VERSION 2011-02

SeaPerch Construction Manual Version 2011-02

2700 South Quincy St., Suite 400, Arlington, VA 22206 www.seaperch.org

Welcome to your SeaPerch journey! Today is an exciting one today is the day you will embark upon your SeaPerch journey. I say journey because it is not simply a one-day experience you will have, or a short course you will take. We envision your participation in the SeaPerch Program as a step along a journey that, we hope, will include other STEM (Science, Technology, Engineering, and Mathematics) activities. Think of SeaPerch as one step along the Yellow Brick Road that might lead you or your students to consider further study or a career in STEM. SeaPerch is a K-12 Educational Outreach program sponsored by the Office of Naval Research (ONR) and managed by the Association for Unmanned Vehicle Systems International Foundation (AUVSIF), designed to help identify the next generation of STEM professionals. We are proud to be one of the Navys signature Outreach programs. Over the past five years, more than 60,000 students have participated in a SeaPerch Build, and over 4,000 teachers and mentors have been trained. We know SeaPerch to be an effective educational program and activity designed to teach and reinforce STEM concepts through hands-on activities and a STEM curriculum. With this one activity alone, students will meet many of the STEM national learning standards designated by the Department of Education. During the build and launch, students learn how to build a propulsion and electrical system, develop a controller, investigate density and buoyancy, use tools safely, and also work together as a team. SeaPerch is designed to generate Awareness, Interest, and eventual Pursuit of STEM careers, and to teach students that working in a STEM field can be fun and engaging. The ultimate goal is that by participating in SeaPerch, awareness and interest in STEM will be ignited, resulting in some students deciding to pursue careers in technical, scientific, and research fields that will fill positions critical to the safety and security of the United States. I encourage you to refer often to the www.seaperch.org website, as we have designed it to be a resource for your continued use. The discussion groups, training and build videos and manuals, curriculum, educational activities and lessons available on the website are continually updated. Our intent is for the website to be the main reference point for information that changes and updates frequently. Go! Take the first step on your SeaPerch journey! Have fun!

Susan Nelson Executive Director, SeaPerch Program AUVSI Foundation

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UNIT 1 ASSEMBLY OF SUBSYSTEM ONE -- THE VEHICLE FRAME

Inthisunit,youwillcutpipepiecesandassembletheSeaPerch'sframe.Holes will be drilled in the elbows and portions of the frames to allow venting and drainingoftheSeaPerchframeandmotormountingslaterinthebuild.

Tools and Materials Needed Tools

Eye Protection (Always Worn) Ruler and Pencil (or Marker) PVC Pipe Cutter (or Saw) Wire-Cutting Pliers (Flush-Cutting Type Preferred) Electric Hand Drill Drill Bit 3/32 Drill Bit

Materials
72" (1.8 m) PVC Pipe (Or Six, one foot. Lengths) 10 4 2 1 8 PVC Elbows PVC Tees Floats 12 x 6.5 (31 x 17 cm) Payload Net 6 Tie Wraps (small black)

Procedure 1.1 Cut the Frame Parts Construction Steps:

1. MeasureandcutthepieceslistedbelowfromlengthsofPVCpipe.Cutthelongestpieces first,incaseamistakeismade(smallerpiecescanbecutfromamiscutlongerpiece).Try tocutstraightacrossthepipe,butdontworryiftheyarenotperfect. TwoPieces6.5(16.5cm)long TwoPieces4(11.4cm)long TwoPieces2(6.4cm)long 2. Useapencilormarkertowritethelengthon themiddleofeachpiecetokeeptrackof cutsandtoeasilyidentifythemlater.Figure 1.11showsthepiecesneededtoassemble theROVframe.Figure1.12(onthenext page)showsonewaytocutthepipepieces fromsix,onefootpipes. FourPieces5(12.7cm)long TwoPieces4(10.2cm)long FourPieces1(3.8cm)long

Figure 1.1-1: PVC Pipe Cutter and Cut PVC Pipe Sections, Elbows, and Tees

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Figure 1.1-2: Cutting Guide to Efficiently Mark and Cut the 16 Required Pipe Sections from the Six 1-Foot Pipe Pieces Provided in SeaPerch ROV Kits

Procedure 1.2 Drill the Drain Holes

NOTE: You will need to create vent and drain holes in vehicle frame in order to allow water to fill the frame when you place your SeaPerch into the water and for the water to drain out when you remove it.

