UHD-III 06 Volume 2 Power, Telemetry, & PDF

Schilling Robotics
UHD-III System 300-0552-06

Volume 2
Power, Telemetry, &
Compensation Systems
Document No. 011-0552-06

Electrical Power Systems & Components
Digital Telemetry System & Components
Surface Rack Node
Compensation System & Components
System Hardware & Components
Copyright © 2015 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 per-
mission of FMC Technologies. Descriptions and specifications are subject to change without notice.
FMC Technologies Schilling Robotics

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Sales Schilling.Sales@fmcti.com • Tech Support Schilling.TS@fmcti.com
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Web Site http://www.fmctechnologies.com/schillingrobotics.aspx
TECHNICAL MANUAL REVISION LOG

PRODUCT: UHD-III System 300-0552-06
TECHNICAL MANUAL: 011-0552-06
Description Date Rev
Manual Release April 2015 A
Table of Contents
Power System Components 7
1. About Power Distribution Unit (PDU) 7
1.1 Power Distribution Unit (PDU): Mobilization 8
1.2 Power Distribution Unit (PDU): System Reference 8
2. PDU Operation 15
2.1 PDU Operation: Control Locations and Descriptions 15
2.2 PDU Operation: Hardware Interlocks 19
2.3 PDU Operation: Power Up 19
2.4 PDU Operation: Ground Fault Bypass Switch 26
3. PDU: Theory of Operation 26
3.1 PDU: Main, Clean, and Control Power 26
3.2 PDU: ROV HPU Circuit 29
3.3 PDU: ROV IPDS Circuit 32
3.4 PDU: TMS PWR Circuit 34
4. PDU: Touchscreen Interface (HMI) 36
4.1 PDU Touchscreen: Features and Screen Hierarchy 36
4.2 PDU Touchscreen: Initial Startup Configuration 37
4.3 PDU Touchscreen: Main Operations Screen 39
4.4 PDU Touchscreen: Main Power 43
4.5 PDU Touchscreen: Clean Power 44
4.6 PDU Touchscreen: Setup and Status 45
4.7 PDU Touchscreen: Alarm Summary 46
4.8 PDU Touchscreen: Alarm History 48
4.9 PDU Touchscreen: PLC Status 48
4.10 PDU Touchscreen: Panel Status 50
4.11 PDU Touchscreen: Modbus and Ethernet Status 51
4.12 PDU Touchscreen: Digital Inputs 53
4.13 PDU Touchscreen: Digital Outputs 53
4.14 PDU Touchscreen: Trends 54
4.15 PDU Touchscreen: Security Logon 58
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4.16 PDU Touchscreen: Soft Shutdown Override 58
4.17 PDU Touchscreen: Voltage Setup Page 61
4.18 PDU Touchscreen: Breaker Settings 63
5. PDU: Maintenance, Configuration, and Service 64
5.1 About PDU Maintenance, Configuration, and Service 64
5.2 PDU: Periodic Maintenance 65
5.3 PDU Panel and Door Designations 65
5.4 PDU: Replace Circuit Breakers and Overload Relay 69
5.5 PDU: Ground Fault Detection Unit (GFD) Settings 69
5.6 PDU PLC/HMI Maintenance 69
6. PQube Usage and Maintenance 74
6.1 About PQube Usage and Maintenance 74
6.2 Setting Up Your PQube 75
6.3 Using Your PQube 77
6.4 Getting Data In and Out of the PQube 97
6.5 Supplemental Data Gathering Instructions 101
6.6 PQube Maintenance 105
7. Instrument Power Distribution System (IPDS) 106
7.1 About the Instrument Power Distribution System (IPDS) 106
7.2 Instrument Power Distribution System (IPDS): Specifications 108
7.3 Instrument Power Distribution System (IPDS): Installation & Connections 110
7.4 Instrument Power Distribution System (IPDS): Troubleshooting 113
7.5 Instrument Power Distribution System (IPDS): Maintenance 119
7.6 Instrument Power Distribution System (IPDS): Service 120
8. Line Isolation (Ground Fault) Troubleshooting 135
8.1 About Line Isolation (Ground Fault) Troubleshooting 135
8.2 Line Isolation: General Troubleshooting Techniques 135
8.3 Line Isolation: Devices Causing Faults 136
9. Deck Power J-Box 144
9.1 About Deck Power J-Box 101-7750 144
9.2 Deck Power J-Box: Specifications 144
9.3 Deck Power J-Box: Installation 144
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9.4 Deck Power J-Box: Troubleshooting, Maintenance, & Service 145
Digital Telemetry System 147
1. About Digital Telemetry System and Components 147
1.1 Core DTS Components 147
2. Digital Telemetry System: Rapid Spanning Tree Protocol (RSTP) 150
2.1 Communication Failures & RSTP 150
2.2 Turning off RSTP 151
3. About DTS Network Viewer Tool 151
3.1 Introduction to DTS Network Viewer 152
3.2 Uses of DTS Network Viewer 152
4. DTS Network Viewer: Getting Started 153
4.1 DTS Network Viewer: Tab 1- System Status 154
4.2 DTS Network Viewer: Tab 2 - Serial Setup 155
4.3 DTS Network Viewer: Tab 3 - Video Setup 159
4.4 DTS Network Viewer: Tab 4 - Port Power Page 161
4.5 DTS Network Viewer: Tab 5 - Reports 161
5. Subsea Node 164
5.1 About Subsea Node 101-7306 164
5.2 Subsea Node: Ports and Modules 165
5.3 Subsea Node: Device Configurations 166
5.4 Subsea Node: Installation & Removal 166
5.5 Subsea Node: Troubleshooting 168
5.6 Subsea Node: Maintenance and Service 170
6. Subsea Node Interface Module 196
6.1 About Subsea Node Interface Modules 196
6.2 Subsea Node Interface Modules: Features 197
6.3 Subsea Node Interface Modules: Node/Port Configuration 199
6.4 Subsea Node Interface Modules: Installation & Removal 199
6.5 Subsea Node Interface Modules: Troubleshooting 200
7. SeaNet Cables and Penetrators 204
7.1 About SeaNet Cables and Penetrators 204
7.2 SeaNet Cables and Penetrators: Features 204
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7.3 SeaNet Cables and Penetrators: Maintenance 205
7.4 SeaNet Cables and Penetrators: Service 206
8. Cable & Slip Ring Terminations 215
8.1 About Cable & Slip Ring Terminations 215
8.2 Cable & Slip Ring: Termination Matrix 215
8.3 Cable & Slip Ring: Service 216
9. Surface Rack Node 242
9.1 About Surface Rack Node (101-7356) & Associated Components 242
9.2 Surface Rack Node: Connections 242
Compensation 247
1. About Compensation 247
1.1 Overview 247
1.2 Compensation Circuits 248
1.3 Compensators 248
1.4 Reference 249
2. Compensation: Specifications 249
2.1 General Specifications 249
2.2 Compensation Fluid 252
3. Compensation: Troubleshooting 252
3.1 Troubleshooting Table 253
3.2 Leaks 254
3.3 Air in Circuit or Low Fluid Volume 255
3.4 No or Incorrect Volume Data on Control Console 255
4. Compensation: Maintenance and Service 256
5. Rapid Fill and Bleed Compensation Cart 274
5.1 Rapid Fill and Bleed Compensation Cart 275
5.2 Rapid Fill and Bleed: Component Overview 277
5.3 Rapid Fill and Bleed ROV Circuits 294
5.4 Rapid Fill and Bleed TMS Circuits 297
Glossary 309
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Power System Components 1. About Power Distribution Unit (PDU)
Power System Components
1. About Power Distribution Unit (PDU) 7

2. PDU Operation 15
3. PDU: Theory of Operation 26
4. PDU: Touchscreen Interface (HMI) 36
5. PDU: Maintenance, Configuration, and Service 64
6. PQube Usage and Maintenance 74
7. Instrument Power Distribution System (IPDS) 106
8. Line Isolation (Ground Fault) Troubleshooting 135
9. Deck Power J-Box 144
1. About Power Distribution Unit (PDU)

WARNING! HIGH VOLTAGE SHOCK HAZARD! Lethal voltages are present inside the PDU even
when the PDU Main circuit breaker is open. Before performing any service, open and lockout/tagout
ALL EXTERNAL circuit breakers controlling power to the PDU.
WARNING! Only qualified and authorized individuals should perform electrical work on the PDU.
The PDU transforms, distributes, and monitors ship power used by the ROV system. PDU components also
include a ground fault detection system and at least one remote E-stop.
PDU information specific to the ROV system, theory of operation, component descriptions, and
troubleshooting information are provided in this manual.
Page 7 011-0552-06
● See the Tinitron, Inc. OEM manual in Support Files for general information about the PDU com-
ponents, electrical schematics, and certifications.
● PDU mobilization information is provided in About PDU Mobilization in Volume 1: ROV & TMS
System Manuals.
Interconnect diagrams for the topside and subsea power components are located in the “System Schematics
& Interconnect Diagrams” section of Volume 4: Drawings and Part Lists.
1.1 Power Distribution Unit (PDU): Mobilization

For PDU mobilization information, see About PDU Mobilization in Volume 1: ROV & TMS System
Manuals.
1.2 Power Distribution Unit (PDU): System Reference

PDU System Reference
System or
Resources
Component
Specifications Specifications for the PDU can be found in the hard copy Tinitron Manual or in the PDU manual PDF
file located on the CD supplied with the Tinitron Manual.
OEM Docu- OEM documentation for the PDU can be found in the hard copy Tinitron Manual or in the PDU manual
ments PDF file located on the CD supplied with the Tinitron Manual.
Component Seri- The serial number log for vehicle components present at the time of shipment is located in Support
alization Files\1 - System Info\FAT Docs\
Page 8 011-0552-06
PDU: Lockout/Tagout (Safety Procedure)

Tools PDU cabinet door key, multimeter
Personnel Per specific job requirements
Parts-Kits Approved lockout/tagout devices (locks, tags)
Safety High-voltage electrical shock hazard, pinching
The PDU contains high voltage, which can be lethal. This service instruction explains how to use lockout
and tagout devices on the Tinitron PDU to protect technicians who are working on the PDU or systems
that receive power from the PDU. Before you do any work or maintenance on the PDU, review this service
instruction.
Terminology
Lockout and tagout refer to devices, practices, and procedures that protect personnel from the unexpected
startup of machinery and equipment or exposure to hazardous energy during service or maintenance work.
Lockout devices keep the energy-isolation devices in a safe or OFF position. Lockout devices are lockable
mechanical fixtures that cannot be removed without a key. When you install the lockout device, keep the
key or place it in an approved, secure location.
Tagout devices are prominent warning signs that authorized personnel fasten to energy-isolating devices to
warn others to NOT re-energize the equipment during service or maintenance. Tagout devices are easier to
remove than lockout devices, and when they are used alone, they provide less protection. When you install
the tagout device, mark it (if appropriate) with the your name and date.
Tagout and lockout devices should be used together whenever possible.

Energy-isolating devices include circuit breakers, switches, valves, wheels, and levers that isolate power to
protect equipment and workers. Once an energy-isolating device is placed into the appropriate position,
lockout and/or tagout devices are installed onto the energy-isolating device to lock it into a safe position.
WARNING! This document is a reference for ROV system equipment only. Use it in conjunction with
site-specific safety procedures or policies. Before you do any work, consult all available local lockout
and tagout documentation. Illustrations in this document reflect recently shipped equipment, and
your equipment may look different.
Page 9 011-0552-06
WARNING! SHOCK HAZARD! Lethal voltages are present throughout the ROV system, including in
the control van, PDU, deck cable, LARS, TMS, and ROV. ALWAYS assume that equipment is energized
until you have CONFIRMED that it is isolated, locked out, and tagged out as directed by applicable
electrical safety regulations and procedures. Observe high-voltage safety practices whenever system
power is enabled.
WARNING! Electrical power used throughout the ROV system can cause lethal electric shock,
burns, and fire. Lesser voltages found in equipment throughout the system can also be lethal under
some conditions.
Preparing for Lockout/Tagout

During lockout/tagout, you must perform the following steps to ensure safety:
● Turn off or disengage the energy source.
● Ensure that no residual energy is present.
● Install lockout and/or tagout devices as needed.
● Ensure that equipment is safe to operate, and notify others before removing any lockout or tagout
devices.
Working on de-energized equipment
Whenever possible, isolate and lock out/tag out electrical power or energy sources to equipment before you
perform any service or troubleshooting. Lockout/tagout procedures must ensure that:
1. The equipment has no potential for stored or residual energy (or accumulation of stored energy after
shutdown) that could harm personnel.
2. All energy sources for the equipment can be readily identified and isolated.
3. The equipment is completely de-energized and deactivated by the isolation, grounding, and
lockout/tagout of the energy source(s).
Preparing to work on equipment
Before you begin service or maintenance, follow the steps below in order. Be sure to also follow any spe-
cific provisions of the appropriate energy-control procedures or operational manuals.
1. Prepare for shutdown.
2. Shut down the equipment to be worked on.
3. Disconnect or isolate the equipment from the energy source(s).
4. Apply the lockout and/or tagout device(s) to the energy-isolating device(s).
5. Release, restrain, or otherwise make safe all potentially hazardous stored or residual energy. If energy
could possibly accumulate during service or maintenance, regularly verify that such energy has not
accumulated to hazardous levels.
6. Verify that the equipment has been isolated and depowered.
Page 10 011-0552-06
PDU Lockout/Tagout
Shut down system power
1. Make sure that equipment connected to the circuit that will be shut down is not in use, and tell others
in the area what you are doing.
2. Perform the normal PDU shut-down procedure as
described in your system maintenance manual.
Then switch off and lock out/tag out all external
power to the PDU cabinet at the power
distribution panel (PDP). This may include deck
generator controls, engine room circuit breakers,
or circuit breakers on remote panels.
WARNING! Ensure that all external power

sources supplying energy to the PDU are dis-
connected or de-energized. Turn PDU power
off at the distribution panel.
Confirm that no hazardous energy is present

1. To confirm that no hazardous voltage or energy is present, measure voltage at the location where the
incoming voltage cables are landed.
Note: Refer to the Tinitron Inc. OEM manual for more details.
2. Take voltage measurements between each leg and from each leg to ground.
Lock out ground switches
Note: Due to the variety of PDUs, your PDU may look different than the images in this service instruc-
tion. The basic components should still be present.
1. Rotate or confirm that the ground switches are set to the GROUND position. Then lock out the ground
wheel/switch with the appropriate locking mechanism.
Page 11 011-0552-06
Examples of locked grounding wheels:
2. Depending on the lockout mechanism used, you

may need to re-index the grounding wheels to
allow lock installation. To do this:
a. Loosen the hex screw located in the hub of
the ground wheel. This lets you pull the wheel
off the rotary shaft.
b. Mark the wheel's position indicator using red
electrical tape.
c. Install the wheel as required and tighten the
hex screw.
Page 12 011-0552-06
Lock out circuit breakers

1. Confirm that the main circuit breaker is set to the
OFF position. (See the PDP image to the right for
the location of the main PDP panel circuit
breaker and the PDU.) With the MAIN (-001)
breaker in the off position, all power is cut off to
the PDU.
Note: Circuit breakers only allow locks to be

installed in the OFF or de-energized position.
2. Before you install the lockout device, inspect the position indicator and set the rotary switches to the
LOCK position.
3. Install lockout devices either into the switch handle or in such a way that the switch cannot be moved
without first removing the lockout device.
4. Once the lockout device is installed, place a padlock through the arms of the lockout device, securing
the switch in position. Keep the key or place it in an appropriate location according to local safety
policy.
Note: In addition to installing a lockout device, you should install tagout devices with your name
and the nature of the work being done. Other workers will then know what work is being done and
who put the lockout device on the system.
Page 13 011-0552-06
Removing Lockout/Tagout Devices

Note: A component may have more than one lockout device on it. Before you remove any lockout or
tagout device, all persons with a lock on a particular component must agree that the system or
machine is in safe condition and ready to be used.
1. Before you remove any lockout or tagout device, take the

following steps and follow any other safety provisions of the
appropriate energy-control or safety procedures.
a. Inspect machines and their components to ensure that they
are operationally intact and that nonessential items have
been removed from the area.
b. Alert all personnel who operate or work with the system, as
well as those in the area where service or maintenance is
performed, that the lockout/tagout devices will be removed
and that the system will be capable of being re-energized.
c. Check to ensure that everyone is positioned safely and away
from the equipment.
d. Remove the lockout and tagout devices.
Additional References
Reference Description
OSHA 3120 Occupational Safety and Health Administration – U.S. Department of Labor (OSHA) Control of Hazardous
Energy – Lockout/Tagout 2002 (revised)
IMCA R 005 International Marine Contractors Association - High Voltage Equipment: Safety Procedures for Working
Rev. 1 on ROVs
MAN-5153- Tinitron Inc. UHD ROV Power Distribution Unit – Operation Manual
001j
MAN-5220- Tinitron Inc. HD ROV power Distribution Unit – Reference Manual
002D
A0DC 060 The International Association of Underwater Engineering Contractors – Safety Procedures for Working on
High Voltage Equipment
Page 14 011-0552-06
Power System Components 2. PDU Operation
2. PDU Operation
2.1 PDU Operation: Control Locations and Descriptions
WARNING! HIGH VOLTAGE SHOCK HAZARD! Lethal voltages will be applied throughout the
LARS, umbilical, tether, ROV, and TMS. Ensure the ROV and TMS are grounded and all enclosures
are closed and secured.
2.1.1 PDU Left Door

Refer to Figure 1 for the locations of the following left door indicators and controls:
PDU Indicators and Controls (Left Door)

Indicator/Control Function
ROV-HPU Circuit Selects the power to the ROV-HPU circuit.
Breaker
ROV-IPDS Circuit Selects the power for the ROV-IPDS circuit
Breaker
TMS-PWR Circuit Selects the power for the TMS-PWR circuit
Breaker
Main Power Phase Amber LED that indicates the main power monitor fault relay has detected a fault. The Main
Fault Breaker cannot be activated while this fault is active.
Main CB ON Green LED that indicates the main circuit breaker is on. The breaker is off or tripped if the LED is
not illuminated.
Clean Power Avail- Green LED that indicates clean power is being received by the PDU.
able
Control Power ON Enables 24 VDC and 230 VAC power throughout the PDU cabinet. Control power must be on for
anything else to operate.
Control Power OFF Disables 24 VDC and 230 VAC power throughout the PDU cabinet.
Hour Meters Counts the number of hours each circuit is active
Alarm Sounder Provides an audible alarm. Can be silenced from the HMI or the ROV control console.
Emergency Stop Press to turn off all high power circuits and main circuit breakers. The button locks in the stop pos-
ition and must be twisted clockwise to release.
Clean Power Meter Displays main voltage, current, and frequency (not available on UHD-III).
(HD and UHD-II
Only)
Page 15 011-0552-06
Figure 1: PDU Left Door (UHD-III)
2.1.2 PDU Right Door

Refer to Figure 2 for the locations of the following right door indicators and controls:
PDU Indicators and Controls (Right Door)

HMI Human Machine Interface. Interactive touchscreen that displays data and can be used to control
the PDU.
Ground Fault Meters Megacon ground fault meters display the insulation resistance of the output cable for insulation
breakdowns and ground faults. An alarm will sound if the resistance drops below 500 Kilohms and
the PLC will show a ground fault. If the fault reaches 300 Kilohms the relay closes and turns off the
entire circuit.
Ground Fault Test Key switches that apply a known resistance across the ground fault meter to verify operation.
Switches
Ground Fault Key switches that allow a technician to bypass the ground fault relay and temporarily resume oper-
Bypass ation of the affected circuit.
Normal/Grounded A green LED indicates the rotary ground switch is in the normal position, while a red LED indicates
Indicators the switch is in the grounded position.
ROV-HPU Power Energizes the ROV-HPU contactor. The green LED in the push button illuminates when the con-
ON tactor is on. The ROV-IPDS contactor must be on before starting the HPU circuit.
Page 16 011-0552-06
PDU Indicators and Controls (Right Door) (continued)

ROV-HPU Power Turns off the ROV-HPU contactor and illuminates the red LED inside the OFF button. ROV-HPU
OFF power should be off when activating control power and the branch circuit breaker.
ROV-IPDS Power Energizes the ROV-IPDS contactor and illuminates the green LED inside the button.
ON
ROV-IPDS Power Turns off the ROV-IPDS contactor and illuminates the red LED inside the button. ROV-IPDS
OFF power should be off when activating control power and the branch circuit breaker.
TMS-PWR ON Energizes the TMS-PWR contactor and illuminates the green LED inside the push button.
TMS-PWR OFF Turns off the TMS-PWR contactor and illuminates the red LED inside the push button. TMS-PWR
power should be off when activating control power and the branch circuit breaker.
ROV-HPU Overload If an overcurrent is detected in the ROV-HPU circuit the red LED will illuminate.
ROV-IPDS Over- If an overcurrent is detected in the ROV-IPDS circuit the red LED will illuminate.
load
TMS-PWR Overload If an overcurrent is detected in the TMS-PWR circuit the red LED will illuminate.
Page 17 011-0552-06
Figure 2: PDU Right Door
2.1.3 Fixed Front Panel

Refer to Figure 3 for the locations of the following controls on the PDU fixed front panel:
PDU Indicators and Controls (Fixed Front Panel)

Ground Switches Rotary switches provide a safety ground to the HV output cables for the HPU, ROV-IPDS, and
TMS-PWR. Rotating the switch through the center position will trip the breaker for the cor-
responding circuit.
Page 18 011-0552-06
Figure 3: Fixed Front Panel
2.2 PDU Operation: Hardware Interlocks

PDU Interlocks
Interlock Function
Doors All doors and removable panels interlock with the Emergency Stop circuit. If a door or panel is opened, all cir-
cuit breakers will be tripped disabling IPDS and HPU power. Control power 230 VAC and 24 VDC supplies
remain active however.
Phase Activates the Emergency Stop under the following conditions:
Sequence ● Phases out of sequence
Monitor
● Phase failure or drop out
● Phase imbalance
Emergency Causes the main power circuit breaker to trip and remove power from all contactor coils except the PLC and
Stop control power.
Control Provides 230 VAC and 24 VDC to contactors and circuit breakers. Circuit breakers will not operate without
Power 24 VDC. There are also circuit breakers on the 230 VAC feeds to each contactor and on the 24 VDC section
of each main power circuit.
HPU Cir- The HPU circuit contains a branch circuit breaker, contactor, step-up transformer, high voltage monitor,
cuit ground fault monitor, and grounding switch. If any element is OFF or showing a fault, the entire circuit will not
operate. If a fault occurs during operation the entire circuit will shut down.
ROV IPDS The IPDS circuit contains a branch circuit breaker, contactor, step-up transformer, high-voltage monitor,
Circuit ground fault monitor, and grounding switch. If any element is OFF or showing a fault, the entire circuit will not
operate. If a fault occurs during operation the entire circuit will shut down.
TMS PWR The TMS PWR circuit contains a branch circuit breaker, contactor, step-up transformer, high-voltage mon-
Circuit itor, ground fault monitor, and ground switch. If any element is OFF or showing a fault, the entire circuit will
not operate. If a fault occurs during operation the entire circuit will shut down.
Note: If the overload relay opens, only the contactor will turn off, unlatching the LV control circuit
for that line, until the circuit cools off and resets enabling a restart.
2.3 PDU Operation: Power Up

Follow the steps below to Power Up the PDU.
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PDU Power Up
Step Action
1 Verify that:
● E-stop buttons are released.
● All doors and panels are properly closed.
● Phase fault is not lit. (PDU panel)
2 Open the door on the PDP cabinet.
3 Turn on the main power breaker Q01.

This makes power available inside the PDP cabinet.
Page 20 011-0552-06
PDU Power Up (continued)

Step Action
4 Turn on breaker Q03 marked PDU CONTROL
POWER located in the top left corner of the PDP.
This sends power to the HMI computer.
5 Wait for the HMI to start up, and confirm 480 VAC is
present by checking on the PDU HMI Main Power
Page or on the ROV console Power page.
Page 21 011-0552-06
PDU Power Up (continued)

Step Action
6 Turn on Control Power by pressing the hardware but-
ton on the PDU door, or the software button on the
HMI Main Page. The Control Power ON green button
will illuminate.
This allows the main breakers to turn on.
7 Turn on the Q02 PDU Breaker.

This sends 480 vac power to the PDU cabinet.
8 Use steps below to turn on ROV IPDS power as needed, see Turn on ROV IPDS Power below.
9 Use steps below to turn on ROV HPU power as needed, see Turn on ROV HPU Power on page 25.
10 Use steps below to turn on TMS power as needed, see Turn on TMS Power on page 25.
Turn on ROV IPDS Power

Step Action
1 Unground the IPDS circuit by turning the ROV—
IPDS ground switch wheel from GROUND to
NORMAL.
Page 22 011-0552-06
Turn on ROV IPDS Power (continued)

Step Action
2 Check that the green NORMAL light is on and the red
GROUNDED light is off
3 Check that the ROV IPDS ground fault meter is indic-

ating infinity. This means the cables are
NOT connected to ground.
Page 23 011-0552-06

Step Action
4 Turn the ROV IPDS breaker to ON.
● Verify that the power OFF push button light is
lit.
5 Turn on ROV IPDS power using the HMI, the push-

button switch below the HMI screen, or the ROV con-
sole Power page.
Page 24 011-0552-06

Step Action
6 Confirm high voltage is on by checking the voltage
feedback on the main page of the PDU HMI.
Turn on ROV HPU Power

Step Action
1 Unground the circuit by turning the ROV HPU ground switch wheel to Normal.
● Check that the green NORMAL light is on and the red GROUNDED light is off.
2 Check that the ROV HPU ground fault detector is indicating infinity.
● If a ground fault is detected.
3 Turn the ROV HPU breaker to ON.
● Verify the power OFF pushbutton light is lit.
4 Confirm the ROV IPDS is on.
5 Turn on ROV HPU power using the HMI, the pushbutton switch below the HMI screen, or the ROV console
Power page.
6 Confirm high voltage is on by checking the voltage feedback on the main power page of the PDU HMI.
Turn on TMS Power

Step Action
1 Unground the circuit by turning the TMS PWR ground switch wheel to NORMAL.
● Check that the green Normal light is on and the red Grounded light is off.
2 Check that the TMS—PWR ground fault detector is indicating infinity.
3 Turn the TMS—PWR breaker to ON.
● Verify the power OFF pushbutton light is lit.
4 Turn on TMS power using the HMI, the pushbutton switch below the HMI, or the ROV console Power page.
5 Confirm high voltage is on by checking the voltage feedback on the main power page of the PDU HMI.
Page 25 011-0552-06
Power System Components 3. PDU: Theory of Operation
2.4 PDU Operation: Ground Fault Bypass Switch

WARNING! HIGH VOLTAGE SHOCK HAZARD! The BYPASS switch removes ground fault pro-
tection from its 4,160 VAC and 6,000 VAC circuits. If a ground fault is present, lethal voltages can
be present on exposed surfaces of the associated vehicle. Use the BYPASS switch with extreme caution
and follow all applicable high voltage safety procedures.
Below each ground fault protection unit is a keyed BYPASS switch which prevents the GFD unit from open-
ing the 4,160 VAC and 6,000 VAC circuit breakers in the event of a ground fault.
The BYPASS switch can be used for emergency system operation:
● When use of the 4,160 VAC and 6,000 VAC circuits is necessary even though the GFD unit has
detected a ground fault and opened the circuit breaker.
● When the GFD unit is malfunctioning.
Use the BYPASS switch with extreme caution, as it removes ground fault protection from its 4,160 VAC and
6,000 VAC circuits. If a ground fault is present while the BYPASS switch in on, lethal voltages can be
present on exposed surfaces of the associated vehicle.
For more information on the GFD unit, see Ground Fault Detection on page 28.
3. PDU: Theory of Operation

3.1 PDU: Main, Clean, and Control Power
Power to the PDU can come from either the ship main or a clean power source and is selected with jump-
ers on the ROV IPDS and TMS PWR breaker.
Power Input Path

Power
Path
Source
Ship (Main) Through Current Transformers (CT) to metering circuit taps (Q01B) and control voltage transformer (Q03),
Power to the main power circuit breaker (3.1)
Clean Power Through top panel transit and clean power CTs to the terminal below CT02 (Figure 4)
3.1.1 Power Input Section Breaker Panel

Figure 4: Clean power and main power change-over
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3.1.2 Power Metering

Main voltage, current, and frequency are measured and monitored by the PDU and visible on the right door
HMI. Current is measured in each leg using current transformers that scale the current and route it
through the PQube on the inside left door. The PQube is a power quality monitoring device that records
faults based on user defined thresholds. For detailed information on the PQube, see About PQube Usage
and Maintenance on page 74.
Power Metering Equipment

Equipment Function
Current Transformers PQ1, Scales current and routes it through the PQube
PQ2, PQ3
PQube Records power quality faults from all line-to-line and line-to-neutral voltages based on user
defined thresholds (Figure 5)
Figure 5: PQube on inside of left front door
3.1.3 Circuit Breaker Interlocks

Each circuit breaker on the PDU requires several other components to be active and functioning to work
properly. If a failure occurs or any of the interlocked components are not active, the circuit breaker will not
allow power to flow.
Breaker Interlocks
Circuit Breaker Interlock
ROV-IPDS Interlocks with the ground switch, and GFD meter.
ROV-HPU Interlocks with the ground switch, and GFD meter.
TMS-PWR Interlocks with the ground switch, and GFD meter.
3.1.4 Control Power

Control power (Figure 6) supplies 230 VAC to the 230 VAC circuit breakers Q03A and Q03B. The 230 VAC
circuit breakers feed 230 VAC to components throughout the PDU. Control power must be on for the PDU
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to function.
Control Power
Component Function
Control Transformer (T20) Converts one phase of the main input voltage to 230 VAC and feeds breakers Q03A and
Q03B.
230 VAC Circuit Breaker Feeds 230 VAC to the fans, contactors, GFD, the 24 VDC power supply (G01), and PLC
(Q03A) power.
230 VAC Circuit Breaker The breaker protects the 230 VAC circuit feeding the ROV HPU, ROV IPDS, and TMS
(Q03B) PWR control circuits.
Figure 6: Control power terminal block
3.1.5 Ground Fault Detection

3.1.5.1 Description
Three Megacon ground fault detection (GFD) units (Figure 7) are mounted in the PDU, each monitoring
the three 4,160 VAC and 6,000 VAC power lines for line-to-ground resistance on one of the three subsea
circuits (ROV HPU, ROV IPDS, and TMS Power). Resistance to ground is displayed on the panel meters,
HMI, and remote GUI.
● A lighted green “NORMAL” LED denotes no ground fault detected (500 kilohms or greater res-
istance).
● Resistance to ground below 500 kilohms turns on the red “ALARM” light on the Megacon display
and an audible alarm.
● Resistance to ground of 300 kilohms or less automatically shuts off the breaker for the circuit.
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Below each ground fault protection unit is a keyed TEST switch for checking its functionality.
Figure 7: Ground fault detection units (GFD)
Note: The alarm and shutoff functions are both subject to an adjustable delay (see PDU: Ground
Fault Detection Unit (GFD) Settings for nominal settings).
3.1.5.2 Bypassing a GFD Unit (Emergency Operation)

For information, see Using the Ground Fault Bypass Switch on page 1.
3.1.6 24 VDC Control Power

24 VDC is supplied by a switching power supply that gets its power from the 230 VAC control power trans-
former on the Q03A branch circuit. The 24 VDC output is for local control and control circuits for each
transformer branch, all of which are activated when the control power relay (K03) is activated.
24 VDC Control Power

Component Function
Switching Power Supply (G01) Receives 230 VAC from Q03A circuit, provides 24 VDC for local control and
transformer control circuits (activated through relay K03)
Circuit Breaker (Q03C) Protects 24 VDC control power
Relay (K03) Pressing the Control power ON switch of the HMI opens relay K03 and applies
24 VDC to the following circuits:
● Main phase sequence relay (U03)
● Door switches
● Emergency Stop
● UV trips
● PLC modules
● HV soft shutdown relay coils
Control Power Branch Circuits, Circuit Delivers 24 VDC to the LEDs, relay coils, and hour meters
Breakers (Q21B, Q22B, Q23B)
3.2 PDU: ROV HPU Circuit

The ROV-HPU circuit transformer (Figure 8) provides up to 6,500 VAC to the umbilical. Main power is
channeled through a circuit breaker (Q21) to a contactor (K21) and overload relay (OL21), and into a three-
phase step-up transformer (T21) that converts it to the selected output voltage. Thermal overloads will
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automatically trip if the current exceeds a preset amount for a given length of time, then reset automatically
when they cool down.
Figure 8: ROV-HPU Circuit Transformer
3.2.1 HPU Interlocks

The ROV HPU can only be turned on if the grounding switch is in the normal position, the ground fault
detector is in the normal range, the main circuit breaker is ON, ROV-IPDS power is on, and the HV soft
shutdown relay is off. If any of these conditions cease to be true, the UV trip will cause the circuit breaker
to trip.
ROV HPU Interlocks

Component Function
Circuit Breaker Feeds 24 VDC to the ROV HPU control circuit.
(Q21B)
three-phase Receives 24 VDC from Q21B and routes power to the grounding switch position sensors. The three-
Breaker (Q21) phase breaker requires the following conditions be met in order to turn on:
● Control power is on
● The grounding switch is in the normal position
● The GFD is in the normal range
● The Main circuit breaker is on
● The HV soft shutdown relay is off
Ground Switch The ground switch has two positions:
(S21) ● Normal: the high voltage circuit is ungrounded and enabled
● Closed: the high voltage circuit is grounded for safety reasons
Ground Fault Detects leakage current between each high voltage circuit and ground.
Detector (P21A)
HV Soft Shutdown The soft shutdown relay trips the breaker when:
Relay (K21D) ● Short circuit current is detected on the HV circuit
● Overload current is detected on the HV circuit
● Over temperature is detected on the HV transformer
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3.2.2 HPU Controls

The ROV-HPU is controlled using 24 VDC control circuits. 24 VDC power is routed through the PDU to the
PDU start switches and the remote stop/start PLC relay (K21C). With all interlocks active, pressing the ON
button turns on the transformer contactor. The ROV-HPU can also be run from the console via the PLC.
The ROV-HPU is also further interlocked and prevented from turning on unless the ROV-IPDS circuit is
active.
ROV HPU Metering

Meter Function
Potential Transformer Steps-down 6,500V to 275V
(T21P)
Transducer (T21L) The transducer converts 275 VAC to 4-20mA. The 4-20mA signal is used by the PLC to
show voltage output.
Current Transducers The current transducers measure the current going through a wire. The result is displayed on
(T21S, T21T, T21) the HMI.
Elapsed Time Meter Records the number of hours the ROV-HPU has been on. Activated whenever the ON button
is pressed.
Ground Fault Meter Located in the PDU right door with a software counterpart in the HMI. Scales from 10 Mohm
to 0 ohms, with three adjustable trip points:
● Normal - normal operation
● Warning - Alarm sounds, indicator on PLC
● Alarm - circuit shuts down at circuit breaker level
Note: In order to handle the high-voltage, the ground fault system requires an adapter. The high-
voltage adapters in this system are located in the high-voltage output area of the rear panel next to
the Potential Transformers.
3.2.3 ROV HPU Indicators

The ROV-HPU circuit has five indicator LEDs located on the PDU right door.
ROV HPU LED Indicators

LED Description
ROV-HPU A lighted green LED indicates the HPU circuit is ON.
ON
ROV-HPU A lighted red LED indicates the HPU circuit is OFF, but available to be turned ON.
OFF
NORMAL A lighted green LED indicates the ground switch is open and the HV circuit is not grounded. The ON and
OFF LEDs will not be active unless the NORMAL green LED is lit.
GROUNDED A lighted red LED indicates the HV circuit is safely grounded. The NORMAL, ON, and OFF LEDs should
be off.
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ROV HPU LED Indicators (continued)

LED Description
OVERLOAD A lighted red LED indicates the overload relay has tripped and no power is present in the HPU circuit. Con-
trol power is still active, however.
3.3 PDU: ROV IPDS Circuit

The ROV-IPDS circuit provides up to 4,300 VAC to the umbilical for driving lights, cameras, and instru-
mentation. The Break-phase step-up transformer (T22) receives main voltage from a circuit breaker (Q22)
and converts it to 6,000 VAC. Thermal overloads will automatically trip if the current exceeds a preset
amount for a given length of time, then reset automatically when they cool down.
Figure 9: ROV IPDS Transformer
3.3.1 IPDS Interlocks

The ROV-IPDS can only be turned on if the grounding switch is in the normal position, the ground fault
detector is in the normal range, the main circuit breaker is ON, and the HV soft shutdown relay is off. If
any of these conditions cease to be true, the UV trip will cause the circuit breaker to trip.
ROV IPDS Interlocks

Component Function
Circuit Breaker Feeds 24 VDC to the ROV HPU control circuit.
(Q22B)
Breaker (Q22) Receives 24 VDC from Q22B, then routes power to the grounding switch position sensors. The three-
phase breaker requires the following conditions to be met in order to turn on:
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ROV IPDS Interlocks (continued)

Component Function
Detector (P22A)
HV Soft Shut- The soft shutdown relay trips the breaker when:
down Relay ● Short circuit current is detected on the HV circuit
(K22D)
● Overtemperature is detected on the HV transformer
3.3.2 IPDS Controls

The ROV-IPDS is controlled using 24 VDC control circuits that provide 230 VAC to the dedicated contactor
coil (K22). The 24 VDC power to the controls is routed through the PDU start switch or remote start PLC
relay (K22C). The ROV-IPDS can also be run from the console via the PLC.
ROV IPDS Metering

Meter Function
Potential Transformer Steps-down 4,250V to 265V
(T22P)
Transducer (T22L) The transducer converts 265 VAC to 4-20mA. The 4-20mA signal is used by the PLC to show
voltage output.
Current Transducers The current transducers measure the current going through a wire. The result is displayed on the
(T22K) HMI.
Elapsed Time Meter Records the number of hours the ROV-IPDS has been on. Activated whenever the ON button is
pressed.
Ground Fault Meter Located in the PDU door with a software counterpart in the HMI. Scales from 10 Mohm to 0 ohms,
with three adjustable trip points:
● Alarm - circuit shuts down at the circuit breaker level
3.3.3 IPDS Indicators

The ROV-IPDS circuit has five indicator LEDs located on the right door.
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ROV IPDS LED Indicators

LED Description
ROV-IPDS A lighted green LED indicates the ROV-IPDS circuit is ON.
ON
ROV-IPDS A lighted red LED indicates the ROV-IPDS circuit is OFF, but available to be turned ON.
OFF
be off.
3.4 PDU: TMS PWR Circuit

The TMS PWR circuit transformer (Figure 10) provides up to 4,250 VAC to the umbilical for driving TMS
lights, cameras, instrumentation, and a winch. Main power passes through a circuit breaker (Q23) to a con-
tactor (K23), an overload relay (OL23), and into a single phase step-up transformer (T23) that converts it to
4,250 VAC. Thermal overloads will automatically trip if the current exceeds a preset amount for a given
length of time, then reset automatically when they cool down.
Figure 10: TMS PWR Circuit Transformer
3.4.1 TMS Interlocks

TMS PWR can only be turned on if the grounding switch is in the normal position, the ground fault mon-
itor is in the normal range, the main circuit breaker is on, and the HV soft shutdown relay is off. If any of
these conditions cease to be true, the UV trip will cause the circuit breaker to trip.
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TMS PWR Interlocks

Component Function
Circuit Breaker Feeds 24 VDC to the TMS PWR control circuit.
(Q23B)
Breaker (Q23) Receives 24 VDC from Q23B and routes power to the grounding switch position sensors. The three-
phase breaker requires the following conditions be met in order to turn on:
Detector (P23A)
HV Soft Shutdown The soft shutdown relay trips the breaker when:
Relay (K23D) ● Short circuit current is detected on the HV circuit
● Over temperature is detected on the HV transformer
3.4.2 TMS Controls

The TMS is controlled using 24 VDC control circuits that provide 230 VAC to a dedicated contactor coil
(K23). 24 VDC power is routed through the PDU start switch or the remote start PLC relay (K23C) to the
controls. TMS power can also be run from the console via the PLC.
TMS PWR Metering

Meter Function
Potential Transformer Steps down 4,250V to 265.625V
(T23P)
Transducer (T23L) The transducer converts 265.625 VAC to 4-20mA. The 4-20mA signal is used by the PLC to show
voltage output.
Current Transducers The current transducers measure the current going through a wire. The result is displayed on the
T23K HMI.
Elapsed Time Meter Records the number of hours the ROV-PWR has been on. Activated whenever the ON button is
pressed.
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Power System Components 4. PDU: Touchscreen Interface (HMI)
TMS PWR Metering (continued)

Meter Function
Ground Fault Meter Located in the PDU door with software counterpart in the HMI. Scales from 10 Mohm to 0 ohms,
with three adjustable trip points:
● Alarm - circuit shuts down at circuit breaker level
3.4.3 TMS Indicators

The TMS PWR circuit has five indicator LEDs located on the PDU right door.
TMS PWR LED Indicators

LED Description
TMS-PWR A lighted green LED indicates the TMS-PWR circuit is ON.
ON
TMS-PWR A lighted red LED indicates the TMS-PWR circuit is OFF, but available to be turned ON.
OFF
be off.
4. PDU: Touchscreen Interface (HMI)

4.1 PDU Touchscreen: Features and Screen Hierarchy
The following sections detail the layout and function of the power distribution unit (PDU) human machine
interface (HMI) screens when using PDU software P/N 014-0969.
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Note: Certain features in the software are system dependent. The following table summarizes the sys-
tems/features. The main difference in the screen appearance is that the HD/UHD-III has 3 controlled
circuits and the UHD-II has four controlled circuits.
Feature UHD-II HD UHD-III

Voltage 3000 4160 6000
Number of Circuits 4 3 3
Soft Fusing Yes Yes Yes
Panel Meters Yes No No
Clean Power Monitoring Yes Yes No
Software 014-0969 014-0969 014-0969
Main Breaker Yes Yes No
50 Hz Capable Yes Yes No
4.2 PDU Touchscreen: Initial Startup Configuration

The initial startup configuration sequence occurs one time only upon the first boot-up after the software
was installed. The initial startup configuration sequence will require configuration of the system type and
voltage settings. The following screen images will assist in understanding this process.
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4.2.0.1 PDU Type Selection

1. When the software boots up for the first time, the
PDU Type selector window should appear. Touch
any of the gray boxes to cycle through PDU types
HD, UHD-II and UHD-III.
2. In the example to the right we have selected the

UHD-II PDU Type. Press next when the desired
PDU Type is highlighted.
Caution! Make sure the correct PDU type is

displayed before selecting NEXT.
Note: If for some reason you need to change

this setting later on, it is possible to access this
screen from the password protected section of
the Setup and Status page.
3. The voltage setup page will appear allowing you to

configure the correct voltage ranges for your
system. Pressing NEXT will conclude the initial
setup sequence and display the main screen.
Note: Your initial voltage setup page may dif-

fer slightly depending upon the PDU type.
a. Touch each of the CHANGE buttons to cycle

through the available voltage settings.
b. Allowed voltage fluctuation values appear in
the white boxes in the center of the screen.
c. Make sure to set the ROV horse power and
the TMS horse power if available.
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4.3 PDU Touchscreen: Main Operations Screen

The Main Page is the primary screen of the PDU HMI for HD and UHD-III and appears when the system
is started up. (After initial configuration has been completed.)
Figure 11: Main Screen HD and UHD-III (3 circuit PDU)
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Figure 12: Forced Off Condition
Forced Off Condition

Under certain situations, a forced off condition may occur that will shut off the indicated power subsystem.
The button will flash the words FORCED OFF as shown in the illustration above, and the power will shut
off. This can happen on HD, UHD-II, or UHD-III systems.
To clear the forced off condition, open the Soft Shutdown Override page, and press the Clear Forced Off
button. For more information, see PDU Touchscreen: Soft Shutdown Override on page 58
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Figure 13: Main Screen UHD-II (4 circuit PDU)
The following functions are available on the Main page.
Main Page
HMI
Function
Feature
PLC Heart- Indicates that the PLC is running. If the number displayed is static the PLC is not operating -- reset power
beat to the PLC.
UV Relay & Indicates if the under voltage (UV) relay inside each breaker is being supplied with 24 VDC. The breaker
Breaker status indicates the current position for the power circuit breaker.
Overload The overload indicator turns red when the primary overload relay is engaged.
Status
Soft Shut- The soft shutdown indicates that one of the following faults has turned off the circuit:
down ● Short circuit
● Overload imbalance
● Transformer temperature
Short Circuit Indicates the presence of a short circuit. Set to 150% of full load amperage (FLA).
Overcurrent Indicates an overcurrent event has occurred. (120% of FLA)
Unbalance Indicates a variance of power between phases. (10% difference in current in any two legs)
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Main Page (continued)

HMI
Function
Feature
Insulation Indicates the current leakage status of the secondary output in respect to the ground.
Resistance
Ground Indicator turns red when a ground fault has occurred, or when the ground wheel is set to the ground
position.
Output Indicates the current output voltage of the step-up transformer.
Voltage
Nominal Indicates the nominal voltage setting as configured in the Voltage Setup Page.
Output Cur- Indicates the current draw on each circuit.
rent
Output Cur- Stores the highest current value recorded on each circuit.
rent (Peak)
Transformer Indicates the current temperature of the step-up transformer.
Temperature
Enable Start Enables the ON key for all circuits.
Contact Press either On or OFF to control power to the indicated system.
ON/OFF/ Forced Off Condition
Forced OFF Under Certain situations, a Forced Off condition may occur, shutting off the contact for indicated power sub-
system. This button will flash Forced Off and the power will shut off. To reset this condition, see the Soft
Shutdown Override page, and select the Clear Forced Off button.
Reset Fault Resets all faults on the page.
Reset Peak Clears the current peak value stored on the main page.
Buzzer Silences the alarm buzzer.
Silence
Control Turn ON or OFF 24 VDC power inside the PDU.
Power
On/Off
Main UV Indicates presence of 24 VDC at the UV relay inside the main breaker. If 24 VDC is not present the main
Relay breaker cannot be turned “ON”
ON/OFF
Phase Indicator light is lit when the primary input feed is improperly connected to the PDU. The order of L1, L2,
Sequence and L3 must be re-arranged.
Fault
Main Indicates the current status of the main breaker, either “ON” or “OFF”.
Breaker
ON/OFF
Remote Indicates whether the Remote Access switch is engaged or disengaged.
Access
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4.4 PDU Touchscreen: Main Power

The Main Power page is used to control and monitor all PDU main functions and contains links to all other
pages.
Figure 14: Main Power
The following functions are available on the Main Power page:
Main Power
HMI Feature Function
Voltage [V] Displays the input voltage from the main feed (L-L is phase to phase voltages).
Current [A] Displays the input current from the main feed.
Frequency [Hz] Displays the input frequency from the main feed.
Power [VA] Displays the apparent power used by the system.
Nominal Input Indicates the nominal voltage value set by the user. This value is set on the “voltage setup” page and
Voltage must match the input nominal voltage.
Peak Voltage Stores the highest voltage value recorded by the system.
Peak Current Stores the highest current value recorded by the system.
Reset Values Reset the stored maximum voltage readings for L1, L2, L3.
Reset Peak Reset the stored peak current readings for L1, L2, L3.
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Main Power (continued)

Read Counter Indicates that the PLC is communicating with the PQube. If the value is not incrementing, the link
between the devices is broken.
LAN Int. OK Indicates the LAN module is operating properly.
LAN OK Indicates communication between the PLC and PQube is ok.
OPEN Indicates whether the port between the PLC and PQube is open or not.
SUCCESS
READ Indicates whether registers are being read from the PQube or not.
SUCCESS
Try Read Forces the PLC to attempt to read the PQube registers.
Try Open Forces the PLC to attempt communications with the PQube.
4.5 PDU Touchscreen: Clean Power

The Clean Power page is used to monitor the clean power input (HD, and UHD-II only). Clean power ori-
ginates from a separate power source and is used for the instrument power circuits for the ROV and TMS.
Figure 15: Clean Power
The following functions are available on the Clean Power page:
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Clean Power
Voltage Displays the input voltage from the main feed (L-E is line to neutral/ground, L-L is phase to phase
voltages).
Current Displays the input current from the main feed.
Frequency Displays the input frequency from the main feed.
Nominal Input Indicates the nominal voltage value set by the user. This value is set on the “voltage setup” page and
Voltage must match the input nominal voltage.
Peak Voltage Stores the highest voltage value recorded by the system.
Peak Current Stores the highest current value recorded by the system.
Reset Values Reset the stored maximum voltage readings for L1, L2, L3.
Reset Peak Reset the stored peak current readings for L1, L2, L3.
4.6 PDU Touchscreen: Setup and Status

The Setup and Status page allows you to access all the pages that contain alarms and settings for the PDU,
and also to access the password protected settings; Soft Shutdown Override, and Voltage Setup.
Figure 16: Setup and Status
The following functions are available on the Setup and Status page:
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Setup and Status

Panel Setup Contains all the information regarding the HMI screen, see PDU Touchscreen: Panel Status on
page 50 for more details.
PLC Setup Contains all information regarding the PLC hardware and software. This page is also used to set
time and date, see PLC: Reload Software Settings via PLC Program Download Device on page 71
for more details.
Modbus & Ethernet Contains all the information regarding the Modbus and Ethernet communication status with
Status external devices to the PLC.
Digital Inputs/Output Contains current status of PLC digital input and output channels.
Status
Analog Input Read- Contains current unscaled readings of all PLC analog inputs.
ing
TMS HV Trends Displays the trends graphing page for high voltage trends on the TMS.
ROV HV Trends Displays the trends graphing page for high voltage trends on the ROV.
Main Power Trends Displays the trends graphing page for high voltage trends for the system.
Edit Users Add or remove users for the system.
Logon Log in to the security protected settings, see PDU Touchscreen: Security Logon on page 58 for
instructions.
Logoff Log out of the security protected settings.
Soft Shutdown Over- Allows the user to bypass software monitored shutdown functions such as short circuits, over cur-
ride (password pro- rent, current imbalance, and temperature.
tected)
Voltage Setup (pass- Used to set up the nominal output and input voltages for main power, clean power, and all step-up
word protected) transformers.
4.7 PDU Touchscreen: Alarm Summary

