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Troubleshooting
Related Manuals for Robotronics Patches & Pumper
Summary of Contents for Robotronics Patches & Pumper
- Page 1 ® Patches & Pumper Robot ™ Operating Manual Version 6C...
- Page 2 ™ Robot Congratulations on your purchase of a ROBOTRONICS, Inc. robot. Your robot has been carefully constructed of the highest quality components. Its design is the result of years of experience building robots. You will find it an extremely effective spokesman for your organization. It is built for ease of operation, maintenance and repair.
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Page 3: Table Of Contents
Contents Contents Warranty Information..................1 PART 1 General Operating Instructions ........3 Chapter 1 Getting Started............3 Operating Hints ..................3 Setup and How To Operate The Robot............. 4 Transporting The Robot ................6 PART 2 Subsystems of the Robot .......... - Page 4 Technical Tips Section* ..................59 * These sections can be used to place additional notes that you would like to record, during your use of the robot and information sent from Robotronics; such as the technical tips section of the newsletter.
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Page 5: Warranty Information
If you need parts sent by air shipment you will be responsible to pay the additional shipping charges. In no event shall ROBOTRONICS, Inc. be liable for any incidental or consequential damages in connection with or arising from the use of the robot. - Page 6 The staff of ROBOTRONICS has taken due care in preparing this manual. Because of parts availability, robots may vary slightly from unit to unit. If you have any questions, please contact our service department.
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Page 7: Part 1 General Operating Instructions
CHAPTER 1 Getting Started OPERATING HINTS ROBOTRONICS, Inc. robots are a unique and exciting tool in the hands of a skilled and trained operator. Much of the excitement the robot conveys is provided by the operator. The selection and training of the operator should be done carefully, so as to provide a person with good judgment and an outgoing personality. -
Page 8: Setup And How To Operate The Robot
Chapter 1 Getting Started: Setup and How to Operate the Robot SETUP AND HOW TO OPERATE THE ROBOT Step # 1 Read the manual Read and study this manual completely before operating the robot. Step # 2 Charge and install the batteries Be certain that the robot battery and radio control transmitter battery are fully charged before operating the robot. - Page 9 Chapter 1 Getting Started: Setup and How to Operate the Robot Step # 5 Tape Player Set Up Put a cassette tape in and press play. The tape player volume can be changed on the tape player itself, which can be accessed through the rear hatch/trunk. Step # 6 Powering up Turn the Radio Control (RC) “ON"...
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Page 10: Transporting The Robot
Chapter 1 Getting Started: Transporting the Robot TRANSPORTING THE ROBOT Before transporting the robot, remove the robot battery from the robot. The vehicle that you use to transport the robot should have adequate shock absorption. Vans and cars used for passengers would be the best. Transporting the robot in a trailer is not recommended because trailers typically do not have the same level of shock absorption as a car or van. -
Page 11: Part 2 Subsystems Of The Robot
Part 2 Subsystems of the Robot Part 2 Subsystems of the Robot Functionally, the robot is made up of the following basic subsystems: A. Radio Control System (Control) B. Voice System and Moving Mouth (Audio) C. Cassette Tape Player (Audio) D. -
Page 12: Radio Control Operating Instructions
Chapter 2 Radio Control System RADIO CONTROL OPERATING INSTRUCTIONS Refer to the diagram showing the radio control transmitter for the location of controls. Check all of the trim adjustments on the transmitter and make sure they are in their center position. -
Page 13: Radio Control Transmitter (Diagram)
Chapter 2 Radio Control System RADIO CONTROL TRANSMITTER (Robbe-Futaba F-14) Switch bank 2 1 2 3 4 5 6 7 8 Switch bank 1 1 2 3 4 5 6 7 8 To remove back cover, slide the tabs as shown. -
Page 14: Radio Control Transmitter Controls
Chapter 2 RC Controls RC TRANSMITTER CONTROLS (Robbe F-14) Telescopic Transmitter Aerial. Transmitter Battery Voltage Meter (Expand Scale Voltmeter) Right control Stick- Up and Down – Robot drive motors, forward and reverse. Right and Left – Robot drive motors steering. Left and right turns. Forward/Reverse Trim lever for right control stick. - Page 15 Chapter 2 RC Controls Special note: The eyelids will also open if you hit any one of the eye switches. Switch bank 2 7. Headlights - Forward On / Back Off 8. Cassette Tape Player - Forward On / Back Off When the battery level goes in the red, the robot should be turned off and the other battery connected.