Construction Steps:
1. Placeanelbowontheendofa6"to12"lengthof"PVCpipe, tousethepipeasahandlewhiledrilling,asinFigure1.21,or secureitinaviseorclamp. 2. Drillfromtheinterioroftheelbowoutward.Drilla"holeinthe corneroftheelbow,suchasshowninFigures1.21and1.22. 3. RepeatSteps1and2forotherPVCelbows. 4. DrillThrustermountingholesintwoofthe5lengthsandoneof the4lengthsasshowninFigure1.23.Besuretocarefully centerthethrustermountingholesonthatpipesothatthe thrusterswillbestraightwhenmountedonthevehicle.

Figure 1.2-1: Drilling Elbow Hole over a Wastebasket

" Hole

Figure 1.2-2: Drain Hole Drilled in a PVC Elbow 3

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5 pieces

4.5 piece

Figure 1.2-3: Motor Mounting holes in two 5 pieces and one 4.5 piece

Procedure 1.3 Assemble the Vehicle Frame Construction Steps:

1. AssembletheframeusingthePVCpartsasshowninFigure1.31.Noglueisusedforanyof theconnections.Orienttheelbowsthatarenearthetopofthevehiclewiththeirholes pointingupward,toletairescapewhentheSEAPERCHisplacedinthewater.Orientthose atthebottomwiththeirholespointingdownwardortotheside,toletthewaterfloodin andouteasily. 2. Withtheframeplacedonthefloororonasturdytabletop,pushdownhardonallpartsof thevehicleframe,turningandpressingfromallsides,sothatthePVCfittingsandpipe sectionsallfittogetherverytightly.BesuretopressHARD,orusearubbermallettofirmly taponallelbowsuntiltheendsofthepipesectionsbottomoutinsidethepipefittings. Adjustthesidesandthebottomoftheframeasneededtosquareupthevehicle,asshown inFigure1.32(ortiltthesidesatanangleifyouwish!).Itisimportanttodothisbefore installingthebottompayloadnetting. NOTE:Ifyouwishtopaintyourvehicle,dosobeforeattachingthepayloadnettingor thrusters,andmakesuretousewaterproofpaint.

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Figure 1.3-1: Initial Frame Assembly

Figure 1.3-2: Assembled ROV Frame with Top Pipes and Foam Floats

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Procedure 1.4 Attach the Payload Net Construction Steps:

1. Placethepayloadnetunderneaththevehicleframe,andtrimittosizeifnecessary. 2. Attachthenettotheframeusingabout8smallblacktiewraps.Pullthemtightusingpliers. MakesurethenetistightandflatonthebottomoftheSeaPerch. DONOTUSETHELARGEBLUETIEWRAPSFORTHIS 3. Trimofftheendsofthetiewrapsusingwirecuttingpliers(asflushaspossible),asshownin Figure1.41.

Figure 1.4-1: Payload Netting Attached to Frame

Congratulations! You have completed the frame for your SeaPerch!

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UNIT 2 ASSEMBLY OF SUBSYSTEM TWO -- THE THRUSTERS

In this unit, you will waterproof the motors using wax, install propellers, waterproofthetethercableandmountthethrustersontotheframe.

Tools and Materials Needed Tools

Eye Protection (Always Worn) Electric Hand Drill 3/32 Drill Bit 1/4 Drill Bit Pliers Needle-Nose Pliers Wire Stripper (18 - 26 AWG Size) Wire-Cutting Pliers Vise Permanent Ink Marking Pen Ruler and Scissors Soldering Iron and Solder Fine Sandpaper or Steel Wool Gloves (Disposable Type)

Materials
~50 (15 m) CAT 5 Tether Cable with RJ-45 Connector Installed on One End 3 3 3 3 3 3 1 1/3 1/2 1 5 6 35 mm Film Canisters, with Caps 12-Volt DC Motors Propellers 4-40 Threaded Propeller Shaft Couplers 4-40 Tee Nuts 4-40 Lock Nuts Super Glue Wax Bowl Ring Butyl Rubber Tape 12-Volt Battery 6 (15 cm) Tie Wraps (small black) 11 Heavy-Duty Tie Wraps (large Blue) Alcohol Pads Paper Towels Electrical Tape

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Procedure 2.1 Seal the Motors So That Wax Cannot Get Inside
NOTE: The entire shell of each motor will be sealed with electrical tape, but the thickness must be minimized in order to allow the motors to fit into the film canister. EVERY hole in each motor's shell must be sealed, and any folds in the tape, where potting wax could pass through, must be avoided.