The Alarm Summary page shows all current PDU faults. If faults are recovered, the alarm line will dis-
appear. Each fault is recorded with time and date stamps.
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Figure 17: Alarm Summary
The alarm manager console provides typical sorting and navigation tools for the alarms.
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Caution! A conductor loss alarm will continue to alarm until the conductor loss function is dis-
abled. See Soft Shutdown Override (UHD-II) on page 59.
4.8 PDU Touchscreen: Alarm History

The Alarm History page stores all faults that have occurred on the PDU. Each fault is recorded with time
and date stamps. Faults that have recovered to a normal condition are shown in green. Faults that did not
recover are shown in red.
Figure 18: Alarm History
4.9 PDU Touchscreen: PLC Status

The PLC Status page (Figure 19) is used to indicate any PLC faults, show the current version, and change
time and date settings.
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Figure 19: PLC Status
The following functions are available on the PLC Setup page:
PLC Status
PLC SOFTWARE Indicates the software version installed on the PLC RAM.
VERSION
PLC Comm (green The flashing green indicator lamp in the top right of the page indicates good communication with
Indicator lamp) the PLC. Steady green means waiting for communication or no communication.
EXPANSION RACK Indicates the Status of extra expansion racks (not applicable on ROV systems).
OK
FAULT Indicates the existence of a fault anywhere on the system.
BATTERY OK Indicates PLC battery status. A “Battery Fault” will require the re-charge or replacement of the
external PLC battery.
OPTION MODULES Indicates the status of optional modules (not applicable on ROV systems).
OK
NO OVERRIDE Indicates if faults are being overridden (not applicable on ROV systems).
MODULES OK Indicates that all PLC modules are properly operating.
I/O MODULES OK Indicates that I/O modules are properly working. A red light indicates that input or output modules
must be replaced.
HARDWARE OK Indicates that all PLC internal components are operating properly.
SOFTWARE OK Indicates that the software is compiled and running without errors.
RESET ALL FAULTS Refreshes all fault indication lights.
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PLC Status (continued)

Year, Month,Day, Allows the user to enter the system year, month, day, hour, minute, and second values. Touch
Hour, Minute, Second the white box to enter values.
WRITE COPY Allows the “Copy time from PLC” and “Write Time to PLC” keys to be operated.
ENABLE
COPY TIME FROM Copy time and date registers from the PLC RAM to the blue colored cells
PLC
WRITE TIME TO Write time and date values from the blue colored cells to the PLC RAM registers. To set the value
PLC in the blue cell, touch the cell and enter the desired value.
4.10 PDU Touchscreen: Panel Status

The Panel Status Page is used to indicate the current panel status, change panel brightness, and syn-
chronize the PLC time to the panel time.
Figure 20: Panel Status
The following functions are available on the Panel Setup page:
Panel Status
PANEL SOFTWARE VERSION Displays the current panel software version.
SYSTEM ERROR Indicates any possible error regarding the panel. A blank indicates nor-
mal operation.
IP ADDRESS Displays the panel IP address.
TIME/DATE Displays the current time and date.
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Panel Status (continued)

PRESS TO SYNCHRONIZE PANEL TIME Press this key to transfer the time and date from PLC RAM to the panel
AND DATE WITH PLC memory.
PANEL BATTERY Indicates the status of the panel internal battery. A red light indicates
that the battery must be replaced.
PANEL BRIGHTNESS Changes the brightness of the panel. Default value is 75.
SETUP & STATUS Navigation button that takes you to the Setup and Status page.
MAIN Navigation button that takes you to Main page.
BUZZER SILENCE Press this button to silence the alarm buzzer.
4.11 PDU Touchscreen: Modbus and Ethernet Status

The Modbus and Ethernet Status page is used to indicate faults present with external devices com-
municating with the PLC. It also contains error messages from each com module.
Figure 21: Modbus and Ethernet Status (UHD-II and HD)
Note: When operating the PDU with a UHD-III type ROV, the Modbus portion of the page will not be
displayed on the screen. See Figure 22 below.
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Figure 22: Modbus and Ethernet Status (UHD-III)
The following functions are available on the Modbus and Ethernet Status page:
Panel Status
Modbus RTU Communication with Power Meter
Initialize New If another meter is connected to the RTU module, this key will initialize the new meter.
Clean Power Meter
Configure New This function will set a new meter after initializing.
Clean Power Meter
Restart Slave 2 If the Rishmaster power meter is not reporting this button will try to re-open the communications link.
Clean Power
Meters
The window will display the Modbus error code for the Rishmaster power meter, and can display; IN
(and display)
PROCESS, SUCCESS, or an error message.
Port 2 (display) Displays status of Rishmaster power meter RS-485 communication, and will display; IDLE,
WAITING FOR RESPONSE, or TIMED OUT AFTER SENDING BROADCAST MESSAGE.
Ethernet Communication with PQube
LAN Interface OK Indicates the LAN module is operating properly.
LAN OK Indicates communication between the PLC and PQube is ok.
OPEN Indicates whether the port between the PLC and PQube is open or not.
SUCCESS/NOT
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Panel Status (continued)

READ Indicates whether registers are being read from the PQube or not.
SUCCESS/NOT
Try Read Forces the PLC to attempt to read the PQube registers.
Try Open Forces the PLC to attempt communications with the PQube.
Read Status Indicates a malfunction on the Ethernet communication link.
Read Error Indicates the status of Ethernet communications.
Read Counter A changing count indicates the proper operation of the Ethernet module.
4.12 PDU Touchscreen: Digital Inputs

The Digital Inputs page displays the status as “ON” or “OFF” state only, with a green ON indicating the pres-
ence of 24 VDC at the input. Inputs are organized per the headings by the location that the inputs appear in
the PDU cabinet. This image shows HD, UHD-II, and UHD-III components.
Figure 23: Digital Inputs
4.13 PDU Touchscreen: Digital Outputs

The Digital Output page displays the status as “ON” or “OFF” state only. The state will display a green ON
when 24 VDC is present at the circuit.
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Figure 24: Digital Outputs
4.14 PDU Touchscreen: Trends

Touching the trends buttons displays a variety of historical data on graphs. The following information is
available; transformer temperatures, main power voltage and current, ROV HPU voltage, TMS HPU voltage
(UHD-II only).
Note: Temperature readings refer to the transformers located inside the PDU for the circuits indic-
ated.
Note: A time scale is indicated across the bottom of the graphs when data is present. Time scales
are not the same for all measurements and must be interpreted for each graph.
Time is displayed as hh:mm:ss from the last time the HPU was started or reset.
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Figure 25: Transformer Temperatures
This screen will display historical values for the temperatures in Celsius for the ROV HPU transformer, the
ROV IPA transformer, the TMS HPU transformer, and the TMS IPA transformer. These transformers are
all located inside the PDU cabinet.
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Figure 26: Main Power Voltage and Current
The main power voltage and current are measured at the input side of the PDU on the line coming in from
the power source.
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Figure 27: ROV HPU Output Voltages and Current
Note: For the for IPA/IPDS only, the values indicated in the CURRENTS graph are 1/10 the value
shown. For example if the trend line appears on the 5 line, the actual value is 0.5 amps. If the indic-
ated trend appears on the 30 line the actual value is 3.0 amps.
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Figure 28: TMS HPU Output Voltages and Current
4.15 PDU Touchscreen: Security Logon

1. From the setup and status screen (Figure 16), press the Logon button in the security group.
2. When the Logon window appears (Figure 29), press the “...” button to the right of the Name field.
Figure 29: Logon window
3. When the keyboard window appears, type Master, and press the OK button.
4. Press the “...” button to the right of the Password field.
5. When the keyboard window appears, type control, and press the OK button.
6. In the Logon window, press the OK button. You now have access to all the HMI/PLC functions.
4.16 PDU Touchscreen: Soft Shutdown Override

The Soft Shutdown Override page (Figure 30) is used to bypass all software protection offered by the PLC.
Enabling an override will defeat the automatic shutdown in the event that a particular component is oper-
ating outside of its normal operating parameters. When enabled the buttons turn red.
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WARNING! Overriding the soft shutdown on any circuit will disable over temperature, short cir-
cuit, and over current alarms. This may result in damage to equipment and injuries to personnel,
and should only be attempted when the functions in the table below are not operating.
Figure 30: Soft Shutdown Override (UHD-II)
Caution! Enabling Conductor Loss will cause an alarm if one of the conductors in the long line
pairs is open or has significant resistance. The alarm will continue even after the alarm is acknow-
ledged until the conductor loss alarm feature is disabled. Operating the system with an open con-
ductor can lead to overheating of the cable or diminished performance of the ROV system.
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Figure 31: Soft Shutdown Override (UHD-III and HD)
The following functions are available on the Soft Shutdown Override page:
Soft Shutdown Override

Over Temperature This will override the automatic shutdown when transformer temperature exceeds 110
degrees Celsius for ROV-HPU, ROV-IPDS, or TMS PWR.
Soft Shutdown When ON this option overrides all automatic shutdowns for high voltage short circuits, over-
load, and current imbalance.
CONDUCTOR LOSS Enabling conductor loss will cause an alarm if one of the conductors in the long line pairs is
ALARMING ON PDU open or has significant resistance.
Clear Forced Off Press this to clear a Forced Off condition as indicated by the contact button on the Main
screen.
Soft Shutdown Information
Short Circuit Displays the percentage of the nominal value at which a short circuit will trigger a shutdown.
Overcurrent Displays the percentage of the nominal value at which an overcurrent will trigger a shut-
down.
Unbalanced Current Displays the percentage of the nominal value at which unbalanced current will trigger a shut-
down.
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Soft Shutdown Override (continued)

Transformer Over Tem- Displays the transformer temperature value that will trigger a shutdown.
perature
mS Shows time in milliseconds the system will wait before acting upon one of the soft shut-
down functions.
4.17 PDU Touchscreen: Voltage Setup Page

The Voltage Setup page (Figure 32) is used to set the input and output voltages on the PDU. Available
options are based on the PDU Type selected and can toggled through by pressing the CHANGE key for each
setting.
Below each voltage button is the allowed voltage fluctuation for HV circuits display. This value is auto-
matically set at +/- 10% of the nominal voltage value selected.
● If reported voltage is lower than 90% of nominal, an alarm will sound.
● If reported voltage is higher than 110% of nominal, an alarm will sound, and the circuit will open.
Figure 32: Voltage Setup Page (UHD-II)
Note: The UHD-II voltage setup page shown above includes the TMS HPU, the ROV HPU HORSE
POWER, the TMS HPU HORSE POWER, and the CONDUCTOR LOSS button. The HD/UHD-III page
shown in the following screen is displaying 6100 volts nominal for an UHD-III configuration.
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Figure 33: Voltage Setup Page (HD / UHD-III)
The following functions may be available on the Voltage Setup page depending upon your PDU Type:
Voltage Setup Page

MAIN POWER Set this value to the nominal input voltage (380, 400, 440, 460, 480 V). (380 not for
UHD-III)
CLEAN POWER * Set this value to the nominal input voltage (380, 400, 440, 460, 480 V).
ROV HPU Set this value to match the step-up transformer setting (4160, 4300, 4400, 4500, 6000
V).
ROV IPDS Set this value to match the step-up transformer setting (4160, 4200, 4250, 4300 V).
TMS PWR Set this value to match step-up transformer setting (4160, 4200, 4250, 4300 V).
CHANGE Press these buttons to cycle through available values.
Allowed voltage fluctuation This value sets the minimum and maximum threshold for input voltage circuits (based
(MAIN POWER / CLEAN on chosen nominal). Default value is 15 volts, and is not user configurable.
POWER)
Allowed voltage fluctuation This value sets the minimum and maximum threshold for output voltage circuits (based
(ROV HPU, ROV IPDS, TMS on chosen nominal). Default value is 10% of nominal value and is not user configurable.
PWR)
BREAKER SETTINGS This opens a data reference page for configuring correct breaker settings for your
system.
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Voltage Setup Page (continued)

SETUP & STATUS Returns to the Setup and Status page.
RESET PDU Press this button to change the PDU type (similar to reinstall).
CONFIGURATION
BUZZER SILENCE Temporarily stops the alarm buzzer.
* Clean Power monitoring not available on UHD-III systems.

** UHD-II only.
4.18 PDU Touchscreen: Breaker Settings

The breaker settings page (accessed from the voltage setup page) displays a table of information for setting
the circuit breaker characteristics for your system.
Caution! Make sure all settings are correct before operating the PDU. Failure to do so may result in
interrupted operation of the ROV/TMS and or related equipment.
Note: The following graphic is an example only, please access the Voltage Setup page, and select the
Breaker Settings button to display settings for your system. See PDU Touchscreen: Setup and Status
on page 45
WARNING! Only authorized personnel should attempt to change breaker settings. Circuits inside
the PDU contain lethal voltages. Make sure lock out and tag out procedures are used before working
on any electrical equipment.
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Power System Components 5. PDU: Maintenance, Configuration, and Service
Figure 34: Breaker Settings
Note: See PDU Touchscreen: Setup and Status on page 45
5. PDU: Maintenance, Configuration, and Service

5.1 About PDU Maintenance, Configuration, and Service
WARNING! HIGH VOLTAGE SHOCK HAZARD! Lethal voltages are present inside the PDU even
when the PDU main circuit breaker is open. Before performing any service, open and lock out/tag out
ALL external circuit breakers that control power to the PDU.
Use the following sections along with the schematics located in the OEM Tinitron PDU manual to maintain
the PDU.
A basic toolbox for maintaining and troubleshooting the PDU should include:
● Screwdrivers - flat and Phillips
● Pliers
● DMM with high-voltage probe and AC amp clamp
● Wrenches - Metric and English
● TORX drivers (must include #30)
● Rittal Door Key - two keys are provided for the doors
● Switch Keys - each switch is provided with two keys, all switches are keyed alike
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● High-voltage Terminal Clamp Key - special T-head insulated hex key used to open the spring clamps
on the high-voltage terminal blocks. One provided with each system.
5.2 PDU: Periodic Maintenance

For a complete list of scheduled items in an excel spread sheet, please refer to the Support Files, planned
maintenance folder. For an online version, See Planned Maintenance.
Weekly tasks
The following items should be checked on a weekly basis:
● Test all E-Stops to make sure they trip breakers.
● Test function of grounding wheels.
● Test Megacon GFD trips. Confirm reading.
● Make sure that opening the PDU cabinet door trips the circuit breaker.
● Clean PDU inlet filters.
● Confirm PDU fan operation.
Monthly tasks
Electrical connections, busbar mounts, and other hardware can loosen over time. At mobilization and every
30 days, check and tighten:
● All electrical connections and terminations.
● Busbar mounting hardware.
● General assembly hardware.
Annual tasks
The following items should be checked annually:
● Check the 480/HV input cable connections for tightness.
Caution! Failure to securely connect power cables and tighten hardware can cause poor or erratic
performance of system components and/or component damage.
5.3 PDU Panel and Door Designations

The PDU is laid out in two main bays -- upper and lower. The lower bay is for the transformers while the
upper bay is for low-voltage control and metering circuits and HV distribution to the umbilical wiring. The
following are the designations given to the various panels and doors in the cabinet:
Left Door: Refer to Figure 1 for locations.
Right Door: Refer to Figure 2 for locations.
Transformer Bay: Refer to Figure 35for locations.
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Transformer Bay Components

Component Name Drawing Notation
Rotary Ground Switches S21, S22, S23
ROV-HPU Transformer T21
ROV-IPDS Transformer T22
TMS-PWR Transformer T23
Figure 35: Transformer Bay
Breaker Panel: Refer to PDU Panel and Door Designations on the previous pagefor locations.
Breaker Panel Components

Main Incoming Current Transformers PQ1, PQ2, PQ3
Clean Power Current Transformers CT2A, CT2B, CT2C
Incoming Control Power Circuit Breaker Q03
Clean Incoming Power Instrumentation Circuit Breaker Q02B
Main Incoming Power Instrumentation Circuit Breaker Q01B
ROV-HPU Incoming Power CB Q21
ROV-IPDS Incoming Power CB Q22
TMS-PWR Incoming Power CB Q23
ROV-HPU Contactor K21
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Breaker Panel Components (continued)

ROV-IPDS Contactor K22
TMS-PWR Contactor K23
Rear Panel: Refer to Figure 36 and Figure 37 for locations.
Rear Panel Components

Control Transformer T20
24 VDC Power Supply G01
ROV-HPU Current Transducer T21S, T21T, T21U
ROV-IPDS Current Transducer T22K
TMS-PWR Current Transducer T23K
ROV-HPU HV Adapter T21A
ROV-IPDS HV Adapter T22A
TMS-PWR HV Adapter T23A
ROV-HPU Potential Transformer T21P
ROV-IPDS Potential Transformer T22P
TMS-PWR Potential Transformer T23P
ROV-HPU Potential Transformer Protection Fuse F21
ROV-IPDS Potential Transformer Protection Fuse F22
TMS-PWR Potential Transformer Protection Fuse F23
HV Terminals (7) HV
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Figure 36: Rear Panel
Figure 37: Rear Panel
5.3.0.1 Opening the PDU

Before opening the PDU for troubleshooting consider the following:
● The circuit breaker operators must be in the off position and locked out in order to open the left
and right doors.
● The door key operates a latch that allows the right hand door to open. The left hand doors have
levers located on the top and bottom of each door that latch them in place.
● Both left and right hand doors have door stays. To close the doors, release the respective door stay,
then close and latch the left door, then close and latch the right door. Be cautious when opening
the door 90 degrees.
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● All of the exterior panels require a #30 TORX driver. The swing panel is hinged on the left edge; the
right edge is held top and bottom with #30 TORX head bolts.
● For maximum accessibility to the rear panel, the left and right door should be opened as far as pos-
sible before opening the swing panel. The swing panel allows access to the rear panel and should not
require opening on a regular basis.
● Full access to the transformer bay can be achieved by opening the lower door panels. These doors
cover the primary and high-voltage transformer terminals.
5.4 PDU: Replace Circuit Breakers and Overload Relay

Caution! Incorrect breaker settings can cause breakers to trip unexpectedly, resulting in inter-
rupted or erratic performance of system components and/or component damage.
A replacement circuit breaker or overload relay must be properly adjusted to the actual voltage supplied to
the PDU. See About ROV System Mobilization in Volume 1: ROV & TMS System Manuals for the adjust-
ment procedure.
5.5 PDU: Ground Fault Detection Unit (GFD) Settings

Three Megacon ground fault monitoring units are mounted in the PDU, each monitoring the three 4,160
VAC power lines for line-to-ground resistance on one of the three subsea circuits (ROV HPU, ROV Instru-
ment Power, and TMS Power).
Nominal settings are shown in Figure 38. Adjust a replacement GFD unit to these settings before install-
ation.
Figure 38: Nominal ground fault protection unit settings
5.6 PDU PLC/HMI Maintenance

It is possible to communicate with the PLC from a remote computer via an Ethernet port on the switch
with the TCP/IP protocol.
The ModBus Serial Communication settings are: 19,200 Baud, 1 stop bit, no parity.
5.6.1 Intranet
Communication between the GE Fanuc 90-30 PLC, Quickpanel View touch screen, PQube Power Monitor,
and the manufacturer control agent is via a standard 10-100 network switch. The PDU Communication
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Network Interconnection Drawing (located in the OEM Tinitron PDU manual) shows these connections in
detail. This switch can be bridged to a larger intranet system and can be enlarged with other devices. IP
addresses for all devices must be unique.
5.6.2 ModBus
Internally in the PDU, the GE Fanuc 90-30 communicates to the RishMaster Clean power monitor via a
ModBus RS485 2 wire cable.
The address for the Rishmaster Clean Power Monitor is 002.
5.6.3 External PLC Battery

The external PLC battery is necessary in order to maintain Alarm settings. If this battery fails all alarm set-
tings will be lost.
5.6.4 Internal Horner RTU Module

Another battery is located in the Horner RTU module in position 8 on the main PLC rack. Access this bat-
tery by removing the top access cover of the module.
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PLC: Reload Software Settings via PLC Program Download

Device
Tools None
Personnel 1 worker
Sub-Procedures None
Parts-Kits Software
Safety Electrical shock hazard
Consumables None
This service instruction explains how to reload the software settings using the PLC Program Download
Device (PPDD). You must reinstall the PLC software settings when:
● A new CPU is installed
● An existing CPU is updated
● The settings become corrupted
● The backup battery fails or has been replaced
● PLC software settings have been installed to the memory stick (USB flash drive) in the PPDD (PLC
Program Download Device) shown in the figure below.
If the updated software is supplied by Technical Support or Customer Service, transfer it to the PPDD
memory stick for installation to the PLC.
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Programming the PLC

1. Verify that the PLC is turned off and incoming power to the PDU is off and locked out.
2. Turn the key to the OFF position and open the cover to expose the 15-pin DSUB connector (see image
below).
3. Open the DSUB cover.

4. Insert the USB flash drive containing the PLC software into the PLC Programmer (P/N 005-6910). Set
the selector switch to the “Store to PLC” position, as indicated in the image below.
5. Connect the PLC Programmer’s 15-pin DSUB connector to the PLC. Hand-tighten the screws on the
connector to secure the connector to the port.
6. Turn on the PLC. The green STATUS LED will flash rapidly for 4 seconds while the PLC Programmer
evaluates the memory stick. If the red STATUS LED turns on, the USB flash drive was not recognized,
or the installed software is corrupted.
7. If the red STATUS LED turns on, try the following:
a. Turn off the PLC and then turn it back on again. If the green status LED is on, go to step 8. If not,
continue to step b.
b. Turn off the PLC, turn the RUN SOFTWARE key to the OFF position, and turn the PLC back on.
If the green status LED is on, go to step 8. If not, continue to step c.
c. Replace the software in the USB flash drive. Format the USB drive as FAT32, then copy a fresh
version of the software onto the drive. Software can be delivered by email if necessary.
8. Make sure that the RUN SOFTWARE key is in the OFF position.
9. Press “Start” on the PLC Programmer.
10. The green status LED will flash and become solid when download is complete. This process may take
between 5 and 10 minutes.
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11. Turn the RUN SOFTWARE key to the ON position. The software is now installed and ready to go.
12. Disconnect the PLC Programmer.
13. If the HMI touch screen software must be installed as well, follow the procedures for 101-7792-WI.
When the HMI touch screen is programmed and the start page has appeared, go to the “PLC Setup”
page by pressing BACK. On the next page, look for the MENU button. On the following page, press
PLC. The PLC Status page will appear, as shown in the image below.
For information see PDU Touchscreen: Features and Screen Hierarchy on page 36
14. Make sure that the following message appears: “014-0871 Rnn,” where “nn” is the revision number
provided with the software. This will confirm that the PLC has the software provided inside the USB
flash drive.
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Power System Components 6. PQube Usage and Maintenance
6. PQube Usage and Maintenance

6.1 About PQube Usage and Maintenance
The following section is excerpted from the PQube OEM manual and covers the most common procedures
needed to access and maintain the PQube unit located on the inside of the PDU left door. If additional
information is needed, see the printed copy of the Tinitron manual.
Label Description
A Battery compartment latch
B SD memory card and adjacent LED
C Select button
D Joystick. Click like a button to return to main menu.
E Heartbeat LED
F Temperature/humidity probe inputs. Optically isolated from local earth.
G L1, L2, L3 voltage inputs. 690 Vrms maximum phase-to-phase (equivalent to 400 Vrms phase-to-earth)
H Neutral terminal - optional connection
I USB port. Optically isolated from local earth. Factory use for Rev 1.2 firmware; user access in free
future firmware upgrades.
J Digital input. 60-volt tolerant. 1.5-volt threshold. Wetted with 5.4 v at 3 microamps.
K Power inputs.24 VAC, or 24 VDC to 48 VDC (either polarity) nominal. 15 VA maximum.
L Earth - functional. Used as the reference voltage.
M Analog inputs. Maximum +60 V to earth. Can be used as differential inputs.
N Signal relay outputs. One is standard, two more are optional (not yet available).
P Optional relay contact output rated at 30 VAC, 60 VDC, 2 amps (not yet available).
6.1.0.1 Calibration Information for Your PQube

Every PQube is calibrated and traced to NIST at the factory. You can download a free NIST trace certificate
that contains the specific calibration information for your PQube by entering your PQube’s serial number at
www.powerstandards.com/CalibCerts.htm.
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6.2 Setting Up Your PQube

Your PQube will work right out of the box. Simply follow the Quickstart Guide (page 10) and your PQube
will begin recording data immediately. The default settings will work for most applications, but if you have
special requirements, you may need to change a few settings.
6.2.1 Setting the Date and Time

You can set the time and date via your PQube's display. For information on how to use your PQube's dis-
play, see Your PQube's Display and User Interface on page 77 Go to the configuration menu and scroll to
the Date/Time screen. Press the select button and then use the joystick to change each field to the present
date and time.
Setting the date and time is important because all of the output files your PQube produces include a time
stamp.
Note that if you have an ETH1 Ethernet module and you are using the SNTP feature (off by default), your
PQube will set its own time to UTC and will override any changes you made to the date and time.
6.2.2 Setting Your Languages

Changing the language setting on your PQube will change your PQube display and the GIF graphs produced
by your PQube. You can set up to two different languages for your PQube. If you set two languages, both lan-
guages will appear on the GIF graphs. This can be useful if you are discussing graphs with someone who is
more comfortable in another language. To change the language settings for your PQube, use the display and
joystick. The Language settings are in the configuration menu.
6.2.3 Setting Your Potential Transformer Ratio

If you are using Potential Transformers (PT) to monitor voltages above 690Vac Phase-to-Phase (400Vac
Phase-to-Earth) you can tell your PQube about the ratio to use to calculate the measured voltage. For
example, to use your PQube on a 24 kilovolt distribution system, you might use a 100:1 potential trans-
former to reduce the 24 kilovolts to 240 volts. In your PQube's Setup.ini file, you would set:
Potential_Transformer_Ratio=24000:240
Or, if you prefer, you could set:
Potential_Transformer_Ratio=100:1
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Note that, if you choose to set the nominal voltage in your PQube's Setup.ini file, you would set:
Nominal _Phase_To_Neutral_Voltage=24000
even though the voltage at your PQube's terminals is 240 volts nominal.
6.2.4 Setting Up Your Optional Current Module

6.2.4.1 Setting Current Transformer Ratio
If you are using a CT4 current sensing module, you don't need to set a CT ratio - your PQube will set it auto-
matically. If you are using an XCT4 current sensing module, you will need to set the CT ratio so that your
PQube can correctly display the amount of current, as well as correctly calculate power and energy usage.
For example, to use your PQube on a system with 200 amps flowing in the power conductors, you might
choose current transformers rated at 300 amps, with a 5-amp secondary. In your PQube's Setup.ini file,
you would set:
Current_Transformer_Ratio=300:5
6.2.4.2 Inverting Current Channels

During installation, it is easy to make a mistake in your current transformer connections, either by revers-
ing the secondary connections (when using an XCT4) or by feeding the main power conductor through
your current transformer backwards (when using a CT4 or XCT4). Of course, you can always correct your
wiring: but an easier alternative is to use your PQube's Setup.ini file to invert one or more of your current
channels. If you realize that you have installed your L2 current transformer backwards, you can fix this eas-
ily:
Invert_L1_Current_Channel=OFF
Invert_L2_Current_Channel=ON
Invert_L3_Current_Channel=OFF
Invert_N_Current_Channel=OFF
Current Transformer Connections

It is important to correctly connect your CTs (or use the method above to correct a wiring error). Power
(watt) calculations are made by multiplying the instantaneous current by the instantaneous voltage. If one
or more of your current transformers is incorrectly set up, your PQube will calculate negative power for
that phase.
6.2.4.3 Calculating Current With a Missing CT

You do not need to connect CTs to all of the conductors that you want to monitor. When current flows
through a system, the net current is always zero. Because of this, you can connect one fewer CT than you
have conductors (for a delta system, you only need two CTs, for a wye/star system you only need 3 CTs).
Your PQube can calculate the current in the missing CT. Note that if you calculate the current in a missing
CT, your PQube will incorrectly show any earth current as flowing in the calculated phase.
If you want to use this feature, change the Calculate_Current_Channel setting in the Setup.ini file on your
SD card.
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6.3 Using Your PQube

6.3.1 Your PQube's Display and User Interface
Joystick and Button
Use the joystick (B) on the front of your PQube to navigate through the displays. Gently push down on the
joystick (B) like a button to return to the Main Menu. Click the button (A) to make a selection. To force the
PQube to reset, hold the button (A) down for 10 seconds.
The PQube Display

Use the joystick on the front of your PQube to navigate through these screens. Use the select button to
choose an item outlined by an orange box.
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6.3.1.1 Configuration
Language
Language 1 sets your PQube's main language, which is used for all of these screens and the GIF output
graphs. Language 2, if you choose one, sets the second language on GIF output graphs. this can be useful if
you expect to discuss these graphs with an engineer who reads another language.
Power Configuration
This screen shows you the power configuration that your PQube is using. If your PQube is hunting for the
correct power configuration, this screen will cycle through the various possible configurations until your
PQube locks onto the correct configurations. Your PQube knows roughly 1,000 different possible power
Page 78 011-0552-06
configurations used around the world, and can identify the correct configuration approximately 10 seconds
after power has been applied to the terminals.
Vectors
Use this screen to verify that your voltage and current inputs are wired up correctly. Full scale voltage is
determined by the nominal voltage found when the PQube locks onto the power configuration. The vertical
bar on the right represents the largest phase magnitude of current. Its range is from zero amps to the value
specified by the Max_Current_of_Interest_in_Amps tag in the setup.ini file. (By default, it is set to the
value shown on your current module, multiplied by the current transformer ratio specified in the setup.ini
tag Current_Transformer_Ratio).
Date/Time
Set your PQube's internal clock-calendar. Your PQube will automatically set the correct day of the week. If
you have an ETH1 Ethernet Module, and you have enabled SNTP in your Setup.ini file, your PQube will
automatically set its clock-calendar to UTC.
Test e-mail
Press the select button to send a test e-mail. If your e-mail succeeds, you will get a green check mark. If
your e-mail does not go through, you will see a red X with an error message.
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6.3.1.2 Meters
L-L voltage meters, L-N voltage meters

These are line-to-line, line-to-neutral, and neutral-to-earth true-RMS voltmeters. Different meters will show
on these screens, depending on your power configuration. (For example, if the power configuration is
"delta", there will not be any L-N meters, because there is no neutral conductor.) If you have set a potential
transformer ratio in your Setup.ini file, then these meters will use that ratio, so these meters will some-
times show their values in kilovolts or even megavolts.
Frequency
This is a frequency meter. It is phase-locked to either L1-E or L2-E, depending on which channel has the
best signal. It measures frequency by timing the zero-crossings, with a 5-pole analog low-pass filter and a
64-cycle digital low-pass filter.
AN/DIG 1
The AN meters show the RMS voltage (equivalent to DC voltage for DC signals) for the AN1 screw terminal
to earth, AN2 screw terminal to earth, and AN1-to-AN2 differential voltage. The DIG1 meter shows the aver-
age value of the DIG1 digital input screw terminal with respect to earth, averaged over one cycle - useful
when the DIG1 signal is changing rapidly, because it will show the duty cycle of the DIG1 signal.
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Probe 2 / Probe 1
These meters show the temperature and humidity of the two TH1 temperature-humidity probes. If one or
both probes are not plugged in, the meters will show "_".
Current
These meters show the true-RMS current. They only appear if you have plugged in an optional XCT4 cur-
rent transformer interface module, or a CT4 current sensing module. If you have set a current transformer
ratio in your Setup.ini file, then these meters will use that ratio, so these meters will sometimes show
their values in kilo-amps or even mega-amps. Different meters will show on this screen, depending on your
power configuration. (For example, if the power configuration is "delta", this screen will not show a neutral
current meter, because there is no neutral conductor in delta power.)
Distortion
These meters show the Total Harmonic Distortion (THD) of the voltage and Total Demand Distortion
(TDD) of the current if you have an optional current sensing module installed).
Unbalance
These meters show the voltage unbalance and the current unbalance (if you have an optional current sens-
ing module installed). Your PQube calculates unbalance using the ANSI C84.1 method.
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Flicker
These meters show you RMS flicker. Pinst is the average absolute difference between URMS 1/2 and 1-second
RMS, in percent of nominal, multiplied by scaling factor for improved compatibility with incandescent
Flicker in IEC 61000-4-15. PST is the mean value of Pinst over previous 10 minutes, synchronized to real-
time clock. PLT is the mean value of Pinst over previous 2 hours, synchronized to real-time clock.
Power
These are the true power readings, and they correctly handle harmonics (distorted voltages and distorted
currents). If you have set a current transformer ratio and/or potential transformer ratio in your Setup.ini
file, then these meters will use those ratios, so these meters can show their values in kilowatts, megawatts,
or even gigawatts.
Carbon
This meter shows the intensity of carbon dioxide output, based roughly from the EPA's measurements for
typical California, USA values. You may edit these values in the Setup.ini file as necessary.
Energy
These three meters show the total energy, apparent energy, and carbon since the last reset of these meters.
You can reset these meters by holding down the select button for three seconds. The date of the last reset
will appear on the screen. You can reset these meters by holding down the select button for three seconds.
The date of the last reset will appear on the screen.
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Peak amps
These three meters show the cycle-by-cycle highest RMS amps; the 1-minute interval with the highest RMS
amps; and the N-minute interval with the highest RMS amps. (The highest RMS amps value is determined
by looking at the highest among all of the active phase conductors. It excludes the neutral conductor.) The
N-minute reading is usually set to 15 minutes, but you can set it to a value between three minutes and 60
minutes in your Setup.ini file. The 1-minute and N-minute readings are automatically synchronized to
your PQube's real time clock. These readings can be useful for evaluating inrush current and circuit breaker
settings, and for sizing power conditioning devices such as UPS and voltage regulating transformers. You
can reset these meters by holding down the select button for three seconds. The date of the last reset will
appear on the screen.
Peak demand
These three meters show the cycle-by-cycle highest RMS amps; the 1-minute interval with the highest RMS
amps; and the N-minute interval with the highest RMS amps. (The highest RMS amps value is determined
by looking at the highest among all of the active phase conductors. It excludes the neutral conductor.) The
N-minute reading is usually set to 15 minutes, but you can set it to a value between three minutes and 60
minutes in your Setup.ini file. The 1-minute and N-minute readings are automatically synchronized to
your PQube's real time clock. You can reset these meters by holding down the select button for three
seconds. The date of the last reset will appear on the screen.
PQube Status
This screen shows you the release version of your PQube's firmware and the release version of your ETH1
Ethernet Module's firmware if it is installed. It also shows you the temperature of the hottest CPU inside
your PQube. A temperature lower than 80 °C (176 °F) is typical.
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Battery
Your PQube's battery voltage will typically be between 3.3V and 4.2 volts. Positive current shows that your
PQube is charging its battery; negative current shows that your PQube is taking power from its battery.
Cycle count shows the number of times your PQube has taken power from this battery. You can reset the
cycle count by holding down the select button for three seconds. The date shows the last time the cycle
count was reset.
6.3.1.3 Recent Events

Your PQube displays the 6 most recent events. (Your PQube stores up to 40,000 events on its SD card,
depending on the size of the SD card and the type of events.)
6.3.1.4 Remove SD Card

You can safely remove the SD memory card from your PQube when you see this screen with a green check
mark. Remove the SD card by pressing it down gently, then let it pop up. Your PQube will automatically
reset when you re-insert an SD card.
6.3.2 Inserting and Removing Your SD Card

To insert the SD card, push it gently into the slot until it clicks. Your PQube will automatically reset itself.
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To remove the SD card, go to the menu screen and select "Remove SD Card". Wait until you see a green
check mark, then push the SD card in gently, then release. Removing the SD card before you see the green
check mark may corrupt the data on the SD card.
There is a light next to the SD card:
SD Card Light
SD card light Meaning
Flashing red SD card is missing
Green Normal
Orange or intermittent red PQube is writing to SD card-do not remove it, Wait until light is green.
Different brands of SD cards have substantially different speeds. Your PQube requires Sandisk* brand SD
cards, purchased directly from Power Standards Lab. Your PQube supports SD cards with capacities of up to
8 Gigabytes.
6.3.3 What Channels Does My PQube Measure?

6.3.3.1 Standard PQube Channels
Mains AC Voltage Measurements
Nominal Voltages
All PQubes measure single-phase and three-phase voltages. All PQubes can be connected to single-phase,
split-single-phase, delta, wye, or star. In addition, all PQubes can be connected to any standard earthing sys-
tem: corner earth, center earth, or single-phase end earth. All PQubes can measure power systems with the
following nominal voltages: 69V, 100V, 120V, 200V, 208V, 230V, 240V, 277V, 350V, 400V, 480V, 600V,
and 690V (maximum 400V with respect to Earth). All PQubes can measure power systems with nominal
frequencies of 50Hz, 60Hz, and 400Hz.
Sampling and accuracy

RMS measurements are better than ±0, 1% of nominal voltage, and sampled at 256 samples per cycle to
ensure full accuracy for all measurements. Your PQube's sampling rate is automatically locked to the fre-
quency, and tracks the frequency as it changes at a rate of up to ±3 Hz per second. In a free future firm-
ware upgrade, you will be able to select up to 1024 samples per cycle for snapshots.
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Frequency
Voltage frequency measurements are phase-locked to either L1-E or L2-E, depending on which channel has
the best signal. It measures frequency by timing the zero-crossings, with a 5-pole analog low-pass filter and
a 64-cycle digital low-pass filter.
Voltage Distortion (THD)

THD is a measurement of the amount of voltage harmonics present in the voltage waveform. Your PQube
uses a Discrete Fourier Transform of phase-locked 256-samples-per cycle to calculate total harmonic dis-
tortion.
Voltage Unbalance
Voltage unbalance is a measurement of the difference in the magnitude voltages in a three-phase system.
Your PQube measures the unbalance of the voltage waveform using the definition from ANSI C84.1. This
measurement is disabled if the power system being monitored is not three-phase.
RMS Flicker
RMS Flicker is an expression of how much the line voltage is varying up and down over several different
time scales. RMS Flicker has three components: Pinst, PST, and PLT. Pinst is the average absolute difference
between URMS1/2 and 1-second RMS, in percent of nominal, multiplied by scaling factor for improved com-
patibility with Incandescent Flicker in IEC 61000-4-15. PST is the mean value of Pinst over previous 10
minutes, synchronized to real-time clock. PLT is the mean value of Pinst over previous 2 hours, synchronized
to a real-time clock.
Auxiliary Analog Measurements

Your PQube has two auxiliary analog input screw terminals labeled AN1 and AN2. They are scaled at #100V
with respect to your PQube's Earth terminal, and are rated at 60VDC with respect to earth, or 30VAC with
respect to earth. One common use for these screw terminals is to monitor a -48VDC system, or to monitor
a 24VAC or 24 VDC system. For example, you might connect these AN monitoring terminals to your
PQube's POWER terminals. Your PQube can monitor the voltages between each of these terminals and the
earth connection, and/or the voltage between these two terminals. It monitors these terminals for voltage
dips and swells. An event on these terminals can be sued to trigger a waveform recording on all channels.
And events on the mains terminals can include the waveforms on these auxiliary analog measurements,
too. If you wish to use these channels, you will want to enable the channel so that it is recorded in the
event files. Enable the appropriate channels in the [Channels] section of the Setup.ini file on your
PQube's SD card.
Digital Input
Your PQube has a single digital input called DIG1. It is a voltage input with respect to your PQube's Earth
terminal. It is rated at 60VDC or 30VAC, maximum, with respect to earth. The digital input is wetted with
+5.4Vdc at 3µA, and has a logic threshold of approximately +1.5V with respect to your PQube's earth ter-
minal. The digital input can be connected to dry contacts, TTL or open-collector outputs, or logic signals
that are 5Vdc, 12Vdc, 24Vdc, or any other signal less than 60Vdc or 30VAC. There is an inherent digital-fil-
ter time constant of approximately 1 millisecond on this DIG1 input. Recordings of events on the mains ter-
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minals include state of the digital input if you turn the channel on in the Setup.ini file. You can use your
PQube's digital input to monitor the state of a switch, or the state of a logic signal.
6.3.3.2 Additional Channels Available With Optional Current Module
Mains Current Measurement

There are two optional types of current inputs into your PQube. The optional CT4-100A current sense mod-
ule allows you to measure up to 100 amps directly (limited by insulated conductor diameter). Simply pass
the mains conductors through the CT4 module. The CT4-20A current sense module is identical, but rated at
20A. The optional XCT4-1A and XCT4-5A current transformer interface modules work with external cur-
rent transformers, with 1-amp or 5-amp secondaries. The optional XCT4-0.333V, XCT4-01V, XCT4-05V,
and XCT-10V current transformer interface modules work with external current sensors, with 0.333-volt, 1-
volt, 5-volt, or 10-volt outputs. The crest factor for all PQube current modules is 3.5 (in other words, a
PQube current module that is rated at 100 amps can measure instantaneous current up to ±350amps).
CT4 Module (attached to a PQube)
XCT4 Module (attached to a PQube)
Current Distortion (TDD)

Total Demand Distortion (TDD) is a measure of the harmonic distortion of the current your PQube is mon-
itoring. Instead of comparing the amount of harmonics to the amount of the fundamental (the method
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used in THD), TDD compares the amount of current harmonics to the total available current. You can
change the total current used for the calculation by changing the TDD_Available_Current_in_Amps setting
in your Setup.ini file on your SD card. See Standard IEEE 519 for a full explanation of TDD.
Current Unbalance
Current unbalance is a measurement of the difference in the magnitude voltages in a three-phase system.
Your PQube measures the unbalance of the current waveform using the definition from ANSI C84.1. This
measurement is disabled if the power system being monitored is not three-phase.
Power
Your PQube makes true power readings, correctly handling harmonics (distorted voltages and distorted cur-
rents). Your PQube measures watts, VA, and tPF. "VA" is apparent power, the product of the RMS voltage
times the RMS current. Your PQube correctly calculates VA and Power for all power configurations, includ-
ing delta configurations, for which it creates a digital metering neutral. "tPF is true power factor, the ratio
of watts to volt-amps. (This is different from dPF, which is the cosine of the angle between the voltage fun-
damental and the current fundamental.) VARs are calculated using the Budeanu algorithm.
Energy
Your PQube measures the amount of energy you have used (both energy - Wh, and apparent energy - VAh).
Your PQube will accumulate energy until you reset the counter. You can reset the energy reading using the
display on your PQube (go to the Energy screen in the Meter section and hold down the action button for
three seconds).
Carbon
Your PQube uses a patent pending method to calculate the amount of CO2 produced by the energy con-
sumption monitored. In order to use this feature you will need to determine the amount of carbon pro-
duced by the different type of power your local utility uses, as well as the mixture of different types. Once
you have this information, you can configure the [Carbon_Intensity] and [Power_Generation_Breakdown]
sections of the Setup.ini file on your SD card.
6.3.3.3 Temperature and Humidity

Optionally, you can plug one or two TH1 temperature-humidity probes into your PQube. The probes may be
located at your PQube, or they may be extended up to 20 meters from your PQube with any 2.5 mm stereo
audio cable. All data flow to and from the temperature-humidity probe is digital, which reduces noise issues.
The temperature-humidity probes are electrically isolated from your PQube. This arrangement eliminates
ground loop issues.
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6.3.4 PQube Recordings

6.3.4.1 Event and Snapshot Recordings
When your PQube detects and event, it records information about the event to its SD card. You can remove
the SD card to look at this data, look at the recent events screen of the display, or (if you have an optional
ETH1 Ethernet module) you can get emails about the event or even look at the event using your web
browser. However you look at the event, the data is always the same.
Interpreting Event and Snapshot Recordings

PQube Event and Snapshot recordings contain the details of the event recorded (for example, Voltage Dip
recordings include the precise start time of the event, the duration of the event, and the magnitude of the
event).
Most events also include the waveforms for the beginning and end of the event, as well as the RMS meas-
urements for the beginning and end of the event. If multiple vents occur very close together (within about
30 seconds of each other) your PQube will record all events, but will only store waveform and RMS data for
the first event. This is because your PQube is still clearing the space that it requires to record the inform-
ation. It is important to note that, as long as your PQube is running, it is almost impossible for it to miss an
event (your PQube can miss an event if more than 4 events of any one type occur within 4 seconds of each
other).
During an event, your PQube will always be sampling the voltage at 256 samples per cycle. You can change
the number of samples per cycle written to an event recording (256, 128, 64, or 32 samples per cycle) by
changing the Recorded_Samples_Per_Cycle setting in the Setup.ini file on your SD card.
Why would I want fewer samples per cycle in my recordings?

