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SeaPerch Remotely Operated Vehicle Construction Manual

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SeaPerch
Remotely Operated Vehicle (ROV)
Construction Manual
Standard and Selected Optional
Assembly Procedures
Version 2010-04NW
2010
August
The SeaPerch educational program was created by Harry
Bohm and Vickie Jensen and published in their 1997 book
"Build Your Own Underwater Robot and Other Wet
Projects." The initial curriculum was developed by the
Massachusetts Institute of Technology, and this version of
the SeaPerch Construction Manual was provided under the
Office of Naval Research National Naval Responsibility for
Naval Engineering (NNRNE) Outreach initiative.

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  • Page 1 Standard and Selected Optional Assembly Procedures 2010 August The SeaPerch educational program was created by Harry Bohm and Vickie Jensen and published in their 1997 book "Build Your Own Underwater Robot and Other Wet Projects." The initial curriculum was developed by the...

  • Page 3: Table Of Contents

    SeaPerch ROV Construction Manual – Version 2010-04NW Table of Contents Introduction ------------------------------------------------------------------------------------------ I-1 SeaPerch ROV Program Overview ------------------------------------------------------------ I-1 What is SeaPerch? ---------------------------------------------------------------------------- I-1 Program History --------------------------------------------------------------------------------- I-2 Original SeaPerch ROV Manual Development ----------------------------------------- I-2 Updated Information in this Manual ------------------------------------------------------------ I-2...
  • Page 4 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL TABLE OF CONTENTS II – PVC TUBE FLOAT OPTION Unit 1 – Assembly of Subsystem One – The Vehicle Frame ----- 1.0-1 Tools and Materials Needed ------------------------------------------------------------------ 1.0-2 Time Needed to Complete Unit 1 ------------------------------------------------------------ 1.0-2 Procedure 1.1 –...
  • Page 5 Initial In-Water Testing in the Classroom, Lab, or Pool ----------------------------------- T-4 Using the SeaPerch ROV Safety Precautions --------------------------------------------------------------------------------- U-1 Environments Suitable for Using a SeaPerch ROV --------------------------------------- U-1 Driving the SeaPerch ROV ----------------------------------------------------------------------- U-2 Post-Run Cleaning and Maintenance of the ROV System ------------------------------ U-3 Appendix A –...

  • Page 7: Introduction

    Outreach effort, with the goal of helping to inspire the next generation of naval architects and marine, ocean, and naval engineers. A SeaPerch is an underwater robot known as a “remotely operated vehicle,” or “ROV.” Students learn best by doing, and during the SeaPerch project, they will completely assemble an inexpensive, yet functional ROV, test it, and then operate it underwater.

  • Page 8: Program History

    SeaPerch ROVs. While much of this revision’s technical content is aligned with the instructions found in previous...

  • Page 9: Expanded Testing And Operating Information

    However, when help is needed, and before taking drastic steps to change ROV parts or re-wire a circuit, ROV builders should refer to Appendix A, “Troubleshooting Your SeaPerch ROV,” which suggests options for solutions to common problems. This appendix is not necessarily intended to be included in the student copies of the construction manual;...
  • Page 10 More options and enhancements will likely be developed from time to time as clever students and their teachers continue to invent and demonstrate new ways to build SeaPerch ROVs. By using the supplement approach and the new page numbering scheme, future new procedures can easily be added to the supplement document and then to individual classroom manuals when needed, without impacting the content of the standard build manual.

  • Page 11: The Seaperch Assembly Process

    The manual contains three building units, for the frame, the thrusters, and the control box. They may be used as a single manual, as assembled here, or they can be removed from this manual and placed into the SeaPerch classroom integration manual at the separate locations indicated therein. In either case, the three unit manuals should always be used in order.

  • Page 12: Tools And Materials

    “12 Volt DC Motor” is used or when a similar component must be substituted due to availability or cost issues. SeaPerch ROVs are often built by a team of two or three students. For efficiency during the build process, each team should have its own set of basic tools, including a screwdriver, flush-type wire cutter, needle-nose pliers, wire stripper, and soldering iron.

