The
opposite end of the umbilical is connected to the TMS IPDS T-Box, where the
TMS PWR circuits branch off to the TMS IPDS and the ROV IPDS circuits are
transferred to the tether and down to the ROV. At the ROV IPDS T-Box, the
circuits branch off to the ROV IPDS and the HPU.

Below is an overview of the power flow through the PDU.

227
 PDU Specifications

228
PDU Incoming Power
There are two places to land incoming power: Clean and Main.

Both sources of power may be on at the same time. Main power is generally used
to power all circuits unless the ship’s main power does not meet the required
power standards (3% total harmonic distortion). In this case a separate Clean
power source may be used to power the ROV and TMS instrument power circuits.

Incoming power to the HPU circuit breaker is turned on when the Main breaker is
enabled. The ROV IPDS circuit can be powered from either the main bus or clean
power by landing the appropriate wires on the breaker.

Readings
 Current: Measured by current transformers (CTs) as power is landed on
the Main breaker and fed to the PQube and PLC
 Voltage: Measured by the PQube power quality meter by leads coming off
the input of the Main Breaker and sent to the PLC

Phase sequence is also checked to be correct by the phase sequence relay. If

phase is not correct the relay illuminates a phase fault light and the system will
not allow the main power breaker to be turned on.

The Main breaker will only turn on if all of the following conditions are met
 The door switches indicate closed
 The phase sequence relay indicates the selected incoming power is not out
of phase
 None of the emergency stop buttons are depressed
 Control Power is ON
Incoming taps are set for 4 transformers:
1. Control Power
2. TMS Power
3. ROV IPDS
4. ROV HPU

229
 Input Power Configuration
Configuring the PDU for specific ship power and system cabling is critical to
optimizing system performance and protecting electrical components from
damage. Configuration of the PDU should occur during the following:
 At the initial mobilization and all subsequent mobilizations
 Anytime there has been a change to the supply voltage (vessel, m-g set,
etc.), umbilical or tether lengths, system electrical components, or power
loads
 When tests of 120V power at the TMS and/or ROV IPDS indicate that the
measured voltages are outside the acceptable range

230
Control Power
Once external power has been turned on to the cabinet, it then runs to the
control power transformer and lands at the appropriate tap setting for the
incoming voltage. This converts incoming power to 230 VAC for use by the PDU
control system. The P-Qube and PLC are also both powered at this time.

The output of the control power transformer is switched on by pressing the

control power ON button from either the PDU human machine interface (HMI)
or the POWER page of the console GUI touch screen.

The 230 VAC then powers the following:

 24 VDC power supply which the PDU uses for DC power for switching
relays, powering the PLC, lights, etc.
 Control power light on the panel to indicate that cabinet is live
 Cabinet fans
 High power contactors

Once control power is on, the Main, ROV HPU, ROV IPDS, and TMS PWR
breakers are ready for use.

231
 Megacon Ground Fault Monitoring (GFM)

Three Megacon ground fault protection units are mounted in the PDU, each one
monitoring the three (3) 4 kV power lines for line-to-ground resistance on one of
the three subsea circuits (ROV HPU, ROV IPDS, and TMS IPDS).

The green “NORMAL” light on the front of the meter denotes no ground fault
detected (500 kΩ or greater resistance). If the resistance to ground falls below
500 kΩ, the red “ALARM” light is lit and an audible alarm is sounded. When
resistance to ground is 300kΩ or less, the unit automatically shuts off the breaker
for the circuit. The alarm and shutoff functions are both subject to an adjustable
1.5 to 2 second delay. Resistance to ground is also displayed on the PLC HMI and
the console GUI touch screen.

232
Below each ground fault protection unit is a keyed TEST switch for checking
its functionality, and a keyed BYPASS switch which, when engaged, prevents it
from opening the 4kV circuit breaker. The BYPASS switch may be used when the
protection unit has an internal malfunction that opens the associated breaker or
when emergency use of the 4kV circuit is a necessity regardless of ground fault
status.