Your PQube records 1024 samples at the beginning of an event and 1024 samples at the end of an event. If
your PQube is configured to record at 256 samples per cycle, it will record 4 cycles at the beginning and 4
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cycles at the end of the event (1024/256=4). If you set the recording rate lower, you get a longer recording
(with fewer points per cycle). For example, if you choose 64 samples per cycle, your PQube will continue to
sample at 256 samples per cycle, but the output recording will be written at 64 samples per cycle. Your
Event recordings will have 16 cycles at the beginning and 16 cycles at the end of the event (1024/64=16). Of
course, you always get many cycles of RMS values. 10 seconds of data at 50Hz or 8.5 seconds of data at
60Hz, regardless of the number of samples per cycle you choose to record.
Event Graph Headers

Every event graph has information in the header that tells you details about the event recorded and inform-
ation about your PQube that recorded the event. This makes it easy to send a graph file to another person
without having to explain the context of the recording. You can set the location name, your PQube ID, and
the notes by editing the Setup.ini file on your SD card.
Graph headers - many of these parameters can be set in your Setup.ini file
Waveform Recordings
Events that include waveform recording will include the exact same data in both a GIF graph file and a CSV
spreadsheet file. Waveform recordings are useful for looking at the fine details of what happened when an
event began and ended. If you prefer an overview of the event, consider using the RMS recording.
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RMS Recordings
Events that include RMS recording will include the exact same data in both a GIF graph file and a CSV
spreadsheet file. Voltage RMS recordings give you a good overview of what happened before, during, and
after the event. RMS recordings use the RMS1/2 reading to get the average reading over the course of a
cycle. Because your PQube records the average reading per cycle, RMS recordings cover more time than
waveform recordings.
Voltage Dips
A voltage dip is a brief decrease in the line voltage.. Dips are most typically caused by large loads starting
nearby or by faults elsewhere on the power system. Your PQube records voltage dips according to IEC
61000-4-30 class A. A dip begins when the 1-cycleRMS of any voltage goes below the threshold (90% of
nominal by default) and ends when all voltages are above the threshold, plus the hysteresis setting (90%
threshold + 2% hysteresis = 92% by default). You can change the threshold for voltage swells by changing
the settings in the [Phase_To_Neutral_Events] and [Phase_To_Phase_Events] sections of the Setup.ini
file on your SD card.
Voltage Swells
A voltage swell is a brief increase in the line voltage. Your PQube records voltage swells according to IEC
61000-4-30 class A. A swell begins when the 1-cycle RMS of any voltage goes above the threshold (110% of
nominal by default) and ends when all voltages are beneath the threshold, minus the hysteresis setting
(110% threshold -2% hysteresis = 108% by default). You can change the threshold for voltage swells by chan-
ging the settings in the [Phase_To_Neutral_Events] and [Phase_To_Phase_Events] sections of the
Setup.ini file on your SD card.
Voltage Interruptions
A voltage interruption occurs when all the line voltage goes away( such as when a breaker trips). Your
PQube records voltage interruptions according to IEC 61000-4-30 class A. An interruption begins when the
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1-cycle RMS of all voltage channels go below the threshold (10% of nominal by default) and ends when any
voltage is above the threshold, plus the hysteresis setting 10% threshold + 2% hysteresis = 12% by default).
You can change the threshold for voltage interruptions by changing the settings in the [Phase_To_Neutral_
Events] and [Phase_To_Phase_Events] sections of the Setup.ini file on your SD card. Note that by defin-
ition, any voltage interruption is also a voltage dip, so your PQube will record each voltage interruption as
two overlapping events (a dip and an interruption).
Frequency Variations
Your PQube records underfrequency and overfrequency events. Each type of event is triggered when the fre-
quency goes under a threshold (99.5% by default) or over a threshold (100.5% by default), respectively.
Underfrequency and overfrequency events end when the voltage frequency approaches the nominal again.
You can change the threshold for underfrequency and overfrequency events by changing the settings in the
[Frequency_Events] section of the Setup.Ini file on your SD card.
High Frequency Impulses

Your PQube includes special hardware used to detect high frequency impulses. These sensors monitor L1-E,
L2-E, L3-E and filter out everything but high frequency events. Your PQube will detect an impulse with a
±450V (or more) peak that lasts for as little as 1 microsecond. When your PQube detects a high frequency
impulse it will make a standard event recording. Note that the sampling rate of your PQube is 256 samples
per cycle, so you may not see the impulse in the recording, but the exact time of the impulse is marked and
recorded.
Analog Dips and Swells

Your PQube includes two analog input channels called AN1 and AN2. You can set up a trigger to record an
event when your PQube detects a dip or a swell on AN1-Earth, AN2-Earth, or AN1-AN2. You can enable
these events and set the thresholds in the [AN1_E_Events], [AN2_E_Events], and [AN1_AN2_Events] sec-
tions of the Setup.ini file on your PQube's SD card.
If you enable these events, you will also want to enable the channel so that it is recorded in event files.
Enable the appropriate channels in the [Channels] section of the Setup.ini file on your PQube's SD card.
If you enable these events, be sure to set the dip and swell voltages carefully. It is important that you not be
"stuck" in an event, as this will prevent your PQube from writing updates about new events. For example, if
you connect AN1-Earth to a 24V nominal signal, but you set the swell threshold to 20 volts, your PQube
will start recording a swell immediately, but it will never finish that event.
Snapshots
Your PQube records events when it senses a problem with the electric power. This information about prob-
lems is useful, but sometimes it can also be helpful to see what your electric power looks like when there
isn't a problem. Snapshots show you what your PQube is monitoring and are triggered by an internal timer
in your PQube (instead of a power quality event). Snapshots record all of the same information that any
other event recording includes. To configure this feature, you can change the [Waveform_Snapshot_Inter-
val_In_Hours] setting in the Setup.ini file on your PQube's SD card. Valid settings are OFF, 1, 6, or 24.
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6.3.4.2 Trends and Statistics Recordings

Your PQube records minimum/average/maximum strip charts, cumulative probability statistics, and load
duration statistics. By default, your PQube will record all of this information over the course of each day,
week, and month. Trends and statistics recordings give you information about what happened on the sys-
tems that your PQube is monitoring, even if there weren't any events. These recordings include readings
every minute (for daily recordings) or every 5 minutes (for weekly and monthly recordings). Your PQube
contains the average reading every one or five minutes as well as the minimum and maximum updated five
times a second.
Times and Dates

Your PQube uses ISO 8601 methods for representing times and dates in Trends and Statistics Recordings.
Days begin at 00:00 Midnight, and end at 11:59pm. Days are displayed as [YYYY]/[MM]/[DD]. Weeks begin
at the midnight between Sunday and Monday, and end at 11:59pm of the next Sunday. Weeks are displayed
as [YYYY]-CW[WW]. (CW = Calendar Week).
Months begin at 00:00 Midnight of the 1st day of the month, and end at the 11:59 of the last
day of the month. Months are displayed as [YYYY]-[MM].
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Minimum/Average/Maximum Values
For polyphase systems, your PQube displays voltage and current trends as single values where applicable:
● The minimum value is the lowest URMS1/2 value out of all the channels.
● The average value is the voltage or current of all channels averaged together over the entire meas-
urement interval.
● The maximum value is the highest URMS1/2 value out of all the channels.
Flags
Whenever an event occurs during an measurement, your PQube will flag the measurement at the appro-
priate time interval. For GIF Trends and Statistics:
This is a voltage dip/swell/interruption as defined by IEC 61000-4-30.
This is a non-IEC 61000-4-30 event. These include frequency changes, high frequency impulses, and ana-
log dips and swells.
This indicates that the PQube reset during the indicated time interval.
For CSV Trends and Statistics

U = Start Up
D = Shut Down
P = Partial Minute
F = 4 - 30 Event
O = Other Event
6.3.4.3 File Formats
Picture Graphs
GIF picture files can be opened by any image program. You don't need any special software. You can also
embed GIF picture files directly in Microsoft PowerPoint* presentations, Microsoft Word* reports, and so
on.
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Spreadsheet (CSV)
CSV files can be opened with Excel* or almost any spreadsheet program. These files are useful if you want
more detailed data, and the ability to sort individual recordings and customize your own graphs. The CSV
files cover the same recording period as the GIF files, and therefore both formats contain the same inform-
ation. The CSV files are more detailed, while the GIF files are easier to work with.
A CSV file (opened with Excel)
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Web Pages (HTML)

Your PQube produces HTML files that can be opened with any web browser (such as Internet Explorer).
Even if you don't have an ETH1 Ethernet module, your PQube will produce HTML files and store them on
your SD card.
HTML files are useful because they are easy to read and the data is well formatted for a human to read. Use
these files for preparing presentations or for sharing data with other users. If you want to write a program
to extract data, automatically, XML format may be a better choice. If you are having trouble changing the
format you may want to use a simpler format, like text.
PQDIF (Power Quality Data Interchange Format)

Your PQube will produce PQDIF files that you can use with most PQDIF viewers. These files are useful if
you use PQDIF files already or if you want to use standard files that utilities and other power quality experts
understand. PQDIF files are in beta for firmware version 1.2 and therefore are not produced by default. To
enable this option, change the [PQDIF_Files] setting to [ON]in the Setup.ini file on your SD card.
Text
Text files are the simplest PQube output file. Almost any program can open a text file. The default Windows
program is Notepad, shown here. Text files are useful when you want to make sure that everyone can read
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the file that you have produced. Text files are still better suited for showing to people. If you want a data
format that is easy for a computer to automatically process, try XML. If you want a format that looks better,
try HTML.
XML
XML format is more difficult for people to read, but there are many software packages that understand
XML. If you are building a monitoring system that will automatically process data from your PQube, con-
sider using XML as your data format. Your PQube's XML files are standard XML and can be opened with
any program that understands that file format. On most computers the default program is Internet
Explorer. If you want to make it easy to share your data directly with other people (and not through a com-
puter program), consider HTML or text format files.
6.4 Getting Data In and Out of the PQube

6.4.1 SD Card
Your PQube records all data to its SD card.. At any time you can follow the directions in Inserting and
Removing Your SD Card on page 84 and look at the files using any computer. Recorded data is stored in
folders with the name of the year that the data was recorded, log files and other useful diagnostics are
stored in the Log folder. Your PQube gets all of its setup information from the Setup.ini file found in the
root directory of the SD card.
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6.4.2 ETH1 Ethernet Module
6.4.2.1 Email
PQube Sending Emails

Your PQube will send an email every time it records an event or snapshot, and every time it records daily,
weekly, and monthly trends and statistics. The email will contain all of the details about the recording and
it will attach any related files (such as spreadsheets or graphs).
Sending Emails To Your PQube

Your PQube can respond to emails that you send it. Se the Setup.ini file for information on configuring
the ETH1 email settings. Whenever your PQube receives an e-mail, it will automatically respond with its
present meter readings (unless the email does not match the incoming email filters, see the Ethernet Setup
section of the Setup.ini documentation).
Sending Your PQube A New Setup File

You can send your PQube a new Setup.ini file via e-mail. Your e-mail must meet all of the filter require-
ments in your existing Setup.ini file, and must have "New Setup File", without the quotation marks, in the
subject of your email. For example, if Subject_Must_Begin_With is set to "PQube" in your existing setup
file, then your PQube will be watching for an e-mail with the subject "PQube New Setup File", without the
quotes. Your new setup file must be named Setup.ini, and must be attached to the e-mail. Your PQube will
send you two reply e-mails: one when it receives the new setup file, and another when the new setup file
has been successfully installed after your PQube automatically resets itself.
6.4.3 Sending Your PQube New Firmware Via Email

You can update your PQube's firmware via e-mail. Your firmware update e-mail must meet all of the filter
requirements in your existing Setup.ini file, and must have "Firmware Update", without the quotation
marks, in the subject of your e-mail. For example, if Subject_Must_Begin_With is set to "PQube" in your
existing setup file, then your PQube will be watching for an e-mail with the subject "PQube Firmware
Update", without the quotes.
You must attach a file called PQube_Firmware_XX_YY_ZZ_FFFFFFFF.pdf which you can obtain
from www.PowerStandards.com. The XX, YY, and ZZ are digits that identify the type of firmware update,
Page 98 011-0552-06
and FFFFFFFF is a checksum. Do not re-name this file. If your PQube receives a valid firmware update, it
will reset itself and perform the update.
Resetting Your PQube via e-mail

You can reset your PQube via e-mail. Your reset e-mail must meet all of the filter requirements in your exist-
ing Setup.ini file, and must have "Reset PQube", without the quotation marks, in the subject of your e-
mail. For example, if Subject_Must_Begin_With is set to "PQube" in your existing setup file, then your
PQube will be watching for an e-mail with the subject "PQube Reset PQube", without the quotes.
Tickling Your PQube's E-mail Watchdog

You can set a watchdog that will automatically reset your PQube if it fails to receive an e-mail periodically.
See the Setup File section. Your PQube's e-mail watchdog can be useful if you want to be certain that your
PQube will automatically reset if it fails to hear from you. Your watchdog e-mail must meet all of the filter
requirements in your existing Setup.ini file, and must have "Watchdog", without the quotation marks, in
the subject of your e-mail. For example, if Subject_Must_Begin_With is set to "PQube" in your existing
setup file, then your PQube will be watching for an e-mail with the subject "PQube Watchdog", without the
quotes.
Requesting Your PQube's Log Files Via E-mail

You can ask your PQube to send you its log files via e-mail. The log files can help diagnose PQube setup
problems, and they show the complete history of your PQube. Your log file request e-mail must meet all of
the filter requirements in your existing Setup.ini file, and must have "Send Logs", without the quotation
marks, in the subject of your e-mail. For example, if Subject_Must_Begin_With is set to "PQube" in your
existing setup file, then your PQube will be watching for an e-mail with the subject "PQube Send Logs",
without the quotes.
6.4.3.1 Web
In order to access your PQube's web site, you will need to set up the web server and determine if the IP
address of your PQube. If you are using a fixed IP, you already know the IP address, but if you are using
DHCP you will need to send a test e-mail from your PQube, which will include the IP address of your
PQube. Simply type this IP address into any web browser (such as Internet Explorer). You will be able to
see the present status of your PQube, real-time meters, and all event, trend, and statistics recordings stored
on your PQube's SD card.
6.4.3.2 FTP
Before using your PQube's FTP server, you will need to set it up. Once you have configured the server, you
can access your PQube using any standard FTP client, with the following restrictions:
● You must restrict your client to 1 simultaneous connection (consult your client's documentation for
details on how to do this).
● You may need to enable FTP keep-alive on your client (your PQube will disconnect automatically
after 5 minutes of inactivity, turning on keep-alive in your client will prevent the disconnection).
● Ask your system administrator if there are firewalls or other protection systems in place that might
affect your ability to connect to your PQube via FTP.
Page 99 011-0552-06
In order to access your PQube's FTP server, you will need to determine the IP address of your PQube. If
you are using a fixed IP, you already know the IP address, but if you are using DHCP you will need to send a
test e-mail from your PQube, which will include the IP address of your PQube.
6.4.3.3 Modbus
Your ETH1 Ethernet Module contains a Modbus-over-TCP slave device that you can use to read meters and
determine when new event or trend recordings are available. The update rate for the registers is approx-
imately one second in most circumstances. Once you have set up the feature, you can connect the device
with a Modbus controller and read registers. The meters consist of two registers that represent a 32-bit float-
ing point number (the two "new recordings" registers are both 16-bit unsigned integers). The register
addresses are expressed as an offset from the base register (7000 by default). The Modbus feature is in beta
for firmware version 1.2. There is a known limitation in this version: your PQube will update the registers
approximately once per second, unless it is busy (such as when your PQube is generating an output file for
an event or for daily trends and statistics). When your PQube is busy, register updates can be as far apart as
120 seconds. Note that for the majority of the time, the update rate is once per second.
Modbus
Offset Register
0-1 L1-E
2-3 L2-E
4-5 L3-E
6-7 N-E
8-9 L1-N
10-11 L2-N
12-13 L3-N
14-15 L1-L2
16-17 L2-L3
18-19 L3-L1
20-21 AN1-E
22-23 AN2-E
24-25 AN1-AN2
26-27 Frequency
28-29 L1 Current
30-31 L2 Current
32-33 L3 Current
34-35 N Current
36-37 Power (W)
38-39 Apparent Power (VA)
40-41 Digital Input
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Modbus (continued)
Offset Register
42-43 Peak Current (1-cycle)
44-45 Peak Current (1-minute)
46-47 Peak Current (N-minute*)
48-49 Peak Power (1-cycle)
50-51 Peak Power (1-minute)
52-53 Peak Power (N-minute*)
54-55 Peak VA (1-cycle)
56-57 Peak VA 1-minute)
58-59 Peak VA (N-minute*)
60-61 Energy (Wh)
62-63 Apparent Energy (VAh)
64-65 Voltage THD
66-67 Current TDD
68-69 Voltage Unbalance
70-71 Current Unbalance
72-73 RMS Flicker P(inst)
74-75 RMS Flicker P(ST)
76-77 RMS Flicker P(LT)
78 New Event Recordings**
79 New Trend Recordings**
* - You can set this demand interval by changing the Peak_Demand_Interval_In_Minutes setting in the
Setup.Ini file on your SD card. The default is 15 minutes, but you can change it to 3, 5, 10, 15, 20, 30, or 60
minutes.
** - These two registers tell you how many new recordings are available since you last read the register (read-
ing the register clears it). You can use this information to determine when to use a web browser or FTP cli-
ent to get new event or trend recordings from the SD card.
6.4.4 The PQube Relay

In Firmware Revision 1.2, your PQube's RLY1 contacts are closed when there is no event, and will open for
at least three seconds (or the duration of the event, whichever is longer) when any event occurs. When
your PQube is reset, these relay contacts are open for several seconds, until your PQube determines the
power configuration and decides that the voltages are correct.
6.5 Supplemental Data Gathering Instructions

Expanded instructions for getting data in and out of your PQube are included below. For basic operations,
see Getting Data In and Out of the PQube on page 97.
1. Remove the SD card from the PQube, see Getting Data In and Out of the PQube on page 97.
Page 101 011-0552-06

2. Insert the SD card into a computer.

3. Open the PQube file.
Figure 39: PQube Data Folder
4. Open the year folder.

5. Open the month folder.
6. Open the day folder. It should look like Figure 40 below. Each day consists of a number of events with
a folder for each event. Each event folder contains 4 folders and 1 file.
Figure 40: PQube Day Folder
Page 102 011-0552-06

7. Open the Graphs folder in the event folder of interest. The Graphs folder contains two .GIF files. One
file shows the rms values for voltage and current during the chosen event (Figure 41 below). The other
files shows the waveforms for current and voltage during the event (Figure 42 below).
Figure 41: RMS Values .GIF Figure 42: Waveform .GIF
8. Open the excel file located in the Spreadsheet folder. It should look like Figure 43 below.
Figure 43: Sample Excel Spreadsheet
9. Select the Insert tab.
Page 103 011-0552-06

10. Select “2D Graph”.

11. Create a chart using the datapoints as desired. Some sample outputs are shown in Figure 44 below and
Figure 45 on the facing page.
Figure 44: Simple 2D Chart
Page 104 011-0552-06

Figure 45: Waveform Chart
6.6 PQube Maintenance

6.6.1 Upgrading Your PQube's Firmware
Power Standards Lab offers free firmware updates to add new features to your PQube and to fix bugs. You
can check www.PQube.com from time to time to see if there is a new version of firmware available. Every
firmware upgrade comes with a guide with detailed instructions on how to perform the update.
6.6.2 Turning Off Your PQube

Your PQube is designed to be a permanently installed monitor. It does not have an on/off switch because it
is designed to run continuously. If you need to turn off your PQube, turn off your PQube's instrument
power (either the power screw terminals on your PQube, the optional PS1 Power Supply Module, or both),
once your PQube is running from battery, reset your PQube by removing and re-inserting your PQube's SD
card. This will cause your PQube to reset and power down as there is no power available). If your PQube
resets and begins to start up again, you have not removed all instrument power.
6.6.3 Replacing Your PQube's Battery

The battery is PSL type "340-000080" followed by a 2-digit revision level. This part must be supplied only
by the PSL or PSL agents. It contains built-in protection. PSL recommends replacing your PQube's battery
after 5 years, or 1,000 uses, whichever comes first. You can find the battery installation date and the num-
ber of times the battery has been used on your PQube's battery status screen, in the Meters menu.
To replace the battery, use a small flat-blade screwdriver to open the battery compartment. Pull on the tab
to slide the battery out, then slide in the new battery in the correct orientation. Seat the new battery gently,
Page 105 011-0552-06

Power System Components 7. Instrument Power Distribution System (IPDS)
then close the battery compartment. Go to the battery status screen, and hold down the Select button for
three seconds - this will reset the installation date and the battery use counter. It is not necessary to remove
power while replacing the battery. Follow local regulations when disposing of the used battery.
6.6.4 Cleaning Instructions

If necessary, wipe the accessible parts of your PQube with a cloth, slightly moistened with clear water. Do
not use abrasives or chemical cleaners.
7. Instrument Power Distribution System (IPDS)

7.1 About the Instrument Power Distribution System (IPDS)
The instrument power distribution system (IPDS) performs subsea power conversion and distribution.
This manual section covers IPDS P/N 101-7723 variants and their associated power adapter modules. Vari-
ant differences are based on the supply voltage (4160 VAC or 3000 VAC) and the quantity and type of
power adapter modules attached to the IPDS. For more information, see:
● Variant part lists: see Volume 4: Drawings and Part Lists.
● Power Adapters & Station Blanks on page 108
System connections to the IPDS are shown on the ROV system interconnect diagram, located in the “Sys-
tem Schematics & Interconnect Diagrams” section of Volume 4: Drawings and Part Lists.
7.1.0.1 Core Component Modules

● T-box: 101-7770 (ROV) and 101-7770-1 (TMS)
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● Transformer: 101-7724 (4160 VAC) or 101-7992 (3000 VAC)

● Backbone: 101-7693 (4160 VAC) or 101-7693-1 (3000 VAC)
● Monitor module: 101-7594
T-Box
PDU power (4160 VAC or 3000 VAC) to and through the IPDS is connected at the T-box, using QD 101-
7444 variants.
Transformer
PDU power is routed to the transformer, which has two windings that supply 120 VAC to the backbone.
Backbone
The backbone routes the two phases of 120 VAC power to fused buses AC1 and AC2. Backbone features
include:
● Four 120 VAC stations (two on AC1 bus, two on AC2 bus) for connecting power adapters
● Four 26 VDC stations on 26V bus for supplying power to the nodes
● Deck power (26V) input connector
● Replaceable fuses for AC1 and AC2 bus circuits
● A relief valve on the 1 atm 120 VAC fuse chamber to relieve pressure if water intrusion causes a
short circuit
Monitor Modules
Two monitor modules (P/N 101-7594 and P/N 101-8417) are used in the field.
Monitor module 101-7594 collects input from:
● The water-detect sensors in the transformer, backbone, DC Pak, and Multi Pak
● The temperature sensor in the transformer
● The insulation monitoring device (IMD) in the multi pak. This adapter also forwards line isolation
sensor data in a survey junction box that is received through its 48V line.
The monitor module also forwards control system commands to the multi pak module for switching the
120 VAC outputs on and off.
The newer monitor module (P/N 101-8417) performs the functions listed above and also contains circuitry
to perform line isolation monitoring of the secondary (120/240 AC) windings in the IPDS transformer. The
circuit is able to detect an unwanted connection between the ROV frame and the windings in the
IPDS transformer or related 120/240 AC circuits. This information is relayed to the control console touch
screens and is interpreted as a voltage leak to ground.
Note: To display the line isolation monitoring information on control console touch screens, the ROV
system must (1) use Silvertip software version 3.9 or later or Hammerhead version 4.1.0 or later, and
(2) the 101-8417 module must be installed. Modules 101-7594 and 101-8417 can both be used with
new or old software, but only the module/software combinations described above will result in dis-
played line isolation monitoring.
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7.1.0.2 Power Adapters & Station Blanks

Power adapters (called Paks) connect to the 120 VAC stations on the backbone. The power adapters pass
along the voltage, combine it, or convert it to DC for use by instruments and other devices (see Instrument
Power Distribution System (IPDS): Specifications below.) A station blank must be installed on unused sta-
tions.
7.2 Instrument Power Distribution System (IPDS): Specifications

IPDS Specifications
Description Specification
Electrical
Input voltage, minimum/maximum ● 4,160 VAC ± 5% (101-7723, 7723-1, 7723-2)
● 3,000 VAC ± 5% (101-7723-3)
Input voltage, frequency 50/60 Hz ± 0.5 Hz
Output voltage (IPDS core) 120 VAC, 2 phase
DC output (using a Power Adapter module) ● 26 VDC, with DC Pak 101-7726 or Multi Pak
101-8003
● 48 VDC, with Multi Pak 101-8003
AC output (using a Power Adapter module) ● 120 VAC, unswitched, with Adapter 101-7732
● 120 VAC, 2x, switchable, with Multi Pak 101-
8003
● 240 VAC with Adapter 101-7730
Fuses ● Backbone: 25A, 2x (005-6709)
● Adapter, 120 VAC: 20A, 1x (005-7227)
Electrical connection for communication SeaNet
Dimensions and Weights
Height 350 mm (13.79 in.)
Width 387 mm (15.24 in.)
Length 578 mm (22.75 in.)
-2 variant: 631 mm (24.85 in.)
Sensors
Water Detect In Backbone, Transformer, DC Pak, Multi Pak
Temperature Transformer
Compensation
Fluid pressure (above ambient) 0.6 - 0.7 bar (8-10 psi)
Relief valve cracking pressure 1.4 bar (20 psi)
Environmental
Operating temperature, minimum/maximum 0 °C to +40 °C (32 °F to 104 °F)
Page 108 011-0552-06

IPDS Specifications (continued)

Storage temperature, minimum/maximum -18 °C to +50 °C (0 °F to 122 °F)
Humidity 0-100%
Depth rating 4,000 msw (13,123 fsw)
IPDS Module Specifications

4160 V Assemblies
Transformer 101-7723 (4160V)
Backbone 101-7693 (4160V)
3000 V Assemblies
Transformer 101-7992 (3000V)
Backbone 101-7693-1 (3000V)
Power Adapter Specifications

DC Pak 101-7726
● Converts 120 VAC to 26 VDC for the Backbone 26 VDC bus.
DC Multi Pak 101-8003

Converts 120 VAC to:
● 26 VDC for the Backbone 26 VDC bus.
● 48 VDC, switched (bottom 8-pin, 20 shell Burton connector).
● 120 VAC, 2 stations, switched (top two 6-pin, 20 shell Burton connectors).
A relief valve on the 1 atm 120 VAC distribution chamber relieves pressure if the entry
of water causes a short.
Page 109 011-0552-06

Power Adapter Specifications (continued)

120 VAC Adapter 101-7732
Routes 120 VAC Backbone station power to a 20 shell, 6-pin Burton connector for use
by external device (unswitched).
240 VAC Adapter 101-7730

● Connects to two 120 VAC ports to produce 240 VAC for the TMS VFD
motors or other devices.
HV PAK, IPDS, 340 VDC 101-9656

Connects to two 120 VAC ports to produce 340 VDC for the DC drive motors.
Station Blank 101-7734

Install a Station Blank on all unused 120V stations on backbone.
7.3 Instrument Power Distribution System (IPDS): Installation & Connections

7.3.1 Mechanical
See Volume 4: Drawings and Part Lists for mounting and installation kits.
Page 110 011-0552-06

7.3.2 HV Electrical
Supply
101-7723, 7723-1, 7723-2 4,160 VAC ± 5%
101-7723-3 3,000 VAC ± 5%
WARNING! SHOCK HAZARD! This equipment uses and produces hazardous voltages. Always lock
out and tag out power sources and connect system grounds before installing or removing power
adapters, connecting or disconnecting cables, or performing any maintenance or service. Follow all
high voltage safety procedures before beginning any work!
TMS
Connect the supply quick disconnect (QD) to the INPUT connector on the T-box. Connect the slip ring
cable QD to the OUTPUT connector on the T-box.
ROV
Connect the supply QD (tether) to the INPUT connector on the T-box. Connect the HPU power cable and
QD to the OUTPUT connector.
QD 101-7444 variants are used to terminate the umbilical, tether, and slip ring cables. For QD details, see
Cable & Slip Ring Terminations on page 215.
7.3.3 Chassis Ground
Connect the ground cable to the M6 terminal at the corner of the backbone (see figure above).
7.3.4 Compensation
Connect the compensation supply lines to the ports on the backbone, transformer, and T-box.
● For port locations, see IPDS Compensation: Fill, Bleed, and Drain on page 122
● Compensation circuit schematics for the ROV and TMS are located in the “System Schematics &
Interconnect Diagrams” section of Volume 4: Drawings and Part Lists.
The four 120V stations on the backbone have a small spring valve that opens to supply compensation fluid
to the connection interface when an adapter is installed and closes when an adapter is removed. This inter-
Page 111 011-0552-06

face volume is very small and cannot be bled. A small amount of fluid is released when an adapter is
removed.
7.3.5 26 VDC (Node Power)

Node power cables are connected to the four 26 VDC stations on the backbone (Figure 46).
Figure 46
7.3.6 Deck Power

The location for connecting the 26V deck power cable is shown in Figure 46.
7.3.7 Power Adapters

Power Adapters are connected at the four 120 VAC stations on the backbone (Figure 47).
Figure 47
For installation instructions that apply to all adapters, see IPDS Power Adapters: Remove and Install on
page 129.
WARNING! Shock hazard! Power to the IPDS must be turned off, locked out, and tagged out before
an adapter is removed or installed.
7.3.8 Operations
IPDS
Power to the IPDS is controlled from the PDU and PDU remote panel.
Page 112 011-0552-06

Multi Pak Switched Outputs (48 VDC and 120 VAC)

The multi pak 120 VAC stations AC1 and AC2 and the 48 VDC station are switched off and on with buttons
in the POWER page (control console GUI). See Volume 3: Operator Controls for details.
7.4 Instrument Power Distribution System (IPDS): Troubleshooting

7.4.1 Alarms
An alarm is produced when an upper or lower limit value is exceeded for the parameters listed below.
● Transformer core temperature
● Water detection (transformer, backbone, multi pak, DC pak)
● Impedance between earth and either of the multi pak 48V conductors (and/or return) as detected
by the insulation monitoring device (IMD).
— The 48V line will also forward line isolation data from a connected survey junction box.
7.4.2 Modules
7.4.2.1 Backbone
Backbone Status LEDs, Fuses, and Sensors

DC STATUS LED
The backbone DC STATUS LED changes color to indicate the status of the 26 VDC bus supplying the four 26V power
stations (transformer water-detect and temperature, backbone water-detect, and monitor module functions are monitored
and affect status).
LED Color Indication Location
Green 26V present, nodes are initialized, no errors detected
Blue Power is cycling on or monitored parameter is near the
limit value
Red A monitored parameter has reached or exceeded the
limit value.
Not lit No 26 VDC power on bus.
● Review alarms for possible causes.
Troubleshoot possible causes.
— No 26V power Adapter is installed
(install).
— DC Pak or multi-pak not work-
ing/status light off (replace).
— No AC bus power (see AC POWER
LEDs troubleshooting, below).
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Backbone Status LEDs, Fuses, and Sensors (continued)

AC POWER LEDs
The backbone AC POWER status indicator is lit by two green LEDs, one for each 120 VAC bus.
WARNING! DO NOT use the “AC POWER” status light to determine whether 4160 VAC or 3000 VAC power
is present in the IPDS.
High voltage supply power can be present in the IPDS when the “AC POWER” indicator is not lit.
Fully Lit 120 VAC present on both buses.

Partially Lit No power on one 120 VAC bus.
● Review alarms for possible causes (water
detected, etc.). Troubleshoot possible causes.
● If no obvious cause, check backbone fuses.
— If a fuse is blown, disconnect all power
adapters and devices/instruments
from the bus replace the fuse.
— If fuse does not blow (nothing con-
nected), identify malfunctioning com-
ponent by installing power adapters
and devices/instruments until the fuse
blows again.
— If fuse blows (nothing connected),
replace transformer.
— If no fuse is blown, replace trans-
former.
Not lit ● Review alarms for possible causes.
Troubleshoot possible causes.
● If no obvious cause, check backbone fuses.
— If fuses are blown, see “Partially Lit”
above to diagnose both buses.
— If fuses are OK, replace transformer
Page 114 011-0552-06

Backbone Status LEDs, Fuses, and Sensors (continued)

AC1 and AC2 Bus Fuses
120 VAC Bus Fuses
The 120V buses and stations are fused as shown at right. Bus/station status is indic-
ated by the AC POWER LEDs (see AC POWER LEDs on the previous page).
To replace a fuse, see IPDS 120 VAC Fuses: Remove and Install on page 124.
Note: If a fuse is blown, identify and correct the cause before replacing it.
Water-Detect Sensor
Water-detect sensor data is routed to the monitor module for use by the control system.
Detected water will produce the following:
● A red WATER indicator light on the ISSUES LIST and DASHBOARD.
● An alarm message on the ALARM page and DASHBOARD.
● An audible alarm (if enabled).
Inspect the component identified in the alarm for damage to interface O-rings or housings that could cause a leak. Repair
or replace as appropriate.
7.4.2.2 Transformer
Transformer Sensors
Transformer Core Temperature Sensor
Transformer core temperature sensor data is routed to the monitor module for use by the control systems.
A temperature above the limit value will produce an alarm.
● Review alarms for IMD or device/instrument problems that could be overloading the transformer.
● If possible, turn off non-critical devices or instruments with high current requirements
Water-Detect Sensor
Water-detect sensor data is routed to the monitor module for use by the control system.
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Transformer Sensors (continued)

Transformer Core Temperature Sensor
Detected water will produce the following:
● A red WATER indicator light on the ISSUES LIST and DASHBOARD.
● An alarm message on the ALARM page and DASHBOARD.
Inspect the component identified in the alarm for damage to interface O-rings or housings that could cause a leak. Repair
or replace as appropriate.
7.4.2.3 DC Pak
DC Pak Status LED

The DC Pak LED changes color to indicate DC status (monitors output and water detection).
Blue Power is cycling on or monitored parameter is near the limit value
Red A monitored parameter has reached or exceeded the limit value. Check
GUI warnings for details.
Not lit No 26V power

● Is the backbone AC POWER status light fully lit?
— If YES, replace DC pak.
— If NO, troubleshoot using the backbone AC POWER
indicator light (see AC POWER LEDs on page 114).
Multi Pak
Multi Pak
Multi Pak Status LEDs & IMD Monitor
26 VDC LED
The 26 VDC LED changes color to indicate 26V status (monitors output and water detection).
Page 116 011-0552-06

Multi Pak (continued)

Blue Power is cycling on or monitored parameter is near the limit
value
Red A monitored parameter has reached or exceeded a limit value.
Check GUI warnings for details.
● Is the Backbone AC POWER status light fully lit?
— If YES, replace Multi Pak.
— If NO, troubleshoot using the Backbone AC
POWER indicator light (see AC POWER
LEDs on page 114).
48 VDC LED
The 48VDC OUT LED by the connector changes color to indicate 48V status
Page 117 011-0552-06


Green Nodes are initialized, no errors detected
Blue Power is cycling on or monitored parameter is near the limit
value
Red A monitored parameter has reached or exceeded the limit
value.
● Confirm 48V power is turned on (see POWER page).
— If YES, replace multi pak.
— If NO, troubleshoot using the backbone AC
LEDs on page 114).
LEDs on page 114).
— If YES, remove connected device/instrument
and cycle switched circuit power.
● Is 48VDC OUT LED now lit?
— If YES, replace device/instrument.
— If NO, replace multi pak.
120 VAC LED
The 120VAC SWITCHED LEDs (AC1 and AC2) light to green when 120 VAC is present.
Not lit No 120 VAC power
● Confirm 120V power is turned on (see POWER page).
LEDs on page 114).
— If YES, remove connected device/instrument
and cycle switched circuit power.
● Is 120VAC SWITCHED LED now lit?
— If YES, replace device/instrument.
— If NO, replace multi pak.
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48V IMD Monitor
The IMD generates an alarm when the impedance between earth and either of the 48V conductors (and/or return) is too
low.
The 48V line will also forward line isolation data from a connected survey junction box.
IMD Alarm
IMD Warnings can be caused by water intrusion, degradation of insulation, or other problems. If an IMD warning appears:
● Inspect the connector interface and O-ring. If water is present, clean Backbone station and Multi Pak connector
interfaces and replace O-ring.
● Inspect the Multi Pak1 atm enclosure. If any damage to housings is found, replace the Multi Pak.
Survey Junction Box Line Isolation Alarm
● See your Survey Junction Box manual for more information.
7.4.2.4 120 VAC Power Adapter
120 VAC Power Adapter

120VAC Adapter Fuse
No 120 VAC power at the Burton connector:
Is bus getting power? (is the other adapter on the same bus functioning? or is AC POWER indicator fully
lit.)
● If YES: Check adapter fuse, see 120V Power Adapter Fuse: Remove and Install on page 133.
— If fuse is blown, disconnect device/instrument and replace fuse.
— If new fuse does not blow, replace device/instrument.
— If fuse blows (nothing connected), replace adapter.
● If NO, check the Backbone bus fuse. If blown, correct the cause and replace the fuse. If fuse is
OK, replace Transformer.
7.5 Instrument Power Distribution System (IPDS): Maintenance

7.5.1 Anodes
Anode Replacement
Replace an anode when less than 1/3 of its volume remains. Use Aqua Shield, or equivalent, on the new anode threads
or mounting hardware.
IPDS Component Anode P/N Qty
Backbone 002-1440 8
DC pak 002-1440 2
Multi pak 002-1440 3
240 VAC adapter 002-1440 2
Page 119 011-0552-06

Anode Replacement (continued)

120 VAC adapter 002-1440 1
T-box None
Transformer None
7.5.2 Fuse Replacement

Backbone 120 VAC Bus
Fuses are located in a one atmosphere enclosure.
IPDS 120 VAC Fuses: Remove and Install on page 124
120V Adapter Power

The fuse is located in a one atmosphere enclosure.
120V Power Adapter Fuse: Remove and Install on page 133
7.5.3 QD/socket Protection

When a QD is disconnected from the T-box, install a QD cover (P/N 010-1611) to the QD and the socket to
protect them while the vehicle is on deck. One side of the QD cover is male and the other female, so it can
be used to blank either type of connection. The clamp on the T-box connection can be used to hold the
cover in place. On QDs, the pressure of the O-ring keeps the cover in place.
Caution! Use Blanking Cover 010-1611 only for surface protection of connections. If submerged it
will leak.
7.5.4 Power Adapters/Backbone

Clean connector interfaces on the backbone 120V stations and power adapters. Lubricate the station O-
rings.
7.6 Instrument Power Distribution System (IPDS): Service

WARNING! SHOCK HAZARD! This equipment uses and produces hazardous voltages. Always lock-
out/tagout power sources and connect system grounds before installing or removing power
adapters, connecting or disconnecting cables, or performing any maintenance or service. Follow all
high voltage safety procedures before beginning any work!
7.6.1 Servicing Module Components

Some IPDS modules and power adapters have expendable components that can be easily replaced. Other
than these components, if a module becomes inoperable it must be replaced as a unit.
Page 120 011-0552-06

Modules with Serviceable Components

Module Serviceable Components
Backbone (P/N 101- ● Anode (see Anodes on page 119)
7693) ● Fuse (P/N 005-6709) (See Instrument Power Distribution System (IPDS): Service on
the previous page.)
● Monitor module (P/N 101-7594) (See Instrument Power Distribution System (IPDS):
Service on the previous page.)
● Station insert (P/N 101-7729)
● Station insert PCA (P/N 101-7728)
120V adapter (P/N 101- ● Anode (see Anodes on page 119)
7532) ● Fuse (P/N 005-2772) (See Instrument Power Distribution System (IPDS): Service on
the previous page.)
Multi pak (P/N 101- Anode (See Anodes on page 119.)
8003)
DC power pak (P/N 101- Anode (See Anodes on page 119.)
7726)
240V adapter (P/N 101- Anode (See Anodes on page 119.)
7530)
Non-Serviceable Modules
Transformer (P/N 101-7724)
T-box (P/N 101-7770)
Monitor module (P/N 101-7594)
7.6.2 Service Instructions Index

IPDS Compensation: Fill, Bleed, and Drain on the next page
HPU Motor & IPDS T-Plate Compensation: Filling, Bleeding, and Draining on page 1
IPDS 120 VAC Fuses: Remove and Install on page 124
IPDS Monitor Module: Remove and Install on page 126
IPDS Transformer Module: Remove and Install on page 128
System Line Isolation and Ground Faults (HD and UHD-III only): Troubleshoot on page 138
IPDS Power Adapters: Remove and Install on page 129
IPDS T-Box: Remove and Install on page 131
120V Power Adapter Fuse: Remove and Install on page 133
Page 121 011-0552-06

IPDS Compensation: Fill, Bleed, and Drain

The IPDS has 3 separate compensation volumes to make it easier to service individual assemblies, these
volumes include:
● Backbone
● Transformer module
● T-box and QDs
This service instruction explains how to fill, bleed, and drain the IPDS compensation volumes. See the ROV
and TMS compensation schematics for more information.
Tools Compensation cart, adjustable wrench, compressed air source 8.23 bar (120 psi)
Personnel 1 worker
Sub-Procedures PDU: Lockout/Tagout (Safety Procedure) on page 9
Parts-Kits None
Safety Electrical shock, compressed air
Consumables Compensation fluid
WARNING! The IPDS has circuits that have full system voltage (3000/4160 VAC), which is lethal.
Before doing any work on the IPDS or related components, make sure to ground and lock out/tag out
the PDU.
Filling, Bleeding, and Draining

Each of the 3 volumes is filled, bled, or drained individually. The specific hydraulic ports that are used for
compensation depend on the physical orientation of the IPDS. Use the compensation cart to bleed each
volume from its highest port and drain from the lowest port.
Compensation Volume 1: Backbone
The backbone compensation volume includes the
interface connectors on the power adapters, and the
monitor module. It is internally isolated from all of
the other IPDS compensated volumes. The fuses are
housed in a 1 atm cavity.
Page 122 011-0552-06

Compensation Volume 2: Transformer Mod-

ule
The transformer module compensation volume is
internally isolated from all of the other IPDS com-
pensated volumes.
Compensation Volume 3: T-Box and QDs

The T-box compensation volume includes any con-
nected QDs. It is internally isolated from all of the
other IPDS compensated volumes.
● On the TMS, the T-box is compensated
through the IPDS compensation circuit and
also passes compensation to the slip ring and
rotating T-boxes.
● On the ROV, the T-box is part of the HPU
motor compensation circuit.
On both vehicles, compensation fluid flows from the
T-box into the QDs. At the umbilical and tether QDs,
the cable itself blocks the compensation fluid from
traveling further.
Page 123 011-0552-06

IPDS 120 VAC Fuses: Remove and Install

This service instruction explains how to remove and install the 120 VAC fuses on the IPDS.
Tools Fuse removal tool, wrench (10 mm), torque wrench (0-10 Nm [0-100 in-lb]), continuity tester (VOM)
Personnel 1 worker
Parts-Kits O-ring (P/N 004-0060)

005-6709 FUSE,25A,250V,LLNRK,RK1
Consumables Cable ties, Dow Corning 111 O-Ring Lubricant (P/N 002-3485)
Fuse AC1 protects 120V stations AC1 and AC3 on the backside of the backbone. Fuse AC2 protects 120V sta-
tions AC2 and AC4. Check the appropriate fuse when both AC1 and AC3 stations or both AC2 and AC4 sta-
tions do not have AC power. A blown fuse could be caused by a rare or unusual power load, or by a com-
ponent failure on any of its stations. Try to identify and correct the cause before replacing a blown fuse.
(See the Troubleshooting section in Volume 3: Operator Controls.)
Removal
1. Prepare the system for safe working conditions.
2. At the PDU, turn off and lockout/tagout power to the IPDS.
3. Remove the fuse cover from the backbone (4X M6 HHCS).
Note: The fuse housing is a 1 atm chamber and does not contain compensation fluid.
4. Pull the fuse(s) from the retaining clips.

5. Test the fuse(s) for continuity. Replace a fuse if it is blown (has no continuity).
Page 124 011-0552-06

Installation
1. Install the new fuse(s).
2. Clean and lubricate the O-ring (P/N 004-0060) with DC 111 and install into the fuse cover. Clean the
sealing surface on the backbone.
3. Install the fuse cover (4x M6 HHCS; 8.8 Nm [78 in-lb]).
Page 125 011-0552-06

IPDS Monitor Module: Remove and Install

This service instruction explains how to remove and install the IPDS monitor module (part number 101-
7594).
Tools Torque wrench 0-10 Nm (0-50 in-lb), wrench/socket (8 mm), compensation cart
Personnel One worker
IPDS Compensation: Fill, Bleed, and Drain on page 122
Parts-Kits O-ring (P/N 004-1033)
Safety Electrical shock
Consumables Cable ties, Dow Corning 111 O-Ring Lube 002-3485, compensation fluid
the PDU.
Removal
2. Turn off and lock out/tag out IPDS power at the PDU.
3. Disconnect the SeaNet cable from the monitor module.
4. Install SeaNet caps and plugs as needed.
5. Disconnect and drain the IPDS backbone compensation (see IPDS Compensation: Fill, Bleed, and
Drain on page 122).
6. Remove the monitor module fasteners (2x M5 HHCS).
7. Carefully remove the monitor module from the IPDS.
8. Inspect the mating connectors for damage.
Page 126 011-0552-06

Installation
1. Confirm that the system is configured for safe working conditions.
2. Clean and inspect the module O-ring (P/N 004-1033) and mating face on the backbone. Lubricate the
O-ring with DC-111 or an equivalent.
3. Orient the module to line up with the connector on the backbone and carefully push the module
straight in until it is seated.
4. Install the fasteners and washers (2x M5; 2.6 Nm [23 in-lb]).
5. Connect the SeaNet cable to the monitor module.
6. Fill and bleed the backbone (see IPDS Compensation: Fill, Bleed, and Drain on page 122).
Page 127 011-0552-06

IPDS Transformer Module: Remove and Install

This service instruction explains how to remove and install the IPDS transformer module.
Tools Lifting device, wrenches (10 mm, 12 mm), torque wrenches (2x 0-10 Nm [0-100 in-lb], 0-60 Nm [0-50 ft-lb])
Personnel 2 workers
Parts-Kits 005-7235, ASSY,XFMR,MTD,3000VAC,5KVA,AEC

005-7225, ASSY,XFMR,MTD,4160VAC,5KVA,AEC
Safety Electrical shock, lifting, pinch, crush
Consumables Cable ties, Dow Corning 111 O-Ring Lubricant (Thick) 002-3485
Note: Select the correct transformer for your system from the parts list above.
Removal
2. Lock out and tag out the PDU.
3. Disconnect and drain compensation fluid from the transformer module (see IPDS Compensation: Fill,
Bleed, and Drain on page 122).
4. Disconnect the transformer module from the backbone:
a. Remove the HHCS (A) along the edge of the IPDS housing. Do not remove the nuts (B) at the
corners (8x M6 HHCS).
b. While one person supports the transformer, remove the nuts (B) from the studs at each corner of
the housing (4x M8 nut).
WARNING! The IPDS transformer module weighs about 40 kg (90 lb). Use a lifting device or a min-
imum of two people to support and move the transformer.
5. Move the transformer module away from the IPDS and out of the vehicle.
Installation
1. Confirm the system is configured for safe working conditions.
2. Inspect and clean the sealing interfaces on the transformer module and the backbone.
3. Inspect the O-ring (P/N 004-0023) and replace if necessary. Apply DC-111.
4. Using a lifting device, or at least two people, carefully mate the transformer module to the backbone
studs and interface connectors. Immediately install the nuts and washers (B) to the corner studs (4x
M8 nuts; 13.5 Nm [10 ft-lb]).
5. Install the HHCS and washers (A) along the edge of the IPDS housing (8x M6 HHCS; 8.8 Nm [78 in-
lb]).
6. Fill and bleed the transformer module compensation (see IPDS Compensation: Fill, Bleed, and Drain
on page 122).
Page 128 011-0552-06

IPDS Power Adapters: Remove and Install

This service instruction explains how to remove and install IPDS power adapters. It applies to the DC pak
(P/N 101-7726), multi pak (P/N 101-8003), 120V adapter pak (P/N 101-7732), 240V adapter pak (P/N 101-
7730), and station blank pak (P/N 101-7734).
Tools Wrench (10 mm)
Personnel 1 worker
Parts-Kits None
Safety Electrical shock, pinch, crush
Consumables Cable ties
the PDU.
Removal
2. Lockout/tag out electrical power to the vehicle.
Note: Draining the backbone compensation is not necessary. The four 120V stations on the backbone
have a small spring valve on the connector interface that closes when an adapter is removed. The inter-
face volume is very small and cannot be bled. The compensation fluid in it is released into the envir-
onment when an adapter is removed.
Note: The main body of all adapters are 1 atmosphere vessels and they do not need to be decom-
pensated.
3. Loosen the power adapter mounting fasteners (the DC pak is shown below) (3x M6; Multi Pak 6x M6).
Note: The fasteners are retained in the power adapter housing.
4. Grip the top and bottom of the power adapter and pull it straight off of the 120V station. Removal
creates a strong vacuum at the connector interface, so carefully and patiently work the power adapter
off of the station.
Page 129 011-0552-06

Installation
2. Clean and lubricate the station O-ring and the mating interface on the power adapter.
3. Line up the connectors and press the power adapter straight onto the station.
4. Tighten the power adapter mounting fasteners (3x M6; 8.8 Nm [78 in-lb]).
Page 130 011-0552-06

IPDS T-Box: Remove and Install

This service instruction explains how to remove and install the IPDS T-box.
Tools 1/4 drive ratchet and short extension, sockets (7 mm, 10 mm), wrenches (7 mm, 10 mm), torque wrench (0-15 Nm
[0-100 in-lb])
Personnel 1 worker
Parts-Kits Blanking covers (P/N 010-1611), O-ring (P/N 004-0203)
Safety Electrical shock
Consumables Cable ties, Dow Corning 111 O-Ring Lube (thick) (P/N 002-3485)
This service instruction applies to the T-box on both the ROV IPDS and the TMS IPDS. For reference, see
assembly drawings 101-7723 (IPDS) and 101-7770 (T-box).
Removal
2. Turn off and lockout/tagout IPDS power at the

PDU. (See PDU: Lockout/Tagout (Safety
Procedure) on page 9.)
3. Disconnect and drain compensation fluid from
the T-box. (See IPDS Compensation: Fill, Bleed,
and Drain on page 122.)
4. Disconnect the fibers from the QDs connected to
the T-box.
5. Remove the HHCS (A) securing the center of the

QD mounting bracket (B). Then, loosen the
remaining two fasteners and slide the QD
mounting bracket out (6x M6 HHCS).
6. Unplug the QDs and cover the connections with
QD blanking covers (P/N 010-1611) with O-ring
(P/N 004-0203).
7. Remove the HHCS (C) from each corner of the T-box and disconnect the T-box from the backbone by
pulling it straight out (4x M6 HHCS).
Page 131 011-0552-06

Installation
2. Inspect and clean the sealing interfaces on the T-box and backbone.
3. Inspect the O-ring (P/N 004-0203) and replace if necessary. Apply DC-111 lubricant.
4. Connect the T-box to the backbone, carefully aligning the electrical contacts. Install the HHCS and
washers (C) to each corner of the T-box (4x M6 HHCS; 8.8 Nm [78 in-lb]).
Note: The T-box will connect even if you install it upside down, but the mounting bolt holes will only
line up in the correct position.
5. Plug the QDs into the T-box.

6. Slide the QD mounting bracket (B) into place, install the center HHCS (A), and tighten all three HHCS
on each QD (6x HHCS; 8.8 Nm [78 in-lb]).
7. Connect the fibers to the QDs (2x M4 SHCS; 5.1 Nm [45 in-lb]).
8. Fill and bleed the T-box compensation (see IPDS Compensation: Fill, Bleed, and Drain on page 122).
Page 132 011-0552-06

120V Power Adapter Fuse: Remove and Install

This service instruction explains how to remove, test, and install the fuse in the 120 VAC power modules.
Tools Continuity tester, fuse removal tool, hex keys, lockout/tagout kit, screwdriver
Personnel 1 worker
Sub-Procedures None
Parts-Kits Fuse (P/N 005-7227; 20A, 250V, 3AB, SLOW, 326SER), O-ring (P/N 004-1187)
Consumables None
System Preparation
1. Install ground connections on the TMS and ROV.
2. Turn off the ROV system power and lock-out/tag-out the system.
WARNING! SHOCK HAZARD! There are lethal voltages throughout the ROV system, including in the
control van, deck cable, LARS, TMS, and ROV. The IPDS is connected to 4160 VAC. Before working on
equipment, shut down power and shunt the power circuit using the ground switches on the PDU.
WARNING! ALWAYS assume equipment is energized until you have CONFIRMED that it is isolated,
locked-out and tagged-out as directed by applicable electrical safety regulations and procedures.
• Observe high voltage safety practices whenever system power is enabled.
• Connect grounding cables to vehicles while they are on deck.
Fuse Replacement
Removal
2. Ground the ROV/TMS systems.
3. At the PDU, turn off and disconnect power. Then, lockout/tagout power to the IPDS.
4. Remove two SHCC and the fuse cover from the 120 V Power adapter.
5. Test for voltage across the fuse and from either side of the fuse to ground to make sure that there is no
power.
6. Pull the fuse from the retaining clips.
Page 133 011-0552-06

Figure 48: Location of fuse in 120 VAC power module
7. Test the fuse for continuity.