  • Page 13: Safety Overview

    Protective Eyewear Students, teachers, and classroom helpers should wear protective eyewear at all times when building SeaPerch ROVs. Although some procedures do not usually involve significant eye hazards, the students often work close to others, who at any time may be performing more potentially hazardous steps.

  • Page 14: Materials Handling Safety

    SeaPerch ROV Construction Manual – Version 2010-04NW Materials Handing Safety Builders of SeaPerch ROVs should be made aware of a few potential hazards related to some of the materials used. The following activities require careful handling of materials.  Soldering: Many common types of solder contain lead along with tin and sometimes other metals.

  • Page 15: Safety While Drilling

    Safety While Drilling Drilling is perhaps the most potentially hazardous activity involved in the SeaPerch project. Some important safety considerations are as follows.  Get Permission to Use Power Tools: Always get the teacher’s permission and adult supervision before using a drill or other power tool.

  • Page 16: Safety While Soldering

    Never just set it down on a tabletop, where it could burn anything it touches. Safety While Potting Motors for Thrusters SeaPerch ROV thrusters are assembled by potting small electric motors in wax. The following safety issues should be reviewed with everyone involved in the potting process.

  • Page 17: Safety With Electricity And Batteries

    Safety With Electricity and Batteries The low-voltage (12 volts, direct current (DC)) battery power source used with SeaPerch ROVs is relatively safe and well-proven in students’ hands. However, they should be cautioned about potential problems from short- circuits as well as electrical safety issues in general.
  • Page 19 Assembly of Subsystem One The Vehicle Frame August 2010 The SeaPerch educational program was created by Harry Bohm and Vickie Jensen and published in their 1997 book "Build Your Own Underwater Robot and Other Wet Projects." The initial curriculum was developed by the...

  • Page 21: Tools And Materials Needed

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURES – FRONT TEES & TUBE FLOATS ENHANCEMENT PROCEDURE – ADDED CAPTURE NET & FRONT PAYLOAD NET STIFFENER Assembly of Subsystem One Unit The Vehicle Frame Tools and Materials Needed Tools Materials 5’...

  • Page 23: Procedure 1.1 - Cut The Frame Parts

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 1.1 – FRONT TEES & PVC TUBE FLOATS Procedure 1.1 – Cut the Frame Parts Tools: Ruler Marker (or Pencil) PVC Pipe Cutter (or Saw) Materials: 5’ (1.5 m) ½” PVC Pipe Figure 1.1-1: PVC Pipe Cutter and Cut PVC Pipe...

  • Page 25: Procedure 1.2 - Drill The Drain Holes

    NOTE: Drain holes are needed in the PVC elbows in order to let air escape and allow water to fill the frame when you put your SeaPerch ROV into the water and also for the water to drain when you take the SeaPerch out. Preventing air from being trapped within the frame will enable the vehicle to have consistent, repeatable buoyancy.

  • Page 27: Procedure 1.3 - Assemble The Vehicle Frame

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 1.3 – FRONT TEES & PVC TUBE FLOATS Procedure 1.3 – Assemble the Vehicle Frame Tools: None Materials: Cut Pieces of Pipe from Procedure 1.1 ½” PVC Elbows with Holes Drilled from Procedure 1.2...

  • Page 29: Procedure1.4A - Assemble The Pvc Tube Floats

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 1.4A – PVC TUBE FLOATS Procedure 1.4A – Assemble the PVC Tube Floats Tools: PVC Pipe Cutter (or Saw) Materials: 28” (71 cm) 1” PVC Pipe (200 PSI) 1” PVC Pipe Caps...
  • Page 30 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 1.4A – PVC TUBE FLOATS Procedure 1.4A – Continued 3. Again, in a well-ventilated area and over the protected floor or table top, quickly apply a thin layer of PVC cement all of the way around one end of one of the 1”...

  • Page 31: Procedure1.4B - Install The Floats And Tighten The Frame

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 1.4B – FRONT TEES & PVC TUBE FLOATS Procedure 1.4B – Install the Floats and Tighten the Frame Tools: Pliers Flush Wire-Cutting Pliers #2 Phillips Screwdriver (Optional) Materials: 14” (36 cm) 1” PVC...