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Page 16: Nickel Metal Hydride (Ni-Mh) R.c. Transmitter Battery
Chapter 2 RC Transmitter Battery THE Nickel Metal Hydride (NI-MH) RC TRANSMITTER BATTERY The NI-MH RC transmitter battery will last about 5-6 hours on a full charge. Charge the battery for 16 hours. A charge jack is provided on the transmitter for recharging its internal batteries. -
Page 17: Charging Adapter And 110 Volt Power Supply Option
Chapter 2 Radio Control: Adapter and 110 V Supply If you have an extra NI-MH RC battery, you can charge this outside the RC. You may want to do this while you are using the robot or if you need to charge both batteries at the same time. -
Page 18: Chapter 3 Voice System Overview
Chapter 3 Voice System CHAPTER 3 Voice System The Voice System consists of two separate communication links. One link transmits the operator's voice to the robot. When you speak into the headset mic, this audio goes to a transmitter on your belt. This audio is transmitted to a receiver in the robot. The audio signal then goes from the receiver through a mixing circuit on the main board. -
Page 19: Belt Transmitter
Chapter 3 Voice System How to Operate the Operator’s Transmitter 1. Open the battery door. 2. Use a 9 volt alkaline battery and insert it according to the diagram inside the battery compartment. 3. Place the headset on your head and adjust the microphone to approximately 1 inch from your mouth. -
Page 20: Robot Receiver
Chapter 3 Voice System How to Operate the Receiver (in Robot) There are two adjustments on the receiver. The volume is on the back of the receiver, which you may set to the desired volume. On the UHF UB-10 you can change the volume on your belt transmitter on the fly. -
Page 21: 151 System (Robot Tx And Belt 151 Receiver)
Chapter 3 Voice System How to Operate the 151 Transmitter (in Robot) No adjustment is needed. The switches will be preset to on at the factory. It receives its power from the robot. No 9 Volt battery is needed. Function of the LED When the robot is turned on, this light flashes and then goes out. -
Page 22: Voice System Troubleshooting
Chapter 3 Voice System: Troubleshooting Warnings 1. Do not unplug or plug in the DC power plug on the robot receiver with the robot power on. If the power is left on, the plug will short out and could damage the receiver. The fuse in line on the power wire that is plugged into this receiver may blow. - Page 23 TEST- Connect robot mic to transmitter. If it now works, problem is in headset. Repair or replace. 7. Still not working. Call Robotronics. Send transmitter, receiver, and headset in. Operator cannot hear 1. Low Battery. LED on steady or no LED flash.
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Page 24: Mouth Operation
Chapter 3 Voice System: Moving Mouth MOVING MOUTH Function- The moving mouth is a feature where the mouth moves as the operator speaks through the robot. The amount of the movement is effected by the level of volume of the voice. This level is effected by the Receiver volume level and the position of the headset microphone to the operator's mouth. -
Page 25: Operator's Voice Headset, Transmitter, And Receiver
Chapter 3 Voice System: Operator’s Voice Transmitter and Receiver (Diagram) Operator’s Voice Transmitter and Receiver 3.5mm Headphones Plug Mic Plug - 3.5mm or 3 Pin mini XLR... -
Page 26: Chapter 4 Cassette Tape Player System
Always remove the cassette tape when not in use. This will prevent flat spots on the capstan roller. There are cassette tapes available from Robotronics with safety songs or you can customize your own tape to work with your program. -
Page 27: Cassette Tape Player Instructions & Diagrams
Chapter 4 Cassette Tape Player System (Diagram) Cassette Tape Player... - Page 28 Chapter 4 Cassette Tape Player System (Diagram)
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Page 29: Chapter 5 Siren
Check if the audio booster is working by testing the voice or activating the cassette player. If you get no voice or cassette audio, check the audio fuse on the fuse block in the main electronics box. Also check the speaker connections at the speakers. Call the Robotronics' Service Department for assistance. -
Page 30: Chapter 6 Robot Battery Systems
Chapter 6 Robot Battery Systems: Pumper Battery CHAPTER 6 Robot Battery System PUMPER ROBOT BATTERY The battery in the robot is a rechargeable sealed lead-acid Gel type battery 12 Volt 31AH. This type of battery is very dependable and safe. It can be repeatedly charged and discharged. -
Page 31: Pumper Robot Battery Charger
Chapter 6 Robot Battery Systems: Pumper Battery Charger ROBOT BATTERY CHARGER Instructions for Proper Use and Operation WARNING: HAZARD OF EXPLOSIVE GAS MIXTURE When charging, a lead acid battery gives off hydrogen gas. The Globe Gel type is a lead acid battery with pressure relief type vents. Although it only gives off a small percentage of the gas that a wet lead acid battery does, the following precautions should be observed:... - Page 32 If the charger does not stay on after 10 minutes, disconnect the charger from the battery. The battery most likely has a shorted cell and needs replacement. In some cases, a battery, which is discharged completely, will not draw any noticeable current when the charger is connected and the power cord plugged in.