8. If the fuse is “blown” (has no continuity), determine the cause and correct it before installing a new
fuse.
Installation
1. Install the new fuse (P/N 005-7227; FUSE, 20A, 250V, 3AB, SLOW, 326SER).
2. Clean and lubricate the fuse cover and O-ring (P/N 004-1187).
3. Install the cover (2x M5 SHCS; 5.1 Nm [45 in-lb]).
Page 134 011-0552-06

Power System Components 8. Line Isolation (Ground Fault) Troubleshooting
8. Line Isolation (Ground Fault) Troubleshooting

8.1 About Line Isolation (Ground Fault) Troubleshooting
Note: Some troubleshooting sections in this manual may not apply to your system, depending on the
supplied components.
The line isolation monitor circuitry is used to detect unwanted connections between system circuits and the
chassis of the machine (ground). If an unwanted voltage leak is present, the line isolation circuits report
this to the control system, and it is interpreted on the screen as a voltage leak to ground.
The isolation circuit works by applying an isolated voltage alternately between each side of the system cir-
cuit and the chassis. If leakage exists, the isolation monitor measures current flow and reports it to the con-
trol system. Resistance is extrapolated from this data and used for alarm and display purposes.
8.2 Line Isolation: General Troubleshooting Techniques

In all cases, a ground fault indicates an unwanted connection between a system circuit and the chassis of
the ROV or TMS. In the lower 26/48-VDC, this can disrupt communication, and cause corrosion, inter-
mittent equipment errors, and equipment malfunctions. Leaking voltage can also create a potential for a ser-
ious safety hazard, especially with higher-voltage leaks.
WARNING! Line isolation faults reported for 120/240-VAC can cause a potential for serious elec-
trical shock. When troubleshooting isolation faults on deck, connect the grounding cables to the sys-
tem and use rubber gloves and observe electrical safety regulations. You must assume that the equip-
ment is hot with respect to ground or the deck of the ship.
Troubleshooting process
Locate the circuit in question and begin disconnecting the segments of the circuit while observing the line
isolation resistance values reported on the user interface screen.
For further details, see System Line Isolation and Ground Faults (HD and UHD-III only): Troubleshoot
on page 138.
8.2.1 26-VDC Line Isolation Functions

Each node is equipped with a line isolation monitor circuit that determines the resistance between the
vehicle frame (“chassis”) and the 26V power (“high-side”) and 26V return (“low-side”) lines of the 26 VDC
bus. The circuit accomplishes this by applying an isolated voltage alternately between the frame of the
vehicle and the +26-VDC bus or the 26RET.
If multiple nodes are connected to the same bus, the line isolation monitor in the software-designated first
node in each platform (TMS or ROV) is enabled. The monitors on the remaining nodes for that platform
are set to standby mode.
The 26V bus power originates in the 26V to 26V power converter and is distributed to the nodes and
devices connected to the nodes.
When high-side or low-side line isolation drops below 100 kilohms anywhere on the 26V bus, the control
system triggers an alarm, creating an entry on the alarm page and turning the GFD (ground fault detector)
indicator on the main menu bar (Silvertip) or the Status Bar (Hammerhead) from green to red. The
Page 135 011-0552-06

resistance is also displayed numerically. You can access this information from the dashboard in Ham-
merhead. See Volume 3: Operator Controls manual for more information.
8.2.2 48-VDC Line Isolation Functions

Line isolation for the 48-VDC circuit is accomplished in the 48-VDC Multi Pack by a circuit that measures
any connection between the 48-VDC circuits and the chassis. Signals for the results are passed back into
the backbone of the IPDS comms pins and then out via the monitor module SeaNet connection. If leakage
is present, the values are presented on the screen as indicated above.
8.2.3 120/240-VAC Line Isolation Functions

The 120/240 line isolation monitor is attached to the bus of the IPDS. Through the bus, the monitor mod-
ule is connected to the secondary windings of the transformer and can detect electrical connections
between the secondary windings or related circuits and the chassis ground. In the case of 120-VAC, there
are two separate secondary windings (AC1 and AC2), and the module connection is cycled between the two
windings. In the case of 240-VAC output on the TMS, the module is connected to each leg of the 240-VAC
and monitors connections to ground. If any leakage is detected, the module sends the data to the control
system where it is interpreted on the user interface screens as discussed above.
The only exception to this is if a lighting control unit (LCU) is installed on the ROV. If an LCU is installed
and is connected to one of the AC circuits (AC1 or AC2), the LCU provides isolation monitoring for the AC
circuit that it receives power from. In this case, the IPDS monitor module performs line isolation mon-
itoring for the other AC circuit. For example, if the LCU is receiving power from AC1, then the monitor
module will monitor AC2 for faults.
8.3 Line Isolation: Devices Causing Faults

Certain devices connected to a node have internal capacitors connected from +26V to the chassis or 26RET
to the chassis, which can interfere with the line isolation monitor.
● As the isolation monitor switches the measurement point between the two buses, these capacitors
are charged and discharged. This can result in a fault on the +26V bus that is reported on the
26RET bus.
● When an actual fault resistance is low enough (about 75k), the capacitors will charge quickly and no
fault will be reported.
Factory-installed devices of this type are listed in Table 1. Customer-supplied equipment with a capacitance
from +26V to Chassis or 26RET to chassis of greater than .01µF should be added to the list and dis-
connected during line isolation troubleshooting.
When interfacing a new device with this issue, eliminating the chassis connection where the device con-
nects to the system will keep the device from interfering with the isolation monitor, but will also disable
line isolation monitoring to this device.
Common causes for a line isolation fault are listed below

● Water intrusion during subsea operation.
● Water intrusion into a SeaNet connector/penetrator interface.
● Incorrect power connections in a device connected to a node port (at startup or when turning on a
node port).
Page 136 011-0552-06

● A device with internal capacitors between the chassis and the +26V or 26RET line.
● A short or leakage between 26RET and chassis.
Page 137 011-0552-06

System Line Isolation and Ground Faults (HD and UHD-III

only): Troubleshoot
This document explains how to troubleshoot line isolation and ground faults in the node 26 VDC circuit on
HD systems only.
Tools Multimeter
Personnel 2 workers
Parts-Kits None
Consumables Terminal cleaner, WD40/water dispersant
Note: A Ground Fault (GFD) is considered to be present if the line insulation monitor on the node
page is in the yellow or red regions of the scale. However, a reading in the green region which is fall-
ing, or is just above the first alarm value (500K), would be an indication of a fault developing.
Note: All nodes are capable of monitoring for ground faults, however, since all the ROV nodes are
on the same 26VDC BUS, only node 4 has the feature enabled.
Warnings and Cautions
WARNING! SHOCK HAZARD! Lethal voltages are present throughout the ROV system, including
the control van, deck cable, LARS, TMS, and ROV. The IPDS is connected to 4160 VAC. Shut down
power and disconnect the power circuit using the ground switches on the PDU prior to working on
equipment.
WARNING! ALWAYS assume equipment is energized until you have CONFIRMED it is isolated,
locked-out and tagged-out as directed by applicable electrical safety regulations and procedures.
Caution! Always turn OFF instrument power before disconnecting or connecting power cables. Fail-
ure to turn off the instrument power before disconnecting or connecting power cables may result in
damage to the equipment and/or misinterpretation of the troubleshooting results.
Page 138 011-0552-06

TROUBLESHOOTING HIGH SIDE FAULTS

A fault that registers as a high side isolation fault indicates a leakage path between +26V bus and the frame
(chassis or earth) of the ROV or TMS. If this type of fault occurs on a device connected to a node port, it
can be isolated by turning off port power.
TROUBLESHOOTING PROCEDURE
1. Install ground connections on the TMS and ROV. Shut down HPU power and use lock out tag out
devices.
2. From the operators screen, turn all devices off, one per second, while watching the high side fault
indicator. Since the response time of the line isolation monitor is approximately 3 seconds, when the
indicator shows the fault is gone, one of the last few devices will contain the fault.
3. Start turning on the last devices that were turned off, waiting 5 seconds between devices. When the
device with the fault is turned on, the fault will reappear on the LINE ISO panel.
4. Turn off the node port, and disconnect the SeaNet cable from the node port. Inspect the connector
and penetrator for water contamination.
— If water is present, use a product such as WD40 to disperse the water and clean the con-
tacts on the SeaNet cable connector and the penetrator. Turn on the port, and see if the
fault appears.
— If the fault disappears the fault is in the cable or the device.
5. Turn off the node port, and reconnect the cable to the node.
6. Disconnect the cable from the device and turn on the node port to determine if the fault is in the cable
or the device.
a. If the fault is present, the issue is in the cable.
b. If the fault is not present the issue is at the device end of the cable or in the device.
Note: If water is found inside the SeaNet connector, it is important to determine how the water got
inside the connector and resolve the issue. Check/replace O-rings and diagnose the source of the leak.
It may be necessary to purge the lines to remove water.
Troubleshooting Low Side Faults

A fault that registers as a low side isolation fault indicates a leakage path between -26V bus and the frame
(chassis or earth) of the ROV or TMS. Low side ground faults can sometimes be located by turning off the
node ports, and looking for a slight improvement in the GFD value. However, in order to properly identify
which node port the GFD is on, the cable must be disconnected. The electrical isolation method can be
tried, particularly if the ROV is not on deck, but the fastest way to locate a low side GFD, is to disconnect
the cables.
ELECTRICAL ISOLATION PROCEDURE
1. To speed the diagnostic process, one by one turn all devices off, one per second, while watching the
LOW SIDE fault indicator. Since the response time of the line isolation monitor is approximately 3
seconds, when the indicator shows the fault is gone, one of the last several devices will contain the
fault.
Page 139 011-0552-06

2. Start turning on the last devices that were turned off, waiting 5 seconds between each device. When the
device with the fault is turned on, the fault will increase on the indicator bar.
3. Turn off the node port and disconnect the cable. Inspect the connector and penetrator for water and or
debris contamination. If water is present, use a product such as WD40 to disperse the water and clean
the contacts on the penetrator and connector. Turn on the port, and see if the fault appears.
— If the fault is still present the problem is with the port or node.
— If the fault does not appear the issue is in the cable or device. Continue to next step.
4. Turn off the node port, and reconnect the cable. Disconnect the cable from the device. Turn on the
node port to determine if the fault is in the cable or the device.
Figure 49: SeaNet connector pin out
1. +26_VDC_SWITCHED (+26VDC_SW)
2. SWITCHED_RETURN_26_VDC (SW_RET26)
3. CHASSIS (CHA)
For information on data pins 4 – 7 see SeaNet Con-
nector Service Instruction 020-02373.
If the electrical isolation procedure is unable to troubleshoot multiple ground faults, try mechanical isol-
ation which is described in the following section.
MECHANICAL ISOLATION PROCEDURE
1. Turn off all node Ports.
2. If the fault is on the ROV, start with the last node (if ROV has nodes 4-7, begin with node 7).
3. With one operator on deck, and one in the control van, start disconnecting cables one at a time. Dis-
connect 4 cables, and if no change, reconnect them. Disconnect the next 4 cables, reconnect and so on.
4. Once the port which is causing the low side GFD has been found, determine if it is the cable or the
device by disconnecting the cable from the device and reconnecting the cable to the node port.
MULTIPLE LOW SIDE GFDS AND NODE GFDS

NODE
1. Ensure power is off and that circuit capacitance has had time to drain.
2. Disconnect the power cable from the last node in the circuit (if the ROV has nodes 4-7 begin with node
7) at the 26V to 26V power converter.
Page 140 011-0552-06

3. Turn on instrument power.

— If the low side GFD has gone, the fault is associated with that node or one of the ports. Turn
off Instrument power and reconnect the node power cable. Proceed to Port section below.
— If the low side GFD remains after disconnecting the power cable from the node the fault is
in another node or possibly the IPDS. Turn off instrument power, and disconnect the power
cable from the next node in the series. Continue this process until the faults are found.
— If a low side GFD still exists with only node 4 connected and all the node port cables
removed, then the fault could be in node 4 or the node 4 power cable. It is also possible the
fault is in the IPDS or the DC Pak, or Multi-Pak if one is installed. Proceed to Power Cable
and IPDS sections below.
PORT/DEVICE
1. Turn off instrument power.
2. Disconnect all the SeaNet cables from the node ports on the faulting node and turn on instrument
power.
— If the fault does not reappear, the problem is with one of the ports or equipment connected
to the port. Reconnect the SeaNet cables one at a time until the fault reappears to determine
which port is at fault.
— If the fault remains after all the SeaNet cables are removed from the ports, the fault is in one
of the ports or the node.
3. Once a port has been identified reconnect the cable to the port and disconnect the device from the
cable and turn on instrument power.
— If the fault is gone the fault is in the device or device connection end of the cable. Check
cable end for debris and see notes at end of section.
— If the fault remains, the fault is in the cable. Proceed to Power Cables.
POWER CABLES
1. Turn off all power to the IPDS.
2. Disconnect node 4 power cable from the IPDS.
3. Check the resistance between the chassis ground pin and return pin on the cable connector.
— If the resistance is above 1.5 megohm, proceed to test the IPDS.
Figure 50: Power cable pin out (facing connector)
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4. If the resistance is below 1.5 megohms disconnect the power cable from node 4 and measure the
resistance between the chassis ground pin and return pin on the power cable.
— If the resistance in the power cable is still below 1.5 megohms, replace the power cable.
— If resistance in the cable is above 1.5 megohms, check the resistance between the chassis
ground and return pin on the power plug on the node.
— If the resistance is below 1.5 megohm on the node, replace the node.
Figure 51: Node power connection test points
IPDS
1. Turn off power to the IPDS.
2. Remove all of the power cables from the IPDS.
3. Measure the resistance between the chassis ground pin and return pin on one of the power connector
ports on the IPDS. See the image below. (26 VDC power on the IPDS connectors are on a common
buss).
— If the resistance is below 1.5 megohm, remove one of the DC Paks and retest.
Figure 52: IPDS 26 VDC power out
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4. Continue testing and removing paks until the faulty pak is discovered, or the fault is isolated to the
IPDS.
— If the resistance is still below 1.5 megohm with all the packs removed, the IPDS must be
replaced.
Figure 53: IPDS backside showing multi-pak, DC pak, and spare cover
DEVICE NOTES
● Some survey devices give an instant full scale low side GFD. This can be seen on deck if the device
housing is in contact with the ROV frame, or, as soon as the device enters the water. Check for this
by shorting the housing to the ROV frame while the device is powered on. This GFD is caused by
the internal wiring of the device, so the GFD will just have to be tolerated. However, a low side GFD
can be tolerated. A high side or the worst case: a high and low side, should not be tolerated.
● Certain devices connected to a node have internal capacitors connected from +26V to chassis or
26RET to chassis which interfere with the line isolation monitor. As the isolation monitor switches
the measurement point between the two busses, these capacitors are charged and discharged. This
can result in a fault on the +26V bus that is reported on the 26RET bus. When an actual fault res-
istance is low enough (about 75k ohms), the capacitors will charge quickly and no fault will be re-
ported.
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Power System Components 9. Deck Power J-Box
9. Deck Power J-Box

9.1 About Deck Power J-Box 101-7750
The deck power J-box (P/N 101-7750) provides 26 VDC power to the ROV and/or TMS
IPDS when the vehicles are on deck. The deck power J-box receives 28 VDC power
from the communications J-box (P/N 101-7825), which in turn receives power from the
28 VDC power supply located on the rack in the control van.
The deck power J-box has two 26 VDC outputs corresponding to PS1 and PS2. To activ-
ate deck power, attach the 8-pin Burton connector from the J-box output to the Burton
input on the IPDS, turn on the 28 VDC power supply on the rack in the control van,
and press the corresponding PS1 or PS2 “ON” button.
9.2 Deck Power J-Box: Specifications

Deck Power J-Box Specifications
Electrical
Input voltage, minimum/maximum 28 VDC
Output voltage, nominal 26 VDC
Input current, nominal 20 A
Output current, maximum 20 A
Connection 8-Pin Burton Connector
Height 406.4 mm (16 in.)
Width 304.8 mm (12 in.)
Length 231.6 mm (9.12 in.)
Weight in air 30 kg (66 lb)
Environmental
Operating temperature, minimum/maximum 0 °C to +40 °C (32 °F to 104 °F)
Storage temperature, minimum/maximum -18 °C to +50 °C (0 °F to 122 °F)
Humidity 0-100%
9.3 Deck Power J-Box: Installation

The deck power J-box (P/N 101-7750) should be installed on the deck of the ship and connected to the con-
trol van via the power cable.
9.3.1 Mechanical
Mount the deck power J-box to the ship near the LARS, using the four tabs on the top and bottom of the
box.
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9.3.2 Electrical
Run cable (P/N 005-6891) from the J-box (P/N 101-7825) located near the control van and connect to the
26 VDC input on the deck power J-box. Use two cables (P/N 005-6993) to connect to the PS1 and PS2 out-
puts.
9.4 Deck Power J-Box: Troubleshooting, Maintenance, & Service

WARNING! HIGH VOLTAGE SHOCK HAZARD! Lethal voltage is present in the deck power J-box.
Only trained electrical personnel should open it for maintenance or service. Ensure all power to the
control van is locked out/tagged out before opening the deck power J-box front panel.
● If the green “ON” lights do not come on when PS1 or PS2 is pressed and the 28 VDC supply power
is on in the control van, check that all cables are connected properly and then tighten all the screws
on the terminals for the push buttons and contactors inside the J-box. If the lights still do not come
on, replace the unit.
● Periodically check the push button and contactor terminals inside the J-box and tighten if neces-
sary.
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Digital Telemetry System 1. About Digital Telemetry System and Components
Digital Telemetry System
1. About Digital Telemetry System and Components 147

2. Digital Telemetry System: Rapid Spanning Tree Protocol (RSTP) 150
3. About DTS Network Viewer Tool 151
4. DTS Network Viewer: Getting Started 153
5. Subsea Node 164
6. Subsea Node Interface Module 196
7. SeaNet Cables and Penetrators 204
8. Cable & Slip Ring Terminations 215
9. Surface Rack Node 242
1. About Digital Telemetry System and Components

The DTS is the communication backbone of the ROV system. All signals and data are transmitted through
the DTS. The DTS consists of the control hardware and software as well as the digital information passing
over these components. The DTS system runs independently of the client computers, the server computer
and the Real Time Computer (RTC.)
The digital telemetry system (DTS) consists of a set of components that process, evaluate, route, send, and
receive digital signals between the control station, the subsea TMS and ROV, and the subsea devices, provid-
ing sensing, control and navigation data. The DTS also supports multiple low-latency video streams from
subsea cameras to the surface.
1.1 Core DTS Components

● Surface rack node which interfaces between the control station computer network and the subsea
nodes
● Subsea nodes which interface between the surface rack nodes and the subsea sensors, controls,
lights, cameras, and other devices
● Fiber optic cables in the tether and umbilical cables that connect subsea and surface telemetry com-
ponents
● Fiber optic cables linking the subsea nodes
● SeaNet cables connecting the subsea sensors, controls, lights, cameras, and other devices to the
node interface modules
Communications between surface and subsea nodes are carried through a dual-fiber Gigabit Ethernet back-
bone connection. The optical portion of the DTS is compatible with standard single mode (9/125) optical
fiber, and utilizes ST connectors. Internally, each subsea node port has a 10/100 Mbps Ethernet interface
to the telemetry backbone (bus).
For an ROV system using the Hammerhead control system, the interconnect diagram for that ROV shows
DTS communication network connections.
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For an ROV system using the (Silvertip) control system, the general data flow in the DTS network is shown
in Figure 1.
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Figure 1: Typical (Silvertip) control communications network with RSTP
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Digital Telemetry System 2. Digital Telemetry System: Rapid Spanning Tree Protocol (RSTP)
2. Digital Telemetry System: Rapid Spanning Tree Protocol (RSTP)

The Digital Telemetry System (DTS) maximizes the quality and reliability of communications by:
● Using two fiber optic cables to connect the rack nodes and subsea nodes
● Implementing rapid spanning tree protocol (RSTP) in the node firmware
Dual fibers provide redundancy to network communication paths. Using RSTP, a node can evaluate fiber
paths 1 and 2 for:
● The presence of a signal
● The fewest pass-through connections to the rack node
● Recent availability
The node can then direct its communications to the best path. The node also disables communications on
the other path to eliminate duplicate data traffic to the RTC.
If a fiber cable or an internal component of a node becomes damaged or nonfunctional during operations,
the dual fibers and RSTP technology allow the other nodes to change their fiber paths within seconds to
maintain communications with the surface node(s) and ensure continued system operation.
Node health, fiber health and status, communications routing, and status are reported on the touch screens
for the ROV control system. Control system screens also let you change or override RSTP settings when
necessary.
● Interconnect diagrams for the topside and subsea DTS components are located in the “System
Schematics & Interconnect Diagrams” section in Volume 4: Drawings and Part Lists.
● For more information on using and configuring the RSTP system, see Volume 3: Operator
Controls.
If one of the nodes on the ROV system does not support RSTP, turn off RSTP on all other nodes (see
Turning off RSTP on the facing page).
2.1 Communication Failures & RSTP

Every two seconds, a software packet is sent between all nodes to assess the quality of the communication
links. If the control system detects an unreliable link, RSTP selects a new communication path that
bypasses that link.
A link between two nodes is considered unreliable if:
● Two consecutive packets fail to be received
● A node’s SFP module detects a drop in the incoming fiber light level to less than -23 dbm (this event
may not appear on the GUI display of fiber light levels if the level dropped only momentarily)
Packet Failure Example

The following example shows the sequence of events for a link’s communication failure and eventual recov-
ery.
1. Node 3 sends packets to node 4, and node 4 does not acknowledge receipt of two consecutive packets.
As a result:
a. The communication link between these two nodes is considered unreliable for the next ten minutes.
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Digital Telemetry System 3. About DTS Network Viewer Tool
b. If a better, alternative path is available, the control system selects it for use.
2. During the ten-minute recovery period, node 3 continues to test its connection to node 4 by sending
packets.
a. If packets are successfully received for the next 10 minutes, the link is considered to be recovered.
b. If another failure occurs (two packets fail to be received on two consecutive attempts) before the
recovery minutes have elapsed, the control system adds another ten minutes to the countdown to
recovery. For example, if a failure occurs 5 minutes into the countdown toward recovery, the
control system adds another 10 minutes to the countdown (for 15 minutes total).
2.2 Turning off RSTP

To turn off RSTP, either:
● Disconnect Fiber 1 or Fiber 2
or
● Use NodeChanger.exe (version 2) to disable RSTP individually on each node; note that the RSTP set-
ting must be the same for all topside and subsea nodes (either all on or all off)
You must also configure the topside software to ignore RSTP (contact Technical Support).
2.2.1 Resetting All RSTP Data

To reset all RSTP data, either:
● Power off all nodes (topside and subsea) for at least 20 seconds.
or
● Clear RSTP data using DTS Viewer.
1. Using the control console, verify that all nodes are communicating with the control system.
2. Set the test computer’s IP address to 172.16.0.225.
3. Set the test computer’s subnet mask to 255.255.0.0.
4. Connect the test computer to a spare NIM on the rack node.
5. Run DTS Viewer (version 1.36 or higher) on the test computer.
6. Press “Scan Nodes 1-10.”
7. Verify that all nodes are visible in the “Node Summary.”
8. Select the “RSTP” drop-down menu and then “Clear All Lost Link Counts.”
3. About DTS Network Viewer Tool

A variety of configuration tasks and diagnostic procedures are performed with the software tool DTS
Viewer. This section discusses the DTS Viewer tool and its uses.
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Digital Telemetry System 3. About DTS Network Viewer Tool
3.1 Introduction to DTS Network Viewer
The software application DTS Network Viewer is found in the diagnostic application suite and labeled as
DTS_Viewer.exe. DTS Network Viewer is a stand-alone software application that can run on any stand-
alone computer connected to the DTS via Ethernet link.
3.2 Uses of DTS Network Viewer

DTS Network Viewer is used to:
● create temporary tunnels between 2 SIMs
● create temporary tunnels between VIMs
● inspect the DTS configuration and status
● temporarily modify serial port parameters
Tunneling: a network technology that creates a direct communication link between 2 node modules.
Stand-alone PC: any computer that is not part of the ROV system.
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Digital Telemetry System 4. DTS Network Viewer: Getting Started
Tunneling is a key feature of the DTS Network Viewer. A stand-alone PC running the application can create
temporary tunnels between 2 Serial Interface Modules (SIMs) and between Video Interface Modules
(VIMs.) Tunnels connect interface modules in a client-server relationship. Once the tunnel is created, the
same stand-alone PC can run diagnostic applications on the device at the other end of the tunnel.
Note: DTS Network Viewer requires Microsoft .NET framework be installed on the Stand-alone PC.
Example: As shown in the illustration above, a subsea device is connected to a SIM on node 5 and the
stand-alone PC is connected to a SIM on node 2. If a tunnel is created between the SIM on node 5 and
the SIM on node 2, the stand-alone PC can communicate directly with the subsea device.
Common uses of DTS Network Viewer

● Testing and configuring new serial or video devices (bench-testing)
● Troubleshooting faults within the ROV node network and devices attached to it
● Diagnosing video issues
● Creating configuration and serialization reports
4. DTS Network Viewer: Getting Started

Connect the stand-alone PC and start DTS Network Viewer
1. Connect the stand-alone computer to any network interface module (NIM) using an Ethernet cable.
2. Set the stand alone computer’s TCP/IP settings to a fixed IP between 172.16.1.220 and 172.16.1.250. If
the stand-alone computer’s TCP/IP settings are set to ‘Obtain an IP address automatically’ or if the IP
address is set out of range, the application will not be able to communicate with the DTS.
a. Start Button > Control Panel > Network Connections
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b. Right click on the Local Area Connection > Properties.

c. Scroll to TCP/IP > Properties.
d. Set to ‘Use the following IP address’ and enter an IP address between 172.16.1.220 and 172.16.1.250).
e. Set the subnet mask as 255.255.0.0
3. Start DTS Network Viewer by double clicking on it.
Note: If the network connection settings are incorrect, the message below will display information to
help correct the issue.
4.1 DTS Network Viewer: Tab 1- System Status

With the application running, click ‘Scan ALL.’ This broadcasts a request across the network to retrieve con-
figuration information about the nodes and ports. Sometimes DTS Network Viewer may not gather inform-
ation about a particular node. This can happen when another part of the ROV system takes network pri-
ority. When this happens, select the node that wasn’t scanned and click ‘1 Node Only.’
The first page (tab labeled System Status) displays system information. The System Status page is divided
into 4 areas labeled Node Summary, Interface Module Summary, Node Properties, and IM Properties.
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The two summary areas on the left of the page (Node Summary and Interface Module Summary) have
selectable fields. When a node and/or module is selected from the left side, the parameters of the selected
components are displayed on the right side. Selections are indicated by the orange box next to the row of
the selected item (shown at 1 and 2.)
1. Select a node from Node Summary. The selected node’s properties will be displayed in the Interface
Module Summary section and the Node Properties section.
2. After selecting a node, a particular Interface Module (NIM, VIM or SIM) can be selected from the
Interface Module Summary section. The properties of the selected Interface module will be displayed in
the IM Properties section.
Note: In the example above, the orange box indicates node 3 is selected in the Node Summary area.
The Interface Module Summary area is displaying the modules on node 3. The orange box in the Inter-
face Module Summary indicates node 3, port 4 is selected and the properties on node 3, port 4 are dis-
played in the IM Properties area to the right.
4.2 DTS Network Viewer: Tab 2 - Serial Setup

The Serial Setup tab provides the tools to setup and configure temporary tunnels between 2 SIMs. The
Serial Setup tab contains 3 areas: Existing Serial Tunnels, Temporary Adjustments to Tunnels, and Tem-
porary Serial Config.
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Serial Setup: Existing Serial Tunnels area

The Existing Serial Tunnels area displays existing tunnels which can include permanent system tunnels
and/or temporary tunnels created with DTS Network Viewer. The screenshot above shows 7 existing tun-
nels. The first tunnel is between the Surface Node 1 Port 1 (N1P1) and the Subsea Node 4 Port 16 (N4P16).
Serial Setup: Temporary Adjustments to Serial Tunnels area

This Temporary Adjustments to Tunnels area is used to create new tunnels between 2 SIMS or to modify
existing tunnels.
To modify an existing tunnel, select it from the Existing Serial Tunnels area and then edit the parameters in
Temporary Adjustments to Tunnels area. To create a new tunnel, select the node and ports of the topside
and subsea modules, specify the properties of the tunnel and then apply the tunnel. This process is
explained in detail below.
Note: DTS Network Viewer creates temporary tunnels. Tunnels created in DTS viewer are forgotten
when the nodes are power cycled or the ROV system is rebooted.
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Serial Setup: Temporary Serial Config area

The Temporary Serial Config area is used to identify and reconfigure a single SIM. The ‘Auto Detect +
Apply’ feature is sometimes useful when creating tunnels.
Clearing an Existing Tunnel

To clear a tunnel, select the tunnel from Existing Serial Tunnels area. Then click ‘Clear tunnel at Subsea’
and click ‘Clear tunnel at Topside’. This will clear the tunnel and remove it from the list of existing tunnels.
Creating and identifying a tunnel between 2 SIMs

Temporary tunnels between 2 SIMs can be created or modified using the Temporary Adjustments to Tun-
nels area.
To create a tunnel:
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1. First, make a serial connection between the stand-alone PC and a topside SIM module. Typically, an RS-
232 cable will be connected to a serial adapter which connects to the serial port on the stand-alone PC.
2. Select the node and port for both topside and subsea module locations.
3. Click ‘Get Parameters’ to load both the current topside and subsea port communication parameters.
Note: The system does not auto detect a device’s correct communication settings (baud rate, data,
etc.); it only reads the current settings.
4. Copy the topside settings to the subsea settings by clicking ‘Copy to Subsea ->’. The two unconfigured
ports may show different settings (data, baud, parity, stop, mode and delay) but these settings should be
the same for the topside and subsea.
5. Set the Interf (interface) and Cross (crossover/straight) fields individually for the device connected to
that particular interface module. Interf and Cross fields are frequently different between the topside and
subsea, unlike Baud, Data, Parity, Stop, Mode and Delay which will be the same for topside and subsea.
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Note: The ‘Auto Detect + Apply’ button in the Temporary Serial Config area can detect ‘Cross’ set-
tings for devices which continually output data. The ‘Cross’ setting for most RS-232 devices can be
auto-detected but a few, such as the UCM, must be manually configured.
6. Click ‘Apply Tunnel + Parameters’ to apply the SIM parameters and the tunnel.
Note: A serial tunnel can have mixed serial interface protocols. A subsea device running RS-485 can
communicate with the stand-alone PC’s serial port (RS-232.)
Detecting and Configuring a Single SIM

The Temporary Serial Config area is used to identify and set the configuration of a single port (rather than
working with 2 ports as a tunnel.) SIM settings can be changed without altering the definition of a tunnel
which is much safer; particularly when dealing with devices used by the RTC.
This area is also used for auto-detecting the serial polarity of a SIM when creating a tunnel.
To inspect or alter a SIM:
1. Select the node and port from the top area.
2. Click ‘Get Params.’ This command interrogates the system to determine the existing set parameters for
baud rate, data bits, parity, stop bit, mode, and inter-character delay.
Note: Any changes need to be manually set. If any changes are made, the parameters need to be
applied using the ‘Apply Params’ button.
3. If the connected device is an RS-232 device, click ‘Auto Detect + Apply’ to detect the Cross
(crossover/straight) parameters. To detect these parameter, each wire on the SIM is measured and the
transmit (Tx) and receive (Rx) wires are identified.
a. For SIMs with firmware version 14 or higher the AutoDetect feature will also measure the baud rate
of incoming RS-232 traffic. This feature requires that the serial device is actively communicating
with the SIM. In a serial tunnel, this is usually the topside SIM.
b. Select the topside SIM in the “Temporary Serial Configuration” panel.
c. Ensure the topside serial device/laptop is communicating.
d. Click “Auto-Detect and Apply”.
Note: Other serial settings, e.g. data bits and parity must still be set manually.
In general, the ‘Auto Detect + Apply’ feature works well on most devices. DTS Network Viewer can
identify most RS-232 devices properly but it will not identify RS-485 devices (circuit limitation). The
auto detect feature also doesn’t work on devices that don’t transmit data in their idle state. For the
few devices that don’t transmit data until requested, such as the UCM, the settings must be known by
the user.
4.3 DTS Network Viewer: Tab 3 - Video Setup

A Video Interface Module (VIM) is identified as either a client module (typically topside) or a server module
(typically subsea.)
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1. Select the node and port number of the client VIM.
Video Setup
Connects to
'Server VIM' Camera
‘Client VIM’ Video Output
Note: Server VIMs can multicast. Multiple Client VIMs can simultaneously display video from a
single Sever VIM.
2. Select the node and port of the server VIM. Only one camera can be selected for any subsea port.
3. Select the camera format (NTSC or PAL.) The server and client formats must match.
4. Click Apply Route.
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Note: If NIM or SIM is selected on the Video Setup page, the program will report an error message
explaining the selected module is not a VIM. See below.
4.4 DTS Network Viewer: Tab 4 - Port Power Page

The Port Power page provides the ability to select and toggle power on particular node and port. If the but-
ton shows orange, the port should be on. If the port is changed from another application (such as the con-
sole) the page won’t show the current port status. Using the “Refresh” button, the current state can be seen.
4.5 DTS Network Viewer: Tab 5 - Reports

There are several types of reports that can be run in DTS viewer. The two most commonly used reports
include:
Network map +firmware versions

— This is report is used to verify the configuration of all nodes and ports. This report is useful
when running Config Application to verify the modules and locations. It is also useful to
determine if your devices are of the current revision level. For example, this is an efficient
way to confirm if all the VIM’s have been upgraded.
Network map + MAC address

— This report is typically used to verify the unique MAC address for all nodes and modules. If
there is a repeated MAC address, the report will indicate the modules with the duplicate
address.
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Querying for Available IP Addresses

DTS Network Viewer can display currently available IP addresses. The pull-down menu labeled ‘Ethernet’
has a utility to display an available IP address for use on the stand-alone PC.
Querying for Available IP Addresses

Baud Data Bit Stop
Device Parity Mode Delay Notes
Rate Depth Bit
Topside Equipment
Avitech MC8000 57,600 8 N 1 RS232 10
Avitech VCC4CIP 57,600 8 N 1 RS232 10
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Querying for Available IP Addresses (continued)

Baud Data Bit Stop
Rate Depth Bit
Avitech VCC8008 57,600 8 N 1 RS232 10
PDU Relay Control 9,600 8 N 1 RS232 10
Survey String 4,800 8 N 1 RS232 10 (Configurable from Repository)
defaults to 4,800 baud at a 2 Hz rate
Ocelott Video Switcher 9,600 8 N 1 RS232 10
ISIS Video Switcher 9,600 8 N 1 RS232 10
(both 16 and 32 channel)
Puck Controller 38,400 8 N 1 RS232 10
Switch Panel 38,400 8 N 1 RS232 10
Vigra Annotator 9,600 8 N 1 RS232 10
Joystick Controller 9600 8 N 1 RS232 10
Kongsberg MS1000 115,200 8 N 1 RS232 10
Sonar Processor
Tritech Dual Frequency 115,200 8 N 1 RS232 10
Sonar Processor
Subsea Equipment
Camera 9,600 8 N 1 RS232 10
TCU 38,400 8 N 1 RS232 10
RotAct 38,400 8 N 1 RS232 10
HPU Control Maniold 38,400 8 N 1 RS232 10
UCM 38,400 8 N 1 RS232 10
Altimeter 9,600 8 N 2* RS232 10 Self streaming device
Depth Sensor 9,600 8 N 1 RS232 10
LCU 38,400 8 N 1 RS232 10
Compass 9,600 8 N 1 RS232 10
ValvePackSA 38,400 8 N 1 RS232 10
RDI DVL 9,600 8 N 1* RS232 10 Self streaming device
Xbow MRU 38,400 8 N 1 RS232 10
CDL MiniPOS/ Mini 115,200 8 N 1 RS232 10
RLP
Octans MRU 115,200 8 N 1 RS232 10 115,200 for navigation
38,400 8 N 1 38,400 for control
T4 19,200 8 E 1 RS232 10
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Digital Telemetry System 5. Subsea Node
Querying for Available IP Addresses (continued)

Baud Data Bit Stop
Rate Depth Bit
CDL/RDI MRU/DVL 115,200 8 N 1 RS232 10 115,200 for navigation
combo 38,400 8 N 1 38,400 for control
3-Station Valve Pack 38,400 8 N 1 RS232 10

RovNav5 9,600 8 N 1 RS232 10
Kongsberg MS1000 115,200 8 N 1 RS232 10
Sonar
Tritech Dual Frequency 115,200 8 N 1 RS232 10
Sonar
Responder 9,600 8 N 1 RS232 10 Use’s TTL channel
Valeport CTD 9,600 8 N 1 RS232 10
Valeport SVS (sound 9,600 8 N 1 RS232 10
velocity sensor)
Pipe/Cable Tracker TSS 9,600 8 N 1 RS232 10 AC power
440/350
5. Subsea Node
5.1 About Subsea Node 101-7306
Subsea node 101-7306 (Figure 2) controls, evaluates, and routes telemetry and 26 VDC power for attached
devices through 16 individual node ports. This model is enabled for RSTP (rapid spanning tree protocol),
which allows it to seek the best of two redundant fiber paths (F1 or F2) to the surface node(s).
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Figure 2: DTS node and interface module features
Other features:
● Nodes can be added to the node chain to provide additional ports.
● Each node is rated for a total output of 30A.
● A line isolation monitor measures the resistance from both sides of the DC bus to the vehicle frame.
If an isolation fault occurs, an alarm will be displayed/sounded at the GUI (graphical user interface).
● LED indicators for 26V power and node “health” are located at the 26V power-in port and visible
through the transparent connector of the 26V power cable.
● Water detection sensing.
● 4 Km depth rating.
5.2 Subsea Node: Ports and Modules

5.2.1 Node Ports
Communication Types
The 16 node ports are configured for serial, video, or Ethernet communication with serial (SIM), video
(VIM), and NIM (network) interface modules. Each module translates external signals through a 10/100
Mbps Ethernet interface for transmission along the Ethernet backbone (bus).
Power Handling
Each port is capable of supplying up to 15A @ 26 VDC continuous electrical power. Since a node is rated for
30A, maximum, all ports cannot provide power at this level. A device requiring high current must only be
Page 165 011-0552-06

connected to a node where the cumulative current draw of ALL devices will not exceed 30 Amps.
Inrush Tolerance
Port inrush currents greater than 15A are tolerated for approximately 100 ms before the “slow-blow” soft-
ware fuse is tripped. An inrush current of 19 Amps or greater trips the “instantaneous” software fuse. Port
power is remotely switchable from the control console GUI. Ports equipped with a SIM (serial interface
module) are also capable of supplying 12 VDC at 750mA.
5.2.2 Port Interface Modules

For information on the port interface modules, see the “Subsea Node Interface Modules” section in this
volume.
Caution! Do not remove any SIM, VIM, NIM, or LIM while the node is powered. THE NODE WILL
BECOME INOPERABLE. Always disable power to the node before changing an interface module. If a
device is powered by a source other than a node but connects to the node, also disable power to the
device before removing the interface module.
5.3 Subsea Node: Device Configurations

5.3.1 Node Configurations
Nodes are supplied with several configurations of interface modules and each configuration is identified by
unique part number (101-7355 and variants). The specific nodes used in this system are identified on the
part list for the vehicle on which they are used.
5.3.2 Node Port/Device Configurations

Specific devices connected to each node, as shipped, are shown on the System Interconnect Diagram loc-
ated in the System Schematics & Interconnect Diagrams section of Volume 4: Drawings and Part Lists.
You can change or reassign node port functions:
● For Silvertip — use the Config App (configuration application)
● For Hammerhead — use the "CONFIGURATION" section from either client
For details, see Volume 3: Operator Controls.
5.4 Subsea Node: Installation & Removal

Drawings and part lists of mounting/installation kits for the components listed below, and/or related assem-
blies that include the components, are located in Volume 4: Drawings and Part Lists.
Caution! Do not replace subsea node model 101-7306 with any older model node. The RSTP func-
tions will be lost.
5.4.1 Mechanical
The node is secured to its mounting brackets by through-bolts at each corner and additional lock nuts
(Figure 3). The through-bolts and their first nuts also secure the node case halves. DO NOT loosen or
remove them. Two of the through-bolts also act as flow-through passages for charging, draining, and bleed-
Page 166 011-0552-06

ing compensation fluid in the node and have O-rings on their shanks. When removing the node from its
brackets, avoid turning these bolts as this can cause premature wear on the O-rings.
Figure 3: Node assembly, mounting, and bleed bolts
5.4.2 Electrical
The node is powered with 26 VDC from the IPDS. To connect the power cable:
1. Ensure power is off and no residual power remains in the power converter status window (LEDs are
fully extinguished).
2. Bleed the power cable hose by depressing the valve in the center of the connector until no air remains
(Figure 4).
3. Ensure the O-ring is installed and align the connector with the three prongs protruding from the node.
Press the connector straight on, making sure the O-ring is not pinched.
4. Install O-rings and shoulder washers onto the bolts and insert the bolts through the connector.
5. Torque the bolts to 2.82 Nm (25 in-lb.)
Figure 4: Power connector cross-section
5.4.3 Fiber Optics

All node communications are carried through fiber cable 101-5010 and its length variants. The node con-
nection points are shown in Figure 3.
To connect the fiber cables:
1. Install a fiber cap over the fiber connector recessed in the node end of the cable assembly and depress
to bleed. DO NOT press directly on the fiber end as this may damage it.
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2. Loosen the M4 screw securing the fiber retaining clip on the fiber dome, lift the clip, and fully insert
the cable connector until it is flush with the dome face. See Figure 5 for fiber orientation.
3. Lower the retaining clip until is rests against the connector and lightly tighten the M4 screw.
Cable part lists and drawings are located in Volume 4: Drawings and Part Lists.
Figure 5: Dome fiber optic connections
5.4.4 Compensation
HD ROV Systems
Fittings (JIC) for connecting a compensation line and bleeding the node are located at opposite corners of
the node frame. See HD Node Compensation: Fill, Bleed, and Drain on page 1 for complete details.
Figure 6: Typical HD node relief valve (bleed) fitting
UHD-III ROV Systems

All nodes are connected to the DC compensation circuit. A fitting (JIC) for connecting the compensation
cart vent line is located near the top of each node. See Rapid Fill and Bleed Compensation Cart on
page 275.
5.5 Subsea Node: Troubleshooting

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5.5.1 Power and Telemetry

LED status indicators for 26 VDC power and node “health” are located at the 26V power-in port and visible
through the transparent connector on the power cable (see Figure 7).
Figure 7: Node status LED indicators
5.5.2 Fast & Slow Software Fuses

Device power (26 VDC) supplied through each node port/interface module is protected with fast and slow
software fuses within the node.
● Inrush currents greater than 15A are tolerated for approximately 1/10 of a second before the “slow-
blow” software fuse is tripped.
● Inrush currents greater than 19 Amps instantaneously trip the fast software fuse.
A tripped software fuse opens the 26V power and return lines to the device and creates an alarm in the con-
trol system touch screen interface. Interface module power is not affected by a tripped fuse.
Typical causes for a tripped fuse are shorts within the device or device cable and excessive current draw by
the device. Disconnect the device and cable, and reset/turn on the port. If the port is OK, replace or test
the cable for shorts and replace the device. If the fuse trips with nothing connected, the short may be
within the interface module or the node.
5.5.3 Water Detection

This component is equipped with a water detection sensor. The presence of water produces a critical alarm,
indicated by:
● Red WATER indicator lights on the main menu bar and DASHBOARD status bar.
● An alarm message on the ALARM screen and the DASHBOARD.
Note: The Hammerhead control software provides additional WATER alarm indicators. See the Con-
trols Manual for more information.
5.5.4 26 VDC Line Isolation (“Ground Fault”) Monitor

Each node is equipped a line isolation monitor circuit that is used to determine the resistance between the
vehicle frame (“chassis”) and the 26 V power (“high-side”) and 26 V Return (“Low-side”) lines of the 26
VDC bus (26 V B\bus power originates in the 26 V to 26 V power converter and is distributed to the nodes
and devices connected to the nodes). If multiple nodes are connected to the same bus, the line isolation
Page 169 011-0552-06

monitor in the software-designated first node in each vehicle (TMS, ROV) is enabled and those on the addi-
tional nodes are set to standby mode.
When high-side or low-side line isolation drops below 100 kilohms anywhere on the 26 V bus, the control
system triggers an alarm in the control system touch screen interface. See Volume 3: Operator Controls for
more information.
Common causes for a line isolation fault are:
● Water intrusion during subsea operation.
● Water intrusion into a SeaNet connector/penetrator interface.
● Incorrect power connections in a device connected to a node port (at startup or when turning on a
node port).
● Short or leakage between the 26RET and chassis.
For detailed information on troubleshooting 26 VDC line isolation faults, see the “Line Isolation (Ground
Fault) Troubleshooting” section.
5.6 Subsea Node: Maintenance and Service

5.6.1 Maintenance
Each node has two anodes. Replace an anode when less than 1/3 of its mass remains. Use Aqua Shield, or
equivalent, on the new anode threads or mounting hardware.
5.6.2 Service
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Subsea Node: Remove and Install

This service instruction explains how to remove and install a subsea node.
Tools Compensation cart (HD systems) or rapid fill and bleed cart (UHD-III systems), hex keys (4 mm, 5 mm, 6 mm),
torque wrench (0-10 Nm [0-75 in-lb])
Personnel 1 worker
Node Compensation: Filling, Bleeding, and Draining on page 1
Parts-Kits None
Safety Electrical shock (26 VDC), compressed air
Consumables Cable ties
The main body of the node is assembled from two machined aluminum housings. The node housings are
mounted to the vehicle by the four bolts at the corner of the node. Two of the four bolts are unmodified
M6 HHCS (P/N 002-8005-45) (A). The other two bolts (P/N 001-7509) (B) are drilled and have O-rings to
provide a compensation fluid path.
Removal
1. Prepare the system for safe working conditions, lock out and tag out the PDU.
Caution! Always power down the instrument circuit.
2. Decompensate and disconnect the QD, separating the node from the compensation (see Node
Compensation: Filling, Bleeding, and Draining on page 1).
3. Disconnect the SeaNet cables from the node and install caps and plugs to the cables and ports.
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26V Power Cable

1. Ensure that the power is off and no residual power remains in
the power converter module status window (LEDs must be
fully off).
— For HD and UHD-III systems, the power converter
is the IPDS HV Pak.
— For UHD-II systems, the power converter is the
Vicor module.
2. Disconnect the 26V power cable from the node [(2x) M5
SHCS].
Compensated Fiber Optic Cable
1. Loosen the M4 screw (H) that secures the fiber retaining clip
(F) to the fiber dome.
2. Remove the fiber optic cable by lifting the retaining clip and carefully pulling each fiber cable
connector from the fiber dome.
3. Install fiber caps over the exposed fiber connectors in the node dome and cables.
Caution! DO NOT press directly on the fiber end. This may damage it.
4. Remove the node from the node mounting brackets by removing the outer-most nuts at the 4 corners
of the node (4x M6).
Caution! Do not loosen the inner lock nuts (C). The compensation bolts (B) can rotate within the
housing and damage the bolt’s O-rings (E).
Installation
26V Power Cable
1. Ensure that the power is off and no residual
power remains in the power converter status
window (LEDs must be fully off).
— For HD and UHD-III systems, the
power converter is the IPDS HV Pak.
— For UHD-II systems, the power con-
verter is the Vicor module.
2. Bleed the power cable by depressing the valve
in the center of the connector.
3. Ensure that the O-ring is on the connector and

press the connector straight into the node socket.
Make sure the O-ring remains in place.
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4. Install the O-rings and shoulder washers onto the bolts. Fasten the power cable to the node (2x M5
SHCS; 5 Nm [45 in-lb]).
Compensated Fiber Optic Cable
1. Bleed each cable before connecting it to the node:
a. Install a fiber cap over the fiber connector recessed in the node-end of the cable assembly.
b. Depress the cap to bleed. Do not press directly on the fiber end, as this may damage it.
2. Lift the retaining clip, and fully insert each cable connector until it is flush with the dome face.
3. Lower the retaining clip until it rests against the connector. Tighten the M4 screw.
Remaining Steps
1. Install the node onto the node mounting brackets (4x M6; 9 Nm [6.5 ft-lb]).
2. Connect the SeaNet cables to the node.
3. Connect the compensation QD to the node.
4. Bleed the node and the SeaNet cables (see Node Compensation: Filling, Bleeding, and Draining on
page 1).
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Subsea Node PCA: Remove and Install

This service instruction explains how to remove and install the printed circuit board (PCA) assembly (P/N
101-7306) housed in a subsea node assembly.
Tools Diagonal cutters, notched pliers, hex keys (1/8", 2.5 mm, 3 mm, 4 mm, and 5 mm), wrenches (5/16", 9/16", 3/4", 7
mm, and 10 mm), sockets (7 mm and 10 mm), vacuum, hand pump, torque wrench (0-10 Nm [0-100 in-lb])
Personnel 1 worker
Sub-Procedures None
Parts-Kits Kit (P/N 010-1475-1)
O-ring, 2-045, Buna 70 (P/N 004-0049) [1x]

O-ring, 2-044, Buna 70 (P/N 004-0103) [1x]
O-ring, 2-046, Buna 70 (P/N 004-0110) [2x]
O-ring, 2-008, Buna 70 (P/N 004-0172) [1x]
O-ring, 2-106, Buna 70 (P/N 004-1011) [9x]
O-ring, 2-382, Buna 70 (P/N 004-1012) [1x]
O-ring, 2-127, Buna 70 (P/N 004-0046) [2x]
Anode, galvanic (P/N 002-1440) [2x]
Safety Electrical assembly work
Consumables O-ring lubricant, cable ties, Loctite #242 blue, compensation fluid, nitrogen for pressure test
Note: The node may contain a residual quantity of oil after the decompensation process. The work
area should be able to accommodate oil. It is also a good idea to have a few small containers to store
the fasteners.
Removal
1. Clear an area of the work bench large enough to accommodate both halves of the node, and all of the
modules. The area should be clean and clear of debris. You can spread rags or paper towels in the area
to lay the components on.
2. Cover the SeaNet connectors on the modules with blanks or rubber covers. Take a note of the type of
module installed on each port.
3. Remove the anodes.
4. Lay the unit down with the fiber dome port and power connector port facing down.
5. Remove all nuts and washers from the port modules (A).
6. Remove all the port modules (B).
7. Remove the dome cover nuts and washers (C).
8. Remove the dome cover.
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Figure 8
9. Disconnect the two fiber optic cables from the board. Push the blue tab to release the fiber optic
cables.
Figure 9
10. Remove the blue and green SFP modules and install them in the new node PCB.
11. Push the fiber optic cables and connectors carefully through the holes in the PCB.
12. Flip the unit over.
Note: In the next step, be careful when you remove and handle the fiber dome components. The fiber
cables in the fiber dome lead through the circuit board and connect to the other side. You can damage
these fiber optic cables if you pull out the dome with the fiber optic cables still connected.
13. Remove the nuts and washers and carefully remove the fiber dome and cables (F).
14. Remove the nuts and washers securing the port modules (D).
15. Remove the port modules (E).
Page 175 011-0552-06

Figure 10
Note: The lower half node case bolts will stay in place as long as you do not move or lift the lower
node housing half (G). Keep the unit on a flat surface.
16. Remove the remaining nuts and washers and the node compensation bolts and corner mounting bolts
from the perimeter of the DTS node housing. Separate the node case nuts and bolts.
17. Separate the DTS node upper housing half.
18. Remove the PCA (H).
19. Remove the perimeter O-ring seal (I).
20. Remove the housing fiber dome O-rings from both halves of the housing (J).
21. Remove the node housing bolt O-rings (K).
22. Remove and inspect the poppet and spring assembly. Remove the three contacts and screws (L).
Page 176 011-0552-06

Figure 11
Printed Circuit Board Installation

1. On older revisions, remove the heat sinks from the two Broadcom chips (if installed) and cut the test
point pins on the PCB to half length.
2. Using the M3x8 SHCS, install the three contacts (L) from the old PCB onto the side of the new PCB
with port numbers 9 through 16. Install hand-tight until seated, and torque to 1.6 Nm (15 in-lb). Use
notched pliers to prevent the contacts from spinning when the SHCS are tightened.
Figure 12
3. Inspect and clean both halves of the node housing.

