Schilling Robotics Conan 7P Manipulator System: Position-Controlled, 3 KM Submersible 24 VDC Base Module

Schilling Robotics Conan 7P
Manipulator System
Position-Controlled, 3 Km Submersible
24 VDC Base Module
Model:
199-0318
Document No. 011–8231

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.
FMC Technologies Schilling Robotics

260 Cousteau Place, Suite 200, Davis, CA 95618 • Ph: (530) 753-6718 • Fax: (530) 753-8092
E-mail: [email protected] • [email protected] • [email protected]
Web Site: http://www.schilling.com
TECHNICAL MANUAL REVISION LOG

PRODUCT: Conan 7P, 199-0318
TECHNICAL MANUAL: 011–8231
Description Date Rev.
Production release Nov. 20, 2010 A
Table of Contents
Specifications
1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Manipulator Arm Specifications. . . . . . . . . . . . . . . . . . . . . . 9
3 Master Controller Specifications . . . . . . . . . . . . . . . . . . . . 10
4 Electrical & Telemetry Requirements . . . . . . . . . . . . . . . . 10
5 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . 10
6 Ranges of Motion/Dimensions . . . . . . . . . . . . . . . . . . . . . 10
7 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.1 Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation
1 User-Supplied Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Slave Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Master Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Electrical Power & Telemetry Connections . . . . . . . . . . . . 15
4.1 Telemetry Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Long-Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Deck Test Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Completing the Installation. . . . . . . . . . . . . . . . . . . . . . . . 18
Operation
1 System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1 The Slave Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2 Base Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3 Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Page 3
1.4 The Master Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Security Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.6 The Control Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.8 Controlling Slave Arm Hydraulics . . . . . . . . . . . . . . . . . . . . . 28
1.9 Slave Arm Operational Status . . . . . . . . . . . . . . . . . . . . . . . . 28
1.10 Avoiding Slave Arm Damage . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 STOW OUT Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Using the MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Using the OPERATE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.6 Using the SHUT DOWN Menu . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Performance Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 OPTIONS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 SETUP Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 System Fault & Error Diagnosis . . . . . . . . . . . . . . . . . . . . . 47
4.1 Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Troubleshooting
1 Diagnostic Approaches. . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Screen-Displayed Symptoms . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2 Master Arm Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Slave Arm Behavior Defined . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4 Entire Slave Arm Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.5 Slave Arm Joint Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . 58
3 System Fault & Error Diagnosis . . . . . . . . . . . . . . . . . . . . . 60
3.1 Control System Orientation . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2 Using the DIAGNOSTICS Menus . . . . . . . . . . . . . . . . . . . . . . 62
3.3 Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4 Electrical Component Diagnosis . . . . . . . . . . . . . . . . . . . . . 68
4.1 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2 Wireway Short & Open Circuits . . . . . . . . . . . . . . . . . . . . . . . 68
4.3 Diagnosing Servo Valve Failures . . . . . . . . . . . . . . . . . . . . . . 69
4.4 Diagnosing Solenoid Valve Failure . . . . . . . . . . . . . . . . . . . . . 69
4.5 Diagnosing Potentiometer Failure . . . . . . . . . . . . . . . . . . . . . 69
4.6 Master Controller PCB Status LEDs . . . . . . . . . . . . . . . . . . . . 70
4.7 Master Controller Voltage Test Points. . . . . . . . . . . . . . . . . . . 72
4.8 Base Module & Slave Arm PC Board Diagnosis . . . . . . . . . . . . 72
5 Factory Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Maintenance & Service

1 Safety First! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Page 4 Table of Contents

1.1 Worksite Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3 Mechanical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.4 Hydraulic Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.5 Deck Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Service Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Service Assumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Long Term Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . 58
4 Important Service Practices & Procedures . . . . . . . . . . . . 59
4.1 Protecting PC Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 Startup After Maintenance or Service . . . . . . . . . . . . . . . . . . 60
5 Junction Box Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6 Master Controller Service & Configuration . . . . . . . . . . . . 61
6.1 PCB Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Accessing Internal Components . . . . . . . . . . . . . . . . . . . . . . 63
6.3 Adjusting the LCD Screen Viewing Angle . . . . . . . . . . . . . . . . 63
6.4 Master Controller Software Selection . . . . . . . . . . . . . . . . . . 64
6.5 Incompatibility Alert Screens . . . . . . . . . . . . . . . . . . . . . . . . 67
7 Base Module Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.1 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.2 Servicing the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . 69
7.3 Accessing Internal Base Module Components. . . . . . . . . . . . . 69
7.4 Replacing the Jaw/Wrist Actuator Controller PCB . . . . . . . . . . 70
7.5 Servicing the Jaw or Wrist Servo Valve . . . . . . . . . . . . . . . . . 71
7.6 Removing the Jaw Bypass Valve . . . . . . . . . . . . . . . . . . . . . 72
8 Slave Arm Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.1 Servicing Slave Arm Servo Valves . . . . . . . . . . . . . . . . . . . . 73
8.2 Servicing Slave Arm Actuator Boards . . . . . . . . . . . . . . . . . . 73
8.3 Wrist Pitch/Yaw Hose Fittings. . . . . . . . . . . . . . . . . . . . . . . . 75
9 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.1 Adjusting Servo Valve Offsets . . . . . . . . . . . . . . . . . . . . . . . 77
9.2 Changing the Communications Protocol . . . . . . . . . . . . . . . . 79
10 Instructions for Serviceable Components . . . . . . . . . . . . 82
10.1 Startup Following Maintenance or Service . . . . . . . . . . . . . . 82
10.2 Work & Service Instruction List . . . . . . . . . . . . . . . . . . . . . 82
Drawings & Part Lists

1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2 Spares Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Table of Contents Page 5

– PAGE BREAK –

Safety & Service Summary
Precautionary Notices
This manual provides precautionary notices which carry important information about
safety risks to personnel and damage to equipment while installing, operating, servic-
ing, or maintaining this equipment.
The form and significance of the notices are shown below.
! WARNING
A WARNING alerts you to a risk of injury or loss of life. It may also
include instructions to help minimize or eliminate the risk.
! Caution
A CAUTION alerts you to a risk of equipment damage or loss.
It may also include instructions to help minimize or elimi-
nate the risk.
NOTE: The absence of WARNING and CAUTION notices does not mean
that risk is absent. Always use appropriate safety procedures, equipment,
and personal protective equipment (PPE) when operating and servicing this
equipment.
Service Assumption
This manual assumes that service personnel are familiar with the general operating
principles, safety guidelines, and service practices associated with the types of equip-
ment represented in this manual.
Table of Contents Page 7

Security Password
Model No.__________________________
Serial No.__________________________
Level 5 Password
This is your level 5 password: 1357
! WARNING
Misuse of the menus accessible with this password can
cause malfunctions of the manipulator system, injury to per-
sonnel, and/or damage to equipment.
The password for security level 5 is set at the factory and cannot be changed. It pro-
vides access to all configurable system menus, including those for setting other secu-
rity levels and passwords for other operators. See the OPERATION module in your
technical manual for complete information on how to use the level 5 password.
Temporary Password, Levels 1-4
The temporary password 0000 is provided for access to security levels 1 through 4
during installation and first startup. This password can be changed to meet your
security level requirements.
Security Level 0
Security level 0 is the default level, always available at system startup and requiring
no password. While permitting operation, it restricts access to almost all system con-
figuration menus and security features. An operator using a correctly configured
manipulator should need no higher privilege level. Levels above 0 require passwords
and allow access to specific manipulator system configuration menus.

Specifications
In This Chapter:
• 1 General Description ........................................................page 9
• 2 Manipulator Arm Specifications.........................................page 9
• 3 Master Controller Specifications ...................................... page 10
• 4 Electrical & Telemetry Requirements ............................... page 10
• 5 Environmental Specifications.......................................... page 10
• 6 Ranges of Motion/Dimensions ........................................ page 10
• 7 Hydraulics ................................................................... page 11
• 8 Compensation .............................................................. page 11
1 General Description
Conan is a 7-function, position-controlled hydraulic slave arm, depth rated to 3000 msw (9800
fsw). The slave arm is remotely directed by a master controller.
Control method. . . . . . closed-loop position control (except wrist and jaw/gripper)
Input device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master controller
Number of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 plus grip
Materials of construction. . . . . . . . . . . . . . . . . . . . . . 6061 aluminum, stainless steel
2 Manipulator Arm Specifications

All specifications are based on the standard system configuration using Shell Tellus Oil 32
hydraulic fluid, input pressure of 207 bar (3,000 psi), and available flow of 19 lpm (5 gpm).
Depth rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 msw (9,843 fsw)
Maximum reach (azimuth pivot to T-bar slot) . . . . . . . . . . . . . . 1,805 mm (71.1-in.)
Weight in air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 kg (235 lb)
Weight in sea water (submersible models . . . . . . . . . . . . . . . . . . . . . . . 73 kg (161 lb)
Lift at full extension, nominal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 kg (350 lb)
Maximum lift, nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 kg (600 lb)
Maximum gripper opening (standard gripper), nominal . . . . . . . 152 mm (6.0-in.)
Grip force, nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,448 N (1,000 lbf)
Wrist torque, nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Nm (150 ft/lb)
Wrist rotate, continuous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360°, 6-35 rpm
Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see table below
011–0912 Page 9
• Specifications
Slave Arm Actuator Functions

Function Type Function Mechanical Range
Azimuth Linear 120°
Shoulder pitch Linear 120°
Elbow pitch Linear 120°
Wrist pitch Linear 120°
Wrist yaw Linear 120°
Wrist rotate Gerotor 360°
Parallel acting jaw Linear 152 mm (6.0-in.)
Intermeshing jaw Linear 198 mm (7.8-in.)
3 Master Controller Specifications

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 mm (18.5 in.)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 mm (7.0 in.)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.6 in.)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 kg (8.2 lbs)
4 Electrical & Telemetry Requirements

System supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 to 260 VAC, 50/60 Hz
Base module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC
Power Consumption:
• Master controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 W start, 3 W run
• Base module plus solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .120 W start, 30 W run
Telemetry . . . . . . . . . . . . user selectable between RS-485 half-duplex and RS-232
5 Environmental Specifications
Operating temperature . . . . . . . . . . . . . . . . . . . . . -2° C to +54° C (28° F to 130° F)
Storage temperature . . . . . . . . . . . . . . . . . . . . . . . . .-15° C to +71° C (5° F to 160° F)
Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0% to 100% condensing
6 Ranges of Motion/Dimensions
See the slave arm drawing for your system in the “Drawings & Part Lists” chapter for:
 Ranges of motion
 Extended dimensions
 Stow dimensions
 See drawing 050-0693 for mounting dimensions
Page 10 • Master Controller Specifications 011–0912

Specifications •
7 Hydraulics
7.1 Fluids
Select a hydraulic fluid based on its maximum temperature during normal operations.
 Lower than 54°C (130°F): Use 22 grade oil.
 Higher than54°C (130°F): Use 32 grade oil.
 For temperatures above 71°C (160°F), below 0°C (32°F), or when in doubt about
which fluid to use, contact your regional technical support representative.
 Do not use water-based fluids.
 If a fluid has been specified for this system to meet special environmental or oper-
ational requirements, use it and disregard the parameters listed above.
7.2 Requirements
Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 cSt to 200 cSt
Available flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7-19.0 l/min (1.5-5.0 gpm)
Pressure . . . . . . . 103 bar (1,500 psi) minimum to 207 bar (3,000 psi) maximum
Hydraulic fluid temperature, maximum . . . . . . . . . . . . . . . . . . . . . . . .54° C (130° F)
Rotary actuator return pressure, maximum . . . . . . . . . . . . . . . . . . 24 bar (350 psi)
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 microns (10 microns absolute)
Customer supplied mating fittings required:
Supply hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4 JIC female, ¼-in.
Return hose fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -6 JIC female, 3/8-in.
NOTE: If hose lengths exceed 20 feet, contact the factory for information about increas-
ing the hose diameters to maintain adequate pressure and flow.
8 Compensation
Fluid requirement . . . . . . . . . . . . . . . . . . . . . . . . Non-conductive, non-water based
Compensator fluid capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 l (0.58 gal)
Fluid pressure (above ambient) . . . . . . . . . . . . . . . . . . 0.55 to 0.69 bar (8 to 10 psi)
Relief valve cracking pressure, nominal . . . . . . . . . . . . . . . . . . . . . . .1.4 bar (20 psi)
NOTE: The compensator and hose are not supplied with system 199-0306-1.
011–0912 Hydraulics • Page 11

• Specifications
This page not used.
Page 12 • Compensation 011–0912

Installation
In This Chapter:
• 1 User-Supplied Equipment .............................................. page 13
• 2 Installation Overview .................................................... page 13
• 3 Mechanical Installation .................................................. page 13
• 4 Electrical Power & Telemetry Connections ........................ page 15
• 5 Completing the Installation ............................................ page 18
1 User-Supplied Equipment
The following services and equipment are required to complete the installation of the slave arm:
 Electrical and hydraulic power sources. See the “Specifications” chapter for
details.
 All hoses and fittings for connecting hydraulic power to the slave controller.
 Topside wiring as needed for integration into long-line system.
 On some systems, the subsea slave cable is supplied by the user. See the 199- part
list for the supplied model.
2 Installation Overview
Long-Line Installation See Figure 2 on page 16.
Deck-Test Installation See Figure 5 on page 17.
3 Mechanical Installation
3.1 Slave Arm
1. Determine a mounting location (See the “Specifications” chapter for information on
slave arm dimensions and ranges-of-motion).
2. Create a sturdy mounting platform that will provide a flat surface for the minimum mounting
footprint and three mounting holes for the azimuth base shown in Figure 1 on page 14.
Three 5/8-in., or M16, hex-head cap screws, flat washers, lock washers, and hex nuts (not
supplied) are required to attach the azimuth base to the mounting platform. The platform
mounting holes may be tapped to receive the fasteners if the platform material and
thickness are determined to be adequate. The material should engage a minimum of one
bolt diameter of the fastener threads.
011–0913 • Page 13
• Installation
Figure 1 Mounting dimensions

3. Move the slave arm to the mounting platform.
4. Lubricate the fasteners with Aqua Lube, install, and torque as specified below:
— 5/8-in. fasteners: 108 Nm (80 ft/lbs)
— M16 fasteners: 95 Nm (70 ft/lbs)
5. Connect the hydraulic supply hose to the base module using a female -4 JIC fitting, and connect
the hydraulic return hose using a female -6 JIC fitting. The base module male fittings for supply
and return are located to the right of the power/telemetry cable connector.
3.1.1 Jaw Configuration Option

The base module contains a bypass valve that causes the jaw to relax its grip when hydraulic
power is disabled, either by the operator-controlled solenoid valve (in the base module), or by a
failure of the hydraulic power system. If you prefer that the jaw remain locked when hydraulic
power is disabled, the bypass valve can removed. Refer to “Removing the Jaw Bypass Valve” in
the “Maintenance & Service” chapter for details.
3.2 Compensator
This Conan system requires active compensation. The compensator, connection hose, and
mounting hardware are customer-supplied with this system.
1. See the “Specifications” chapter for compensation requirements.
2. Connect the hose from the customer-supplied compensator to the -4 “COMP” port on the base
module.
3. Charging the compensation system is completed in section 5, “Completing the Installation,” on
page 18.
3.3 Junction Box

The junction box (below, left) is used for deck testing. It has no mounting hardware and can be
placed on any flat, dry surface.
Page 14 • 3 Mechanical Installation 011–0913

Installation •
Master Arm
3.4 Master Controller

The master controller (above, right), has no mounting hardware, and can be placed on any flat,
dry surface. It is usually located at or near the system control console for use by the pilot or co-
pilot.
! Caution
Do not use the master arm to lift or carry the master controller. It is a
precision instrument and can be damaged.
4 Electrical Power & Telemetry Connections

4.1 Telemetry Configuration
The default, factory-set telemetry protocol is RS-232. The system can also be configured to RS-
485 telemetry. For detailed instructions see “Changing the Communications Protocol” in the
“Maintenance and Service” chapter.
4.2 Long-Line Connections

In typical ship-based applications, the slave arm and base module of the Conan Manipulator Sys-
tem are mounted to a remotely operated vehicle (ROV) andconnected as shown in Figure 2.
1. Complete the two sections listed below.
Subsea Wiring and Connections See section 4.2.1 on page 16
Topside/Surface Wiring and Connections See section 4.2.2 on page 16
011–0913 4 Electrical Power & Telemetry Connections • Page 15

• Installation
Figure 2 Long-line power and telemetry options
4.2.1 Subsea Wiring and Connections

Reference: see the drawings and schematics for your system’s deck cable, junction box, and base
module.
1. Make a subsea cable for connecting the base module to ROV power and telemetry.
Connector pin assignments are shown in Figure 3.
Figure 3 subsea cable pin assignments,
4.2.2 Topside/Surface Wiring and Connections

1. Mount the supplied bulkhead connector 005-1839 to your control panel where it is
convenient to connect the master controller cable.
2. Use pins 005-0239 to wire the connector to system telemetry/comms and to 90-240 VAC power
as shown in Figure 4.
Page 16 • 4 Electrical Power & Telemetry Connections 011–0913

Installation •
Figure 4 Bulkhead connector wiring

3. Connect the master controller whip.
4.3 Deck Test Connections

The Conan manipulator system includes components needed for deck-testing or local operation
(see Figure 5).
1. Connect the junction box AC power cord P1 to a 90-260 VAC power source.
2. Connect the cable from the master controller to connector P2 on the junction box.
3. Connect the deck test cable between connector P3 on the junction box and the Burton connector
on the base module.
4. If the Conan manipulator is equipped with a video camera, the signal is available at the BNC
connector on the junction box.
5. Provide a deck cart to power slave arm hydraulics.
6. Proceed to “Completing the Installation” section on page 18.
Figure 5 Deck-test connection
011–0913 4 Electrical Power & Telemetry Connections • Page 17

• Installation
5 Completing the Installation
After all the components are installed, the manipulator system is connected first in the deck-test
configuration and started up to confirm operation, set the Stow In/Stow Out (deploy) and travel
limits menus for safe operation, and charge/bleed the compensation system. Then the system is
connected in the long-lines configuration for final testing. The process is described below. Refer
to the “Operation” chapter, as needed, for additional information.
Part 1: Start System & Test Functions
! Caution
NEW USERS ONLY! If you are unfamiliar with Conan manipulator sys-
tems, please review sections 1 through 3 of the “Operation” chapter
before proceeding.
1. Set up the manipulator system for deck-testing (see section 4.3). Connect a deck cart to
the slave arm to supply hydraulic power.
2. Complete the following checks before you start-up the manipulator system.
 All system fasteners, fittings, and connectors are correctly installed and properly tightened.
 All hoses and cables are safely routed to allow full travel of the slave arm and are without
kinks, snagging, and contact with sharp edges or rough surfaces.
3. Move all personnel, equipment, and installation supports outside the range-of-motion of the slave
arm.
4. Apply hydraulic power to the supply line (does not energize arm).
— Check the hydraulic lines for leaks.
— Turn on any other hydraulic equipment using the same return line. Confirm
that the return pressure does not exceed 500 psi (34.5 bar).
NOTE: Filters and other hydraulic equipment sharing the return line may cause the re-
turn circuit pressure to rise. If pressure exceeds 500 psi (34.5 bar), hydraulic fluid will
be released from the return relief valve on the upper arm.
5. Turn on electrical power to the junction box and master controller.

6. Complete master controller startup.
— For startup details, see the “Operation” chapter, section 2.2, “Startup
Sequence,” on page 29.
NOTE: Air in hydraulic lines or components can cause very rapid or jerky slave arm
movement upon start-up.
! Caution
As you proceed, if the response of the slave arm or the master con-
troller does not appear normal, IMMEDIATELY disable slave arm
hydraulics and refer to the appropriate section of the “Operation”
chapter for guidance. Return to this procedure only when you have
determined that the system is functioning safely and correctly.
Page 18 • 5 Completing the Installation 011–0913

Installation •
7. From the master controller, turn on hydraulics to the slave arm. Carefully test basic slave arm
functions.
! WARNING
When testing a slave arm on deck:
• Move all personnel outside the slave arm's range of motion when
hydraulic pressure is applied and functions are tested.
• Direct the slave arm to point away from personnel and critical or
sensitive areas while testing jaw functions.
Part 3 Set Stow Positions and Travel Limits

8. Set a stow sequence that will allow the slave arm to be safely stowed within its environment.
— see the “Operation” chapter, section 3.2.5, “Setting the Stow In/Stow Out
Sequence,” on page 44).
NOTE: The factory default stowed and deployed slave arm positions are the same: the
position of the slave arm in the shipping container.
9. Set slave arm travel limits that allow safe operation of the slave arm within its environment.
— see the Operation chapter, section 3.2.4, “Setting Slave Arm Movement Lim-
its,” on page 42).
NOTE: The factory default allows full slave arm travel.
Part 3: Charge the Compensation System
! Caution
Compensated components can be damaged if the compensation fluid
is conductive or water-based, or if the slave arm is submerged with
large amounts of air in the compensation system.
NOTE: The compensator, connection hose, and mounting hardware are customer-sup-
plied with this system.
10. Charge the compensator with fluid and bleed off any air.
11. Loosen, but do not remove, the self-sealing bleed screw (Phillips head) on the yaw actuator control
module. Let the compensator pressure fill the supply hose, base module, and yaw wireway hose.
Add fluid to keep the compensator filled. When hydraulic fluid starts to run out of the yaw bleed
screw, tighten it.
12. Loosen the bleed screws on the remaining actuator control modules to allow air to be bled from
the wireways (except the elbow actuator module, which is not accessible).
13. Bleed off air in the base module by loosening the -4 plug on the top.
14. After all compensated volumes are bled, bleed any remaining air from the compensator and
charge until full.
15. Inspect compensation system for leaks and correct as needed.
Part 4: Testing Long-Line Connections
011–0913 5 Completing the Installation • Page 19

• Installation
16. After the compensation system has been charged, connect the manipulator system for long-line
operation and confirm slave arm functions.
17. Refer to the “Operation” chapter for complete information about system functions, configuration,
operation, and diagnostics.
Page 20 • 5 Completing the Installation 011–0913

Operation
In This Chapter:
• 1 System Overview ......................................................... page 21
• 2 Operation .................................................................... page 29
• 3 Performance Options..................................................... page 37
• 4 System Fault & Error Diagnosis ...................................... page 47
1 System Overview
Conan is a hydraulically powered, remotely controlled manipulator system, composed of the fol-
lowing parts:
 The hydraulically powered, seven function slave arm, tipped with a jaw tool to
grasp and manipulate objects.
 The base module, which serves as a hub for the control and distribution of
hydraulic fluid to the slave arm, the distribution of electrical power to slave arm
electrical assemblies, and the routing and processing of control telemetry between
the master controller and slave arm.
 The master controller, which controls the slave arm. This assembly contains:
— The master arm, a small replica of the slave arm, which the operator manipu-
lates to direct the slave arm.
— An LCD (liquid crystal display) screen flanked by function and control keys.
The operator uses the keys to select operating options, and uses the screen to
view system information.
— Electronic assemblies and software that control telemetry between the master
arm and base module.
 A junction box that connects to an electrical power source, and links the master
controller with the base module and slave arm.
 Electrical cables and hydraulic hoses that connect system components.
 Submersible models are supplied with a compensator unit that provides compen-
sated pressure for the base module, actuator control modules, and telemetry wire-
ways.
011–0914 Page 21
• Operation
1.1 The Slave Arm
The position-controlled Conan slave arm is a hydraulically powered, electrically controlled
manipulator with azimuth yaw, shoulder pitch, elbow pitch, wrist pitch, wrist yaw, wrist rotate,
and jaw open/close functions.
The azimuth, upper arm, forearm, and wrist pitch/yaw assemblies are the major structural mem-
bers of the slave arm, and are cast from aluminum. Linking these structural members are the
shoulder, elbow, wrist pitch, and wrist yaw joints, which pivot on stainless steel shafts.
Large hydraulic linear actuators control movement of the azimuth, shoulder, elbow, wrist pitch,
and wrist yaw joints. Each of these actuators has a pressure relief valve, a position sensor, and an
actuator control module containing microprocessor electronics and a servo valve. Lock valves in
the azimuth, shoulder, and elbow actuators freeze these joints when the actuators are not active,
or when hydraulic pressure is disabled. The wrist uses a rotary actuator and the jaw uses a small
linear actuator. (A bypass valve in the base module causes the jaw to relax and open when
hydraulic pressure is disabled.) The wrist and jaw actuators have no position sensors.
1.2 Base Module

The base module is mounted to the azimuth base and serves as the hub for reception and transfer
of hydraulic power, compensation (for submersible systems), electrical power, and control
telemetry. Hydraulic supply and return lines from the user-supplied hydraulic power unit termi-
nate at the base module, where the supply fluid is filtered. The base module contains servo valves
for the wrist and jaw actuators, manifolds for the slave arm supply and return lines, and an oper-
ator-controlled solenoid valve for enabling and disabling hydraulic power to the slave arm. Wire
way hoses, carrying DC power and control telemetry, connect the slave arm-mounted actuator
control modules to the base module. AC power and master controller telemetry reach the base
module through a cable from the junction box. A power supply mounted to the top of the base
module converts the input (90-240 VAC or 24 VDC) to +12 and -12 VDC (the base module can
also be powered by a local +12 and -12 VDC source).
1.3 Compensator
Submersible models are supplied with a compensator unit that provides compensated pressure
for the base module, actuator control modules, and wire way hoses.
1.4 The Master Controller

Use the master controller to operate, configure, and diagnose the manipulator system.To direct
the slave arm, move the controller's master arm (Figure 1). Configure and diagnose manipulator
system operation by accessing appropriate master controller menus and making changes
through keystroke inputs.
Master Controller features are described below.
1.4.1 Master Arm

The master arm is a miniature replica of the slave arm (Figure 1). Each master arm joint or func-
tion matches a similar joint or function on the slave arm.
The small size of the master arm allows you to easily control all functions with the wrist and fin-
gers. These functions include:
Page 22 • System Overview 011–0914

Operation •
Slave arm joint movement Moving a master arm joint moves the corresponding slave arm
joint.
Slave arm freeze Pressing the button on the end of the master arm freezes the slave arm in
its current position.
Master
Arm
Control
Keys
LCD Screen
Jaw Switch
Function
Power Switch Keys
Figure 1 Master controller
Wrist rotate Rotating the collar from its null point initiates continuous slave arm wrist rota-
tion in the same direction, with speed (rate) increasing with the degree of collar rotation.
Jaw grip Squeezing the textured jaw bands on the master arm wrist activates the grip func-
tion. The precise way in which the jaws will respond to this action depends on the current jaw
mode setting.
 TOG (toggle): Squeezing the forward jaw band fully opens or closes the jaw.
 POS (position): The jaw moves as long as the jaw band is squeezed.
— Forward band = jaw closes
— Rear band = jaw opens
 LOCK: This menu selection disables master arm input, leaving the jaw in its cur-
rent position.
— To escape from the LOCK mode, press the JAW MD: key and toggle to the
TOG or POS mode.
NOTE: When hydraulics are disabled, whether through operator control or hydraulic
failure, a bypass valve in the slave controller causes the jaw to relax its grip. If you pre-
fer that the jaw lock when hydraulic power is disabled, the bypass valve can be removed.
Refer to “Removing the Jaw Bypass Valve” in the “Maintenance & Service” chapter.
011–0914 System Overview • Page 23

• Operation
1.4.2 Auxiliary Jaw Switch
The auxiliary jaw switch is located opposite the master arm and provides the same functions as
the jaw bands on the master arm.
 Move switch forward = jaw closes
 Move switch rearward = jaw opens
1.4.3 Power Switch

The rocker switch at the left of the LCD screen controls electrical power for the master controller
only. The master controller power switch is normally turned off only after the slave arm has been
moved to a safe position (stowed), frozen, and slave arm have been hydraulics disabled.
1.4.4 Data Display Screen

An LCD screen in the center of the master controller front panel provides you with information
about system status and available operating options. Example screens are used throughout this
section. In most menus, the operational state of the slave arm is shown in the upper right corner
of each menu using one of the following signs:
Slave Arm Operational Status
The operational status of the slave arm is shown in the upper right hand corner of the Main
Menu screen. Three states are possible:
 REIN (reindex) = Master arm is enabled to control the slave arm, starting at their cur-
rent positions.
— Pushing the freeze button (at the tip of the master arm) toggles between REIN
and FRZ status (freeze).
 FRZ (freeze) = Master arm control of the slave arm is disabled (slave arm is frozen at
its present position).
— Opening most menus automatically engages FRZ status.
— Pushing the freeze button (at the tip of the master arm) toggles between REIN
and FRZ status (freeze).
 LOCK = Control system locked. LOCK status engages automatically:
— in certain menus or states in which the slave arm should not be operated. (To
unlock the slave arm, move to another menu where REIN or FRZ is the
default status.)
— when telemetry errors could cause erratic or uncontrolled slave arm move-
ments.
Adjusting the LCD Screen Viewing Angle
The LCD screen is provided with a temperature sensor and compensation circuit that maintains
the viewing angle over a broad temperature range. However, if the viewing angle is not accept-
able, the compensation range can be shifted to suit local viewing or temperature conditions by
adjusting a trimmer potentiometer inside the master controller (see “Adjusting the LCD Screen
Viewing Angle” in the “Maintenance & Service” chapter).

Operation •
1.4.5 Function Keys
Eight function keys flank the LCD screen as shown on Figure 1. These keys are used to select
menus, enter programming data, or to activate/deactivate functions. In each menu, the function
of each active key is displayed on the screen beside the key. (If no key label appears on the
screen, the corresponding key is not used in that menu.)
1.4.6 Control Keys

The four control keys in the diamond pattern on the right side of the
UP display have various uses, which are called out in the appropriate
menus, startup, or warning screens, or in the applicable section of the
LEFT RIGHT “Operation” chapter.
DOWN NOTE: While in most menus, the red “UP” key (arrow) can be
pressed to disable hydraulic power to the slave arm.
1.5 Security Levels

The master controller offers a default operation level and two security levels for accessing menus
that allow configuration of sensitive or critical system functions (two of the levels are password-
protected):
 Level 0 (zero) is the default level available at system startup. No password is
required. Full system operation is available at level 0, including access to menus
for error-checking, diagnostics, and configuration of some functions. A level 0
operator using a fully configured manipulator system will usually need no higher
security level.
 Levels 1 through 4 require a password, and allow access to the SET LIMITS, SET
STOW, and SET SV (servo valve) OFFSET menus. (Levels 2 through 4 are func-
tionally equivalent to level 1 on this model and may be disregarded.)
 Level 5 requires the factory-assigned password, and allows access to all configura-
tion and security menus. Level 5 access is required to set or change passwords for
security levels 1 through 4 (and to edit the master memory under factory supervi-
sion).
1.6 The Control Process

Control processes are diagrammed in Figure 2. Conan control telemetry uses an RS-485 serial
interface. All slave arm control functions connected on a common bus. Telemetry is bi-direc-
tional and the control of each slave arm function (except wrist and the jaw) utilizes a closed loop:
position feedback from each slave arm joint is compared with position data from each master
arm joint (as adjusted by the operator) and any differential initiates the application of hydraulic
power to appropriate slave arm joints until position correspondence is achieved. Slave arm posi-
tion data is also sent to the master controller for use in diagnostic menus where it can be com-
pared with master arm data for troubleshooting the system.