! WARNING!
The BYPASS switch should be used with extreme caution as it removes ground fault
protection from the 4 kV circuit, allowing ground faults with lethal voltages to be present
on exposed parts of the associated vehicle.

233
 Ground Switches
Rotary switches provide a safety ground to the high voltage output cables for
the ROV HPU, ROV IPDS, and TMS IPDS. Rotating the switch through the center
position will trip the breaker for the corresponding circuit.

There are three 3-position rotatry switches that can ground an individual system
circuit. The 3-positions include:

 Ground: Grounds both legs of the circuit and drains residual voltage in the
circuit and transformer. The breaker feeding power will trip if the circuit is
energized with the switch in this position. The switch should always be in
this position unless the system is actually being used
 Open: The switch is connected to nothing in this position and serves as
an intermediary between GROUND and NORMAL. This ensures that high
voltage will never be sent straight to ground causing a direct short and
possible damage to the circuit (known as break-before-make)
 Normal: Closes a micro switch that closes the control circuit for the
selected circuit

234
Circuit Protection and Safety Devices
 HPU and Instrument Power Interlocks: Prevents the HPU circuit from
being activated if the ROV IPDS circuit is not active ensuring the HPU is not
started without control or monitoring
 Circuit Breakers: Some of the breakers for the system are settable to fine
tune their trip points
 Under Voltage Trip: Each input circuit breaker is equipped with a circuit
that opens if the voltage drops below a predetermined limit, which in turn
trips the breaker and opens the circuit so as not to place a strain on the
equipment in an under voltage condition
 Door Interlocks: All doors and removable panels interlock with the
emergency stop circuit (if a door or panel is opened, all circuit breakers will
be tripped disabling IPDS and HPU power; control power (230 VAC and 24
VDC) supplies remain active however)
 Emergency Stop Switches: E-Stop buttons in the system, one on the front
of the cabinet and one on the console. If any of these are depressed then
main power will shut off and trip all activated input breakers
 Phase Sequence: The monitor activates the emergency stop circuit during
phase imbalance, failure, or out of sequence

235
 Human Machine Interface
(HMI)
The interactive touchscreen displays data and can control the PDU.

236
Programmable Logic Computer
(PLC)
The Programmable Logic Computer (PLC) receives input commands from the
control system or the HMI. The computer transmits system power data such as
amperage and voltage to the GUI displays and server computer. The server uses
this data for power management calculations and relays data to the GUI screens
for status display. Once a command is received, the PLC sends a signal to the
appropriate relay to turn a circuit ON or OFF. All circuits switch through this
device.

Circuit protection is designed into the HD system software which receives

data from the PLC. If a fault is detected by the system it will shut off a circuit
automatically through the PLC. Faults include the following:
 Low oil volume
 High oil temperature
 High motor temperature
 Sustained over current

The PLC has a panel of LEDs that illuminate to indicate which circuit is being
commanded on.

237
 PQube
Main voltage, current, and frequency are measured and monitored by the
PDU and visible on the HMI. Current is measured in each leg using current
transformers that scale the current and route it through the PQube on the inside
left door. The PQube is a power quality monitoring device that records faults
from all line-to-line and line-to-neutral voltages based on user defined thresholds.

The PQube is used to perform the following:

 Verifies power quality
 Keeps a log of events
–– Low voltage
–– Phase loss
–– Low power factor
–– Keeps a time based table of voltage and current readings.

A removable memory card for extracting data is contained in the PQube,

allowing data to be uploaded into a computer for troubleshooting purposes.