Construction Steps:
1. Findthereddotonthewhitepartofeachofthemotors,nearitselectricalterminals.The reddotmarksthepositive(+)terminal.Markthe(+)terminal(nearestthereddot)withthe marker. 2. Tokeepthetapeonthesidesofthemotorthinenoughtofitintothehousing,it'sbestto firstcoverbothendsofthemotor,thentrimtheendtapesflushwiththesides,andcover thesideslast.Usefive,short,1piecesoftapeontheends,suchasintheprocessbelow. Figure2.11showstheinitialtapingsteps.

Figure 2.1-1: Tape Sealing Process

Ontheterminalend,gentlypushapieceoftapeoveroneterminaltopokeit throughthetape.Carefullyplacetheedgeofthistapeupalongthesideofthe motorshaftboss(raisedareainthecenter). Continuedoingthisforallfivetapepieces,overlappingthemaroundtheterminal endofthemotortofullycoverit. Thentrimoffalltapethat extendspasttheedgeofthe motorshell(cutwithscissors tiltedtowardthemotorendto getaclean,flushedge).
One, Thin, Layer Of Tape on Sides NO Folds or Gaps

3. Repeatthistapingprocessontheother endofthemotor.Besuretocutthe tapepiecesflushattheedgeofthe motorasbefore.

NO Side "Lumps" at Ends Figure 2.1-2: Properly Sealed Motor

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4. Forthesides,wraptapearoundthemotor.Startatoneendwiththeedgeofthetape extendingabout1/16(~2mm)pasttheendofthemotor,sothatitcanstretchoverthe endtoformagoodseal.Pullthetapetightasyouwrap.IMPORTANT:Tapeonlyasingle layeraroundthemotor(sothatitwillfitintothethrusterhousingcanisterwithspaceleft forthewax,Pressittosealtheedgeassmoothlyaspossible. 5. RepeatSteps2and3fortheothermotors.Thesealedmotorsshouldlookliketheonein Figure2.12. 6. EnsurethatALLoftheholesinthemotorsaresealedwellbypressing,rubbing,and squeezingthetapeovertheentiresurfaceofeachmotorshell. 7. Verifythatthesealedmotorsallfitintoathrusterhousingwithspaceremainingaroundit forthepottingwax.

Procedure 2.2 Drill Holes in the Thruster Housings Construction Steps:

1. Beforedrilling,thecapsandthruster housings,scrapeoffanyplasticlumpsthat maybeinthedrillingarea,usingyour fingernailorasmalltool. 2. Usingthe3/32drillbit,slowlydrillahole throughthecenterofeachofthethree thrusterhousingcaps,asshowninFigure2.2 1. 3. Verycarefullydrilla3/32holethroughthe centerofeachthrusterhousing.Makesure thedrillisheldstraightsothattheholeisnot onanangle.

Figure 2.2-1: Holes Drilled in Thruster Housings

4. Removeanyplasticburrsfromtheholesinthebottomsofthehousingsthatmaybeleft afterdrilling.Dothisbyremovingthe3/32drillbitfromthedrillandpassingitslowlyby handstraightthroughtheholes,frombothdirections,afewtimes,withouttwisting.

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Procedure 2.3 Connect the Tether Cable Wires to the Motors

NOTE: Each motor must be connected to one of the color-coded pairs of wires in the tether cable. The CAT 5 tether cable has four wire pairs inside. The brown wire pair is not utilized for the SeaPerch. The other three of them will be used for the standard SeaPerch.

Construction Steps:
1. Ontheendofthetethercablethat hasnoconnectorinstalled,use scissorstoslitopentheouterjacket andexposethefirstinchofwiresas showninFigure2.31 2. Thenpullingthebrownpairofwires tearthejacketbackabout15(38 cm)asshowninFigure2.32and Figure2.33 3. Trimthetorncoveroffbeingvery carefulnottonickanyofthewiresas showninFigure2.34 4. Threadabout2(5cm)ofeachpair throughtheholeinathrusterhousing cap,andtieaknotontheinwardside ofthecaps,asshowninFigure2.35.