4. Install a new perimeter O-ring (P/N 004-1012) (I) in the groove of the case.
Page 177 011-0552-06

5. Verify that a new O-ring (P/N 004-0172) (L) is in the dovetail groove of the poppet.
6. Install new O-rings (P/N 004-1011) (K) onto the case bolts in nine places in the center region of case,
as shown in Figure 12 on the previous page.
7. Slide the spring over the center tube of the power connector plate, and install the poppet over the
spring in the power plate.
8. Install new O-rings (P/N 004-0110) (J) into the grooves around the fiber-housing opening in both
halves of the case. Use a generous amount of O-ring lubricant to secure the O-ring in the groove.
9. Install the PCB onto the case with contacts (L) facing up. Ensure that the poppet pushes freely up and
down through the PCB.
10. Install the O-ring (P/N 004-0046) into the groove on the upper and lower half of the housings around
the power connector opening. Use a generous amount of O-ring lubricant to secure the O-ring in the
groove.
Figure 13
11. Lower the case over the studs with the logo side facing upwards. Install wave washers on each
protruding stud. Apply hand pressure surrounding the case studs in the center of the case to fit the
case halves together.
Page 178 011-0552-06

Figure 14
12. Apply Loctite to the case bolts. Hand-thread the case nuts over the center studs and secure them
finger-tight.
13. Apply Loctite and hand-thread the balance of the case nuts onto the protruding studs.
14. Verify that the perimeter O-ring is in the proper position.
15. Starting at the center of the assembly and working outwards, torque the case nuts first to 1.6 Nm (20
in-lb), then to 2.7 Nm (25 in-lb).
16. Install the SHCS nuts, each with two wave washers and Loctite, in the five remaining holes in the
perimeter of the case. Torque the nuts first to 1.6 Nm (20 in-lb), then to 2.7 Nm (25 in-lb).
17. Referring to the assembly drawing, verify that the torque of the case nuts and hex nuts is correct.
Verify that each bolt and nut has a wave washer between it and the case.
18. Inspect the inner edge of the large oval region to make sure that the O-rings on both sides of the board
are not visible.
19. Install bleed hose (P/N 101-5309) assembly into corner location adjacent to port 1.
20. Install fill hose assembly into corner adjacent to port 8.
21. Install the corner bushings, bolts, washers, and Loctite nuts into the remaining two corner locations.
Bolts should face the same direction as other two corner bolts. Torque the nuts to 5.4 Nm (48 in-lb).
22. If they were removed, install the SFP modules into the PCB SFP cages.
23. Install new O-rings (P/Ns 004-0049 and 004-0103) onto the fiber dome.
Page 179 011-0552-06

Figure 15
24. Feed the fiber connectors from the fiber dome through the PCB, starting from the power contact side
and moving to the fiber SFP side. Lay the fiber cable out and install the fiber dome into the case.
Attach the dome with the hex nuts and washers and torque to 2.7 Nm (25 in-lb).
Note: You may need to hold the case nut and bolt to prevent them from turning in the case.
Note: To make it easier, remove the fiber dome test port plugs to reduce the back pressure when seat-
ing. Place the dome down evenly and press equally on both ends of the dome to seat the O-rings cor-
rectly.
25. Make sure that all of the fiber connections are clean and free of any debris.
26. Connect the fiber connectors from the fiber dome to the SFP modules. Route the fiber cables to absorb
cable slack (as show in Figure 16 below) to avoid pinching the cables during dome installation.
27. Verify that the cables lead straight out of the pressure connectors with no tight bends before they go
up through the slots in the PCB.
Figure 16
28. Install the blank dome into the case. Attach the dome with hex nuts and washers (2.7 Nm [25 in-lb]).
Note: You may need to hold the case nut and bolt to prevent them from turning in the case.
29. Inspect the anodes. Discard them if they are more than 20% depleted. Install new anodes hand-tight
into the housings using Aqua Shield grease.
Page 180 011-0552-06

Module Installation
Install all of the correct modules in the proper locations. Check to make sure that the O-rings are clean and
the modules free of any dirt or moisture.
Testing for Leaks

Pressure Test
1. Cover all module ports, and block one compensation/bleed hose.
2. Attach the pressure gauge and nitrogen tank or compensation cart to the other compensation/bleed
hose.
3. Pressurize the compensated volume to 15 psi, and let it sit for one hour.
4. The test is successful if there is no drop in pressure.
Vacuum Test
1. Remove all hex head plugs from the domes. Install two ST adapters from the vacuum test kit into the
O-ring port of the dome.
2. Attach the hose and hand vacuum pump to the dome. Pull 25 in/Hg of vacuum and hold it for 15
minutes. Repeat this process for the opposite side O-ring cavity. The test is successful if no vacuum is
lost.
3. Install the vacuum adapter into the dome. Repeat the above steps for the other two ports. Ensure that
all plugs remain uninstalled until the test is complete. The test is successful if no vacuum is lost.
4. Install the plugs into the ports on the dome.
Page 181 011-0552-06

Subsea Node: Configure ID Number, RSTP and VLAN Status

This service instruction explains how to configure subsea nodes for identification (ID) number, RSTP
status, and VLAN status. You must use this procedure when you add a node to an ROV system or replace a
node with a spare.
Note: This service instruction applies only to ROV systems using Hammerhead version 4.2 and
above.
Note: VLAN status is typically used with UHD-III ROV systems but not HD ROV systems.
Tools Laptop (PC), Node Changer software (P/N 014-0757), RJ-45 Ethernet cable (P/N 005-3941), AC to 24 VDC (P/N 101-
5530), rack node test NIM (P/N 101-5117-2)
Personnel 1 worker
Sub-Procedures Node Compensation: Fill, Bleed, and Drain on page 1
Subsea Node: Remove and Install on page 171
Parts-Kits None
Safety General shop conditions, electrical shock hazard, high-pressure hydraulic systems
Consumables None
For reference, see:

● ROV system interconnect drawing (the sheet with node configuration information)
● DTS node (P/N 101-7306) drawing and part list
Each node has a unique identification (ID) number which locates its position in the node chain from top-
side (#1) to the last node on the ROV. The ID numbver also matches the third number in the node's IP
address in the form 172.16.X.17, where X is the ID number.
When you install a spare node (a factory-configured spare or a previously installed spare), you must con-
figure the spare node’s ID/IP address to match the ID/IP address of the node it is replacing. The software
program Node Changer is supplied with the technical manual digital files to let you configure the new node.
Configuring a new node is easiest to do on a service bench, but can also be done while the node is mounted
on ROV system equipment. The items that are needed to configure the new node are located in spares kit
008-0317.
Caution! Do not replace a node model 101-7306 with any older model, or you will lose RSTP and
VLAN capability.
Installing Node Changer

To use Node Changer, the program must first be installed on a computer (PC) that can be attached to the
node.
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1. If the Node Changer program in not already installed on the computer that you will use for the node
configuration, you must copy Node Changer from Support Files\4 - Test Software\ on the CD/flash
drive. The folder name will include the Node Changer part number (P/N 014-0757). Be sure that you
copy the correct version of Node Changer for your control system software version.
2. Copy the folder and all its contents onto the computer that you will attach to the node.
3. Go to the folder containing the Node Changer software.
4. Double-click Setup.exe to begin the Node Changer installation wizard, and follow steps in the wizard to
install Node Changer. (If the Microsoft .NET framework has not already been installed on the
computer, part of the wizard will include .NET installation.)
Changing a Node's ID Number, RSTP Status, and VLAN Status

1. Connect to the node a computer that contains the installed Node Changer program.
a. Disable power to the node.
b. If the node contains compensation fluid, drain the fluid (see Node Compensation: Fill, Bleed, and
Drain on page 1).
c. If the node is already installed on ROV system equipment, disconnect its fiber cables.
d. Remove any interface module (can be a SIM, VIM, or NIM) from the node and replace it with a
rack node test NIM (P/N 101-5117-2). Make sure that the test NIM is firmly seated. Connect an
Ethernet cable (P/N 005-3941 or equivalent) between the PC and the NIM.
2. If the node is on a bench, connect power

converter 101-5530. If the node is on ROV system
equipment, connect the 26V power cable. Be
prepared to observe the green LED, which will
indicate the node ID number as explained below.
● The illuminated red LED indicates that 26V
power is present in the node. The illuminated
green LED indicates that the node has passed
its internal self checks and is ready to operate.
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● When 26V power is first applied to nodes that have identification (ID) numbers 1 through 10, the
green LED will flash to indicate the node’s identification number (once for node 1, twice for node
2, etc.), will pause, and then will remain lit. (If the LED does not blink, the node ID number is
likely zero, which is the number assigned to node factory spares.) You will need the node’s current
ID number to assign a new one.
3. Verify that the computer’s IP address is set to communicate with the node.
Note: Before you make any changes to computer settings, record current settings so they can be reset
if necessary.
a. Select Start > Settings > Network Connections (or Control Panel > Network Connections).
b. Double-click the Local Area Connection> for the desired Ethernet port, and then select Properties.
c. Select Internet Protocol (TCP/IP) and then Properties.
d. Confirm or set the following:
— Check Use the following IP address.
— Set IP address to 172.16.1.220.
— Set Subnet mask to: 255.255.0.0.
— Select OK.
e. If you were unable to use the green flashing LED to determine the node ID number, run DTS
Network Viewer software (see the “DTS Test & Configuration Software” section) to learn the node
ID number.
4. Next, start up the Node Changer program by clicking Node Changer icon on your desktop or by
selecting Node Changer from the Windows START menu.
The Node Changer startup screen then displays, with fields showing default settings of 0 (zero) and
“WAITING.”
5. In the TARGET NODE panel, select the node’s current ID number from the NODE drop-down list.
Page 184 011-0552-06

6. Click QUERY.
● If the node ID number and all configuration connections are correct, the STATUS box turns green
and displays CONNECTED. Fields in the TARGET NODE panel are automatically filled in with
information for that node.
● If the node number that you selected is not the correct number, or if there is a connection or node
malfunction, the STATUS box turns red and displays FAILED. If this happens, confirm that the
node number is correct, all configuration connections are correct, and that the node and all con-
figuration components are powered and functional. Then click QUERY again.
● When the STATUS box displays CONNECTED, go to the next step.

7. In the CHANGE NODE panel, select the new ID number for the node from the drop-down list. (The
ID number must match the ID number of the node that it is being replaced.) If the node will be used
on an HD system using the Hammerhead control system, you should click the RSTP check box. If the
node will be used on a UHD-III system, you should click the RSTP and VLAN check boxes.
Page 185 011-0552-06

Caution! Ensure that the ID number you have selected matches the ID number for the node you are
replacing. If two nodes in an ROV system are configured with the same ID number, communications
will fail to one or more nodes when the ROV control system starts up.
8. Click CHANGE AND RESET.
Page 186 011-0552-06

● If the node ID number and IP address are successfully changed, the RESULT box turns green and
displays CHANGED. The RSTP box indicates whether RSTP is enabled, and the VLAN box indic-
ates whether VLAN is enabled. (VLAN is typically not used in HD ROV systems.) A pop-up message
tells you that the node ID number has been updated and the node is rebooting (undergoing a soft
reset). Do not turn off power to the node.
● If the node’s new ID number could not be assigned, the RESULT box turns red and displays
FAILED. If this happens, confirm that all configuration connections are correct and that the node
and all configuration components are powered and functional. Then click CHANGE AND RESET
again.
9. Wait 20 seconds, and then test to ensure that node has retained your changes:
a. In the TARGET NODE panel, select the node ID number that should now be assigned to the node.
b. Click QUERY.
If the STATUS field displays CONNECTED, the new number is confirmed. Also check that
configuration settings for RSTP and VLAN are correct.
10. Turn off power to the node and disconnect temporary power and Ethernet cables. Remove the rack
node test NIM (P/N 101-5117-2) and replace it with the desired interface module.
11. Install the node in the ROV system as described in these service instructions:
— Subsea Node: Remove and Install on page 171
— Node Compensation: Filling, Bleeding, and Draining on page 1
Page 187 011-0552-06

Fiber Dome: Remove and Install

This service instruction explains how to remove and install node fiber domes. For reference, see drawing
and part list 101-7306.
Tools Nut drivers, vacuum pump with gauge
Personnel 1 worker
Sub-Procedures None
Parts-Kits P/N 004-0049: O-RING, 2-045 BUNA 70

P/N 004-0103: O-RING, 2-044 BUNA 70
Consumables Cable ties, Dow Corning 111 O-Ring Lube (Thick) (P/N 002-3485)
In the event of SFP (Small Form-Factor Pluggable) failure, fiber whip failure, or subsea node PCB replace-
ment, you will need to remove the DTS node fiber dome. Follow these steps to avoid damaging the fibers.
Removal
1. Remove the three vacuum plugs from the node fiber domes, as shown in the figure below.
Figure 17
2. Remove the node dome without the fiber penetrators (item 26), as shown in the figure below.
Page 188 011-0552-06

Figure 18
3. Unplug the fibers from the green and blue SFP modules (items 28 and 29) by grasping the connector,
depressing the retaining clips, and pulling firmly but gently out, as shown in Figure 17 on the previous
page. The vacuum seal can make removing the connectors difficult, but be sure not to pull on the cable
itself.
Caution! Do not pull on the fiber cables directly. Doing so can damage the delicate fibers and cause
signal degradation. Always handle fiber cables by the connectors and avoid a bend radius smaller
than 1.9 cm.
Figure 19
4. From the other side of the node, unbolt the node dome with the fiber penetrators (item 25), as shown
in Figure 18 above. As you remove the dome, take care not to scratch the O-ring sealing surfaces.
Page 189 011-0552-06

Figure 20
5. Carefully pull the dome away from the node, feeding the fiber through the opening in the PCB
assembly (item 1) as you remove the dome, as shown in Figure 19 on the previous page. Note that
newer versions of the node PCB have one opening on each side rather than a single opening at the top.
Thread one fiber through each hole. Be sure not to snag the retaining clips of the fiber connectors on
the opening as they pass through.
Figure 21
Installation
1. Starting with the penetrated node dome (item 25), ensure that both O-rings are glued into place with
either DC 111 or DC 55 silicon grease. Add a light coating of silicon grease to the node housing in the
area of O-ring contact.
Page 190 011-0552-06

2. Carefully pass the fibers through the opening on the PCB assembly (circled in Figure 20 on the
previous page) from the side of the node with the 26 VDC power connection. Note that newer versions
of the node PCB have one opening on each side rather than a single opening at the top. Thread one
fiber through each hole.
Figure 22
3. Keep the fiber taut as you bring the dome to the PCB. Take care not to bend the fiber. Install the dome
to the node. Ensure that the O-rings remain in place, flush with the surface and not rolled or extruded.
Secure with M4 hex nut (item 18) and torque to 2.8 Nm (25 in-lb).
Figure 23
4. From the other side, feed the fiber back through the opening in the PCB until you have just enough to
plug it into the fiber module. Take care when feeding the fiber back through to minimize the bend in
the fiber, as a bend tighter than 1.9 cm will lead to a loss of signal.
5. Plug the “A” fiber into the blue SFP module and the “B” fiber into the green SFP module by grasping
the cable by the connector and pushing it into the appropriate module, as shown in Figure 22 above.
Page 191 011-0552-06

Figure 24
6. Check that there are no fibers in the area around the node dome sealing surface.
7. Verify that the O-rings are glued in place on the node dome (item 26) and add a light coating of silicon
grease to the node housing in the area of O-ring contact.
8. Install the remaining dome (item 26), making sure the O-rings are flush with the surface and not rolled
or extruded. Secure with M4 hex nut (item 18) and torque to 2.8 Nm (25 in-lb).
Figure 25
9. Remove all three vacuum plugs from the node domes, and individually check each of the three
compartments for a vacuum tight seal, as shown in Figure 23 on the previous page. All three plugs
must be out when testing or potential leaks will not be detected.
Page 192 011-0552-06

Figure 26
10. Re-install the plugs (see Figure 24 on the previous page).
Page 193 011-0552-06

Node SFP Module: Remove and Install

This service instruction explains how to remove and install the node SFP module.
Tools See sub-procedures
Personnel 1 worker
Sub-Procedures Service Guidelines in Volume 1: ROV & TMS System Manuals, Fiber Dome: Remove and Install on page 188
Parts-Kits None
Safety Electric shock, pinch
Consumables Cable tie
Caution! Nodes contain ESD-sensitive components. Follow ESD guidelines when you are servicing
nodes (see Fiber Dome: Remove and Install on page 188).
Removal
2. Remove the node from the ROV, TMS, or rack (see Subsea Node: Remove and Install on page 171).
Note: Subsea nodes are decompensated during the removal process.
3. Remove the cover over the SFP module:

— For subsea nodes, remove the fiber dome assembly (see Fiber Dome: Remove and Install
on page 188).
— For surface rack nodes, remove the top cover of the surface node [(4x) Phillips screws].
4. Disconnect the fiber optic ST connector from the SFP module by pressing down on the locking tab
and gently pulling the connector away from the SFP module.
Note: Make sure to mark the cable orientation.
Note: Do not pull on the cable. This will cause damage. Instead, pull directly on the ST connector.
5. Remove the SFP module from the SFP cage:

a. Pull the SFP latching mechanism (bar) in the direction the module slides out of the cage. This will
loosen the module.
b. Gently pull the SFP module out of the cage to remove it from the node.
Page 194 011-0552-06

Installation
1. Identify and confirm the correct SFP module with the correct SFP cage:
— Blue SFP module (Tx: 1310 Rx: 1550) with SFP cage labeled ‘A’ on the node PCB
— Green SFP module (Tx: 1550 Rx: 1310) with SFP cage labeled ‘B’ on the node PCB
2. Insert the SFP module into the SFP cage. Make sure that it is fully seated and the label is face up.
3. Move the latching mechanism (bar) into the locked position.
4. Insert the corresponding fiber optic ST connector into the SFP module. A “click” sound from the
locking tab indicates the connector is fully seated.
5. Install the cover over the SFP modules:
— For subsea nodes, install the fiber dome assembly (see Fiber Dome: Remove and Install on
page 188).
— For surface rack nodes, install the top cover of the surface node (4x Phillips screws).
6. Install the node into the ROV, TMS, or rack (see Subsea Node: Remove and Install on page 171.) Be
sure to fill and bleed a subsea node.
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Digital Telemetry System 6. Subsea Node Interface Module
6. Subsea Node Interface Module

6.1 About Subsea Node Interface Modules
Each subsea node controls and routes telemetry and 26 VDC power to 16 individual node ports. Ports are
configured for serial, video, Ethernet, or TMS latch communication through four basic types of “Interface
Modules.”
● SIM (serial interface module) for serial (RS-232 or RS-485) communications
● VIM (video interface module) for video (PAL/NTSC digital or analog) signals
● NIM (network interface module) for Ethernet communications
● LIM (latch interface module), providing two SeaNet power connections on a single node port (for
example, to power two TMS electric latches)
Each module translates external signals through a 10/100 Mbps Ethernet interface for transmission along
the Ethernet backbone (bus). Port modules can be moved or replaced to configure each node to suit device
and sensor requirements. Like any subsea penetrator or connector, an unused port module connector
MUST be capped for submerged operation (cap P/N 101-4357).
Each module can supply up to 250W of continuous electrical power (at 26 VDC), and can handle inrush cur-
rents of up to 1000W for 100ms. Power can be remotely switched from the control console GUI.
Interface modules are available in several configurations to accommodate a wide variety of devices and con-
nectors. Modules with SeaNet penetrators use the SeaNet cable connector to provide diagnostic LEDs for
power and data. Modules using proprietary connectors have internally mounted diagnostic LEDs. Most
modules are rated for 6 km operation, but a few are rated for 4 km. These are identified on their part lists,
see Volume 4: Drawings and Part Lists.
The following table shows the module part number, description, and anodized color coding for iden-
tification.
Note: Anodized colors can fade over time when exposed to UV light. Always check the part number
on the module to make sure of compatibility.
Subsea IM Description Anodize Color

101-7324-1 SIM Hard Clear
101-8511 Dual Seanet SIM Hard Clear
101-7633 TTL SIM (Seanet) Hard Clear
101-7332 SIM/VIM (for T4) Hard Clear
101-7335 SIM/SIM (13pin Burton) Hard Clear
101-7337 SIM/SIM (21pin Burton) Hard Clear
101-7921 VIM Red
101-5075-3 NIM Blue
Page 196 011-0552-06

Subsea IM Description Anodize Color

101-8095 LIM Gold
101-9584 SDVIM (flow thru) Green
101-9798 SDVIM (feed thru - for T4) Purple
101-7339 base thru -9 8pin, 20shell Burton SIMs N/A
101-9575 8pin, 15shell Burton SIM N/A
6.2 Subsea Node Interface Modules: Features

Interface modules are available in a variety of configurations to accommodate various uses, devices, and con-
nectors. They are described in the following sections. Also see the drawings for specific modules.
6.2.1 SIM
A serial interface module (SIM) can be equipped with a SeaNet connector or a Burton connector.
The SIM translates RS-232 and RS-485 serial data into an Ethernet format suitable for delivery over the
DTS. The SIM can be configured for baud rates (from 1200 to 230k baud), data bits, parity, and number of
stop bits using the control system. See Volume 3: Operator Controls for information.
The SIM can detect when an RS-232 signal is applied and swap RX and TX if a device is connected incor-
rectly. Since RS-485 devices are half-duplex, it is not possible to detect such a device. However RX and TX
can be swapped on any SIM using the control system, eliminating the need to rewire any component. See
Volume 3: Operator Controls for information.
A SIM module can detect a 5 V TTL logic pulse and send notification to another SIM to produce a pulse.
This functionality is useful for triggering acoustic beacons.
BiCast Functionality
The BiCast SIM mirrors the “transmit” serial data sent to the topside primary SIM and sends it to a sec-
ondary topside SIM, allowing survey and other activities to receive real-time data from ROV sensors and
other system devices. To use the BiCast feature requires control software version 3.4 or higher and either a
7000 series SIM or a reprogrammed older SIM. Setup of a SIM to transmit to a secondary topside SIM is
performed from the control system client GUI. See Volume 3: Operator Controls for information.
Burton SIM Diagnostic LEDs

The Burton SIM has diagnostic LED indicators for data in, data out, Ethernet link, 26 VDC power with 12
V, 750 mA power option, and Ethernet activity (see Diagnostic LEDs on page 200).
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6.2.2 VIM (101-5075-2 and 101-5075-8)

Common Features
The subsea video interface module (VIM) converts standard composite video to Ethernet packets for trans-
mission over the DTS (the topside VIM converts the Ethernet stream back to composite video for display
on an analog monitor). The VIM supports both NTSC and PAL at 30 frames per second and D1 resolution.
The system is specially designed to provide less than 10 0mS latency from capture to display, in order to
facilitate real-time control of subsea tasks.
The VIM supports RS-232 communications at up to 38,400 baud for cameras with zoom and focus con-
trols.
6.2.2.1 101-5075-8
The 101-5075-8 VIM has a highly filtered 26 V output to the camera which removes the majority of video
noise caused by pan and tilt motors and greatly improves the overall video on most cameras. Maximum cur-
rent supplied to the camera, including zoom and focus requirements, is 700 mA. If camera current require-
ments are higher than 700 ma, use the 101-5075-2 VIM which can supply 2A, maximum.
6.2.2.2 101-5075-2
Use the 101-5075-2 VIM when camera and zoom/focus current requirements are between 700 mA and 2 A
(maximum). Because of its higher current rating, video noise rejection for this VIM is less than for VIM
101-5075-8.
6.2.2.3 VIM Troubleshooting
Video Roll/Split
Solution: Restart server (subsea) VIM using the DTS Viewer test software and instructions provided in Sup-
port Files\4 - Test Software\014-0751 DTS_Viewer\.
6.2.3 NIM (101-5075-3) Features

The network interface module (NIM) allows connection of a device directly to the 10/100 Mbps Ethernet
backbone of the system.
6.2.4 SDVIM (101-9584 and 101-9798)

The standard-definition video interface module (SDVIM) is used only in ROV systems that have HDEVS
(high-definition Ethernet video system).
An ROV system with HDEVS still needs to process video from standard-definition (SD) cameras that output
composite video signals (for example, a TITAN 4 wrist camera). These SD cameras must be attached to an
SDVIM.
The SDVIM has two models:
● Flow-through SDVIM, part number 101-9584 (green module). Required when the node’s com-
pensation circuit is used to compensate the SeaNet cable attached to the SDVIM. (A typical SD cam-
era is attached to an SDVIM.)
Page 198 011-0552-06

● Feed-through SDVIM, part number 101-9798 (purple module). Required when the SeaNet cable con-
nected to the SDVIM is compensated by the device attached to the SeaNet cable (for example, a
TITAN 4 wrist camera).
6.2.5 Dual SIM/VIM (101-7332)

This dual interface module accepts separate SIM and VIM connections and can be used to connect the
Titan 4 manipulator system (serial) and the Titan 4 wrist camera (video), and other devices that require dual
serial or serial and video communications.
6.2.6 Dual SIM for Lights

Dual SeaNet SIM 101-8511 controls and dims two LED lights, as long as their combined power con-
sumption is less than 300W. Electrical power is supplied to the SIM through the DTS node and is dis-
tributed to the two SeaNet connections. Lights connected to SIM 101-8511 are protected by the node fuse.
6.2.7 NIM/VIM/USB Server 101-6141

Use this interface module for devices requiring video, network, and USB interfaces. Typical applications
include:
● A digital camera requiring a video interface to monitor camera output.
● The network interface for triggering the camera shutter.
● The USB interface to transmit the picture to the surface.
6.2.8 LIM (101-8095) Features

The latch interface module (LIM), which contains two SeaNet penetrators, allows two devices to attach to a
single node port. (For example, two TMS latches can attach to one node port.) The connections provide
power, but not telemetry.
Power is provided at 26 VDC, 8 A maximum for each SeaNet penetrator.
If a LIM is being used for TMS latch control, power to the LIM is automatically handled by the ROV con-
trol system. If the LIM is not being used for TMS latch control, you can turn on power to the LIM’s SeaNet
penetrators using node port power controls (see Volume 3: Operator Controls). The penetrators cannot be
powered separately; they must be either both on or both off.
6.3 Subsea Node Interface Modules: Node/Port Configuration

Node and port interface module configurations are shown on the System Interconnect Diagram located in
the “System Schematics & Interconnect Diagrams” section of Volume 4: Drawings and Part Lists.
You can change or reassign node port functions using the control system touch screen interface. For
details, see Volume 3: Operator Controls.
6.4 Subsea Node Interface Modules: Installation & Removal

Page 199 011-0552-06

Node Interface Module (NIM): Remove and Install on page 202
6.4.1 Connections
Modules with SeaNet penetrators are connected to devices using standard SeaNet cables or SeaNet Adapter
cables, as required by the device penetrator. Modules with Burton or other connector types require cables
with the appropriate plug.
For information on SeaNet cables, see the section entitled “SeaNet Cables, Adapter, and Accessories.”
6.4.2 Compensation
Interface modules receive active compensation through the node and can pass compensation fluid to
devices if connected with a SeaNet or SeaNet adapter cable.
6.4.3 Unused Ports or Modules

Unused ports (ports not fitted with a functional interface module) must be fitted
with a dummy module (P/N 101-5075).
Unused modules must be sealed and protected with a SeaNet cap 101-5791 (Fig-
ure, below) or an appropriate Burton dummy plug.
Caution! Unused SeaNet penetrators MUST BE CAPPED if they will be sub-

merged.
6.5 Subsea Node Interface Modules: Troubleshooting

6.5.1 Fast & Slow Software Fuses
A tripped software fuse opens the 26 V power and return lines to the device and creates an alarm that dis-
plays on the control system touch screen interface. Node motherboard to interface module power is not
affected by a tripped fuse.
Typical causes for a tripped fuse are shorts within the device or device cable and excessive current draw by
the device. Disconnect the device and cable, and reset/turn on the port. If port is OK, replace or test the
cable for shorts and replace the device. If the fuse trips with nothing connected, the short may be within
the interface module or the node.
6.5.2 Diagnostic LEDs

Interface modules with SeaNet connectors have no diagnostic LEDs; instead, use the diagnostic LEDs on
the SeaNet cable.
The Burton SIM has diagnostic LED indicators for data in, data out, Ethernet activity, Ethernet link, and
26 VDC power (see Figure 27).
Page 200 011-0552-06

Figure 27: Burton SIM diagnostic LEDs
Page 201 011-0552-06

Node Interface Module (NIM): Remove and Install

Tools 10 mm wrench or nut driver, lockout/tagout devices
Personnel 1 worker
Sub-Procedures None
Parts-Kits 004-1033
Safety Electrical shock hazard, assembly room procedures
Consumables Cable ties, compensation fluid
Refer to this document when removing and installing any node IM (interface module).
Installation & Removal

device is connected to a node, but draws power from another source, disable the power source to the
device before disconnecting the module.
Remove
1. Disable power to the node by switching off high power at the PDU or deck power as needed. See the
OEM PDU manual provided with your system for additional details.
2. Connect a compensation cart to the node QD and drain the compensation fluid from the node.
3. Remove the SeaNet connector if connected.
4. Remove the M6 nylock nut and washer from each stud.
5. Pull the module straight out of the node socket.
Install
1. Disable power to the node by switching off high power at the PDU or deck power as needed. See the
OEM PDU manual provided with your system for additional details.
2. Confirm that the O-ring (inside face of the module housing) is present and apply O-ring lubricant.
3. Place the module over the two port studs on the node and press it down into place, mating the PC board
connectors.
4. Install an M6 washer and nylock nut to each stud.
5. Connect the compensation cart and fill the node with compensation fluid.
6. Reconnect the node QD to the compensation circuit.
Connections
Modules with SeaNet penetrators are connected to devices using standard SeaNet cables or SeaNet adapter
cables, as required by the device penetrator. Modules with Burton or other connector types require cables
with the appropriate plug.
Page 202 011-0552-06

Compensation
Interface modules receive active compensation through the node and can pass compensation fluid to
devices if connected with the correct SeaNet or SeaNet adapter cable.
Unused Ports or Modules

Unused ports (ports not fitted with a functional interface module) must be fitted with a dummy module
(P/N 101-5075).
Unused modules must be sealed and protected with a SeaNet cap (P/N 101-5791) or an appropriate Burton
dummy plug.
Caution! Unused SeaNet penetrators MUST BE CAPPED before diving the system, and should be
capped when not in use to protect the assembly.
Page 203 011-0552-06

Digital Telemetry System 7. SeaNet Cables and Penetrators
7. SeaNet Cables and Penetrators

7.1 About SeaNet Cables and Penetrators
SeaNet cables, adapter cables, and penetrators provide 26 VDC electrical power and data connections
between remotely-operated devices (including slave arms, sensors, cameras, lights, thrusters, actuators, and
tools) and the vehicles on which they are used. Standard SeaNet cables, when used with SeaNet flow-
through penetrators, can also supply compensation fluid. SeaNet components fall into four general cat-
egories.
● SeaNet-to-SeaNet cables connect devices fitted with a SeaNet penetrator to DTS node ports or other
components fitted with a SeaNet penetrator. The cables come in several standard lengths, from 2m
(6.5 ft) to 7.5m (24.5 ft).
● SeaNet Adapter cables (SeaNet-to-Burton, Impulse, and other OEM connector types) connect (1) a
DTS node port to a device fitted with an OEM penetrator, or (2) connect a device fitted with a
SeaNet penetrator to an OEM penetrator.
● SeaNet penetrators, feed-through and flow-through types, connect to SeaNet cables.
● SeaNet caps and plugs protect disconnected SeaNet cables and penetrators.
7.2 SeaNet Cables and Penetrators: Features

7.2.1 SeaNet Cable and Whip Features
● Status indicator LEDs for power and signals in the connector head.
● Pressure-balanced, oil-filled (PBOF) cable; almost neutral-buoyant in seawater.
● Positive locking feature allows cable disconnection only when locking bail is open.
● Right-angle cable exit with 360° connector clocking.
● Fluid check-valves to prevent leakage when demated.
● Two compensation bleed screws.
7.2.2 Flow-through vs. Feed-through Penetrators

Press on the mating face (with concentric contacts) of the penetrator.
● A mating face that can be depressed slightly (to allow compensation fluid to pass) indicates a flow-
through penetrator.
● A firm mating face indicates a feed-through-only penetrator that will not pass compensation fluid.
7.2.3 Penetrator Features

● SeaNet penetrators can adapt virtually any device with a 3/4-16 or SAE MS16142-8 port requiring
telemetry or 26 VDC power.
● Feed-through-only models for 1 atm components; flow-through models for oil-filled, actively-com-
pensated components.
● Fluid check-valve to prevent leakage when demated (flow-through types).
Page 204 011-0552-06

7.3 SeaNet Cables and Penetrators: Maintenance

For information about SeaNet conductor designations and status indicator LEDs, see SeaNet Connector:
Use and Care on page 207.
7.3.1 Mate, Demate, and Bleed

Figure 28: Mate, demate, and bleed SeaNet connectors
Caution! Do not connect or disconnect a SeaNet cable when 26 VDC is present. Arcing can damage
contacts and power supply equipment.
The SeaNet connector latch provides easily recognizable “click = open” and “click = latched” feedback (Fig-
ure 1). Cable disconnection is only possible when the connector bail is unlatched and raised.
A fluid check valve in the SeaNet connector face prevents compensation fluid leakage when disconnected; a
screw in the connector head is used to bleed the cable (Figure 1). SeaNet cables with adapters can be bled by
removing the screw on the top of the adapter boot.
7.3.2 Cable Care

the power supply or penetrator ring traces.
● Periodically clean and lubricate the connector O-ring.

● Install SeaNet plugs (P/N 001-5959) to protect and seal unused SeaNet cable connectors.
Caution! Unplugged SeaNet cable connectors will leak if submerged.
● Install SeaNet cap (P/N 101-5791) to protect and seal unused SeaNet penetrators.
Caution! Uncapped SeaNet penetrators will leak if submerged.
Page 205 011-0552-06

7.3.3 Routing & Bending

● Secure the cables at regular intervals. Coil and secure any excess lengths. Ties must not constrict
hose.
● Make sure the cables are not kinked, pinched, or impeding the flow of compensation fluid in any
other way.
— Minimum bend radius:
— Static 50 mm (2 in.)
— Dynamic 75 mm (3 in.)
7.4 SeaNet Cables and Penetrators: Service

SeaNet cables are field serviceable and most problems can easily be fixed by replacing or repairing parts of
the assembly. Typical reasons for servicing a SeaNet cable are:
● Repair punctured cables
● Replace leaking housing
● Replace a failed PCB
● Update older SeaNet cables using the redesigned components
Service Instructions
SeaNet Connector: Use and Care on the facing page
SeaNet (3rd Generation): Repair Kit Instructions on page 211
Page 206 011-0552-06

SeaNet Connector: Use and Care

This document explains the types, uses, and maintenance for the SeaNet cable and connector.
Tools Straight blade screwdriver, special wrench (SeaNet shell, P/N 010-0835 )
Personnel 1 worker
Sub-Procedures None
Parts-Kits None
Safety Deck safety hazard
Consumables None
SeaNet cables, adapter cables, and penetrators provide 26 VDC electrical power and data connections
between remotely-operated devices (including slave arms, sensors, cameras, lights, thrusters, actuators, and
tools) and the vehicles on which they are used. Standard SeaNet cables, when used with SeaNet flow-
through penetrators, can also supply compensation fluid. SeaNet components fall into four general cat-
egories.
● SeaNet-to-SeaNet cables connect devices fitted with a SeaNet penetrator to DTS node ports or other
components fitted with a SeaNet penetrator. The cables come in several standard lengths, from 2 m
(6.5 ft) to 7.5 m (24.5 ft).
● SeaNet Adapter cables (SeaNet-to-Burton, Impulse, and other OEM connector types) connect (1) a
DTS node port to a device fitted with an OEM penetrator, or (2) connect a device fitted with a
SeaNet penetrator to an OEM penetrator.
● SeaNet penetrators, feed-through and flow-through types, connect to SeaNet cables.
● SeaNet caps and plugs protect disconnected SeaNet cables and penetrators.
SeaNet Cable and Whip Features

● Status indicator LEDs for power and signals in the connector head.
● Pressure-balanced, oil-filled (PBOF) cable; almost neutral-buoyant in seawater.
● Positive locking feature allows cable disconnection only when locking bail is open.
● Right-angle cable exit with 360° connector clocking.
● Fluid check-valves to prevent leakage when disconnected.
● Compensation bleed screw.
Penetrator Features
● SeaNet penetrators can adapt virtually any device with a 3/4-16 or SAE MS16142-8 port requiring
telemetry or 26 VDC power.
● Feed-through-only models for 1 ATM components; flow-through models for oil-filled, actively-com-
pensated components.
● Fluid check-valve to prevent leakage when disconnected (flow-through types).
How to Distinguish Flow-Through from Feed-Through Penetrators

Press on the mating face (with concentric contacts) of the penetrator.
Page 207 011-0552-06

● A mating face that can be depressed slightly (to allow compensation fluid to pass) indicates a flow-
through penetrator.
● A firm mating face indicates a feed-through-only penetrator that will not pass compensation fluid.
SeaNet Connectors: Mating, De-mating, and Bleeding
Lift bail to vertical pos-

Pull on bail tab with Pull connector straight To bleed SeaNet: loosen
ition.
thumb. off penetrator. screws on connector (arrows)
Click = open
Mate: (bail up) push con-

Push over bail (click = Press down bail (click = To bleed adaptor, remove
nector
closing) latched) screw on top.
straight onto penetrator.
contacts and power supply equipment.
The SeaNet connector latch provides easily recognizable “click = open” and “click = latched” feedback.
Cable disconnection is only possible when the connector bail is unlatched and raised.
A fluid check valve in the SeaNet connector face prevents compensation fluid leakage when disconnected; a
screw in the connector head is used to bleed the cable. SeaNet cables with adapters can be bled by removing
the screw on the top of the adapter boot.
Cable Care
● Do not connect or disconnect a SeaNet cable when 26 VDC is present. Arcing can damage the
power supply or penetrator ring traces.
● Periodically clean and lubricate the connector O-ring.
● Install SeaNet plugs 001-5959 to protect and seal unused SeaNet cable connectors.
Page 208 011-0552-06

Caution! Unplugged SeaNet cable connectors will leak if submerged.
● Install SeaNet cap 101-5791 to protect and seal unused SeaNet penetrators.
Caution! Uncapped SeaNet penetrators will leak if submerged.
Routing & Bending

Secure the cables at regular intervals. Coil and secure any excess lengths. Ties must not constrict hose.
Make sure the cables are not kinked, pinched, or impeding the flow of compensation fluid in any other
way.
Minimum bend radius
Static 50 mm (2 in.)
Dynamic 75 mm (3 in.)
SeaNet Conductor Designations

Standard SeaNet cables contain seven conductors. Nominal SeaNet contact and conductor characteristics
for all ROV systems and devices are shown below. Some adapter cables intended for specific purposes may
not be supplied with all four signal lines. (Electrical data taken from drawing 130-0170)
SeaNet Electrical Usage

Wire
SeaNet Pin # See Illustration
Maximum Cur- FUNCTION
below AWC Mm3 Color
rent
1 18 0.75 RD 8A +26_VDC_SWITCHED (+26VDC_SW)
2 18 0.75 BK 8A SWITCHED_RETURN_26_VDC (SW_
RET26)
3 22 0.34 GN/YE --- CHASSIS (CHA)
SIM
Interface Module Type VIM NIM LIM
RS-232 RS-485
4 22 0.34 OG 0.2 --- --- --- RD- ---
5 22 0.34 BU 0.2 S>M D- S>M RD+ ---
6 22 0.34 WH 0.2 M>S D+ M>S TD-
7 22 0.34 YE 0.2 --- --- VIDEO TD+ ---
Page 209 011-0552-06

Figure 29: SeaNet contact pin out diagram (see table above)
Status Indicator LEDs

You can monitor SeaNet power and signal (signal/video) lines by looking at status indicator lights (LEDs) in
the SeaNet connector head.
Power and signal indicator lights

● All status indicator LEDs flash briefly as a self-test when the node port is turned on.
● The spare signal line (4) has no status LED.
Page 210 011-0552-06

SeaNet (3rd Generation): Repair Kit Instructions

This service instruction explains how to disassemble, rebuild, and repair 3rd-generation SeaNet cables using
the SeaNet repair kit (P/N 008-0654).
Tools Pliers, screwdriver, 3/32 needle punch, soft jaw vice, multimeter, small hex keys
Personnel 2 workers
Sub-Procedures None
Parts-Kits SeaNet Repair Kit (P/N 008-0654)
Safety General shop procedures
Consumables Dow Corning 55 O-Ring Lube (Thin) (P/N 002-0359), tubing
You will be able to fix most problems just by replacing the broken part(s) of the SeaNet cable, so depending
on the repair, some steps in this instruction will be unnecessary. Skip steps when it is appropriate.
Additional Resources and Tools

In addition to this document, the following items are potentially useful:
Documents:
● Bill of Material: 101-7230 CABLE ASSY, SEANET GEN 3
● Assembly Drawing: 101-7230 CABLE ASSY, SEANET GEN 3
Additional Tools:
● Multimeter
● O-ring lubricant
● Hex keys
● Screwdriver
Parts:
● SeaNet Repair Kit (P/N 008-0654)
● Tubing (stored outside repair kit case)
SeaNet Generations
This procedure and the associated rebuild kit (P/N 008-0654) is for 3rd-generation SeaNet cables (P/N
101-7230) only. The 1st- and 2nd-generation cables cannot be repaired using this kit.
● The 1st-generation SeaNet cable looks very different and is obsolete.
● The 2nd-generation SeaNet cable (P/N 101-4155) looks like a 3rd-generation cable, but there are
simple ways to distinguish between the two. In a 3rd-generation cable:
— There is an additional bleed screw (shown below) to improve serviceability
— The poppet valve is larger and has been relocated on the tubing-side of the housing
Page 211 011-0552-06

Disassembly
1. Remove the cap:
a. Move the latching bail (A) to the unlatched
position.
b. Remove the cap fasteners (4x Phillips Cap
Screw).
c. Slide the cap (B) and its O-ring (C) towards
the cable.
2. Remove the latching bail (A) by pinching its sides
inward.
3. Disconnect the wires from the PCB:

a. Disconnect the 3 copper wires (F) using the kit’s screw driver.
b. Disconnect the 4 coaxial cables (G) by gently pulling upward.
Note: The coaxial cable connectors are delicate. Remove only when needed.
4. Optional: Remove the latches if they need to be replaced. The pins holding in the latches use a press
fit and can only be installed a few times. You will need a soft-jawed vice or equivalent tool to hold the
SeaNet housing when pressing the latch pins in or out. To remove the latches:
a. Use a 3/32 in punch (D) to press out the
larger pins (2x). To maintain the press-fit
tolerance between the pin and the housing,
press the pins out so the notched end passes
through the housing only once.
b. Remove the latch by pivoting it past the lower
1/16 in pins (2x).
c. If replacing them, press out the lower pins
using a 1/16 in punch (E).
5. Remove the PCB (H) and PCB O-ring (J) (2x 4-40 SHCS).
Page 212 011-0552-06

6. Optional: The PCB poppet valve (I), poppet valve spring, and O-ring can be replaced if needed.
7. Pull the wires, from the other end of the SeaNet, into the tubing so the wires won’t accidentally be cut
in the following step.
8. Use a fresh, single-edged razor to cut the tubing flush to the end of the housing. Be careful not to cut
the wires inside the tube.
9. Remove the tubing ferrule (K) by pushing it to the inside of the housing. Discard the used ferrule.
Assembly
1. Feed the tube and wires into the housing.
2. Continue pushing the tubing and wires into the SeaNet housing until approximately 6 inches of tubing
is coming out of the SeaNet.
3. Install the tubing ferrule (K):
a. Push the wires (from the opposite end of the
cable) so the wires stick out of the end of the
tubing.
b. Place a new tubing ferrule (K) over the ferrule
installation tool (L).
c. Feed the wires through the ferrule and ferrule
installation tool.
d. Press the ferrule into the end of the tubing
using the ferrule installation tool.
Note: The ferrule installation tool controls the depth and orientation of the ferrule within the tubing.
The ferrule makes a wedge seal when the tubing is pulled back into SeaNet housing.
Page 213 011-0552-06

4. Pull firmly on the hose and the housing until the ferrule seats in the housing. Make certain the hose
does not extend into the housing area and interfere with the PCB.
Note: It is helpful to use a small amount of O-ring lubricant around the hose where the ferrule is
installed.
5. Optional: Install a new poppet O-ring, poppet valve and spring into the PCB if they were removed.
6. Install a NEW PCB O-ring (J) into the SeaNet housing.
7. Install the PCB (H) (2x 4-40 SHCS; 0.106 Nm [15 in-oz]).
Note: Be careful not to strip the threads with your torque wrench.
8. Install and connect the wires to the PCB. Drawing 101-7230 shows the wire routing and connections.
a. Connect the 4 coaxial cables (G) by gently pushing down on the head of the connector.
b. Connect the 3 copper wires (F) using a screwdriver.
9. Test the cable wiring using a multimeter to confirm continuity between pins on both sides of the cable.
10. Optional: Install the latches and pins if they were removed. A soft-jawed vice (or equivalent) is
needed to hold the housing while pressing in the pins.
a. Install the upper 3/32 in pins using the 3/32 in punch (D).
b. Install the lower 1/16 in pins using the 1/16 in punch (E).
11. Install a new O-ring into the SeaNet cap. Before installing, apply O-ring lubricant in the gland to hold
the O-ring in place.
12. Install the latching bail (A) by pinching inward on the bail.
13. Install the cap:
a. Move the latching bail (A) to the unlatched position.
b. Install the cap (B) and its O-ring (C) onto the SeaNet.
c. Install the cap fasteners (4x Phillips head screws; 0.45 Nm [4 in-lb].
Page 214 011-0552-06

Digital Telemetry System 8. Cable & Slip Ring Terminations
8. Cable & Slip Ring Terminations

8.1 About Cable & Slip Ring Terminations
This manual provides information for components used to connect or terminate
the deck, umbilical, tether, and HPU cables.
Terminations, from the TMS IPDS to the ROV HPU and IPDS, use the man-
ufacturer’s quick-disconnect (QD) connector, shown at right, which integrates HV
power and fiber optic cables into a single connector.
8.2 Cable & Slip Ring: Termination Matrix

To identify the primary cable termination locations, termination types, termination kits, service instruc-
tions, and helpful references, see the Termination Matrix below.
Other information resources:
● System Interconnect Diagram in the “System Schematics & Interconnect Diagrams” section of
Volume 4: Drawings and Part Lists.
● Tether and umbilical OEM manuals are located Support Files\3 - OEM Docs\Cables\ on the CD/-
flash drive.
● Hardware and kits can be found in Volume 4: Drawings and Part Lists.
● Umbilical and deck cable part numbers are usually located on the 300- level system part lists.
● The tether part number is usually located on the TMS part list.
Note: Some cables and/or procedures may not apply to your system. Confirm the cable type/cross
section before proceeding with termination or testing.
Termination Matrix
QD
Termination Service
Cables Location Reterm.
Type Instruction or Reference
Kit
Deck & LARS LARS 101-7563, Sta- N/A Drawings and Part Lists:
Slip Ring tionary J-Box ● LARS J-Box Interconnect Diagram, HD, 035-
0871
101-7562, Rotating
● Kit, Install, LARS 9.4T, J-Box, Dynacon, 101-
J-Box
7573
Umbilical LARS 101-7562. Rotating N/A
● Kit, Install, HD, J-Box, Dynacon/Nexans,
J-Box
101-7573-1
● Rotating LARS J-Box, HD, 101-7562
● Stationary LARS J-Box, HD, 101-7563
Tyco TMS IPDS QD 101-7444-1 008-0624-1 Service Instruction:
Nexan TMS IPDS QD 101-7444-5 008-0624-5 Quick Disconnect, Umbilical: Terminate on page 223
Page 215 011-0552-06

Termination Matrix (continued)

QD
Termination Service
Cables Location Reterm.
Type Instruction or Reference
Kit
Tyco/Nexan TMS Mechanical, docking N/A Service Instruction:
head/bullet Umbilical, TMS Bullet: Assemble Mechanical
Termination and Test Load on page 234
TMS Slip Ring TMS IPDS QD 101-7444-2 008-0624-2 ● Drawing 101-7444, sheet 3
TMS, Rotat- ● Slip ring kit 101-7469 (425-m tether) or 101-
ing T-Box 8545 (850-m tether)
Tether, Tyco TMS, Rotat- QD 101-7444-3 008-0624-3 Service Instruction:
ing T-Box Tether Kit 101-7677- Quick Disconnect, Tether: Terminate on the facing
ROV IPDS 1 page
Tether, Nexan TMS, Rotat- QD 101-7444-6 008-0624-6
ing T-Box Tether Kit 101-7677-
ROV IPDS 2
ROV HPU IPDS 101-7444-4 008-0624-4 Drawing 101-7444, sheet 5
motor
8.3 Cable & Slip Ring: Service

WARNING! SHOCK HAZARD! This equipment uses and produces hazardous voltages. Use extreme
caution when connecting or disconnecting power cables. Always lockout/tagout power sources and
verify system grounds are connected before any service. Follow all high voltage safety procedures
before beginning any work!
8.3.1 Service Instruction Index

Quick Disconnect, Tether: Terminate on the facing page
Quick Disconnect, Umbilical: Terminate on page 223
TMS Slip Ring: Remove and Install, 425-m/850-m on page 230
Slip Ring Compensation: Filling, Bleeding, and Draining on page 1
Umbilical, TMS Bullet: Assemble Mechanical Termination and Test Load on page 234
Page 216 011-0552-06

Quick Disconnect, Tether: Terminate

This service instruction explains how to terminate the quick disconnect on the tether.
Tools Solder-less connector crimp tool, wire stripper, wire cutters, knife, permanent marker, tape measure
Personnel 2 workers
Parts-Kits Tools
Safety Electrical shock hazards, general shop safety
Consumables WD40, isopropyl alcohol, cable ties
WARNING! Do not work on the tether until all electrical power to it is locked out and tagged out. If
you come in contact with the tether while electrical power is on, you may be injured or killed.
Termination
1. Refer to drawing 101-7677-1 for the tether insulation dimensions.
2. Clean the insulation with WD40 or isopropyl alcohol.
3. Cut and strip off about 61 cm (24 in) of the orange or black jacket (see the image below). This jacket
material is soft; if you cut too deeply, you may damage the wires inside.
Figure 30
Note: This drawing is not to scale. Some wires are not shown.
4. Install the O-rings onto the socket connecter (P/N 101-7616) and seal housing (P/N 001-12412).
5. Slide the QD components onto the tether in the order and orientation shown in the image below,
starting from the left.
Figure 31
6. Remove any foil and plastic wrapping from the conductors.