• Operation
Electrical Power
Source
Analog master arm Digitized slave arm

joint position data command data
Master Arm Master Controller

Position data for diagnostics Junction Box
Electrical power Electrical power
Digitized slave arm command data
Position data for diagnostics
Electrical power
Hydraulic Supply
Slave Controller
Current to Solenoid Valve
Digitized slave arm
position data control valve
Digitized slave arm command

data & electrical power
Actuator Actuator
Controller Board Controller Board
Current to Current to
control valve control valve
Analog slave arm joint position data
Servo Valve Servo Valve

Electrical power
Hydraulic Hydraulic
fluid fluid
Slave Arm Slave Arm

Hydraulic Hydraulic
Actuator Actuator
Open-Loop Control
(jaw)
Slave Arm Joint

Potentiometer
Figure 2 Control system

Operator inputs to the master controller are generated by moving master arm joints, pressing the
master arm freeze button (to idle the slave arm in its current position), and squeezing the master
arm jaw bands (to initiate the jaw functions). Each physical action is translated into a varying
analog voltage by the potentiometer in each joint of the master arm (or by switches for the jaw
function). The analog data from each joint is converted to a digital “command” value, given a dig-
ital address specific to its function, and all commands of a given instant are grouped into a
packet. This packet is sent to the base module and distributed to all the actuator controller
boards. A DIP switch on each board is configured to only accept a command with its address and
disregard all others.
Simultaneously, potentiometers in the slave arm are translating physical positions into varying
analog voltages which are also converted into a digital value. The actuator controller board then

Operation •
compares the joint's position data with the command position data sent by the master controller.
If the data are the same, no slave arm joint movement results. If the data are not the same, the
actuator controller board applies a voltage to that joint’s servo valve, causing the servo valve to
release fluid to the appropriate port of its hydraulic actuator. The resulting actuator movement
drives the slave arm joint towards the commanded position. When the joint feedback data corre-
sponds with the position data commanded by the master controller the servo is closed and slave
arm stops moving.
The jaw does not have a potentiometer to provide position feedback: instead, master controller
commands can only move the jaw in a specific direction (toggle open or closed) or move the jaw
as long as a jaw band (or auxiliary jaw switch) is squeezed (position mode). Opening or closing
the jaw to a specific position is only possible with visual guidance.
1.7 Menu Structure

The operator operates and configures the manipulator system by accessing appropriate master
controller menus and making keystroke and master arm inputs. The menu structure and hierar-
chy is shown in Figure 3.
Establishing Communications with

Slave Arm
Incompatible
EPROM
Warnings: Startup System

Keys Error Screen Errors
Stow In Error
Deploy
Menu
Deploy
Stow
Stop
Main
Menu
Operate Options Setup Shutdown Diagnostics

Menu Menu Menu Menu Menu
Set Limits
Set Stow Master
Hydraulics Speed (Dyn) Slave
Set SV Offset
Scale toggle Jaw Speed Show Errors
Set ERR Checks
Jaw Mode Scale
Memory
Wrist Mode Deploy
Security
Freeze Stow
Security Stop
Menu Hydraulics
Set Password
Set Level
Figure 3 Block diagram of menus

• Operation
1.8 Controlling Slave Arm Hydraulics
Use the master controller to control hydraulic power to the slave arm.
 Hydraulic (supply) pressure to all slave arm functions is controlled with a single
isolation valve located in the upper arm
 The Startup, OPERATE, and SHOW ERRORS menu screens designate keys for
controlling the isolation valve and show hydraulics status:
— Hydr: ON = Hydraulics enabled
— Hydr: OFF = Hydraulics disabled
NOTE: To avoid unexpected movements, always enable slave arm hydraulics before
you unfreeze the slave arm.
1.8.1 Emergency Disable

Hydraulics can be disabled at any time, regardless of menu, by press-
UP
ing the red UP control key (Figure left, arrow).
LEFT RIGHT If you disable the hydraulics by pressing the UP key, use the OPER-
ATE menu to re-enable (see “Using the OPERATE Menu” section on
DOWN
page 33).
1.8.2 Automatic Disable

Some system errors automatically disable the hydraulics. See “Diagnosing & Resetting System
Errors” section on page 50 and “Enabling & Disabling System Error Checking” section on page
51.
1.9 Slave Arm Operational Status

The operational status of the slave arm is shown in the upper right corner of most menus using
the following designations:
 REIN (reindex) indicates the master arm control of the slave arm is enabled.
 FRZ (freeze) indicates that master arm control of the slave arm is disabled and the
slave arm is idle (frozen). FRZ status occurs when opening certain menus or after
pushing the freeze button at the tip of the master arm. Press the freeze button
again to activate the master arm for control of the slave arm.
 LOCK indicates that the arm is frozen and cannot be unfrozen from the current
menu. The manipulator control system automatically locks the slave arm for
menus or states in which the slave arm should not be operated. To unfreeze the
slave arm, you must move to another menu. Communications errors may also
lock the system to prevent damage.
1.10 Avoiding Slave Arm Damage

The Conan is designed with safety factors well in excess of its rated capacities. However, situa-
tions can occur in operation where safety factors may be exceeded, placing the slave arm and sur-
rounding equipment/personnel at risk. These situations include:
 Collisions

Operation •
 Collisions while manipulating extreme loads
 Collisions and/or extreme loads while at the slave arm’s mechanical limits
The best protection is anticipating risky situations and planning slave arm operations to
avoid or minimize them.
NOTE: Collisions and extreme loads can cause unusual joint movements (reversed,
overly slow or accelerated) that may trigger automatic system shutdown by error-
checking software.
If necessary, error checking can be disabled in order to assure uninterrupted operation.
However, disabled error checking puts the slave arm at greater risk. (For details see
“Enabling and Disabling System Error Checking” on page 45.)
2 Operation
NOTE: If wrist drain/return pressure exceeds 350 psi above ambient, the relief valve
will crack and release hydraulic fluid into the environment.
2.1 Pre-Start Checks

Each time you prepare to start up the manipulator system, make the following checks:
 All fasteners and fittings are properly tightened and in good condition.
 All hoses are safely routed to avoid kinks, snagging, and contact with sharp edges
or rough surfaces.
 Hydraulic components, hoses, and fittings are sound and free of leaking.
 Air has been purged from the hydraulic system if any connections have been
opened for service or maintenance.
 All electrical connections between the master controller, junction box, base mod-
ule, and slave arm are secure; electrical cables are safely routed to avoid damage.
2.2 Startup Sequence

To start up the system, follow the steps below.
1. Clear personnel and equipment from the slave arm’s range of motion. Turn on electrical
power to the system with the switch on the junction box. If your system has independent
electrical power to the base module, enable base module power first; then turn on power
at junction box and/or master controller.
2. Turn on power to the master controller with the switch on the left side of the controller front
panel. The message “Establishing Communications with slave arm” will appear briefly and then
default automatically to the next message screen.
NOTE: If the master controller fails to establish communication with the base module, a
“fatal telemetry error” message will appear. Refer to the “Troubleshooting” chapter for
more information on correcting the cause of the malfunction.
011–0914 Operation • Page 29

• Operation
SCHILLING ROBOTIC SYSTEMS

CONAN-7P MANIPULATOR SYSTEM
--------------------------------
Startup Procedure:
1.Verify arm position.
2.Turn on HPU power.
3.Enable arm hydraulics.
4.Turn hydraulics off if
the slave arm moves from
its current position.
5.Press DOWN key to exit.
Hydr:OFF <8
--------------------------------
Figure 4 Startup procedure screen

3. If the slave arm is near the stow position, and all system equipment and communications are
functioning correctly, the Startup Procedure screen (Figure 4) will follow the “establishing
communications” message.
— If the system was shutdown without returning the slave arm to the stowed
position or keyboard errors are present, a decriptive WARNINGS: screen will
appear as an alert (see example, Figure 5)
SCHILLING ROBOTIC SYSTEMS

CONAN-7P MANIPULATOR SYSTEM
--------------------------------
WARNINGS:
Arm not near STOW point
(STOW OUT will be bypassed)
Exit <8
--------------------------------
Figure 5 WARNINGS screen

a. Press the Exit <8 key to proceed to the Startup Procedure screen (Figure 4).
b. Complete the startup steps. Press the DOWN key to exit. The STOW OUT menu will
be bypassed and the MAIN menu will open.
c. From the MAIN menu you can choose to diagnose errors or proceed to the OPERATE
menu.
NOTE: Keyboard errors need not be corrected if emergency operation of the slave arm
is essential. To correct them, refer to the “Troubleshooting” chapter and/or “System
Fault & Error Diagnosis” section on page 47 in this chapter to diagnose.
— The appearance of other warning screens or the system error screen indicates
a communication or system problem. Refer to “System Fault & Error Diagno-
sis” section on page 47, and/or the “Troubleshooting” chapter.
Page 30 • Operation 011–0914

Operation •
4. Perform the steps listed in the Startup screen.
NOTE: The pitch, yaw, wrist, and jaw are not equipped with lock valves. They may sag
or drift during shutdown or when hydraulic power is disabled. It is normal for them to
return to their last commanded or stow position when hydraulic power is enabled.
The azimuth, shoulder, and elbow joints are equipped with lock valves to maintain their
positions during shutdown and regardless of hydraulic or slave arm status. They should
not move more than slightly when hydraulics are enabled (unless they have been manu-
ally repositioned while the system was shutdown). If they begin moving more than a
slight distance, immediately press 8> HYDR again to disable hydraulic power to the
slave arm until the cause can be determined.
5. Press the DOWN control key (exits to the STOW OUT menu).
UP
LEFT RIGHT
DOWN
2.3 STOW OUT Menu

Use the STOW OUT menu (Figure 6) to automatically move the slave arm to a deployed position
or to a compact stowed position.
 Movement of the slave arm to either position follows a set of up to 16 points (posi-
tions) that are user programmed in the SET STOW menu (MAIN/SETUP/SET
STOW), as described section 3.2.5 on page 44.
STOW OUT
--------------------------------
STOW OUT <5
STOW IN <6
pnt:IN STOP <7
EXIT <8
--------------------------------
After stowing out press exit KEY
Figure 6 STOW OUT menu
2.3.1 Command Options

 STOW OUT <5 (deploy): Press the STOW OUT <5 key to deploy the slave arm to
the operational position. As the slave arm moves, the pnt: field displays the next
point in the sequence to which the slave arm is moving.
 STOW IN <6 (stow): Press the STOW IN <6 key to move the slave arm to the
stowed position.

• Operation
NOTE: The slave arm will move first to the Stow Out (deployed) position before begin-
ning the Stow In sequence. To avoid major automatic movements, position the slave arm
at or near the stow out position before pressing the STOW IN <6 key.
 pnt: ... STOP <7: The next programmed point is displayed the pnt: ... field. Press
the pnt: ... <7 key to stop the slave arm at the next programmed point.
— To immediately stop the slave arm in an emergency, press the UP control key
to disable hydraulic power.
 EXIT <8: Press the EXIT <8 key to return to the MAIN menu.
2.4 Using the MAIN MENU
MAIN MENU LOCK

--------------------------------
1> OPERATE SHUT DOWN <5
2> OPTIONS
3> SETUP
4> DIAGNOSE
--------------------------------
UP key turns hydraulics OFF
Figure 7 MAIN MENU

The MAIN MENU provides access to the five submenus described below. Press the key adjacent
to the menu to select it (Figure 7).
 1> OPERATE: Select this menu to direct the slave arm with the master arm. Key
controls toggle between jaw operation modes, different slave arm scaling values,
and enable or disable slave arm hydraulics. Slave arm joints can be selectively fro-
zen in the FREEZE submenu. All controls and menus are accessible at security
level 0 (zero).
 2> OPTIONS: Submenus are provided to configure slave arm speed and jaw
speed, and to scale the degree of slave arm movement relative to master arm
movement. All menus are accessible at security level 0 (zero).
 3> SETUP: Submenus are provided to configure slave arm movement limits, pro-
gram the stow in/stow out sequence, set system error checking, set security levels
and passwords, and edit master controller memory locations. These submenus
require a password or a security level higher than 0 (zero) to use.
 4> DIAGNOSE: Used to view diagnostic information about the master arm, slave
arm and master controller, and to view details of system error conditions. All
menus are accessible at security level 0 (zero).
 SHUT DOWN <5: Used to stow the slave arm and disable slave arm hydraulics in
preparation for shutting down the manipulator system. All menus are accessible
at security level 0 (zero).

Operation •
2.5 Using the OPERATE Menu
Access path: MAIN/OPERATE
OPERATE FRZ
--------------------------------
1> FREEZE Jaw Md:TOG <5
2> Hydr:OFF
3> Scale Tog:100%
EXIT <8
--------------------------------
Turn on hydraulics
Figure 8 OPERATE menu

Normal operation of the manipulator system takes place in the OPERATE menu. Use the master
arm for direct control of the slave arm. Use the master controller keys to select among function
options, enter the FREEZE submenu, control hydraulic power, or exit back to the main menu.
The slave arm is stowed and the manipulator system is disabled in the SHUT DOWN menu. To
prevent unintended or unexpected movement, the OPERATE menu always opens with the slave
arm in the freeze (FRZ) state (Figure 8).
1. From the MAIN MENU press the 1> OPERATE key to access the OPERATE menu
(Figure 8).
2. Air in hydraulic lines or components may cause very rapid or jerky slave arm movements. Sagging
joints may return to their original position when hydraulics are enabled. Clear personnel and
equipment from the slave arm’s range of motion before startup.
3. If hydraulic power is not enabled, press the 2> Hydr key.
2.5.1 Using the Master Arm

1. Verify that the status field (at upper right) reads FRZ (Figure 8). Grip the master arm,
move it from its parked location, and position it for convenient operation of the slave
arm. Then press the freeze button at the tip of the master arm (status field changes to
LIVE): the slave arm will now move to match the movements of the master arm.
NOTE: The freeze function is also useful when a manipulation task results in an awk-
ward position for the master arm. Press the Freeze button, reposition the master arm for
more comfortable operation, and press the Freeze button again (to resume operation).
These actions re-index the new master arm position to the existing position of the slave
arm.
2. Operate the slave arm as desired. To optimize the Conan for a specific task and/or work site, refer
to “Performance Options” section on page 37, for information on system functions that can be
selected, set, and/or reconfigured using the OPERATE, OPTIONS, and SETUP menus.

• Operation
NOTE: If the wrist continues to turn when frozen when the slave arm is frozen, the
wrist’s servo offset may need adjustment. The procedure is described in the “Mainte-
nance & Service” chapter.
2.5.2 Selecting the Jaw Operating Mode (Toggle)

Access path: MAIN/OPERATE/Jaw Md (see Figure 8)
Press the Jaw Md: <5 key to toggle between the three jaw function modes (POS, TOG, and
LOCK):
 TOG (toggle): Squeezing the forward band toggles the jaw between fully closed
and fully opened. The rear band has no function.
 POS (position): Squeezing the forward band causes the jaw to close until the band
is released. Squeezing the rear band causes the jaw to open until the band is
released.
NOTE: The POS (position) option is lost if the master controller software image is
changed by adjusting the PCB mode switches, replacing the EPROM (if used), or loading
a new image from an SD card. To re-enable the POS option after one of these events has
occurred, see “Re-enabling POS (Position) Jaw Control in section 6.4, “Master Controller
Software Selection,” on page 64 in the “Maintenance & Service” chapter.
 LOCK: The jaw is frozen in its current position and operator inputs to the jaw
bands are ignored until you select another mode.
2.5.3 Scaling Slave Arm Movement (Toggle)

Access path: MAIN/OPERATE/SCALE TOG
The 3> Scale Tog key toggles between the default scale value of 100% and a lesser pre-selected
scale value. A scale value of 100% produces one-to-one travel correspondence between master
arm and slave arm movement. (For example, rotating the master arm elbow joint 50° causes the
slave arm elbow joint to move 50°.) Toggling to a scale value of less than 100% reduces slave arm
movement to that percentage of master arm movement, allowing finer slave arm control. The
manipulator system offers position scaling from 10% to 100% in increments of 10%. At startup
the selectable scale defaults to 100% and must be reset if lesser values are required.
1. Use the master arm tip to freeze the slave arm.
2. Press the 3> Scale Tog key to toggle between the standard 100% scale of slave arm movement and
a pre-selected lesser scale. Scaling affects only the azimuth, shoulder, elbow, forearm roll, and
wrist pitch functions (wrist roll and jaw functions always remain at 100%). You must freeze the
slave arm before toggling between scales. The speed of slave arm movements is not affected by
changes in scaling.
Although the alternate scale value is retained when power to the master controller is interrupted,
the OPERATE menu always reopens with the Scale Tog value at 100%.
2.5.4 Setting the Scale Value

Access path: MAIN/OPTIONS/SCALE SEL
To set the alternate scaling value, follow these steps:

Operation •
1. From the MAIN MENU press the 2> OPTIONS key to display the OPTIONS menu
(Figure 9).
2. The number next to 3> Scale Sel shows the current alternate scaling value. Press the 3> Scale Sel
key to increment this number by 10%. (At 100%, the value defaults to 10%.)
3. When the desired alternate scaling value is displayed, press the EXIT <8 key to save and return to
the MAIN MENU.
The Scale Sel setting is retained in memory even if power to the master controller is interrupted.
OPTIONS FRZ
--------------------------------
1> Dyn:FAST
2> Jaw Speed:2
3> Scale Sel:050%
EXIT <8
--------------------------------
Figure 9 OPTIONS menu
2.5.5 Freezing Individual Slave Arm Joints (Toggle)

Access path: MAIN/OPERATE/FREEZE
FREEZE FRZ
--------------------------------
1> Azi: REIN Yaw: FRZ <5
2> Sho: REIN Wrs: REIN <6
3> Elb: REIN REIN all <7
4> Pit: REIN EXIT <8

--------------------------------
Figure 10 FREEZE menu

Freezing individual joints is useful for tasks where only some joints are required to move and/or
where greater stability of specific individual slave arm joints is desired.
1. From the OPERATE menu press the 1> FREEZE key. The FREEZE menu (Figure 10)
allows individual slave arm joints to be frozen so that they will not respond to master arm
movements. Select among 1> Azi (azimuth), 2> Sho (shoulder), 3> Elb (elbow), 4> Pit
(wrist pitch), Yaw <5 (wrist yaw), and Wrs <6 (wrist). To unfreeze all joints, press the
REIN all <7 key.

• Operation
2. Press the key next to each joint to toggle the field between FRZ and REIN.
3. After making your selections, press the EXIT <8 key to return to the OPERATE menu. Press the
master arm freeze button to unfreeze the slave arm. Joints set to FRZ in the FREEZE menu will
remain frozen. Joints set to REIN can be directed with the master arm.
All FREEZE menu joint settings return to the default value (REIN) when power to the master
controller is interrupted.
2.6 Using the SHUT DOWN Menu

Access path: MAIN/SHUT DOWN
SHUT DOWN LOCK

--------------------------------
Stow Out <5
Stow In <6
Pnt:IN Stop <7
4> Hydr to OFF EXIT <8

--------------------------------
After stow, turn off hydraulics
Figure 11 SHUT DOWN menu

To shut down the manipulator system, follow these steps:
! Caution
Be sure to release objects from the jaws before shutdown. The jaw
relaxes after hydraulics are turned off, and a grasped object will be
dropped.
1. Release any objects from the grasp of the jaw.
2. Move the slave arm to a position that approximates the final stow out position. Exit the operation
menu.
3. From the MAIN MENU, press the SHUT DOWN <5 key to display the SHUT DOWN menu
(Figure 11). The status field shows that the slave arm is locked, preventing operation by the master
arm.
! Caution
When you press the Stow In <6 key, the slave arm will first return to
the final STOW OUT position before beginning the stow in sequence.
Be prepared for this movement.
4. Press the Stow In <6 key to move the slave arm to its stowed position.
Note that:
a. Before beginning the stow sequence, the slave arm will first return to the deployed
position.

Operation •
b. As the slave arm moves towards stow, the PNT: field displays each successive point
number in the sequence. The final point (01) is displayed as IN.
c. You can stop the sequence by pressing the Stop <7 key. The slave arm will halt when
it reaches the next point in the sequence.
d. You can reverse the stow sequence at any time by pressing the Stow Out <5 key.
5. Press the 4> Hydr key to close the base module hydraulic isolation valve.
6. Turn off power to the hydraulic power unit.
7. Turn off power to the master controller with the switch on the left side of the faceplate. Turn off
power to the base module (if independently supplied).
3 Performance Options
The Conan can be optimized for a specific task and/or work site by selecting, setting, or configur-
ing system functions using the OPTIONS and SETUP menus.
3.1 OPTIONS Menu

Access path: MAIN/OPTIONS
OPTIONS FRZ
--------------------------------
1> Dyn:FAST
2> Jaw Speed:2
3> Scale Sel:050%
EXIT <8
--------------------------------
Figure 12 OPTIONS menu

Dyn (slave arm speed) and Jaw Speed settings return to default values when power to the master
controller in interrupted or turned off. The Scale Sel setting is retained.
3.1.1 Controlling Slave Arm Dynamics

Access path: MAIN/OPTIONS/DYN
Slave arm speed can be toggled between two dynamic modes: FAST and SLOW. In the FAST
mode, the speed of slave arm movement matches all but the most rapid movements of the master
controller. This speed is useful in operations where quick response and close correspondence to
rapid movements of the master arm are useful, and in submersible operation where slave arm
movements are slowed by water resistance. SLOW mode is intended for use where speed-limited
movements are needed for specific tasks or equipment handling.
1. Press the 1> Dyn key to toggle between SLOW and FAST modes.
011–0914 Performance Options • Page 37

• Operation
2. Press EXIT <8 to save setting and return to the MAIN MENU.
Slave arm speed defaults to FAST when power to the master controller is interrupted.
NOTE: When the manipulator system is operating in SLOW mode, avoid rapid move-
ments of the master arm. Slave arm response will lag and may make it difficult to avoid
obstacles or direct the slave arm to an exact position. For exact slave arm movements or
positioning, slow your movements of the master arm until the slave arm can match
them.
3.1.2 Controlling Jaw Opening and Closing Speed

Access path: MAIN/OPTIONS (Figure 12, OPTIONS menu on page 37)
When the jaw is in POSITION mode, you can specify the speed of jaw movement with the Jaw
Speed function. In the OPTIONS menu (Figure 12 on page 37), the number next to 2> Jaw Speed
shows the current jaw speed. The higher the number, the greater the jaw speed. Possible jaw
speeds range from 1 (slowest) to 4 (fastest).
1. Press the 2> Jaw Speed key to increment the speed by 1. After jaw speed 4 the value
defaults to 1.
2. Press EXIT <8 to save setting and return to the MAIN MENU.
Jaw speed defaults to 1 when power to the master controller is interrupted or turned off.
3.1.3 Slave Arm Scale Selection

Access path: MAIN/OPTIONS
The 3> Scale Tog key in the OPERATE menu toggles between the default scale value of 100% and
a lesser pre-selected scale value. A scale value of 100% produces one-to-one correspondence
between master arm and slave arm movement. A scale value of less than 100% reduces slave arm
movement to that percentage of master arm movement, allowing finer slave arm control. Scaling
is selectable in increments of 10% from 10% to 100%. Although the alternate scale value is
retained when power to the master controller is interrupted, the OPERATE menu always
reopens with the Scale Tog value at 100%.
To set the alternate scaling value, follow these steps:
1. From the MAIN MENU press the 2> OPTIONS key to display the OPTIONS menu
(Figure 12 on page 37).
2. The number next to 3> Scale Sel shows the current alternate scaling value. Press the 3> Scale Sel
key to increment this number by 10%. (At 100%, the value defaults to 10%.)
3. When the desired alternate scaling value is displayed, press the EXIT <8 key to save and return to
the MAIN MENU.
3.2 SETUP Menu

Access path: MAIN/SETUP
The SETUP menu contains the following sub-menus for configuring functions (Figure 13):
 1> SET LIMITS (set slave arm movement limits).
 2> SET STOW (program the stow and deploy sequences).
Page 38 • Performance Options 011–0914

Operation •
 3> SET SV OFFSET (Set servo valve offsets). See the “Maintenance & Service”
chapter for information about adjusting the servo valve offsets.
 4> SET ERR CHECKS (set system error checking parameters).
 MEMORY <5 (edit master controller memory locations).
! Caution
Edit memory locations only under direction from manufacturer service
personnel.
 SECURITY <6 (set and access security levels, set passwords)
SETUP LOCK
--------------------------------
1> SET LIMITS MEMORY <5
2> SET STOW SECURITY <6
3> SET SV OFFSET
4> SET ERR CHECKS EXIT <8

--------------------------------
Figure 13 SETUP menu

To configure the menus within the Setup menu, except MEMORY<5, you must first access secu-
rity level 1 or higher by entering a local- (or factory-assigned level 5) password in the SECURITY
menu. Only the level 5, factory-assigned password will provide access for configuring the MEM-
ORY <5 menu.
Settings in all SETUP submenus are retained even if power to the master controller is inter-
rupted or turned off.
3.2.1 SECURITY Menu

Access path: MAIN/SETUP/SECURITY
Security level: 1 or higher
NOTE: A factory-assigned password can be found at the end of the Table of Contents.

• Operation
SECURITY LOCK
--------------------------------
1> SET LEVEL
2> SET PASSWORD
EXIT <8
--------------------------------
Figure 14 SECURITY menu

The master controller offers a default operation level and two password-protected security levels
for accessing menus that allow configuration of sensitive or critical system functions:
1. Level 0 (zero) is the default level available at system startup. No password is required.
Full system operation is available at level 0, including access to error-checking and
diagnostic menus. While level 0 does allow operator access to the SET ERR CHECKS
menu, all other SETUP submenus are inaccessible. A level 0 operator using a fully
configured manipulator system will usually need no higher security level.
2. Levels 1 through 4 require a password, and allow access to the SET LIMITS, SET STOW, and SET
SV OFFSET menus. (Levels 2 through 4 are functionally equivalent to level 1 on this model and
may be disregarded.)
3. Level 5 requires the factory-assigned password, and allows access to all configuration and security
menus. Level 5 access is required to set or change passwords for security levels 1 through 4.
Table 1 lists configuration menus and the security level needed to make changes.
Table 1
Required
Function Security
Levels
Setting the stow in/stow out sequence 1-5
Setting joint movement limits 1-5
Setting servo offset 1-5
Setting new passwords for security levels 1-4 5
Directly editing master controller memory locations 0-5
All other functions 0-5
Entering or changing the passwords for each level is done via the SECURITY menu, which is
accessed by pressing the 6> SECURITY key in the SETUP menu.
3.2.2 The SET LEVEL Menu: Entering Passwords

Access path: MAIN/SETUP/SECURITY/SET LEVEL

Operation •
SET LEVEL
--------------------------------
Level:1 Inc <5
Password:****
Dec <6
Select <7
Current user's
Privilege Level:0 EXIT <8
--------------------------------
Figure 15 SET LEVEL menu

Menus requiring security levels above 0 (zero) are accessed using a local- or factory-assigned
password. To enter a password, perform the following steps:
1. From the SETUP menu, press the SECURITY <6 key to access the SECURITY menu.
2. From the SECURITY menu, press the 1> SET LEVEL key to display the SET LEVEL menu (Figure
15). The cursor will appear in the Level: field (the current security level is displayed at the bottom
of the screen). To change the current level, press the Inc <5 or Dec <6 keys until the desired level
is displayed. Press the Select <7 key to enter the level.
3. After selecting a security level, the cursor will drop to the first digit of the Password: field,
changing the asterisk (*) to a 0 (zero). Press the 5> Inc or 6> Dec keys until the first number of the
four-digit password appears. Press the Select <7 key to enter the number and move on to the next
password number. Repeat until all four numbers of the password have been entered.
4. Press the Select <7 key once more to enter the password. The Current User’s Security Level: field
will show the new level.
5. Press the EXIT <8 key until you exit to the desired menu.
3.2.3 Setting & Changing Passwords

Access path: MAIN/SETUP/SECURITY/SET PASSWORD
The SET PASSWORD menu allows an operator with the factory-assigned level 5 password to set
or change passwords for security levels 1 through 4. If the SET PASSWORD menu is selected
while in security level 4 or lower, the message “INSUFFICIENT SECURITY LEVEL” appears
below the menu. The password for security level 5 cannot be changed.
To set a password, follow these steps:
1. Ensure that the current security level is 5. (If you aren’t sure what the current level is,
access the SET LEVEL menu (MAIN/SETUP/SECURITY/SET LEVEL) and note the level
displayed on the screen). Enter the level 5 password if necessary.
2. From the SETUP menu, press the 6> SECURITY key.

• Operation
3. From the SECURITY menu, press the 2> SET PASSWORD key to display the SET PASSWORD
menu (Figure 16).
SET PASSWORD
--------------------------------
Level:1 Inc <5
Password:****
Dec <6
Select <7
Current user's
Privilege Level:5 EXIT <8
--------------------------------
Figure 16 SET PASSWORD menu

4. The cursor will appear next to the Level: field. Press the Inc <5 or Dec <6 key until the desired
level is displayed. Press the Select <7 key to enter the level.
5. The cursor will then drop to the first digit of the Password: field. Press the 5> Inc or 6> Dec key to
set the first number of the password. Press the 7> Select key to move on to the next password
digit. Repeat until all numbers of the new password have been entered.
6. Press the EXIT <8 key until you exit to the desired menu.
3.2.4 Setting Slave Arm Movement Limits

Access path: MAIN/SETUP/SET LIMITS
Slave arm joint movements are ultimately limited by the mechanical range of each joint. For the
protection of the slave arm or personnel and equipment within the operational envelope of the
slave arm it is often necessary to software-limit the movement range of slave arm joints. The
software set limits for each joint (excluding the wrist and jaw) are configured in the SET LIMITS
menu (Figure 17).
SET LIMITS FRZ

--------------------------------
COUNT:01 Last <5
LIMIT: Next <6

AZI LEFT
Teach <7
EXIT <8
--------------------------------
Figure 17 SET LIMITS menu

Operation •
Accessing the SET LIMITS menu requires a security level of 1 or higher. If the SET LIMITS menu
is selected while in security level 0 (zero), the message “INSUFFICIENT SECURITY LEVEL”
appears below the menu.
To set movement limits for individual slave arm joints, follow these steps:
1. Ensure that the current security level is 1 or higher. If you aren’t sure what the current
level is, display the SET LEVEL menu (MAIN/SETUP/SECURITY/SET LEVEL) and note
the level displayed on the screen. Enter a 1 or higher security level password if necessary.
2. From the SETUP menu, press the 1> SET LIMITS key to display the SET LIMITS menu.
! Caution
While the SET LIMITS menu is open, slave arm joints are capable of
full mechanical travel. Previously set limits (if retained) or newly set
limits will not engage until you have exited from the SET LIMITS
menu.
3. The SET LIMITS menu will identify the joint function by a number (in the COUNT: field) and the
function description (in the LIMIT: field) for the limit being set. The sequence of joint functions
and their corresponding numbers are shown in Table 2. (There are no movement limits for the
wrist and jaw.)
As the table shows, the azimuth left limit is the first function in the sequence. The
COUNT: field will display 1, while the LIMIT: field will display AZI LEFT.
Table 2
SET LIMITS Sequence

Joint Travel Limit Limit No.
Azimuth Yaw LEFT 01
RIGHT 02
Shoulder Pitch DOWN 03
UP 04
Elbow Pitch DOWN 05
UP 06
Pitch DOWN 07
UP 08
Yaw LEFT 09
RIGHT 10
4. Unfreeze the arm by pressing the master arm freeze button. Move the slave arm to the farthest left
desired position for the azimuth function. To set this limit close to the mechanical limit, move the
azimuth gently to the limit, then slightly back. All movement limits should be at least slightly less
than the mechanical limits.
5. Press the Teach <7 key to enter that position as the limit. The counter will automatically
increment to the next function/number.
6. Repeat steps 4 and 5 to set limits for the remaining joints. You may return to and reteach a
previous limit by pressing the Last <5 key until the desired function appears on the screen. You

• Operation
may skip functions by pressing the Next <6 key instead of Teach <7. If you do this, the existing
limit setting for the skipped function will be retained when you exit the SET LIMITS menu.
7. When all limits have been set, move the arm to any position inside the new limits, freeze the slave
arm, and press the EXIT <8 key. The new or retained movement limits will be saved. (If you have
positioned any joint outside these limits, the arm will move to a position within the limits the next
time the arm is unfrozen.)
8. You should immediately test the new limits to ensure that the slave arm’s range of movement is
acceptable. Use caution near equipment until you are certain that the new limits prevent
collisions.
3.2.5 Setting the Stow In/Stow Out Sequence

Access path: MAIN/SETUP/SET STOW
SET STOW FRZ

--------------------------------
POINT:03 Last <5
Next <6
Teach <7
Last Stow
4> Point:05 EXIT <8
--------------------------------
Figure 18 SET STOW menu

The stow in/stow out path is a sequence of up to 16 fixed slave arm points (or positions) that the
operator selects in the SET STOW menu (Figure 18). The stow in/stow out sequence can be reset
at any time to accommodate changes in operational needs or the operating environment.
The stow in/stow out sequence is used in the STOW OUT menu (automatically displayed as part
of the startup process) and the SHUT DOWN menu. In either menu, when the Stow Out <5 key is
pressed, the slave arm moves from its stow in position to its stow out position; when the Stow In
<6 key is pressed, the slave arm first moves to the stow out position and then moves to the
stowed in position.
In planning a stow in/stow out sequence for your manipulator system, the following factors
should be considered:
 You can issue a command to stop the slave arm at any time during the sequence,
but the slave arm will continue to move until it reaches the next programmed
point in the sequence. A stow in/stow out sequence with more points can be
stopped sooner.
 Be sure to program enough points into the sequence to guide the slave arm
around obstacles and equipment.
To set a new stow in/stow out sequence, follow these steps:

Operation •
1. Set the security level to 1 or higher.
2. Access the SET STOW menu (Figure 18 on page 44): MAIN/SETUP/SET STOW.
— The POINT field opens to the 01 (Stow In) point.
3. Press the 4> Last Stow Point:... key to change the number of points you want to use for the path
sequence.
 POINT 01 = the Stow In position.
 Last Stow Point = the final Stow Out position.
 Select any number of points between 2 and 16 to reach the Stow Out point.
4. Unfreeze the arm.
5. Move the arm to the desired Stow In point (01). Press Teach<7 to record the position. The POINT:
field will increment to the next point.
NOTE: Slave arm travel limits set in the SET LIMITS menu will apply to and limit fu-
ture changes to settings in the SET STOW menu. Existing stow settings are not affected.
6. Move the slave arm to the next position and press Teach<7. Repeat this step to record each point
in the stow sequence.
— Last<5 key = return to a previous point and reteach.
— Next<6 key = skip ahead. Skipped points retain existing settings.
— The last point taught = the final Stow Out point.
7. After recording the last point, press the EXIT <8 key to save the recorded path.
3.2.6 Enabling and Disabling System Error Checking

Access path: MAIN/SETUP/SET ERR CHECKS
Security level: 0 (zero) or higher
SET ERR CHECKS LOCK

--------------------------------
[01]Contin
Change <5
Check:ENA
2> Last Disable all <6
3> Next Enable all <7
4> Save as default EXIT <8

--------------------------------
Figure 19 SET ERR CHECKS menu

The set error checks function allows you to selectively enable and disable monitoring of Control,
Continuity and Telemetry errors. (Timeout errors cannot be disabled.) Normally, all system error
monitoring should be left enabled so that operational faults will shut down the slave arm and
prevent damage to the arm or its surroundings. However, there may be circumstances where

• Operation
uninterrupted operation of the arm is necessary despite a known fault (such as a faulty position
sensor), to diagnose a fault, or because collisions or extreme loads are likely to cause repeated
system shutdowns. Good judgment is a necessity: error monitoring exists to protect the slave
arm (and its surroundings) from damage. An automatic shutdown due to error checking indi-
cates the slave arm is at risk. Disabling error checking indicates the operator's awareness and
acceptance of increased risk.
See “Diagnosing & Resetting System Errors” section on page 50 for a detailed description of the
four types of system errors.
To enable and disable system error checks, follow these steps:
1. From the MAIN MENU, select 3> SETUP. The SETUP menu (Figure 13 on page 39) will
appear.
2. From the SETUP menu, press the 4> SET ERR CHECKS key to display the SET ERR CHECKS
menu (Figure 19).
The system error type and its current status will appear in the upper left of the screen. The three
error types that can appear are:
 [01] Contin (Continuity)
 [02] Control
 [03] Telem (Telemetry)
The type 04 error, Timeout, cannot be disabled and thus does not appear in this menu.
The flag in the Check: field specifies whether or not the selected error check is enabled (ENA) or
disabled (DIS). Enabled, an occurrence of the error type will cause a system error condition and
a resulting shutdown of the slave arm hydraulics. Disabled, errors of this type will not result in a
shutdown and the system will continue operating. (The condition causing the error may result in
limited or erratic performance of the slave arm, however.)
3. To view and set the other error types, press 2> Last and 3> Next until the desired error type is
displayed.
4. To enable or disable checking for the displayed error type, press the Change <5 key to toggle the
Check: flag between ENA and DIS. To disable checking for all error types, press the Disable all <6
key. To enable checking for all error types, press the Enable all <7 key.
5. If you wish the changes to error checking to be temporary (lasting for the current session only),
you can exit the SET ERR CHECKS menu by pressing the EXIT <8 key. If you want the changes to
be permanent (until changed again), press the 4> Save as default key.
Press the EXIT <8 key to exit the SET ERR CHECKS menu.
3.2.7 Set SV Offset

Use of this menu is described in “Adjusting Servo Valve Offsets” on page 19 in the “Maintenance
& Service” chapter.
3.2.8 Memory
This menu should only be used under direction from factory service personnel.