238
Umbilical
The small diameter HD umbilical allows a compact overall winch package with a
standard system capacity of 3,300 m installed, with 4,300 m umbilical capacity
option. The umbilical takes advantage of high voltage conductor and insulation
technology to minimize copper conductor cross section.
 Two layers of lift (armored) cable
 Three conductors for ROV HPU
 Four conductors for ROV and TMS instrument power
 Fiber optic cable tube
 Ground wires

Winch
Dynacon’s hydraulically-operated winch is common to all system options from
2,000 msw - 4,000 msw rated systems. The winch shares a hydraulic power pack
with the A-frame. The winch can be fitted with either a standard or right angle
overhead level wind unit.

239
 Umbilical, Winch, and HPU Specifications
Umbilical
Manufacturer Tyco
Part No. EPD 1139955 Rev A
Length Options 2,300/3,300/4,300m
Max Depth Rating 4,000msw
Diameter 28.5mm
Armour Dual Layer Steel Wire
Weight in Air 2,606 kg/km
Weight in Seawater 1,945 kg/km
Minimum Bend Diameter 940mm
Safe Working Load 109kN
Peak Working Load 125kN
Minimum Break Load 430kN
Fiber 7 SM, Fiber in Steel Tube

Standard Umbilical Winch

Safe Working Load, Full Drum 9,500kg 20,944lb
Maximum Line Pull, Bare Drum 13,000kg 28,660lb
Line Speed, Average 32mpm 105fpm
Umbilical Diameter 28.5mm 1.12in
Capacity, Standard 3,300m 10,821ft
Capacity, Option 4,300m 14,108ft
TARE Weight, RA Levelwind 17,259kg 38,050lb
Gross Weight, 3,300m 25,859kg 57,009lb
Gross Weight, 4, 300m 28,465kg 62,755lb
Height 4,624mm 182in
Length 3,761mm 148in
Width 2,240mm 96in

HPU
Power Supply 460VAC 3 Phase 60Hz 200A
Drive (2) 60HP 1,750rpm
Weight, with Oil 3,692kg 8,140lb
Length 2,362mm 93in
Width 1,439mm 57in
Height 2,235mm 88in
Capacity 100USG 378L

240
Tether & Slipring
Tether Cross-Section
Outer sheath: Aramid-reinforced TPR, yellow
Inner sheath: Polyethylene
Installed length: 425 m
Diameter: 28 mm
Minimum Bend Radius: 200 mm
Weight (Air): 675 kg/km
Weight (Water): 45 kg/km
Safe Working Load: 20 kN (2,039 kg)
Armor Break Strength: 110 kN (11,217 kg)

The tether includes the following components:

 3 Power Conductors 4 mm
 2 Power Conductors, 0.82 mm
 1 Fiber Optic Element, 12 SM
 Ground wires

241
 Sliprings
The TMS slipring is designed to maintain all of the power and fiber optic circuit
connections while the drum assembly rotates. The slipring unit is housed in the
center of the drum and is designed to be oil filled and pressure compensated.
Power is fed to the umbilical through a slip ring in the LARS.

The fiber optics pass through a prism assembly inside the slipring made up of an
array of hyper-precise mirrors, called fiber optic rotary joints (FORJ). There are
three fiber optic passes in the slip ring.

The slipring is serviceable but will void manufacturer’s warranty:

 Brush replacement kits are available
 New light FORJ is available

NOTE: The slip ring in the umbilical winch and the TMS are physically different and are
not interchangeable. When using a Megger to check the system, never exceed 5,000 volts
when passing through the slip ring as this will result in damage to the internal workings.

242
High-Voltage Quick Disconnect (QD)
There are four QDs on the TMS, two on the IPDS and two on the slipring. The
umbilical, tether, and HPU leads are terminated into their own high-voltage
QD. Each high-voltage QD transfers the electrical connections at each vehicle
IPDS, while fiber connections for the umbilical and tether are made outside the
electrical mating face.

243
 Instrument Power Distribution
System (IPDS)
The instrument power distribution system (IPDS) is used for subsea power
conversion and distribution. The IPDS is comprised of modular components
which provide for rapid maintenance and repair.