7. Clean the conductors with alcohol.
8. Straighten the conductors.
Page 217 011-0552-06

9. Separate the conductors into 3 groups so that Figure 32

they are easier to work with:
— HPU wires (10 AWG)
— IP wires (18 AWG for NEXANS, 20
AWG for TYCO)
— Ground (drain) wires
10. Cut the conductors to the correct lengths according to the dimensions shown in the image above. The
grounds/drains will be prepared in a few steps.
11. Strip the ends of the conductors to the correct lengths according to the dimensions shown in the
image above.
12. If you have a NEXANS tether: Cut the three Figure 33
grounds to 12.7 cm (5 in) and strip the ends off of
them. Twist these grounds together and land
them into a single ring lug. Then, skip to step 15.
If you have a TYCO tether: Cut 2 drain wires

to 12.7 cm (5 in). Cut all remaining grounds down
to 38 mm (1.5 in). Then, continue to step 13.
13. Pull the drain wires back over the insulation.
14. Install the kit’s largest Oetiker clamp over the

drain wires, at the edge of the insulation.
15. Twist the two long drain wires together to create a thick ground (see the image above).
16. Install a ring lug onto the end of this ground wire.
17. Assemble the green/yellow ground according to dimensions given in the image below.
Figure 34
18. Install pins onto the ends of the conductors, including the ground assembled in step 15.
Note: Verify that you are using the correct crimpers, pins, and settings, as shown below.
Page 218 011-0552-06

Figure 35
Note: Use the tool on the left with die #10 to crimp high-power conductors (10 AWG). Use the tool on
the right to crimp instrument power conductors (18 AWG for NEXANS, 20 AWG for TYCO); use wire
size 18 or 20 and select the red setting (if applicable).
19. Install the assembled ground wire into the QD socket in location #6.
20. Install the conductors into the QD socket according to the diagram shown in the image below
21. Check that the conductors are securely in place by Figure 36
pushing on them lightly with a small screwdriver
from the mating side.
Termination
Socket
Conductor Color Location
Orange (10 AWG) 1
N/A 2
Blue (10 AWG) 3
White (10 AWG) 4
N/A 5
Green/yellow (assembled ground) 6
Gray (18 or 20 AWG) 7
Green or red (18 or 20 AWG) 8
22. Remove the insulation from the fiber tube using a Figure 37
utility knife, as shown in the image to the right.
Leave 1 inch of insulation.
Page 219 011-0552-06

23. Using the tube-cutting tool, score the tubing 1.8 Figure 38
inch from the insulation, as shown in the image
to the right. Work the tube in your hands to break
it, then remove it carefully so as not to damage
any of the fibers. Do not cut completely through
the metal with the cutting tool; only score it.
24. Slide the two small Oetiker clamps onto the fiber tube. The small one should go on first, followed by
the larger (see the image below).
25. Install the black fiber housing onto the fiber tube. The housing should bottom out on the metal fiber
tube.
26. Install the larger Oetiker on the fiber housing to permanently fix it in place.
27. Install the smaller Oetiker around the metal fiber tube and the 18 AWG green/yellow ground wire.
Figure 39
Page 220 011-0552-06

28. Fan out the fibers and clean them with alcohol. Figure 40
29. Apply WD-40 to the fibers once they are clean.
30. Spray WD-40 into the fiber whip and its furcation
tubing. This will make inserting the fibers easier.
31. Insert the fibers into the furcation tubing

according to the chart provided.
Note: NEXANS brand tether fibers are labeled

with colored rings. Only use fibers with 25 mm
(1 in) colored ring spacing. Fibers with 50 mm
(2 in) colored ring spacing can be cut off and
discarded.
Fibers Figure 41
TYCO NEXANS Furcation

ID# Fiber Color Fiber Color
Color
F1 Red Red Orange
F2 Green Green Green
F3 Brown Blue Blue
Spare Yellow Yellow Gray
Spare Orange Natural Brown
Spare Natural White White
Page 221 011-0552-06

32. Snap the fiber whip into the housing and orient it Figure 42
face down into the socket, as shown in Figure 40
on the previous page
33. Cable tie the housing in place, as shown in Figure

40 on the previous page
34. Terminate fibers F1, F2, and F3, and attach their
connectors.
35. Trim the excess parts of the unused fibers that are
protruding out of their furcation tubing. They will
serve as spares.
36. Wind the fibers around the QD socket and plug them into the QD socket ID#, according to the chart
provided above.
37. Tuck the unused fibers under the cable tie.
38. Land both ground ring lugs onto the QD nut with Figure 43
the provided screw and lock washer. The ground
conductors should have some slack in them and
not be pulled too tight (see Figure 41 on the
previous page).
39. Slide the metal QD housing forward and install
the two set screws (45 in-lb) (see the image to the
right).
40. Apply anti-seize to the QD nut. Tighten the QD
nut against the QD body to a 1/2 turn past finger-
tight.
41. Tap one lock washer tang into a notch on the QD
nut.
42. Insert the seal package into the rear of the QD.
43. Apply anti-seize to the seal nut. Tighten 1.5 turns past finger-tight.
Note: If the QD is not going into immediate service, install dust caps.
Page 222 011-0552-06

Quick Disconnect, Umbilical: Terminate

This service instruction explains how to terminate the quick disconnect on the umbilical.
Tools Solder-less connector crimp tool, wire stripper, wire cutters, knife, permanent marker, tape measure
Personnel 2 workers
Parts-Kits See spares list for specific system
Safety Electrical shock hazards, general shop safety
Consumables WD40, isopropyl alcohol, cable ties
WARNING! Do not work on the umbilical cable until all electrical power to it is locked out and
tagged out. If you come in contact with the umbilical cable while electrical power is on, you may be
injured or killed.
Procedure
1. Clean the insulation with WD40 or isopropyl alcohol.
2. Cut and strip off about 61 cm (24 in) of the orange or black jacket (see the image below). This jacket
material is soft; if you cut too deeply, you may damage the wires inside.
Figure 44
Note: This drawing is not to scale. Some wires are not shown.
3. Install the O-rings onto the socket connecter (P/N 101-7616) and seal housing (P/N 001-12412).
4. Slide the QD components onto the tether in the order and orientation shown in the image below,
starting from the left.
Figure 45
5. Remove any foil and plastic wrapping from the conductors.

6. Clean the conductors with alcohol.
7. Straighten the conductors.
Page 223 011-0552-06

8. Separate the conductors into 3 groups so that Figure 46

they are easier to work with:
— HPU wires (8+ AWG for TYCO, 10
AWG for NEXANS)
— IP wires (18 AWG)
— Ground (drain) wires
Note: Tyco 8 AWG wires require the use of

special crimper jaw 010-2774. See caution
below step 17.
9. Cut the conductors to the correct lengths according to the dimensions shown in the image above. The
grounds/drains will be prepared in a few steps.
10. Strip the ends of the conductors to the correct lengths according to the dimensions shown in the
image above.
11. Cut two drain wires to 12.7 cm (5 in). Cut all Figure 47
remaining grounds down to 38 mm (1.5 in).
Note: If you are working with a NEXANS

umbilical, strip all of the drain wires so that
the bare metal is exposed.
12. Pull the drain wires back over the insulation.
13. Install the kit’s largest Oetiker clamp over the

drain wires, at the edge of the insulation.
14. Twist the two long drain wires together to create a thick ground (see the image above).
15. Install a ring lug onto the end of this ground wire.
16. Assemble the green/yellow ground according to the dimensions given in the image below.
Figure 48
17. Install pins onto the ends of the conductors, including the ground assembled in step 14.
Note: Verify that you are using the correct crimpers, pins, and settings, as shown in the image
below.
Page 224 011-0552-06

Figure 49
Note: Use the tool on the left to crimp high-power conductors (8 AWG for TYCO, 10 AWG for
NEXANS); use die #8+ or #10, respectively. Use the tool on the right to crimp instrument power con-
ductors (18 AWG); use wire size 18 and select the red setting (if applicable).
Caution! TYCO 8 AWG conductors are slightly larger than standard 8 AWG wire and will require
the use of a special jaw for 8+ AWG (P/N 010-2774) installed in the crimp tool. This special jaw is
included in spares kit 010-1701. Use ONLY with TYCO 8 AWG wire.
18. Install the assembled ground wire into the QD socket in location #6.
19. Install the conductors into the QD socket according to the diagram shown in the image below.
Page 225 011-0552-06

20. Check that the conductors are securely in place by Figure 50

pushing on them lightly with a small screwdriver
from the mating side.
Termination
Socket
Conductor Color Location
Orange (8 or 10 AWG) 1
Violet (18 AWG) 2
Blue (8 or 10 AWG) 3
White (8 or 10 AWG) 4
Brown (18 AWG) 5
Green/yellow (assembled ground 6
Gray (18 AWG) 7
Green or red (18 AWG) 8
Note: TYCO 8 AWG wire requires the use of a

special crimp jaw (P/N 010-2774). See caution
above step 18.
21. Using a utility knife, remove the insulation from Figure 51

the fiber tube, as shown in the image to the right.
Leave 1 inch of insulation.
Page 226 011-0552-06

22. Using the tube-cutting tool, score the tubing 1.8 Figure 52
inches from the TPE casing, as shown in the
image to the right. Work the tube in your hands
to break it, then remove it carefully so as not to
damage any of the fibers.
Caution! Do not cut completely through the

metal with the cutting tool; only score it.
23. Slide the two small Oetiker clamps onto the fiber tube. The small one should go on first, followed by
the larger (see the image below).
24. Install the black* (*white if using TYCO) fiber housing onto the fiber tube. The housing should bottom
out on the metal fiber tube.
25. Install the larger Oetiker on the fiber housing to permanently fix it in place.
26. Install the smaller Oetiker around the metal fiber tube and the 18 AWG green/yellow ground wire.
Figure 53
Page 227 011-0552-06

27. Fan out the fibers and clean them with alcohol. Figure 54
28. Apply WD-40 to the fibers once they are clean.
29. Spray WD-40 into the fiber whip and its furcation
tubing. This will make inserting the fibers easier.
30. Insert the fibers into the furcation tubing

according to the chart provided.
Note: NEXANS brand umbilical fibers are

labeled with colored rings. Only use fibers with
25 mm (1 in) colored ring spacing. Fibers with
50 mm (2 in) colored ring spacing can be cut
off and discarded.
Fibers Figure 55
ID# TYCO Fiber NEXANS Fiber Furcation

Color Color Color
F1 Red Red Orange
F2 Green Green Green
F3 Brown Blue Blue
Spare Yellow Yellow Gray
Spare Orange Natural Brown
Spare Natural White White
Note: Some TYCO cables come with fiber col-

ors that match the furcation device. Check
your cable, if colors match don't use the table
and just connect same colors together.
Page 228 011-0552-06

31. Snap the fiber whip into the housing and orient Figure 56
face down into the socket as shown in Figure 54
on the previous page
32. Cable tie the housing in place as shown, as shown

in Figure 54 on the previous page
33. Terminate fibers F1, F2, and F3, and attach their
connectors.
34. Trim the excess parts of the unused fibers that are
protruding out of their furcation tubing. They will
serve as spares.
35. Wind the fibers around the QD socket and plug them into the QD socket ID# according to the chart
provided above.
36. Tuck the unused fibers under the cable tie.
37. Land both ground ring lugs onto the QD nut with Figure 57
the provided screw and lock washer. The ground
conductors should have some slack in them and
not be pulled too tight (see Figure 55 on the
previous page).
38. Slide the metal QD housing forward and install
the two set screws (45 in-lb) (see Figure 56
above).
39. Apply anti-seize to the QD nut. Tighten the QD
nut against the QD body to a 1/2 turn past finger-
tight.
40. Tap one lock washer tang into a notch on the QD
nut.
41. Insert the seal package into the rear of the QD.
42. Apply anti-seize to the seal nut. Tighten 1.5 turns past finger-tight.
Note: If the QD is not going into immediate service, install dust caps.
Page 229 011-0552-06

TMS Slip Ring: Remove and Install, 425-m/850-m

This service instruction explains how to remove and install the TMS slip ring.
Tools Wrenches (10 mm, 14 mm, 3/8 in), safety harness if working aloft
Personnel 2 workers
Slip Ring Compensation: Filling, Bleeding, and Draining on page 1
Parts-Kits None
Safety Lifting, pinch, crush
Caution! It is easy to damage the Quick Disconnect (QD) conductor and fiber connectors when they
are exposed. Install QD covers over all exposed QD interfaces.
Removal
1. Lock out and tag out the system.
2. Remove the cross brace guard (A) from the TMS
frame (8x M10 HHCS).
3. Decompensate the slip ring compensation circuit
and drain as much oil from the slip ring as
possible (see Slip Ring Compensation: Fill, Bleed,
and Drain on page 1).
4. Remove the slip ring anti-rotation bracket (B) (4x
3/8-16 HHCS; 4x M10 HHCS).
5. Reinstall the slip ring fasteners to the seal slip
ring (4x 3/8-16 HHCS).
6. Disconnect the tether QD (C) from the rotating T-
box (D) (3x M6 SHCS).
a. Install protective covers (P/N 010-1611) over
the exposed QD interfaces.
b. Let the tether QD hang safely away from the
slip ring working area and secure it with cable
ties.
7. Disconnect the rotating T-box (D) from its mounting bracket (2x M10 HHCS).
a. Unwrap the rotating T-box and the attached QD and hose. Move the parts safely away from the slip
ring working area and secure them with cable ties.
b. Leave the rotating T-box mounting bracket installed on the slip ring. (The T-box mounting bracket
supports the bulkhead-mounted bleed port and the slip ring compensation line.)
Page 230 011-0552-06

Page 231 011-0552-06

8. Disconnect the slip ring QD (E) from the IPDS

and install QD covers.
9. Disconnect the IPDS-to-slip ring cable

mount/bleed point (F) from the frame (2x M10
HHCS).
10. Move the QDs away from the working area and
secure them to a safe area within the TMS frame.
11. Remove the mounting hardware (G) that joins the

slip ring to the drum stub shaft (6x M10 HHCS).
12. Support the T-box mounting bracket by running

cable ties through two of the three bolt holes.
Note: You can remove the cable support

bracket by cutting the cable ties off of the
tether.
13. Support the attached components and pull the

slip ring from the drum.
Installation
1. Align the bleed port hard line with the shallow notch in the drum journal stub-shaft and slide the slip
ring assembly into the drum.
2. Install the mounting hardware (G) to join the slip ring and cable support bracket to the drum stub
shaft (6x M10 HHCS; 41 Nm [30 ft-lb]).
3. Install cable ties onto the cable support bracket to support the nearby cables.
Page 232 011-0552-06

4. Connect the IPDS-to-slip ring cable mount/bleed point (F) to the frame (2x M10 HHCS; 41 Nm [30 ft-
lb]).
5. Connect the slip ring QD (E) to the IPDS (3x M6 HHCS; 8.8 Nm [6.5 ft-lb]).
6. Route and install the rotating T-box (D) onto the rotating T-box mounting bracket (2x M10 HHCS; 41
Nm [30 ft-lb]).
7. Install the tether QD (C) onto the rotating T-box (D) (3x M6 HHCS; 8.8 Nm [6.5 ft-lb]).
8. Install the slip ring anti-rotation bracket (B) (4x 3/8-16 HHCS, 4x M10 HHCS; 41 Nm [30 ft-lb]).
9. Fill and bleed the slip ring compensation circuit (see Slip Ring Compensation: Fill, Bleed, and Drain
on page 1).
10. Install the cross brace guard (A) into the TMS frame (8x M10 HHCS; 41 Nm [30 ft-lb]).
Page 233 011-0552-06

Umbilical, TMS Bullet: Assemble Mechanical Termination

and Test Load
This service instruction explains how to assemble the mechanical termination of the umbilical cable to a
TMS bullet (P/N 001-11872-CR).
Tools See list below
Personnel 2 workers
Parts-Kits Termination kit (P/N 008-0196), resin/socket casting resin (P/N 002-2392)
Safety Electrical shock, power tools, grinder
Consumables See list below
WARNING! The termination assembly must pass a proof load test that is 125% of safe working
load before the TMS is lifted or operated. For mechanical termination of the umbilical at the
LARS/winch end, use the instructions provided by the LARS/winch manufacturer.
WARNING! If the proof load test is not completed and passed, you or others may be injured or
killed and equipment may be damaged or lost.
WARNING! Never work under or place hands or arms under a suspended load.
WARNING! Do not work on the umbilical cable until all electrical power to it is locked out and
tagged out. If you come in contact with the umbilical cable while electrical power is on, you may be
injured or killed.
WARNING! Certain solvents must not be used to clean the umbilical metal strands or insulation.
Do not use acid, soda, methyl hydrate, or acetone. Use only approved solvents.
WARNING! Brakleen and other solvents are extremely flammable; do not use them in enclosed
areas, do not use near open flame or hot work, or near sources of electrical or magnetic ignition.
Gloves and clothing exposed to solvents are very flammable and will retain the hazard until properly
cleaned.
WARNING! Brakleen is an asphyxiate, do not breath the vapors. Vapors are toxic, and can cause
dizziness at concentration levels around 200 ppm. Always use with proper ventilation.
Note: The illustrations in this document are not drawn to scale. References to ABOVE indicate
toward the ship, references to BELOW indicate toward the end of the cable.
Materials Required
Miscellaneous:
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● Termination kit (P/N 008-0196) ● Brakleen® or similar product

● Paper towels or rags ● Acid brushes
● ScotchBright® cleaning pad ● Permanent ink marker
● Plumbers putty ● Resin/socket casting resin (P/N 002-2392)
● LPS brand D'Gel Cable Gel solvent or diesel ● Mixing container & mixing stick
fuel, kerosene, or mineral spirits. ● Fiberglass tape or duct tape
● Isopropyl alcohol
Tools:
● 2.5 cm (3 in) abrasive cutting disk (2x) ● Vise grips
● Utility knife ● Wire-straightening tool, 15-20 cm (6-8in)
● Wire brush, small steel tube, I.D. slightly larger than armor
wires
● Cordless drill driver with socket or flat blade
screwdriver (for hose clamps)
● Air powered ● 1½ in diameter

grinder hose clamp, worm
drive (10x, P/N
002-2251)
Caution! Do not rush this procedure. If the con-

ductor jacket is damaged in any way at any time dur-
ing the procedure, you must start over.
Part 1 - Preparation and Inspection

1. Inspect the umbilical for physical damage. If there is damage, find the spot where the damage ends;
the remaining length of cable is still usable. Wrap an area at least 1 m (3.3 ft) away from the damage
with fiberglass or duct tape. Install a hose clamp over the tape (A in drawings).
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2. If re-terminating a TMS bullet that has old resin and umbilical already in it, cut the umbilical as close
as possible to the bullet. Use a large punch and hammer or a press to remove the old resin and um-
umbilical. It may be necessary to soften the old resin by heating it to no more than 176 °C (350 °F)
with a heat gun.
WARNING! Do not use a torch or other source of excessive heat to soften old resin. The strength
characteristics of the TMS bullet may be permanently altered by excessive heat. Heated resin may
give off noxious fumes. Take appropriate ventilation precautions and use PPE as needed.
Part 2 - Removing the Outer Armor

1. From point A, install hose clamp C at a distance of 9.6 m (31.5 ft).
2. Install a hose clamp 13 cm (5 in) before point A.
3. Cut completely through the umbilical using a high

speed cutting wheel 2.5 cm (1 in) before point A.
4. To minimize contamination of the spelter socket, clean the umbilical between point A and point C
with D'Gel, diesel, kerosene, or mineral spirits.
5. Place the spelter socket on the umbilical before
removing the clamp at A. Remove the clamp after
the spelter is in place.
6. Slide the spelter up the umbilical to point C. Keep
the umbilical as straight as possible to avoid
unwinding the wires.
7. Install hose clamp B 0.6 m (2 ft) below point C.
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8. Install additional hose clamps between point B and the spelter. These clamps will help keep the armor
tightly wound.
9. Cut through OUTER ARMOR LAYER ONLY, just
before point B. It is OK if the inner armor is
partially cut. If you damage the inner conductor
jacket, you must return to Part 1, Step 1.
10. Install two hose clamps 15 cm (5.75 in) above the

cut you made in the previous step.
11. Remove outer armor from point B back to point A. Work with small groups of armor instead of trying
to remove all armor at once. This will make the armor more manageable as it is unwound.
Note: If there is more than one inner armor layer (example illustrated here), cut and remove all but
the last layer, one layer at a time, in the same manner. The inner armor layer may be wrapped in a
tar covered plastic tape. Unravel and remove this tape before attempting to remove further armor lay-
ers.
Part 3 - Removing the Inner Armor

1. Partially cut through the inner armor layer, working in small segments at a time.
Caution! If the conductor jacket is damaged in any way while the armor is being cut, do not con-
tinue this procedure. You must cut off the damaged section and start over.
2. Begin unwinding the inner armor in small groups, starting from point A. When you reach point B,
remove all but about 2 feet of the armor.
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Note: Trimming the excess armor to a shorter length will make it easier to remove the inner armor.
3. Bend the partially cut armor strands away from the conductor jacket. Work them back and forth until
they break off. Work in small groups until all of the inner armor has been removed.
4. Tyco cable users: peel off the thin blue covering and skip to Part 4 - Brooming, Cleaning, and
Abrading the Armor Wires.
Nexan cable users: clean all grease off of the inner cable with a solvent specified in the beginning of
this document. Solvents may require a soak time to fully dissolve grease and residue. Do a final
cleaning with isopropyl alcohol to remove any traces of petroleum-based solvents as much as possible.
Part 4 - Brooming, Cleaning, and Abrading the Armor Wires

1. Remove the hose clamp at location B.
2. Using the wire straightening tool, straighten each armor wire so it projects from the hose clamp in
the same direction as the helical lay of the cable. Wires should be bent 35 degrees away from the
umbilical.
WARNING! You must completely clean and dry each armor wire. If you do not, the resin will not
properly bond and the termination will fail the proof load test or later in service.
3. Straighten, broom, and clean the outer armor layer before

moving on to the inner layer(s). Each armor wire requires
brooming and cleaning. Use Brakleen or similar product to
thoroughly clean each strand. Wipe with clean, lint free cloth and
reapply cleaner.
Part 5 - Preparing the Spelter for Potting

1. Install the supplied section of heat shrink as far under the broomed armor as possible. This will protect
the conductor jacket from the armor strands.
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2. Use Alcohol to clean out the inside of the spelter as much as possible. Slide the spelter back onto the
broomed wires. Only rotate the spelter in the same direction as the helical lay of the umbilical armor.
Loosen and slide, or remove and install, hose clamps as necessary to keep the armor from unraveling.
All hose clamps between the spelter and broom will be removed. No clamps or foreign material of any
kind should remain inside the spelter socket. Install a hose clamp directly above the spelter. Install
Band-It clamps or additional hose clamps 0.3 m (1 ft), 0.9 m (3 ft), and 1.8 m (6 ft) beyond the first.
3. Orient the spelter so that it is exactly vertical and the umbilical is centered inside. Follow these tips
when orienting the spelter and umbilical:
— If possible, use potting fixture 010-1685 to ensure proper spelter/umbilical orientation.
— When moving it to a vertical position, avoid placing strong bending forces on the umbilical.
— Make sure that the setup is stable and settled so that the parts do not move during the cast-
ing.
— Make sure that the broom is fully seated inside the spelter before pouring resin.
— Confirm that the resin is within its expiration date. Take a picture of the batch number and
expiration date.
4. Install a strip of putty in the gap between the spelter and umbilical. This will prevent the resin from
leaking through while it is curing.
WARNING! If resin leaks out of the dam area, this may cause voids in the resin, weakening the
joint. Make sure that resin does not leak out.
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Part 6 - Casting the Resin in the Spelter

Caution! Do not use resin that has passed its expiration date. If you use expired resin, the ter-
mination may fail the proof load test.
1. Mix the resin according to the manufacturer’s instructions. Follow the instructions on the container
regarding setup time, working temperatures, and special conditions.
2. Pour the resin, filling to the edge of the angled section. The ends of the wires may be exposed. Follow
these tips when casting the resin into the spelter socket:
— The resin will settle as it cures. Verify that the broomed armor is still covered after the resin
has had time to settle.
— Pour slowly from 0.3-0.6 m (1-2 ft) above the spelter. This allows the resin to flow in a thin
stream and minimizes bubbling.
— Tap on the spelter with a rubber hammer while pouring. This helps the resin flow deeper
and allows bubbles to escape.
Part 7 - Proof Load Testing

Purpose of load testing: After verifying that the TMS mechanical termination has been installed, you
must load-test the system to confirm that the termination can stand up to the forces it will encounter dur-
ing use.
For information regarding the mechanical connection components required for load testing, see
ROV/TMS Equipment: Lifting on page 1.
WARNING! Proving the load worthiness of the termination is a critical step in the termination pro-
cess, because it is the only way to verify that the termination is sound. If you do not test the mech-
anical termination, this may affect warranty claims, equipment may be severely damaged, and you or
others may be injured or killed.
Note: When performing a load test, fill out the following load testing data record.
Load Weight: The HD umbilical mechanical termination should be load-tested to a proof load equal to
125% of the maximum in-air weight of the total ROV system, including the weight of the TMS and through
frame lift, added weights, and any other equipment added to the system.
Caution! When load testing the spelter, do not exceed the maximum rated peak working loads or
minimum bend radius of the umbilical cable. This may damage the optical fibers or copper con-
ductors.
Load testing guidelines

● You can load test the TMS mechanical termination by attaching the clevis joint on the spelter socket
with an inline tension transducer to a fixed object that can withstand the test loads. The spelter
socket should not be attached to the TMS for load testing.
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● You can apply force to the umbilical using the LARS winch and a tension transducer to monitor the
applied forces.
● You should apply load to the umbilical in a slow controlled manner (no shock loading) up to the
determined proof load. The proof load should be held for up to 1 minute and then slowly released.
● Note that resin will shrink 1.5-2% as it cures. It is normal for the resin to slip slightly and wedge
more tightly into the spelter socket.
● References:
— FMC Schilling Robotics Service Bulletin 012-0088; TMS Lift point Maximum Static Test
Load.
— IMCA R 011; The Initial and Periodic Examination, Testing and Certification of ROV Hand-
ling Systems.
TMS Mechanical Termination Load Testing Data Record

TMS Mechanical Termination Load Testing Data Record
Termination Date:
Personnel Performing Termination:
Umbilical Manufacturer and Model Number:
Umbilical Mechanical Rated Load:
Mechanical Termination Manufacturer/Model:
Mechanical Termination Load Rating:
Expiration Date of Epoxy Resin:
Load Testing Date:
Load Testing Personnel:
Test Load:
Witness Signature: ________________________ Date: _______________________
Page 241 011-0552-06

Digital Telemetry System 9. Surface Rack Node
9. Surface Rack Node

9.1 About Surface Rack Node (101-7356) & Associated Components
Primary active components in the Digital Telemetry System (DTS) are the sur-
face rack node and the subsea nodes and node ports, which interface with tele-
metry and DC power to a variety of subsea devices.
The RSTP-enabled surface rack node interfaces with the subsea system fiber
optic lines A and B and connects subsea video and control data to the RTC com-
puter.
Up to 16 subsea video and data channels can also be ported to the front panel for non-system control uses.
Channels/ports are selected using the control system (see Volume 3: Operator Controls).
9.1.1 Surface Rack Node: Configuration

Channels/ports are selected using the ROV control system (see Volume 3: Operator Controls).
9.2 Surface Rack Node: Connections

Interconnect diagrams for the topside and subsea DTS components are located in the “System Schematics
& Interconnect Diagrams” section of Volume 4: Drawings and Part Lists.
9.2.0.1 Interface Modules
9.2.0.2 SIM & NIM Serial Pinouts

Both the SIM and the NIM outputs on the rack node use an 8-pin female RJ-45 connector. The 8 pin RJ-
45 female connector can also mate with RJ-11 and RJ-12 male connectors (see SIM & NIM Connections
below). The RJ-11 has four pins and will connect with pins 3-6 on the RJ-45. The RJ-12 has six pins and
connects with pins 2-7 on the RJ-45. Note that although the functions match up between the connectors in
the table below, the pin numbers for each type of connector DO NOT. Also note that the faceplate on the
SIM RJ-45 female connector is narrowed and prohibits insertion of an 8-pin RJ-45 male.
SIM & NIM Connections
RJ-45 Female RJ-12 Male RJ-11 Male
Pin Function Pin Function Pin Function

1 NC
2 NC 1 NC
3 S>M (Uplink) 2 S>M (Uplink) 1 S>M (Uplink)
Page 242 011-0552-06

SIM & NIM Connections (continued)
RJ-45 Female RJ-12 Male RJ-11 Male
Pin Function Pin Function Pin Function

4 Signal common 3 Signal common 2 Signal common
5 NC 4 NC 3 NC
6 M>S (Downlink) 5 M>S (Downlink) 4 M>S (Downlink)
7 NC 6 NC
8 NC
9.2.0.3 Modular Adapters, RJ11 to DB9

Many topside devices are connected with RJ11 (4-pin) patch cables. When the device has
a male or female DB9 connector, a modular adapter (right) must be used. The modular
adapters have a male or female DB9 connector at one end and a 6-pin, RJ12 female con-
nector at the other that accepts the RJ11 cable connectors. Since DB9 pin functions are
standardized and RJ11 connectors are not, different adapters are needed to provide the
correct TX/RX/crossover configurations. The adapters are color coded for ease of iden-
tification and use.
● Devices that connect to a node or directly to a circuit board use a green adapter
(standard wiring) or a yellow adapter (“reverse”—crossover or null modem wiring).
● Devices that connect to the Digi Serial Expander use a blue adapter (standard wiring) or a red
adapter (“reverse”—crossover or null modem wiring).
The table below provides more information on each type of modular adapter.
Modular Adapters
P/N Color DB9 P/N Color DB9
005-4320 Green Female 005-4322 Yellow Female
005-4321 Green Male 005-4323 Yellow Male
005-4986 Blue Male 005-4988 Red Male

005-4987 Blue Female 005-4989 Red Female
Page 243 011-0552-06

Modular Adapters (continued)

P/N Color DB9 P/N Color DB9
Note: The 6P4C, RJ11-terminated cables comes in several lengths: 005-4999-7 (7 ft), 005-4999-14 (14 ft),
005-4999-25 (25 ft), 005-4999-50 (50 ft)
Page 244 011-0552-06

Node SFP Module: Remove and Install

This service instruction explains how to remove and install the node SFP module.
Tools See sub-procedures
Personnel 1 worker
Sub-Procedures Service Guidelines in Volume 1: ROV & TMS System Manuals, Fiber Dome: Remove and Install on page 188
Parts-Kits None
Safety Electric shock, pinch
Consumables Cable tie
Caution! Nodes contain ESD-sensitive components. Follow ESD guidelines when you are servicing
nodes (see Fiber Dome: Remove and Install on page 188).
Removal
2. Remove the node from the ROV, TMS, or rack (see Subsea Node: Remove and Install on page 171).
Note: Subsea nodes are decompensated during the removal process.
3. Remove the cover over the SFP module:

— For subsea nodes, remove the fiber dome assembly (see Fiber Dome: Remove and Install
on page 188).
— For surface rack nodes, remove the top cover of the surface node [(4x) Phillips screws].
4. Disconnect the fiber optic ST connector from the SFP module by pressing down on the locking tab
and gently pulling the connector away from the SFP module.
Note: Make sure to mark the cable orientation.
Note: Do not pull on the cable. This will cause damage. Instead, pull directly on the ST connector.
5. Remove the SFP module from the SFP cage:

a. Pull the SFP latching mechanism (bar) in the direction the module slides out of the cage. This will
loosen the module.
b. Gently pull the SFP module out of the cage to remove it from the node.
Page 245 011-0552-06

Installation
1. Identify and confirm the correct SFP module with the correct SFP cage:
— Blue SFP module (Tx: 1310 Rx: 1550) with SFP cage labeled ‘A’ on the node PCB
— Green SFP module (Tx: 1550 Rx: 1310) with SFP cage labeled ‘B’ on the node PCB
2. Insert the SFP module into the SFP cage. Make sure that it is fully seated and the label is face up.
3. Move the latching mechanism (bar) into the locked position.
4. Insert the corresponding fiber optic ST connector into the SFP module. A “click” sound from the
locking tab indicates the connector is fully seated.
5. Install the cover over the SFP modules:
— For subsea nodes, install the fiber dome assembly (see Fiber Dome: Remove and Install on
page 188).
— For surface rack nodes, install the top cover of the surface node (4x Phillips screws).
6. Install the node into the ROV, TMS, or rack (see Subsea Node: Remove and Install on page 171.) Be
sure to fill and bleed a subsea node.
Page 246 011-0552-06

Compensation 1. About Compensation
Compensation
1. About Compensation 247

2. Compensation: Specifications 249
3. Compensation: Troubleshooting 252
4. Compensation: Maintenance and Service 256
5. Rapid Fill and Bleed Compensation Cart 274
1. About Compensation
1.1 Overview
Compensation is a method of equalizing the pressure on the walls of enclosed housings to prevent subsea
pressure from collapsing the housings. This is accomplished by using a spring loaded oil filled diaphragm
compensator to apply ambient subsea pressure to the inside of the enclosed housing.
TMS and ROV components requiring active compensation are supplied with fluid from 2.2-liter com-
pensators (core model 101-4163) or 8-liter compensators (P/N 101-8905). The compensators can be used as
a single supply source or ganged to provide larger volumes of fluid.
Used singly or ganged, compensators store and supply fluid to components requiring active pressure com-
pensation when submerged in water. A spring-loaded accumulator raises the pressure slightly higher than
the ambient water pressure to prevent the intrusion of seawater into the compensated volumes. Com-
pensators can also be used as reservoirs for HPU fluid.
As installed, compensators will have a visual fluid level indicator and/or a level-sensing module to provide
data for a graphic display of the fluid level on the control console.
Page 247 011-0552-06

Compensation 1. About Compensation
Note: It should be noted that these devices can also be used as reservoirs. Reservoirs are connected
to hydraulic circuits to provide additional capacity for the hydraulic fluid or absorb expansion as the
oil heats up under use. For more about reservoirs, see About 2.2-L and 8-L Reservoirs in Volume
1: ROV & TMS System Manuals. The primary difference between a compensator and a reservoir is
defined not by design but by the application. Reservoirs provide additional hydraulic fluid capacity
for existing hydraulic systems, and may have built in filters. Compensators supply ambient pressure
for enclosed subsea housings. Compensators do not have filters.
1.2 Compensation Circuits

The TMS and ROV each have several compensation circuits. Each circuit is independent and has one or
more compensators, a fill point, a volume sensor, and one or more connected devices. Each circuit may
also have one or more quick disconnects for isolating devices and allowing them to be drained without
affecting the entire circuit. Circuits can be filled and drained using the compensation cart (P/N 101-4462,
HD only) or the rapid fill and bleed (P/N 101-9644, UHD-III only).
1.3 Compensators
ROV and TMS components requiring active compensation are supplied with fluid from 2.2-liter com-
pensators or 8-liter compensators. 2.2-liter compensators attach directly to node ports and must be cal-
ibrated before use. All 8-liter compensators attach to a position sensor array (which reports fluid levels) and
do not require calibration.
The UHD-III ROV includes the following compensators:
● 2.2-liter compensators (two)
— One for all thruster bearings
— One for the TITAN 4 manipulator arm
● 8-liter compensators (two)
— One for AC devices
— One for DC devices
● 8-liter compensators acting as reservoirs (three)
— One for the ROV main hydraulics
— One for isolation pump circuit #1
— One for isolation pump circuit #2
The UHD-III TMS includes the following compensators:
● 2.2-liter compensator (one)
— Node and solenoids
● 8-liter compensator (one)
— IPDS, motors, and slip ring
Page 248 011-0552-06

Compensation 2. Compensation: Specifications
1.4 Reference
TMS and ROV compensation schematics, drawings, and part lists (including compensator kits and mount-
ing hardware) are located in Volume 4: Drawings and Part Lists.
2. Compensation: Specifications
2.1 General Specifications
2.2-liter Compensator
Model Variants
101-4163 This variant is typically used in gang-mounted installations where one other compensator
is fitted with a level-sensing UCM to monitor fluid level from the control console.
101-4163-5 Adds a level-sensing UCM.
101-4163-7 Adds a level-sensing UCM.
Height 20.8 cm (8.2 in)
Width 19.1 cm (7.5 in)
Length 37.1 cm (14.6 in)
Weight in air (without com- 5.4 kg (12 lb)
pensation fluid)
Weight in seawater (without 1.4 kg (3.1 lb)
compensation fluid)
Electrical (UCM equipped models only)
Input voltage, min- 26 VDC (22 to 30 VDC)
imum/maximum
Input current, inrush (at star- 500 mA
tup)
Input current, nominal 250 mA
Isolation from ground, > 5 megohms
input/output
Cables in (various lengths 101-4155, 101-7230
denoted by -x after part num-
ber)
Telemetry (UCM equipped models only)
Communication standard Master/slave, half-duplex, RS-232
Node port configuration 38400 bits per second, 8 data bits, no parity, 1 stop bit
Hydraulic
Volume 2.2 L (0.58 gal)
Page 249 011-0552-06

2.2-liter Compensator (continued)

Operating pressure (above 0.58 bar to 0.7 bar (8 to 10 psi)
ambient)
Relief valve cracking pressure 1.4 bar (20 psig)
(above ambient)
Charge fitting/port 2x 1/4 NPT and 2x 1/2 NPT
Fluid viscosity, min- 45 SSU to 64 SSU
imum/maximum
Sensors (UCM equipped models only)
Fluid level Hall-effect position sensor
Environmental
Operating temperature, min- 0 °C to +40 °C (32 °F to 104 °F)
imum/maximum
Storage temperature, min- -18 °C to +50 °C (0 °F to 122 °F)
imum/maximum
Humidity 0 - 100%
Depth rating 6,000 MSW (19,685 fsw)
Note: For more information about the UCM, see About Universal Control Modules (UCM) on page 1
in Volume 1: ROV & TMS System Manuals.
8-liter Compensator
Part number 101-8905
Height 29.2 cm (11.5 in)
Width 30.5 cm (12.0 in)
Weight in air (without compensation fluid) 14.9 kg (33 lb)
Weight in air (with compensation fluid) 21.3 kg (47 lb)
Weight in seawater (without compensation fluid) 9.5 kg (21 lb)
Weight in seawater (with compensation fluid) 8.2 kg (18 lb)
Hydraulic
Volume 8 L (2.11 gal)
Operating pressure (above ambient) 0.41 bar to 0.76 bar (6 to 11 psi)
Relief valve cracking pressure (above ambient) 1.38 bar (20 psi)
Page 250 011-0552-06

8-liter Compensator (continued)

Approved fluids General hydraulic oil:
● Hydrocarbons
● Oils
● Hydraulic fluids
Fluid viscosity, minimum/maximum
Hydraulic connections and fittings (2) custom pluggable in -8ST ports
Sensors
Fluid level 101-9512
Environmental
Operating temperature, minimum/maximum -2 °C (28.4 °F)/80 °C (176 °F) oil temp
Storage temperature, minimum/maximum -2 °C (28.4 °F)/45 °C (113 °F)
Humidity
8-liter Reservoir
Part numbers 101-8909, 101-8909-1, 101-8909-2
Height 29 cm (11.4 in)
Width 26.7 cm (10.5 in)
Weight in air (without compensation fluid) 21.8 kg (48 lb)
Weight in air (with compensation fluid) 28.8 kg (62 lb)
Sensor
Fluid level 101-9512
Hydraulic
Exchange volume 8 L (2.1 gal)
Usable volume 8 L (2.1 gal)
Approved fluids Hydraulic oil
Operating pressure 0.41 bar to 0.76 bar (6 to 11 psi)
Flow 189.25 lpm (50 gpm)
Return pressure, maximum 0.76 bar (11 psi)
Relief valve cracking pressure 1.72 bar (25 psi)
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Compensation 3. Compensation: Troubleshooting
8-liter Reservoir (continued)

Fluid temperature, maximum 80 °C (176 °F)
Hydraulic fittings -20 ORFS, custom
Environmental
Operating temperature, minimum/maximum -2 °C (28.4 °F)/80 °C (176 °F) oil temp
Storage temperature, minimum/maximum -2 °C (28.4 °F)/45 °C (113 °F)
Humidity
2.2 Compensation Fluid

Parameters for choosing a compensation fluid:
● Use Shell Tellus or Royal Purple Marine Hydraulic Oil only.
● Viscosity should be as low as practical so flow is adequate to ensure the compensation of com-
ponents and cables.
— Do not use white mineral oil as it does not contain anti-oxidizing agents.
— Do not use water-based fluids as they can corrode internal components of the hydraulic cir-
cuit.
— Do not use used fluids that have been filtered.
● For commonality, try to use the same fluid in the high pressure hydraulic systems and in the com-
pensation circuits.
● When in doubt about which fluid to use, contact the Technical Support Group at
schilling.TS@fmcti.com.
3. Compensation: Troubleshooting
Troubleshooting symptoms, causes, correction, and prevention of compensation problems are outlined in
the table below. Related procedures are described in the following sections.
Caution! Although some compensation problems are caused by mechanical failures or mal-
functions, many are the result of human error, such as:
● Failure to fully reconnect or tighten compensation quick disconnects (QDs), hoses, fittings, plugs,
connectors, or other hardware after a circuit has been opened for service;
● Failure to completely fill and bleed all compensated volumes and supply lines;
● Failure to tighten other hardware removed or loosened during maintenance, inspection, or a ser-
vice procedure; and
● Failure to inspect the compensation circuits before a dive to verify that each one is filled and all
lines and devices are bled.
Careful and consistent inspection, maintenance, and service of compensation circuits is far more efficient
than the repair or replacement of components and devices damaged or destroyed by a compensation fail-
ure.
Page 252 011-0552-06

3.1 Troubleshooting Table

Troubleshooting
Symptoms Causes Inspect and Correct Prevention
Fluid on equipment or deck ● Fluid leak ● Bleed circuit com- Pre-dive:
● Compensators ponents and lines. ● Inspect circuit components
not completely Inspect com- for low fluid, leaks, loose
Low or diminishing volume filled pensators for low hardware, open connections,
in a compensator or repor- volumes. pinched or kinked hoses or
● Air in circuit
ted on the control console, lines or com- ● Inspect circuit for cables, etc.
low volume alarm ponents the mechanical fail- ● After opening a circuit for ser-
ure of a hose, fitting, vice, be sure to fully recon-
O-ring, connector, or nect and tighten all hoses, fit-
Water intrusion indicator or other seal-related tings, plugs, connectors, and
alarm on the control con- component. other seal-related com-
sole ● Inspect circuit for ponents.
loose or uncon- ● Completely fill and bleed all
nected com- circuit components and sup-
Water in a device pensation hoses, fit- ply lines.
tings, plugs,
Any time:
connectors, or other
● Be sure to replace and
Failure or malfunction of a hardware.
tighten other hardware
device due to water ● Inspect circuit for
removed or loosened during
other hardware
a maintenance, inspection,
removed or
or service procedure.
Crushed or collapsed loosened during a
device maintenance,
inspection, or ser-
vice procedure.
Difficulty or slowness filling ● Broken com- ● Compensator Viscosity should be as low as prac-
and bleeding components pensator tical
and circuits spring
● Pinched or ● Hoses and cables
kinked hose or
cable
● Fluid viscosity ● Fluid
too high
Page 253 011-0552-06

Troubleshooting (continued)
Symptoms Causes Inspect and Correct Prevention
Level reading absent or ● Air in circuit ● Bleed circuit com- Pre-dive:
inconsistent with lines or components and lines. ● Inspect circuit components
compensator ponents ● Inspect circuit for for low fluid, leaks, loose
● Fluid leak the mechanical fail- hardware, open connections,
● Malfunctioning ure of a hose, fitting, pinched or kinked hoses or
sensor O-ring, connector, or cables, etc.
other seal-related ● After opening a circuit for ser-
component. vice, be sure to fully recon-
● Inspect circuit for nect and tighten all hoses, fit-
loose or uncon- tings, plugs, connectors, and
nected com- other seal-related com-
pensation hoses, fit- ponents.
tings, plugs, ● Completely fill and bleed all
connectors, or other circuit components and sup-
hardware. ply lines.
● Inspect circuit for Any time:
other hardware
● Be sure to replace and
removed or
tighten other hardware
loosened during a
removed or loosened during
maintenance,
a maintenance, inspection,
inspection, or ser-
or service procedure.
vice procedure.
● Inspect level sensor
and PSA, replace
sensor if needed
3.2 Leaks
Individual circuits are shown on the ROV and TMS compensation schematics (see Volume 4: Drawings
and Part Lists).
Caution! If a QD is damaged, disconnected, or improperly connected, every part of the circuit past
the QD will not be compensated, allowing water to enter.
Basic Troubleshooting
If a compensation circuit volume is low or diminishing, do the following:
1. Use the compensation schematic to identify all lines and devices in the circuit. Note that compensation
fluid may be supplied through a SeaNet cable or a separate line.
2. Look for oil. If you find oil on or under the ROV, trace it back to the source.
3. If oil can’t be found or you cannot determine where it is leaking from, see the following sections.
Page 254 011-0552-06

When Compensation is Supplied Through a Node

A node distributes fluid to all connected SeaNet cables and some of the connected devices.
1. To determine if a leak is from the node or in the SeaNet cables and devices, disconnect half of the
SeaNet cables from the node.
— If the loss of fluid stops, reconnect the SeaNet cables (one at a time) until the leak reappears.
Inspect the SeaNet cable and device for leaks.
2. If the loss of fluid continues, disconnect the remaining SeaNet cables.
— If the loss of fluid stops, reconnect the SeaNet cables (one at a time) until the leak reappears.
Then check the SeaNet cable and connected devices for leaks.
3. If the loss of fluid continues, carefully inspect the node and compensation supply lines to the node for
leaks.
4. Determine the cause of the leak.
— If the leak was the result of a mechanical failure of a properly connected and maintained line
or device, determine the cause and correct it.
— If the leak was caused by human error, review connection, inspection, maintenance, and ser-
vice procedures for possible corrections.
3.3 Air in Circuit or Low Fluid Volume

Perform these steps when the lack of fluid is NOT due to a leak.
1. Inspect the circuit to be sure fluid is NOT leaking.
2. Fill all of the circuit compensators. (See Rapid Fill and Bleed Cart: Operation on page 283.)
3. Use the compensation schematic to identify all lines and devices in the circuit.
4. Bleed all lines and devices in the circuit. (See Rapid Fill and Bleed Cart: Operation on page 283.)
5. Refill compensators as needed.
6. Review pre-dive procedures to determine why the circuit was not inspected, filled, and bled before dive.
3.4 No or Incorrect Volume Data on Control Console

One compensator in each circuit has a volume sensor (connected to a node SIM with a SeaNet cable) which
supplies the data for the control console volume display. If the volume display is not functional or is incor-
rect, perform the following tests.
2.2-liter Compensator
1. Verify that the SeaNet cable to the volume sensor is connected correctly and latched.
2. Verify that the Signal 1 up (slave to master) blue LED is lit and blinking.
— If the blue LED is not lit and blinking, replace the SeaNet cable with a known-good spare.
— If the replacement cable blue LED is not lit and blinking, replace or adjust the volume sensor
in the compensator.
8-liter Compensator
1. Verify that the level sensor and PSA are connected correctly.
2. Verify that the PSA is functioning correctly.
Page 255 011-0552-06

Compensation 4. Compensation: Maintenance and Service
3. Verify that the level sensor shaft spins and the pin feature on the spring pack is intact.
4. Compensation: Maintenance and Service

Schedule
Component Action
Period
Compensators Every 12 Replace used compensation fluid with new fluid.
and reservoirs months
Caution! Do not replace compensation fluid with used fluid that has been
filtered. Filtering does not reduce the acidity of the fluid (which increases as a
fluid degrades through use). Acidic fluids can corrode metal components, damage
seals, accelerate wear, form deposits, and increase viscosity.
Reservoirs Pre-dive or Inspect for fluid contamination, loss, and air; charge and bleed as needed.
post-dive
Sliders Weekly Inspect and replace if worn.
Anodes Weekly Inspect and replace when 1/3 of original volume remains.
Page 256 011-0552-06

2.2-Liter Compensator: Remove, Install, Dry-test, and Fill

This service instruction explains how to remove, install, dry-test, and fill the 2.2-liter compensator (P/N
101-4163).
Tools Compensation cart, wrench (10 mm), torque wrench (0-10 Nm [0-100 in-lb ])
Personnel 1 worker
Sub-Procedures 2.2-Liter Compensator: Remove, Install, Dry-test, and Fill above
Parts-Kits None
Safety Deck safety
WARNING! Do not loosen or remove the compensator housing clamp unless you have restrained
the spring and piston as directed by a service instruction. Uncontrolled release of the spring can ser-
iously injure you or others and damage surrounding equipment.
Note: The spring, piston, and spring guide are not field serviceable. Return the assembly to the fact-
ory for service.
Removal
1. Disconnect the compensator from the compensator lines at the quick disconnect (QD) fitting.
2. Disconnect the SeaNet cable from the UCM (level sensor), if present.
3. Remove the compensator from its mounting site or brackets, saving the mounting hardware.
4. Attach a compensation cart to the QD fitting and drain the compensator.
Install
1. Install fittings on the new compensator to match the orientation as previously installed.
— Use only polytetrafluoroethylene (PTFE) tape on the threads, but to prevent fluid con-
tamination, do not apply it to the first one or two threads.
— Install the fittings finger-tight, then tighten 1 1/2 turns further to achieve the correct
torque.
2. Mount the compensator to the mounting site or bracket, using the original or replacement M10 nylock
hardware. Torque the mounting bolts to 5.7 Nm (50 in-lb).
Caution! Do not use thread-locking compounds containing bisphenol A fumarate resin on any hard-
ware or fittings installed into the polyurethane compensator housings. These compounds will cause
crazing.
Note: If the remainder of the compensation system remains sealed, the compensator can be pre-filled
and bled before installation.
3. Connect the compensation line and SeaNet cable (if equipped with level-sensing).
4. Charge and bleed the components as needed (see the Fill on the next page
Page 257 011-0552-06