Operation •
4 System Fault & Error Diagnosis
Access path: MAIN/DIAGNOSE
DIAGNOSTICS LOCK
--------------------------------
1> MASTER
2> SLAVE
3> SHOW ERRORS
EXIT <8
--------------------------------
Figure 20 DIAGNOSTICS menu

The DIAGNOSTICS menu (Figure 20) provides access to menus that display system diagnostic
information. The options under this menu can be used to diagnose faults in the slave arm posi-
tion sensors, master arm and master controller, and to display, reset, and configure system error
checking.
To enter the DIAGNOSTICS menu, press the 4> DIAGNOSE key from the MAIN menu (Figure
20 on page 47).
4.1 Diagnosing Problems

 If the master arm is not properly responding to control inputs, proceed to “Diag-
nosing Master Arm Joint Problems” section on page 47.
 If you suspect that one or more of the master controller keys, or the master arm
freeze button is not working properly, proceed to “Diagnosing Master Controller
Key & Freeze Button Failures” section on page 48.
 If you suspect that the slave arm is not properly positioning itself, or that the cor-
respondence between the master arm and the slave arm is not accurate, proceed
to “Diagnosing Slave Arm Positioning Failures” section on page 49.
 If the slave arm has frozen automatically and an ERR flag is appearing in the top
line of the LCD display, proceed to “Diagnosing & Resetting System Errors” sec-
tion on page 50.
4.1.1 Diagnosing Master Arm Joint Problems

Access path: MAIN/DIAGNOSE/MASTER
Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST screen
(Figure 21). The slave arm is automatically locked in this menu, allowing the master arm to be
safely moved for diagnostic purposes.
011–0914 System Fault & Error Diagnosis • Page 47

• Operation
MASTER TEST LOCK

--------------------------------
Position: Jaw Bands:
Azi +0120 -0021
Sho +0415 +0004
Elb -1021
Pit -0045
Yaw +0924
Wrs +1011
Keys:00000100000000 EXIT <8
--------------------------------
Figure 21 MASTER TEST menu

For this procedure, you will be viewing the values displayed for each joint in the Position: col-
umn and the jaw bands in the Jaw Bands: column. A value of 0 (zero) indicates that the joint is at
the approximate midpoint of its range of motion. Positive values indicate movement either up, to
the right, or clockwise (when the master arm is viewed from behind); negative numbers indicate
movement down, to the left, or counterclockwise. The two jaw band values will jump from a very
low (near-zero) value to a very high (1000 or more) value when squeezed.
If a master arm joint is not being moved, the position value should either not change or should
fluctuate only slightly. A changing position value for an immobile joint probably indicates a fail-
ure in a master arm potentiometer or a master controller printed circuit board. Conversely, a
position value that does not change or changes only slightly when the joint is moved also indi-
cates a failure of this type.
Apparent discontinuity in master arm data (for example, a slight movement of a master arm
joint causes a large change in position data, or vice versa) may indicate a failed master arm joint
potentiometer.
4.1.2 Diagnosing Master Controller Key & Freeze Button Failures

Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST screen
(Figure 21 on page 48). For this diagnostic procedure, you will be viewing the binary values (0 or
1) in the Keys: field.
The digits in this field display the status of each key and the freeze button, which lets you diag-
nose problems with master controller keys or the master arm freeze button.
Each digit in this field corresponds to one key or to the freeze button. If the key or button is oper-
ating correctly, the character for that key or button will be 0 (zero) when it is not being pressed
and 1 when it is pressed. If a failure has occurred, the display will show the same value for the
corresponding digit whether the key or button is pressed or not.
Use Table 3 to identify the functions in the Keys: field. In this table, the “character position” col-
umn indicates how far from the left the character is. (For example, the eleventh character from
the left shows the status of the down key.)
Page 48 • System Fault & Error Diagnosis 011–0914

Operation •
Table 3
Keys & Freeze Button Guide

Character
Position Function
(from left)
1 Function key 1
2 Function key 2
3 Function key 3
4 Function key 4
5 Up key (UP)
6 Left key (LF)
7 Left master arm freeze button (functional in
dual-arm systems only)
8 Master arm freeze button (in dual-arm sys-
tems, for the right master arm only)
9 Function key 5
10 Function key 6
11 Down key (DN)
12 Right key (RT)
13 Function key 8
4.1.3 Diagnosing Slave Arm Positioning Failures

Access path: MAIN/DIAGNOSE/SLAVE
Press the 2> SLAVE key in the DIAGNOSTICS menu to display the SLAVE TEST screen (Figure
22).
The slave arm will be frozen when you enter this menu (while the slave arm is frozen, master arm
position values are not read, so the display will not change as you move the master arm). Press
the master arm freeze button to unfreeze it and evaluate the master arm to slave arm positioning
correspondence:
When the master arm is moved, the master arm position values in the Cmd: (command) column
should change as rapidly as the arm is moved. (If they do not, you should evaluate the master
arm’s performance as described in “Diagnosing Master Arm Joint Problems” section on page 47)
The values in the Fdbk: (feedback) column, representing the position sensor information from
the slave arm, should catch up with the Cmd: values whenever the movement of the master arm
is halted. Although the values in the Diff (difference) column may reach the high hundreds when
the master arm is moved quickly, they should drop to single digits (indicating close correspon-
dence between the master and slave arm positioners) whenever the master arm is not being
moved.
If a large difference between the command and feedback values persists (for example, a value
greater than 25 in the difference column), check the servo offset value for that joint. (Refer to the

• Operation
“Maintenance & Service” chapter for details.) If the servo offset is properly nulled, or cannot be
nulled, a faulty slave arm position sensor is most likely at fault.
Since the wrist and jaw have no position sensors, no feedback or difference values are displayed
for these joints.
SLAVE TEST FRZ

--------------------------------
Cmd: Fdbk: Diff:
Azi: +0101 +0099 -0002
Sho: +0427 +0427 +0000
Elb: -0005 -0010 +0005
Pit: +0026 +0026 +0000
Yaw: +0900 +0924 +0024
Wrs: -1025
Jaw: +0036
EXIT <8
--------------------------------
Figure 22 SLAVE TEST screen
4.1.4 Diagnosing & Resetting System Errors

Access path: MAIN/DIAGNOSE/SHOW ERRORS
All menus are accessible at security level 0 (zero).
Press the 3> SHOW ERRORS key in the DIAGNOSTICS menu to display the SHOW ERRORS
screen (Figure 23).
SHOW ERRORS ERR LOCK

--------------------------------
ERRORS: Clr Errs <5
CONTROL [S,P]
Warnings: Update <6
Hydr OFF
Hydr On <7
EXIT <8
--------------------------------
Hydr OFF
Figure 23 SHOW ERROR menu

If the ERR flag has appeared in the top line of all menus, the system error information will
appear on the left side of the display. If there is no system error, or if the Clr Errs <5 key has been
pressed, “No Errors” will appear instead. There are four error types that may appear in this
screen:
 Control errors indicate there is a large difference between the actual and com-
manded position. The Control flag will be followed by one or more letters in

Operation •
brackets, which indicate the joint or joints experiencing control errors (Azimuth,
Shoulder, Elbow, Pitch, and Yaw). In addition to system errors, collision, driving
the slave arm against an immovable object, or an extreme load may also trigger a
control error.
 Continuity errors indicate that a joint position sensor reported an unexpectedly
large position change in a short time. This error may indicate that the sensor has
failed, or that an external force, such as a collision or an extreme or immovable
load) has pushed the joint out of position. The Contin flag will be followed by one
or more letters in brackets, indicating the joint or joints experiencing continuity
errors (azimuth, shoulder, elbow, pitch, and yaw).
 Telemetry errors occur when the master controller loses contact with one or more
actuator control modules. This error may be caused by faulty position sensor, by a
faulty connection between the master controller and the slave arm, or by a failure
of the slave arm base module. The Telem flag will be followed by one or more let-
ters in brackets, indicating the source of the error (azimuth, shoulder, elbow,
pitch, yaw, wrist, jaw, base module).
 Timeout errors occur when the slave arm base module receives no communica-
tions for 500 milliseconds (one-half second) or longer. This error may be caused
by a failure of electrical power to the slave arm base module, or by a faulty con-
nection between the master controller and the base module.
To clear a system error condition, press the Clr Errs <5 key. New control, continuity, telemetry
and timeout errors will not generate a new display. If the ERR flag reappears in the top line of
the menu, press the Update <6 key to display the new errors.
All except timeout errors may be disabled in the SET ERROR CHECKS menu. See “Enabling &
Disabling System Error Checking” for details.
Some errors may be followed by warnings. The most common warning is that slave arm hydrau-
lics have been disabled (for safety reasons). When the error has been corrected, slave arm
hydraulics may be re-enabled by pressing the Hydr On <7 key.
Press the EXIT <8 key to exit the SHOW ERRORS menu.
4.1.5 Enabling & Disabling System Error Checking

The Set Error Checks function allows you to selectively enable and disable monitoring of Control,
Continuity and Telemetry errors. (Timeout errors cannot be disabled.) Normally, all system error
prevent damage to the arm or its surroundings. However, there may be circumstances where
uninterrupted operation of the arm is necessary despite a known fault (such as a faulty position
sensor), to diagnose a fault, or because collisions or extreme loads are likely to cause repeated
system shutdowns.
Good judgment is a necessity: error monitoring exists to protect the slave arm (and its surround-
ings) from damage. An automatic shutdown due to error checking indicates the slave arm is at
risk. Disabling error checking indicates the operator's awareness and acceptance of increased
risk.

• Operation
See “Diagnosing & Resetting System Errors” section on page 50 for a detailed description of the
four types of system errors.
1. From the MAIN MENU, select 3> SETUP. The SETUP menu will appear.
2. From the SETUP menu, press the 4> SET ERR CHECKS key to display the SET ERR CHECKS
menu (Figure 24).
SET ERR CHECKS LOCK

--------------------------------
[01]Contin
Change <5
Check:ENA

--------------------------------
The system error type and its current status will appear in the upper left of the screen. The three
 [02] Control
The type 04 error, Timeout, cannot be disabled and thus does not appear in this menu.
disabled (DIS). Enabled, an occurrence of the error type will cause a system error condition and
a resulting shutdown of the slave arm hydraulics. Disabled, errors of this type will not result in a
shutdown and the system will continue operating. (The condition causing the error may result in
limited or erratic performance of the slave arm, however.)
3. To view and set the other error types, press 2> Last and 3> Next until the desired error type is
displayed.
4. To enable or disable checking for the displayed error type, press the Change <5 key to toggle the
Check: flag between ENA and DIS. To disable checking for all error types, press the Disable all <6
key. To enable checking for all error types, press the Enable all <7 key.
5. If you wish the changes to error checking to be temporary (lasting for the current session only),
you can exit the SET ERR CHECKS menu by pressing the EXIT <8 key. If you want the changes to
be permanent (until changed again), press the 4> Save as default key.

Troubleshooting
In This Chapter:
• 1 Diagnostic Approaches .................................................. page 53
• 2 Troubleshooting Tables .................................................. page 54
• 3 System Fault & Error Diagnosis ...................................... page 60
• 4 Electrical Component Diagnosis ...................................... page 68
• 5 Factory Assistance ........................................................ page 75
1 Diagnostic Approaches
This chapter has three main troubleshooting sections, each with a different diagnostic format or
method:
 Troubleshooting Tables:
Use these tables to diagnose observable performance or the behavior of major
slave arm or system components.
 System Fault and Error Diagnosis:
Use the master controller’s diagnostic menu to troubleshoot slave arm perfor-
mance and control malfunctions.
 Electrical Component Diagnosis:
Discusses symptoms and troubleshooting within the context of individual electri-
cal and control components.
The essential materials in each section are interrelated in many ways and it is worth becoming
familiar all of them. Then, if a satisfactory diagnosis cannot be achieved using one format,
another one is readily available.
Since major manipulator system components are interactive, the component that displays a
symptom may or may not be the cause of the malfunction. To narrow the field of possible causes,
regardless of your diagnostic approach, first eliminate those that are the easiest to check or cor-
rect:
1. Thoroughly inspect all system components for obvious faults or damage (damaged or
disconnected cables, hydraulic leaks, etc.
2. Make sure components are receiving the specified electrical power:
a. The junction box is connected to an electrical power source, the power switch is on,
and the fuse is intact.
b. If you are not using the junction box, check that the master controller and base
controller are connected to an appropriate power source.
011–0915 Page 53
• Troubleshooting
c. If the base controller is powered by a separate or local source, make sure the power
source is operational and that power is reaching the cable connector at the base
controller.
Correct electrical supply problems before continuing diagnostics.
3. Make sure the base controller is receiving the specified hydraulic power:
a. Supply pressure/flow and return pressure are within the specified range.
b. Isolation valve is working (sounds/hose twitch).
c. The HPU reservoir is full and the filters are clean.
Correct hydraulic supply and return problems before continuing diagnostics.
4. Test electrical cables for continuity, shorts, and insulation resistance, or substitute with known
functional spare cables.
5. Use the master controller’s DIAGNOSTICS menu to eliminate or isolate telemetry malfunctions.
6. Substitute new or known functional spares for easily accessible suspect components.
Remedy or rule out each possible cause of the malfunction until the source is isolated.
2 Troubleshooting Tables
The troubleshooting tables are organized by major component:
 Master controller screen
 Master arm
 Entire slave arm
 Individual slave arm joints
References within each table may direct you to other sections in this chapter providing addi-
tional information or diagnostic tools for determining the cause and correction of a malfunction.
2.1 Screen-Displayed Symptoms

The master controller displays present diagnostic data, warning, and error screens to help you
diagnose symptoms, and alerts you to other abnormal conditions.
Use Table 1 to troubleshoot screen-displayed symptoms.
Table 1
Screen-Displayed Symptoms
Symptom Possible Cause Remedy
Master controller power is on, but the Transient electrical problem. Turn master controller
screen display is blank. power switch off, then on.
Loose connection to the face- Secure connection.
plate assembly.
LCD display screen failure. Replace display.
Master processor PCB failure. Replace board.
Master controller display Replace board.
board failure.
Page 54 • Troubleshooting Tables 011–0915

Troubleshooting •
Screen-Displayed Symptoms (cont.)

Error flag appears on the screen. (see “System Fault & Error Diagnosis” section on page
60)
Message Fatal telemetry error appears on (see “Diagnosing & Resetting System Errors” section on
the screen. page 65)
Pressing a key does not execute the appro- Contaminated key switch Clean key switch contacts.
priate function; master arm data screen contacts.
confirms that key failure has occurred (see Master processor PCB failure. Replace board.
“Diagnosing Master Controller Key & Freeze
Button Failures” section on page 64). Keypad gasket failure. Replace keypad gasket.
Keypad switch board failure. Replace board.
On MASTER TEST screen, position data for Master processor PCB failure. Replace board.
one joint changes even though the joint is Master arm potentiometer Replace master arm.
not moving (also see “Diagnosing Prob- failure.
lems” section on page 62).
On MASTER TEST screen, position data for Loose connection to PC Secure connection.
multiple joints changes even though the board.
joints are not moving (also see “Diagnosing Master processor PCB failure. Replace board.
Problems” section on page 62).
Defective master arm. Replace master arm.
On SLAVE TEST screen, position data for Loose position sensor con- Secure connection.
one or more joint changes even though the nection.
slave arm is frozen (also see“Diagnosing Position sensor failure. Replace sensor.
Slave Arm Positioning Failures” section on
page 63). Slave controller PC board Replace board.
failure.
On SLAVE TEST screen, position data for all Slave controller PC board Replace board.
joints changes even though the slave arm failure.
is frozen (also see“Diagnosing Slave Arm
Positioning Failures” section on page 63).
On SLAVE TEST screen, position data for Mechanical interference with Inspect joint and remove
one joint at its hard stop is not within range joint. debris.
of the corresponding value in Table 4 on Loose position sensor con- Secure connection.
page 58 (also see “Diagnosing Slave Arm nection.
Positioning Failures” section on page 63).
Position sensor failure. Replace sensor.
Slave controller PC board Replace board.
failure.
On SLAVE TEST screen position data for Slave controller analog board Replace board.
multiple joints at their hard stops are not failure.
within ranges of the corresponding values Slave controller PC board Replace board.
in Table 4 on page 58 (also see “Diagnosing failure.
Slave Arm Positioning Failures” section on
page 63).
2.2 Master Arm Symptoms

If the problem affects one or more slave arm joints, see “Using the DIAGNOSTICS Menus” on
page 62 for information on determining whether a master arm or slave joint is at fault.
If you have identified a joint problem using the master arm data display, see Table 2 on page 56,
for fault isolation information.
011–0915 Troubleshooting Tables • Page 55

• Troubleshooting
Table 2
Master Arm Symptoms

Master arm freeze button works Master arm wiring failure or freeze Replace master arm.
intermittently or not at all. button failure.
Master processor PCB failure. Replace board.
Wrist collar does not actuate slave Master processor PCB failure. Replace board.
arm wrist. Wrist collar failure. Replace master arm.
Base controller analog board failure. Replace board.
Wrist potentiometer failure. Replace potentiometer.
Wrist servo valve failure. Replace servo valve.
Actuator controller board failure. Replace board.
Pressing jaw bands/jaw switch Master processor PCB failure. Replace board.
does not actuate slave arm jaw. Jaw band failure. Replace master arm.
Jaw switch failure. Replace jaw switch.
Base controller analog board failure. Replace board.
Jaw servo valve failure. Replace servo valve.
2.3 Slave Arm Behavior Defined

The following tables use the terms below to describe slave arm behavior.
— Unresponsive: Does not respond to control input.
— Sluggish: Responds predictably but slowly to control input.
— Erratic: Responds unpredictably to control input.
— Sagging: Fails to remain in position in the absence of control input.
— Hard over: Locked firmly against limit of mechanical travel.
2.4 Entire Slave Arm Symptoms

Use Table 3 to troubleshoot problems that affect all slave arm joints. If only one joint is affected,
see Table 4 on page 58.

Troubleshooting •
Table 3
Entire Slave Arm Symptoms

Slave arm is unrespon- Damaged wiring or loose con- Check cable/connectors for continuity and
sive. nection in any cable between shorts. Check connections.
master controller and slave arm.
Electrical power failure to mas- Restore electrical power. Check cables and
ter controller or base controller. connectors for continuity.
Blown fuses in master controller, Determine and repair cause. Replace with
junction box, or base controller. new fuse (base controller fuses are auto-
resetting and non-replaceable).
Master arm or master processor (see Table 2 on page 56)
PCB failure
Supply solenoid valve failure. Replace solenoid valve.
Very low or no hydraulic pres- Restore electrical power to HPU.
sure and/or flow. Adjust or repair HPU.
Reservoir low. Add hydraulic fluid.
Filters clogged. Clean or replace.
Blocked, pinched, or kinked sup- Clear, reposition, or protect hoses to
ply or control hoses. ensure free flow.
Load exceeds slave arm capac- Reduce load. Use shoulder joint to lift
ity. heavy loads.
Slave arm is receiving Supply solenoid valve failure. Replace/repair solenoid valve.
hydraulic power even Base module analog board fail- Replace board.
though disabled by ure.
master controller. TURN
OFF HPU IMMEDIATELY!
Entire slave arm is Intermittent fault in cables, Substitute components.
erratic. master controller, or base con-
troller.
Damaged slave arm wiring har- Replace wiring harness.
ness.
Base module CPU board failure. Replace board.
Air in hydraulic lines. Bleed hydraulic system.
Low hydraulic fluid level (possi- Add hydraulic fluid. Increase HPU fluid
bly intermittent). capacity.
High HPU demand (steady or Reduce or stage HPU demand, or increase
intermittent). HPU capacity.
Partially blocked, pinched, or Clear, reposition, or protect hoses to
kinked supply or control hoses. ensure free flow.
Intermittent electrical power to Check power supply, cables, and connec-
HPU, master controller, or base tors.
controller.

• Troubleshooting
Entire Slave Arm Symptoms (cont.)

Entire slave arm is slug- Low hydraulic pressure/flow. Adjust or repair HPU.
gish. Fluid level low. Add hydraulic fluid.
Filters clogged. Clean or replace.
Partially blocked, pinched, or Clear, reposition, or protect hoses to
kinked supply or control hoses. ensure free flow.
Excessive demand on HPU Turn off other hydraulic equipment,
reduce or stage HPU demand, or increase
HPU capacity.
Control or supply hoses not Increase hose diameter to provide ade-
sized for distance from mani- quate pressure and flow to slave arm.
fold.
Hydraulic fluid dirty, contami- Replace fluid if dirty, contaminated, or
nated or incorrect type or vis- incorrect type or viscosity. Install heater
cosity, temperature too high or or cooler to keep viscosity within specifi-
too low to maintain viscosity. cation.
Load at or near slave arm Reduce load. Use shoulder joint to lift
capacity. heavy loads.
Severe hydraulic leak. Repair leak source.
2.5 Slave Arm Joint Symptoms

Use Table 4 to troubleshoot problems that affect one or more joints. If all joints are affected, see
Table 3 on page 57.
See “Diagnosing Master Arm Joint Problems” on page 62 for information on determining
whether a slave arm joint symptom is actually being caused by the master arm.
Table 4
Slave Arm Joint Symptoms

Joint leaks hydraulic Actuator/hose leak (from any slave Replace actuator seals. Tighten or
fluid. arm actuator). replace hose.
One or more joints are Master arm potentiometer or master (see Table 2 on page 56)
hard over. controller board problem
Servo valve failure. Replace servo valve.
Actuator potentiometer failure. Replace potentiometer.
Actuator controller board failure Replace board.
Faulty actuator seal or component. Repair or replace actuator seal or
component.

Troubleshooting •
Slave Arm Joint Symptoms (cont.)

One joint is unrespon- Master arm potentiometer or master (see Table 2 on page 56 and “Diag-
sive. controller board failure. nosing Master Arm Joint Problems”
section on page 62)
Joint potentiometer failure. Replace potentiometer.
Incorrect actuator controller board Set correct address.
address.
One joint is erratic. Master arm joint or master controller (see Table 2 on page 56)
board failure.
Joint potentiometer failure. Replace potentiometer.
Incorrect actuator controller board Set correct address.
address.
One joint is sluggish. Servo valve failure. Replace servo valve.
Master arm joint or master processor (see Table 2 on page 56)
PCB failure
Load at or near joint’s capacity near Reduce load. Use shoulder for heavy
limit. loads.
Control hose clogged, pinched, Clear, reposition, protect, or replace
kinked, or leaking. hose to ensure full flow.
Partial failure of actuator seal or com- Repair or replace seal or component.
ponent.
Stuck or faulty relief valve. Repair or replace relief valve.
(Wrist only) Incorrect wrist motor Service wrist joint and set correct
preload. motor preload.
(Wrist only) Excessive return/drain Clear return line. Check for internal
pressure. leak in wrist. Adjust return manifold.
Multiple joints are Master processor PCB failure. Replace board.
unresponsive.
Azimuth, shoulder, or Lock valve failure. Replace lock valve.
elbow sags or moves
freely when hydraulics
are off.
A joint moves when Actuator controller board failure. Replace board.
there is no command
Master arm potentiometer or master (see “Master Arm Symptoms” section
to move.
processor PCB failure. on page 55)
Slave arm joint potentiometer failure. Replace potentiometer.
Incorrect actuator controller board Set correct address (see “Special Ser-
address. vice and Configuration” of the “Main-
tenance and Service” chapter

• Troubleshooting
Slave Arm Joint Symptoms (cont.)

Single joint/actuator Faulty actuator seal or component. Repair or replace actuator seal or
sagging or drifting. component.
Faulty relief valve. Repair or replace relief valve.
Hydraulic leak. Repair leak.
Extreme load on linear actuator or Reduce or balance load. Sagging lin-
unbalanced load on roll actuator. ear actuators or drifting roll joints are
normal with extreme or unbalanced
loads.
3 System Fault & Error Diagnosis

3.1 Control System Orientation
The control of each slave arm function (except the wrist and jaw) utilizes a closed loop, in which
control software compares position feedback from each slave arm joint with operator inputs to
the master controller and directs hydraulic power to the slave arm as needed to achieve corre-
spondence. Control functions are diagrammed in Figure 1 on page 61. Standard Conan control
telemetry is bi-directional and uses an RS-485 serial interface. All slave arm control functions
are connected on a common bus.
Operator inputs to the master controller are generated by moving master arm joints, pressing the
master arm freeze button (to freeze the slave arm in its current position), and squeezing the mas-
ter arm jaw bands or pressing the auxiliary jaw switch (to operate the jaw functions). Each physi-
cal action is translated into a varying analog voltage by the potentiometer in each joint of the
master arm (or by switches for the jaw function).
An A-D (analog to digital) converter in the master controller converts the analog data into a digi-
tal value (or “command”). Then, a digital address for the corresponding slave arm joint is added
to each command and all commands of a given instant are grouped into a packet. This packet is
sent to the base controller and distributed to all the actuator controller boards. Each board is
configured to accept commands with its address and to disregard all others.
Simultaneously with the creation and distribution of digital command values, potentiometers in
each slave arm joint are translating physical positions into varying analog voltages. An analog-
to-digital converter on each actuator controller board converts each joint’s analog data into a
digital value. The actuator controller board then compares the joint's position data with the com-
mand position data sent by the master controller.
If the data are the same, no slave arm joint movement results. If the data are not the same, the
actuator controller board applies a voltage to that joint’s servo valve, causing the servo valve to
release fluid to the appropriate port of its hydraulic actuator. The resulting actuator movement
drives the slave arm joint towards the commanded position. When the joint feedback data corre-
sponds with the position data commanded by the master controller the servo is closed and slave
arm stops moving.
The wrist and jaw do not have a potentiometer to provide position feedback. For the jaw, master
controller commands can only move the jaw in a specific direction (toggle open or closed), move

Troubleshooting •
the jaw as long as a jaw band is squeezed, or the auxiliary jaw switch is pressed (position mode),
or switch the jaw to a software initiated function (clamp mode). Directing the jaw to a specific
position is only possible with visual guidance. Control of the wrist is limited to direction of rota-
tion and speed of rotation.
Diagnostic Feedback Data
Master arm and slave arm digital position data are also provided to diagnostic menus within the
master controller. This information can be displayed on the master controller screen for evaluat-
ing master controller and slave arm problems.
Electrical Power
Source
Analog master arm Digitized slave arm

joint position data command data
Position data for diagnostics

Master Arm Master Controller Junction Box
Electrical power Electrical power
Digitized slave arm command data
Digitized slave arm position data
Electrical power
Digitized slave arm Current to

position data
Slave Controller
control valve Hydraulic Supply
Solenoid Valve
Digitized slave arm command

data & electrical power
Actuator Actuator
Controller Board Controller Board
Current to Current to
control valve control valve
Servo Valve Servo Valve

Analog slave arm joint position data
Electrical power
Hydraulic Hydraulic
fluid fluid
Slave Arm Slave Arm

Hydraulic Hydraulic
Actuator Actuator
Open-Loop Control
(jaw)
Closed-Loop Control
Slave Arm Joint (azimuth, shoulder,
elbow, wrist yaw,
Potentiometer wrist pitch & wrist
roll)
Figure 1 Control system

• Troubleshooting
3.2 Using the DIAGNOSTICS Menus
Access path: MAIN/DIAGNOSE
DIAGNOSTICS LOCK
--------------------------------
1> MASTER
2> SLAVE
3> SHOW ERRORS
EXIT <8
--------------------------------
Figure 2 DIAGNOSTICS menu

The DIAGNOSTICS menu (Figure 2) provides access to menus that display system diagnostic
information. The options under this menu can be used to diagnose faults in the slave arm posi-
tion-sensing potentiometers, master arm, and master controller, and to display, reset, and con-
figure system error checking.
To enter the DIAGNOSTICS menu, press the 4> DIAGNOSE key from the MAIN MENU.
3.3 Diagnosing Problems

 If the master arm or slave arm is not properly responding to operator inputs, pro-
ceed to “Diagnosing Master Arm Joint Problems” section on page 62.
 If you suspect that the slave arm is not properly positioning itself, or that the cor-
respondence between the master arm and the slave arm is not accurate, proceed
to“Diagnosing Slave Arm Positioning Failures” section on page 63.
 If you suspect that one or more of the master controller keys, or the master arm
freeze button is not working properly, proceed to “Diagnosing Master Controller
Key & Freeze Button Failures” section on page 64.
 If the slave arm has frozen automatically and an ERR flag is appearing in the top
line of the LCD display, proceed to “Diagnosing & Resetting System Errors” sec-
tion on page 65.
3.3.1 Diagnosing Master Arm Joint Problems

Access path: MAIN/DIAGNOSE/MASTER TEST

Troubleshooting •
MASTER TEST LOCK

--------------------------------
Position: Jaw Bands:
Azi +0120 -0021
Sho +0415 +0004
Elb -1021
Pit -0045
Yaw +0924
Wrs +1011
Keys:00000100000000 EXIT <8
--------------------------------
Figure 3 MASTER TEST screen

Principal control components in the master arm are the potentiometers measuring joint posi-
tions and the jaw band switch. Failure of these components is likely to be exhibited as problem
with the corresponding joint on the slave arm.
NOTE: Since other system component failures can also affect single slave arm joints,
the problem can be isolated by using the stow or deploy command to move the slave
arm. If the slave arm joint exhibiting a problem moves properly while following the stow
or deploy command, the cause is probably in the corresponding master arm joint.
Use the MASTER TEST display to check the data output of each master arm joint for problems or
inconsistencies. Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER
TEST screen (see Figure 3). The slave arm is automatically locked in this menu, allowing the
master arm to be safely moved for diagnostic purposes. The screen displays the values for each
joint in the Position: column and the jaw bands in the Jaw Bands: column. A value of zero indi-
cates that the joint is at the approximate midpoint of its range of motion. Positive values indicate
movement either up, to the right, or clockwise (when the master arm is viewed from behind);
negative numbers indicate movement down, to the left, or counterclockwise. The two jaw band
values will jump from a very low (near-zero) value to a very high (1000 or more) value when
squeezed.
Carefully observe the position values while the master arm is moving and while it is at rest. A
highly varying position value for an immobile joint or an unvarying position value for a moving
joint indicates a failure in a master arm potentiometer or a master controller printed circuit
board. Other inconsistencies in master arm data (for example, a slight movement of a master
arm joint causes a large change in position data, or vice versa) indicate a failed master arm joint
potentiometer.
3.3.2 Diagnosing Slave Arm Positioning Failures

Access path: MAIN/DIAGNOSE/SLAVE

• Troubleshooting
SLAVE TEST FRZ

--------------------------------
Cmd: Fdbk: Diff:
Azi: +0101 +0099 -0002
Sho: +0427 +0427 +0000
Elb: -0005 -0010 +0005
Pit: +0026 +0026 +0000
Yaw: +0900 +0924 +0024
Wrs: -1025
Jaw: +0036
EXIT <8
--------------------------------
Figure 4 SLAVE TEST screen

Press the 2> SLAVE key in the DIAGNOSTICS menu to display the SLAVE TEST screen (see Fig-
ure 4).
The slave arm is frozen when this menu opens. Pressing the master arm freeze button allows the
master arm position Cmd (command) data to be read and displayed, allows the master arm to
direct the slave arm, and displays position Fdbk (feedback) from the potentiometers in the slave
arm actuators. The difference between the position commanded by the master arm and the
actual position of the slave arm is shown in the Diff (difference) column of the display.
The values in the Cmd: column should change as rapidly as the master arm is moved. (If they do
not, you should evaluate the master arm’s performance as described in “Diagnosing Master Arm
Joint Problems” on page 62) The values in the Fdbk: column should catch up with the Cmd: val-
ues whenever the movement of the master arm is halted. The values in the Diff (difference) col-
umn may reach the high hundreds when the master arm is moved quickly, but should drop to
single digits (indicating close correspondence between the master and slave arm positioners)
whenever the master arm is not being moved. A changing feedback value when the slave arm is
frozen indicates a failure of a slave arm potentiometer or actuator control board.
If a large difference between the command and feedback values persists (greater than 25 in the
Diff column) when the master arm is at rest, the servo offset value for that joint may need adjust-
ment. (Refer to the “Maintenance & Service” chapter for details.) If the servo offset is properly
nulled (and the high Diff values remain) or the offset cannot be nulled, a faulty slave arm posi-
tion sensor is most likely at fault.
The jaw has no position sensor, so no Fdbk or Diff values can be displayed for this function.
3.3.3 Diagnosing Master Controller Key & Freeze Button Failures

All menus are accessible at security level 0 (zero).
Press the 1> MASTER key in the DIAGNOSTICS menu to display the MASTER TEST screen (see
Figure 3 on page 63). For this diagnostic procedure, you will be viewing the binary values (0 or 1)
in the Keys: field.

Troubleshooting •
The status of each key and the freeze button is shown at the bottom of the display. Each charac-
ter on the display corresponds to a key or to the freeze button. If the key or button is operating
correctly, the character for that key or button will be “0” when it is not being pressed and “1”
when it is pressed. If a failure has occurred, the display will show either “0” or “1” both when the
key or button is pressed and when it is not.
Use Table 5 to identify the functions in the Keys: field. In this table, the “character position” col-
umn indicates how far from the left the character is. (For example, the eleventh character from
the left shows the status of the down key.)
Table 5
Keys & Freeze Button Identification

Character
Position Function
(from left)
1 Function key 1
2 Function key 2
3 Function key 3
4 Function key 4
5 Up key (UP)
6 Left key (LF)
7 Left master arm freeze button (functional in dual-arm systems only)
8 Master arm freeze button (in dual-arm systems, for the right master
arm only)
9 Function key 5
10 Function key 6
11 Down key (DN)
12 Right key (RT)
13 Function key 8
3.3.4 Diagnosing & Resetting System Errors

Access path: MAIN/DIAGNOSE/SHOW ERRORS
System errors are announced with an ERR flag in the top line of all menus. Press the 3> SHOW
ERRORS key in the DIAGNOSTICS menu to access the SHOW ERRORS menu (see Figure 5)
and display system error information (left side of screen). Control, continuity, and telemetry
errors are identified by joint or function using the following letter code:
— A = Azimuth
S = Shoulder
E = Elbow
P = Pitch
Y = Yaw
W = Wrist

• Troubleshooting
J = Jaw
B = Base module
SHOW ERRORS ERR LOCK

--------------------------------
ERRORS: Clr Errs <5
Telem [A,S,E,P,Y,W,J,B]
Timeout
Warnings: Update <6
Hydr OFF
Hydr On <7
EXIT <8
--------------------------------
Hydr OFF
Figure 5 SHOW ERROR menu

If no system error exists, or if the Clr Errs <5 (clear errors) key has been pressed, “No Errors”
will appear instead. There are four system error types that may appear in this screen:
 Control errors indicate that the system is unable to accurately control one or more
joints. The Control flag will be followed by one or more letters in brackets indicat-
ing the joints with control errors. Control errors may be triggered by conditions
within the manipulator control system or by collision, driving the slave arm
against an immovable object, or an extreme load.
 Contin (continuity) errors indicate that a joint potentiometer reported an unex-
pectedly large position change in a short time. This error may indicate that the
sensor has failed, or that an external force, such as a collision or an extreme or
immovable load) has pushed the joint away from its commanded position. The
Contin flag will be followed by one or more letters in brackets, indicating the
joints experiencing continuity errors.
 Telem (telemetry) errors occur when the master controller loses contact with one
or more joint potentiometers. This error may be caused by faulty potentiometer,
actuator control board, a faulty connection or cable anywhere between the master
controller and the slave arm, or by a failure of other base controller circuitry. The
Telem flag will be followed by one or more letters in brackets, indicating the
source of the error.
 Timeout errors occur when the slave arm base controller receives no communica-
tions for 500 milliseconds (one-half second) or longer. This error may be caused
by a failure of electrical power to the base controller, or by a faulty connection
somewhere between the master controller and the base controller.
To clear a system error condition, press the Clr Errs <5 key. New or continuing control, continu-
ity, telemetry and timeout errors will cause to ERR flag to be displayed in the top line of the
menu but won’t automatically generate a new display in the SHOW ERRORS menu. Press the
Update <6 key to display any new errors.
All except timeout errors may be disabled in the SET ERROR CHECKS menu. See “Diagnosing &
Resetting System Errors” section on page 65 for details.