Figure 2.3-1

Figure 2.3-2

Figure 2.3-3

Figure 2.3-4

5. Stripabout(7mm)ofinsulationfromthe endofeachwire,forthegreen,blue,and orangepairs. 6. Selectapairofwiresandoneofthetaped motors.Attachthesolidcolorwiretothe positiveterminalmarkedinstep2.1.The stripedwireattachestotheotherterminal. Bendthestrippedendofeachwirethrough theterminal,andsqueezethewiretightly ontotheterminalusingneedlenosepliers. 7. Solderthewiresontothetwoterminalsof themotor,asshowninFigure2.36. 8. RepeatSteps5and6fortheothermotors andtheirtetherwirepairs.

About 2

Figure 2.3-5: A Motors Wires Passed through a Thruster Housing Cap and Knotted

Figure 2.3-6: Tether Cable Wires Soldered Onto a Thruster Motor's Terminals

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Procedure 2.4 Pot (Waterproof) the Motors with Wax

Wearing disposable gloves is recommended during the potting process. Always wear proper eye protection.

Construction Steps:
1. Rollanacornsizeballofwaxinyourgloved handsforaminuteorsountilitissoftened, asshowninFigure2.41. 2. Pushandflattenthehandwarmedballof waxacrosstheendofthemotor,about1/4" thickandthediameterofthemotor,as showninFigure2.42. 3. Insertthecoatedmotorintothethruster housing,untiltheshaftpokesthroughthe holeinthebottomofthehousing,asshown inFigure2.43. 4. Pressfirmlyonthebackofthemotorto slowlymoveittothebottomofthehousing whilethewaxinthebottompushesup aroundthemotoruntiltheshaftfully protrudesfromthebottom,asshownin Figure2.44. 5. Coilthewiresintotheendofthehousing andpressamarblesizedpieceofroom temperaturewaxontopofthecoiledwires toholdtheminplace,andthenpressthe waxdowntofillinanyremainingspace aroundthesidesofthemotor.Adjustthe amountofthewaxtofilltheremainderof theareaatthetopofthehousing,leaving justenoughspaceforthecaptogoon,as showninFigure2.45.

Figure 2.4-1

Figure 2.4-2

Figure 2.4-3

Figure 2.4-4

Figure 2.4-5

6. Movethelidontothehousing,asshowninFigure2.46,andpress hardtoseatitintoplace.Thenuseapapertoweltowipeallwax residuefromtheoutsideofthehousingandthemotorshaft. 7. Repeatsteps3through12fortheotherthrusters.

Figure 2.4-6 11

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Testing:
1. Ifapremade,"knowntobegood"controlboxisavailable,testthethrustersbyattaching thetethercable'sRJ45connectortothecontrolbox.Presseachswitch,oneatatime,and observetheoperationofeachthrustermotor. 2. Themotorshaftshouldspinrapidly,indicatingthatthethrusterisgood.
Ifyoumotordoesnotspin,orspinsslowly,gentlytwistitinbothdirectionsbyhand,orifitseems stuck,useplierstoturntheshaft,andrepeatthetest. Ifitstilldoesnotwork,inspectthewiresfornicksthatmayhavebrokenawire.Repairabreakby strippingofinsulationfromtheendsandsplicingthembacktogether(twistthewires,solder,and covertheconnectionwithelectricaltape). Ifthethrusterstilldoesnotwork,itmayhaveabrokenwireinsidethethrusterhousing.Thethruster canbeopenedtoseeifawiremayhavebrokenawayfromoneoftheelectricalterminalsonthe motor.Waxcanberemovedfromthebackareaofthehousingtoallowtheconnectiontobe repaired,andthenthewaxandcapcanbereplaced.Ifthatisnottheproblemandthemotorstill doesn'twork,waxmayhaveenteredthemotor,anditwillneedtobereplacedbycuttingthe thrusterwireascloseaspossibletothenonworkingthrusterhousingandrepeatingprocedures2.2 through2.4foranewthruster. Testanyneworrepairedthrustersasabovetomakesurethattheyspinproperly.

