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Blue Robotics BlueROV2 Build Instructions

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Assembly Intro
The BlueROV2 kit comes almost ready to dive. The assembly can be completed with basic
hand tools; no soldering or potting is required. We have included a couple of the tools to
make assembly and regular use as easy as possible.
Safety
When working with electricity, especially in water, always practice caution. Always
ensure that connections are secure and watertight. Keep your body away from spinning
motors and propellers.
When working with silicone grease and threadlocker, take care to minimize skin
contact. Wear protective nitrile or PVC gloves when handling.
Only apply threadlocker to screws contacting metal or the HDPE frame. Most
threadlockers are not chemically compatible with with polycarbonate, and will damage the
thrusters, fairings, and dome flange if used here. Refer to the documentation and chemical
compatibility notes of your threadlocker of choice for more information.
Required Tools (Not Included)
#2 Phillips head screwdriver
Wire cutters or scissors (for cutting zip ties)
Medium-strength (blue) threadlocker such as
Isopropyl alcohol or isopropyl alcohol wipes
2 mm flat head screw driver
Assembling the Frame
Mounting the Battery Enclosure to the Bottom Panel
To mount the battery enclosure to the bottom panel, you will need the following parts and
tools:
2 x Enclosure Clamp (3" Series)
1 x Threadlocker
1 x Bottom panel
1 x Bag with four M4x14 socket head cap screws and four M3x12 socket head cap
screws
1 x Watertight Enclosure for ROV/AUV (3" Series)
1 x 3 mm hex key
1 x 2.5 mm hex driver
1. Remove the Aluminium End Cap with 4 Holes (3" Series) to open the Watertight
Enclosure for ROV/AUV (3" Series) and set the bags inside of it to the side, except for
the bag with four M4x14 and four M3x12 screws in it.
2. Apply one drop of threadlocker to the bottom of each M4x14 socket head cap screw.
Roll the screws around on a paper towel to evenly spread the threadlocker and to
remove excess threadlocker.
Loctite 243
1
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Summary of Contents for Blue Robotics BlueROV2

  • Page 1 Assembly Intro The BlueROV2 kit comes almost ready to dive. The assembly can be completed with basic hand tools; no soldering or potting is required. We have included a couple of the tools to make assembly and regular use as easy as possible.
  • Page 2 3. Attach one of the Enclosure Clamps (3” Series) to the bottom panel using the four M4x14 socket head cap screws. Be sure that the screw head is in the counterbore. The bottom panel is only counterbored on one side. Tighten the screws until you can feel them start to dig into the bottom panel.
  • Page 3 on both sides evenly. Take care not to overtighten the screws. Keep the battery enclosure approximately centered in the Enclosure Clamps (3” Series). When you are finished tightening the screws, both sides should look similar to this: of 40...
  • Page 4 Assembling the Center Panels To assemble the center panels, you will need the following parts and tools: 2 x Enclosure Cradle (4” Series) • 2 x Front center panels • 2 x Rear center panels • 1 x Threadlocker • 1 x Bag with eight M4x18 socket head cap screws •...
  • Page 5: Assembling The Frame

    Assembling the Frame To assemble the frame, you will need the following parts and tools: 1 x Threadlocker • 1 x Bag with 12 M5x16 button head cap screws • 2 x Side panels • 1 x Bottom panel with the Watertight Enclosure for ROV/AUV (3” Series) installed •...
  • Page 6 3 mm hex key. Hold the short end of the 3 mm hex key while you are tightening the M5x16 screws. Do not tighten beyond the tightness you can achieve holding the short end of the 3 mm hex key. Now the BlueROV2 should look like the picture below: of 40...
  • Page 7 of 40...
  • Page 8 Electronics Enclosure Overview The images below show orientation of the main pieces of hardware in the electronics enclosure. They also point out the names of several of the important parts for assembly that will be discussed in the remaining instructions. Top View Starboard View Port View...
  • Page 9: Connection Diagrams