Troubleshooting •
Some errors may be followed by warnings. The most common warning is that slave arm hydrau-
lics have been disabled (for safety reasons). Slave arm hydraulics may be re-enabled by pressing
the Hydr On <7 key.
Press the EXIT <8 key to exit the SHOW ERRORS menu.
3.3.5 Enabling and Disabling System Error Checking

All menus are accessible at security level 0 (zero)
The SET ERR CHECKS menu allows you to selectively enable and disable monitoring of control,
continuity and telemetry errors. (Timeout errors cannot be disabled.) Normally, all system error
prevent damage to the arm or its surroundings.
! Caution
Error checking may be disabled when uninterrupted operation of the
arm is necessary despite a known fault (such as a faulty potentiome-
ter), to diagnose a fault, or because collisions or extreme loads are
likely to cause repeated system error shutdowns.
Good judgment is a necessity: error monitoring exists to protect the
slave arm and its surroundings from damage. An automatic shutdown
because of a system error indicates the slave arm is at risk. In dis-
abling error checking the operator accepts responsibility for increased
risk.
1. From the MAIN MENU, press the 3> SETUP key. From the SETUP menu press the 4>
SET ERR CHECKS key to display the SET ERR CHECKS menu (see Figure 6).
SET ERR CHECKS LOCK

--------------------------------
[01]Contin
Change <5
Check:ENA

--------------------------------

2. The system error type and its current status will appear in the upper left of the screen. The three
 [02] Control

• Troubleshooting
The type 04 error, timeout, cannot be disabled and thus does not appear in this menu. See “Diag-
nosing & Resetting System Errors” section on page 65 for a detailed description of the four types
of system errors.
disabled (DIS). Enabled, an occurrence of the error causes a system error condition and a shut-
down of the slave arm hydraulics. Disabled, errors do not result in a shutdown and the system
can continue to be operated. (The condition causing the error remains, however, and the opera-
tor should anticipate limited or erratic performance of the slave arm.)
 To view and set the other error types, press 2> Last and 3> Next until the desired
error type is displayed.
 To enable or disable checking for the displayed error type, press the Change <5
key to toggle the Check: flag between ENA and DIS. To disable checking for all
error types, press the Disable all <6 key. To enable checking for all error types,
press the Enable all <7 key.
 If you want the changes to error checking to be temporary (lasting for the current
session only), exit the SET ERR CHECKS menu by pressing the EXIT <8 key. If
you want the changes to be permanent (until changed again), press the 4> Save as
default key.
4 Electrical Component Diagnosis

4.1 Fuses
A single-use, replaceable fuse is present in the junction box. The base module is protected by
auto resetting, non-replaceable fuses. A blown or tripped fuse in any of these components may be
caused by a surge or spike in the supplied power or an internal malfunction. The result is a non-
operational manipulator system until the cause is corrected and the fuse replaced. If the base
controller fuse has tripped, operation may resume when it resets. If the cause hasn’t been cor-
rected, it will trip again.
If a fuse has tripped, first verify that power supplied to the junction box (and base controller, if
independently supplied) is stable and within the specified voltage and Her (see “Specifications”
and “Installation” chapters). Check cables for visible damage. Test cable power conductors for
continuity, internal shorts, and shorts to ground. Correct any problems. To rule out a supply
surge or spike as the cause, replace any blown fuses and turn on power to the system. If the fuse
blows again, look for internal failures. See “Master Controller Voltage Test Points” section on
page 72 for information on diagnosing circuit board problems.
4.2 Wireway Short & Open Circuits

Wireways are the transparent tubing and wires that run between the position-sensing potenti-
ometers in the slave arm joints and the base controller. An individual wireway that gets pinched
or damaged could produce an intermittent, short, or open circuit to the enclosed wires. The wires
are also susceptible to damage or faulty termination at the potentiometer and the controller
board within the base controller.
Page 68 • Electrical Component Diagnosis 011–0915

Troubleshooting •
The symptoms of an intermittent connection are erratic or jerky operation of the affected joint. A
shorted or open connection usually results in an unresponsive or hard-over joint (see Table 4 on
page 58). Diagnosis using the SLAVE TEST diagnostic screen would show unchanging or erratic
data in the feedback column, similar to the feedback from a faulty potentiometer (also see “Diag-
nosing Slave Arm Positioning Failures” section on page 63 and “Actuator Controller Board” sec-
tion on page 72).
NOTE: Always inspect and test wireway wires and terminations before troubleshooting
or replacing a potentiometer or any control board.
4.3 Diagnosing Servo Valve Failures

In the most common failure mode, the servo valve opens wide in one direction and remains
open. This is called a “hard-over” condition, because the faulty servo valve drives the corre-
sponding slave arm joint hard to its mechanical limit. The joint remains in this position and does
not respond to master controller inputs.
A servo valve can also fail by only partially opening, causing the corresponding joint to respond
sluggishly to control inputs.
If joint travel velocity is faster in one direction than the other, the servo valve offset voltage may
require adjustment (see the “Maintenance & Service” chapter). This condition does not necessar-
ily indicate servo valve failure and most commonly occurs after a servo valve or other control
software or hardware has been replaced without resetting the offset voltage.
You can conclusively diagnose a faulty servo valve by replacing the suspect valve with a spare,
but first eliminate master controller and base controller telemetry errors using the master con-
troller diagnostics menu described in “System Fault & Error Diagnosis” section on page 60.
4.4 Diagnosing Solenoid Valve Failure

The solenoid valve in the base module controls the slave arm hydraulic supply. This valve can
malfunction by failing to open (resulting in an unresponsive slave arm), partially opening
(resulting in sluggish slave arm movement), or failing to close (resulting in slave arm movement
even when the master controller display says hydraulics are off).
To determine if an unresponsive slave arm is being caused by solenoid valve failure, enable slave
arm hydraulics and listen for the valve to click as it opens. If this test is inconclusive, disable
slave arm hydraulics at the master controller. Open the base module to expose the base control-
ler board, and then enable slave arm hydraulics. If the LED 6 indicator light on the board lights
up, current is being sent to the solenoid valve. Listen for the valve to click as it goes on. If it does
not, either the solenoid valve or its cartridge may need to be replaced (see “Base Module/SCU
Board LED Diagnostics” section on page 73 for more information).
4.5 Diagnosing Potentiometer Failure

For each slave arm or master arm joint except the jaw, the degree of extension or rotation is mea-
sured with a potentiometer. A 5VDC reference voltage is applied across the resistor element.
Actuator travel moves a wiper along the element and produces a voltage that varies with the
wiper position. This analog voltage is converted to a digital value in the master controller or actu-
ator controller board for use by control software.
011–0915 Electrical Component Diagnosis • Page 69

• Troubleshooting
Potentiometer failures in both the master arm or slave arm typically produce either a hard-over
condition in the associated joint or in jerky or erratic joint movement. Potentiometer outputs
(after conversion from analog voltages to digital position data) should be checked in the MAS-
TER TEST and SLAVE TEST diagnostic screens (access path: MAIN/DIAGNOSE) on the master
controller before disassembling or servicing any hardware (see “Using the DIAGNOSTICS
Menus” section on page 62 for additional information about interpreting this data for trouble-
shooting purposes).
Hard-over or unresponsive conditions can result under the following conditions:
 The wiper is broken or stuck.
 Potentiometer conductors are open or shorted.
 Potentiometer signals are prevented from reaching the actuator controller board
by an open connection or broken wire between the potentiometer (slave arm) and
the actuator controller board (base controller or actuator module).
 The actuator controller board is not producing the proper reference voltage (5v).
Jerky or erratic movement can result from:
 A wiper contact or ribbon that is worn or contaminated.
 A wiper that does not move smoothly.
 An intermittent connection between the potentiometer and the controller board.
See the slave arm wiring diagram in the “Drawings & Part Lists” chapter for information neces-
sary to check potentiometer reference and output voltages. connector for proper voltages. A
functional potentiometer should show a varying voltage from the wiper that changes proportion-
ally with movement of the joint. Disconnected from its controller module, a faulty potentiometer
will show infinite resistance between any two potentiometer leads (also see “Actuator Controller
Board” section on page 72).
Slave arm potentiometers and the complete master arm assembly are not considered to be user
serviceable. You can conclusively diagnose a faulty slave arm potentiometer by replacing the sus-
pect unit with a spare. A suspect master arm potentiometer can be checked by either replacing
the master arm assembly or the complete master controller unit.
NOTE: Newer master controllers (with the curved case) and older controllers fitted
with the single PCB upgrade can be reconfigured for testing with Conan systems. See
“Master Controller Software Selection,” in the “Service & Maintenance” chapter of this
manual.
! Caution
Confirm that a replacement master controller has a compatible oper-
ating voltage. Older models use 110 VAC only. Newer models are
rated for 90-260 VAC.
4.6 Master Controller PCB Status LEDs

The master controller processor board has seven diagnostic LEDs (Figure 7).

Troubleshooting •
NOTE: There are no user-serviceable parts on the master controller processor board. If
the board fails to function, replace it with a spare.
4.6.1 Power
Pwr When the master processor is turned on, the “Pwr” (power) LED will illuminate and the
program image will load according to the position of the hex switches.
Vref LF and RF LEDs Vref RF and Vref LF, adjacent to master arm connectors P4 and P5
(top of Figure 7), illuminate when the 4VDC reference is present. Failure of either LED to light
could indicate a short circuit in the master arm (disconnect the master arm connector to check)
or a failure of the A/D converter.
4V Reference voltage LEDs for

left and right master arms
Pwr, Proc, TX, and RX LEDs
Done LED
Figure 7
4.6.2 Communications
Done The “Done” LED lights when the program successfully loads. Observing the operation on
the LCD while turning on power to the master controller, the LCD will indicate which image is
being loaded (“Loading master.001” for example—additional LCD text will be dependent on the
type of manipulator being operated).
Proc The “Proc” (processor) LED (“heartbeat”) will blink at 1 Hz to indicate the master proces-
sor is functioning correctly. If no software image is installed, the LED is continuously lit. If the
LED does not illuminate, the board is either damaged or has not been programmed.
TX The TX LED will blink each time a packet is sent to the slave controller.
RX If a response is received from the slave controller, the RX LED will illuminate. Check all
connections between master controller and slave controller, mux/demux configuration, and so
on.

• Troubleshooting
4.7 Master Controller Voltage Test Points
The first step in troubleshooting is to ensure that the correct voltages are present at all test
points. There are test-points on the master processor board for -16V, +12V, +5V, +3.3V, +2.5V,
+1.2V, and ground (Figure 8). The power LED should be illuminated whenever +5V is available
to the board from the AC-DC or DC-DC converter.
NOTE: There are no user-serviceable parts on the master controller PCB. If the board
fails to function, replace it with a spare.
Ground
2.5V
1.2V
+12V
3.3V -16V
5V
Ground
Figure 8 Voltage and ground test points
4.8 Base Module & Slave Arm PC Board Diagnosis

If you suspect that a printed circuit board has failed, the easiest way to confirm a failure is to
replace the suspect board with a spare.
4.8.1 Actuator Controller Board

Each actuator control module on the base controller motherboard board provides the 5V refer-
ence voltage to its position-sensing potentiometer and the A-D (analog to digital) conversion of
the potentiometer’s feedback voltage.
If SLAVE TEST feedback data for a joint indicates a problem (see “Diagnosing Slave Arm Posi-
tioning Failures” section on page 63) check the reference voltage (+5V) and feedback voltage (0-
5V) at the terminal strip of the appropriate actuator controller board.
 If the reference and feedback voltages appear normal, the actuator controller
board’s A-D converter may be at fault.
 If the reference voltage is OK, but the feedback voltage is erratic or absent, the
potentiometer or its wiring may be at fault.
 If the reference voltage is erratic or absent, the actuator board’s voltage regulator
may be at fault.
Each actuator control module is configured with a specific address for the joint/actuator its servo
will control. When the master controller generates a command packet to the slave arm, each
individual command is encoded with its unique address. Every actuator controller board receives
the complete packet, but accepts only the command encoded with its address. Commands with
other address are disregarded.

Troubleshooting •
If a replacement board is not configured, or configured with the wrong address, the actuator it
controls will not function as intended. Wrong addresses can have two consequences:
 If the board is configured with an address the control system does not recognize,
the board will disregard all master controller movement commands and the joint
will remain unresponsive.
 If the board is configured with the address of a different joint, it will respond to
commands for that joint. For example, if the actuator controller board for the
shoulder is configured with the azimuth’s address, the shoulder will attempt to
comply with azimuth movement commands.
An incorrect address can be diagnosed using the FREEZE menu (access path: MAIN/OPERATE/
FREEZE). Freeze the malfunctioning joint. If the joint continues to respond to general master
arm movements, its address may be incorrect. Careful manipulation of the master arm and
observation of slave arm responses may indicate the other joint with which it shares an address.
Another approach is to continue freezing joints until it becomes inactive.
Instructions for setting actuator board addresses can be found in the “Maintenance & Service”
chapter.
4.8.2 Base Module Board

The base module’s LED indicator lights can be used to diagnose some manipulator system com-
munication failures and failure of the solenoid valve that controls slave arm hydraulic supply.
See “Base Module/SCU Board LED Diagnostics” for more information.
Two components on the base module board (U4 and U5) contain software programs that must
be compatible with software in the master controller. Before you replace a base module board
with a spare, verify that these parts on the spare are marked with the same part and revision
number as those on the original board. Contact the manufacturer if you need assistance with this
verification.
4.8.3 Base Module/SCU Board LED Diagnostics

You can use the diagnostic LEDs on the base module board to diagnose some manipulator sys-
tem communication problems and failure of the solenoid valve that controls slave arm hydraulic
supply. Figure 9 shows the location of each LED on the board.
The LEDs function as described in Table 6. Some LEDs are used only if your system uses the RS-
485 communication protocol; others are used only for the RS-232 communication protocol.

• Troubleshooting
Figure 9 Base module LED indicator lights
Table 6
Base Module Board LED Indicators

LED Protocol State Explanation
On Data is being transmitted from the master controller to the base module
LED 1 RS-232 board. In your system, this light should always be on.
Off No data is being transmitted from the master controller to the base
module board.
On Data is being transmitted from the base module board or an actuator
LED 2 RS-232 controller board to the master controller.
Off No data is being transmitted from the base module board or an actuator
controller board to the master controller.
On The base module board is receiving data from the master controller. In
LED 3 RS-485 your system, this light should always be on.
Off The base module board is not receiving data from the master controller.
On An actuator controller board or the base module board is transmitting
LED 4 RS-485 data to the master controller.
Off No transmissions are taking place from an actuator controller board or
the base module board to the master controller.

Troubleshooting •
Base Module Board LED Indicators (cont.)

LED Protocol State Explanation
On The base module board is set to receive a data transmission from the
master controller. This light should always be on.
LED 5 RS-485 Off The base module board is set to send a data transmission to the master
controller. The transmitted data could be from the base module board or
an actuator controller board.
LED 6 Not in use.
LED 7 Not in use.
On Current is being sent to the solenoid valve that controls slave arm
hydraulic supply (enabling the slave arm hydraulic supply).
LED 8 N/A Off Current is not being sent to the solenoid valve that controls slave arm
hydraulic supply (disabling the slave arm hydraulic supply).
5 Factory Assistance
To help speed diagnosis and problem resolution, please have the following information available
when you contact Customer Service.
1. What are the symptoms of the problem?
2. Are the symptoms intermittent or constant?
3. If the problem is intermittent, under what conditions does it occur?
4. Was the affected part of the manipulator system subjected to excessive loads or adverse conditions
(such as vibration, heat, or shock)?
5. Did the problem occur suddenly or gradually?
6. Does the problem appear to affect other functions?
7. What system functions are still operable?
8. Has anyone tried to fix the problem? If so, have actuators and/or actuator control modules been
interchanged with those from another Conan slave arm or from spares?
9. What is the system serial number? (You can find the serial number on the slave arm base
segment.) If the problem is appears to be electrical or software-related, what is the part number of
the master controller?
10. Are there other relevant details?
011–0915 Factory Assistance • Page 75

• Troubleshooting
This page not used.
Page 76 • Factory Assistance 011–0915

In This Chapter:
• 1 Safety First!................................................................. page 53
• 2 Service Guidelines ........................................................ page 55
• 3 Maintenance ................................................................ page 57
• 4 Important Service Practices & Procedures ........................ page 59
• 5 Junction Box Service ..................................................... page 60
• 6 Master Controller Service & Configuration ........................ page 61
• 7 Base Module Service ..................................................... page 69
• 8 Slave Arm Service ........................................................ page 72
• 9 System Configuration.................................................... page 77
• 10 Instructions for Serviceable Components ....................... page 82
1 Safety First!
These guidelines, warning, and cautions are a reminder of the safety issues present when main-
taining or servicing a slave arm or manipulator system. They do not cover every possible safety
risk and are not meant to supersede or replace existing vessel/operator safety policies, stan-
dards, processes, and practices.
Please Note:
This slave arm or manipulator system is not an isolated piece of
equipment. Be sure to know and use the safety and service guidelines
provided in the technical manual for the system or vehicle on which it
is used.
1.1 Worksite Safety
! WARNING
ELECTRICAL, HYDRAULIC, AND MECHANICAL HAZARDS! Before any
contact with this equipment:
• Notify the appropriate personnel of your activities.
• Be sure you have a safe electrical, hydraulic, and mechanical work-
ing environment. Turn off, lock out/tag out, and/or isolate surround-
ing equipment that could be a safety hazard to you.
• Observe all safety regulations and procedures in effect at the work-
site.
• Wear personal protective equipment (PPE) appropriate for the task.
011–0923 Page 53
• Maintenance & Service
1.2 Electrical Safety
! WARNING
SHOCK HAZARD! Lethal voltages can be present in the manipulator
system (see the Specification chapter for specific voltages).
 Before any contact with this equipment, CONFIRM that it is electri-
cally isolated, locked-out and tagged-out as directed by applicable
electrical safety regulations and procedures.
 Wear personal protective equipment (PPE) appropriate for the task.
1.3 Mechanical Safety
! WARNING
Slave arm components are heavy and can move, drop, shift, or col-
lapse suddenly when hydraulic pressure is removed or relieved.
 Support the slave arm at the elbow and jaw when relieving hydrau-
lic pressure or opening any hydraulic connection.
1.4 Hydraulic Safety
! WARNING
Slave arm components are heavy and can move, drop, shift, or col-
lapse when hydraulic pressure is removed or relieved.
 Support the slave arm at the elbow and jaw when relieving hydrau-
lic pressure or opening any hydraulic connection.
! WARNING
Failure to follow safety procedures for working with high-pressure
hydraulic equipment can result in serious injury or death. ALWAYS
assume that hydraulic equipment is energized until you have CON-
FIRMED that it is isolated, locked out, and tagged out as directed by
applicable hydraulic safety regulations and procedures, that all pres-
sure gauges indicate zero pressure, and that all stored and residual
pressures have been isolated or relieved.
Common causes of serious injury and death from high-pressure hydraulic equipment include:
 Injection of pressurized hydraulic fluid into the body.
 Blunt force trauma to the body from flailing, pressurized hoses and forcefully
ejected fittings.
 Bodily contact with hot hydraulic fluids and sprays or ignited fluids, sprays, or
mists.
 Falls caused by slipping on spilled fluids.
Page 54 • Safety First! 011–0923

Maintenance & Service •
To prevent injury or death while working with high-pressure hydraulic equipment, always follow
all applicable hydraulic safety regulations and procedures. The instructions listed below provide
general guidelines and are not meant to replace or modify existing safety regulations and proce-
dures.
 Always lock out and tag out hydraulic equipment before it is serviced so that it
cannot be accidentally energized.
 Provide support for equipment and components that can move, drop, shift, or col-
lapse when hydraulic pressure is removed or relieved.
 Always wear safety glasses and other required personal protective equipment
(PPE).
 Confirm that equipment pressure gauges indicate zero pressure.
 Before loosening any fittings, isolate or relieve any stored or residual pressure
that remains in components even when the hydraulic system is de-energized.
 Never use any part of your hand or body to check for hydraulic fluid leaks, even if
you are wearing personal protective equipment. High-pressure hydraulic fluid
injects easily into any body part, and an injection wound, regardless of size, must
be evaluated immediately by a physician as a surgical emergency.
 Service hydraulic equipment away from sparks or open flame.
 Immediately clean up spilled hydraulic fluid from floors or other surfaces.
 Before returning the equipment to service, tighten all fittings and connections as
specified by the equipment manufacturer.
 Move all personnel away from serviced hydraulic equipment before pressurizing
it and testing for safe operation.
Only qualified and authorized personnel should perform hydraulic work on this equipment. A
qualified person is one who has the required skills and knowledge to perform hydraulic work
safely, even under adverse environmental conditions, and who knows the hazards associated
with hydraulic work and the methods for reducing the risk of accidents from those hazards.
1.5 Deck Testing
! WARNING
Use extreme caution when testing a slave arm on deck:
• Move all personnel outside the slave arm's range of motion when
hydraulic pressure is applied and functions are tested.
• Direct the slave arm to point away from personnel and critical or
sensitive areas while testing jaw functions.
2 Service Guidelines
2.1 Service Assumption
Instructions in this manual assume that service personnel are familiar with the general operating
principles, safety guidelines, and service practices associated with the types of equipment
described in this manual.
011–0923 Service Guidelines • Page 55

2.2 Guidelines
2.2.1 ESD-Sensitive Devices
! Caution
Electrostatic discharge (ESD) can permanently damage sensitive elec-
trical components like printed circuit boards (PCBs), integrated cir-
cuits (ICs), and other ESD-sensitive components. To prevent damage,
always handle these components according to ESD prevention guide-
lines.
Microelectronic devices are very susceptible to ESD. Careless handling may cause immediate
component failure. It may also make a component more vulnerable to future damage, which can
be difficult to detect and often results in faulty performance and intermittent failures. When you
handle PCBs, ICs, and other ESD-sensitive components, follow the basic ESD prevention guide-
lines below.
 Prepare an ESD workstation by grounding all items in the work area (work sur-
faces, people, equipment, etc.) to the same electrical ground point (called the
common point ground). Keep the work area free of nonessential insulators (such
as plastic cups, bags, and envelopes).
 If possible, disconnect all power sources, signal sources, and loads connected to
the component before you begin maintenance or service.
 Always ground yourself before you touch ESD-sensitive equipment. Discharge
any static electricity by touching ground on the workstation each time that you
approach and sit at the workbench.
 Ground all tools that may come into contact with the ESD-sensitive equipment.
 Before you handle PCBs, ICs, and other ESD-sensitive components, attach a
grounding wrist strap and confirm that the strap is connected to the grounding
pad.
 Handle PCBs by the base or edges; always avoid contact with pins.
 Do not unnecessarily pick up, hold, or carry ESD-sensitive devices that are not in
shielded packaging.
 Always store and seal ESD-sensitive components in the anti-static packaging in
which they were shipped, or in equivalent storage material.
2.2.2 Torque Specifications

See the “Maintenance & Service” section, service or work instructions, and/or drawings in the
“Drawings & Part Lists” sections for torque specifications.
 When a torque specification differs between manual text and engineering draw-
ing, use the specification on the drawing.
 When no torque specification is present, use prevailing industry standards and
common sense.
Page 56 • Service Guidelines 011–0923

2.2.3 Nylock (“Patch”) Fasteners
Under ideal conditions, Nylock (“patch”) fasteners can be reused up to 5 times. Because tracking
their use is difficult and operating conditions are always less than ideal, Nylock fasteners should
be replaced whenever they are removed.
! Caution
DO NOT replace Nylock fasteners with standard fasteners. Standard
fasteners may loosen and cause component failure or loss.
2.2.4 Fastener Lubrication

 Stainless steel to stainless steel or titanium:
Apply nickel or molybdenum-based anti-seize compound (Bostik® Never-Seez, or
equivalent) when assembling stainless steel fasteners or threading them into
stainless steel or titanium components (including nylon-patch/Nylock fasteners).
 Stainless steel to aluminum:
Apply waterproof grease (Aqua Lube®, or equivalent) when assembling stainless
steel fasteners to aluminum IF they are exposed to seawater.
 Do NOT use Aqua Lube on fasteners penetrating hydraulic or compensated areas,
unless directed otherwise in a service instruction or engineering drawing.
2.2.5 O-rings
Inspect o-rings for damage during routine maintenance.
 Replace o-rings that are broken, damaged, or hardened.
 Lubricate o-rings prior to installation (Dow Corning® 55 O-ring lube, petroleum
jelly, or equivalent).
2.2.6 Connection Identification

Before disconnecting any hose, cable, or conductor, make sure the item and its matching fitting,
connector, or terminal are adequately labeled for correct re-assembly.
2.2.7 Drawings & Part Lists

Engineering drawings and part lists are supplied to assist in servicing and maintaining the
equipment. They can be a valuable source for determining torque values and the part numbers
for serviceable components. Most are located in the “Drawings & Part Lists” section.
3 Maintenance
3.1 Daily Maintenance
Perform the following steps daily, or after every duty cycle:
Submersible Models
1. Thoroughly rinse the slave arm and slave controller with clean, fresh water.
2. Apply a spray lubricant to the slave arm jaw assembly and actuator rods to displace any water.
011–0923 Maintenance • Page 57

All Models
Inspect slave arm for:
1. Damage:
If the slave arm has had severe service or a collision, inspect slave arm components,
— inspect all joints, actuator shaft pivot pins, and joint pivot pins.
— inspect the linear actuator body and shaft for dents, bends, or damaged com-
ponents.
— check all hoses, fittings, and electrical cables.
— repair or replace damaged components.
2. Loose or missing fasteners
— Replace or retighten fasteners, as needed. Vibration and temperature cycles
may cause fasteners to loosen.
3. Loose or dirty electrical connectors.
— Re-tighten as needed. Clean and lubricate o-rings prior to mating. Vibration
and temperature cycles may cause electrical connectors to loosen.
4. Trapped debris
— Remove debris and inspect for damage.
5. Hydraulic leaks
— Repair any leaks, replace lost fluid, and bleed air, as needed.
6. Damaged hydraulic hoses
— Repair or replace hoses, as necessary. If possible, install protection or reroute
hoses to prevent future damage.
7. Anode consumption
— Inspect all anodes and replace when 2/3 or more is consumed.
3.2 Long Term Periodic Maintenance

Efficient and reliable long-term operation depends on the following three steps:
1. Inspect components and observe performance frequently.
— Do this starting with the first use. You will then be able to develop a schedule
of inspection, maintenance, and service for hydraulic and mechanical compo-
nents that meet the needs of the slave arm’s operating environment and duty
cycles.
2. Perform the inspections, maintenance, or service as scheduled.
— Staying with the schedule below will help keep the slave arm in good working
condition.
3. Keep a log of all inspection, maintenance, and service actions.
— Keeping a log will help you understand when and why problems are occurring.
Then you can modify your schedule based on this knowledge.
Page 58 • Maintenance 011–0923

Table 1 contains a minimum schedule for performing regular long-term maintenance.
Table 1
Recommended Long Term Maintenance Schedule

Schedule Period Maintenance Task
Every 100 operating hours Tighten all external slave arm fasteners to the specified torque.
Check a sample of hydraulic fluid for water and particulates.
Replace if contaminated.
Apply anti-corrosion paint wherever an anodized surface is dam-
aged and aluminum is exposed.
Submersible: Recoat pivot pins and pivot pin bores with silicone
grease such as DC-5.
Every 2000 operating hours Replace worn or damaged actuator pins and bushings.
Every 2000 operating hours or Replace all actuator o-rings and seals. Lubricate with Dow Corn-
every 3 years (whichever ing® DC-4. Clean all o-ring grooves and surfaces.
comes first)
4 Important Service Practices & Procedures

Key practices and procedures for successful manipulator system service:
 Clean, degrease, and inspect disassembled parts before reassembling.
 Replace o-rings that are broken, damaged, or shows signs of wear.
 Lubricate all o-rings with o-ring lubricant (Dow Corning® 55 or petroleum jelly).
NOTE: Do not use lubricants that contain suspended particles such as molybdenum or
graphite—the particles can be drawn into the hydraulic system and clog filters.
 Apply Aqua Lube (or equivalent) to all fastener threads, EXCEPT:

— when threads are exposed to the hydraulic system.
— when you are directed otherwise by the work instruction or engineering draw-
ing.
 Torque all fasteners as specified. Torque specifications on engineering drawings
take precedence over all other text references.
4.1 Protecting PC Boards
! Caution
Electrostatic discharge (ESD) can permanently damage sensitive elec-
trical components like printed circuit boards (PCBs), integrated cir-
cuits (ICs), and other ESD-sensitive components. To prevent damage,
always handle these components according to ESD prevention guide-
lines.
Microelectronic devices are very susceptible to ESD. Careless handling may cause immediate
component failure. It may also make a component more vulnerable to future damage, which can
be difficult to detect and often results in faulty performance and intermittent failures. When you
011–0923 Important Service Practices & Procedures • Page 59

handle PCBs, ICs, and other ESD-sensitive components, follow the basic ESD prevention guide-
lines below.
 Prepare an ESD workstation by grounding all items in the work area (work sur-
faces, people, equipment, etc.) to the same electrical ground point (called the
common point ground). Keep the work area free of nonessential insulators (such
as plastic cups, bags, and envelopes).
 If possible, disconnect all power sources, signal sources, and loads connected to
the component before you begin maintenance or service.
 Always ground yourself before you touch ESD-sensitive equipment. Discharge
any static electricity by touching ground on the workstation each time that you
approach and sit at the workbench.
 Ground all tools that may come into contact with the ESD-sensitive equipment.
 Before you handle PCBs, ICs, and other ESD-sensitive components, attach a
grounding wrist strap and confirm that the strap is connected to the grounding
pad.
 Handle PCBs by the base or edges; always avoid contact with pins.
 Do not unnecessarily pick up, hold, or carry ESD-sensitive devices that are not in
shielded packaging.
 Always store and seal ESD-sensitive components in the anti-static packaging in
which they were shipped, or in equivalent storage material.
4.2 Startup After Maintenance or Service

4.2.1 After Minor Maintenance or Service
1. Follow steps in the “Pre-Start Check” and “Startup” sections of the “Operation” chapter.
2. Be sure to replace hydraulic and compensation fluids lost during maintenance or service.
4.2.2 After Major Service

1. Follow the procedures in “Completing the Installation” in the “Installation” chapter
before resuming normal operation.
2. If the hydraulic or compensation fluid has been contaminated, flush the system and refill with
fresh fluid.
5 Junction Box Service

This section contains special maintenance and service procedures not covered in the Work
Instructions. For additional details, refer to the junction box drawing and part list in the “Draw-
ings & Part Lists” chapter.
Fuse Replacement . . . . . . . . . . . . . . Littlefuse T 6.3AL 250V (SRS P/N 005-0587)
The fuse is located under the fuse symbol, between the power switch and the power-in socket.
Use the tab on the fuse cover to pry out the fuse for replacement or inspection.
Page 60 • Junction Box Service 011–0923

6 Master Controller Service & Configuration
Instructions. For additional details, refer to master controller, 101-5781 in the “Drawings & Part
Lists” chapter.
This section contains special maintenance, service, and configuration procedures not covered in
the Work Instructions.
PCB Features and Functions .................................................. page 61
Accessing Internal Components ............................................. page 63
Adjusting the LCD Screen Viewing Angle ................................. page 63
Master Controller Software Selection ...................................... page 64
Incompatibility Alert Screens ................................................. page 67
6.1 PCB Features and Functions

The master processor board performs the following functions:
 Communicates with the slave controller.
 Reads master arm potentiometer positions for use by the control algorithm.
 Detects front panel switch inputs for use by the control algorithm.
 Displays operation information on the LCD display.
 Contains the program information for each system.
 Stores system parameters in non-volatile memory for use by the control algo-
rithm.
 Illuminates status LED's to assist troubleshooting and diagnostics.
The master processor board operates on 90-260VAC (standard) or 18-36VDC (optional). Power
is supplied by either the supplied AC junction box, or by a user installed CPC connector mounted
near the operating station. A 4 pin power connector (P7) plugs into the board. An adjacent 4 pin
plug (P2) connects to a SPST on/off switch mounted in the controller faceplate. An in-line fuse
(F1) provides over-current protection to the PCB.
Communication between the master processor board and the slave controller board is via RS-
232 or RS-485. A 9 pin connector is plugged into the appropriate receptacle (Either P1A or P1B)
depending on system requirements. An auxiliary RS-232 connection is also present on both con-
nectors for applications that require an additional serial port connection. (The auxiliary RS-232
is not used for connection to the slave controller board)
A telemetry daughter (inductive isolation) board is plugged into connectors J1 and J2. The pur-
pose of the telemetry board is to provide electrical isolation and protection from over-voltage or
voltage spikes between the telemetry conductors and the PCB electronics.
Two hex switches marked “Mode H” (high bit) and “Mode L” (low bit)' are used to select which
program to load during startup. This allows the PCB to be pre-loaded with all standard product
program software and allows the user to reconfigure the PCB for other systems without the need
for additional ICs or programming. A table provides the switch position options.
The master arm connects to 12-pin circular connector P4 (Standard). In a dual arm system, the
additional master arm connects to P5. The master processor board sends a 4VDC reference volt-
011–0923 Master Controller Service & Configuration • Page 61

age to each of the potentiometers in the master arm. An analog to digital converter interprets the
voltage as a numerical value that is used by the control algorithm.
The USB port (J6) can be used in place of the auxiliary RS-232 connector for applications that
require serial port connection. (The USB port cannot be used for connection to the slave control-
ler board)
The 20 pin DIP connector (J7) can be used to run legacy LCD displays that have a ribbon cable
interconnection. Current displays connect via spring loaded pins onto contacts (J4) on the back
side of the PCB. Two additional SIP receptacles marked “LCD backlight” are also used with leg-
acy LCD displays and provide ~80VAC to power the backlight via two wires coming from the leg-
acy display. Two spring loaded pins are used on current displays.
6.1.1 Adjusting the LCD

A potentiometer (VR1) is used to set the optimal contrast between the black text and the blue-
gray background at the desired viewing angle. Once the potentiometer is adjusted, it will auto-
matically compensate for changes in temperature so the display remains viewable throughout
the operating temperature range. See “Adjusting the LCD Screen Viewing Angle” section on page
63.
6.1.2 Changing the Software Image

Changing software image (Titan to Conan, Orion to Titan, etc.) is accomplished by selecting the
appropriate hex switch settings on the PCB and then cycling power to the master processor. See
“Selecting Pre-Loaded Software Images” section on page 64.
The master processor can also be run from a legacy EPROM installed in the 28 pin DIP socket
(U11). This connector was installed to ensure the master processor board is fully backwards com-
patible with existing master controllers. See “Installing an EPROM” section on page 65.
The Secure Digital card slot (J5) allows new software, when available, to be loaded into memory
on the PCB. See “Installing Images from an SD Card” section on page 65.
For more information on changing the software image, see “Master Controller Software Selec-
tion” section on page 64.
6.1.3 Troubleshooting the PCB

Communications
The master controller PCB has seven LEDS to indicate the status of PCB power, master arm ref-
erence voltage, image loading, processor function, and communication with the slave controller
(TX and RX). See the “Troubleshooting” chapter for details.
Power
There are test-points on the master controller PCB for -16V, +12V, +5V, +3.3V, +2.5V, +1.2V,
and ground. See the “Troubleshooting” chapter for details.
NOTE: There are no user-serviceable parts on the master controller PCB. If the board
fails to function, replace it with a spare.
Page 62 • Master Controller Service & Configuration 011–0923

6.2 Accessing Internal Components
6.2.1 Removing the Faceplate
1. Turn off the master controller and disconnect the whip from its power source.
2. Remove the four screws holding the master controller
faceplate to the enclosure (Figure, right). Remove
screws (4X)
3. Lift the faceplate assembly out of the enclosure. Turn it over
to expose the face of the PC board. Take care to immobilize
the master arm(s) and avoid stressing the cables connected to
the boards in the enclosure.
6.2.2 Installing the Faceplate

4. Carefully swing the faceplate assembly back over and seat it on the enclosure. Reinstall the four
mounting screws.
 Check that no wires or cables are pinched between the faceplate and the enclosure.
6.3 Adjusting the LCD Screen Viewing Angle

The LCD screen comes with a temperature sensor and compensation circuit that keeps the view-
ing angle stable over a broad temperature range. If you find the viewing angle is not acceptable
for your work environment, adjust it as follows:
! WARNING
SHOCK HAZARD! Be aware that potentially lethal voltages are present while
adjusting the LCD viewing angle potentiometer. Always observe appropri-
ate safety procedures.
1. While keeping power supplied to the master controller, open the assembly as described in
“Removing the Faceplate” section on page 63.
2. Identify the LCD adjustment potentiometer (labeled VR1 on the PC board), located at the bottom
right of the board (Figure 1).
Figure 1 LCD Adjustment potentiometer

3. Using a small flat blade screwdriver, adjust this potentiometer for the desired viewing angle.
4. Close the master controller as described in “Installing the Faceplate” section on page 63.