Procedure 2.5 Mount the Propellers onto the Shafts Construction Steps:
1. Wipetheshaftofeachmotor usinganalcoholpad(orapaper toweldampenedwithrubbing alcohol)toremoveexcesswax thatmaybeleftafterthe pottingprocess,asshownin Figure2.51.Thenuseasmall Figure 2.5-1: Cleaning, Roughening, and Re-cleaning a Motor Shaft pieceofsandpapertoroughen thesurfaceofeachofthemotor shafts(thiscanbedonebyspinningtheshaftagainstthesandpaperwhileturningonthe thrusterusingapremadecontrolbox).Thenwipeeachthrustershaftagainwithanother alcoholpad(nottheoneusedtoremovewaxabove).Cleaningtheshaftiscriticalinorder fortheadhesivetosticktoit!

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2. Useaviseorpairofplierstoholda threadedcoupler,asshowninFigure2.51. 3. Threadtheteenutallthewaydownthe threadedcoupler.Apairofpliersmaybe requiredtogettheteenutstartenonthe threadedcoupler,asshowninFigure2.52 andFigure2.53 4. Lookcloselyatapropellerandnotethat onesidehasaslot(groove)init,asshown inFigure2.54.Thisisthesidethatmust beplacednearestthemotor.Placethe propellerontothethreadedcouplerwith theslotsidetotheteenut,asshownin Figure2.55. 5. Threadalocknutontothethreaded coupler,asshowninFigure2.56. 6. Usingpliersornutdriver,drivethe assemblytogetherbytighteningthelock nut.AfinishedassemblyisshowninFigure 2.57. 7. RepeatSteps26fortheotherpropellers.
Figure 2.5-5 Figure 2.5-6 Figure 2.5-1 Figure 2.5-2

Figure 2.5-3

Figure 2.5-4

Figure 2.5-7: Finished Propeller assembly

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8. PlaceadropofSuperglueinthehollowendof theshaftcouplerandonthetipofthemotor shaft,asinFigure2.61.Pushthehollowendof theshaftcouplerontothemotorshaft.A completedthrusterisshowninFigure2.62. 9. RepeatSteps1fortheothertwothrusters. 10. Putyourthrustersasideandallowtheadhesive toharden,undisturbed,for10minutestoreach handlingstrength.Donotapplypowertothe motorsorotherwisestresstheglued connectionsuntilthattimehaspassed.

Figure 2.6-1: Adhesive on Tip of Roughened Motor Shaft and In Hollow End of Shaft Coupler

11. After10minutes,turneachmotorbyhandtofreeup thenewlyintsalledasemblies.

Procedure 2.6 Mount the Thrusters onto the Vehicle Frame

NOTE:ThethrusterswilleachbeheldontotheROV frameusingtwolargeblueheavydutytiewraps.To enableeasyadjustmentofthethrusterpointingangles, Figure 2.6-2: Propeller and Shaft Coupler Mounted on a Thruster Motors Shaft anextraholewillbedrilledineachpipetowhicha thrusterismounted,enablingascrewdrivertobeusedtotwistthepipe.Therearthrusters canbeplacedontheinsideortheoutsideoftheSeaPerchframedependingonyour prefrence.

Construction Steps:
1. Threadalarge,heavydutytiewrapthroughthetwothruster mountingholesateachofthethreethrusterlocations,asshownin Figure2.64. 2. Placetheappropriatethrusterintheloopformedbyeachtiewrap, andtightenthetiewraparoundthethruster,asshowninFigure 2.65.RefertoTable2.61forthrusterplacement.Besureto mounttheverticalthrusterwithitspropellerpointingupward.
Table2.61ThrustersIdentificationforPlacementonthe VehicleFrame Green/GreenStriped Blue/BlueStriped Orange/OrangeStriped Starboard(Right) Port(Left) Vertical(upandDown) Figure 2.6-4: Tie Wrap Threaded Through ThrusterMounting Holes

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3. Installasecondheavydutytiewraparoundthefirsttiewrap,betweenthethrusterandthe pipe,ateachofthethreelocations,andtighteneachsecurelytoholdthethrustersinplace. 4. Cutoffthetiewraptailsasflushaspossibletoavoidleavingsharpends.