  • Page 33: Procedure 1.5 - Attach The Thruster Mounts

    SeaPerch ROV Construction Manual – Version 2010-04NW Procedure 1.5 – Attach the Thruster Mounts Tools: Marker (or Pencil) Drill 5/64” Drill Bit #2 Phillips Screwdriver Materials: Vehicle Frame 3 Thruster Mounts 6 #8 x ½” Phillips-Head Sheet Metal Screws 6 #8 Washers (Optional) Figure 1.5-1: Thruster Mount Placement...

  • Page 35: Procedure 1.6 - Attach The Payload Net

    Painting the ROV should be avoided if parts such as PVC tees and elbows will later be “recycled” for use on another SeaPerch ROV. Construction Steps: 1.
  • Page 36 SeaPerch ROV Construction Manual – Version 2010-04NW ENHANCEMENT PROCEDURE 1.6 – ADDED CAPTURE NET & FRONT PAYLOAD NET STIFFENER Procedure 1.6 – Continued 4. Trim off the ends of the tie wraps using flush wire-cutting pliers (not scissors, which can leave very sharp ends that can easily scratch skin) as shown in Figure 1.6-2.
  • Page 37 SeaPerch ROV Construction Manual – Version 2010-04NW ENHANCEMENT PROCEDURE 1.6 – ADDED CAPTURE NET & FRONT PAYLOAD NET STIFFENER Procedure 1.6 – Continued 7. Using a hack saw or other metal cutting tool, cut an 11-inch (28 cm) length of wire from an ordinary wire coat hanger.
  • Page 39 Assembly of Subsystem Two The Thrusters August 2010 The SeaPerch educational program was created by Harry Bohm and Vickie Jensen and published in their 1997 book "Build Your Own Underwater Robot and Other Wet Projects." The initial curriculum was developed by the...

  • Page 41: Tools And Materials Needed

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURES – FILM CANISTERS, ALTERNATE MOTOR 1, & NON-ADHESIVE PROPELLER MOUNTING Assembly of Subsystem Two Unit The Thrusters Tools and Materials Needed Tools Materials Eye Protection (Always Worn) ~40’ (12 m) Tether Cable (CAT 3, 5, 5e, or 6)

  • Page 43: Procedure 2.1 - Build A Motor Potting Holder (If Not Provided)

    SeaPerch ROV Construction Manual – Version 2010-04NW Procedure 2.1 – Build a Motor Potting Holder (If Not Provided) Tools: Drill (or Drill Press) ¼” Drill Bit 1-3/8” Flat Drill Bit* (Or a “Forstner” Bit for a Flat- Bottomed Hole) Permanent Ink Marker Ruler *Use a 1¼”...

  • Page 45: Procedure 2.2 - Test The Motors And Mark Their Terminals' Polarity

    - DO NOT CONNECT WIRE OR METAL FROM ONE BATTERY TERMINAL TO THE OTHER! NOTE: Small 12-volt DC motors of various types are available for SeaPerch kits, such as those shown in Figure 2.2-1. Some may come with wire leads already attached. In that case, the wires must be removed prior to testing the motors and assembling the thrusters.
  • Page 46 This is the correct polarity for the SeaPerch ROV thrusters, so mark the motor terminal that is connected to the black wire to show that it is the “negative” terminal by using a black marker pen to color one side of that terminal black..

  • Page 47: Procedure 2.3 - Seal The Motors So That Wax Cannot Get Inside

    The care with which this is done will help determine whether your thrusters will work and how long they will last. Some motors used for SeaPerch ROVs may be larger than others. To ensure good coverage of the tape and minimize its thickness, so that the motors will still fit easily into...
  • Page 48 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.3 – ALTERNATE MOTOR 1 Procedure 2.3 – Continued 3. Cover both ends of the motor first with several short pieces of tape, and then cut around the motor ends using scissors to remove excess tape (cut at a tilt toward the motor to remove all tape that extends past the edge of the shell) using the process below.
  • Page 49 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.3 – ALTERNATE MOTOR 1 Procedure 2.3 – Continued 4. Wrap a longer piece of tape around the sides of the motor. Start at one end with the edge of the tape extending about 1/16” (~2 mm) past the end of the motor, so that it can be folded down to form a good seal.