6.4 Master Controller Software Selection
The master processor board is shipped with several pre-loaded software images, allowing the
master controller to be used with different Schilling Robotics slave arms. The software is user-
selectable by configuring two Mode switches located on the main PC board.
Software can also be loaded from:
 an existing EPROM using the 28-pin connector on the PC board
 a Secure Digital card using slot (J5).
The three methods are described in the following sections.
NOTE: The jaw mode POS (position) option is lost when the software image is changed.
To re-enable it after a software change, see section 6.4, “Master Controller Software Se-
lection,” on page 64.
6.4.1 Preparation
1. Turn off the master controller and disconnect the whip from its power source.
2. Open the master controller as described in “Removing the Faceplate” on page 63.
! Caution
PC board components can be damaged by static electricity. Wear a
grounded anti-static wrist band handling PC boards or chips.
6.4.2 Selecting Pre-Loaded Software Images

The two hexadecimal Mode switches (H and L) are located at the top center of the processor
board (Figure 3, left). The available software is listed in a table at the right of Figure 3, and the
switch settings for the “H” and “L” switches are shown as well.
H L Description
0 0 Titan 4, Titan 3, Titan 2
0 1 Orion 7P
0 2 Conan 7P
0 3 Dual T3
0 4 Dual Orion
0 5 Dual Conan
0 6 T3 Spaceball FLX
0 7 T3 Robotics
0 8 Titan 4, Enhanced
0 9 Titan 4, Dual
F F EPROM
F 0 SD Card Read
0 F SD Card Write
4 0 Buzzer Test
Figure 3 Hexadecimal switch orientation and software values
1. Using a small, flat head screwdriver, adjust each switch so the “H” and “L” values match
those shown for the software you want to use.
2. Close the master controller as described in “Installing the Faceplate” on page 63 and reconnect the
whip.

3. Power up the master controller and view the LCD display. If a compatibility issue occurs between
the new system parameters and the old software image, a message will appear on the screen
asking you to Ignore, Overwrite, or Update the version number only. If in doubt, overwrite; there
are no irreparable consequences due to overwriting the image. (Overwriting loads the factory
default values for system parameters, gains, limits, and stow positions.)
6.4.3 Installing an EPROM

To install an EPROM chip on the master controller processor board, perform the following steps
(also refer to the master controller drawing in the “Drawings & Part Lists” chapter).
The 28-pin connector is located at the lower left corner of the processor board (see Figure 4).
1. Confirm that all pins on the EPROM are aligned and straight. Orient the EPROM with its
notch towards the edge of the PCB and press it gently into the socket until the
locking clips snap into place.
EPROM notch to this end

Figure 4 EPROM 28-pin connector
! Caution
Installing the chip backwards will damage system electronic assem-
blies. Locate the notch on the chip to the edge of master processor
board.
2. Set each hexadecimal switch to “F” (see Figure 3 on page 64 for an example of the hexadecimal
switches and the EPROM switch settings).
3. Close the master controller as described in “Installing the Faceplate” on page 63.
4. Power on the master controller to load the new software.
NOTE: You can also load the EPROM image into the master processor board memory
by moving the hex switch to F 0, and then switch to 0 F while the processor board is
powered. The EPROM can then be removed from the board and the EPROM image will
be available for loading by selecting the hex switch position 0 F. A different EPROM can
be installed and the image loaded by selecting hex switch position F F, however if you
overwrite the image by selecting F 0 then 0 F, the image from the first EPROM is lost.
6.4.4 Installing Images from an SD Card

The Secure Digital card slot (J5) allows new software, when available, to be loaded into memory
on the PCB. Binary images containing the manipulator programs can be loaded onto the SD
cards root directory. When the card in inserted into the slot, changing the hex switch settings

from F 0 then to 0 F while the processor is running loads the images into memory. The program
can then be loaded by selecting the appropriate hex switch positions. After loading into memory,
the SD card can be removed.
6.4.5 Re-enabling POS (Position) Jaw Control

The jaw mode POS (position) option is lost when the master controller software image is
changed by:
 adjusting the PCB mode switches.
 replacing the EPROM (if used).
 loading a new image from an SD card.
To re-enable position jaw control when one of these events has occurred, edit the MEMORY
menu as described below.
1. Reconnect the master controller to the manipulator system. Do not provide hydraulic
power to the slave controller.
2. Turn on electrical power at the junction box and/or master controller, and the base module.
3. Cycle through the startup menus to the MAIN MENU. Press the 3>SETUP key. Press the
SECURITY <6 menu and set the security level to 1 or higher.
4. Press the MEMORY <5 key to enter the MEMORY menu.
— Use the RT and LF control keys to move the cursor (^) along the address line.
Using the UP and DN control keys to select numerals and letters, change the
address line from [0:0000-FFFF] to [5:00F0-0000] (FFFF changes to 0000
automatically) as shown in Figure 5.
MEMORY EDIT LOCK

--------------------------------
1> Edit:OFF
2> View:OFF
LF & RT keys control the cursor.
UP & DN keys control the numeral.
[5:00F0-0000]
^ EXIT <8
--------------------------------
<CAUTION>-CONSULT MANUAL BEFORE
USING THIS MENU
Figure 5 MEMORY EDIT menu with new address

5. Press the 1> Edit key to display 1> Edit:0000 (+0000).
— Use the control keys to change the fourth zero (0) to 1, and the line reads 1>
Edit: 0001 (+0001).
6. Press the 1> Edit key to turn the edit function to OFF. The address line now reflects your editing as
shown in Figure 6.

MEMORY EDIT LOCK

--------------------------------
1> Edit:OFF
2> View:OFF
LF & RT keys control the cursor.
UP & DN keys control the numeral.
[5:00F0-0001]
^ EXIT <8
--------------------------------
<CAUTION>-CONSULT MANUAL BEFORE
USING THIS MENU
Figure 6 Address line after editing

7. Press the EXIT <8 key to return to the SETUP menu. Exit the SETUP menu and shut down the
system. The editing changes will not take affect until the master controller has been turned off and
restarted.
6.5 Incompatibility Alert Screens

Incompatibility alert screens may occur during startup when (1) a master controller is used as-is
to operate a slave arm other than the one it was supplied with, or (2) when the master controller
software configuration has been changed to operate a slave arm other than the one it was sup-
plied with, and (3) the software encounters a setting, ID code, or other condition that differs
from what it is expecting. This difference may range from unimportant to critical.
The alert screen typically offers an option and the user may have other options for proceeding.
These are described in the following sections. No matter which option is chosen, proceed
with extreme caution during the startup and operation of the slave arm.
! Caution
When an incompatibility alert screen appears, use extreme caution if
you continue operation. Be prepared to quickly disable hydraulics if
the slave arm behaves erratically.
NOTE: A “Fatal Telemetry Error” message at startup is NOT an incompatibility alert

screen. It indicates a communications failure caused by component or connection prob-
lems, or that the master controller and slave controller/slave arm are completely differ-
ent models (that is, a master controller configured with Conan software has been
connected to an Orion slave controller/slave arm, etc.).
6.5.1 Incompatible User-Configurable Settings

The user-configurable settings (such as joint travel limits, stow sequence, etc.) remain in non-
volatile memory even after the master controller has been configured with new software. If they
are not compatible with the software currently loaded, the alert screen in Figure 7 will be dis-
played.
You have three options.

a. Press the 4> Overwrite EEPROM button to install the default system non-volatile
user-settings.
b. Press 3> Ignore to operate the slave arm with the current user-settings. Use
extreme caution when testing the slave arm for safe and successful
operation. Note that the alert screen will reappear each time the master controller
is turned on.
c. Press the <7 Update EEPROM Version # only button to operate the slave arm with
the current user-settings on a continuing basis—the version number is updated to
prevent the alert screen from appearing each time the master controller is turned on.
Use this option only if you have successfully tried option b.
SCHILLING ROBOTICS, INC

XXXXX MANIPULATOR SYSTEM
--------------------------------
Non-volatile memory (EEPROM) is
not compatible with this ROM ver-
sion. Danger exists if the sys-
tem is operated without the
correct memory value.
3> Ignore Update EEPROM <7
Version # only
4> Overwrite EEPROM
--------------------------------
Figure 7 “Non-volatile memory (EEPROM)...” warning screen
6.5.2 Incompatible Slave Arms/Controllers

If the master controller is configured for a standard manipulator system and is connected to an
incompatible or custom slave arm and slave controller, you may see the alert screen shown in
Figure 8.
SCHILLING ROBOTICS, LLC

XXXXX MANIPULATOR SYSTEM
--------------------------------
The Master Controller software
is not compatible with the
slave arm. Further operation
may risk damage to equipment.
Select [Yes] only if you would
like to proceed anyway.
4> Yes
--------------------------------
Figure 8 Incompatibility screen

You have three options.
a. Recommended: Do not use the master controller with this slave arm. Connect a
compatible model instead.

b. Operate the slave arm with the software on its original EPROM: if the original
EPROM (“PROM”) used with the slave arm is available, install it in the master
controller as described in section 6.4.3, “Installing an EPROM,” on page 65.
c. Pressing the 4> Yes key updates the user-configurable memory with the factory
default settings for the currently loaded software. Use extreme caution when
testing the slave arm for safe and successful operation.
6.5.3 Incompatible Systems

A master controller configured for use with one type of manipulator system (Titan, Conan, or
Orion) cannot communicate with a slave arm of a different type system, and if connected, will
display a “Fatal Telemetry Error” screen at startup.
7 Base Module Service

Instructions. For additional details, refer to the drawing and part list 101-3655 in the “Drawings
& Part Lists” chapter.
7.1 Fuse Replacement

Base module circuits are protected by self-resetting, non-replaceable fuses.
7.2 Servicing the Hydraulic Filter

The base module contains a tubular, mesh-screen hydraulic filter which can be removed for
cleaning. The most common symptom of a clogged filter is sluggish operation of all slave arm
functions despite adequate hydraulic pressure and flow from the HPU.
Refer to drawing and the parts list for 101-3655 for this procedure.
! WARNING
Bleed off all pressure to all slave arm hydraulic lines before continu-
ing. Hydraulic fluid is under high pressure and may cause injury.
1. Disable electrical power and hydraulic power to the base controller.
2. Remove the hydraulic pressure hose from the -4 hydraulic fitting (34).
3. Remove the reducer fitting (35) from the manifold block (1). Pull the filter from the manifold
block.
4. Remove the filter (11) from the filter base (12). You may install a new filter or replace the original
filter after cleaning it with ultrasound. Remove the two o-rings (14 & 15) from the filter base.
5. Lubricate two new o-rings with o-ring lube and install onto the filter base. Insert the filter into the
manifold block.
6. Install the reducer fitting, with the -4 hydraulic fitting, onto the manifold block.
7. Install the hydraulic pressure hose.
7.3 Accessing Internal Base Module Components

The base module must be opened to perform the following procedures:
011–0923 Base Module Service • Page 69

Replacing the Jaw/Wrist Actuator Controller PCB ...................... page 70
Servicing the Jaw or Wrist Servo Valve ................................... page 71
Removing the Jaw Bypass Valve............................................. page 72
7.3.1 Opening the Base Module

Refer to drawing and the parts list for 101-3655 for this procedure. To access internal base con-
troller components, follow the procedure below:
1. Disable hydraulic power to the manipulator system.
2. Disable power by turning off the power switch on the junction box or disconnecting local power to
the base module.
3. Isolate the compensation system and drain the compensation fluid from the base module.
4. Remove the four HHCS (13) and washers (17) and separate the power supply cover (4) and
manifold cover (power supply atmospheric container) (2) from the base module case. Disconnect
the wiring harness coming from the power supply (21).
! Caution
When you handle the PC boards or other electronic components, wear
an anti-static wrist band attached to earth ground or a large metal
object.
7.3.2 Closing the Base Module

To reinstall the power supply cover (4) and manifold cover (2) follow the procedure below:
1. Check that all wire harnesses are connected and that no wires will be pinched when the
covers are reinstalled.
2. Lubricate two new o-rings (26) with o-ring lube and install onto the power supply cover and the
manifold block.
3. As you lower the manifold cover into place, connect the wiring harness to the power supply.
4. Install the power supply cover. Install the four HHCS and washers. Torque to 9 ft/lb (12Nm).
7.4 Replacing the Jaw/Wrist Actuator Controller PCB

1. Open the base module as described in “Opening the Base Module” section on page 70.
2. At the controller board (3), remove the wire harness coming from the servo valve (7). Remove the
five wires going to J4 from the base module board (36).
3. Remove the three SHCS (37) and washers (38) that hold the actuator control board in place.
! Caution
When any actuator controller board is replaced, the new board’s DIP
switch must be set with the address of the actuator it will control. If
the controller board has the wrong address, the actuator may not
respond to commands or may respond to commands intended for a
different actuator.
4. Set the DIP switches on the replacement controller board as outlined below:
Page 70 • Base Module Service 011–0923

The DIP switch unit is shown in Figure 9 on page 71. The individual switches are labeled,
left to right, with numbers from 1 through 8 across the bottom of the switch unit. Each
switch contains a sliding tab. The switch is in the ON position when the sliding tab is
moved towards the ON label. The switch is in the OFF position when the sliding tab is
moved closest to its number.
Figure 9 Setting controller board address switches

Switch settings for each joint are shown in Table 2 and Table 3. Use a non-conducting tool for
moving switches.
Table 2
DIP Switch Settings, Right-Hand Slave Arm

Joint Joint SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
No. Name
5 Wrist Off On Off On On On On Off
6 Jaw On Off Off On On On On Off
Table 3 Left-hand Slave Arm DIP Switch Settings
DIP Switch Settings, Left-Hand Slave Arm

Joint Joint
No. Name SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
5 Wrist Off On Off Off On On On Off
6 Jaw On Off Off Off On On On Off
5. Install the replacement controller board. While installing the board, be careful not to damage the
pins that the boards seats on.
6. Install the three SHCS (37) and washers (38) that hold the actuator control board in place.
7. Install the five wires going to J4 from the base module board and secure them with a harness tie.
Install the wire harness coming from the servo valve.
8. Close the base module as described in “Closing the Base Module” on page 70.
7.5 Servicing the Jaw or Wrist Servo Valve

1. Open the base module as described in “Opening the Base Module” on page 70.
2. At the controller board (3), remove the wire harness coming from the servo valve (7).
3. Remove the four SHCS (8) from the servo valve.
011–0923 Base Module Service • Page 71

4. Remove the four o-rings (49) from beneath the servo valve.
5. Lube four new o-rings (49) with o-ring lube and install to the underside of the servo valve.
6. Place the new servo valve in position and install with four SHCS. Torque to 9 ft/lb (12Nm).
7. Connect the wire harness to the controller board.
8. Close the base module as described in “Closing the Base Module” section on page 70.
7.6 Removing the Jaw Bypass Valve

When hydraulics are disabled, because of operator control or hydraulic failure, a bypass valve in
the base module causes the jaw to relax its grip. Objects held by the jaw may be released or
dropped. If you prefer that the jaw lock when hydraulic power is disabled, the bypass valve must
be removed. To service the jaw bypass valve, complete the steps in “Accessing Internal Base
Module Components” section on page 69. Then proceed to the steps below:
! Caution
This procedure requires four new SHCS, 10-24 x 1-1/2-in (manufac-
turer P/N 002-0197, and cannot be completed without them (see
Conan Spares Kit 008-0090, item 7-37).
NOTE: It is not necessary to separate the servo valve from the lock valve for this proce-
dure.
1. Open the base module as described in “Opening the Base Module” section on page 70.
2. Locate the jaw servo valve.
3. Remove the four SHCS (46) that secure the servo valve/lock valve assembly (7 & 31) and the jaw
bypass valve to the manifold block (1).
4. Carefully lift the servo valve/lock valve assembly and remove the bypass valve block (81) and four
o-rings (47).
5. Lubricate four new o-rings with o-ring lube and install to the bottom of the servo valve/lock valve
assembly. Place the servo valve/lock valve assembly onto the base controller manifold and align
the mounting holes.
6. Install the four new SHCS 10-24 x 1-1/2-in (P/N 002-0197) and torque to 45 in/lb (5.1Nm).
7. Close the base module as described in “Closing the Base Module” section on page 70.
8 Slave Arm Service

Instructions. For additional details, refer to the slave arm drawing and part list in the “Drawings
& Part Lists” chapter.
Servicing Slave Arm Servo Valves .......................................... page 73
Servicing Slave Arm Actuator Boards ...................................... page 73
Wrist Pitch/Yaw Hose Fittings................................................. page 75
Page 72 • Slave Arm Service 011–0923

8.1 Servicing Slave Arm Servo Valves
To replace the azimuth, shoulder, elbow, pitch, or yaw actuator servo valve, you will need to gain
access to the control module (containing the servo valve).
1. Position the slave arm or disconnect slave arm components as needed to allow the control
module cover to be removed.
2. Remove the four SHCS (5) from the cover (2).
3. Gently remove the cover. Try to leave the base of the control module attached to the actuator. This
will retain the o-rings located between the control module and the actuator. As you remove the
cover, disconnect the five wires from J4 on the controller board (9). Remove the o-ring (12) from
the cover (2).
4. Disconnect the wire harness that leads from the servo valve (4) to the controller board at J5.
5. Remove the four nuts (8) holding the servo valve in place. Lift the servo valve off the manifold (1).
6. Lubricate four new o-rings (004-0561) with o-ring lube and install to the bottom of the
replacement valve.
7. Install the valve. Install the four nuts that hold the valve in place.
8. Install the wire harness from the valve to the controller board (J5).
9. Lubricate a new o-ring with o-ring lube and install into the cover. As you install the cover, connect
the five wires to J4 on the controller board. Note that the wires are color coded to the J4
connector.
10. Install the four SHCS to hold the cover in place.
11. Reconnect slave arm components disconnected to gain control module access.
8.2 Servicing Slave Arm Actuator Boards

To service the azimuth, shoulder, elbow, pitch, or yaw actuator board, you will need to gain
access to the control module (containing the actuator board).
! Caution
When you handle the PC boards or other electronic components, wear
an anti-static wrist band attached to earth ground or a large metal
object.
1. Position the slave arm or disconnect slave arm components so the control module cover
can be removed.
2. Remove the four SHCS (5) from the cover (2).
3. Gently remove the cover. Try to leave the base of the control module attached to the actuator. This
will retain the o-rings located between the control module and the actuator. As you remove the
cover, disconnect the five wires from J4 on the controller board (9). Remove the o-ring (12) from
the cover (2).
4. Disconnect the wire harness that leads from the servo valve (4) to the controller board at J5.
5. Remove the three SHCS (14) and washers (15) that hold the controller board in place. Remove the
controller board.
NOTE: When an actuator controller board is replaced, the new board’s DIP switch must
be set with the address of the actuator/function it will control. If the controller board has
011–0923 Slave Arm Service • Page 73

the wrong address, the actuator may not respond to commands or may respond to com-
mands intended for a different actuator.
6. Set the address on the replacement controller board as outlined below:

The DIP switch unit is shown Figure 10. The individual switches are labeled, left to right,
with numbers from 1 through 8 across the bottom of the switch unit. Each switch
contains a sliding tab. The switch is in the ON position when the sliding tab is moved
towards the ON label. The switch is in the OFF position when the sliding tab is moved
closest to its number.
Figure 10 Setting controller board address switches

Switch settings for each joint are shown in Table 4 and Table 5. Use a non-conducting
tool for moving switches.
Table 4
Switch Settings, Right-Hand Slave Arm

Joint Joint
No. Name SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
0 Azimuth On On On On On On On On
1 Shoulder Off On On On On On On On
2 Elbow On Off On On On On On On
3 Pitch Off Off On On On On On On
4 Yaw On On Off On On On On On
Table 5
Switch Settings, Left-Hand Slave Arm

Joint Joint SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
No. Name
0 Azimuth On On On Off On On On On
1 Shoulder Off On On Off On On On On
2 Elbow On Off On Off On On On On
3 Pitch Off Off On Off On On On On
4 Yaw On On Off Off On On On On
7. Install the controller board using the three SHCS and washers.
8. Install the wire harness from the valve to the controller board (J5).

9. Lubricate a new o-ring with o-ring lube and install into the cover. As you install the cover, connect
the five wires to J4 on the controller board. Note that the wires are color coded to the J4
connector.
10. Install the four SHCS to hold the cover in place.
11. Reconnect slave arm components that were disconnected to gain control module access.
8.3 Wrist Pitch/Yaw Hose Fittings

Wrist pitch and yaw hoses are supplied with reusable fittings at the ends connected to the base
module. These fittings must be removed to extract the hoses from the slave arm. Replacement
wrist pitch and wrist yaw hydraulic hoses are supplied without the fittings installed so they can
be installed through the pitch and yaw structural segments. See the fitting installation instruc-
tions below.
Installing Reusable Fitting 006-1205

The following instructions describes how to shorten a hydraulic
hose and/or terminate it with reusable fitting 006-1205 (OEM
Aeroquip 63-190600-4).
1. Determine the required hose length and mark the hose at the cut-off point.
Disconnect both ends of the hose from components.
2. Wrap the hose with masking tape at the cut-

off point and cut square through the taped
area using a cut-off saw fitted with an abrasive
blade (you can also use a fine-tooth hacksaw,
as shownin figure, left). Remove the tape and
trim any loose wires flush with the tube stock.
Remove any burrs on the bore of the tube
stock with a knife.
1-1/2” 3. Trim the hose jacket back about 1-1/2 in. from
the end, exposing the braid, as shown at left.
4. Install the socket onto the hose end. Push the

new sleeve over the end of the tube and under
the wire braid by hand ( figure left, arrow).
Complete positioning of the sleeve by pushing
the hose end against a flat surface.
It is critical that the tube stock butts against
the inside shoulder of the sleeve (nearly flush
with the flat end-face of the sleeve). Visually
confirm this orientation.
011–0923 Slave Arm Service • Page 75

Installing Reusable Fitting 006-1205 (cont.)
5. Clamp the hex of the nipple in a vise (male

fitting shown). Push the hose and sleeve over
nipple as shown in Figure, left. Work the hose
with twisting motion until it is seated against
the nipple chamfer (at the base of the nipple).
6. As shown in Figure A, below, push the socket forward on the hose and thread onto
the nipple.
7. As shown in Figure B, below, use a wrench to tighten the nipple hex until it bottoms
on the socket hex and the corners of nipple and socket hexes align.
A B
8. Clean interior of hose assembly with compressed air or flush with mineral spirits or
hot water (65°C/150° F max.). If the hose will not be reconnected immediately, cap
or plug end fittings.
9. Inspect the fitting assembly. The gap between the nipple hex and the socket should
be 1/32-in. or less. The nut on a female fitting should swivel freely.
10. Proof testing:
! Caution
Conduct hose tests with adequate safeguards to protect
personnel in the test area.
Test the hose assembly at 6000 psi (twice the recommended working pressure of
the hose). Hold the test pressure for not more than one minute and not less than 30
seconds. When test pressure is reached, visually inspect hose assembly for any
leaks, bulges, or any movement of the hose in relation to the hose fitting. Correct
any defects before placing the hose into service.\
11. Install the hose between the slave arm and base module, matching the hose and
fitting codes.
12. When hose installation is completed, apply hydraulic pressure to the slave arm,
operate the affected slave arm joint, and inspect the new fitting for leaks or any
movement of hose within the hose fitting.

9 System Configuration
Adjusting Servo Valve Offsets ................................................ page 77
Changing the Communications Protocol .................................. page 79
9.1 Adjusting Servo Valve Offsets

Access path: MAIN/SETUP/SET SV OFFSET
The servo offset adjustment balances the response of a servo valve to control input so the speed
of actuator movements is consistent in both directions of travel. Correct adjustment also keeps
the actuators without lock valves (wrist pitch/yaw, wrist, jaw) immobile when the servo valve is
inactive (no control input pending) and reduces sag and/or drift when hydraulics are disabled.
The key physical symptoms indicating the need for adjustment are:
 A joint that moves faster in one direction than the other (given similar control
inputs). This is most noticeable following a high speed movement of the master
arm, when the servo valve is fully driven.
 Spontaneous joint drift in the wrist pitch/yaw, wrist, or jaw functions
 An increase in the sag or drift of the wrist pitch/yaw, wrist, or jaw functions when
hydraulics are disabled.
The servo valve offset for each function is set at the factory but should be checked and adjusted
when a servo valve, control module, actuator, or other control software or hardware within the
master controller, base module, or control module has been serviced or replaced. Component
wear, temperature, and other environmental factors may also affect the servo valve response and
initiate the need for offset adjustment.
The servo offset for each joint (including the wrist and jaw) is set independently, and does not
affect the offset for any other joint. The goal is to equalize the servo valve's null position so that
when it is activated the servo can provide an equivalent hydraulic flow to either port of the actua-
tor. This will ensure balanced travel rates and minimize sagging and drift in the functions with-
out lock valve.
To set the slave arm servo offsets, follow these steps:
1. Set the current privilege level to 1 or higher. (If you aren't sure what the current level is,
display the SET LEVEL menu, as described in the Operation chapter, and note the level
displayed on the screen). Enter the password and change to a higher privilege level if
necessary.
2. From the OPERATE menu toggle the jaw mode to POS. Make sure hydraulics are enabled (ON).
3. From the MAIN menu, select the 3> SETUP menu. From the SETUP menu, select the SET SV
OFFSET <7 menu (Figure 11).
011–0923 System Configuration • Page 77

SET SV OFFSET FRZ

--------------------------------
1> Joint:Azimuth Inc Offset <5
Pos Error:+0004
Dec Offset <6
SV Offset:-050
EXIT <8
--------------------------------
Figure 11 Setting servo offsets

4. The slave arm should be positioned so that all joints are near the centers of their ranges of motion.
If any of the joints are at or near their limits, unfreeze the arm and reposition it, then freeze it
again.
5. The joint for which servo offset is being set will appear in the 1> Joint: field. You can cycle through
the joints by pressing 1> Joint.
6. For each joint, a value will appear in the Pos Error: field. The goal is to get this value as close to
zero as possible. (In practice, the lowest absolute value between +0009 and -0009 is acceptable.)
If the displayed value is not near-zero, press the 5> Inc Offset and 6> Dec Offset keys to adjust the
value in the SV Offset: field until the Pos Error: field value is lowest.
NOTE: The slave arm will move slightly after each increment or decrement of the servo
offset. You should wait a few seconds after each change for the arm, and the values, to
stabilize.
7. Press 1> Joint: to move to the next joint. Repeat steps 6 and 7 until the servo offsets for all joints
except the wrist and jaw (azimuth, shoulder, elbow, pitch and yaw) have been nulled.
8. Wrist offset adjustment: If necessary, reposition the arm so that you can see the wrist, and freeze
the arm again.
The wrist does not have position feedback, so adjustment of its servo offset is less precise.
Normally, you will need to adjust the wrist servo offset only if the servo valve has been
serviced, or if the wrist rotates spontaneously. To null the wrist servo offset, perform the
following adjustment procedure:
a. Press 1> Joint until the adjacent field reads WRI.
b. Press 5> Inc Offset until the wrist begins rotating slowly. Note the SV Offset value (it
may be relatively large).
c. Press 6> Dec Offset until the wrist begins rotating slowly in the opposite direction.
Again note the SV Offset value.
d. Add the two offset values algebraically (that is., include the plus or minus signs). If,
for example, the positive offset value was +260 and the negative offset value was -60,
their algebraic sum is +200. Divide this value by 2. Increment or decrement the SV
offset to match this result (+100, in the example).
Page 78 • System Configuration 011–0923

9. Jaw offset adjustment: If necessary, reposition the arm so that you can see the jaw, and freeze the
arm again. The jaw mode must be set, in the OPERATE menu, to POS for this step.
The jaw does not have position feedback, so adjustment of its servo offset is less precise.
Normally, you will need to adjust the jaw servo offset only if the servo valve has been
serviced, or if the jaw slowly opens or closes spontaneously. To null the jaw servo offset,
perform the following adjustment procedure:
a. Press 1> Joint until the adjacent field reads JAW.
b. Press 5> Inc Offset until the jaw begins closing slowly. Note the SV Offset value (it
may be relatively large). (Allow the jaw to close all or most of the way.)
c. Press 6> Dec Offset until the jaw begins opening slowly. Again note the SV Offset
value.
d. Add the two offset values algebraically (that is, include the plus or minus signs). If, for
example, the positive offset value was +500 and the negative offset value was -240,
their algebraic sum is +260. Divide this value by 2. Increment or decrement the SV
offset to match this result (+130, in the example).
10. Press 8> EXIT to exit the SET SV OFFSET menu and save the new settings.
! Caution
Changes to the servo offsets can change the positioning response of
the slave arm joints. Reset the slave arm movement limits and/or
stow sequence immediately if their settings are needed to prevent
damage to the slave arm or work area (see “Setting Slave Arm Move-
ment Limits” and “Setting the Stow In/Stow Out Sequence” in the
“Operation” chapter for details).
9.2 Changing the Communications Protocol

This manipulator system can be operated using RS-232 (factory default) or RS-485 protocol. To
change the telemetry configuration you must move a connector on the master controller master
processor PC board and change jumper settings on the Base Module PC board.
9.2.1 Configuring the Master Processor Board

1. Open the master controller as described in “Removing the Faceplate” section on page 63.
The RS-232 (P1A) connector (default) and the RS-485 (P1B) connector are located at the
upper right side of the processor board (Figure 12).
Figure 12 RS-232 / RS-485 connection points

2. To select RS-232 or RS-485 protocol in the master controller, install the J1 connector (terminating
the power/telemetry wire bundle) to the appropriate connector on the PC board. In Figure 12, the
J1 connector is connected to the RS-232 (P1A) connector.
3. Swing the faceplate assembly back over and seat it on the enclosure. Make sure that no wires or
cables are pinched between the faceplate and the enclosure.
4. Do not install the four cover mounting screws at this time.
9.2.2 Configuring the Base Module PC Board

Refer to the base module drawing in the “Drawings & Part Lists” chapter. To access the base
module/SCU PC board, perform the following steps:
1. Open the base module as described in section 7.3.1, “Opening the Base Module,” on page
70.
2. Remove the three SHCS (37) and washers (38), and separate one of the actuator controller boards
from the base module/SCU PC board (36). Repeat for the second board.
3. Set the jumpers on the base module/SCU PC board for the desired telemetry option using Table 6
and Figure 13. This telemetry option must match the telemetry option set on the master controller
PCB (RS-232 or RS-485).
Table 6
Base Module Jumper Settings

Jumper RS-422(-485) RS-232
Number HALF DUPLEX (DEFAULT)
JP1 1-2 1-2
JP2 1-2 1-2
JP3 2-3 2-3
JP4 1-2 2-3
JP5 1-2 2-3
JP6 1-2 1-2
JP7 1-2 1-2
JP8 1-2 2-3
JP9 1-2 2-3
Page 80 • System Configuration 011–0923

DEFAULT
= RS-422 (-485) HD
= RS-232 (DEFAULT)
Figure 13 Telemetry jumper settings

4. Return one of the actuator controller boards to the standoffs (39) on the base module/SCU PC
board (36). Install the three SHCS (37) and washers (38). Repeat for the second board.
5. Do not close up the base module. Proceed to the sext section.
9.2.3 Testing the Protocol Configuration

1. Before closing up the master controller and base module, connect all manipulator system
components and confirm system operation. If the system starts and operates correctly,
proceed to the next step.
If the system fails to start or the message “FATAL TELEMETRY ERROR” appears on the
display, check for the following problems and correct them before proceeding:
a. Are the settings in the master controller or base module for the same protocol?
b. Has a jumper or pin been damaged or bent?
c. Does the manipulator system operate correctly when connected for deck-testing (long
lines bypassed)?
d. Are the connections to multiplexed long lines consistent, end to end, for
slave>master/master>slave or RS-485/RS-232 communications.
2. If the system is operating correctly, close the master controller as described in “Installing the
Faceplate” on page 63
3. Close the base module as described in “Closing the Base Module” on page 70.