2ND TIE WRAP AROUND THE 1ST

Figure 2.6-5: One Heavy-Duty Tie Wrap Holds the Thruster to the Pipe, and a Second Tie Wrap Tightens the First to Secure the Thruster Tightly to the Frame

Figure 2.6-6: Thruster Angles Can Be Easily Adjusted By Inserting a Screwdriver into the Angle-Adjustment Holes and Twisting the Pipes

5. Youcannowuseascrewdriver,insertedthroughtheangleadjustmentholes,asshownin Figure2.66,togentlyturnthePVCpipesonwhichthethrustersaremountedsothatthe thrustersareorientedinthedirectionsthatyouwant.

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Procedure 2.7 Waterproof and Mount the Tether Cable Construction Steps:
1. Usinga(1.5cm)pieceofbutylrubbertape,stretchthetapetoabouttwiceitsrelaxed lengthandwinditamongandaroundthefourwirepairswheretheyemergefromtheouter jacketofthethrusterendofthetethercable.Pressitoverthejacketopeningsothatit extendsatleastoneachsideoftheopening,asshowninFigure2.71.Kneadandwork itinbetweenthewireswellsothatitsealsbotharoundandbetweenthewiresandformsa smoothsealoverthejacketopeningtopreventwaterfromgettinginsidethetethercable.

Figure 2.7-1. Butyl Rubber Tape Wrapped to Waterproof the Tether Cable Sheath's Opening

2. Wrapelectricaltapeoverthebutylrubbertapetokeepitfromstickingtoanything. 3. Installtwocrossedtiewrapstocapturethetethercablewhereitpassesoverthecenterof thepipeattherearoftheROV,asshowninFigure2.72. 4. Coilthebrownwirepairoutofthewayandtiewrapittothepayloadnet. 5. Pullalltiewrapstightwithpliers,andtrimtheendsflush.

TIP:Itisimportanttokeepthetethercable centeredandpointingstraightbackfrom theROVsothatitsinwaterdragdoesnot tendtopulltheROVmoretoonesidethan theother,possiblymakingturningtheROV inonedirectionmoredifficultcomparedto theotherdirection.Don'tforgettousetwo crossedtiewrapstohelpkeepitstraight.

USE TWO CROSSED TIE WRAPS

Figure 2.7-2. Tether Cable secured to the Frame and to the Payload Net with Tie Wraps

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UNIT 3 ASSEMBLY OF SUBSYSTEM THREE -- THE CONTROL BOX

In this unit, you will build the ROV's control box by mounting electrical components on a printed circuit board, assembling and connecting the power cord,andmountingthecircuitboardintheplasticcontrolbox.

Tools and Materials Needed Tools

Eye Protection (Always Worn) Ruler Scissors Pliers Wire Stripper (18 - 26 AWG Size) Wire-Cutting Pliers (Flush Type Preferred) Soldering Iron and Solder #2 Phillips Screwdriver

Materials
ROV Frame with Thrusters and Tether Cable Installed 1 Pre-Drilled Control Box with Lid and Screws (Black) 1 Printed Circuit Board (PCB) 4 PCB Mounting Screws (Silver) 6 (~2 m) #18 Speaker Wire (Or Lamp Cord) 2 Alligator Clips (With Red and Black Covers) 1 Fuse Socket 1 6.3 Amp Fuse 1 12-Volt Battery 2 Double-Pole, Double-Throw (DPDT) Toggle Switches 2 Single-Pole, Double-Throw (SPDT) Pushbutton Switches 1 Type RJ45 CAT-5 Modular Connector Jack Electrical Tape

Procedure 3.1 Gather the Parts for the Control Box Assembly Construction Steps:
1. Gather,identify,andinventorythepartsneededforthecontrolbox,asshowninFigure3.1 1.Someparts,suchastheswitches,maylookabitdifferent,butalltypesofitemsshown shouldbeinthekit.Ifanyaremissing,notifyyourinstructorwhomayhavespareparts. 2. Locatethetwotoggleswitches.Iftheyhavenutsand/orwashersinstalledontheir threadedmountingshafts,removeallnutsandthewashers;useplierstoloosenthenutsif needed. 3. Gathertheeightsmallscrewsandputtheminasafeplace(suchastapingthemtothe insideofthevehiclestoragetotebagorbin)topreventthemfrombeingmisplacedduring theassemblyprocess.