Dry-test
1. If the compensation system fittings or components have been opened or replaced, dry-test the
compensation system for leaks before charging it with fluid. Use one of these two methods:
a. Fill the compensation system with air or nitrogen to one atmosphere (15 psi). Spray all connections
and compensated components with a mild detergent or window cleaner to check for leaks. Active
bubbles or foam indicate a leak.
b. Install a pressure gauge on the compensation system. Fill the system with air to one atmosphere
(15 psi). Allow the air pressure to stabilize. Then, monitor the pressure gauge over a period of at
least two hours. If you notice any drop in pressure, check for leaks using the detergent method
described in the previous step.
Fill
Charge and bleed the compensation system only after verifying that all compensated components are func-
tioning correctly and that the bleed fittings are accessible.
Caution! If compensated components are submerged while large amounts of air remain in the com-
pensation system, the components or enclosures may be damaged. Verify that the compensator is cor-
rectly installed and that air has been bled from all compensated components.
1. Charge the compensator through one of its unused fittings. Temporarily disconnect any other lines
that may become filled with air expelled from the compensator during the charging process.
Note: Charging pressures above 1.4 bar (20 psig) will cause compensation fluid or vapor to escape
from the relief valve.
2. Pump fluid into the compensator until the yellow band on the piston approaches the “full” band on the
housing. Do not fill completely. Crack the fitting seal at the top of the compensator and bleed off
any air in the accumulator.
3. Re-connect the compensation lines that were disconnected during removal.
4. Starting with the lowest, open each compensated component’s bleed plug or relief valve poppet and
bleed off all air. Reseal when compensation fluid emerges. Continue adding fluid to the compensator as
needed.
5. Bleed any remaining air from the compensator and fill the compensator until the yellow band on the
piston approaches the “F” (full) band on the housing.
Note: Do NOT fill the compensator completely. Leave a small amount of diaphragm travel for
thermal expansion.
6. Inspect the compensation system components, hoses, and connections for leaks. Correct all leaks.
Page 258 011-0552-06

2.2-Liter Compensator Diaphragm: Remove and Install

(without UCM)
This service instruction explains how to remove and install the diaphragm of the 2.2-liter compensator
(non-UCM).
Tools Bolt or pin (12 mm diameter), wrench (10 mm), torque wrench (0-10 Nm [0-100 in-lb])
Personnel 1 worker
Sub-Procedures 2.2-Liter Compensator: Remove, Install, Dry-test, and Fill on page 257
Parts-Kits 004-0895, DIAPHRAGM,COMP,2 LITER
Safety Spring under tension
Consumables Dow Corning 55 O-Ring Lube (Thin) (P/N 002-0359)
WARNING! Do not loosen or remove the central housing clamp unless you have restrained the
spring and piston as directed in a service instruction. Uncontrolled release of the spring can seriously
injure you or others and damage surrounding equipment.
Removal
1. Remove and drain the compensator (see 2.2-Liter Compensator: Remove,
Install, Dry-test, and Fill on page 257). Thoroughly wash out the water-side
housing to remove all internal debris.
2. Restrain the piston and spring by inserting a 12 mm diameter bolt or pin

through both sides of the water-side housing and piston skirt holes (A). Secure
in place with tape or a nut.
Caution! If you use threaded bolts to restrain the piston and spring, tape
the threads to prevent damage to the plastic coating on the spring. If the
plastic coating is damaged, the spring can corrode and fail.
3. Mark the orientation of the housings and housing clamp with a felt pen so
they can be replaced in the same positions.
Page 259 011-0552-06

4. Slowly loosen and remove the housing clamp (B). Do not open it too wide; this
will distort its shape. (It is normal for spring pressure to separate the oil and
water-side housing flanges by 2-3 mm [0.062-0.125 in] when the housing
clamp is removed.) Separate the oil and water-side housings.
5. Remove the M6 x 25 sealing screw (C) and separate the diaphragm guide (D),
O-ring (E), and diaphragm (F) from the piston.
6. Remove and discard the damaged diaphragm.
7. Thoroughly clean all components.
Installation
1. Install the replacement diaphragm, seating the D-profile lip into the flange of the water-side housing
(with the flat side facing out). Form and smooth the diaphragm over the piston.
2. Apply O-ring lubricant to the mating surfaces of the sealing screw and diaphragm guide O-ring (P/N
004-0015). Install the diaphragm guide and O-ring onto the diaphragm and piston.
3. Install the M6 x 25 sealing screw (3-4 Nm [35 in-lb]).
4. Install the oil-side housing onto the water-side housing, aligning marks and making sure that the D-
profile bead on the diaphragm remains seated in the flange of the water-side housing.
5. Apply DC-55 O-ring lubricant to the inner faces of the clamp and the outer flanges of the housings that
contact the clamp.
6. Using clamps or with the help of another person, press the housings together. Make sure the oil-side
housing is seated within the perimeter of the water-side flange. Install the housing clamp to the
position marked with the felt pen.
Note: To help the clamp seat fully and draw the housings together, tap lightly around its perimeter
with a rubber mallet while tightening the clamp nut [housing clamp; (7.3 Nm [65 in-lb]).
7. Inspect the assembly and confirm that:

— The oil-side housing is seated within the water-side flange
— The housing clamp is fully and correctly seated
— The clamp torque is correct
8. Remove the bolt or pin securing the piston in the compensator.
Page 260 011-0552-06

2.2-Liter Compensator Diaphragm: Remove and Install (with

UCM)
This service instruction explains how to remove and install the diaphragm of the 2.2-liter compensator
equipped with the universal control module (UCM).
Tools Bolt or pin (12 mm diameter), wrench (10 mm), torque wrench (0-10 Nm [0-100 in-lb])
Personnel 1 worker
Parts-Kits 004-0895 DIAPHRAGM,COMP,2 LITER
Safety Spring under tension
spring and piston as directed in a service instruction. Uncontrolled release of the spring can seriously
injure you or others and damage surrounding equipment.
Removal
1. Remove and drain the compensator (see 2.2-Liter Compensator: Remove, Install, Dry-test, and Fill
on page 257). Thoroughly wash out the water-side housing to remove all internal debris.
2. Remove the UCM (level sensor) (H) from the water-side housing.
3. While holding the carrier, unscrew the magnet sleeve (I). Note how many turns are needed to remove
it so it can be reinstalled in the same position.
Figure 1
Page 261 011-0552-06

Figure 2
4. Slide a 12-inch long, 3/8-inch drive extension into the sensor spring assembly (G) until it is seated in
the socket in the inner spring retainer. Unscrew the spring assembly from the sealing screw while
turning the spring retainer end to keep the spring from being damaged.
5. Restrain the piston and spring by inserting a 12 mm diameter bolt or
pin through both sides of the water-side housing and piston skirt
holes (A). Secure in place with tape or a nut.
Caution! If you use threaded bolts to restrain the piston and

spring, tape the threads to prevent damage to the plastic coating
on the spring. If the plastic coating is damaged, the spring can
corrode and fail.
6. Mark the orientation of the housings and housing clamp with a felt
pen so they can be replaced in the same positions.
Page 262 011-0552-06

7. Slowly loosen and remove the housing clamp (B). Do not open it too
wide; this will distort its shape. (It is normal for spring pressure to
separate the oil and water-side housing flanges by 2-3 mm [0.062-
0.125 in] when the housing clamp is removed.) Separate the oil and
water-side housings.
8. Remove the M6 x 25 sealing screw (C) and separate the diaphragm
guide (D), O-ring (E), and diaphragm (F) from the piston.
9. Remove and discard the damaged diaphragm.
10. Thoroughly clean all components.
Installation
1. Install the replacement diaphragm, seating the D-profile lip into the flange of the water-side housing
(with the flat side facing out). Form and smooth the diaphragm over the piston.
2. Apply O-ring lubricant to the mating surfaces of the sealing screw and diaphragm guide O-ring (P/N
004-0015). Install the diaphragm guide and O-ring onto the diaphragm and piston.
3. Install the M6 x 25 sealing screw (3.4 Nm [35 in-lb]).
4. Install the oil-side housing onto the water-side housing, aligning marks and making sure that the D-
profile bead on the diaphragm remains seated in the flange of the water-side housing.
contact the clamp.
6. Using clamps or the help of another person, press the housings together. Make sure the oil-side
with a rubber mallet while tightening the clamp nut (housing clamp; 7.3 Nm [65 in-lb]).

Page 263 011-0552-06

Installation and Calibration of Level-Sensing Hardware

1. Fill the compensator to make installing the spring assembly easier. Use compressed air (recommended)
or fresh fluid, as you may need to drain the compensator during calibration.
2. Slide a 12-inch long, 3/8-inch drive extension into the spring assembly until it is seated in the socket in
the inner spring retainer. Grasp the spring assembly by the carrier and stretch the spring up the
extension. Insert the assembly into the compensator housing and thread onto the sealing screw (see
Figure 2 on page 262).
Note: Be sure to rotate the spring assembly along with the extension. During installation, do not
allow the outer spring retainer to seat onto the two pins on the spring guide, because the spring may
disengage from the retainers or carrier.
3. While carefully holding the spring assembly by the carrier, remove the extension. Slowly allow the
spring to pull the remainder of the assembly into the housing until the outer spring retainer seats onto
the two pins on the spring guide.
4. Screw the magnet sleeve into the carrier the same numbers of turns as when it was removed (see
Figure 1 on page 261).
5. Install the UCM (level sensor) onto the compensator housing. Only hand-tighten the mounting screws
at this time.
6. Move the compensator to near where it was installed and connect the SeaNet cable. Apply 26 VDC
deck power to the assembly on which the compensator is mounted.
7. Verify that the compensator is still full, or fill it as needed until it is full.
8. On the compensation dock, observe the volume level to see if the magnet sleeve needs to be adjusted
and/or if the compensator software needs to be calibrated.
● If the displayed level is 100% (full), remove the UCM and turn the magnet sleeve clockwise until
the readout shows less than 100%. Then, turn counterclockwise until the level again reaches 100%.
● If the level that is displayed is not correct, adjust the magnet sleeve counterclockwise to raise level
readout or clockwise to lower the readout. Then, replace the UCM and check the displayed level.
— Confirm the readout at other levels by draining the compensator to ¾ (75%), ½ (50%), ¼
(25%), and E (0%). Note that accuracy can vary up to 15% from actual compensator volume.
— When you are satisfied with the range of readings, tighten the sensor module screws (1.1
Nm [10 in-lb]).
Page 264 011-0552-06

2.2-Liter Compensator, Oil-Side Housing: Remove and

Install
This service instruction explains how to remove and install the 2.2-liter compensator oil-side housing.
Tools Two 1/2x2" (12 mm) smooth shank bolts, torque wrench (0-10 Nm [0-100 in-lb])
Personnel 1 worker
Parts-Kits 004-0895, DIAPHRAGM,COMP,2 LITER; 906-0027, MOLDED,HOUSING,COMP,OIL SIDE
Safety Coil spring under tension
spring and piston as directed in a service instruction. Uncontrolled release of the compensator spring
can seriously injure you or others and damage surrounding equipment.
Removal
1. Remove and drain the compensator (see 2.2-Liter Compensator: Remove, Install, Dry-test, and Fill
on page 257). Thoroughly wash out the water-side housing to remove all internal debris.
2. Remove all fittings from the oil-side housing (C),
noting their locations.
Note: Mark the orientation of the water-side

housing and housing clamp (A & B) with a felt
pen so they can be replaced in the same pos-
itions.
Page 265 011-0552-06

3. Obtain two 1/2 x 2 inch smooth shank bolts to be

used as spring retainers.
Caution! If you use threaded bolts to

restrain the piston and spring, tape the
threads to prevent damage to the plastic coat-
ing on the spring. If the plastic coating is dam-
aged, the spring can corrode and fail.
4. Restrain the piston and spring by inserting a 12

mm diameter smooth shank bolt or pin through
both sides of the water-side housing and into
holes in the piston skirt (A).
Note: In the event the piston skirt holes do

not line up with the water side housing holes,
it may be possible to slightly rotate the piston
by inserting a round shaft Phillips screwdriver
or rod and levering the piston into position.
Caution! In the event the holes cannot be

made to line up by rotating the piston, the
unit is NOT field serviceable and must be
returned to the factory for repair.
5. Once the bolts are in place to secure the piston,

wrap tape around the bolts to make sure they do
not fall out during handling.
Page 266 011-0552-06

6. Slowly loosen and remove the housing clamp (B). Do not open it too wide; this will distort its shape. (It
is normal for spring pressure to separate the oil and water-side housing flanges by 2-3 mm [0.062-
0.125 in] when the housing clamp is removed.) Separate the oil and water-side housings.
WARNING! Once the clamp is removed, handle the water side housing carefully and place in a
secure location.
7. Remove and discard the oil-side housing (C).
Installation
1. Inspect and clean the diaphragm (P/N 004-0895). Replace as needed.
2. Install the replacement oil-side housing diaphragm, making sure that the D-profile bead on the
diaphragm remains fully seated in the flange of the water-side housing.
contact the clamp.
4. Using clamps or the help of another person, press the housings together. Make sure the oil-side

Page 267 011-0552-06

2.2-Liter Compensator: Install Sensor Spring Assemblies

This service instruction explains how to install the sensor spring assemblies on the 2.2-liter compensator.
Tools 12" long 3/8" ratchet extension, 26 VDC deck power, medium straight blade screwdriver
Personnel One worker
Sub-Procedures N/a
Parts-Kits N/a
Safety Compressed air
Consumables N/a
Installation
1. Fill the compensator to make installing the spring assembly easier. Use fresh fluid or compressed air or
nitrogen, as you may need to “drain” the compensator during calibration.
2. Unscrew the magnet sleeve from the carrier (see Figure A, below). Count the turns so it can be re-
installed to the same position.
3. Slide a 12-inch long, 3/8-inch drive extension into the spring assembly until it seats in the socket in the
inner spring retainer. Grasp the spring assembly by the carrier and stretch the spring up the extension.
Then, insert the assembly into the compensator housing and thread onto the sealing screw (see Figure
B, above). Hand-tighten only.
Note: When threading the spring assembly onto the sealing screw, be sure to rotate it along with the
extension.
Note: During installation, do not allow the outer spring retainer to seat onto the two pins on the
spring guide. If you do, the spring may disengage from the retainers or carrier.
4. Carefully holding the spring assembly by the carrier, remove the extension. Then, slowly allow the
spring to pull the remainder of the assembly into the housing until the outer spring retainer seats onto
the two pins on the spring guide.
5. Screw the magnet sleeve back to its original position in the carrier.
6. Install the level sensor onto the compensator housing. For now, hand-tighten the mounting screws.
7. Temporarily return the compensator to its installed position and connect the SeaNet cable. Apply 26
VDC deck power to the assembly on which the compensator is mounted.
Page 268 011-0552-06

8. On the compensation dock, observe the level sensor readout to see if an adjustment of the magnet
sleeve is needed (this assumes the compensator is at 100%, or Full).
— If the level readout is less than 100%, remove the sensor module and screw the magnet
sleeve counterclockwise (moving it closer to the sensor). Replace the sensor and check the
reading. Adjust it counterclockwise to raise the readout, and clockwise to lower the readout.
— If the readout is 100%, turn the magnet sleeve clockwise until the readout shows less than
100%. Then, turn it counterclockwise until it is at 100% again.
Confirm the readout at other levels by draining the compensator to 3/4 (75%), 1/2 (50%), 1/4 (25%),
and E (0%). Note that accuracy can vary up to 15% from the actual compensator level.
9. When you are satisfied with the range of readings, tighten the sensor module screws to 1.1 Nm (10 in-
lb).
Installing the Carrier and Retainer to the Spring (reference)
If the outer retainer or carrier are dislodged from the spring during service, follow these steps to re-install
them.
1. Install the carrier (17) onto the spring (16). Start by feeding the spring through the first slot and
progress through the second, third, and fourth slots. Rotate the carrier on the spring until its position
matches the picture below.
2. Feed the spring end into the alignment hole in the retainer (21) and work the spring into all retainer
slots. Adjust the carrier so its holes align with the alignment hole in the retainer, as shown in the
picture below.
Page 269 011-0552-06

8-Liter Compensator: Disassemble and Reassemble

This service instruction explains how to disassemble and reassemble the 8-liter compensator.
Tools Wrench (10 mm), torque wrench (0-10 Nm [0-100 in-lb]), M6 X 25 sealing screw, Phillips #2 screw, 5 mm hex key
Personnel 1 worker
Related 8-Liter Compensator: Remove, Install, Dry-test, and Fill on page 272
Procedures
Parts-Kits 001-13794: HOUSING,FLUID,COMPENSATOR,8L
004-1248: DIAPHRAGM, 9" OD, 4.22" STROKE
101-8906: SPRING PACK, COMPENSATOR, 8L
Safety Spring under compression
WARNING! Do not remove any of the three pins retaining the spring.
Uncontrolled release of the spring can seriously injure you or others and
damage surrounding equipment.
Disassembly
1. Drain and remove the compensator (see 8-Liter Compensator: Remove,
Install, Dry-test, and Fill on page 272).
2. Mark the orientation of the housings and housing clamp with a felt pen
so they can be replaced in the same positions.
3. Slowly loosen and remove the housing clamp (A). Do not open it too
wide; this will distort the shape of the clamp. (It is normal for spring
pressure to separate the oil-side housing and spring pack flanges by 2-3
mm [0.062-0.125 in] when the housing clamp is removed.) Separate the
oil-side housing (B) from the spring pack. Thoroughly wash out the
spring pack to remove all internal debris.
Note: To replace the oil-side housing only, discard the housing and
skip to step 4 under Reassembly on the facing page.
Page 270 011-0552-06

4. Remove the M6 x 25 sealing screw (C) and separate the retaining plate
(D), O-ring (E), and diaphragm (F) from the spring pack piston (G).
5. To remove the level sensor, use the 5mm hex key to unscrew the four
M6 x 12 screws and separate the sensor (H) from the spring pack.
6. Inspect all components (including fittings) and discard any that are
damaged.
7. Thoroughly clean all components that will be reused.
Reassembly
1. Install the original or replacement level sensor onto the spring pack and attach with four M6 x 12
screws (3.4 Nm [35 in-lb]).
Note: Ensure that the compensation slider pin lines up with the spiral cutout in the shaft.
2. Install the original or replacement diaphragm onto the spring pack piston, seating the D-profile lip into
the flange of the spring pack (with the rubber side facing out). Form and smooth the diaphragm over
the piston.
3. Apply O-ring lubricant to the mating surfaces of the sealing screw and retaining plate O-ring (P/N 004-
0015). Install the O-ring and retaining plate onto the diaphragm and piston.
4. Install the M6 x 25 sealing screw (3.4 Nm [35 in-lb]).
5. Install the original or replacement oil-side housing onto the spring pack, aligning the high fill fitting
with the level sensor slot. Make sure that the D-profile bead on the diaphragm remains seated in the
flange of the spring pack.
contact the clamp.
7. Install the housing clamp so that the latch is aligned with the level sensor.

— The oil-side housing is seated within the spring pack flange
Page 271 011-0552-06

8-Liter Compensator: Remove, Install, Dry-test, and Fill

This service instruction describes how to remove, install, dry-test, and fill the 8-liter compensator (P/N 101-
8905).
Tools Compensation cart (P/N 101-9164), wrenches (10 mm, 17 mm), torque wrench (0-40 Nm [0-30 ft-lb])
Personnel 1 worker
Related Procedures Rapid Fill and Bleed Cart: Operation on page 283
Parts-Kits 101-9086: KIT, MTG, 8L COMP, ROV SLE
Safety Deck safety
Note: The spring, piston, and spring guide are not field serviceable. Return the assembly to the fact-
ory for service.
Removal
1. Drain the compensator using the compensation cart. (See Rapid Fill and Bleed Cart: Operation on
page 283.)
2. Disconnect the position sensor array cable from the level sensor, if present.
3. Remove the compensator from its mounting site or bracket.
Installation
1. Mount the compensator to the mounting site or bracket, using the original or replacement hardware.
Torque the mounting bolts to 40 Nm (30 ft-lb).
2. Connect the position sensor array cable to the level sensor, if present.
Dry-testing
1. If the compensation system fittings or components have been opened or replaced, dry-test the
compensation system for leaks before charging it with fluid. Use one of the two following methods.
a. Fill the compensation system with air or nitrogen to one atmosphere (15 psi). Spray all connections
and compensated components with a mild detergent or window cleaner to check for leaks. Active
bubbles or foam indicate a leak.
b. Install a pressure gauge on the compensation system. Fill the system with air to one atmosphere
(15 psi). Allow the air pressure to stabilize. Then, monitor the pressure gauge over a period of at
least two hours. If you notice any drop in pressure, check for leaks using the detergent method
described in the previous method.
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Filling
1. Fill the compensator using the compensation cart. (See Rapid Fill and Bleed Cart: Operation on
page 283.)
Note: Charge and bleed the compensation system only after verifying that all compensated com-
ponents are functioning correctly and that the bleed fittings are accessible.
Caution! If compensated components are submerged while large amounts of air remains in the com-
pensation system, the components or enclosures may be damaged. Verify that the compensator is cor-
rectly installed and that air has been bled from all compensated components.
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Compensation 5. Rapid Fill and Bleed Compensation Cart
8-Liter Compensator, Level Sensor: Disassemble and

Reassemble
This service instruction describes how to disassemble and reassemble the 8-liter compensator level sensor
(P/N 101-9512).
Tools 5 mm hex key, torque wrench
Personnel 1 worker
Related Procedures None
Parts-Kits Kits, Spares, UHD-III Compensation System (P/N 008-0904)
Safety Deck safety
Consumables Dow Corning 55 O-ring Lube (Thin) (P/N 002-0359)
Disassembly
1. Unscrew the four M 6 x 12 screws and separate the sensor from the spring pack.
2. Unscrew the two M 6 x 16 screws from the end of the level sensor and separate the position array
bracket from the sensor body.
3. Slide the level sensor shaft out of the body of the sensor assembly.
4. Inspect all components (including O-rings), discard and replace any parts that are damaged.
5. Thoroughly clean all components that will be reused.
Reassembly
1. Install the original or replacement O-rings onto the shaft.
2. Slide the shaft back into the body of the sensor assembly.
3. Re-install the position array bracket and the two M 6 x 16 screws.
4. Re-attach the level sensor to the spring pack, using the four M 6 x 12 screws.
5. Rapid Fill and Bleed Compensation Cart
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5.1 Rapid Fill and Bleed Compensation Cart
5.1.1 Overview
The rapid fill and bleedcompensation cart (101-9644) is used to service compensation circuits on the UHD-
III ROV and TMS. Cart features include a closed loop drain and fill platform, air-powered pump, controls
for selecting operation mode and circuit , and a nozzle/QD interface manifold.
The cart has 5 operational modes for performing service on the ROV or TMS compensation circuits. For
instructions on using each of the modes refer to, Rapid Fill and Bleed Cart: Operation on page 283.
Rapid Fill and Bleed Cart Features

For details on specific components, see Rapid Fill and Bleed: Component Overview on page 277.
● Closed loop hydraulic circuit to fill and drain components

● QD nozzle with device/compensator selector valve
● Flow indicator
● Air inlet filter
● Hydraulic fluid tank with level indicator sight tube and vent filter.
● Particulate and water filter for compensation fluid
● Two-way on/off air supply valve
● Fill/bleed quality test button and results gauge
● Fill/bleed directional flow indicator
● Vent line bubble indicator (to determine when air has been bled
from system)
● Front and rear lift bars (to assist with moving the cart)
Closed Loop Drain and Fill Circuit

The closed loop platform uses a fill/drain hose and a vent hose to form a leak free circuit. When the nozzle
and vent hose are connected to the ROV or TMS this forms a closed loop hydraulic circuit that allows you
to drain/fill and vent a typical compensation circuit easily and quickly without the risk of overflow spills.
This eliminates the need to manually open vent plugs on the deck.
Note: The T4 manipulator and the thruster circuits are not closed circuits. You will need to manu-
ally bleed these circuits to remove the air.
The closed loop platform produces a more complete fill by using the flow of oil through the device to help
drive out air bubbles. You can keep the pump connected and running to flow oil through and remove
bubbles for as long as is needed. The cart vent hose has a clear tube section that allows you to visually verify
that the circuit is properly filled and free of any excess air.
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For a list and location of the ROV and TMS connection locations, see Rapid Fill and Bleed ROV Circuits on
page 294, and Rapid Fill and Bleed TMS Circuits on page 297.
Air-powered Diaphragm Pump

The cart uses an air-powered diaphragm pump to quickly fill or drain compensation lines and components,
and move fluid through the filter. The pump is lite weight, explosion proof, corrosion resistant, and can be
removed and disassembled for cleaning or service. An air supply valve is located on the front of the cart to
start and stop the pump.
When the mode selector valve is set to drain, 12 psi of compressed air is applied to the vent hose to help
speed up oil removal from devices.
Operation Mode and Circuit Selector Valves

On the top of the rapid fill and bleed cart is an operation mode rotary handle that you can set to route oil to
the correct location for each operation.
The nozzle has a circuit selector valve so you can choose to service the compensator or the device side of
the compensation circuits. Setting the circuit selector valve to the center position will stop the flow of fluid
through the nozzle.
Nozzle and QD Interface Manifold

The nozzle and the QD interface manifold have a special functionality when connected together. This is
because of the sleeve valve inside the QD manifold. Normally the QD manifold connects the device and
Page 276 011-0552-06

compensator lines together. When the nozzle is connected to the QD manifold, the sleeve valve separates
the two lines and connects the lines directly to the circuit selector valve in the nozzle.
5.1.2 Specifications
Compensation Cart
Description Specifications
Compressed air input 5.52 to 8.62 bar (80 to 125 psi) @ 8-10 CFM (1.51 l/s)
Output Compensation fluid @ <1 bar (15 psi)
Tank 37.85 L (10 gal)
Particulate/water filter element
OEM Cim-Tek 20 Series #70137, 30 MICRON PARTICULATE
REMOVAL, 175 PSI, 22 GPM MAX 20 SERIES, CIM70137
Schilling Part # 006-3140
Air filter element
OEM Applied Industrial Technologies - # DES-CASE-DC-XD-6
Schilling Part # 006-3138
Spares Kit
008-0973 Rapid Fill and Drain Spares Kit
5.2 Rapid Fill and Bleed: Component Overview
The rapid fill and bleed compensation cart Compensation cart

(101-9644) allows quick maintenance of the
compensation fluids on the UHD-III ROV and
TMS. The ROV has four fill/drain quick dis-
connect (QD) fittings, and 21 vent QDs. The
TMS has two fill/drain QD fittings and 14 vent
QDs.
Note: The T4 manipulator and the

thruster circuits do not have vent QDs.
You will need to manually open the
vent ports to bleed or vent these cir-
cuits.
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The compensation cart has an operation Compensation cart operation mode handle
mode handle that enables the cart to perform
five tasks:
● Fill the ROV and TMS compensation
circuits from the comp cart reservoir.
● Drain the ROV and TMS circuits by
pumping the compensation fluid out of
a circuit using the comp cart pump.
(Also used to fill the comp cart reser-
voir with new oil.)
● Used oil bypass routes com-
pensation fluid drained from a circuit
through the cart pump and diverts the
oil to an exit port on the front of the
cart
● Filter reservoir will cycle oil from
the cart reservoir, through the cart
filer, and back into the cart reservoir.
● Test comp circuits by applying pres-
sure to insure that all air has been
removed and no leaks are present.
The test gauge located on the top of the cart Compensation cart test gauge
indicates the results of circuit pressure testing.
The gauge and Start Test button are used to
test the compensation fill quality for the fol-
lowing circuits:
● TMS AC
● ROV AC
● ROV DC
● TMS DC
● Titan 4
Note: Pressure tests cannot be per-

formed on the ROV thruster bearing
circuit.
The comp cart fluid flow indicator located on Compensation cart flow indicator
the front of the cart shows when fluid is
flowing through the cart.
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Air supply valve and supply air inlet fitting. Air supply valve
● Connect the air supply inlet fitting to a
source of compressed air at 125 psi (5-
8 cfm).
● The air supply valve shuts off all air to
the rapid fill cart (pump and controls).
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The QD nozzle is equipped with a QD latching Compensation cart QD nozzle

handle and a selector valve.
● The QD nozzle can be connected to or
removed from the QD manifold at any
time with the selector valve in any pos-
ition.
● The QD nozzle has an internal pres-
sure regulator that limits output pres-
sure to 17 psi.
● The QD nozzle selector valve has three
positions:
— When the QD nozzle is con-
nected to a circuit and the
selector valve is in the center Compensation cart QD nozzle and selector valve (top
position, the cart supply line, view)
circuit compensator, and cir-
cuit devices are all isolated
from each other. You can use
this position to stop the all
fluid flow at the QD nozzle.
— Toggling the QD nozzle
selector valve to “device” will
configure the QD nozzle to
interface with the circuit's
devices*.
— Toggling the QD nozzle
selector valve to “comp” will
configure the QD nozzle to
interface with the circuit's com-
pensator.
● When the QD nozzle is connected and
filling a device you can move the
selector to the comp position without
stopping the pump. This saves time
and reduces the chance of spills.
Note: Connecting the QD nozzle to the

QD interface manifold changes the oil
flow path inside the QD interface man-
ifold. See QD interface manifold below.
Page 280 011-0552-06

Note: There is also an adaptor tool

used to connect the cart QD nozzle to
other devices. See below for more
information.
* A device is any component that is filled with

compensation fluid (excluding spring loaded
compensators).
Each QD interface manifold is used to con- QD interface manifold
nect the compensator cart QD nozzle to the
ROV and TMS device and comp circuits.
There are two ports on the back of the QD
interface manifold, one marked Device and
one marked Comp. These ports are joined at
the sleeve valve connector passage inside the
QD interface manifold.
When the rapid fill and bleed QD nozzle is
disconnected, the QD interface manifold
sleeve valve connects the comp and device cir-
cuits together at the connector passage so the
compensator can keep the device com-
pensated while diving.
When the rapid fill and bleed QD nozzle is
connected to the QD interface manifold, the
sleeve valve is pushed in by the QD nozzle.
This separates the comp and device circuit
connection, and routes the comp and device
lines directly into the rapid fill and bleed QD
nozzle selector valve.
The selector lever on top of the nozzle allows
you to select between the device or comp cir-
cuits. This way with one connection you can
service the comp or device circuits indi-
vidually. This process reduces the chance of
spills, and saves time. Since the two circuits
are separated when the nozzle is connected,
this is a handy way of working on the device
side of the circuit without draining the com-
pensator.
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The ROV QD mounting plate is located on the ROV compensation fill QD mounting plate
port side of the vehicle frame. The cart QD
nozzle connects to the ROV QD manifolds on
the plate. There are four QD connections:
● AC compensation (AC COMP)
● DC compensation (DC COMP)
● Thruster Bearing (BRG COMP)
● T4 manipulator (T4 COMP)
The TMS QD mounting plate is located TMS compensation fill QD mounting plate
between the two TMS compensators. The cart
nozzle connects to the TMS QDs. There are
two QD connections:
● AC compensation (AC COMP)
● DC compensation (DC COMP)
The vent hose is located on the right side of Vent hose

the rapid fill and bleed cart and is mounted on
a recoil spool. You will connect this hose to
the vent QD connection on devices or com-
pensators to vent air in or out of the com-
pensated circuit.
● During the FILL process air bubbles
and excess oil will exit the com-
pensation circuit and return through
the vent hose to the cart reservoir.
● During the DRAIN process this hose is
charged with 12 psi of air pressure to
help push oil out of compensated cir-
cuits.
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Vent QDs allow air in or out of compensated Vent QD

devices when draining or filling . The vent
QDs are located on the upper side of most
compensated devices and compensators. You
will connect the vent hose from the cart to
the vent QD to form a closed circuit. The use
of a closed circuit enables system to be filled
and drained quickly, and reduce the chance of
spills.
The barrel adapter is used to fill the Barrel adaptor
compensation cart reservoir from a supply
container, such as a 55 gallon barrel. Connect
the compensation cart QD nozzle to the
barrel adaptor and set the compensation cart
mode handle to the Drain position.
The SeaNet adapter is connected between the SeaNet adapter

vent hose bubble viewer and a SeaNet cap so
you can purge air from SeaNet cables.
The vent hose bubble viewer allows you to see
air bubbles in the oil flow to verify if air
remains in the circuit.
Rapid Fill and Bleed Cart: Operation

This service instruction explains how to operate the rapid fill and bleed compensation cart P/N 101-9644.
Tools Compensation cart (101-9644), compressed air supply (5-8 cfm)
Personnel 1 worker
Sub-Procedures None
Parts-Kits Hydraulic filter replacement; Cim-Tek 70067, 30 micron nominal (006-0041); air filter replacement; Wilkerson FRP-
95-115 (006-1736)
Safety Air pressure
Page 283 011-0552-06

Consumables Cable ties, compensation fluid, shop air supply 5.52 to 8.62 bar (80 to 125 psi) @ 3.2 cfm (1.51 l/s)
To operate the system, connect the QD nozzle and vent hoses to the ROV or TMS as shown in the fol-
lowing diagram. Refer to the individual steps below for detail on each operation.
Safety First:
WARNING! The ROV system uses lethal voltage. Before work begins, turn off ROV and TMS power,
ground the switches at the PDU, lock out and tag out the power switches, install ground cables to the
ROV and TMS, and alert other workers in the area.
WARNING! High pressure pneumatic and hydraulic systems have energy that can pierce the skin
or cause blindness. Wear eye protection and use appropriate caution.
Quick Links to Sections in this Document

● Fill and Bleed a Compensation Circuit below
● Drain a Compensation Circuit on page 287
● Filtering Oil in the Cart Reservoir on page 289
● Testing for Air in Compensation Circuits on page 290
● Filling the Compensation Cart Reservoir with Hydraulic Fluid on page 292
Fill and Bleed a Compensation Circuit

Use the fill mode to fill and bleed (remove air) whenever a compensation circuit has been opened or a com-
ponent has been removed for service. For details on specific circuits, see the documentation for the com-
pensated item.
Compensation circuits have two parts; the COMP circuit (connected to a spring loaded compensator) and
the DEVICE circuit (connected to any compensated device). You can use the circuit selector valve on the
QD nozzle to choose which part of the circuit you want to service.
Note: If a device has been contaminated with water, you can use the fill process to purge the device
and remove contaminates. Just follow the steps, and in the last step after all the air has been
removed, let the pump run for a bit longer than normal to purge the device with filtered oil.
Caution! Do not allow contaminated hydraulic oil to come in contact with any electronic com-
ponents on the ROV/TMS system. Do not put oil from components with moving parts into com-
ponents with electronic parts.
Page 284 011-0552-06

1. Set the circuit selector valve to the center

position.
— Device mode - connects the nozzle
flow to the device side of the circuit.
— Comp mode - connects the nozzle to
the compensator side of the circuit.
— Center - shuts off the nozzle and
keeps comp cart, device, and comp
circuits separated. (You can use the
center position to momentarily stop
the filling process at any time, even
with the pump running. Do not
leave the cart unattended in this
mode. Anytime you are finished
using the cart, turn off the air supply
valve and disconnect the air supply
line).
Note: If both device and comp circuits

require filling, you can save a bit of time by
filling the comp circuit first because you
wont have to shut off the pump when switch-
ing the return line over to the other half of
the circuit. See note in step 8 below.
2. Verify that on the circuit you are working with,

all lines, component, ports, and fittings are
closed or sealed.
3. Connect the compensation cart nozzle to the
desired QD interface manifold.
Note: See Rapid Fill and Bleed: Component

Overview on page 277 for the locations of the
rapid fill and vent quick disconnects. Also,
see drawing 025-0180 for the Rapid Fill and
Bleed Hydraulic Schematic.
Note: When filling a compensator, turn the

circuit selector to Comp. You can switch the
selector valve without stopping the pump.
Page 285 011-0552-06

4. Connect the vent hose on the cart to the vent

QD on the circuit being filled.
5. Turn the compensation cart mode selector to

the Fill position.
6. Turn on the air supply to the cart to start compensation fluid moving through the lines and into the
circuit.
Caution! If you disconnect the QD nozzle from the QD manifold while the vent hose is still connected
to a device, the compensator for that circuit will push oil (if holding oil) into the comp cart through the
vent hose. Always remove the vent QD before disconnecting the QD nozzle.
Page 286 011-0552-06

7. Continue filling the circuit until no bubbles are

seen in the bubble viewer on the vent hose.
8. When you are satisfied that the air has been
removed, turn off the air supply to stop the
pump.
Note: If you are filling a compensator

and wish to add volume after all the air has
been removed, disconnect the vent hose while
the pump is still running. The pump pres-
sure will fill the compensator. While the
comp is filling, move the vent hose to the
vent QD on the device side of the circuit.
When the compensator reaches the correct
level, simply switch the selector valve to the
DEVICE position to start filling the device.
Filling the compensator first saves a bit of
time because you wont have to shut off the
pump when switching to the other circuit.
9. If filling other devices on the same circuit, set

the selector valve to the center (off) position,
leave the QD nozzle connected and disconnect
the vent hose, and continue on to the next step.
10. Connect the vent hose to the next vent QD on the circuit. (See Rapid Fill and Bleed ROV Circuits on
page 294 and Rapid Fill and Bleed TMS Circuits on page 297 for locations of the vent valves.) Turn the
selector valve to the Device position to start flowing oil.
Note: If filling a device that is compensated via SeaNet cable, use the SeaNet adapter tool to fill the
node with oil and remove any remaining air.
11. Repeat the steps until all circuits are filled.
Drain a Compensation Circuit

In this procedure you will use the drain mode on the compensation cart to remove most of the fluid from
the circuit. For details on specific circuits, see See Rapid Fill and Bleed ROV Circuits on page 294 and
Rapid Fill and Bleed TMS Circuits on page 297 for locations of the vent valves. In drain mode the cart will
apply 12 psi of air pressure to the vent hose to push oil, and use the diaphragm pump to vacuum oil out of
the circuit. The oil will travel back through the QD nozzle and into the reservoir in the cart.
ponents on the ROV or TMS. Do not put oil from circuits with moving parts into circuits with elec-
tronic parts.
Page 287 011-0552-06

1. Ensure selector valve is turned to the Device

position.
2. Connect the compensation cart QD nozzle to

the desired circuit QD manifold. (Labels are
on the QD manifold mounting plate.)
Note: See Rapid Fill and Bleed:

Component Overview on page 277 for the
locations of the rapid fill and vent quick
disconnects. Also, see drawing 025-0180
for the Rapid Fill and Bleed Hydraulic
Schematic.
3. Connect the vent hose to the vent QD on the

circuit being drained.
4. Move the compensation cart mode selector

lever to the Drain position. This will apply 12
psi of air pressure to the vent hose to help
push the oil out of the device, when the air
supply valve is on.
Page 288 011-0552-06

5. Turn on air supply to the cart, to start the draining process.
Note: When draining a compensator, turn the nozzle selector to Comp. The remaining steps are the
same as for draining a Device.
6. Allow the pump to run until you hear the pump speed up a bit. The change in pump speed will indicate
the pump is pumping air, (if the vent hose is connected, or bleed ports are open) and all the oil has
been removed.
Note: When draining a compensator, the vent hose does not need to be hooked up as the comp spring
will provide pressure to help push the fluid out. To remove all the remaining oil, connect the vent hose
after the compensator spring has fully extended.
Filtering Oil in the Cart Reservoir

In this procedure you will use the filter reservoir mode on the compensation cart to cycle oil from the cart
reservoir through the filter and return the oil back to the reservoir. This process will help to remove con-
taminates and small amounts of water from the oil.
The comp cart is NOT connected to the ROV or TMS in this procedure.
Note: With this process you are drawing oil from the same location you are returning filtered oil
into, so it is a progressive cleaning process, the longer you run the pump the cleaner the oil will
become.
ponents. Do not put oil from components with moving parts into components with electronic parts.
1. The QD nozzle should be stored in the cart.

2. The vent hose is stored in the cart.
Page 289 011-0552-06

3. Move the compensation cart mode selector

lever to the Filter reservoir position.
4. Turn on air supply to the cart. The cart will now start cycling the reservoir oil through the filter and
return the oil back to the cart reservoir.
Testing for Air in Compensation Circuits

In this procedure you will use the test mode to verify that the device circuit has been filled correctly and
no air remains in the circuit.
Caution! This test is for devices only and not for the comp side of the circuit.
For details on specific circuits, see See Rapid Fill and Bleed ROV Circuits on page 294 and Rapid Fill and
Bleed TMS Circuits on page 297 for locations of the vent valves.
1. Ensure nozzle selector valve is turned to Device
position.
2. Verify that all circuit lines, component, ports, and fittings for the circuit being tested are tight and
sealed.
Note: The bearings on the thrusters are not enclosed and will leak fluid while under pressure. Due to
this, the thruster bearing circuit cannot be tested using the compensation cart.
Page 290 011-0552-06

3. Connect the compensation cart QD nozzle to the

desired QD manifold.
4. Connect the vent hose to the vent QD on the

circuit being tested.
Caution! Do not connect the vent hose to a

SeaNet cable.
5. Move the compensation cart mode selector to the

Fill position.
Note: This step is to remove any air in the

vent hose.
6. Turn on air supply to the cart.

7. If the circuit was just bled using a SeaNet, there may still be air in the vent hose that will affect the test
reading. Run the pump a few minutes to cycle oil long enough to ensure any recently bled air has the
opportunity to get back into the comp cart reservoir.
Caution! Air must NOT be in the vent hose during testing. Run the pump to remove air before test-
ing.
Page 291 011-0552-06

8. Move the compensation cart mode selector lever

to the Test position.
Note: (The pump may continue to run slowly

but it will not pump oil through the circuit in
test mode.)
9. Wait 2 minutes (or more) for the pressure in the

circuit to bleed down as close to zero psi as
possible.
10. Press the test button and hold it down. The
needle on the gauge will rise until it holds a
position on the dial.
Note: Sometimes the gauge will overshoot the

specified range on the dial. If it does, wait for
it to stop moving (no more than 1 needle width
in 5 seconds)
11. Look at the graphic around the gauge for the

circuit being tested, and see if the reading is in the
green zone for that circuit.
Caution! If for any reason during the test the

Start Test button is released, the above process
must be started over, which includes running
the pump in fill mode for at least 5 pumps (10
to 15 seconds)– this is to reset the internal test
circuit in the cart.
Note: If a test was just completed and you want to do another test, release the Start Test button and
let the pump run for at least 5 pumps (10-15 seconds) to reset the internal test circuit in the cart.
Filling the Compensation Cart Reservoir with Hydraulic Fluid

Use this process to refill the compensator reservoir with clean oil.
Page 292 011-0552-06

1. Connect the air pressure supply line to the cart.

2. Set the mode selector to the Drain position.
3. Connect the compensation cart nozzle to the

adapter tool, and place the other end of the
adaptor into a reservoir or 55 gallon barrel that
contains fresh oil.
Caution! Do NOT allow debris to enter the

adaptor tool or the comp cart hoses or lines.
Debris can foul the plumbing and valves inside
the rapid fill and bleed cart, rendering it inop-
erable.
4. Set the selector valve to the comp position.
Note: The selector valve must correspond to

the port the extension tube is plumbed into on
the back of the QD manifold adaptor fitting.
ponents. Do not put oil from circuits with moving parts into circuits with electronic parts.
Page 293 011-0552-06

5. Turn on the air supply valve. Fluid will now start

moving into the reservoir. (Fluid will pass through
the comp cart filter on the way to the reservoir.)
The cart reservoir holds 37.8 L (10 gal) and it will
take about 8 - 10 minutes to fill an empty
reservoir.
Note: If you overfill the reservoir, the fluid will begin to leak out of the breather valve underneath the
desiccant filter.
5.3 Rapid Fill and Bleed ROV Circuits

The ROV rapid fill and bleed QD manifolds are located on the port
side of the ROV A-frame. This is the connection point for the ROV
compensation circuits. The circuits are labeled on the mounting
plate.
The words COMP and DEVICE are visible on the sides of each QD
manifold. This corresponds to the ports and circuit plumbing on
the back of each QD manifold. Comp ports are on the left as you
face the QD manifold, device ports are on the right.
A brief description of each ROV compensation circuit and the
related drawing number (in parenthesis) is listed below.
5.3.1 ROV Rapid Fill and Bleed Circuit Descriptions

AC Comp Circuit (101-9666) The AC compensation circuit on the ROV connects to all compensated elec-
trical devices using 50 volts or more.
● The 8L compensator (inside the frame, starboard side forward) – Includes one vent QD on the top
of the 8L compensator.
● LCU (light rack top center) – Includes one vent QD at top of the device.
● IPDS (starboard side aft) – Includes three vent QDs (one on the top left of the backbone, one on the
top of the T-box, and one at the top of the transformer module).
● HPU electric motor (aft) – Includes two vent QDs (one on the top of each head plate).
AC J-box (101-9761-1) The AC J-box is an optional device that is plumbed to the AC comp circuit.
● Located on the ROV deck, port side center adjacent to the navigation device – There is one vent QD
at the top right corner of the device.
DC Comp Circuit (101-9666) The DC compensation circuit is for all electrical devices using 48 volts or
less.
● The 8L compensator (inside the frame, port side forward) – Includes one vent QD.
● Forward TCU (forward center beneath buoyancy) – Includes one vent QD at the top of the device.
Page 294 011-0552-06

● Nodes 4 & 5 (port side forward, swinging rack) – Includes one vent QD at top of each device.
● Node 6 (starboard side forward, swinging rack) – Includes one vent QD at top of the node.
● Aft TCU (aft center beneath buoyancy) – Includes one vent QD at top of device.
● ISOL-8 pump control housing (aft center above HPU) – Includes one vent QD on top of the ISOL-8
pump control housing.
Thruster Bearing Comp Circuit (101-9667) The thruster bearing circuit is connected to a rapid fill QD
manifold but does not have a vent QD on the thruster bearing housing. Without a vent QD, the circuit is
not a closed loop and can be drained and bled only by loosening a vent fastener on the thruster bearing
housing.
● The 2.2-liter compensator (located inside the frame, aft end middle of stack) – Includes one vent
QD.
● All the thruster bearings on the ROV.
Note: The compensator and device plumbing for the thruster bearing circuit are connected together
at a tee fitting and lead to only the COMP port on the QD manifold. The device port is not used. This
means that the circuits are NOT separated when the nozzle is plugged in. This feature is unique to the
thruster bearing compensation circuit. Therefore, you must select the Comp position on the fill/drain
nozzle selector to service this circuit. Both the compensator and the bearing housings are serviced at
the same time.
Caution! Oil will spill out of the thruster vent if you open the vent when the compensator has pres-
sure - This can happen even if the nozzle is installed on the QD manifold.
T4 Comp Circuit (101-9668) The T4 compensation circuit is connected to a rapid fill QD manifold but it
does not have a vent QD. Without the vent QD, the circuit is not a closed loop and can be drained and bled
only by loosening vent fastener on the T4 manipulator.
● The 2.2-liter compensator located inside the frame, aft end of the bottom of stack – Includes one
vent QD.
● The T4 manipulator arm.
5.3.2 ROV Rapid Fill and Bleed Vent QD Locations

The following images show the rapid fill and bleed vent QDs in blue.
Note: To improve the view of these valves, some of the ROV parts have been removed from the draw-
ings (example: the side guard rails).
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Figure 3: Rapid Fill and Bleed Vent Valves - Front View
Figure 4: Rapid Fill and Bleed Vent Valves - Starboard View
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Figure 5: Rapid Fill and Bleed Vent Valves- Figure 6: Rapid Fill and Bleed Vent Valves-
IPDS Nodes
Figure 7: Rapid Fill and Bleed Vent Valves- Aft View
5.4 Rapid Fill and Bleed TMS Circuits
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The TMS rapid fill and bleed QD manifolds are mounted on

the TMS compensator bracket on the TMS frame between
the 2L and 8L compensators. This is the connection point for
the TMS compensation circuits. The circuits are labeled on
the mounting plate.
The words COMP and DEVICE are visible on the edges of
each QD manifold. This corresponds to the ports and circuit
plumbing on the back of each QD manifold.
A brief description of each TMS compensation circuit and the
related drawing number (in parenthesis) is listed below.
Note: See drawing 101-9653 for compensator and QD manifold locations.
5.4.1 TMS Rapid Fill and Bleed Circuit Descriptions

AC Comp Circuit (101-9757) The AC compensation circuit on the TMS connects to all compensated elec-
trical devices using 50 volts or more.
● The 8L compensator — Includes one vent QD.
● Slip ring — Includes four vent QDs (three at the slip ring body plus one for the discriminator hose).
● IPDS — Includes four vent QDs (one at the top of the backbone, one at the top of the T-box, one at
the top of the transformer, and one at the top of the HV Pak).
● DC Drive Motors — Includes four vent QDs (two on top of each motor) (2 motors).
● Rotating T-box — Includes one vent QD on the T-box.
DC Comp Circuit (101-9758) The DC compensation circuit is for all electrical devices using 48 volts or
less.
● The 2L compensator — Includes one vent QD inside the lower box frame.
● Latch solenoids (4 latches) — Includes four vent QDs (one on top of each latch solenoid).
● Node — Includes one vent QD on the top front of the node.
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5.4.2 TMS Rapid Fill and Bleed Vent QD Locations

Figure 8: TMS compensator bracket
Figure 9: 2L compensator Figure 10: 8L compensator
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Figure 11: TMS slip ring body, discriminator hose Figure 12: TMS node assembly
and T-box
Figure 13: IPDS backbone, T-box, and transformer Figure 14: TMS HV Pak
Page 300 011-0552-06

Figure 15: DC drive motors (two locations) Figure 16: TMS latch assembly
Rapid Fill and Bleed Cart: Service

This service instruction explains how to service the rapid fill and bleed compensation cart P/N 101-9644.
Tools Compensation cart (101-9644)
Personnel 1 worker
Sub-Procedures None
Parts-Kits Hydraulic filter replacement; Cim-Tek 70067, 30 micron nominal (006-0041); air filter replacement; Wilkerson FRP-
95-115 (006-1736)
Safety Air pressure, pressurized hydraulic fluid
Consumables Cable ties, compensation fluid, shop air supply 5.52 to 8.62 bar (80 to 125 psi) @ 3.2 cfm (1.51 l/s)
WARNING! High pressure pneumatic systems contain energy that can pierce the skin or cause
blindness. Wear eye protection and use appropriate caution.
The cart has a replaceable spin on oil filter that should be changed yearly or anytime the filtering process
becomes slow.
There is a replaceable inlet air filter that should be changed yearly or anytime the diaphragm pump speed is
slow due to diminished air flow. The cart also has a reservoir desiccant breather that has an indicator that
turns pink when breather replacement is required.
The front tank cover can be removed to inspect or clean the inside of the tank.
Quick Links to Sections in this Document

● Oil Filter Replacement on the next page
● Desiccant Breather and Supply Air Filter Replacement on page 303
● Reservoir Inspection on page 304
Page 301 011-0552-06

Oil Filter Replacement

The filter must be changed if; you notice that the diaphragm pump speed is slow, the oil has become con-
taminated with water or another substance, or on an annual basis which ever comes first.
1. Disconnect the air pressure supply line.
2. Remove four M6 BHCS across the top of the rear
cover.
3. Remove two more M6 BHCS in the middle of the
rear cover.
4. Loosen the two lower M6 BHCS, but do not
remove them. Upon reassembly you can rest the
rear cover on the lower screws to align the holes.
5. Remove the rear cover.
6. Unscrew the spin-on filter.