4. Charge and bleed the base module compensation system (see the “Installation” chapter for
details).
10 Instructions for Serviceable Components

 Service instructions are written specifically to repair or overhaul a component,
and describe the complete disassembly and reassembly processes.
 Work instructions are written for factory assembly and some steps do not
apply to field service or maintenance. Disregard the steps under Initial Prepara-
tion and the quality control (QC) tests. To disassemble a component for service or
maintenance, perform the steps in reverse order until the desired parts are
exposed.
 Service and work instructions are supported by their associated part lists and
drawings in the “Drawings & Part Lists” chapter.
10.1 Startup Following Maintenance or Service

Startup After Minor Maintenance or Service
1. Follow steps in the “Pre-Start Checks” and “Startup Sequence” sections of the
“Operation” chapter.
2. Be sure to replace hydraulic and compensation fluids lost during maintenance or service
Startup After Major Service
1. Follow the procedures in “Completing the Installation” in the “Installation” chapter
before resuming normal operation.
2. If the hydraulic or compensation fluid has been contaminated, flush the system and refill with
fresh fluid.
10.2 Work & Service Instruction List

See the following page.
Page 82 • Instructions for Serviceable Components 011–0923

•
Use the list below to find the work or service instruction that you need.
Jaw Kit, 6-inch, 101-3299 ..................................................... page 84
Wrist Motor Assembly, 101-3372............................................ page 86
Control Module, Actuator, 101-3657 ....................................... page 88
Linear Actuator, 2.6-in x 1.75-in, 101-3658 ............................. page 90
Linear Actuator, 2.25-in x 6-in, 101-3659................................ page 92
Slave Arm, 101-3665-4 ........................................................ page 95
Wrist with Parallel-Acting Jaw, 101-3683 ............................... page 100
Wrist, Orion, 101-3786 ....................................................... page 102
Master Controller, Aux. Jaw Switch, 101-5781........................ page 106
Base Module, 101-7854 ...................................................... page 112
011–0909 • Page 83
Jaw Kit, 6-inch, 101-3299
Work Instructions
Assembly Number: 101-3299 Description: Jaw Kit, 6 Inch
Product Family: Conan
Job Number: Qty: Date: Dwg Rev:
Tech: Due Date: BOM Rev:
Process Specifications, Procedures or Remarks:
Work Instructions: Drawing: BOM:

Do not revise Do not revise Do not revise
Revise Revise Revise
Materials Required:
Adhesives:
Loctite® 271 002-0795
Chemicals:
AquaLube
Tools:
Bench Vise
1/8 inch dia. punch
Hammer
Initial Preparation:
Serialization:
Serialization is not required.
Workmanship:
For the duration of the assembly process, verify that there are no sharp edges or scratches
on any exposed surfaces; that there are no missing parts; and that all hoses, cables, or
wires are routed correctly. Determine that all threaded fasteners have been torqued to the
correct values. Record your findings on the data sheet.
Completeness of assembly:
Verify that all assembly components listed on the bill of material are in the kit. Record
your findings on the data sheet.
Assembly:
101-3299-WI-A1F Page 1 of 3 2/4/2008
011–0909 • • Page 84
[ ]1. Using Loctite #271, glue bearings (1-2), (2-2), and (3-2) into rocker links (1-1), (2-
1) and (3-1) respectively.
[ ]2. Insert rocker link (3) and two bearings (14) into jaw (1) as shown. Insert the .499
pin (7) through jaw flanges, bearings, and rocker link. Align the .125 diameter
hole in pin with hole in rocker link. Press, or drive, the spring pin (17) into the
.125 diameter hole until flush with rocker link surface.
[ ]3. Insert the .499 diameter pin (8) into jaw (1) as shown. Install thrust washer (15),
idler link (2) with chamfer facing away from jaw, thrust washer (15), jaw washer
(12), and HHCS (11) onto both ends of pin (8). Torque the HHCS (11) as
indicated on the assembly drawing.
[ ]4. Q.C. Point 1. Verify bearings (1-2), (2-2), (3-2) and (14), spring pin (17), thrust
washers (15) have been installed and torque of HHCS (11). Record your findings
on the data sheet.
[ ]5. Install bearing (19) and shafts (6) into rocker link (3). Slide the thrust washer (13)
and spacer (5) over each end of the shaft (6). Also install the thrust washers (15)
over each end of the two idler plates (4).
[ ]6. Install the idler plate (4) through the two idler links (2) and onto the two shafts (6)
as shown on the assembly drawing. Repeat the process on the opposite side of the
unit.
[ ]7. Install HHCS (9) and washer (10) onto each end of the shafts (6).
[ ]8. Q.C. Point 2. Verify that the bearings (19), shafts (6) and rocker links (3) have
been assembled correctly. Also check that the spacer (5) and thrust washer (15)
have been installed over the shaft (6) and that the thrust washers (15) have been
installed over the idler plates (4). Verify that the idler plates (4) were installed
correctly and the HHCS (9) and washer (10) are installed correctly. Record your
findings on the data sheet.
Remarks:
Record any pertinent findings or information not directly called for on the data sheet. For
example: corrective action that may have been taken for the assembly to pass any of the
above tests, failed tests, or problems encountered during assembly or testing.
Acceptance:
Record the name of person inspecting the assembly and affix the acceptance tag.
Record Military Specification (as required) to which the assembly was tested, and date
that the test was completed.
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Wrist Motor Assembly, 101-3372
Version: Q
Work Instructions
Assembly Number: 101-3372 Description: Wrist Motor Assembly
Product Family: Conan/RigMaster
Materials Required:
Chemicals:
Aqua Lube (002-0805) O-ring lubricant (Dow Corning® 55) Never-Seez® (002-1925)
Petroleum jelly Valvoline® Val-plex EP® grease
Miscellaneous:
Nitrile gloves Safety glasses Paper towels
Tools:
010-0173 010-0175 010-0557
010-0174 010-0804 010-0991
Serialization:
Serialize, using steel stamps, in location shown on the assembly drawing, using the last
five digits of the job number, the assembly number and BOM revision letter. Add the
designation -1, -2, -3, etc. for jobs consisting of more than one assembly. (i.e. 101-3372
X__XXXXX-X) Record the serial number of each assembly at the top of it data sheet.
Workmanship:
on any exposed surfaces; that no parts are missing; and that all hoses, cables, or wires are
routed correctly. Verify that all threaded fasteners have been torqued to the correct
values. Record your findings on the data sheet.
Follow all standard Shop Practices during assembly process. If unsure of what
the practices are, see the Manufacturing Supervisor
Assembly:
[ ]1. Install the two rod bearings (7-8) into the noseblock (7-5).
[ ]2. Install the seals (7-9) into the noseblock (7-5). See the assembly drawing for the
correct orientation and placement of the seals.
[ ]3. Install the backup ring (7-7) and then the o-ring (7-6) into the groove in the nose
block (7-5) as shown on the assembly drawing.
[ ]4. Install the jaw bolt (7-13) into the counterbore of the T-bar plate (7-12) per note 9,
as shown on the assembly drawing.
[ ]5. Q.C. Point 1. Verify that the bearings (7-8) and the backup ring (7-7) are installed.
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Check that the seals (7-9) and o-ring (7-6) are installed. Verify the orientation and
installation of the T-bar plate (7-12). Record your findings on the data sheet.
[ ]6. Apply anti-seize (7-11) to the threads and under bolt head of jaw bolt (7-13).
[ ]7. Install the piston (7-2) into the nose block (7-5) using tool 010-0804 and then
install the jaw bolt (7-13) into the piston. Place the assembly onto the fixture 010-
0991 and torque as indicated as shown on the assembly drawing. Ensure that the
T-bare plate does not damage the noseblock when torqueing by placing a
protective layer (popsicle stick) between T-bare plate and noseblock on both sides.
[ ]8. Install the bearings (7-3) and then the seal (7-4) onto the jaw piston (7-2) using
tool 010-0174 as shown on the assembly drawing. Remove the bearings and then
resize the seal with tool 010-0175. Reinstall the bearings.
[ ]9. Q.C. Point 2. Verify the correct assembly of the nose block unit (7) and that the
bearings (7-3) and the seal (7-4) are installed. Record your findings on the data
sheet.
[ ]10. Using the four HHCS (7-14) and washers (7-16) install the nose block unit (7)
onto the wrist motor (2) as shown on the assembly drawing. Torque the HHCS (7-
14) as indicated on assembly drawing.
[ ]11. Test 1. Jaw Functionality Test: Use compressed air to extend and retract the jaw
rod several times. Apply pressure to the C1 port and observe that there is no
pressure leaking from the C2 port. Record your findings on the data sheet.
[ ]12. Q.C. Point 3. Verify the torque of the HHCS (7-14). Verify the results of Test 1.
Record your findings on the data sheet.
[ ]13. Affix acceptance tag and route to stock.
Remarks:
Record on the data sheet any pertinent findings or information not directly called for. For
example, record failed tests, problems encountered during assembly or testing, or
corrective action taken for the assembly to pass any of the tests.
Acceptance:
Record on the data sheet your name and the date on which the test was completed.
Record the inspector’s name on the data sheet, and affix the appropriate acceptance tag.
Record the Military Specification (as required) that the assembly was tested to and the
date on which the test was completed.
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Control Module, Actuator, 101-3657
Work Instructions
Assembly Number: 101-3657 Description: Control Module, Actuator, Bidirection
Materials Required:
Adhesives:
Loctite® 271 002-0795 Epoxy 2043 (90 sec.) 002-1509
Chemicals:
O-ring lubricant (Dow Corning® 55) Aqua Lube 002-0805
Tools:
Serialization:
Serialize the actuator control module in the location shown on the assembly drawing,
with the vibro engraver, using the last five digits of the job number. Add the designation
-1, -2, -3, etc. for jobs consisting of more than one assembly. Record the serial number of
each assembly at the top of its individual data sheet.
Also record the serial numbers of the servo valve (4) and PCB (9) subassemblies in the
spaces provided on the data sheet.
Workmanship:
on any exposed surfaces, that there are no missing parts, and that any cables or wires are
routed correctly. Check for the presence of any foreign matter. Record your findings on
the data sheet.
Verify that all assembly components listed on the bill of material are present in the kit.
Follow all standard Shop Practices during assembly process. If unsure of what the
practices are, see the Manufacturing Supervisor
[ ]1. Press the spiral pin (10) into the manifold (1) until it bottoms out in the hole.
[ ]2. Apply Loctite 271 (24) to the male end of the three standoffs (13) and install them
into the manifold as shown on the assembly drawing.
[ ]3. Q.C. Point 1. Ensure the spiral pin protrudes approximately .295 inch (max).
Assembly:
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[ ]1. Use the four SHCS (8) to secure the servo valve (4) to the manifold (1). Make
sure that the servo valve is correctly oriented and that all o-rings are present in the
grooves on the bottom of the servo valve.
[ ]2. Secure the PC board (9) to the three standoffs (13) using the three SHCS (14), five
washers (15), and two SHCS (16) as shown on the assembly drawing. The
connector from the PC board must seat in the large bore of the manifold (1). Do
not over tighten screws and ensure that the nylon washers (15) do not deform.
[ ]3. Connect the whip from the servo valve (4) to the PC board (9), and secure it to the
body of the servo valve with a cable tie (27). Make sure that the whip is not routed
over the top of the servo valve and that the cable tie end is toward the PC board.
Trim the excess cable tie with flush cutters.
[ ]4. Secure the cable tie (26) to the inside of the cover (2) with the SHCS (18) as
shown in section A-A of the assembly drawing. Install the cable tie so that it does
not hit or rub against the inside of the cover (2) when it is installed.
[ ]5. Install the self-sealing screw (22) with the orange o-ring, in the cover (2) as shown
on the assembly drawing.
[ ]6. Q.C. Point 2. Check the installation of the servo valve (4) and the PC board (9).
Ensure that the cable tie (27) is securing the whip from the servo valve that is
connected to the PC board. Verify installation and orientation of cable ties (26),
and (27) and SHCS (18). Check the installation of the self-sealing screw (22).
[ ]7. Slide the cover (2) over the unit. Bag items (6),(12),(5),(20),(19),(3),(21) and send
to stock in a small cardboard box.
Remarks:
Acceptance:
Record your name and the date that the test was completed.
Record the military specification (as required) to which the assembly was tested, and the
date that the test was completed.
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Linear Actuator, 2.6-in x 1.75-in, 101-3658
Work Instructions
Assembly Number: 101-3658 Description: Linear Actuator, 2.6" X 1.75"

Materials Required:
Adhesives:
Loctite® 271 (002-0795)
Loctite® PST Nuclear grade (002-1618)
Chemicals:
O-ring Lubricant (Dow Corning® 55) petroleum jelly
Valvoline® Val-plex EP® grease
Tools:
010-0184 010-0185 010-0203 010-0236 010-0523 010-0563
Serialization:
Serialize the actuator body, using the stamp and ink, as shown on the assembly drawing.
Use the last five digits of the job number for the serial number. Add a designation of -1, -
2, -3, etc. for jobs consisting of more than one assembly. Record the serial number of
each assembly at the top of its respective data sheet.
Workmanship:
For the duration of the assembly process verify that there are no sharp edges or scratches
on any exposed surfaces, and that there are no missing parts. Check that all threaded
fasteners are torqued correctly. Record your findings on the data sheet.
Verify that each of the components of the assembly called for on the bill of material are
present, and record findings on the data sheet.
[ ]1. Install the composite bearing (12) in the rod end (11). Clean the parts well and use
Loctite® 271 (16) when pressing the bearing into the bore.
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[ ]2. Install the two Cv plugs (15) into the actuator body (1) using Loctite® PST (18),
and tool #010-0523 (23), as described in SRS specification 130-0098-1.
Assembly:
[ ]1. Install the bearings (7) in its groove in the nose nut (6).
[ ]2. Install the seals (8) and scraper (9) in their grooves in the nose nut (6).
[ ]3. Install o-ring (10) into the groove on the outside diameter of the nose nut (6).
[ ]4. Use tool #010-0563 (24) to install o-ring (13) onto the rod end (11).
[ ]5. Q.C. point 1. Verify that the Cv plugs (15) have been installed correctly. Check to
see that the bearings (7) and (12), seals (8) and (9) and o-rings (10) and (13) are
installed correctly. Record your findings on the data sheet.
[ ]6. Use tool 010-0203 (19) to resize the seals and bearing strips in the nose nut (6).
Screw the tool into one end of the shaft (2) and lube both the shaft and the tool
well. Carefully slide the bullet shaped tool through the nose gland making sure the
orientation is as shown on the assembly drawing.
[ ]7. Unscrew the tool and apply Loctite® 271 (16) to the male threads of the rod end
(11). Thread the rod end (11) into the end of the piston (2). Using tool #010-0238
(24) to clamp the piston, torque the piston/shaft/rod end unit to 60 ft-lb.
[ ]8. Install the bearing (4) into its groove on the piston (2). Using tool # 010-0184 (20)
install the o-ring (3) and the seal (17) into its groove on the piston. Use tool # 010-
0185 (21) to resize the seal (17).
[ ]9. Q.C. point 2. Check that the seal (17) and the bearing (4) are installed on the
piston (2). Record your findings on the data sheet.
[ ]10. Apply a film of petroleum jelly to the inner surfaces of the body (1). Also apply a
film of petroleum jelly or o-ring lube to the bearings and seal on the piston. Apply
a light film of EP® lube to the threads of the actuator housing.
[ ]11. Carefully slide the piston (2) into the bore of the actuator body (1) until it is about
half way down the bore. Slide the nose nut (6) down the piston rod and down into
the bore of the body. You will feel the o-ring slide past the chamfer in the bore,
continue to thread the gland down until it bottoms out on the step in the bore.
Torque the nose nut (6) to 100 ft-lb.
[ ]12. Q.C. point 3. Check the final configuration on the assembly. Record findings on
data sheet, affix acceptance tag, bag and return to stock.
Remarks:
101-3658-WI-A1F Page 2 of 4 2/4/2008
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Linear Actuator, 2.25-in x 6-in, 101-3659
Work Instructions
Assembly Number: 101-3659 Description: Linear Actuator, 2.25" X 6"

________________________________________________________________________
Materials Required:
Adhesives:
Loctite® 271 (002-0795)
Loctite® PST Nuclear grade (002-1618)
Chemicals:
O-ring lubricant (Dow Corning® 55) petroleum jelly
Valvoline® Val-plex EP® grease
Tools:
010-0523 010-0546 010-0236
010-0563 010-0203 010-0173/010-0218
010-0174 010-0175/010-0217 010-0486
Serialization:
Serialize the linear actuator body, using the stamp and ink, as shown on the assembly
drawing using the last five digits of the job number, the assembly number and BOM
revision letter. Add the designation -1, -2, -3, etc. for jobs consisting of more than one
assembly. (i.e. 101-XXXX X__XXXXX-X) Record the serial number of each assembly
at the top of its individual data sheet.
Workmanship:
For the duration of the assembly process verify that there are no sharp edges or scratches
on any exposed surfaces, and that there are no missing parts. Check that all threaded
fasteners are torqued correctly. Record your findings on the data sheet.
Verify that each of the components of the assembly called for on the bill of material are
present, and record findings on the data sheet.
101-3659-WI-A1G Page 1 of 4 2/4/2008
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[ ]1. Install the composite bearing (14) in the rod end (13). Clean the parts well and use
Loctite® 271 (25) when pressing the bearing into the bore.
[ ]2. Install the eight Cv plugs (21) and the Cv plug (22) into the actuator body (1) using
Loctite® PST (26) and tools 010-0523 (30) and 010-0546 (31) to install Cv plugs
per SRS specification 130-0098-1.
[ ]3. Place two of the thrust bearings (2) into the bottom of the side bores of the actuator
body (1) and then press the two bearings (3) into those same bores.
Assembly:
[ ]1. Install the bearing (9) in the shallower, wider groove in the nose nut (8).
[ ]2. Install the seals (10) and scraper (11) in their grooves in the nose nut (8).
[ ]3. Install o-ring (12) into the groove on the outside diameter of the nose nut (8).
[ ]4. Use tool 010-0563 (32) to install o-ring (15) onto the rod end (13).
[ ]5. Install the two fittings (24) as shown on the assembly drawing.
[ ]6. Q.C. point 1. Verify that the Cv plugs (21) and (22) are installed. Check to see that
the bearings (2), (3), (9) and (14), the seals (10) and (11), the o-rings (15) and (12)
and the fittings (24) are installed correctly. Record your findings on the data sheet.
[ ]7. Use tool 010-0203 (29) to resize the seals and bearing strips in the nose nut (8).
Screw the tool into one end of the piston shaft (4). Carefully slide the bullet
shaped tool through the nose gland making sure the orientation is as shown on the
assembly drawing.
[ ]8. Unscrew the tool and apply Loctite® 271 (25) to the male threads of the rod end
(13). Thread the rod end (13) into the end of the piston shaft (4). Using tool # 010-
0173/010-0218 (33) to clamp the piston, torque the piston/shaft/rod end unit, using
tool #010-0486, to 60 ft-lb.
[ ]9. Install the bearing (6) into its groove on the piston (4). Use tool 010-0174 (27) to
install the o-ring and seal (5) into the smaller groove on the piston (4).
[ ]10. Use tool # 010-0175/010-0217 (28) to resize the seal (5).
[ ]11. Q.C. point 2. Check that the seal (5) and the bearing (6) are installed on the piston
(4). Record your findings on the data sheet.
[ ]12. Apply a film of petroleum jelly to the inner surfaces of the body (1). Also apply a
film of petroleum jelly or o-ring lube to the bearings and seal on the piston. Apply
a light film of EP® lube to the threads of the actuator housing.
[ ]13. Carefully slide the piston (4) into the bore of the actuator body (1) until it is about
half way down the bore. Slide the nose nut (8) down the piston rod and down into
the bore of the body. You will feel the o-ring slide past the chamfer in the bore,
101-3659-WI-A1G Page 2 of 4 2/4/2008
011–0909 • • Page 93
continue to thread the gland down until it bottoms out on the step in the bore.
Torque the nose nut (8) to 100 ft-lb.
[ ]14. Q.C. point 3. Check the final configuration on the assembly. Record findings on
data sheet, affix acceptance tag, bag and return to stock.
Remarks:
Acceptance:
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Slave Arm, 101-3665-4
Work Instructions
Assembly Number: 101-3665-4 Description: Slave Arm, 7P, PA Jaw, SMD
Product Family: Conan 24V
Materials Required:
Adhesives:
Loctite® Black Max 38050 002-0814 Loctite® 290 002-0796
Chemicals:
O-ring lubricant (Dow Corning® 55) 002-0359
Aqua Lube 002-0805
Dow Corning® DC-5 Silicon Grease 002-0799
Tools:
1 5/8” socket, machined.
Serialization:
If sold without a control system, stamp the serial number of the slave arm onto the serial
number label (12) using the last five digits of the job number, the assembly number and
BOM revision letter. Add the designation -1, -2, -3, etc. for jobs consisting of more than
one assembly. (i.e. 101-3665-4 X__XXXXX-X) Otherwise, bag serial label (12) and
drive screws (15) for later assembly. Record the serial number of each assembly at the
top of its individual data sheet if needed.
Also record the serial numbers of the wrist, linear actuator, base module actuator module
and transducer subassemblies in the spaces provided on the data sheet.
Workmanship:
on any exposed surfaces, that there are no missing parts, and that any hoses, cables, or
wires are routed correctly. Check for the presence of any foreign matter. Record your
Assembly:
[ ]1. Install the magnets from the transducer assemblies (8), (9) into the pistons of the
five linear actuators (1-5), (2-2), (3-3). The white polarity mark on each magnet
should be visible after installation. Reassemble the actuators and torque the nose
nuts to 100 ft-lb. Retract each actuator to the hard stop prior to step 2.
[ ]2. Install the five transducer assemblies (8), (9) into the five actuators (1-5), (2-2), (3-
3) using the two FHMS from each transducer assembly. Orient the transducer
connector so that the small notch in the transducer is aligned with the arrow and
101-3665-4-WI.doc Rev: A 1 of 7 6/14/2011
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“ALIGN” marked in the back of each actuator. Extend each actuator to
approximately mid stroke prior to step 3. Pack the connector with DC5.
[ ]3. Q.C. Surveillance Required for Step 3. Install the three “lock valve kits” (7)
[consisting of parts (7-1), (7-2), (7-3), (7-4) and (7-5)] into the three linear
actuators (1-5) as shown on sheet 5 of the assembly drawing. Note the orientation
of the lock valve (7-1) and the flow spacers (7-3). Torque the SHSS (7-5) to
64 in-lb.
[ ]4. Q.C. Point 1. From Q.C. surveillance in step 3, verify the installation of the
o-rings (7-4), orientation of lock valves (7-1), orientation of flow springs (7-3),
and spacers (7-2). Verify torque of SHSS (7-5). Record your findings on the data
sheet.
[ ]5. Install the ten relief valves (17) as shown on sheet 6 of the assembly drawing.
Torque the SHSS to 30 in-lb. Apply a single drop of Loctite 290 to each SHSS.
[ ]6. Install the hoses from the coax hose assembly (10) into the adapters from the
control modules (6) as shown on sheet 7 of the assembly drawing. Note the
orientation of each of the hose/adapter units (on sheet 7 of the assembly drawing)
and then attach each adapter to a cover. Use the cable tie secured to the inside of
the cover to route the colored wires.
[ ]6. Set the DIP switches on each actuator controller PCB as shown on the graph
below or the wiring diagram (29). **In-Process Q.C. Point.
Joint Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8
0. Azimuth ON ON ON ON ON ON ON ON
1. Shoulder OFF ON ON ON ON ON ON ON
2. Elbow ON OFF ON ON ON ON ON ON
3. Pitch OFF OFF ON ON ON ON ON ON
4. Yaw ON ON OFF ON ON ON ON ON
5. Wrist OFF ON OFF ON ON ON ON OFF
6. Jaw ON OFF OFF ON ON ON ON OFF
[ ]7. Connect the color-coded wires from the coax hose to the color-coded connector on
the actuator control PCB. Install YAW coax to YAW controller PCB etc. Pack
the electrical components of each actuator control PCB with Dow Corning® DC-5
silicon grease. Install the twenty o-rings on the bottom of the manifolds. Use the
SHCS supplied with the control module assemblies to secure each assembly to the
actuators. Torque the SHCS to 8 ft-lb.
[ ]8. Install the markers (11-21), the backups (11-19) and the o-rings (11-18) onto the
hoses (11-1),(11-2),(11-3),(11-4),(11-5),(11-6),(11-7),(11-9),(11-12),(11-15) and
(11-16) as shown on sheet 8 of the assembly drawing. Install the hose assemblies
onto the three actuators (1-5), into the forearm (1-4), the yaw (3-1), onto the wrist
(4) and onto the two manifolds (11-10) as shown on sheet 9 of the assembly
drawing. Install the four fittings (11-17) onto the hoses (11-4) and (11-5) per SRS
specification 130-0082. Record the actuator serial numbers on the data sheet.
101-3665-4-WI.doc Rev: A 2 of 7 6/14/2011
011–0909 • • Page 96
[ ]9. Install the shoulder bumper (1-21) onto the hard stop plate (1-11) using the two
FHMS (1-22). Torque the FHMS to 2 ft-lb. Install the hard stop plate onto the
shoulder actuator using the four washers (1-19) and the four HHCS (1-18) as
shown on sheet 2 of assembly drawing. Torque the HHCS to 35 ft-lb.
[ ]10. Install the linear slides (2-10) and (3-12) onto the forearm (1-4) and the yaw (3-1)
using the four FHMS (2-11) and (3-13) as shown on sheets 3 and 4 of the
assembly drawing. Torque the FHMS to 8 ft-lb.
[ ]11. Attach the hose guard (21) to the forearm (1-4) using the two HHCS (22), the two
washers (24) and the two nuts (23) as shown on sheet 1 of the assembly drawing.
Torque the nuts to 8 ft-lb.
[ ]12. Install the anodes (13) onto the base (1-1), the azimuth (1-2), the upper arm (1-3),
the forearm (1-4) and the yaw (3-1). Install the anodes (16) onto the wrist (4) and
the three actuators (1-5) as shown on sheet 1 of the assembly drawing. Torque
“hand tight” with pliers.
[ ]13. Install the spring pins (1-24) into the center of the two conterbores on the azimuth.
Install the upperarm bumpers (1-25) onto the ends of the spring pins and into the
counterbores.
[ ]14. Attach the yaw (3-1) to the forearm (1-4) using two of the pivot pins (2-6), two of
the thrust bearings (2-4), two of the retainers (2-12) and four of the HHCS (2-14)
as shown on sheet 3 of the assembly drawing. Torque the HHCS to 8 ft-lb.
[ ]15. Install the serial number label (12) onto the base using the two drive screws (15).
[ ]16. Q.C. Point 2. Check the installation of the shoulder bumper (1-21), hard stop plate
(1-11), the two linear slides (2-10),(3-12), the hose guard (21), the two pivot pins
(2-6) and the two retainers (2-12). Verify the torque of the six FHMS (1-22), (2-
11), and (3-13) and the four HHCS (2-14). Check the installation of the four o-
rings (11-18) and the backups (11-19). Check that all hose assemblies have been
properly marked, and have been installed as shown on sheets 7, 8 and 9 of the
assembly drawing. Check that the anodes (13) & (16) have been installed. Check
the installation of the spring pins (1-24) and upperarm bumpers (1-25). Check that
the actuator, transducer, base module and actuator module serial numbers have
been recorded. Check that the serial number label (12) is stamped and installed.
[ ]17. Install the pitch actuator (2-5) onto the forearm using the four washers (2-16) and
the four HHCS (2-17) as shown on sheet 3 of the assembly drawing. Torque the
HHCS to 60 ft-lb.
[ ]18. Install the yaw actuator (3-7) onto the yaw using the four washers (3-19) and the
four HHCS (3-20) as shown on sheet 4 of the assembly drawing. Torque the
HHCS to 60 ft-lb.
[ ]19. Install the azimuth actuator (0P, 0R) onto the base using two of the pivots (1-6),
twenty of the washers (1-16) and HHCS (1-20) as shown on sheet 2 of the
assembly drawing. Torque the HHCS to 8 ft-lb.
101-3665-4-WI.doc Rev: A 3 of 7 6/14/2011
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[ ]20. Install the remaining two actuators (1P, 1R) and (2P, 2R) into the upper arm (1-3)
using the remaining forty washers (1-16) and HHCS (1-20) as shown on sheets 2
and 9 of the assembly drawing. Torque the HHCS to 8 ft-lb. Route the elbow
hoses into the upper arm as shown on sheet 9 of the assembly drawing.
[ ]21. Attach the azimuth (1-2) to the base using two of the pivot pins (1-8), two of the
retainers (1-14), and four of the HHCS (1-17) as shown on sheet 2 of the assembly
drawing. Attach the rod end of the azimuth actuator to the azimuth using one of
the pins (1-7), one of the retainers (1-14), and two of the HHCS (1-17). Torque
all six HHCS to 8 ft-lb.
[ ]22. Attach the upper arm to the azimuth using two of the pivot pins (1-8), two of the
retainers (1-14), and four of the HHCS (1-17) as shown on sheet 2 of the assembly
drawing. Attach the rod end of the shoulder actuator to the azimuth using one of
the pins (1-7), one of the retainers (1-14), and two of the HHCS (1-17). Torque
all six HHCS to 8 ft-lb.
[ ]23. Attach the forearm (1-4) to the upper arm using the two remaining pivot pins (1-
8), two of the retainers (1-14), and four of the HHCS (1-17) as shown on sheet 2 of
the assembly drawing. Attach the rod end of the elbow actuator to the forearm
using the remaining pin (1-7), one of the retainers (1-14), and two of the HHCS (1-
17). Torque all six HHCS to 8 ft-lb.
[ ]24. Attach the wrist (4) to the yaw using the two remaining pivot pins (3-8), two of the
thrust bearings (3-6), two of the retainers (3-14), and four of the HHCS (3-15) as
shown on sheet 4 of the assembly drawing. Torque the HHCS to 8 ft-lb.
[ ]25. Route the pitch, yaw, wrist, jaw, comp and coax hoses through the slave arm as
show on sheets 7 and 9 of the assembly drawing. Connect the hydraulic hoses to
the manifold (11-10) and the base module (5) and connect the coax hoses to the
base module as shown on sheet 7 and 9 of the assembly drawing.
[ ]26. Install the base module (5) onto the base using the HHCS and washers supplied
with the base module. Torque the HHCS to 8 ft-lb. Assembly tip: Attach the
nylon washers to the base module with Loctite Black Max.
[ ]27. Install the four side plates (2-2), (2-3), (3-3), (3-4) onto the two top plates (2-1),
(3-2) using the sixteen HHCS (2-4), (3-5) as shown on sheets 3 and 4 of the
assembly drawing. Torque the HHCS to 8 ft-lb.
[ ]28. Install one of the link assemblies onto the yaw using the bearings (2-9), the spacer
(2-7), the retainers (2-12), the HHCS (2-14), and the pivot pins (2-8),(2-15) as
shown on sheet 3 of the assembly drawing. Torque the HHCS to 8 ft-lb.
[ ]29. Install the remaining link assembly onto the wrist base using the bearings (3-6),
the spacer (3-9), the retainers (3-14), the HHCS (3-15), and the pivot pins (3-10),
(3-18) as shown on sheet 4 of the assembly drawing. Torque the HHCS to 8 ft-lb.
[ ]30. Remove the cover and intermediate block from the base module (5) to expose the
PC board. Connect the color-coded wires to the color-coded connectors on the PC
board inside the manifold according to the wiring diagram (29). Start with the
101-3665-4-WI.doc Rev: A 4 of 7 6/14/2011
011–0909 • • Page 98
wires from azimuth function on the lowest connector, shoulder function on the
next connector up, and so on, until all coax wires are connected.
[ ]31. Q.C. Point 3. Check that the pitch and yaw actuators (2-5) and (3-7) have been
properly installed. Check the installation of the six pivots (1-6), the eleven pivot
pins (1-7), (1-8), (3-8) and the eleven retainers (1-14), (3-14). Check the torque of
the ninety HHCS (1-17), (1-20), (2-17), (3-15) and (3-20). Check that the
actuators have been properly oriented and the hoses have been properly routed and
connected as shown on sheet 7 and 9 of the assembly drawing. Check that the
HHCS securing the base module are torqued. Check the proper installation of the
pitch and yaw links. Check the torque of the HHCS (2-4), (2-14), (3-5) and (3-
15). Check the DIP switch settings on the Wrist and Jaw actuator controller PCB
(the two smaller PCBs). Verify that they match the appropriate table on wiring
diagram (29). Record your findings on the data sheet.
[ ]32. Test 1. {Note: If sold without control system, perform a manipulator functionality
test. Otherwise test completed at next level.} Make the appropriate electrical and
hydraulic connections to power up the system. Operate the manipulator for
approximately one half hour, making sure to run all joints throughout their
respective range of motion. Verify that all functions are operating correctly and
that there are no hydraulic leaks. Record your findings on the data sheet.
[ ]33. Reassemble the base module using the supplied HHCS and washers. Torque the
HHCS to 8 ft-lb.
[ ]7. Q.C. Point 4. Check installation of base module and block and verify torque of
HHCS (5). Record your findings on the data sheet.
Remarks:
Acceptance:
Record the military specification (as required) to which the assembly was tested, and the
date that the test was completed.
101-3665-4-WI.doc Rev: A 5 of 7 6/14/2011
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Wrist with Parallel-Acting Jaw, 101-3683
Work Instructions
Assembly Number: 101-3683 Description: Wrist, w/PA Jaw

Materials Required:
Chemicals:
Aqua Lube 002-0805
Dow Corning® DC 5 (Silicon Grease) 002-0799
O-ring Lube (Dow Corning® 55) 002-0359
Tools:
No special tools are required.
Serialization:
Serialize the wrist base using the stamp and special ink as shown on the assembly
drawing using the last five digits of the job number. Add the designation -1, -2, -3, etc.
for jobs consisting of more than one assembly. Record the serial number and part number
with revision of each assembly at the top of its individual data sheet.
Workmanship:
on any exposed surfaces, that there are no missing parts, and that any hoses, cables or
wires are routed correctly. Check for the presence of any foreign matter. Record your
Assembly:
[ ]1. Record the serial number of the wrist module (2) on the data sheet prior to step 2.
101-3683-WI-A1B Page 1 of 3 2/4/2008
011–0909 • • Page 100

[ ]2. Install the jaw assembly (44), using the special vise jaws, onto the wrist assembly
(2) as shown on the assembly drawing. Torque the four HHCS (44-11) to 21 ft-lb.
Torque the four HHCS (44-9) to 40 ft-lb.
[ ]3. Install the five fittings (50) into the wrist base (1). Torque the fittings to 15 ft-lb.
[ ]4. Install the five o-rings (48) into the wrist base as shown on the assembly drawing.
[ ]5. Install the o-ring (49) into the groove on the wrist manifold as shown on the
assembly drawing.
[ ]6. Q.C. Point 1. Check that the serial number of wrist module (2) is recorded. Check
that the jaw assembly (44) is correct and its eight HHCS (44-9),(44-11) are
torqued. Check that the five fittings (50), five o-rings (48) and the o-ring (49) have
been installed. Record your findings on the data sheet.
[ ]7. Install the wrist base (1) onto the wrist assembly (2) using the four HHCS (12) and
washers (45) as shown on the assembly drawing. Note that the orientation of these
parts is critical. Torque the HHCS to 25 ft-lb.
[ ]8. Test 1. Using compressed air, operate the jaw function. Insure that there is no port
to port leakage. Record your findings on the data sheet.
[ ]9. Cap the wrist fittings.
[ ]10. Q.C. Point 2. Check the correct orientation of the wrist base (1). Check the torque
of the HHCS (12). Check results of Test 1. Check that the final assembly is
complete and correct. Record your findings on the data sheet.
Remarks:
Acceptance:
Record Military Specification (as required) to which the assembly was tested, and date
101-3683-WI-A1B 101-3683-WI-A1B Page 2 of 3
011–0909 • • Page 101

Wrist, Orion, 101-3786
Work Instructions
Assembly Number: 101-3786 Description: Wrist, Orion
Product Family: Orion
Materials Required:
Adhesives:
Loctite® 271 (002-0795) Loctite® Primer ‘N’ (002-0291)
Chemicals:
Aqua Lube (002-0805) O-ring lubricant (Dow Corning® 55)
Petroleum jelly Valvoline® Val-plex EP® grease
Miscellaneous:
Nitrile gloves Safety glasses Cotton swabs Paper towels
Tools:
010-0194 010-0236 010-0525 010-0613
Serialization:
Serialize in location shown on the assembly drawing with the ink and rubber stamp,
using the last five digits of the job number, the assembly number and BOM revision
letter. Add the designation -1, -2, -3, etc. for jobs consisting of more than one assembly.
(i.e. 101-3786 X__XXXXX-X) Record the serial number of each assembly at the top of
its individual data sheet.
Workmanship:
on any exposed surfaces; that no parts are missing; and that all hoses, cables, or wires are
routed correctly. Verify that all threaded fasteners have been torqued to the correct
values. Record your findings on the data sheet.
[ ]1. Use tool 010-0236 to press the needle roller bearing (21), with the printed edge
visible, into the centerbore of the wrist manifold (20) until it seats on the bottom of
the counterbore. Degrease and pack the bearing with Valvoline® Val-plex EP®
grease.
[ ]2. Press the caged needle roller bearing (4), with the printed edge visible, into the
housing (2). Degrease and pack the bearing with Valvoline® Val-plex EP® grease.
Phantom Assembly:
101-3786-WI-A1F Page 1 of 6 5/15/2008
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[ ]3. Verify installation of inserts (2-5) and CV plugs (2-2) into slip ring (2-1) per SR
spec 130-0098 and phantom assembly 101-3784.
[ ]4. Verify installation of CV plug (1-2) into drive shaft (1-1) per SR spec 130-0098
and phantom 101-3785.
[ ]5. Verify installation of CV plug (20-2) into wrist manifold (20-1) per SR spec 130-
0098 and phantom 101-3782.
Assembly:
[ ]6. Install the roto glyd seals (5) into the three grooves of the housing (2) as shown on
the assembly drawing.
[ ]7. Lightly lubricate the bearing (7) and install into the housing (2).
[ ]8. Install the eight crush washers (27) onto the five SHCS (29), the two oil supply
bolts (22), and the oil return bolt (23). Slide the crush washers down to the bolt
heads.
[ ]9. Use tool 010-0194 to install the two o-rings (24) into the grooves on the tips of the
two oil supply bolts (22).
[ ]10. Slide the two oil supply bolts (22) into the wrist manifold (20) at the locations that
correspond to the outside pin plug holes located on the outside of the wrist
manifold, and slide the oil return bolt (23) into the hole that corresponds to the
middle pin plug on the outside of the manifold. Slide the five SHCS (29) into the
remaining five holes of the wrist manifold.
[ ]11. Install the two bushings (25) and then the two o-rings (26) over the oil supply
bolts (22) already placed in the countersunk locations on the wrist manifold (20).
[ ]12. Install the o-ring (19) into the groove in the wrist manifold (20).
[ ]13. Install the o-rings (16), (17), and (18) into the grooves of the valve plate (14) as
shown on the assembly drawing.
[ ]14. Loosely install the SHCS (33) into the clamp nut (32).
[ ]15. Degrease the thrust washer (8) and thrust bearing (9). Using Valvoline® Val-plex
EP® grease as an adhesive, install the thrust washer, thrust bearing and the seal
backup (10) onto the drive shaft (1) as shown on the assembly drawing.
[ ]16. Install the lip seal (12) onto drive shaft (1) as shown on the assembly drawing.
[ ]17. Use o-ring lubricant to lubricate the bores below the heli-coils in the housing (2).
[ ]18. Q.C. Point 1. Verify that the bearings (4),(7),(8),(9),(21) and the backup (10) are
installed. Check that the seals (5),(12) , and o-rings (16),(17),(18),(19),(24),(26)
are correctly installed. Check that the crush washers (27) have been installed.
Verify the orientation and installation of the SHCS (22),(23),(29),(33) and
bushings (25). Record your findings on the data sheet.
101-3786-WI-A1FF Page 2 of 6 5/15/2008
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[ ]19. Lightly lubricate the sealing surfaces of the driveshaft (1) and then orient it with
the splined end upward. Install the housing (2) onto the driveshaft as shown on
[ ]20. Install the wear plate (11) onto the drive shaft (1). You may need an arbor press to
fully seat the wear plate over the seal and onto the bearing. Align the eight bolt
holes to the eight threaded holes of the housing.
[ ]21. Lightly lubricate the pieces of the gerotor assembly (13) (shown in figure 1 below)
and install it onto the driveshaft (1) as shown on the assembly drawing. Note:
install the locating ring with the “funnels” or the “small groove” up. Gerotor valve
plate should be installed with “T” shaped ports up and “bell” shaped ports down.
The bearings should not be visible through the “T” shaped port.
Figure 1.
[ ]22. Install the lip seal (15) onto the drive shaft (1) using tool 010-0525 as shown on
101-3786-WI-A1F Page 3 of 6 5/15/2008
011–0909 • • Page 104