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Page 33: Chapter 7 Drive Motor System
Chapter 7 Drive Motor System CHAPTER 7 Drive Motor System Your robot is provided with two high quality industrial grade drive motors. Each motor controls a drive wheel-left and right. Steering of the robot is accomplished by varying the speed and direction of these motors. For example, when the left motor runs faster than the right, the robot turns to the right. - Page 34 -Drive circuit-(motor control) If the drive motor is good, the drive circuit (motor control) could be the cause of the fuse blowing. If this is the case, check for broken or shorted wires and if nothing is found, contact the Robotronics' service department for assistance.
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Page 35: Chapter 8 Patches Head Turning Motor System
Chapter 8 Patches Head Turning System CHAPTER 8 Patches Head Turning System The main components of this system consist of the head turning motor, motor control circuit, and the feedback pot. When you move the joystick on the radio control, a signal is sent to the receiver in the Pumper. -
Page 36: Chapter 9 Eyelids And Eyes Left And Right
Chapter 9 Eyes System CHAPTER 9 Eyelids and Eyes Left and Right The eyelid and eyes left and right movement is accomplished by three servo motors in Patches. When the switch on the radio control is activated, this signal is sent to the radio control receiver in the robot. -
Page 37: Chapter 10 Optional Accessories
ALWAYS make sure the water line is plugged in when using the water squirter or water may damage the electronics. If you have any questions or need help in learning to operate your new water squirter option, please feel free to contact Robotronics' Customer Service Department at (801) 489-4466. -
Page 38: Pitch Shifter (Voice Modifier)
Chapter 10 Optional Accessories: Voice Modifier OPTIONAL ACCESSORIES: VOICE MODIFIER (PITCH SHIFTER ) INSTRUCTIONS The pitch shifter (voice modifier) can change the operators voice to disguise it and create a robot character type voice. The operators voice signal is received like normal by the voice receiver in the robot. -
Page 39: Part 3 Assembly & Disassembly
Chapter 11 Assembly & Disassembly PART 3 CHAPTER 11 Assembly & Disassembly Installing the robot battery: 1. Position the robot battery so that the posts face the rear of the robot. In this position, the battery wire will naturally run to the robot battery connector. 2. - Page 40 Chapter 11 Assembly & Disassembly 3. The box can now be removed. When removing, do it slowly, making sure that all wires are disconnected. Removing the drive base from the body: ( This would be necessary only if you needed to get to the drive pulleys, belts or remove a drive motor.) 1.
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Page 41: Part 4 Maintenance
Chapter 12 Maintenance: Checklist PART 4 CHAPTER 12 Maintenance Regular Maintenance Checklist Periodically the robot should receive a thorough inspection. Examine the exterior of the robot and make repairs as necessary. See the robot body repair instructions if needed. Remove the upper robot. Check all bolts and nuts for tightness. Examine electrical wiring and connectors for looseness and wear. - Page 42 Chapter 12 Maintenance: Recommended Tool Kit Recommended Tool Kit Fuses- 1, 3, 5, 15, 20, 30 Amp (AGC Type) 4" cable ties #53 Miniature bayonet bulbs (automotive panel type) Precision regular Phillips screw drivers Screwdrivers (flat head and Phillips) Socket and ratchet set Needle nose pliers Crimper/Wire strippers Wire cutters (diagonal cutters)
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Page 43: Care Of Patches' Fur
Chapter 12 Maintenance: Fur Care FUR CARE General maintenance of your robot should include caring for the robots fur. After each use, clean and brush the robot’s fur and clothing so the oils and dirt do not become permanent. This may be done with a cloth or brush. Keep the robot covered when not in use to keep dust and dirt off and to protect the fur and clothing. -
Page 44: Painting Of The Body
Chapter 12 Maintenance: Painting of the Body PAINTING OF THE ROBOT BODY The following information are only suggestions of painting methods. Contact a professional for assistance. Preparing the surface: The robot body is an ABS plastic and should be cleaned before painting to remove oils and dirt. -
Page 45: Repair Of The Body
Chapter 12 Maintenance: Repair of the Body REPAIR OF THE ROBOT BODY Materials Super glue ABS or PVC clear medium bodied glue Fiberglass mesh rubber gloves 1. Hold the crack together tightly so that the glue you put on the inside of the body does not run through the crack on to the outside of the body. -
Page 46: Storage
Chapter 12 Maintenance: Storage STORAGE Storing your robot for any length of time. Remove robot battery and charge fully as per instructions in battery section. (Storing the battery for any length of time without being fully charged will permanently damage the battery.) Charge the RC battery as per instructions. -
Page 47: Appendix A
APPENDIX A... -
Page 48: Quick Reference Troubleshooting
Power wire or plug is broken or not connected. Replace plug or re-connect the wire. Radio control or tape circuit not working Contact Robotronics for help. No siren, or voice either. Audio fuse blown. Replace the fuse. See fuse block diagram. - Page 49 Move drive stick sliders to center or position to when the stick is in the center. neutral the robot. Joystick potentiometer broken. Send to Robotronics for repair. Robot not driving straight. One motor pulley set screw loose. Tighten set screws.