  • Page 51: Procedure 2.4 - Drill Holes In The Thruster Housings

    0.078” shaft diameter. If you are instead using the standard SeaPerch motor with a shaft diameter of 0.091”, you should substitute a 3/32” drill bit in the procedure steps below that call for a 5/64” drill bit, so that the motor shafts will not be too tight for the holes drilled in the thruster housings.
  • Page 52 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.4 – FILM CANISTERS & 0.078” MOTOR SHAFTS Procedure 2.4 – Continued 3. Carefully remove any plastic burrs from the hole in the bottom of the thruster housing, which may be left after the drilling process. When using the standard plastic vials, made of a rather soft material, some burrs usually remain in or around the holes after drilling.

  • Page 53: Tips On Soldering - Safety And Techniques

    SeaPerch ROV Construction Manual – Version 2010-04NW Tips on Soldering – Safety and Techniques Soldering Safety Reminders: Eye Protection: Always wear safety glasses or goggles when soldering or near someone who is soldering. Solder Hazards: Some solder contains lead, which is poisonous. Never put it in your mouth, and wash your hands after working with it.

  • Page 55: Procedure 2.5 - Connect The Tether Cable Wires To The Motors

    NOTE: Each motor must be connected to one of the color-coded pairs of wires in the tether cable, as shown in Figure 2.5-1. The CAT 3, CAT 5, or CAT 6 cable types have four wire pairs inside. Three of them will be used for the standard SeaPerch ROV. Construction Steps: 1.
  • Page 56 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.5 – ALTERNATE MOTOR 1 Procedure 2.5 – Continued 3. If the wires in the tether cable are not already twisted into pairs, refer to Table 2.5-1 to pair them together by colors (“orange” with “white & orange,” etc.).

  • Page 57: Tips On Wax Melting - Safety And Techniques

    Don’t Get Burned: Bowl ring wax usually melts at a rather low 150 degrees Fahrenheit (F). The wax-melting approach used for SeaPerch ROVs is to melt the wax in a water bath, usually employing an electric skillet to heat the water (and wax). It is important NOT to let the water evaporate (keep adding water to maintain it at about ½”...

  • Page 59: Procedure 2.6 - Pot (Waterproof) The Motors With Wax

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.6A – FILM CANISTERS & ALTERNATE MOTOR 1 Procedure 2.6 – Pot (Waterproof) the Motors with Wax Tools: Metal Cup(s) Electric Skillet Potting Holder Scissors Apron / Gloves (Optional) Materials: 3 Motors Sealed with Tape...
  • Page 60 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.6A – FILM CANISTERS & ALTERNATE MOTOR 1 Procedure 2.6 – Continued 2. Your teacher will probably have already melted wax for your use, using a set-up similar to that shown in Figure 2.6-3. If not, see the wax melting tips on page 2.6-1.
  • Page 61 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.6A – FILM CANISTERS & ALTERNATE MOTOR 1 Procedure 2.6 – Continued Figure 2.6-5: Figure 2.6-6: Figure 2.6-7: Figure 2.6-8: Figure 2.6-9: Motor Shaft Tip Motor Shaft Tip Pouring Initial Settling Motor into Wax Moved Part ¼”...
  • Page 62 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.6A – FILM CANISTERS & ALTERNATE MOTOR 1 Procedure 2.6 – Continued 15. Once the wax has solidified, push the caps up to the knots in the wires and coil the wires into the housings as shown in Figure 2.6-12.
  • Page 63 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.6A – FILM CANISTERS & ALTERNATE MOTOR 1 Procedure 2.6 – Continued 18. Repeat Steps 15 and 16 for the other two motors. The potted motors should look like those in Figure 2.6-16 when they have been completed, after cooling.

  • Page 65: Procedure 2.7 - Mount The Propellers Onto The Motors' Shafts

    Figure 2.7-1: Propeller Mounted on a Motor’s Shaft Rubbing Alcohol NOTE: Various propeller types may be used on SeaPerch ROVs. This vehicle will use small boat (underwater) propellers. They fit onto the shafts of the thruster motors, as shown in Figure 2.7-1. A 1/8” diameter plastic bushing will be used to match the size of the hole in the propeller to the diameter of the motor shaft.
  • Page 66 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.7 – NO-ADHESIVE PROPELLER MOUNTING Procedure 2.7 – Continued 4. Tightly clamp the tip of the locking thin-nosed pliers to the motor shaft as shown in Figure 2.7-2. Re-adjust the pliers as needed to clamp on tightly, and place just the tip of the pliers on the shaft, as close to the face of the thruster housing as possible.