[ ]27. Degrease and then install the two thrust washers (30) and the thrust bearing (31)
onto the wrist manifold (20) as shown on the assembly drawing. Lubricate the
bearing with Valvoline® Val-plex EP® grease.
[ ]28. Install the clamp nut (32), with the three threaded holes facing up, onto the drive
shaft (1). Torque the nut to 75 ft-lb. Loosen the nut and then retorque to 10 ft-lb.
Torque the SHCS (33) to 5 ft-lb.
[ ]29. Install the lip seal (3) into the housing (2) as shown on the assembly drawing.
[ ]30. Q.C. Point 3. Verify the correct installation of the seal (3). Check the torque of
the SHCS (22),(23),(29),(33).
[ ]31. Install test plate 010-0613 onto wrist using HHCS (73). Torque HHCS to 73 ft-
lbs.
[ ]32. Test 1. Wrist functionality test. Connect the wrist assembly to the servo C1 and
C2 ports of the hydraulic test bench and operate the wrist at 3000 psi in both
directions for several minutes to see if it is operating correctly. You may adjust
the clamping nut (32) to achieve proper wrist operation. Do not lower the torque
of the clamping nut below 10 lb-ft or any higher than 110 lb-ft. Stop the wrist from
rotating and then gradually drive the servo valve until the wrist just begins to
rotate. This is the “breakaway RPM,” or the lowest speed at which the motor will
operate. Observe the number of revolutions in one minute and record the reading
on the data sheet. The value should be no more than 6 RPM. Repeat this process
for the opposite direction.
[ ]33. Test 2. Wrist torque test. Test the wrist torque using tool 010-0577. The wrist
torque shall be a minimum of 75 ft. Lb in both directions. You may adjust the
clamping nut (32) to achieve proper wrist torque. Do not lower the torque of the
clamping nut below 10 lb-ft or any higher than 110 lb-ft. Record the final
clamping nut torque value on the data sheet and stamp the value on the face of the
nut itself.
[ ]34. Q.C. Point 4. Verify the results of Test 1 and 2 and that the torque value of the
clamping nut (33) has been stamped into its face. Record your findings on the data
sheet.
[ ]35. Affix acceptance tag and route to stock.
Remarks:
Acceptance:
Record the inspector’s name on the data sheet, and affix the appropriate acceptance tag.
Record the Military Specification (as required) that the assembly was tested to and the
date on which the test was completed.
101-3786-WI-A1FF Page 4 of 6 5/15/2008
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Master Controller, Aux. Jaw Switch, 101-5781
Work Instructions
Assembly Number: 101-5781 Description: Master Controller, Universal Input, Gen II
Product Family: Titan
Materials Required:
Test Equipment:
• 101-1780: Junction box T3

• 005-3600/101-3242 test box
Chemicals:
• 002-1839: Loctite ® 242 (or equivalent)
Prepare Documentation Package:
The assembly technician shall print a copy of the Test Data Sheet for the purpose of
recording the serial number, traceability of components (where applicable) and step-by-
step conformance with the procedure. The technician shall check off each step as they
are completed. The technician shall initial and date the last page of the Test Data Sheet
upon completion of the procedure. The Test Data Sheet shall remain with the assembly at
all times. The Assembly Steps is a technical reference document that does not need to be
retained after the build is complete.
BOM Required for Assembly
Print BOM(s): 101-5781
General Notes:
1. The following steps may be performed out of sequence.
2. Install components and hardware in accordance with posted shop standards.
3. Record QC acceptance details on the Test Data Sheets pertaining to each sub-
assembly. Completed TDS documents for each sub-assembly shall be combined
with the top level TDS document for this procedure
101-5781-WI-A1B Page 1 of 9 2/5/2008
011–0909 • • Page 106

Serialization:
Serialize item 33 of the assembly drawing, using the last five digits of the job number. Add a
designation of -1, -2, -3, etc. for jobs consisting of more than one assembly. Record the serial
number of each assembly at the top of its individual data sheet.
In addition, record the serial numbers of the faceplate (1), the master control arm (3), the
processor (2), and the telemetry board (5) in the spaces provided on the data sheet.
Label Information:
Add the part number (P/N) followed by a space and the BOM revision to the label (33). Also add
the following voltage input data to the label:
Volts: 90-260VAC
Amps: 1
Hz: 50/60
Workmanship:
For the duration of the assembly process, verify that there are no sharp edges or scratches on
any exposed surfaces; that no parts are missing; and that cables and wires are routed correctly.
Verify that all threaded fasteners have been torqued to the correct values. Record your findings
on the data sheet.
Verify that all assembly components listed on the bill of material are in the kit. Record your
Assembly:
[ ]1. Stick the four rubber feet (17) to the four corners on the bottom of the housing (16).
[ ]2. Install label (51) onto housing (16) as per the drawing.
[ ]3. Install the MCA (3) to the faceplate assembly (1) using the four screws (11), (32) and the
clamp (10) as shown on the assembly-drawing. Be careful not to over-tighten the screws
(11) because the Delrin threads in the MCA can easily be stripped.
[ ]4. Connect the jaw switch three-wire connector to the three-wire connector of the MCA.
[ ]5. Install item (56) onto the face plate assembly (1) per detail F.
[ ]6. Install the telemetry board (5) onto the processor boards (2) J1 and J2 connector. Secure
the telemetry board per the drawing.
[ ]7. Align the SIP connectors to the processor board (2) with the sip connectors of the display
(56) and secure the processor board to the faceplate, using the four nuts (39) and two
screws (32) as per the drawing.
[ ]8. Insert the power switch connector from the faceplate assembly (1) into the processor
boards (2) P2 connector.
101-5781-WI-A1B Page 2 of 9 2/5/2008
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[ ]9. Connect the cable from the MCA (3) to P4 on the motherboard (2).
[ ]10. Connect Wire 1 (53) and (54) to the face plate assembly (1) per the drawing at location F
using screw (9).
[ ]11. Feed the wires of cable (7) through the hole in the housing (16) as shown in the drawing
and secure the cable to the housing.
[ ]12. Connect the wires of cable (7) to the J1 and J2 connector supplied with cable (7) per the
drawing detail G.
[ ]13. Connect the ground wire from J2 of cable (7) and Wire 1 (53) (54) onto the housing (16),
using the washer (23) and the screws (24) as shown on the assembly drawing.
QC Point 1:
[ ]14. Check the rubber feet (17), the MCA (3), the clamp (10), the processor board (2), the
telemetry board (5), and the cable (7) have been properly installed and wired to the J1
and J2 connector. Verify that the fasteners (9), (11), (24), (32), and (38) have been
tightened. Record your findings on the test datasheet.
[ ]15. Connect cable A to the P7 connector of the processor board (2). Connect cable B to the
P1B connector of the processor board (2) (RS-485).
Note: Reference the processor boards (2) drawing for locations of P1 and P7.
[ ]16. Install the faceplate (1) onto the housing (16) using the four screws (8) as shown on the
assembly drawing. Tighten the screws hand tight.
[ ]17. Attach the nameplate (19) to the center of the faceplate as shown on the assembly
drawing.
NOTE: Clean the area under label with alcohol and Q-tip to ensure good adhesion.
[ ]18. Apply the voltage label (33) as shown on the assembly drawing.
NOTE: Clean the area under label with alcohol and a Q-tip to ensure good adhesion.
Test 1:
Note: For service or used units, document the following communications and software
configuration of the consolette:
• Communications configuration of cable B (J1) to the P1A or P1B connector on the 005-
5195 processor board.
• Switch position on the hex switches SW1 and SW2.
19. Set the hex switch setting as follows:

• SW1 0
• SW2 2 (Conan)
20. Plug consolette into J-box. Plug 005-3600 test box into J-box.
21. Ensure Conan base module is plugged in to fixture.
101-5781-WI-A1B Page 3 of 9 2/5/2008
011–0909 • • Page 108

22. Set the base module up for RS-485 communications on the 005-3600 base module in the test
box as follows:
Jumper Pin connection
JP1 1 to 2
JP4 1 to 2
JP5 1 to 2
JP6 1 to 2
JP7 1 to 2
JP8 1 to 2
JP9 1 to 2
23. Ensure at least one of the 101-3656 actuators, on the test set up has a pot and servo LED
assembly installed (see 101-3656 test procedure for configuration).
24. Power on J-box.
25. Power on master consolette.
Note: The power button should be oriented such that power is on when the switch is toggled
down towards the top of the master controller (away from the operator) and powered off when
the switch is toggled down towards the bottom of the master controller (towards the operator).
26. Adjust pot VR1 on 005-5195 processor board so that vertical lines just barely appear on the
display.
Note: The lines will fade as the assembly warms up. Readjust the pot if necessary when
testing is complete.
27. Check the back-light of the display by cupping your eyes over the display with your hands.
The display should still be visible in darkness.
28. Select Overwrite EEPROM. Select Diagnose/Show Errors. Verify there are no errors.
29. Select Diagnose/Master. Rotate each joint through its motion of travel. All joint maximum
values should be within the tolerances listed below.
Titan Arm
Positive Value Tol. Negative Value Tol.
Azimuth 1931 to 1370 -1931 to -1370

Shoulder 679 to 400 -679 to -400
Elbow 1524 to 950 -1500 to -950
Pitch 1346 to 900 -1889 to -1137
Yaw 1200 to 900 -1200 to 900 (for arm serial # >699)
1317 to 915 -1317 to 915 (for arm serial # <700)
Wrist 2047 to 1488 -2047 to -1488
101-5781-WI-A1B Page 4 of 9 2/5/2008
011–0909 • • Page 109

30. Squeeze the bands at the end of the arm. The band closest to the end of the arm should
initiate the jaw close value (the top right screen number). The inner band should initiate the
jaw open value (the number just below the jaw open value). Pressing the bands should
indicate a value of at least +1850 counts when initiated.
31. On the controller face plate assembly, test the jaw switch by pressing on the jaw switch to the
jaw close position. Rocking the switch to the jaw close position should indicate a jaw close
condition (the top right screen number). Depressing the jaw switch to the jaw open position
should indicate a jaw open condition (the number just below jaw open). Both jaw open and
close values should indicate at least +1850 counts when initiated.
32. Test all buttons for proper functionality. There are 16 buttons on the faceplate. There is also
a button on the end of the arm. Press each button and verify bit operation at the bottom of the
display screen of the consolette.
Bit # Button Function
0 Left top (#1) function button

1 Left #2
2 Left #3
3 Left #4
4 Right side top keypad button
5 Right side left keypad button
6 No function
7 Button on end of arm.
8 Right side top (#1) function button
9 Right side #2
10 Right side bottom keypad button
11 Right side right key pad button
12 Exit button (Right #4)
13 Right side #3
33. Select the Diagnose menu. `

34. Select the Slave menu.
35. Adjust the pot on actuator board and verify position feedback for the joint changes relative to
the rotation of the resistor pot attached to the actuator board.
36. Power off consolette and J-box.
37. Set the base module up for RS-232 communications on the 005-3600 base module in the test
box as follows:
Jumper Pin connection
JP1 1 to 2
JP4 2 to 3
JP5 2 to 3
JP6 1 to 2
JP7 1 to 2
JP8 2 to 3
JP9 2 to 3
101-5781-WI-A1B Page 5 of 9 2/5/2008
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38. Set up the consolette for RS-232 communications by connecting the J1 connector of the 101-
5992 cable to P1A on the 005-5195 processor board.
39. Power on J-box.
40. Power on master consolette.
41. Go to the Diagnose menu.
42. Select Show Errors. Verify there are no errors.
43. Exit from the Show Errors menu and select the Slave menu.
44. Adjust the pot on the actuator board of the test set up. Verify that there is positional feedback
from the corresponding joint attached to the actuator board. Verify that as the pot is rotated
that changes occur in the Fdbk (Feedback) numbers.
45. Power off consolette and J-box.
46. Disconnect consolette from J-box.
47. Set the SW1 and SW2 hex switch settings on the 005-5195 processor board as follows:
• SW1 0
• SW2 0 (Titan 4)
Note: For Service or used- units, reconfigure the consolette communications system to the
original configuration documented at the start of the test procedure.
[ ]50. Reinstall the faceplate (1) onto the housing (16) using the four face plate screws (8) as
shown on the assembly drawing. Tighten the screws hand tight.
Q.C. Point 2:
[ ]51. Check that the screws (8) are installed and not loose tight. Verify that the name plate (19)
and the voltage label (33) have been installed and are correct. Verify the results of Test 1
and check the general configuration of the assembly. Record your findings on the
datasheet.
[ ]52. Place the assembly into its shipping case (50).
Remarks:
example, record failed tests, problems encountered during assembly or testing, or corrective
action taken for the assembly to pass any of the tests.
Acceptance:
Record the inspectors name on the data sheet and affix the acceptance tag to the assembly.
Record the Military Specification (as required) to which the assembly was tested, and the date on
which the test was completed.
101-5781-WI-A1B Page 6 of 9 2/5/2008
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Base Module, 101-7854
Work Instructions
Assembly Number: 101-7854 Description: Base Module Control SMD
Materials Required:
Adhesives:
Locktite® 271 002-0795

Locktite PST® pipe sealant 56747 002-0797
Chemicals:
Aqua Lube 002-0805

O-ring Lube (DC 55) 002-0359
Electrical Related Items:
Cable Tie 3" 002-0524

Cable Tie 8" 002-0846
Prepare Documentation Package:
The assembly technician shall print a copy of the Test Data Sheet for the purpose of
recording the serial number, traceability of components (where applicable) and step-by-
step conformance with the procedure. The technician shall check off each step as they
are completed. The technician shall initial and date the last page of the Test Data Sheet
upon completion of the procedure. The Test Data Sheet shall remain with the assembly at
all times. The Assembly Steps is a technical reference document that does not need to be
retained after the build is complete
BOM Required for Assembly
Print BOM(s): 101-7854
101-7854-WI.doc Rev: A 1 of 7 6/14/2011
011–0909 • • Page 112

General Notes:
1. The following steps may be performed out of sequence.
2. Install components and hardware in accordance with posted shop standards.
3. Record QC acceptance details on the Test Data Sheets pertaining to each sub-
assembly. Completed TDS documents for each sub-assembly shall be combined
with the top level TDS document for this procedure
Serialization:
Serialize the block (1), with label (45), as shown on the assembly drawing using the last
five digits of the job number. Add the designation -1, -2, -3, etc. for jobs consisting of
more than one assembly. Record the serial number of each assembly at the top of its
individual data sheet.
Also record the serial numbers of the base module PC board (36), the two actuator
control PC boards (3), lock-valve (31), and the two servo valve subassemblies (7) in the
spaces provided on the data sheet.
Label Information:
Add the part number (P/N) followed by a space and the BOM revision to the label (45).
Also add the following voltage input data to the label (45):
Volts: 18-36 VDC
AMPS: 1.5
HZ: N/A
Workmanship:
For the duration of the assembly process, verify that there are no sharp edges or
scratches on any exposed surfaces, that there are no missing parts, and that any hoses,
cables or wires are routed correctly. Check for the presence of any foreign matter.
Assembly:
[ ]1. Install the backup ring (15) and o-ring (14) onto filter base (12). Make sure the orientation
of the backup ring is correct.
[ ]2. Install the filter (11) into the filter base (12).
[ ]3. Install the solenoid cartridge (17) into the manifold block (1) as shown on the assembly
drawing. Torque to cartridge (17) as indicated on assembly drawing.
101-7854-WI.doc Rev: A 2 of 7 6/14/2011
011–0909 • • Page 113

[ ]4. Apply Locktite 271 (65) to six SHCS (37) and secure the six standoffs (39) to the base
module PC board (36), and then install the four threaded standoffs (40) into the manifold
block (1) as shown on the assembly drawing.
[ ]5. Install the solenoid coil (18) onto the solenoid cartridge (17) as shown on the assembly
drawing. Connect the two leads to pins 7 and 8 of J11 on the base module PCB (36) as
shown in section B-3 of the wiring diagram (56). Torque cartridge nut (17) as indicated on
assembly drawing.
[ ]6. Install the wiring harness (5) into the manifold block (1) as shown on the assembly
drawing, and then terminate to J11 pins 1 to 6 of the base module PC board (36) as
shown in section C-3 of the wiring diagram (56).
[ ]7. Install the base module PC board (36) onto the four standoffs (40) with three SHCS (41).
Verify that the communication setting for the base module board (36) is properly set for
jumpers JP1 to JP9. Refer to the sales order for configuration and the chart on the wiring
diagram (section A/B-2) for verification. Reconfigure as necessary.
Note: the lower left hole is not filled with a SHCS to allow more room for the wires entering
through the bulkhead.
[ ]8. Q.C. Point 1. Verify the setting of the JP1 to JP9 jumpers on the base module board (36).
Verify installation of solenoid coil (18). Indicate the communication setting for the base
module board on the test datasheet.
[ ]9. Install the two actuator controller PC boards (3) onto the six standoffs (39) using the
remaining six SHCS (37) and the six nylon washers (38) as shown on the assembly
drawing. Then set the DIP switches in the default “right hand” setting as shown in section
B-4 of the wiring diagram (56).
[ ]10. Cut and strip the

colored wires (51), Figure 1. Wire detail.
(52), (53), (54), and
(55), as shown in
figure 1.
In Process QC Req:
Tin and inspect all
wire ends by a
qualified electrical
tech.
Use the wires to

terminate the actuator
controller boards (3) to J1 and J2 of the base module PC board (36) as shown in sections
A/B-3 of the wiring diagram (56).
[ ]11. Install the seven fittings (10) onto the manifold block (1) as shown on the assembly
drawing.
[ ]12. Install fittings (22) and (44), the two fittings (24), the three fittings (42) and the five fittings
(59) onto the manifold block (1) as shown on the assembly drawing. Install the fitting (34)
into fitting (35) and the two fittings (43) as shown on the assembly drawing. Torque
fittings (42) as indicated on assembly drawing.
101-7854-WI.doc Rev: A 3 of 7 6/14/2011
011–0909 • • Page 114

[ ]13. Apply Locktite PST (66) to relief valve (19) and install into manifold (1) as show on
assembly drawing.
[ ]14. Loosely install the four HHCS (28), four of the washers (27), and the four nylon washers
(25) onto the manifold block (1) as shown on the assembly drawing.
[ ]15. Use the two SHCS (83) to secure the 24V converter (21) to the adapter plate (84).
[ ]16. Use the four SHCS (82) to secure the adapter plate (84) in the cover/mount (2).
[ ]17. Install the penetrator wiring harness (6) in the cover/mount (2) and retain it with the two
washers (9) and two of the SHCS (8). Connect the leads of the wiring harness to the
power supply (21) as shown in section C/D-3 of the wiring diagram (56).
[ ]18. Using the remaining eight SHCS (8), install the two servo valves (7) onto the adapter plate
(29) and the lock valve assembly (31).
[ ]19. Install the o-rings (30), (32) into the grooves on the bottom of the adapter plate (29).
Install four o-rings (47) into the counter-bores of the lock valve assembly (31). Install the
remaining four o-rings (47) into the counter-bores of the bypass valve assembly (81).
[ ]20. Install the two o-rings (26) in the groove in the manifold block (1) and cover/mount (2).
[ ]21. Q.C. Point 2. Check the backup ring (15) and the o-rings (14), (26), (30), (32) and (47).
Check that the filter base (12) is on the filter. Check the installation of the cartridge (17),
the base module PCB (36), the two actuator PC boards (3), the wiring harness (5), the
fittings (10),(19),(22),(24),(34),(42),(43),(44) and (59), the 24V converter (21) and the
adapter plate (84), the penetrator (6), and the two servo valves (7) onto the adapter plate
(29) and lock valve (31). Verify that the DIP switches are set correctly. Verify that the
wiring harness (5) and the two actuator controller PC boards (3) are properly wired to the
base manifold PC board (36). Check that the penetrator (6) is correctly wired to the power
supply (21). Record your findings on the data sheet.
[ ]22. Install the servo/adapter plate, servo/lock valve and bypass valve units onto the manifold
block (1) using the four SHCS (33) and the four SHCS (46). Note the orientation and the
placement of each unit on the assembly drawing.
[ ]23. Install the filter (11) into the manifold block (1) as shown on the assembly drawing.
[ ]24. Connect the six-pin connector of the penetrator (6) to its mate on the wiring harness (5).
[ ]25. Q.C. Point 3. Verify the correct orientation and placement of the servo/adapter and
servo/lock valve unit. Check installation of filter (11). Check that the penetrator (6) and
the wiring harness (5) are connected. Record your findings on the data sheet.
[ ]26. Using the four HHCS (13) and the remaining washers (27), install the cover (4) and the
cover/mount (2) onto the manifold block (1). Torque the HHCS to 9 ft-lb.
[ ]27. Install the fitting (35) onto the manifold block (1) as shown on the assembly drawing.
Note: Skip Step 28 if this assembly is going directly into an in house system.
[ ]28. Test 1. Cap the fittings (59) and install the compensation pressure test tool in the open -4
port in the side of the manifold block. Pressurize to 15 psi for at least 30 minutes and
check for leaks. Record your findings on the data sheet.
[ ]29. Install the fitting (23) as shown on the assembly drawing.
101-7854-WI.doc Rev: A 4 of 7 6/14/2011
011–0909 • • Page 115

[ ]30. Q.C. Point 4. Check the harness (5) for pins to case short circuits. Check the final
configuration of the assembly. Record your findings on the data sheet along with the
results of the pressure test.
[ ]31. Bag the remaining wire ties (57) and (58) and route to stock.
Remarks:
example, record failed tests, problems encountered during assembly or testing, or corrective
action taken for the assembly to pass any of the tests.
Acceptance:
Record the military specification (as required) to which the assembly was tested, and the date
101-7854-WI.doc Rev: A 5 of 7 6/14/2011
011–0909 • • Page 116

Drawings & Part Lists
1 Index
Manipulator Systems
Conan 7P System, PA Jaw, Seacon 1508, 199-0318................ page 188
Hydraulic Schematic
Hydraulic, Schematic, 025-0049 .......................................... page 123
Cables
Cable Ass’y, Deck Test, 8 Pin, 15 Shell, 101-6926-3................ page 181
Master Controller
PCB Assembly, In Arm Telemetry Schematic, 005-4645........... page 122
Master Arm Wiring, 035-0027.............................................. page 124
Master Controller Wiring Diagram, 035-0731 ......................... page 126
Master Controller, Univ Input, Gen 2, 101-5781 ..................... page 174
Face Plate, Master Controller, 101-5782 ................................ page 178
Junction Box
Junction Box, 101-4898 ...................................................... page 171
Base Module
Base Module/SCU PC Board, 005-3600 ................................. page 119
Actuator Controller Schematic, 035-0522 .............................. page 125
Base Module Wiring Schematic, see:
Slave Arm Wiring Schematic, 035-0899 ............................ page 127
Control Module, Actuator, 101-3657 ..................................... page 138
Lock Valve Assembly, 101-3258 ........................................... page 129
Wiring Harness, Penetrator, 101-6829 .................................. page 180
Wiring Harness, C7P Base Module, Seacon, 101-7853 ............. page 182
Base Module, C7P, Seacon 1508, 101-7854 ........................... page 183
Slave Arm
Slave Arm Wiring Schematic, 035-0899 ................................ page 127
Jaw Kit, Parallel-Acting, 6-in., 101-3299................................ page 131
Wrist Assembly, 101-3372 .................................................. page 134
Relief Valve Assembly, 101-3574.......................................... page 137
Actuator Assembly, 2.6 x 1.75-in. Bore, 101-3658 ................. page 140
Actuator Assembly, 6.0 X 2.25-in. Bore, 101-3659 ................. page 142
Slave Arm, PA Jaw, Seacon 1508, 101-3665-4 ....................... page 144
Wrist Base, 101-3671......................................................... page 161
Wrist w/PA Jaw 101-3683 ................................................... page 163
011–0917 Page 117

• Drawings & Part Lists
Wrist Motor, 101-3786 ........................................................ page 165
Nose Block Kit, 101-3853.................................................... page 170
Mounting Template
Conan Slave Arm Mounting Template, 050-0693 .................... page 128
2 Spares Kits
Spares Kit, Conan 7P, Seacon 1508, 008-0651....................... page 190
Sub-Kits under Spares Kit
Item 1: Spares Kit, Conan, Small Actuator, 101-3342 ............. page 190
Item 2: Spares Kit, Conan, Large Actuator, 101-3343 ............. page 190
Item 5: Spares Kit, Conan Hardware, 101-3346 ..................... page 191
Item 6: Tool Kit, Conan/RigMaster, 010-0689......................... page 192
Item 7: Kit, Position Control, Seacon 1508, 101-7856............. page 193
Item 11: Spares Kit, Wrist, Gamma, 008-0096 ...................... page 194
Page 118 • Spares Kits 011–0917

Base Module/SCU PC Board, 005-3600
NOTE: Sheets 3, 4, and 5 only.

011–0917 • Spares Kits • Page 119
PCB Assembly, In Arm Telemetry Schematic, 005-4645
NOTE: Sheet 3 only.

Hydraulic, Schematic, 025-0049

Master Arm Wiring, 035-0027

Actuator Controller Schematic, 035-0522

Master Controller Wiring Diagram, 035-0731

Slave Arm Wiring Schematic, 035-0899

Conan Slave Arm Mounting Template, 050-0693

Lock Valve Assembly, 101-3258
Rev. C
Item P/N Description Qty
1 001-4373 PL,LOCKV,CRTG,150 PSI 1
2 006-1185 VALVE,CHECK,PILOT,150 PSI, 2
3 001-3866 SPR,FLOW 2
4 001-4325 PLUG,SPR,.077 2
5 002-1475 SCR,SET,7/16-20X3/8,SS 2
6 004-0222 O-RING,2-010 BUNA 90 6
7 006-1513 PLUG,CV,CVES1258281A,316SS,SHO 4
8 006-1282 PLUG, CV, CVES1568180A, 316 SS 12
9 006-1497 PLUG,CV,CVES2188281A, 316 SS,S 1
10 006-2631 RESTRICTOR,.014 DIA,10-32 THD 1
20 010-0473 TOOL,INSTL,CV PLUG 125 0
22 010-0546 TOOL,INSTL,CV PLUG,218,SHORT 0
40 101-3258-WI WORK INSTRUCITONS 0

Jaw Kit, Parallel-Acting, 6-in., 101-3299
Rev. B
1 101-4111 JAW,PA,W/BRG 2
2 101-4110 LINK,IDLER,W/BRG 4
3 101-4109 LINK,ROCKER,W/BRG 2
4 007-0308 WLDMT,IDLER PL 2
5 001-4491 SPACER,DELRIN 4
6 001-4492 PIN,.749DIA. 2
7 001-4493 PIN,.499 DIA X 3.030 LG 2
8 001-4494 PIN,.499 DIA X 4.148 LG. 2
9 002-0277 HHCS,1/2-20X3/4~L,316SS 4
10 002-0071 WSHR,1/2,316SS 4
11 002-0050 NAS 6404U2 4
12 001-2071 WSHR,T2 JAW 4
13 003-0006 BRG,THR,0.75X1.50X0.078 4
14 003-0173 BRG,THR,0.0513X1.00X0.078 4
15 001-1985 WSHR,THR JAW 16
17 002-1427 PIN,SPR,.125 DIA.X1IN.,SS 2
19 001-2908 BRG,ACTR,BRZ 2
25 010-0468 BRG,PUSHER,.75DIA. 0
50 101-3299-WI WORK INSTRUCTIONS 0

Wrist Assembly, 101-3372

Rev. B
2 101-3786 WRIST MOTOR,ALUM,2.25IN BORE 1
7 101-3853 NOSE BLOCK KIT,CONAN/RIGMASTER 1
12 010-0174 TOOL,INSTALL,M,2.25 0
13 010-0175 TOOL,SIZING,F,2.25 0

Relief Valve Assembly, 101-3574
Rev. A
1 001-4578 SEAT,RLF V 1
2 001-4579 SL,RLF V 1
3 001-4581 SEAT,SPR,RLF V 1
4 002-0089 SPHERE,1/8 +.0001,440C VM GR-1 1
5 002-1680 SPR,CPRSION,SPC-54255,CENTURY 1
6 001-4580 PLUG,RLF V 1
7 004-0225 O-RING,2-008 BUNA 90 1
8 004-0102 O-RING,2-009 BUNA 70 1
9 002-1626 SCR,SET,7/16-20X.25,CUP POINT 1
10 010-0570 RLF V TEST FXTR 0

Control Module, Actuator, 101-3657
Rev. F
1 001-4362 MANF,MOOG,BRAZED 1
2 001-4363 COV,MDL 1
3 001-4364 ADPTR,MDL COV 1
4 101-3100 SERVO V ASSY,MOOG #30 1
5 002-0262 SHCS,1/4-20X1,SS 4
6 004-0222 O-RING,2-010 BUNA 90 4
7 004-0561 O-RING,.228X.040,BUNA 70 0
8 002-0933 SHCS,6-32,5/16LONG,ALLOY STL 4
9 101-3656 PCB ASSY,ACTUATOR CONTROL BD 1
10 002-0549 PIN,SPIROL,1/8X1/2,SS 1
12 004-0219 O-RING,2-042 BUNA 70 1
13 002-1507 STDF,3/16 HEX X .25LG,M-F 4-40 3
14 002-0358 SHCS,4-40X.18,SS 3
15 002-0451 WSHR,NYL #4,.032THK 5
16 002-0228 SHCS,4-40X1/2,SS 2
18 002-0096 SHCS,4-40X1/4,SS 1
19 002-0158 SHCS,8-32X1/2,SS 2
20 002-0405 WSHR,FLAT,#8,SS 2
21 004-0062 O-RING,2-013 BUNA 70 1
22 002-1472 SCR,SELF-SEALING,W/ORING,B90 1
24 002-0795 ADH,#271 RED LOCTITE 50ML 0
26 002-1485 CA,TIE,.10X4.5LG,#4 SCR EYE 1
27 002-0846 CA TIE,8IN.X.14 WIDE 1
60 101-3657-WI WORK INSTRUCITONS 0

NOTE: This assembly does not include transducer or lock/relief valves.
Actuator Assembly, 2.6 x 1.75-in. Bore, 101-3658
Rev. B
1 001-4757 HSG,ACTR,1.75 in. W/RLF V 1
2 001-4283 PSTN,1.75DIA.,SINGLE BRG 1
3 004-0046 O-RING,2-127 BUNA 70 1
4 003-0150 BRG,PSTN,LUYTEX 1
6 001-3738 NUT, NOSE GLAND, ACTR,1.75 IN. 1
7 003-0151 BRG,SFT,LUYTEX 2
8 004-0508 STEPSEAL,S48270-4203-109P 2
9 004-0509 SCRAPER,S48302-0108A-56 1
10 004-0966 O-RING,2-031,DISOGRIN 70 DURO 1
11 001-3547 ROD,END,THDED 1
12 003-0065 BRG,CJ16E18-10,DIXON 1
13 004-0805 O-RING,2-113,B90 1
15 006-1495 PLUG,CV,CVES1568281A,316 SS,SH 2
17 004-0646 SEAL,JAW PSTN,GAMMA 1
18 002-0797 SEALANT,W/TEFLON,LOCTITE #5674 0
19 010-0203 TOOL,SIZING,M,1.0 0
20 010-0184 TOOL,INSTL,M,1.75 0
21 010-0185 TOOL,SIZING,F,1.75 0
22 010-0523 TOOL,INSTL,CV PLUG 156 SHORT 0
23 010-0563 INSTL TOOL,CON ROD END O-RING 0
24 010-0238 CLR,JAW PSTN 0


\

Actuator Assembly, 6.0 X 2.25-in. Bore, 101-3659
Rev. D
1 001-4756 HSG,ACTR,6.00 in.,W/RLF V 1
2 003-0006 BRG,THR,0.75X1.50X0.078 2
3 003-0164 BRG,FLG,1.50 ID,1.625OD 2
4 001-4303 PSTN,2.25DIA. 1
5 004-0616 SEAL,PSTN,SHAMBAN,34G02250-A46 1
6 001-2946 BRG,2.25 BORE PSTN,GAMMA 1
8 001-3546 NUT,NOSE,GLAND,2.25 IN. BORE 1
10 004-0508 STEPSEAL,S48270-4203-109P 2
11 004-0509 SCRAPER,S48302-0108A-56 1
13 001-3547 ROD,END,THDED 1
14 003-0065 BRG,CJ16E18-10,DIXON 1
15 004-0805 O-RING,2-113,B90 1
21 006-1282 PLUG, CV, CVES1568180A, 316 SS 4
22 006-1497 PLUG,CV,CVES2188281A, 316 SS,S 1
24 006-0015 FTG,HYD,-4 JIC,-4 ST,4F50X-SS 2
27 010-0174 TOOL,INSTALL,M,2.25 0
28 010-0175 TOOL,SIZING,F,2.25 0
29 010-0203 TOOL,SIZING,M,1.0 0
31 010-0546 TOOL,INSTL,CV PLUG,218,SHORT 0
32 010-0563 INSTL TOOL,CON ROD END O-RING 0
33 006-1304 FIT,PLUG,2HP5ONSS,-2 HOL,HEX/S 1


NOTE: Slave arm assemblies are itemized on the part list below.
 Item 4 (101-3683), Item 5 (101-7854), Item 6 (101-3657), and Item 17 (101-3574)

have drawings and part lists under their own part numbers. For location see the
drawings and part lists index at the beginning of this chapter.
 Part lists for the remaining 101- assembly items begin on the following page. Item
numbers are referenced to the slave arm drawing.
NOTE: Part list only. Use drawing 101-3665 for reference.