- Page 50 Appendix A: Quick Reference Troubleshooting Chart More detailed troubleshooting by system is included with each subsystem. For additional help or parts call our service dept. at 801-489-4466. Problem Cause Solution Water Squirter In-line fuse blown. Replace the 5 Amp fuse which is in-line on the Cannot fill reservoir wire.
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Page 51: Robot Circuit Block Diagram (Non-Removable Patches)
Appendix A: Robot Functional Block Diagram Robot Functional Block Diagram... -
Page 52: Appendix B Robot Parts Identification
APPENDIX B ROBOT PARTS IDENTIFICATION... -
Page 53: Lower Robot - Top View
Appendix B: Lower Robot Top View Lower Robot - Top View Serial/Model # 151 Voice Transmitter Sticker Water Reservoir Water Pump Audio Booster Speaker Speaker 37 Pin Connection Wire to upper robot connects here Water Squirter Switch Battery Connector Water Connector Connect Filler Bottle Here Battery Robot... -
Page 54: Lower Robot Bottom View-Motor Pulley Set Screws
Appendix B: Lower Robot Bottom View Lower Robot - Bottom View Front Transport Cart Eye Hooks Front Caster Wheels Motor Pully Set Screws Allen wrench sizes Super Motors= 1/8” Standard Motors- 3/32” Motor Pully Drive Belt Wheel Pully Rear Caster Wheels Rear Transport Cart Eye Hooks... -
Page 55: Main Electronics Box
Appendix B: Main Electronics Box-Pumper Main Electronics Box Main Electronics Box On/Off Switch Pitch Shifter Tape Player Voice Modifier Audio Booster 331 RX Antenna 37 Pin Connector 331 Voice Receiver and antenna 331 1 Amp Fuse Note: The Fuse Block Link Lock Latches is located inside this main electronics box. -
Page 56: Pumper Main Electronics Board
Appendix B: Pumper Main Electronics Board Pumper Main Electronics Board Cass. 3 Volt Regulator Cass. 3 Volts Switching Headlight Beacon Mouth Sens. Adjust Output Output 9V To Voice Modifier Cassette 3V Power Siren 5 V to Receiver Frequency Siren Volume Reset Siren Mode select... -
Page 57: Pumper Fuse Block Detail
Appendix B: Pumper Fuse Block Detail Pumper Fuse Block Detail All Fuses are AGC type fuses. 0 brown wire 1 blue wire 2 blue wire 3 white wire 4 yellow wire 5 purple wire LEFT RIGHT SWITCHED AUDIO DRIVE DRIVE 5 VOLT OUTPUTS 5 VOLT... -
Page 58: Patches Head-Inside View
Appendix B: Patches Head Patches Head - Inside View Eyes Left/Right Servo Eyelid Rod Servo Arm Set Screw Set Screw Left Eyelid Right Eyelid Servo Servo Mouth arm In-line connectors for each servo... -
Page 59: Eyes Servo Board
Appendix B: Eyes Servo Board - Patches Eyes Servo Board (Opto-Shift Register Board) Version With Two 4 Pin Connections White Black Red 4 Pin Connectors COPYRIGHT 1993 COPYRIGHT 1993 ROBOTRONICS ROBOTRONICS Gray 1 Left Eyelid Black 2 Right Eyelid Yellow 3 Left Hand... -
Page 60: Upper Robot Bottom View
Appendix B: Upper Robot Bottom View Upper Robot Bottom View Steering Servo Connector Servo Rod Servo Arm (Set Screw) Steering Wheel Servo Head Turning Motor Body Latch Body Latch Head Turning Patches Control Feedback Pot Board 37 Pin Eyes Servo Board Connector Body Latches See Patches Control Board Diagram for detail of... -
Page 61: Patches Control Board
Appendix B: Control Board- Character Character Control Board Signal to Eyes Signal From Lower Servo Board Mouth Trigger Mouth Switching Power Robot RC Receiver Yell./Gray/Blk/- Purple jumper/purple (Black/Yellow) (Blue/Black/Orange) 5 Volts to Eye Servo Board Black/Red 12V power Head Turn Motor Wire from lower (Blue/Yellow) robot... -
Page 62: Notes Section
Notes... -
Page 63: Technical Tips Section
Technical Tips...
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