IPDS Features:
 Quick-disconnect tether termination
 Modular transformer and power adapter components
 Multiple AC and DC power delivery options
 Power supply instrumentation [voltage/current monitoring]
 Line-isolation monitoring
 SeaNet for ground-fault detection (GFD) and diagnostics
 Isolated compensation circuits for the backbone, transformer, and high-
voltage QD “T-Box” for easier servicing capability

IPDS Components

244
High-Voltage QD “T-Box”
4160 VAC PDU power to and through the IPDS is connected at the T-Box. There
are landings for two QDs, one for incoming power and one for outgoing power.
T-Box compensation is provided by the HPU motor compensation circuit.

Transformer
Incoming 4160 VAC power is routed to the transformer, which has two
windings supplying 120 VAC to the Backbone. Transformer core temperature
is monitored for use by the control system, and the case surrounding the
transformer is actively compensated.

245
 IPDS Backbone
The backbone of the IPDS routes the two phases of 120 VAC power from the
transformer and provides the central connection point for the modular power
components. The backbone has the following features:
 Mounting for the T-Box and transformer
 Four 120 VAC ports for connecting power adapters
 Two 120 VAC fuses, one for each 120 VAC bus, in a one atmosphere
housing
 Four 26 VDC stations for supplying power to the nodes
 Deck Power (26 VDC) input connector
 Power diagnostic LEDs
–– The AC POWER ON status indicator is lit by two green LEDs, one for
each 120 VAC bus. If only one LED is lit, one 120 VAC bus does not
have power
–– The DC STATUS light changes color to indicate the status of the
26 VDC bus supplying the four node power stations. A green light
indicates 26 VDC is present and the nodes are initialized. A blue
light indicates power is cycling or near the limit value, and a red light
means the limit value has been reached or exceeded

! WARNING !
High voltage supply power can be present in the IPDS when the
AC POWER indicator is not lit.

A monitor module on the backone is used to provide GFD and diagnostic data to
the control system. The monitor module also forwards control system commands
to the multi pack for switching the 120 VAC outputs on and off.

The monitor module collects input from the:

 Water-detect sensors in the transformer, backbone, and power adapters
 Temperature sensor in the transformer
 Insulation monitoring device (IMD) in the optional multi pack power
adapter

246
IPDS Power Adapters
Power adapters connect to the 120 VAC ports on the IPDS backbone. These
adapters transmit, combine, or convert voltage AC to DC for use by external
devices and equipment. Up to four adapters can be used on the IPDS, and a
blank-off can be installed on unused ports.

DC Packs
The DC pack converts 120 VAC to 26 VDC for the IPDS backbone 26 VDC node
power bus. Typically, two DC Packs are required to power up to three nodes.

The DC pack has an LED that changes color to indicate DC status (voltage output
and water detection):
 Green indicates 26 VDC is present, the nodes are initialized, and no errors
are detected
 Blue means power is cycling on or a monitored parameter is near the limit
value
 Red means a monitored parameter has reached or exceeded the limit value

247
 Multi Pack
A multi pack may be used to provide several different voltage configurations in a
single power adapter. The multi pack mounts to two of the IPDS backbone 120
VAC power ports. The 120 VAC stations and the 48 VDC station are switched
off and on from the POWER page.

The multi pack converts 120 VAC to:

 26 VDC for the IPDS backbone 26 VDC node power bus
 One 48 VDC output with 8-pin Burton connector
 Two 120 VAC outputs with 6-pin Burton connectors

The multi pack has status indicator LEDs for each voltage output:
 The 26 VDC light changes color to indicate status (green, blue, and red)
 The 48 VDC light changes color to indicate status (green, blue, and red)
 The 120 VAC LEDs are green when 120 VAC is present