    Front View Connection diagrams These diagrams outline all of the electrical connections between components in the ROV. There is a different diagram for each version of the ROV that Blue Robotics has produced. BlueROV2 with red-wire (BEC) ESCs (Pre-2018) •...
  • Page 10: Installing The Cables

    Installing the Cables Removing the Electronics Enclosure Endcap The endcap will need to be removed from the electronics enclosure in order to install the cable penetrators. To remove the endcap, you will need the following parts and tools: 1 x Large flat head screw driver (Optional) •...
  • Page 11 Installing the Penetrators To install the Penetrators, you will need the following parts and tools: 1 x Cable Penetrator Nut (Black for Standard Tether/Red for Slim Tether), and O-ring • from one end of the Tether 6 x Cable Penetrator Nut (red), and O-ring from bag inside each Thruster tube •...
  • Page 12 of 40...
  • Page 13 If you install the remaining penetrators as shown in the diagram below, it will keep everything neat and organized. 1. Remove eight of the O-rings and apply silicone grease to them. Keep the other O-ring in the bag, you will need it in a minute. 2.
  • Page 14 then use the provided wrench to tighten them an additional ~1/16 of a turn. If you can’t loosen them with your fingers, they are tight enough. 1. Thruster 1 (CCW propeller) with red penetrator nut 2. Thruster 5 (CCW propeller) with red penetrator nut 3.
  • Page 15 Finishing the Battery Enclosure To complete the assembly of the battery enclosure, you need the following parts and tools: 1 x Bag labelled “Extra Blank Penetrators [2]” • 1 x Silicone Grease - 10g Tube • 1 x End Cap with 4 Holes (3” Series) •...
  • Page 16 7. Install the XT90 to bullet connector adapter to the battery power wire. 8. If you wish to do the Optional Preliminary Vacuum Test, remove the Vent Plug from the Vent Penetrator Bolt and install the endcap onto the battery enclosure. You will also need to remove the Vent Plug for the Vent Penetrator Bolt on the electronics enclosure.
  • Page 17 Optional (recommended) Preliminary Vacuum Test This point is the best time in the assembly process to perform a vacuum test. Since you have installed all of the penetrators, but have not done any of the wiring, troubleshooting will be as easy as possible. You will need to use the vacuum pump that comes with the kit. 1.
  • Page 18 1. Test your vacuum pump to ensure that it is not leaking. See our Testing the Test Setup Tutorial for detailed instructions. 2. Insert one of the vacuum plugs into the battery enclosure vent penetrator. 3. Insert the other vacuum plug into the electronics enclosure vent penetrator. 4.
  • Page 19 5. Let the BlueROV2 and pump sit for 15 minutes. 6. If the gauge reads above 9 in. Hg [31 kPa] after 15 minutes, your seals are acceptable. If the gauge reads below 9 in. Hg [31 kPa] vacuum after 15 minutes, you should check the following: 1.
  • Page 20 If you are still having trouble holding vacuum, please contact us support@bluerobotics.com To continue assembling the BlueROV2, remove the acrylic tube and dome from the electronics enclosure. Installing the Power Wires from the Penetrators...
  • Page 21 cable routing neat, bring the cable through the ESC wires and take out most of the slack. 3. Connect the Lumen ground wire (black) to the Power Terminal Block with the other black wires. Use the rear screw terminal that is second from the bottom. To help keep the cable routing neat, bring the cable through the ESC wires and take out most of the slack.
  • Page 22 Installing the Signal Wires from the Penetrators To install the wires from the penetrators you will need the following parts and tools: 1 x Small (~2 mm) flat head screw driver • 1. Connect the Lumen signal wire to the Pixhawk channel 7 with the yellow wire oriented toward the bottom of the Pixhawk.
  • Page 23 of 40...
  • Page 24 2. Connect the Bar30 cable to the I C port on the Pixhawk. 3. Connect the motor wires to the motor wire terminal block, as shown in the diagrams below. of 40...
  • Page 25 4. Connect the female tether wire connector with BLUE and WHITE wires to the extension cable that is connected to the Fathom-X Tether Interface Board. The other 6 wires can do not need to be connected to anything the operate the ROV. They are for future expansion.
  • Page 26: Cable Routing