  • Page 67: Procedure 2.8 - Mount The Thrusters Onto The Vehicle Frame

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.8 – FILM CANISTERS & NO-ADHESIVE PROPELLERS Procedure 2.8 – Mount the Thrusters Onto the Vehicle Frame Tools: #2 Phillips Screwdriver Pliers Materials: Assembled Thrusters Assembled Frame Electrical Tape Figure 2.8-1: Thrusters Mounted on ROV Frame NOTES: The thruster housings should be positioned within the thruster mounts such that the back end of each motor (estimate where it is inside the thruster if you can’t see it) is...
  • Page 68 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 2.8 – FILM CANISTERS & NO-ADHESIVE PROPELLERS Procedure 2.8 – Continued 3. Reattach each thruster mount, with thruster, to the frame, as shown in Figure 2.8-1. It’s alright if the thrusters get squeezed a little. Tighten the screws just enough to hold the thruster firmly;...

  • Page 69: Procedure 2.9 - Waterproof And Mount The Tether Cable

    SeaPerch ROV Construction Manual – Version 2010-04NW Procedure 2.9 – Waterproof and Mount the Tether Cable Tools: #2 Phillips Screwdriver Pliers Flush Wire-Cutting Pliers Materials: Completed Frame with Thrusters Mounted 1” (2.5 cm) Butyl Rubber Tape Electrical Tape Figure 2.9-1: Tether Cable Tied in a Strain Relief Loop 5 6”...
  • Page 70 Coil the brown wire pair out of the way and tie-wrap it to the payload net; it may be needed later for accessories or for a thruster wire repair. This completes assembly of your SeaPerch ROV Thrusters! 2.9-2...
  • Page 71 Assembly of Subsystem Three The Control Box August 2010 The SeaPerch educational program was created by Harry Bohm and Vickie Jensen and published in their 1997 book "Build Your Own Underwater Robot and Other Wet Projects." The initial curriculum was developed by the...

  • Page 73: Tools And Materials Needed

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURES – THREE TOGGLE SWITCHES Assembly of Subsystem Three Unit The Control Box Tools and Materials Needed Tools Materials Completed Vehicle Frame with Thrusters Installed Eye Protection (Always Worn) Control Box Hand Drill or Drill Press 6’...

  • Page 74: Seaperch Rov Electrical Circuit Diagram

    OPTIONAL PROCEDURES – THREE TOGGLE SWITCHES SeaPerch Electrical Circuit Diagram In this unit, you will build the control box for your SeaPerch ROV. Below is a circuit diagram (or “schematic”) which shows all the electrical connections that will be made. This diagram is a technical representation to show the components and how they are connected, but is not drawn to scale, and it leaves out everything but the wires and electrical components.

  • Page 75: Procedure 3.1 - Gather The Parts For The Control Box Assembly

    Figure 3.1-2. The tether (umbilical) cable shown is the one that is already attached to the thrusters on the ROV Figure 3.1-2: Electrical Components for the SeaPerch ROV frame assembly, Control Box completed in Unit 2. 3.1-1...

  • Page 77: Procedure 3.2 - Prepare The Control Box

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.2 – THREE TOGGLE SWITCHES Procedure 3.2 – Prepare the Control Box Tools: #2 Phillips Screwdriver Drill (or Drill Press) ¼” Drill Bit Marker (or Pencil) Ruler Vise or Clamp Materials:...
  • Page 78 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.2 – THREE TOGGLE SWITCHES Procedure 3.2 – Continued 3. Check the diameters of the threaded mounting shafts of the switches. If any require a mounting hole smaller or larger than the usual ¼” holes called for in these instructions, you may need to use a different drill bit.