7. Install a new filter, and tighten the filter about ½
turn after the filter gasket comes in contact with
the filter base.
8. Operate the cart in filter mode for a minute or
two to check for leaks.
9. Replace the rear cover.
10. Tighten all the M6 BHCS to 5 Nm (45 in-lb).
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Desiccant Breather and Supply Air Filter Replacement

The desiccant breather keeps moister and small particles out of the fluid system.
Periodically check the desiccant breather. When the window on the breather changes from blue to pink, it
is time to replace the breather.
The supply air filter can be inspected or serviced when the desiccant filter has been removed.
Caution! If you overfill the reservoir the fluid will begin to leak out of the breather valve underneath
the desiccant filter. If the cart should tip over or is overfilled the filter may become plugged and will
need replacement.
1. Disconnect the supply air pressure line.

2. Remove six M6 BHCS, and remove the front
cover.
3. Tilt the lower side of the front cover out, so the

top lip clears the control panel face.
4. Remove the front cover.
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5. Inspect the breather color indicator, and if

necessary, unscrew the filter to change it.
Note: Now is a good time to inspect the air

inlet filter before replacing the breather
because it is much easier to access the air inlet
filter with the breather removed. See next step.
6. Check the water trap on the air inlet filter. The

filter is auto draining so water should not be in
the filter. If water or debris is in the housing,
unscrew the housing and clean it, and check the
filter for air flow resistance (see next step).
7. To check the filter for air flow resistance, remove
the filter, place one end of the filter against the
palm of your hand and gently blow through the
filter, any noticeable air flow resistance means the
filter must be replaced.
8. Replace all filters.
9. Replace the cover.
10. Tighten all the M6 BHCS to 5 Nm (45 in-lb).
Reservoir Inspection
In this procedure you will drain all the oil out of the reservoir, and then open the inspection cover on the
front of the cart to inspect or service items inside the cart reservoir. If the cart is already empty, skip to
"Removing the Inspection Cover" below.
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Emptying the cart reservoir into an alternate container

1. Connect the barrel adaptor to the nozzle, and
obtain a suitable container to hold 37.85 L (10
gal) of oil.
2. Set the mode selector to fill.
3. Connect the cart to an air supply.

4. Turn on the air supply valve. The cart will start pumping oil out of the reservoir and into the alternate
container.
5. Continue pumping oil until the cart reservoir is
empty. The pump speed will increase when the
reservoir is empty.
Note: In the Fill mode, all oil passes through

the filter on its way out of the nozzle. If the oil
is contaminated, you should change the filter.
Page 305 011-0552-06

Removing the clean out cover

1. Remove the HHCS on the front of the cover. This
will release the tank clean out cover.
2. Remove the cover. The bracket is supported by

holders inside the reservoir.
3. To remove the bracket reach in and lift it up
slightly.
4. The tank is now ready for inspection.
Page 306 011-0552-06

5. To reassemble the cover, center the bracket in the

bracket holders with the flange down, and place
the gasket, cover, washer, and HHCS in place.
Note: When threading the HHCS into the

bracket, it may be necessary to tilt the HHCS
to align it with the threads in the bracket.
6. Tighten the HHCS enought to prevent leaks, do

not over torque or you may crush the gasket.
Page 307 011-0552-06

Page 308 011-0552-06

Glossary
Glossary
A
AC
Alternating current (AC) reverses direction at a regular cycle and is measured in Hz. In contrast,
direct current (DC) is the flow of electric charge in only one direction.
AC J-box
The AC junction box (AC J-box) supplies four circuits of 120 VAC power for externally connected
devices. Three circuits are rated at 3A/250 Watts. The fourth circuit is rated at 17A. Devices are
connected to the junction box using Burton 8-pin cables on the box side and with SeaNet cables
on the device side. This component is equipped with a water detection sensor.
annotation
In TAVS (video system), information that is added to video using a third-party annotator that is
attached to the ROV control system. Added information can include graphics (like a logo) or data
(like a date/time stamp or the ROV heading). Also see "overlay."
anode
A piece of "sacrificial metal" used for subsea corrosion protection. The anode is attached to a
piece of metal that needs protection from corosion. The anode then corrodes instead of the
protected metal. When anodes become too corroded, they must be replaced.
APBOF
Actively pressure-balanced, oil filled
APU
Auxiliary power unit - A device that provides on-deck hydraulic power for testing and servicing
ROVs.
Aqua Shield
A high-tack, multi-purpose lubricant, corrosion inhibitor, and sealant that is compounded
specifically to cling to metal and O-ring surfaces. It provides long-term lubrication and prevents
corrosion.
ASME
American Society of Mechanical Engineers - A professional organization that enables
collaboration, knowledge sharing, and skill development for engineers.
attitude
ROV pitch or roll. Also called "attitude." The TRIMS auto function applies constant thrustin one or
more designated directions.
auto-configuration
A device that, when plugged into a node port, is automatically added to and configured in the
control system.
AutoFollow
Control software that lets a pan and tilt camera automatically follow a manipulator.
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Glossary
AutoTrack
Control software that lets a survey computer control ROV flight to follow pre-planned routes or
streaming waypoints from survey computers.
aux
Abbreviation for auxiliary. For example, the aux hydraulic system can provide auxiliary hydraulic
power for tooling. See also aux circuit 1 or 2.
Aux
AUX
aux circuit 1
In the UHD-III hydraulic configuration, an auxiliary (tooling) circuit powered by the ISOL-8
pump. In the eight-cylinder ISOL-8 model, aux circuit 1 uses six cylinders. In the four-cylinder
ISOL-8 model, aux circuit 1 uses all four cylinders.
aux circuit 2
In the UHD-III hydraulic configuration, an auxiliary (tooling) circuit powered by the ISOL-8
pump. In the eight-cylinder ISOL-8 model, aux circuit 2 uses two cylinders.
auxilary lift point

Used for lifting the ROV system when the docking head has been removed. The auxiliary liftpoint
is not rated for performing umbilical mechanical termination proof testing.
auxiliary liftpoint
Used for lifting the ROV system when the docking head has been removed. The auxiliary liftpoint
is not rated for performing umbilical mechanical termination proof testing.
AWG
American wire gauge - A standardized wire gauge system.
AWS
American Welding Society - A nonprofit organization to advance the science, technology and
application of welding and related joining disciplines.
B
BHCS
Button-head cap screw
BHCSs
Button-head cap screw
blowout preventer
A valve or similar mechanical device used to control and/or seal oil and gas wells.
Page 310 011-0552-06

Glossary
body coordinates
A control type in which ROV trim (pitch or roll) affects vehicle movement. (For example, if the
ROV is pitched down, moving the ROV forward also causes it to move down. (Contrasts with flight
in inertial coordinates, where ROV pitch and yaw do not affect movement.) Body coordinates are
used in BOTTOM mode.
Boolean
A type of search allowing users to combine keywords with operators such as AND, NOT and OR to
produce more relevant results. For example, a Boolean search could be "ROV" AND "Hydraulics,"
limiting the search results to only those documents containing both keywords.
BOP
Blowout prevente - A valve or similar mechanical device used to control and/or seal oil and gas
wells.
BOP intervention circuit

The ISOL-8 pump hydraulic circuit (typically aux circuit 1) that is used to pump fluid during a BOP
intervention.
BTU
British thermal unit - A traditional unit of energy equal to about 1055 joules. It is the amount of
energy needed to cool or heat one pound of water by one degree Fahrenheit.
bullet
See TMS bullet or ROV bullet. The bullet is the connector on top of the ROV or TMS that fits into
the latching mechanisim on the componet above.
buoyancy
Force that enables anything to float. ROVs are equipped with buoyancy blocks made with a
polyurethane outer shell. The blocks are sized to give the ROV neutral buoyant weight in water.
To assure this neutral weight, lead blocks are added or removed from the ROV to counter any
equipment that is installed on or removed from the ROV.
C
CB
Circuit breaker - An automatically operated electrical switch that protects an electrical circuit
from damage caused by overload or short circuit by detecting the fault condition and interrupting
current flow.
cc
Cubic centimeter - A commonly used unit of volume with a mass of approximately one gram.
ccw
Counterclockwise
CCW
Counterclockwise
CG
Center of gravity - The point at which all of the weight of an object appears to be concentrated.
Page 311 011-0552-06

Glossary
CIG
Crescent internal gear (fixed-displacement, hydraulic pump) - Two rotating gears, one internal
gear with teeth on the outside and one external gear with teeth on the inside.
clevis
The mechanical interface plate that connects the top of the TMS to the yoke and is the main
connection point for the system’s load path.
Clevis
The mechanical interface plate that connects the top of the TMS to the yoke and is the main
connection point for the system’s load path.
CoG
Center of gravity - The point at which all of the weight of an object appears to be concentrated.
CoM
Center of mass - The point at which all of the weight of an object appears to be concentrated.
compensation cart
HD and UHD-II systems only. Mobile cart used to drain and fill the compensation systems on the
ROV and TMS. See rapid fill and bleed compensation cart for UHD-III systems.
COTS
Commercial off-the-shelf - Term for commercial items, including services, available in the
commercial marketplace and that can be bought and used.
CP
Cathodic protection - A technique for controlling corrosion in which an anode (a piece of
"sacrificial metal") is attached to a piece of metal that needs protection from corosion. The anode
then corrodes instead of the protected metal.
CPR
Cross port relief (valve)
cw
Clockwise
CW
Clockwise
CWDM
Coarse wavelength division multiplexer - A method of combining multiple signals on laser beams
at various wavelengths for transmission along fiber optic cables. The number of channels is
fewer than in dense wavelength division multiplexing (DWDM) but more than in standard
wavelength division multiplexing (WDM).
D
DAF
Dynamic amplification factor - During offshore lifting, an object is rigged onboard and moved to
the seafloor by a vessel crane. When the object passes through the splash-zone, it experiences
hydrodynamic forces that cause the object to undergo heave and pitch motions. This causes the
Page 312 011-0552-06

Glossary
lifting slings to undergo alternating motions of loosening and tensioning. A dynamic amplification
factor is applied to the physical system to ensure that slings do not snap.
data logger
Used to acquire and store information from sensors.
DC
Direct curren - The flow of electric current in only one direction. In contrast, AC (alternating
current) reverses direction at a regular cycle and is measured in Hz.
DC J-box
A device mounted on the deck near the LARS; serves as a connector point for 26-VDC deck power
for the ROV or TMS.
DC motor
A direct-drive electric motor used in the TMS to power the drum drive and the pinch wheel.
Replaces the variable frequency drive motors used in other TMS units.
DC Pak
IPDS converter module that converts 120 VAC to 26 VDC for the IPDS backbone 26 VDC bus.
Deadband
The mechanical range within which the control system ignores joystick input.
decoder
A device that attached to a monitor to process video for display. Used in HDEVS.
demux
Multiplex/demultiplex (mux/demux) - a method for combining multiple analog message signals
or digital data streams into one signal.
Device Config App

The stand-alone Device (Node/Port) Configuration Application. Used to configure devices for
ROVs using the Silvertip ROV control system.
diamond screw
A subassembly of the TMS levelwind. The pawl assembly and tang travel along the grooved
diamong screw to facilitate smooth tether wraping and unwrapping on the drum (see pawl and
tang).
DNV
Det Norske Veritas - An international classification society that provides certification standards
for equipment.
docking head
The receptical portion of the LARS that accepts and latches onto the TMS bullet. Once the docking
head has latched onto the TMS, the umbilical cable no longer carries the load of the TMS and
ROV, and the entire load is carried by the LARS frame. The docking head also incorporates
swivel, tilt, and buffer mechanisims.
Page 313 011-0552-06

Glossary
Docking head
The receptical portion of the LARS that accepts and latches onto the TMS bullet. Once the docking
head has latched onto the TMS, the umbilical cable no longer carries the load of the TMS and
ROV, and the entire load is carried by the LARS frame. The docking head also incorporates
swivel, tilt, and buffer mechanisims.
DP
Dynamic positioning - A computer control system that automatically maintains a vessel's position
and heading by using the ship's propellers and thrusters.
drum drive
The motor and components that control rotation of the TMS drum and diamond screw.
Drum Drive
drumdrive
DSPL
DeepSea Power and Light - Manufacturer of oceanographic equipment, including underwater
lights, cameras, batteries, and lasers.
DTS
Digital Telemetry System - An automated communications process by which measurements are
made and other data collected at remote points and transmitted to receiving equipment for
monitoring and control functions.
DVD
Digital video disc - A type of compact disc able to store large amounts of data, especially high-
resolution audiovisual material.
DVL
Doppler velocity log - Underwater navigation system that tracks the ROV's location. The ROV
must be a minimum distance from the seafloor for the DVL to operate.
dynamic braking
When you release the joystick (to stop commanding thrust), dynamic braking reverses thrusters
to minimize overshoot due to ROV inertia. Available only when the ROV is in MANUAL VELOCITY
mode.
dynamic positioning
A method that uses ROV thrusters to keep an ROV stationary over a fixed location on the
seafloor. A computer directs power to each thruster when necessary based upon input from GPS,
compass, motion sensors, current meters, acoustic navigation equipment, and other devices.
E
e1600
ennn = The payout distance for an electric TMS system, where nnn equals the payout distance
(e425 = 425 meters, e850 = 850 meters, and e1600 = 1600 meters).
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Glossary
e425
e850
Ethernet
A system for connecting a number of computer systems, devices, and servers to form a local
area network.
external memory device

A removable device (like a USB flash drive or an external hard drive) that can be connected to a
computer for importing or exporting data.
F
FAT
Factory acceptance test - A test that takes place before equipment shipment to ensure that the
equipment meets pre-set specifications and is fully functional.
FDM
Frequency division multiplexer - A technique that divides the total bandwidth available in a
communication medium into a series of non-overlapping frequency sub-bands, each of which can
carry a separate signal.
FHCS
Flat-head cap screw
FHCSs
Flat-head cap screw
FICM
Fluid intervention control module - Pumps high-pressure fluid from the ROV into a client’s subsea
equipment.
flat file
A database file that contains records generated by the ROV control system. This file is used to
configure the control system at startup. The flat file can be archived to be used to reconfigure the
system when control software is being reinstalled.
fleet angle
The lateral angle that a cable aproaches or exits a spool or drum as it is being spooled on or off.
Incorrect fleet angle will cause the cable to skip a wrap or jump up. An improperly laid wrap may
cause the tether to stack up and bind or jam in the pinchwheel.
FLOT
Flying lead orientation tool - Allows positioning in real time without the need for re-configuration.
The FLOT allows for positioning and guide the tool into the stab plates on subsea equipment. The
FLOT provides pitch and roll capabilities for maneuvering of tools.
Page 315 011-0552-06

Glossary
flow gain
A control that lets you adjust flow rate for a valve.
fpm
Feet per minute - an unit of speed; the number of linear feet that a rotating component travels in
one minute.
ft-lb
Foot-pound of force (torque value) - A unit of work or energy in the United States customary and
imperial units of measure. It is the energy transferred when one pound of force (lbf) is applied
through a displacement of one foot.
FTP
File transfer protocol - A standard method used to transfer computer files from one computer to
another over a network like the Internet.
G
galling
Abnormal wear caused by friction or impact of two parts; unintended material transfer between
two moving components.
Galling
Abnormal wear caused by friction or impact of two parts; unintended material transfer between
two moving components.
GFD
Ground fault detection - A device that indicates whether a ground is present in an electrical
circuit. Use includes safety equipment intended to identify problems in a circuit before the circuit
malfunctions.
GFI
Ground fault interrupter - A device that shuts off an electric circuit when it detects that current is
flowing along an unintended path, possibly through water or through a person. It is used to
reduce the risk of electric shock.
GFM
Ground fault monitor - A device that monitors electrical currents to identify a risk of electric
shock. See ground fault interrupter (GFI).
gpm
Gallons per minute - A measure of liquid capacity in both the US customary units and the British
imperial systems of measurement.
GPS
Global positioning system - A geo positioning system that uses a network of satellites to calculate
location anywhere on the earth.
GUI
Graphical user interface - See also HMI (human-machine interface).
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Glossary
H
Hammerhead
A graphical user controls interface for operating the ROV and TMS. Used on HD and UHD-III ROV
systems.
HD
When referring to an ROV system model, Heavy Duty. When referring to video, high-definition
(video with higher resolution and quality than standard-definition video).
HD hydraulic configuration
On HD systems, the hydraulic configuration with (1) one HPU pump powering the main hydraulic
circuit and (2) a second HPU pump powering an auxiliary (aux) circuit.
HD hydraulic system
For HD systems, the hydraulic system has an HPU with two pumps, one for the ROV’s main
hydraulic circuit (which supplies the thrusters and the manipulators) and one for the auxiliary
circuit (which supplies tooling).
HDEVS
High-definition Ethernet video system - A system of high-definition cameras and video-
processing equipment, including a video computer that overlays and records video. Used on
UHD-III ROV systems. Contrasted with TAVS, a system using separate, third-party devices for
recording and annotating.
heartbeat
Viability of a control computer signal
HHCS
Hex-head cap screw
HHCSs
Hex-head cap screw
HID
High-intensity discharge -An electrical gas-discharge lamp that produces light by means of an
electric arc between tungsten electrodes.
HMI
Human-machine interface - Screens on the power distribution unit (PDU) that an operator uses to
configure, operate, and monitor the PDU. See also GUI (graphical user interface).
hp
Horsepower - A measurement of power over time that gives a rate at which work is done. The
most common conversion factor, especially for electrical power, is 1 hp = 746 watts.
HPU
Hydraulic power unit - Provides a stable, clean supply of hydraulic fluid to remotely operated
subsea valves.
HUD
Heads-up display - Overlay of graphics and data on monitor screens.
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Glossary
HV
High voltage
HV Pak
High voltage pak, specifically for the TMS DC motor drive system. This pak bolts onto the IPDS to
provide 340 volts of power for the TMS DC motors.
HVAC
Refers either to (1) high-voltage alternating current or to (2) a heating, ventilation, and air
conditioning unit used to regulate temperature in the control and work vans.
HVI
High viscosity index - A number describing how the viscosity of a fluid changes with temperature.
Fluids affected by temperature extremes have a low viscosity index, while fluids that maintain
viscosity have a high viscosity index.
HVTTR
High voltage transformer and terminations rack
hyperlink
An electronic link providing direct access from one distinctively marked place in a document to
another in the same or a different document.
Hz
Hertz (cycles per second) - The unit of frequency in the International System of Units. It is
defined as one cycle per second.
I
IMD
Insulation monitoring devices - these devices monitor the resistance between power phases and
chassis. Mounted on the front of the PDU.
IMR
Inspection, maintenance, repair - Includes integrity/deterioration monitoring of subsea assets
and light construction work. See also IRM.
inertial coordinates
A control type in which ROV trim (pitch or roll) does not affect vehicle movement. For example, if
the ROV is pitched down, moving the ROV forward does not cause it to also move down.
Contrasts with flight in body coordinates, where ROV pitch and yaw do affect movement. In the
ROV's default flight mode, the ROV flies using inertial coordinates.
INS
Inertial navigation system - A navigation aid that uses a computer, motion sensors
(accelerometers,) and rotation sensors (gyroscopes) to continuously calculate via dead
reckoning the position, orientation, and velocity (direction and speed of movement) of a moving
object without the need for external references.
IPA
Instrument power assembly
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Glossary
IPDS
Instrument power distribution system - A device that converts and distributes subsea power.
IRM
Inspection, repair, and maintenance - Includes integrity/deterioration monitoring of subsea
assets and light construction work. See also IMR.
ISO
International Standards Organization - An independent, non-governmental membership
organization and the world's largest developer of voluntary international standards.
ISOL-8
An auxiliary pump that can deliver hydraulic power using a range of fluids (including seawater) at
sustained high pressure and high flow rates. The eight-cylinder pump model has two hydraulic
circuits, each with its own fluid reservoir. The four-cylinder pump model has one hydraulic circuit
and one fluid reservoir.
J
J-box
Junction box - An enclosure that houses and protects electric wires, cables, and hydraulics that
are joined.
JIC
Joint Industry Council - a standard for sizing fittings and connectors.
K
keeper
Part of a fastener assembly used as retention point along with pins and bearings to keep the
movable joint in place.
Keeper
Part of a fastener assembly used as retention point along with pins and bearings to keep the
movable joint in place.
kgf
Kilograms of force - a unit of measurement; gravitational metric unit of force.
knuckle
A universal joint that connects the docking head to the clevis using pins. Also known as yoke.
ko
Kilohm - A unit of electric resistance equal to 1000 ohms.
kV
Kilovolts - a unit of electric resistance equal to 1000 ohms.
kVA
Kilovolt ampere - A unit of electrical power in an AC circuit equal to the power dissipated when 1
volt produces a current of 1 ampere.
Page 319 011-0552-06

Glossary
KVM
Keyboard, video, mouse - a hardware device that that allows a user to control multiple
computers from one or more console's keyboard, video, and mouse from one computer to
another.
kW
Kilowatt - a unit of electrical power measurement that is equal to 1,000 watts.
L
LARS
Launch and recovery system – Typically contains a winch to hold umbilical cable and an A-frame
or crane to lift and overboard the ROV. An HPU provides power to the winch and A frame.
lbf-ft
Use ft-lb instead. Foot-pound of force (torque value) a unit of work or energy in the Engineering
and Gravitational Systems in United States customary and imperial units of measure. It is the
energy transferred on applying a force of one pound-force (lbf) through a displacement of one
foot.
LCD
Liquid crystal display - a flat panel display, electronic visual display, or video display that uses
the light-modulating properties of liquid crystals.
LCU
Lighting control unit - Controls multiple lights through a single SeaNet cable. The lights can be
turned on and off and dimmed from the console touch screen. The LCU can also collect over
current and water detection data from the AC J- box (if used) and transmit this information to the
control system.
LED
Light-emitting diode - A semiconductor device that emits infrared or visible light when charged
with an electric current.
left client computer

A control system computer that processes and communicates information for the left control
station.
levelwind
A hinged assembly on the TMS used in conjunction with the pinch wheel. The levelwind assembly
moves from side to side across the drum to position the tether on the drum.
lift point assembly

The complete assembly that includes the clevis, docking head, and a method to attach the two
together; either with link plates, or a knuckle.
LIM
Latch interface module - A model of DTS node port. Provides two SeaNet power connections on a
single node port (example, to power two TMS electric latches).
Page 320 011-0552-06

Glossary
line ISO
Line isolation monitor circuitry is used to detect unwanted connections between system circuits
and the chassis of the machine (ground). If an unwanted voltage leak is present, the line
isolation circuits report this to the control system, and it is interpreted on the screen as a voltage
leak to ground.
Line ISO
leak to ground.
line isolation
leak to ground.
link plates
The flat plates that connect the docking head to the clevis using pins.
load test adapter

Adapter used for performing proof load testing of an umbilical mechanical termination. Some
models can also be used as an auxiliary lifting adapter.
lock out
lockout/tagout - The process of safely securing an electrical breaker system
lockout
lock-out
lockout and tagout

Long line
The entire high-voltage electrical path starting at the secondary output side of the HV
transformers inside the PDU, and continuing through the deck cable, winch slip ring, umbilical,
TMS slip ring, tether, HPU motor windings, and back to the PDU HV transformers.
LOTO
lpm
Liters per minute - a volumetric flow rate of a gas or liquid corrected to "standardized" conditions
of temperature and pressure.
LRU
Lowest replaceable unit - an item that must be replaced rather than repaired)
Page 321 011-0552-06

Glossary
LVI
Low Viscosity Index - a number describing how the viscosity of a fluid changes with temperature.
Fluids affected by temperature extremes have a low viscosity index, while fluids that maintain
viscosity have a high viscosity index.
M
main circuit
For HD systems: The main hydraulic power circuit originating at the port HPU pump that that
powers the manipulators and thrusters. For UHD-III systems, main refers to the circuit
originating at both port and starboard HPU pumps, and powers the thrusters, 8-ST valve pack,
manipulators, and the ISOL-8 pump.
Main Menu
In the Hammerhead control system, a menu (on the left side of the Status Bar) that lets you
access categories of screen pages.
max static test load

Maximum static test load (MSTL) - the maximum load that may be applied to a component, or
assembly in a static state, such as during an umbilical proof test.
M-G set
Motor generator set (an M–G set or a dynamotor for dynamo–motor) A device for converting
electrical power to another form. Motor–generator sets are used to convert frequency, voltage,
or phase of power. They may also be used to isolate electrical loads from the electrical power
supply line.
mirroring
Occurs in the ROV control system software when a device's signals are duplicated and sent to two
locations. For example, DVL signals are sent to the RTC for use in StationKeep and other
automatic control modes, but they can simultaneously be sent to a survey computer.
mobilization
The process of installing an ROV system (including launch/recovery equipment and power
equipment) on a ship.
module summary
A data display window in the DTS Network Viewer software that shows information about the
installed interface modules on the nodes. (A node must be selected in Node Summary window).
Shows module type, on off state, amperage draw etc.
Module Summary
A data display window in the DTS Network Viewer software that shows information about the
installed interface modules on the nodes. (A node must be selected in Node Summary window).
Shows module type, on off state, amperage draw etc.
motion sensor
Measure heave, pitch and roll – Typically on surface vessels. Correcting for vessel motion is
critical for multi-beam hydrographic surveys.
Page 322 011-0552-06

Glossary
MPEG
Movie Picture Experts Group - A standard for audio and video compression and transmission.
MRU
Motion reference unit - a Gyro that can measure pitch, roll, heave, and heading.
MSTL
See Max static test load
msw
Meters of sea water
mushroom
See docking head
mux
Multiplex/demultiplex (mux/demux) - a method for combining multiple analog message signals
or digital data streams into one signal.
MWSK
Mid-Water StationKeep - holds the ROV stationary above a designated point on the seafloor even
when the ROV is out of DVL range of the seafloor.
N
Ncm
Newton centimeter - A metric unit of torque.
NDT
Non-destructive testing - a wide group of analysis techniques used in science and industry to
evaluate the properties of a material, component, or system without causing damage.
neutral position
The resting position of a tactile control (the mechanical position taken by the control when the
operator is not touching or moving the control). For the flight joystick, the neutral position is the
center position.
NIM
Network interface module - allows transmission of Ethernet signals through a node port.
NJIC
National Joint Industry Council - a statutory council of employers and trade unions. It is a
workplace partnership institution that serves for a forum of consultation between employees and
employers. See also JIC.
Nm
Newton meter - a metric unit of torque.
node
A component of the ROV communications system, connecting devices using 26 VDC power on the
ROV, TMS, and tool skid to the ROV control system. Each node contains 16 ports for attaching
devices.
Page 323 011-0552-06

Glossary
Node Changer
An FMC Schilling Robotics-supplied software application used to configure a spare (a factory-
configured spare or a previously installed spare) node’s ID/IP address to match the ID/IP
address of a node that is being replaced. Node Changer is supplied with the technical manual
digital files to let you configure the new node.
node summary
A data display field in the DTS Network Viewer software that displays electrical power
information for each node on the system: volts, amps, watt, degrees C etc.
Node Summary
A data display field in the DTS Network Viewer software that displays electrical power
information for each node on the system: volts, amps, watt, degrees C etc.
nonproportional control
A control device (like a switch) is either on or off. In contrast, a proportional control (like a knob
or joystick) lets you select a range of values (for speeds, flow, etc.).
NTSC
National Television Standards Committee (NTSC) - the committee responsible for developing a
set of standard protocol for television (TV) broadcast transmission and reception in the United
States. Two other standards - Phase Alternation Line (PAL) and the French Sequential Couleur
avec Memoire (SECAM or Sequential Color with Memory in English) - are used in other parts of
the world. The NTSC standards have not changed significantly since their inception, except for
the addition of new parameters for color signals. NTSC signals are not directly compatible with
computer systems.
O
OD
Outside diameter - the outer diameter of a pipe, including the wall thickness.
OEM
Original equipment - a manufacturer is a term used when one company makes a part or
subsystem that is used in another company's end product.
ORFS
O-ring face seal - a hydraulic sealing system for hoses and fittings.
OTDR
Optical time-domain reflectometer (OTDR) - an optoelectronic instrument used to characterize
an optical fiber. (see reflectometer)
overlay
In HDEVS (video system), information that is overlaid on a video stream using the video
computer. Added information can include graphics (like a logo) or data (like a date/time stamp
or the ROV heading).
Page 324 011-0552-06

Glossary
P
P/N
Part number
PAL
Phase alternation line (PAL) video format is the analog television display standard that is used in
Europe and certain other parts of the world. PAL is one of the three major TV standards together
with the American National Television Systems Committee (NTSC) color television system and
the French Sequential Couleur avec Memoire (SECAM or Sequential Color with Memory in
English). NTSC is also used in Japan. SECAM is used in countries of the former Soviet Union.
pan & tilt

Positioning devices used to remotely move cameras, lights, sonars and, other devices. Pan
refers to movement along the horizontal axis and tilt refers to movement in the vertical axis.
pan and tilt

pan/tilt
pawl
The pawl assembly includes a tang. The tang protrudes from the pawl and runs along the groove
in the diamond screw on the TMS. (see tang and diamond screw)
pay in
Winding tether onto the TMS drum using the drum motor.
pay out
Unwinding tether off the TMS drum using the drum motor.
payin
pay-in
payout
pay-out
PBOF
Pressure balanced, oil-filled is a hose cable assemblies with electric and fiber optic connectors.
Typically can be wet mated at any depth, because they are pressure equalized.
PCA
Printed circuit assembly - is a printed circuit board that contains electronic components.
Page 325 011-0552-06

Glossary
PCB
Printed circuit board - a bare board without electronic components.
PCI
Peripheral component interconnec - an interconnection system between a microprocessor and
attached devices in which expansion slots are spaced closely for high speed operation.
PDF
Portable document format - a file with the .PDF extension that can be displayed by most
computers and software applications.
PDP
Power Distribution Panel - the primary power breaker panel in the control van that breaks the
input line from the control van. The PDP panel also houses sub breakers for the air conditioning
system, PDU, computer rack, and other equipment.
PDU
Power distribution unit - a multi-input isolation transformer that drives several circuits, each with
its own circuit breaker protection. Provide isolation, power distribution, and protection for
several circuits.
pinch wheel
A rubber-lined pulley (sheave) that grips the tether for controlled pay out or pay in. The tether is
pinched between the pinch wheel and roller guides so that the tether does not slip or run free.
The pinch wheel is driven by the pinch wheel motor.
pinchwheel
A rubber-lined pulley (sheave) that grips the tether for controlled pay out or pay in. The tether is
pinched between the pinch wheel and roller guides so that the tether does not slip or run free.
The pinch wheel is driven by the pinch wheel motor.
pins
Electrical: General reference to any of the connector points on an electrical component or circuit
board. Mechanical: The load bearing cylindrical axis shaft that provides pivot points and rotation
where movement is needed.
Pins
Electrical: General reference to any of the connector points on an electrical component or circuit
board. Mechanical: The load bearing cylindrical axis shaft that provides pivot points and rotation
where movement is needed.
platform
A primary component of an ROV system, such as an ROV, TMS, and work skid. For diagnostic
purposes, topside equipment and the telemetry system are considered to be platforms.
PLC
Programmable logic controller - A digital computer used for automation of typically industrial
electromechanical processes, such as control of machinery.
Page 326 011-0552-06

Glossary
PM
Preventive Maintenance - a planned or scheduled routine maintenance that will hopefully reduce
unplanned down time as a result of equipment failure.
port
In electrical or hydraulic circuits: A connection point. ROV direction reference: The side of a ship
or vehicle that is on the left when one is facing forward.
PORT
In electrical or hydraulic circuits: A connection point. ROV direction reference: The side of a ship
or vehicle that is on the left when one is facing forward.
PPE
Personal protective equipment - equipment or clothing worn to minimize exposure to hazards
that can cause workplace injuries and illnesses. May include gloves, safety glasses and shoes,
earplugs or muffs, hard hats, respirators, coveralls, vests, and full body suits.
pressure compensated housings

A fluid-filled housing used to maintain ambient pressure.
proof testing
The process of applying a known load to a new mechanical termination to prove its strength and
load carrying ability.
proportional control
A control device (like a knob or joystick) that lets you select a range of values (for speeds, flow,
etc.). In contrast, a non-proportional control (like a switch) is either on or off.
Prove Dead
A Prove Dead safety test is always conducted by a qualified electrical power technician on power
cables prior to working on connections. The purpose is to prove that the cables do not contain
electrical energy. The test requires proper PPE and special insulated test equipment to verify
voltage between conductors and between conductors and ground.
PRV
Pressure reducing valve - a valve that automatically cuts off the flow of a liquid at a certain
pressure. Used to allow high-pressure fluid supply lines or tanks to be reduced to safe and/or
usable pressures for various applications.
PSA
Position sensor array - an array of eight sensors that can attach to a single subsea node.
PSI
Pressure per square inch - a measurement of pressure in force per unit area applied in a
direction perpendicular to the surface of an object.
PSU
Power supply unit - hardware that supplies power to an electrical device. It receives AC
(alternating current) power and converts the current to DC (direct current).
Page 327 011-0552-06

Glossary
Q
QD
Quick disconnect - a connector shell that permits rapid locking and unlocking of two connector
halves.
QMS
Quality management system - a set of policies, processes and procedures required for planning
and execution (production/development/service) in the core business area of an organization.
quad tiled
A monitor that has been divided into four sections to display four separate video streams.
quad tiling
Dividing a monitor into four sections to display four separate streams.
R
rapid fill and bleed
UHD-III systems only. Mobile cart used to quickly drain and fill the compensation systems on the
ROV and TMS. See compensation cart for HD and UHD-II systems.
rapid fill and bleed compensation cart

UHD-III systems only. Mobile cart used to quickly drain and fill the compensation systems on the
ROV and TMS. See compensation cart for HD and UHD-II systems.
Reflectometer
An optical time-domain reflectometer (OTDR) is an optoelectronic instrument used to
characterize an optical fiber.
remote sensing
Subsea data collected by sensors on the ROV.
render
Tether is being pulled off the drum by some force other than the TMS motors (for example, by
ROV movement or currents),
RHC
Rate hand controller - a device on the tool control pod that lets you operate rate-controlled
devices (like a rate-controlled manipulator arm).
right client computer

A control system computer that processes and communicates information for the left control
station.
Rotating J-box
Used on the winch, this box connects the winch slip ring electrical and fiber to the umbilical cable
on the winch.
ROV bullet
Attached to the top of the ROV; the part that connects into the TMS latching device. See also TMS
latch.
Page 328 011-0552-06

Glossary
RSTP
Rapid spanning tree protocol - a communications network scheme that includes redundant
connections to reduce communication failures.
RTC
Real-time computer - a control system computer that handles all information transmitted
between devices in the ROV system and the control console.
RTSP
Real time streaming protocol is used in the Schilling HDEVS equipment
RX
Receive (incoming) buffer used to regulate the flow of data frames
S
safe working load
(SWL) – The maximum load that may be applied to a component or assembly in a dynamic state,
such as normal system operations.
SD
Standard-definition - a video feed with lower resolution and quality than high-definition video.
SD video topside encoder

Allows four deck cameras to connect to HDEVS.
SDI
Serial digital interface - a standard for digital video transmission over coaxial cable.
SDVIM
Standard-definition video interface module (SDVIM) - converts video signals to Ethernet signals.
In ROV systems with HDEVS, SD cameras (for example, a TITAN 4 wrist camera) must be
connected to a node through an SDVIM.
SeaNet
Subsea cabling and connector system from FMC Schilling Robotics
set point
A value or range commanded by the operator (for example, a value for an ROV depth or a valve
flow rate). The control system then operates devices (thrusters, valves, etc.) to reach and/or
hold that commanded value.
SFP
Small form pluggable - a compact, hot-pluggable transceiver used in subsea nodes and rack
nodes for communications applications.
SHCS
Socket-head cap screw
SHCSs
Socket-head cap screw
SHFS
Socket-head flat screw
Page 329 011-0552-06

Glossary
SHFSs
Socket-head flat screw
shp
Shaft horsepower - The power output from an engine after it is put through the gear train and
other components that result in a loss of power. Used as the power output from a cars gearbox.
Silvertip
A graphical user controls interface for operating the ROV and TMS. Used on UHD-II and some HD
ROV systems.
SIM
Serial interface module - allows transmission of serial signals through a node port.
SK
StationKeep - control function that holds the ROV stationary above a designated point on the
seafloor.
slip ring
A electromechanical device that allows the transmission of power and electrical signals (and
possibly optical signals) from a stationary structure to a rotating object. Also called a rotary
electrical joint, collector or electric swivel.
sonar
SOund, NAvigation and Ranging. The sonar unit emits a pulse of sound ("ping") into the water and
then listens for an echo when the signal is reflected off an object. To measure the distance to an
object, the sonar measures the time from emission of a pulse to reception. Typically used to
measure depth, but can also be mounted horizontally to gauge distance to objects.
spelter socket
See docking head
SSV
Seawater suction valve - a valve that can be opened to seawater, allowing the Aux circuit 1 to
use seawater as an unlimited fluid source.
starboard
The side of a ship or vehicle that is on the right when one is facing forward.
Station Keep
Holds the ROV stationary above a designated point on the seafloor; requires that the ROV be
within DVL range of the seafloor. Also see MWSK (Mid-Water StationKeep).
Stationary J-box
Used on the LARS winch - connects the van cable electrical and fiber to the winch slip ring.
StationKeep
Holds the ROV stationary above a designated point on the seafloor; requires that the ROV be
within DVL range of the seafloor. Also see MWSK (Mid-Water StationKeep).
STBD
The side of a ship or vehicle that is on the right when one is facing forward.
Page 330 011-0552-06

Glossary
subsystem
Related components that work together in an ROV, TMS, or skid. For example, the ROV HPU
subsystem includes pumps and valve packs, and the compensation subsystem includes
compensators and reservoirs.
survey string
ROV motion and position data that can be output by the ROV control system for use with survey
software.
SWL
Safe working load - the manufacturer's recommended maximum weight load for a lifting device
or component.
T
tactile control
A mechanical device that, when you move the device, issues commands to the ROV system.
Includes joysticks, the tether foot pedal, and items on the tool control pod and flight pod.
tag out
tagout
tag-out
tang
The tang is part of the pawl assembly. The tang protrudes from the pawl and runs along the
groove in the diamond screw on the TMS. (see pawl and diamond screw)
TAVS
Tunneled analog video system - a video system that uses separate, third-party devices for video
recording (a DVR) and annotating (an annotator). Used on UHD-II and HD ROV systems.
Contrasted with HDEVS, a video system using the video computer for integrated recording and
annotating functions.
TCM
Thruster control manifold - a manifold with proportional pressure control.
TCU
Thruster control unit - a dedicated valve pack that controls up to four thrusters from a single
node port. The TCU contains proportional pressure-reducing valves, a relief valve, and a control
PCA in a compensated volume.
tether
Cable used to control the ROV from the TMS to the ROV. A conduit through which power, controls,
and communication signals are transferred from the TMS to the ROV. Typically neutral buoyant in
water. See also umbilical.
Page 331 011-0552-06

Glossary
TFL
Through-frame lift - Any weight that must be supported by the TMS or ROV frame. The TMS TFL
rating is the maximum weight that the TMS latching interface can support. This value includes
any weight suspended below the TMS, including the weight of the ROV, utility skid, and any
customer-installed equipment on the ROV. The ROV TFL rating is the maximum weight that the
ROV can support from the four-point TFL attachment location under the ROV. The combined
weight of all tooling attached to the ROV may not exceed the ROV TFL rating.
Through-frame lift
Through-frame lift - Any weight that must be supported by the TMS or ROV frame. The TMS TFL
rating is the maximum weight that the TMS latching interface can support. This value includes
any weight suspended below the TMS, including the weight of the ROV, utility skid, and any
customer-installed equipment on the ROV. The ROV TFL rating is the maximum weight that the
ROV can support from the four-point TFL attachment location under the ROV. The combined
weight of all tooling attached to the ROV may not exceed the ROV TFL rating.
TMS Bullet
A conical component that fits into the latch mechanisim on the LARS docking head. See also
docking head.
TMS latch
A two-stage mechanical latching mechanisim that is fitted to the lower side of the TMS. The ROV
bullet fits into this latch, and secures the ROV to the TMS during loading and handling.
TPR
Thermoplastic rubber - rubber that does not require chemical vulcanization and will repeatedly
soften when heated and stiffen when cooled.
trim
ROV pitch or roll. Also called "attitude." The TRIMS auto function applies constant thrustin one or
more designated directions.
TTL
Transistor—transistor logic - a class of digital circuits built from bipolar junction transistors (BJT)
and resistors.
two-circuit HPU
For HD systems, the hydraulic system has an HPU with two pumps, one for the ROV’s main
hydraulic circuit (which supplies the thrusters and the manipulators) and one for the auxiliary
circuit (which supplies tooling).
TX
Transmit (outgoing) buffer used to regulate the flow of data frames. Also, in a SeaNet connector,
a specific signal line with a direction and an indicator light.
U
UCM
Universal control module - a printed circuit assembly that allows for serializing/de-serializing of
devices that are not serial in nature.
Page 332 011-0552-06

Glossary
UHD-II
Ultra Heavy-Duty II ROV - FMC Schilling Robotics second-generation ROV system.
UHD-III
Ultra Heavy-Duty Generation III (UHD-III) - an ROV system that delivers the performance and
hydraulic power required to complete a wide variety of heavy construction tasks as demanded by
the offshore subsea industry. The UHD-III has incorporated the latest technologies provided in
the HD vehicle line with the UHD line and introduced additional advancements in technology in
the system hydraulics, video and automation areas to provide an extremely reliable ROV system.
UHD-III hydraulic configuration

A hydraulic configuration, with two HPU pumps powering the main hydraulic circuit and an ISOL-
8 pump for auxiliary (tooling) hydraulics.
UHD-III hydraulic system

The hydraulic system has an HPU with two pumps. The output of both pumps is combined into a
single oil circuit (the ROV’s main hydraulic circuit) that supplies the thrusters and the
manipulators. The hydraulic system also features the ISOL-8 pump, which provides two auxiliary
circuits for tooling.
umbilical
A conduit through which power, controls, and communication signals are transferred from the
topside ship to the TMS. See also tether.
UPS
Uninterruptible power supply - an electrical device that provides emergency power to a load
when the input power source (typically mains power) fails. A UPS differs from an auxiliary or
emergency power system or standby generator in that it provides near-instantaneous protection
from input power interruptions by supplying energy stored in batteries.
USB
Universal serial bus - an industry standard that defines the cables, connectors and
communications protocols used in a bus for connection, communication, and power supply
between computers and electronic devices. The standard enables the connection of computer
peripherals (including keyboards, pointing devices, digital cameras, printers, portable media
players, disk drives and network adapters) to personal computers, both to communicate and to
supply electric power.
USBL
Ultra-short baseline - an underwater positioning system that uses a vessel-mounted transceiver
to detect the range and bearing to a target using acoustic signals.
User Setting Config App

User Settings Configuration Application used to configure control system settings.
UV
Under-voltage - occurs when a load is suddenly connected to a power supply and the load start to
draw current, causing the voltage to temporarily drop. Can cause premature shutdown of a
circuit and data loss.
Page 333 011-0552-06

Glossary
V
v
Volt - the standard unit of potential difference and electromotive force in the International
System of Units (SI).
VAC
Volts alternating current - the flow of electric charge periodically reverses direction. In direct
current (DC), the flow of electric charge is only in one direction. The abbreviations AC and DC are
often used to mean simply alternating and direct, as when they modify current or voltage.
VDC
Volts direct curren - the unidirectional flow of electric charge. Direct current is produced by
sources such as batteries, thermocouples, solar cells, and commutator-type electric machines of
the dynamo type. Direct current may flow in a conductor such as a wire, but can also flow
through semiconductors, insulators, or even through a vacuum as in electron or ion beams. The
electric current flows in a constant direction, distinguishing it from alternating current (AC). A
term formerly used for direct current was galvanic current.
VFD
Variable frequency drive - a motor controller that drives an electric motor by varying the
frequency and voltage supplied to the electric motor.
video computer
For HDEVS, a computer in the control console that overlays and records video.
Video Computer App

An application (run from the video computer) that overlays and records video from ROV system
cameras. This application is used only with HDEVS.
VIM
Video interface module - allows transmission of video signals through a node port.
VLAN
Virtual LAN) - a network of computers that behave as if they are connected to the same wire
even though they may actually be physically located on different segments of a LAN.
W
w
Watt - the standard unit of power in the International System of Units (SI).
WDM
Wave division multiplexer - a technology that multiplexes a number of optical carrier signals
onto a single optical fiber by using different wavelengths of laser light. See CWDM.
Weight in Air
Tthe weight of an item when weighed on a flat stable surface with out any motion. (not on board
a pitching deck of a ship). This is important when calculateing total thrugh frame safe working
load. See also weight in sea water.
Page 334 011-0552-06

Glossary
Weight in Sea Water

The weight of an item when submerged in seawater. The exact weight may vary becuse the
density of seawater is affected by depth, salinity, and temperature of the local seawater, but the
net result is less than the weight of the item in air. See weight in air. Weight in sea water is
critical for dertermining bouyancy of added components.
winch
The part of a launch and recovery system that feeds out umbilical cable to the TMS. The winch
hydraulic motor and a spool device are used to pay out, pay in, and store cable on a drum. The
winch typically uses a levelwind mechanism to evenly spool umbilical cable onto the drum.
WROV
Work-class remotely operated vehicle - an ROV powered electrically and hydraulically, enabling
more capabilities than a standard ROV. The Work Class Vehicle ROV does generally include a
seven-function manipulator and a five-function grabber. Most of this class of ROV is deployed in
the drilling and construction support sector, as well as pipeline inspection.
X
XTE
Cross-track error - the distance you are off from the desired course in either direction. Used for
the survey AutoTrack function.
Y
yoke
A universal joint that connects the docking head to the clevis using pins and serves as the pivot
point between the two assemblies. Similar to a universal joint. Also known as knuckle.
Yoke
A universal joint that connects the docking head to the clevis using pins and serves as the pivot
point between the two assemblies. Similar to a universal joint. Also known as knuckle.
Page 335 011-0552-06

Glossary
Page 336 011-0552-06

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Schilling Robotics

UHD-III System 300-0552-06

Document No. 011-0552-06

FMC Technologies Schilling Robotics

TECHNICAL MANUAL REVISION LOG

Power System Components

1. About Power Distribution Unit (PDU) 7

1. About Power Distribution Unit (PDU)

1.1 Power Distribution Unit (PDU): Mobilization

1.2 Power Distribution Unit (PDU): System Reference

PDU: Lockout/Tagout (Safety Procedure)

Personnel Per specific job requirements

Parts-Kits Approved lockout/tagout devices (locks, tags)

Safety High-voltage electrical shock hazard, pinching

Tagout and lockout devices should be used together whenever possible.

Preparing for Lockout/Tagout

WARNING! Ensure that all external power

Confirm that no hazardous energy is present

Examples of locked grounding wheels:

2. Depending on the lockout mechanism used, you

Lock out circuit breakers

Note: Circuit breakers only allow locks to be

Removing Lockout/Tagout Devices

1. Before you remove any lockout or tagout device, take the

2.1.1 PDU Left Door

PDU Indicators and Controls (Left Door)

Figure 1: PDU Left Door (UHD-III)

2.1.2 PDU Right Door

PDU Indicators and Controls (Right Door)

PDU Indicators and Controls (Right Door) (continued)

Figure 2: PDU Right Door

2.1.3 Fixed Front Panel

PDU Indicators and Controls (Fixed Front Panel)

Figure 3: Fixed Front Panel

2.2 PDU Operation: Hardware Interlocks

2.3 PDU Operation: Power Up

3 Turn on the main power breaker Q01.

PDU Power Up (continued)

PDU Power Up (continued)

7 Turn on the Q02 PDU Breaker.

Turn on ROV IPDS Power

Turn on ROV IPDS Power (continued)

3 Check that the ROV IPDS ground fault meter is indic-

Turn on ROV IPDS Power (continued)

5 Turn on ROV IPDS power using the HMI, the push-

Turn on ROV IPDS Power (continued)

Turn on ROV HPU Power

Turn on TMS Power

2.4 PDU Operation: Ground Fault Bypass Switch

3. PDU: Theory of Operation

Power Input Path

3.1.1 Power Input Section Breaker Panel

3.1.2 Power Metering

Power Metering Equipment

Figure 5: PQube on inside of left front door

3.1.3 Circuit Breaker Interlocks

3.1.4 Control Power

Figure 6: Control power terminal block

3.1.5 Ground Fault Detection