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TIP:Itisimportantto followtherecommended orderwhenadding componentstotheprinted circuitboard(PCB); otherwiseitwillbedifficult toholdtheminplacewhile soldering.Usethe sequencepresentedhere fortheeasiestassembly. Remember,ALLofthe partsgoonthesideofthe PCBwiththewhite lettering.Ifyoulook closelyonthebackofthe boardthereisamessage tohelpyoutoremember. Figure 3.1-1: Electrical Components Required for the SeaPerch ROV Control Box

Procedure 3.2 Assemble the Power Cord Construction Steps:

1. Findthepowercordwire,anddeterminewhichofitstwo conductorswillbepositiveandwhichwillbenegative.For thisproject,wewillcallthecoppersidethepositive(+) wire,andthesilversidethenegative()wire. 2. Oneachendofthewire,carefullyseparatethetwo conductorsforalengthofabout3inches(7.6cm). 3. Strip5/8inch(16mm)ofinsulationoffofallfourendsof thepowercordwire.Twistthestrandsoneachofthe ends(individually,notalltogether)tightlytoprevent fraying.
Figure 3.2-1: Alligator Clip Covers Installed on Power Cord Wires

4. Ononeendofthecord,slidetheredalligatorclipcover(smallendfirst)ontothepositive wire,asshowninFigure3.21.Slidetheblackalligatorclipcoverontotheother(negative) wireofthepowercord.

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5. Attachthetwoalligatorclipstothepowercordwiresby pushingthewiresinthroughthebacksoftheclipsand upthroughtheholesnearthescrews.Loosenthe screws,wrapthewiresaroundthemtightlyina clockwisedirection,andthenretightenthem.The connectedalligatorclipsshouldlookliketheonein Figure3.22,withmostofthewirecapturedunderthe screw'shead. 6. Movethecoversovertheclips(insertapencilorother smallobjectintothe"mouth"ofeachalligatorclipto makeiteasiertopushthecoversovertherearpartof theclip).Thefinishedpowercordshouldlooklike Figure3.23.ItsotherendwillbeconnectedtothePCB later,inProcedure3.4.

Figure 3.2-2: Wire Properly Connected to an Alligator Clip

Screw

Procedure 3.3 Install the Printed Circuit Board Components Construction Steps:

Figure 3.2-3: Completed Power Cord

7. ReviewFigure3.31,andrefertoitasneededduringthefollowingassemblysteps.The partswillbeinstalledinorderaccordingtotheirsize,smallestfirst.DONOTINSTALL COMPONENTSUNTILISISCALLEDFORINTHEINSTRUCTIONS

Figure 3.3-1: Component Placement for the Control Box PCB Assembly

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8. Locatethefusesocket.Placeitstwopinsthrough theholesatthelocationontheboardlabeled "F1,"asshowninFigure3.32(remember,all componentsgoonthesideofthePCBthathas thewhitelettering).Useasmallpieceof electricaltapetoholdthesocketinplace.Flipthe boardoverandplaceitonatabletop.Pressdown onthePCBtoholdthesocketflatagainstthe board,andsolderthetwoconnections.Meltonly Figure 3.3-2: Fuse Socket Installed at the Location Labeled "F1" about1/4"ofsolderintoeachconnection,let themcoolforafewsecondsbeforemovinganything,andmakesurethatthereareno solderbridgesbetweentheconnections.(Removeexcesssolderifneededbytouchingthe solderbridgebrieflywithaclean,hot,solderingirontip.)
TIPSPCBandComponentSoldering: Whensoldering,alwaysweareyeprotection! BesurethatthecomponentsareplacedfirmlyagainstthePCBbeforesolderingthem;althoughit ispossibletomakecorrectionslater,itcanbedifficult. CleanthesolderingirontipbeforeEVERYsolderingstep,andthentouchsoldertotipofthe solderingironto"tin"itbrieflybeforestartingtosolderacomponent.Keepsolderonthetip betweenuses. Whilesoldering,touchthesolderonlytothe"pad"(theroundcontactonthePCB)andthe componentwireorpin,nottothesolderingirontip. Touchtheiron'stiponlyonthepads,nottheboard. Heateachconnectionforafewsecondsbeforeapplyingsoldersothatthesolderwillflow completelyoverthepadaswellasthecomponentwirethatpassesthroughtheholeinthepad. However,donotoverheatthepads,astheymightliftoffoftheboardoritmaybecome scorched;severalsecondsofheatingisusuallyenough. Whendonesoldering,removethesolderfromthepadfirst,thentheiron. Whensolderingtheswitches,pauseafewsecondsbetweeneachconnection,sothatplasticparts insidetheswitchesdon'toverheatandpossiblygetdamaged. AftersolderingeachconnectionletthesoldercoolforseveralsecondsbeforemovingthePCB,so thatthesolderwillformagoodconductiveconnection.Theyshouldbeshiny,notroughordull looking;iftheydon'tlookshiny,simplyreheatthemandkeepthemstillwhilecooling. Usejustenoughsoldertocovertheconnection;toomuchcancausetheexcesstobridge betweencloselyspacedconnections.Checkforsolderbridgesaftersolderingeachcomponent.