248
IPDS Specifications
Input voltage (min/max)..........................................4,160 VAC ± 5%/3,000 VAC ± 5%
Input voltage, frequency.......................................................................... 50/60 Hz ± 0.5 Hz
Output voltage (IPDS core)...................................................................120 VAC, 2 phase

VDC Outputs (using a power adapter module)

 Four 26 VDC with a DC Pack or Multi Pack
 One 48 VDC with a Multi Pack

VAC Outputs (using a power adapter module)

 Two 120 VAC (switchable), with a Multi Pack
 One 240 VAC with a TMS Adapter

Fuses
Backbone.......................................................................................................................25A, 2x
Adapter, 120 VAC........................................................................................................20A, 1x

Sensors
Water Detect............................................Backbone, Transformer, DC Pack, Multi Pack
Temperature....................................................................................................... Transformer

Compensation
Fluid pressure (above ambient).................................................... 0.6 - 0.7 Bar (8-10 psi)
Relief valve cracking pressure...................................................................1.4 Bar (20 psi)

Environmental
Operating temperature (min/max).............................. 0° C to +40° C (32° F to 104° F)
Storage temperature (min/max)................................. -18° C to +50° C (0° F to 122° F)
Depth rating...................................................................................4,000 msw (13,123 fsw)

Dimensions
Height........................................................................................................350 mm (13.79 in)
Width.........................................................................................................387 mm (15.24 in)
Length....................................................................................................... 578 mm (22.75 in)

! WARNING !
SHOCK HAZARD! This equipment uses and produces hazardous voltages. Always lockout
and tagout power sources and verify system grounds are connected before disconnecting
any QD or performing any service.

249
Notes
Notes
Notes
Notes
 Future Training
FMC Schilling Robotics is focused on serving our customers through classroom,
hands-on, simulation, and on-site training. Training courses are available for
installing, operating, maintaining, and repairing all of our product lines. Hands-on
training sessions are conducted by experienced instructors, and detailed training
Student Guides are provided to each student.

254
Customer Satisfaction
As the fastest growing independent ROV system supplier, FMC Schilling Robotics
demonstrates a commitment to its customers resulting in 100% customer
retention. This ever-increasing core customer base has allowed a continued focus
on delivering cost-effective solutions. FMC Schilling Robotics has successfully
provided over 25 years of leadership in the global subsea ROV market and has a
proven track record of partnering with its customers to achieve success.

“FMC Schilling Robotics systems are state of the art: friendly to be used and
maintained. I believe that a training program shall be implemented when the
buyer is not familiar with the system, but in general they are very reliable!”

“FMC Schilling Robotics systems are the best ones we have ever worked with.”

“FMC Schilling Robotics vehicles have technical and performance superiority

over others…this is the main reason we have decided to use only FMC Schilling
Robotics’ systems.”

“FMC Schilling Robotics’ support and level of partnership…are part of our daily
operations meetings! FMC Schilling Robotics is always there when we need!”

255
FMC Technologies FMC Technologies
Schilling Robotics, LLC Schilling Robotics, Ltd.
260 Cousteau Place Unit 4, Kirkhill Commercial Park
Davis, CA 95618 U.S.A. Dyce Avenue
P: +1 530.753.6718 Aberdeen AB21 0LQ U.K.
E: [email protected] P: +44 o.1224.215300
E: [email protected]
FMC Technologies
Schilling Robotics, LLC FMC Technologies, Ltd.
201 Cousteau Place 149 Gul Circle
Davis, CA 95618 U.S.A. Singapore
P: +1 530.747.2801 T: +65 6861.3011
E: [email protected] E: [email protected]

FMC Technologies
Schilling Robotics, LLC FMC Technologies CBV
7102 W Sam Houston Pkwy N Rodovia Amaral Peixoto s/n KM187
Suite 100 Lote 1, Quadra 1, Cabiunas
Houston, TX 77040 U.S.A. Macaé - CEP 27913-350 Brazil
P: +1 281.598.4100 P: +55 22.2773.0718
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