    If you received your BlueROV2 prior to August 7th, 2018, the following step applies to R1 tethers: Connect the tether wires to the Fathom-X Tether Interface Board. The other 6 wires can do not need to be connected to anything to operate the ROV. They are for future expansion.
  • Page 27: Final Assembly

    Final Assembly Adding Desiccant to the Electronics Enclosure This step is optional, but it will improve the usability of the BlueROV2, especially if you are planning on operating your ROV in humid environments with cold water. The desiccant will absorb humidity that is inside of the Electronics Enclosure to prevent the dome from fogging up during dives.
  • Page 28 2. Install the desiccant bag near the Fathom-X Tether Interface. This step will have to be combined with installing the Watertight Enclosure (4” Series) over the Electronics Tray since the bag will be “floating” inside of the enclosure [Pictures Coming Soon] Mounting the Electronics Enclosure onto the Frame To mount the Electronics Enclosure to the frame, you need the following parts and tools: 1 x Watertight Enclosure for ROV/AUV (4”...
  • Page 29 Mounting the Thrusters to the Frame To mount the thrusters to the frame, you need the following parts and tools: 1 x 2.5 mm hex driver • 3 x T200 Thruster with Clockwise Propeller installed • 3 x T200 Thruster with Counter-Clockwise Propeller installed •...
  • Page 30 To mount the thrusters at 30° use the holes shown in the pictures below. The hole with the asterisk is the hole that should be closest to the nose cone on the thruster. For the sake of clarity, the hole with the asterisk on the thruster shown below is the hole that is closest to the nose cone (see next diagram).
  • Page 31 Here is a diagram of where the thrusters go, and how they should be oriented. The green thrusters should have counter-clockwise propellers and blue thrusters should have clockwise propellers. The order of installation matters here. You cannot get the front thrusters on if the rear ones were installed first.
  • Page 32 1 x Bag with four M3x12 socket head cap screws • 1 x 2.5 mm hex driver • 1 x BlueROV2 frame • 1 x Threadlocker • 1. Apply one drop of threadlocker to each of the M3x12 screws. Roll the screws around on a paper towel to evenly spread the threadlocker and to remove excess threadlocker.
  • Page 33 1. Loop the tether around the plastic thimble at a point about 12 inches (30 cm) away from the tether penetrator. 2. Firmly attach 3 of the zip ties, alternating directions as they are installed, around the tether right where it enters and exits the thimble. Hold the tether firmly in place against the thimble until it is secured.
  • Page 34 you have finished routing the cables. Below are some examples of what the cable routing should look like. of 40...
  • Page 35 Installing the Fairings and Buoyancy The buoyancy comes preinstalled in the fairings, but make sure it is still in all of the fairings prior to installing the fairings. To install the fairings, you will need the following parts and tools: 4 x Fairings with buoyancy installed •...
  • Page 36 ROV close to balanced from front to back in water and close to neutrally buoyant. Trimming the ballast may involve a bit of trial and error. The pictures below should provide a good starting point for mounting ballast if you have a stock BlueROV2 with recommended battery.
  • Page 37 of 40...
  • Page 38 BlueROV2 with 4 Lumen Lights of 40...
  • Page 39 Topside Setup Attaching the Fathom X Tether Interface Insert the Binder connector from your Fathom ROV Tether (or Spool extension cable) onto the connector bulkhead receptacle so the WHITE ARROW on the plug aligns with the white line. Rotate the connector head clockwise until the connector locks in place and the GREEN LOCK symbol is in the 12 o’clock position.
  • Page 40: Next Steps

    Below is one example of how FXTI can be used to neatly connect the Water Linked Underwater GPS / BlueROV2 Integration Kit and omit the earlier connections to a terminal block. Next Steps First, set up the software on your topside computer. Please see our Software Setup page.