Slave Arm, PA Jaw, Seacon 1508, 101-3665-4
Rev. 0
1 101-3660 LWR ARM KIT 1
2 101-3661 PITCH KIT 1
3 101-3662 YAW KIT 1
4 101-3683 WRIST,CON W/PA JAW 1
5 101-7854 BASE MDL,C7P,SEACON 1508 1
6 101-3657 CONT MDL,ACTR,CON 5
7 101-3101 LOCK V KIT,CON,POSN CONT 3
8 101-3252 XDCR,2.6IN.,CON 2
9 101-3253 XDCR,6IN.,CON 3
10 101-3262 KIT,CA 1
11 101-3241 HOSE SET,CON7P 1
12 001-5006 LABEL,SERIAL NUMBER 1
13 002-3135 ANODE,GALVANIC,1.05 X .75 5
15 002-1527 SCR,DRIVE,SS,#6X3/8LONG,.120IN 2
16 002-1440 ANODE,GALVANIC 4
17 101-3574 RLF VALVE ASSY 10
21 001-4420 HOSE GUARD,FOREARM,CONAN 1
22 002-1492 HHCS,1/4-20X1.25,SS 2
23 002-0183 NUT,1/4-20,SS,NYLINSR 2
24 002-0790 WSHR,1/4IDX.5OD,SS .032THK 4
25 002-0796 ADH,#290 GRN LOCTITE 50ML 0
28 025-0049 HYD SCHEM 0
29 035-0899 SCHEMATIC CONAN 7P SEACON 1508 0
40 101-3665-4-WI WORK INSTRUCTIONS 0

Item 1 of 101-3665-4
Lower Arm Kit, 101-3660

Rev. A
1 101-3231-3 BASE,ANODIZED 1
2 001-4268 AZIMUTH,CONAN 1
3 101-3229-3 UPR ARM,ANODIZED 1
4 101-3669 FA,CON 1
5 101-3659 ACTR ASSY,6.0X2.25IN. BORE 3
6 001-4271 PIVOT FLANGE MOUNT,CONAN 6
7 001-4410 PIN,ACTUATOR SLOTTED,CONAN 3
8 001-3861 PIN,PVT,LWR ARM,CON 6
11 001-4299 PLATE,HARD STOP 1
14 001-4342 RETAINER, PIN 9
16 002-0790 WSHR,1/4IDX.5OD,SS .032THK 60
17 002-0065 HHCS,1/4-20X5/8,SS 18
18 002-1241 HHCS,1/2-13X1,SS 4
19 002-0811 WSHR,1/2,AN SS 4
20 002-0134 HHCS,1/4-20X1,SS 60
21 001-4414 BUMPER,SHOULDER,ACTUATOR 1
22 002-1438 FHMS,1/4-20X3/4,82 DEG.,SS 2
24 002-1427 PIN,SPR,.125 DIA.X1IN.,SS 2
25 001-4637 BUMPER,UPR ARM 2
Item 2 of 101-3665-4
Pitch Kit, 101-3661

Rev. C
1 001-7246 PLATE,TOP,CONAN LINK 1
2 001-7245-1 PLATE,SIDE,RIGHT,CONAN LINK 1
3 001-7245-2 PLATE,SIDE,LEFT,CONAN LINK 1
4 002-0134P HHCS,1/4-20X1,SS,NYLOCK 8
6 001-4775 PIN,PIVOT,5/8 X 2.00 IN. 2
7 001-4776 SPACER,LINK,CONAN 1
8 001-7247 PIN 1.0 DIA X 5.07 LONG 1
9 003-0213 BRG,THR,IGUS LTI-1018-01 6
10 001-4286 SLIDE,LINEAR,.505 TALL 1
11 002-1438 FHMS,1/4-20X3/4,82 DEG.,SS 2
14 002-0065 HHCS,1/4-20X5/8,SS 8
15 001-4774 PIN, .625 O.D. X 6.79 LONG 1
16 002-0811 WSHR,1/2,AN SS 4
17 002-1494P HHCS,1/2-20 X 2-1/4,SS,NLK 4

Item 3 of 101-3665-4
Yaw Kit, 101-3662

Rev. D
1 101-3670 YAW,CON 1
2 001-7246 PLATE,TOP,CONAN LINK 1
3 001-7245-1 PLATE,SIDE,RIGHT,CONAN LINK 1
4 001-7245-2 PLATE,SIDE,LEFT,CONAN LINK 1
5 002-0134P HHCS,1/4-20X1,SS,NYLOCK 8
6 003-0213 BRG,THR,IGUS LTI-1018-01 6
8 001-4775 PIN,PIVOT,5/8 X 2.00 IN. 2
9 001-4776 SPACER,LINK,CONAN 1
10 001-7247 PIN 1.0 DIA X 5.07 LONG 1
12 001-4286 SLIDE,LINEAR,.505 TALL 1
13 002-1438 FHMS,1/4-20X3/4,82 DEG.,SS 2
15 002-0065 HHCS,1/4-20X5/8,SS 8
18 001-4774 PIN, .625 O.D. X 6.79 LONG 1
19 002-0811 WSHR,1/2,AN SS 4
20 002-1494P HHCS,1/2-20 X 2-1/4,SS,NLK 4
21 002-0790 WSHR,1/4IDX.5OD,SS .032THK 8
Item 7 of 101-3665-4
Lock Valve ,Kit,, 101-3101

,
Rev. A
1 006-1082 LOCKVALVE,PILOT OPR,TESTED 2
2 001-4334 PLUG,SPACER 2
3 001-3866 SPR,FLOW 2
4 004-0222 O-RING,2-010 BUNA 90 6
5 002-1274 SCR,SET,7/16-20X.50 2
Item 10 of 101-3665-4
Cable Kit, 101-3262

Rev. A
6 101-3265 HOSE,COAX,AZ,LIN ACTR 1
7 101-3266 HOSE,COAX,SHLDR,LIN ACTR 1
8 101-3267 HOSE,COAX,ELB,LIN ACTR 1
9 101-3263 HOSE,COAX,PITCH,LIN ACTR 1
10 101-3264 HOSE,COAX,YAW,LIN ACTR 1

Item 11 of 101-3665-4
Hose Set, 101-3241

Rev. A
1 006-1228 HOSE ASSY,TELEFLEX,TEFZEL,-4JI 4
4 101-3238 HOSE ASSY,PITCH,CON 47IN 2
5 101-3239 HOSE ASSY,YAW,CON 53IN 2
10 101-3597 MANF ASSY,PRS./RTN,UPR ARM 1
17 006-1205 FIT,HYD,-4 JIC TO HOSE,RE-USAB 4
18 004-0022 O-RING,2-010 BUNA 70 4
19 004-0410 RING,BACK-UP 8-010 B90 4
21 005-3165 HOSE LABEL KIT,CON7P 1
32 002-0298 CA TIE,11~ BLK,PLT3H-D100 1

Wrist Base, 101-3671
S S , 0 36
Rev. D
1 001-4772 WRIST BASE 1
9 003-0211 BRG,.625 IDX.5,DIXON CJ10E12-4 2
10 003-0212 BRG,.625 IDX.375,DIXON CJ10E12 2
12 006-1304 FIT,PLUG,2HP5ONSS,-2 HOL,HEX/S 5
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Spares Kits

• Page 162
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Wrist w/PA Jaw 101-3683
Rev. A
1 101-3671 WRIST BASE 1
2 101-3372 WRIST,CON/RIG 1
12 002-1572 HHCS,3/8-16X1.75,316SS 4
44 101-3299 JAW,PA,6IN. 1
45 002-1574 WSHR,.625ODX.385 IDX.125THK,31 4
48 004-0222 O-RING,2-010 BUNA 90 5
49 004-0017 O-RING,2-031 BUNA 70 1

Wrist Motor, 101-3786
Rev. G
1 101-3785 SFT,WR,SUB-ASSY 1
2 101-3784 HSG,AL,SR WR,GAMMA 1
3 004-0617 SEAL,FLUROCARBON #AR10400-418- 1
4 003-0031 BRG,NEEDLE,TORRINGTON B-5612 1
5 004-0803 SEAL,SHAMBAN,TGZF-S4016NA 3
7 001-4454 BRG,SLYDRING,2.875IDX3.063X.25 1
8 003-0074 WSHR,THR,TRA2840,TORRINGTON 1
9 003-0013 TORRINGTON,NTA 2840 1
10 001-4437 RING,SEAL BACKUP 1
11 001-2060 PL,WEAR,WR MOTOR 1
12 004-0575 SEAL,AR10103-214-UH,FLUROCARBO 1
13 101-3373 GEROTOR,W/O WR RING 1
14 001-1832 VALVE,PL,WR MOTOR 1
16 004-0081 O-RING,2-035 BUNA 70 1
17 004-0017 O-RING,2-031 BUNA 70 1
18 004-0413 O-RING,2-026 V75 1
19 004-0110 O-RING,2-046 BUNA 70 1
20 101-3782 MANF,WR,GAMMA 1
21 003-0011 TORRINGTON,B148 1
22 001-4448 BOLT,OIL SPLY,WR 2
23 001-4449 BOLT,OIL RTN,WR 1
24 004-0445 O-RING,2-006 V90 2
25 001-1984 BSHG,WR OIL SPLY TUBE 2
27 004-0576 WSHR,CRUSH,5/16 8
29 001-4577 SHCS,5/16-18X3,CADMIUM PLD,UNB 5
30 003-0092 WSHR,THR,TORRINGTON #TRC 1427 2
31 003-0091 BRG,THR,TORRINGTON #NTC 1427 1
32 001-5103 NUT,CLPING,7/8-20,1.5HEX 1
33 002-1133 SHCS 10-32 X 5/8,UNBRAKO 1
64 010-0236 TOOL,BRG PUSHER,T2/3 0
69 010-0525 TOOL,SEALINSTL 0
70 010-0556 INSTL TOOL,RIG/CON,O-RING 0
72 010-0613 PL,TEST,WR,ORION 0
73 002-1628 NAS6406U3 0
111 011-5014 SVCE INSTR,O7P,WRIST 0
112 011-5002 SVCE INSTR,O7R,WRIST 0
113 011-5030 SVCE INSTR,WR,RIG 0

NOTE: Applicable sheets only.

Nose Block Kit, 101-3853
Rev. V
2 001-5395 PISTON,1 PIECE,2.25 DIA,JAW 1
3 001-5399 BRG,PSTN,2.25DIA,ORKOT 1
5 001-4465 BLOCK,NOSE,CONAN/RIGMASTER 1
6 004-0542 O-RING,2-034 BUNA 70 1
7 004-0541 RING,BACKUP,8-034 BUNA 90 1
8 001-5398 BRG,ROD,1.0DIA,ORKOT 2
9 004-0650 SEAL,ROD,LIN ACTR,GAMMA 2
10 003-0113 BEARING,JAW,GAMMA 4
11 003-0050 BRG,CJ12E144 DIXON 4
12 001-5396 PLATE,T-BAR,LOCKING 1
13 001-7520 BOLT,6 PT,5/8-18,STD 1
14 002-1135 NAS 6406U4 4
15 011-5011 SVCE INSTR,ITMSHG JAW NOSE BLK 0
16 002-1439 WSHR,3/8ID,5/8OD 4
18 010-0991 TOOL,CONAN JAW BOLT 0
23 002-1925 ANTI-SIEZE,1 OZ TUBE 0

Junction Box, 101-4898
Rev. H
1 005-0554 CONN,RECP,DB25(SKTS)205207-11, 1
2 005-5567 ENCLOSURE,14PIN,9PIN,DB-25,GND 1
3 003-0007 FEET,RUB,STICK ON MA CONT HSG 4
4 005-2513 RING,TERM,16-22 AWG,1/4IN. STU 1
5 005-1839 CONN,CPC,17-14,RVS SEXRCPT 1
6 005-0263 SW,PWR MDL WTH SW & FUSE,06A2D 1
7 005-1627 TBG,SHRINK,3/16~,SURF IRRADIAT .15
8 002-0159 BHCS,6-32X3/8,SS 8
9 005-0555 CONN,PIN FEM,D-SUB(66682-4 AMP 4
10 005-0239 CONN,SKT,CPC,66594-2,AMP 18
12 005-3134 CONN,CPC 17-9,RVS SEX,SQ FLG,R 1
13 005-0587 FUSE,6.3A,250V,SLO-BLO,5x20mm 2
15 005-1760 WIRE,18 AWG,BLK,600V,TEFLON 4
16 005-0603 CONN,SCRLOCK FOR DB CONNS 2
17 005-0264 CA,PWR CORDSET(86537030 PANEL 1
18 005-0219 WIRE,22 AWG.,7/32 TEFLON,BLK,. 4
19 001-1463 LABEL,I.D. W/ OPNDATA 1
20 002-0524 CABLE, TIE, 3 IN X .09 WIDE 4
21 002-1787 FHMS,4-40X.25LG,82DEG,18-8,NYL 4
22 002-0226 NUT,4-40,SS 4
23 005-0448 TBG,SHRINK,1/4,SURF IRRADIATED .15
25 002-1507 STDF,3/16 HEX X .25LG,M-F 4-40 4
29 005-4650 CONN,3 PIN,HSG,.156 SPACE,RAMP 1
30 005-4647 CONN,4 PIN,HSG,.156 SPACE,RAMP 1
31 005-1871 PIN,CRIMP,18-24 AWG,GOLD 4
33 005-5568 PWR SPLY MDL,AC-DC,24V,60W 1
34 005-2858 CONN,BNC CHASSIS,ISOLATED 1
35 005-2857 CONN,CAP/CHAIN,MALE BNC 1
36 002-0426 BHCS,4-40X3/8,SS 1

NOTE: Drawing sheets 1 and 2 only apply.
Master Controller, Univ Input, Gen 2, 101-5781
Rev. A
1 101-5782 FACEPLATE,ASSY,MA,CONT,GEN II 1
2 005-5195 PCB,MASTER PROCESSOR,MCU 1
3 101-1645 MA CONT ARM 1
5 005-4645 PCB ASSY,IN ARM TELEMETRY,T4 1
7 101-5992 CABLE ASSY,POWER/CONTROL,MCU 1
8 002-0137 SHCS,6-32X3/8,SS 4
9 002-0011 BHCS,6-32X1/4,18-8,SS 1
10 002-0161 CLP,CA,1/8 1
11 002-0082 SHCS,10-24X5/8,SS 3
16 001-8895 HOUSING,UNIV CONTROLLER 1
17 003-0007 FEET,RUB,STICK ON MA CONT HSG 4
19 001-3893 NAMEPLATE,SCHILLING ROBOTICS 1
23 002-0862 WSHR,#8 LOCKINTL TOOTH,SS 1
24 002-0403 SHCS,8-32X1/4,SS 1
25 035-0731 WRG DIG,MCU,85-264VAC IN,W/MP 0
32 002-0020 SHCS,10-24X3/4,SS 1
37 002-3648 STANDOFF,4-40 X 11/32,SS 1
38 002-3647 BHCS,6-32,3/16,SS,SELF LOCKING 2
39 002-0119 NUT,6-32,SS,NYLOCK 4
40 002-0006 BHCS,4-40X1/4,SS 2
50 002-0279 CASE,SHIPPING,MA CONT 1
51 002-2660 LABEL,ELEC SHOCK,2.3"TRIANGLE 1
53 005-3853 TERM,RING,26-22AWG,#8 STUD,UNI 2
54 005-4886 WIRE,22 AWG,GRN/YEL,TEFZEL .8
56 005-5571 SOCKET STRIP,13 PIN,MCU 1

Face Plate, Master Controller, 101-5782
Rev. A
1 002-3646 STANDOFF,6-32,9/16 LONG,SS 4
3 101-1819 POWER SWITCH ASSY,MA 1
4 001-8896 FACEPLATE,UNIV MASTER CONT 1
5 004-0113 O-RING,2-047 BUNA 70 1
6 001-8894 LENS,FACEPLATE,MCU 1
7 004-1054 O-RING,4.378 X .071 BUNA 70 1
8 005-0033 PCB,SW,TIT,MA 1
10 001-8911 ADAPTER,SCD,MCU,GEN II 1
12 101-5901-1 LCD DISPLAY ASSEMBLY 1
14 001-8873 BUTTON,FACEPLATE,MCU,BLACK 11
15 001-0365 PL,MCA BACKUP 12
16 005-0185 KEYPAD,SINGLE BTN,SPST,CNDCT R 12
17 002-0124 FHMS,6-32X1/4,SS,HEXDRIVE 1
19 001-8873-1 BUTTON,FACEPLATE,MCU,RED 1
22 002-0011 BHCS,6-32X1/4,18-8,SS 3
23 002-0429 FHMS,PH,6-32X3/8,100DEG,C'SINK 4
24 002-3479 STANDOFF,6-32x3/16,1/4 HEX,MCU 2
25 005-5570 INTERCONNECT STRIP,13 PIN,MCU 1
26 002-3649 SCREW,SET,6-32 X .75, SS 4
27 101-5943 ASSY,JAWSWITCH,MCU,GEN II 1

REV ZONE DESCRIPTION DATE BY APPR
0 - PRELIMINARY 1/5/07 JG SLW

NOTES: 19 0 - RELEASED FOR PROTOTYPE 1/12/07 JG SLW
1 - ADDED NOTE 1, ITEM 12 BALLOON, VIEW A; 7/19/07 JG SLW
REF UPDATED ITEMS 3 AND 27
1 SERIALIZE FACE PLATE IN LOCATION SHOWN AS DESCRIBED A - RELEASED FOR PRODUCTION 11/1/07 NLH SLW
IN WORK INSTRUCTIONS.
D D
POSITION THIS SIDE
TOWARDS TOP EDGE OF THE
FACE PLATE (ITEM 4)
DETAIL A
SCALE 2:1
C TOP EDGE 14 15 16
C
OF FACE PLATE 4
11 12 12
011–0917
DETAIL B
•
27
26 8 SCALE 2 : 1.75
A 7
4 1 12 PLACES
4
23
4
NOTE ORIENTATION B
Spares Kits
3
12
B B
• Page 179
24
2
PIN 1
6
1 22
PIN 13 3
5
10
17 25 GENERAL NOTES NEXT ASSEMBLY
A INTERPRET DIMENSIONING AND TOLERANCING
A
101-5781
PER ASME Y14.5M-1994. IN ADDITION, S
DENOTES REGARDLESS OF FEATURE SIZE.
REMOVE ALL BURRS AND BREAK ALL SHARP
EDGES
ALL MACHINED SURFACES TO BE 63 RMS PROJECT T4
19 15 16 FINISH UNLESS OTHERWISE NOTED. SIGNATURE DATE
TITLE
1 REF REF DIMENSIONS ARE IN INCHES UNLESS
OTHERWISE NOTED. DRAWN JG 1/5/07 FACEPLATE, ASSEMBLY,
TOLERANCES DESIGNED
PROPRIETARY MM 1/5/07 MA, CONTROLLER, GEN II
RELEASED FOR DECIMALS FRACTIONS ANGLES
THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO CHECKED SCALE: DRAWING NUMBER SIZE SHEET REV
SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR .X ±.1 .X ±30'
USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT .XX ±.02 ±1/16 .XX ±15' LEAD OF
AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING. PRODUCTION .XXX ±.005 SLW 1:1.75 101-5782 C 1 1 A
Wiring Harness, Penetrator, 101-6829
NOTE: Drawing only.

Cable Ass’y, Deck Test, 8 Pin, 15 Shell, 101-6926-3
Rev. 0
1 005-3243-12 CONN,8 PIN,15 SHELL,BURTON 12 1
2 005-3133 CONN,CPC 17-9,RVS SEXPLUG 1
3 005-1794 PIN,CONN,CPC,AMP #66587-2 8
4 005-1850 CONN,STRAIN RLF CPC 17 SHELL L 1
5 005-4096 LABEL,3/8 IN,PANDUIT 0
1000 101-6926-3-WI WORK INSTRUCTIONS 0

Wiring Harness, C7P Base Module, Seacon, 101-7853
Rev. 1
1 005-7106 CONN,8 PIN,15 SHELL SEACON 1
2 005-0561 CONN,PIN,FEM,02-06-5103,MOLEX 5
3 005-2823 CONN,6 CKT RECEPT,MOLEX03-06-1 1
4 005-2521 WIRE,22 AWG,BLK,STRD,TEFZEL 6
11 005-0474 TBG,SHRINK,1/8,SURF IRRADIATED 1
14 005-1966 MKR,CA,VINYL CLOTH,1/4X1 1/2 0
15 005-1532 TBG,SHRINK,POLYOLY,CLEAR,3/32 .5
16 001-12019 ADAPTER,3/4-16 TO 5/8-18 1
17 004-0912 O-RING,2-021, BUNA 90 1

Base Module, C7P, Seacon 1508, 101-7854
Rev. 0
1 001-3894 BLK,MANF,CON 1
2 001-4389 COV/MT,MANF 1
4 001-4390 COV,PWR SPLY,MANF 1
5 101-7853 WRG,HARN,C7P BASE MOD,SEACO 1
6 101-6829 WRG HARN,PENETRATOR,SS7,24V 1
8 002-0933 SHCS,6-32,5/16LONG,ALLOY STL 10
9 002-0407 WSHR,FLAT,#6,SS 2
10 006-0108 FIT,HYD,-4,JIC,-4 ST,ELB,MALE 7
11 006-0362 FLTR ELEM 10 MIC. NOM,25MIC AB 1
12 001-4057 BASE,FLTR,HIGH PRESS 1
13 002-1499 HHCS,1/4-20X3.25 4
14 004-0100 O-RING,2-018 BUNA 70 1
15 004-0125 RING,BACKUP,8-018 BUNA 90 1
17 006-0042 VALVE,POPPET,2-WAY,NC 1
18 006-0432 COIL ASSY,24 VDC,WATERMAN #704 1
19 006-0612 VALVE,RL,RLF,NUPRO 350-600 PSI 1
21 005-5953 CONV,DC/DC,+/-12VDC,30W,+24 IN 1
22 006-0777 FIT,HYD,-6 JIC,-6 ST,CONN,MALE 1
23 006-0029 FTG,HYD,-4ST PLUG,4HP50N-SS 1
24 006-0116 FIT,HYD,-4,JIC,-4,ST,EL,MALE,4 2
25 002-0081 WSHR,1/4,NYL 4
26 004-0359 O-RING,2-169 V75 2
27 002-0790 WSHR,1/4IDX.5OD,SS .032THK 8
28 002-0134 HHCS,1/4-20X1,SS 4
29 001-4372 PL,ADPTR 1
30 004-0670 O-RING,.070X.040,BUNA 70 APPLE 1
31 101-3258 LOCKV ASSY,KEPNER CRTG,150 PSI 1
32 004-0136 O-RING,.315x.039 BUNA 90 APPLE 4
33 002-0156 SHCS,10-24X1/2,SS 4
34 006-1255 FIT,HYD,-4 JIC,-8,ST,CONN,MALE 1
35 006-1189 FIT,HYD,-12,ST,-8,ST,RDCR,SS 1
36 005-3600 PCB ASSEMBLY,BASE MODULE/SCU 1
37 002-0358 SHCS,4-40X.18,SS 12
38 002-0451 WSHR,NYL #4,.032THK 6
39 002-1486 STANDOFF,#4X1/2LONG 6
40 002-1487 STANDOFF,#10X3/8LONG 4
41 002-0860 SHCS,10-32X5/16,SS 3
43 006-0027 FIT,HYD,-4,JIC,CAP-S(4FNTX-S) 2
44 006-0028 FIT,HYD,-6,JIC,CAP-S(6FNTX-S) 1

Base Module, C7P, Seacon 1508, 101-7854 (cont.)
Rev. 0
46 002-0198 SHCS,10-24X2,SS 4
47 004-0222 O-RING,2-010 BUNA 90 8
49 004-0561 O-RING,.228X.040,BUNA 70 0
52 005-2788 WIRE,22 AWG,STRANDED,WHT 1
53 005-2789 WIRE,22 AWG,STRANDED,RED 1
54 005-2790 WIRE,22 AWG,STRANDED,GRN 1
55 005-2791 WIRE,22 AWG,STRANDED,BLUE 1
56 035-0804 WRG SCHEM,CONAN,SS7,24VDC 0
57 002-0524 CABLE, TIE, 3 IN X .09 WIDE 4
58 002-0846 CA TIE,8IN.X.14 WIDE 1
59 001-4523 FIT,HYD,-4 JIC,-4 ST,45 DEG.,D 5
81 101-3924 VALVE,BYP 1
82 002-0228 SHCS,4-40X1/2,SS 4
83 002-8044-8 SHCS,M3 X 8,316 SS 2
84 001-10360 ADAPTER PLATE,CONAN 24VDC 1
85 004-0912 O-RING,2-021, BUNA 90 0
86 004-0889 O-RING,2-116,BUNA 70 0

Conan 7P System, PA Jaw, Seacon 1508, 199-0318
Rev. 1
1 101-3665-4 SL ARM,CYN INC PA JAW,SEACON 1
2 011-8231 MAN,C7P,24V BM,199-0318 2
3 002-1462 CRATE,SHPNG,SL ARM,CON 1
6 101-5781 MASTER CONT,UNIV INPUT,GEN 2 1
7 101-4898 J-BOX,DECK TEST,T4 1
8 101-6926-3 CA ASSY,DECK TEST,8PIN15 SHELL 1
9 101-3827 SOFTWARE GROUP,CON7P 0
13 005-1839 CONN,CPC,17-14,RVS SEXRCPT 1
14 005-0239 CONN,SKT,CPC,66594-2,AMP 10
15 005-3133 CONN,CPC 17-9,RVS SEXPLUG 1
16 005-1794 PIN,CONN,CPC,AMP #66587-2 9
17 005-1850 CONN,STRAIN RLF CPC 17 SHELL L 1
20 008-0651 SPS KIT,CON7P,SEACON 1508 0
23 008-0129 KIT,MTING,CON CRATE 1
101 199-0305-ET CONAN 24V PRESSURE TEST 0

Spares Kit, Conan 7P, Seacon 1508, 008-0651
Rev. A
1 101-3342 SPS KIT,CON SMALL ACTR 1
2 101-3343 SPS KIT,CON LARGE ACTR 1
5 101-3346 SPS KIT,CON HDW 1
6 010-0689 TOOL KIT,CON/RIG 1
7 101-7856 KIT,CON POSN CONT,SEACON 1508 1
11 008-0096 SP KIT, RIG, WRIST 1
12 001-7520 BOLT,6 PT,5/8-18,STD 2
13 001-5396 PLATE,T-BAR,LOCKING 2
14 002-1925 ANTI-SIEZE,1 OZ TUBE 1
NOTE: Part lists for spares sub-kits and assemblies shown in the “Item” column begin
below.
Item 1: Spares Kit, Conan, Small Actuator, 101-3342

Rev. B
1 003-0065 BRG,CJ16E18-10,DIXON 2
2 003-0150 BRG,PSTN,LUYTEX 2
4 004-0046 O-RING,2-127 BUNA 70 2
5 004-0805 O-RING,2-113,B90 4
6 004-0508 STEPSEAL,S48270-4203-109P 3
7 004-0509 SCRAPER,S48302-0108A-56 2
8 004-0646 SEAL,JAW PSTN,GAMMA 2
Item 2: Spares Kit, Conan, Large Actuator, 101-3343

Rev. B
2 003-0006 BRG,THR,0.75X1.50X0.078 3
3 003-0065 BRG,CJ16E18-10,DIXON 2
5 003-0164 BRG,FLG,1.50 ID,1.625OD 3
6 004-0805 O-RING,2-113,B90 2
7 004-0508 STEPSEAL,S48270-4203-109P 3
8 004-0509 SCRAPER,S48302-0108A-56 2
13 002-1274 SCR,SET,7/16-20X.50 2

Item 5: Spares Kit, Conan Hardware, 101-3346
Rev. B
1 002-0065 HHCS,1/4-20X5/8,SS 10
2 002-0068 WSHR,FL,1/4,316SS .625 OD,.050 5
3 002-0166 NUT,3/8-16,SS 4
4 002-0257 HHCS,1/4-20X.75,SS 5
5 002-0262 SHCS,1/4-20X1,SS 10
6 002-0811 WSHR,1/2,AN SS 8
7 002-1241 HHCS,1/2-13X1,SS 4
8 002-0790 WSHR,1/4IDX.5OD,SS .032THK 30
9 002-1281 INSR,1/2-20 SS,MS51830-206 4
10 002-0134 HHCS,1/4-20X1,SS 30
11 002-1572 HHCS,3/8-16X1.75,316SS 4
12 002-1430 HHCS,3/8-24X1.5,SS 4
13 002-1438 FHMS,1/4-20X3/4,82 DEG.,SS 6
14 002-1439 WSHR,3/8ID,5/8OD 4
15 002-1440 ANODE,GALVANIC 5
16 002-3135 ANODE,GALVANIC,1.05 X .75 6
17 002-1494P HHCS,1/2-20 X 2-1/4,SS,NLK 4
18 002-1574 WSHR,.625ODX.385 IDX.125THK,31 4
20 003-0050 BRG,CJ12E144 DIXON 4
21 003-0211 BRG,.625 IDX.5,DIXON CJ10E12-4 7
22 003-0212 BRG,.625 IDX.375,DIXON CJ10E12 5
23 003-0213 BRG,THR,IGUS LTI-1018-01 10

Item 6: Tool Kit, Conan/RigMaster, 010-0689
Rev. E
1 010-0099 SKT,MOD,7/16,6PT.,1/4 DRIVE(SN 1
2 010-0173 TOOL,CLP,JAW 1
3 010-0174 TOOL,INSTALL,M,2.25 1
4 010-0175 TOOL,SIZING,F,2.25 1
5 010-0184 TOOL,INSTL,M,1.75 1
6 010-0185 TOOL,SIZING,F,1.75 1
7 010-0203 TOOL,SIZING,M,1.0 1
8 010-0804 TOOL,PISTON ROD,JAW 1
9 010-0237 TOOL,RESIZING 1
10 010-0238 CLR,JAW PSTN 1
11 010-0759 CROWSFOOT,OPEN END,1 5/8 1
12 010-0525 TOOL,SEALINSTL 1
13 010-0480 NUT,CLPING,WR,PIN 0
14 010-0760 CROWSFOOT,OPEN END,1 1/4~ 1
15 010-0991 TOOL,CONAN JAW BOLT 1
16 010-1117 WRIST CLAMP TOOL 2
17 010-1202 TOOL,CONAN,RELIEF VALVE 1
18 010-0239 TOOL,BRGINSTL 1
19 010-0240 TOOL,JAW ROD SL 1

Item 7: Kit, Position Control, Seacon 1508, 101-7856
Rev. A
1 002-1484 CLP,HOSE,CRIMP,OETIKER,14MM 10
2 004-0022 O-RING,2-010 BUNA 70 5
3 004-0410 RING,BACK-UP 8-010 B90 5
4 004-0508 STEPSEAL,S48270-4203-109P 8
6 005-2788 WIRE,22 AWG,STRANDED,WHT 10
7 005-2789 WIRE,22 AWG,STRANDED,RED 10
8 005-2790 WIRE,22 AWG,STRANDED,GRN 10
9 005-2791 WIRE,22 AWG,STRANDED,BLUE 10
10 005-5953 CONV,DC/DC,+/-12VDC,30W,+24 IN 1
11 006-0432 COIL ASSY,24 VDC,WATERMAN #704 1
12 006-1205 FIT,HYD,-4 JIC TO HOSE,RE-USAB 2
13 006-1206 HOSE,1/4IDX1/2OD,SUPERTHANE 10
26 101-3238 HOSE ASSY,PITCH,CON 47IN 1
27 101-3239 HOSE ASSY,YAW,CON 53IN 1
28 005-3600 PCB ASSEMBLY,BASE MODULE/SCU 1
29 101-3252 XDCR,2.6IN.,CON 1
30 101-3253 XDCR,6IN.,CON 1
31 101-7853 WRG,HARN,C7P BASE MOD,SEACO 1
32 101-6829 WRG HARN,PENETRATOR,SS7,24V 1
33 004-0190 O-RING,2-012 BUNA 90 5
34 004-0062 O-RING,2-013 BUNA 70 5
35 004-0064 RING,BACKUP,8-013 BUNA 90 5
36 002-0198 SHCS,10-24X2,SS 4
37 002-0197 SHCS,10-24X1-1/2,SS 4
38 004-0219 O-RING,2-042 BUNA 70 10

Item 11: Spares Kit, Wrist, Gamma, 008-0096
Rev. B
1 004-0222 O-RING,2-010 BUNA 90 5
2 003-0174 BSHG,FL.,1/4X5/16X1/4LG.,NYL 1
3 004-0617 SEAL,FLUROCARBON #AR10400-418- 1
4 002-1544 WSHR,G10,5/16X9/16X1/16 1
5 004-0803 SEAL,SHAMBAN,TGZF-S4016NA 3
7 001-4454 BRG,SLYDRING,2.875IDX3.063X.25 1
8 003-0074 WSHR,THR,TRA2840,TORRINGTON 1
9 003-0013 TORRINGTON,NTA 2840 1
16 004-0081 O-RING,2-035 BUNA 70 1
17 004-0017 O-RING,2-031 BUNA 70 2
18 004-0413 O-RING,2-026 V75 1
19 004-0110 O-RING,2-046 BUNA 70 1
22 001-4448 BOLT,OIL SPLY,WR 2
23 001-4449 BOLT,OIL RTN,WR 1
24 004-0445 O-RING,2-006 V90 2
25 001-1984 BSHG,WR OIL SPLY TUBE 2
27 004-0576 WSHR,CRUSH,5/16 16
29 001-4577 SHCS,5/16-18X3,CADMIUM PLD,UNB 5
30 003-0092 WSHR,THR,TORRINGTON #TRC 1427 2
31 003-0091 BRG,THR,TORRINGTON #NTC 1427 1
33 002-0139 SHCS,10-32X3/4,SS 1
34 003-0078 BRG,CJ08E10-4,DIXON,.5X.625X.5 4
39 004-0542 O-RING,2-034 BUNA 70 1
40 004-0541 RING,BACKUP,8-034 BUNA 90 1
41 001-0893 BRG,ROD 2
42 004-0508 STEPSEAL,S48270-4203-109P 2
44 004-0619 O-RING,2-114,N90 1
48 003-0050 BRG,CJ12E144 DIXON 4
49 004-0650 SEAL,ROD,LIN ACTR,GAMMA 0

Schilling Robotics Conan 7P Manipulator System: Position-Controlled, 3 KM Submersible 24 VDC Base Module

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Schilling Robotics Conan 7P Manipulator System: Position-Controlled, 3 KM Submersible 24 VDC Base Module

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Schilling Robotics Conan 7P

Document No. 011–8231

FMC Technologies Schilling Robotics

TECHNICAL MANUAL REVISION LOG

Maintenance & Service

Page 4 Table of Contents

Drawings & Part Lists

Table of Contents Page 5

Page 6 Table of Contents

Table of Contents Page 7

Page 8 Table of Contents

2 Manipulator Arm Specifications

Slave Arm Actuator Functions

3 Master Controller Specifications

4 Electrical & Telemetry Requirements

Page 10 • Master Controller Specifications 011–0912

011–0912 Hydraulics • Page 11

This page not used.

Page 12 • Compensation 011–0912

Deck-Test Installation See Figure 5 on page 17.

Figure 1 Mounting dimensions

3.1.1 Jaw Configuration Option

3.3 Junction Box

Page 14 • 3 Mechanical Installation 011–0913

3.4 Master Controller

4 Electrical Power & Telemetry Connections

4.2 Long-Line Connections

Subsea Wiring and Connections See section 4.2.1 on page 16

Topside/Surface Wiring and Connections See section 4.2.2 on page 16

011–0913 4 Electrical Power & Telemetry Connections • Page 15

Figure 2 Long-line power and telemetry options

4.2.1 Subsea Wiring and Connections

Figure 3 subsea cable pin assignments,

4.2.2 Topside/Surface Wiring and Connections

Page 16 • 4 Electrical Power & Telemetry Connections 011–0913

Figure 4 Bulkhead connector wiring

4.3 Deck Test Connections

Figure 5 Deck-test connection

011–0913 4 Electrical Power & Telemetry Connections • Page 17

Part 1: Start System & Test Functions

5. Turn on electrical power to the junction box and master controller.

Page 18 • 5 Completing the Installation 011–0913

Part 3 Set Stow Positions and Travel Limits

NOTE: The factory default allows full slave arm travel.

Part 3: Charge the Compensation System

Part 4: Testing Long-Line Connections

011–0913 5 Completing the Installation • Page 19

Page 20 • 5 Completing the Installation 011–0913

1.2 Base Module

1.4 The Master Controller

1.4.1 Master Arm

Page 22 • System Overview 011–0914

Figure 1 Master controller

011–0914 System Overview • Page 23

1.4.3 Power Switch

1.4.4 Data Display Screen

Page 24 • System Overview 011–0914

1.4.6 Control Keys

1.5 Security Levels