  • Page 79: Procedure 3.3 - Assemble The Power Cord

    Assembly Installed in the Control Box Electrical Tape NOTE: In this step you will build the power cord for your SeaPerch ROV, as shown in Figure 3.3-1. A wiring diagram of the power cord is show in Figure 3.3-2. Construction Steps: 1.
  • Page 80 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.3 – THREE TOGGLE SWITCHES Procedure 3.3 – Continued 3. Gather the ½” stripped ends of the three red wires and twist them all together, as shown in Figure 3.3-3. 4. Do the same with the three black wires. These spliced wire bundles will distribute power in your control box.
  • Page 81 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.3 – THREE TOGGLE SWITCHES Procedure 3.3 – Continued 10. Attach the fuse holder wire to the positive (ribbed / marked / copper) side of the power cord wire, where you previously cut off the 13” (33 cm) piece. Twist the wires tightly together (in-line, as shown in Figure 3.3-4), solder the connection,...
  • Page 82 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.3 – THREE TOGGLE SWITCHES Procedure 3.3 – Continued ~6” Length, Beyond Knot Figure 3.3-6: Power Cord Strain-Relief Knot in Control Box 14. Take the spliced bundle of three red “+” wires, and twist the bundled end onto the wire from the positive (ribbed / marked / copper) side of the speaker wire.
  • Page 83 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.3 – THREE TOGGLE SWITCHES Procedure 3.3 – Continued NOTE: In order to stabilize the switches during the wiring process, when a bench vise is not available, the control box may be used as a temporary switch holder, by mounting the switches “inside-out,”...

  • Page 85: Procedure 3.4 - Wire The Vertical Thruster Control Switch

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.4 – THREE TOGGLE SWITCHES Procedure 3.4 – Wire the Vertical Thruster Control Switch Tools: Soldering Iron and Solder Small Needle-Nose Pliers Flush Wire-Cutting Pliers Wire Strippers Vise or Clamp Materials:...
  • Page 86 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.4 – THREE TOGGLE SWITCHES Procedure 3.4 – Continued Figure 3.4-2: Vertical Thruster Control Circuit Diagram “Crisscross” Wires Used to Reverse Polarity Figure 3.4-3: Vertical Thruster Wiring Diagram 3.4-2...
  • Page 87 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.4 – THREE TOGGLE SWITCHES Procedure 3.4 – Continued 4. Separate the four twisted wire pairs (if the wires do not come already twisted into pairs, you should twist the matching colored wires together).
  • Page 88 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.4 – THREE TOGGLE SWITCHES Procedure 3.4 – Continued 12. Using a well-heated soldering iron, with a clean, freshly “tinned” tip, solder just the red-wire (left, center) terminal on the switch, being careful not to use too much solder (use just enough to flow over the connection) or to overheat the switch (which could melt internal components, permanently damaging the switch).
  • Page 89 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.4 – THREE TOGGLE SWITCHES Procedure 3.4 – Continued 18. Insert the orange wire from the tether cable into the bottom left terminal on the toggle switch (on the side that has the red wire on the center terminal), adding it to the orange wire already in place on that terminal, as shown in Figure 3.4-3.

  • Page 91: Procedure 3.5 - Wire The Horizontal Thruster Control Switches

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.5 – THREE TOGGLE SWITCHES Procedure 3.5 – Wire the Horizontal Thruster Control Switches Tools: Soldering Iron and Solder Small Needle-Nose Pliers Flush Wire-Cutting Pliers Wire Strippers Vise or Clamp Materials:...
  • Page 92 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.5 – THREE TOGGLE SWITCHES Procedure 3.5 – Continued Figure 3.5-2: Horizontal Thruster Control Circuit Diagram Figure 3.5-3: Horizontal Thruster Control Toggle Switch Wiring Diagram 3.5-2...
  • Page 93 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.5 – THREE TOGGLE SWITCHES Procedure 3.5 – Continued 6. Using a well-heated soldering iron, with a clean, freshly “tinned” tip, solder just the red-wire (left, center) terminal on the switch, being careful not to use...
  • Page 94 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.5 – THREE TOGGLE SWITCHES Procedure 3.5 – Continued 16. Insert the remaining red (+) wire from your power cord through the left center terminal on the “port” (left) toggle switch, again being careful to have all of the small strands of wire pass through the hole in the terminal.
  • Page 95 SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.5 – THREE TOGGLE SWITCHES Procedure 3.5 – Continued 28. Check all terminals on the switch to make sure that there are no stray wire strands or solder bridges between the terminals. The wired switch should look like the other horizontal thruster switch, similar to the one shown in Figure 3.5-1...

  • Page 97: Procedure 3.6 - Finish The Control Box

    SeaPerch ROV Construction Manual – Version 2010-04NW OPTIONAL PROCEDURE 3.6 – THREE TOGGLE SWITCHES Procedure 3.6 – Finish the Control Box Tools: Pliers #2 Phillips Screwdriver Materials: Control Box with Wired Switches Control Box Cover Control Box Cover Screws Switch Mounting Hardware Figure 3.6-1: Completed Control Box...
  • Page 98 A completed ROV system is shown in Figure 3.6-3. Figure 3.6-3: Completed SeaPerch ROV System, Ready for Testing and Ballasting CONGRATULATIONS, you have finished the construction of your SeaPerch ROV! Now it’s time to get it ballasted and tested!

  • Page 99: Testing And Ballasting The Rov

    SeaPerch ROV Construction Manual – Version 2010-04NW Testing and Ballasting the ROV Time Needed to Complete Testing and Ballasting of the ROV Combined Testing and Ballasting Time: Initial electrical testing usually requires much less than 1 hour, unless the vehicle does not function properly, in which case several hours may be required to resolve the problem(s).

  • Page 100: Ballasting And Trimming The Rov

    “forward” position for the horizontal thrusters and for the “down” position of the vertical thruster. If any thruster spins in the wrong direction or does not spin properly, see Appendix A, “Troubleshooting Your SeaPerch ROV” for some common solutions. Students should try to solve the problems on their...
  • Page 101 The standard cylindrical foam floats or fixed-buoyancy net floats that are often used for SeaPerch ROVs have a significant amount of buoyancy that must be counteracted by adding quite a bit of ballast weight to the ROV, typically up to about ten ounces or more for a basic ROV without sensors or other accessories.

  • Page 102: Initial In-Water Testing In The Classroom, Lab, Or Pool

    ROV to adjust its trim. Thruster and Control Test: Beyond getting the SeaPerch ROV properly ballasted and trimmed, the in- water test provides an opportunity to make sure that its thrusters can drive it straight and predictably, that it can dive and surface, and that the controls work reliably.
  • Page 103 Post-Test Cleaning: Always make sure to rinse your SeaPerch ROV thoroughly with fresh water when you have finished operating it in a swimming pool (or a natural marine environment).

  • Page 105: Using The Seaperch Rov

    Environments Suitable for Using a SeaPerch ROV SeaPerch ROVs can be used in fresh water or saltwater, in man-made pools or natural marine environments. However, ballasting as well as post- operation cleaning requirements are different for the two types of environments.

  • Page 106: Driving The Seaperch Rov

    SeaPerch ROV Construction Manual – Version 2010-04NW Driving the ROV Vertical Motion (Diving and Surfacing). A properly operating SeaPerch ROV should be able to submerge or return to the surface under its own power, and a submerged ROV should slowly return to the surface when the thrusters are off.

  • Page 107: Post-Run Cleaning And Maintenance Of The Rov System

    In such cases, the used thrusters can provide valuable spares, so they should be cleaned carefully. Battery Maintenance. The lead acid batteries normally used with SeaPerch ROVs should be kept in a fully-charged condition for maximum service life. Always recharge the batteries with the recommended charger and charging method soon after use, and then keep them “float”...

  • Page 109: Appendix A - Troubleshooting Your Seaperch Rov

    Things to Try Before Re-Wiring the ROV or Changing ROV Parts Solving Directional Control Problems: Sometimes SeaPerch controls are found to be reversed, such as the port switch controlling the starboard thruster. Often one or more thrusters operate in the reverse direction from that intended.

  • Page 110: Solving Thruster Operational Problems

    SeaPerch ROV Construction Manual – Version 2010-04NW Solving Thruster Operational Problems:  Initial Operational Problems. Sometimes SeaPerch thrusters do not work properly due to problems in the waterproofing process. Frequently, a thruster seems to be frozen when first energized after the potting process, and then it works fine after simply being spun a few revolutions by hand (or using pliers if the shaft won’t turn by hand), possibly freeing up the shaft from being stuck on...

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