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9. Placethepinsofthetwopushbuttonswitchesthrough thepadsinthePCBatthelocationslabeled"SW3"and "SW5,"asshowninFigure3.33,aftermakingsurethat theirpinsareallstraight(perpendiculartotheswitch body).[Youmayhavelargerswitchesthanshown, whichfitinsteadintotheothersetofthreeholesatthe "SW4"and"SW6"locations.]Whileholdingthe switchesinplacewithapieceofelectricaltape,flipthe PCBoverandplaceitonatabletop.Pressdownonthe PCBtoholdtheswitchesflatagainsttheboard,and solderallconnectionsoneachswitch. 10. Findthetwotoggleswitchesandthecontrolboxlid. Placetheswitchesinthe"SW1"and"SW2"locations onthePCB,asshowninFigure3.34.Itisalso importanttokeeptheseswitchesflatagainstthe boardwhiletheyaresolderedintoplace,sothatthey willbestraightwhenthecontrolboxisfinished.A goodwaytodothisistousethecontrolboxlidto holdtheswitcheswhilesoldering.Putthetoggle handlesthroughthetwocenterholesinthecontrol boxlid(theymaybetight).Then,whileholdingthe PCBagainstthebackoftheswitches,turnthe assemblyoverandplaceitacrosstheopentopofthe controlbox,asshowninFigure3.34.HoldthePCB downflatwhilesolderingthefirstofthe12switch connections,tomakesurethatitwillbetightagainst theswitches. 11. Soldertheremaining11connections,takingcarenot tooverheattheswitches(waitafewsecondsbetween connections,oralternatebetweenthetwoswitches). Thenremovethenutsandthelid. 12. CheckthesmallpinsonthebottomoftheRJ45 connectorjacktomakesurethattheyarenotbent, andthencarefullyputthemthroughthePCBholesat location"J1,"asshowninFigure3.35.Pressonthe jacktosnapitintoplace.

Figure 3.3-3: Pushbutton Switches Installed in the "SW3" and "SW5" Locations

Figure 3.3-4: Toggle Switches Held Straight by the Control Box Lid uring the Soldering Process

Figure 3.3-5: Toggle Switches Installed in the "SW1" and "SW2" Locations

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Figure 3.3-5: RJ45 Connector Jack Installed at Location "J1"

Figure 3.3-6: Bottom of a PCB after Soldering All Components

13. PlacethePCBbackontopofthecontrolbox,andsoldertheeightpins,beingcarefulnotto usetoomuchsolder,whichmightcreatesolderbridgesbetweentheverycloselyspaced connections. 14. ReexamineallofthesolderconnectionsonthePCBasafinalcheckforsolderbridgesor connectionsthatdon'tseemtohaveenoughsolder.Resolderthemifneeded.The solderedsideofthecompletedPCBshouldlooksimilartotheoneshowninFigure3.36. ThecompletedPCBshouldlooklikeFigure3.37.

Figure 3.3-7: A Completed PCB

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Procedure 3.4 Connect the Power Cord Construction Steps:

1. Twistthestrandsofthetwopowercordwires,andpass themthroughthecordholeinthecontrolboxlid,from thetopside.Thentieaknotinthetwowires,about oneinchfromtheends,ontheundersideofthelid,as showninFigure3.41. 2. Retwistthestrandsofeachofthetwowiressothat theycanpassthroughthePCB'ssolderpadholes,and placethepositive(copper)wireintothe"+12V"(RED) powerwirehole,andthenegative(silver)wireintothe "12V"(BLK)powerwirehole,bothenteringtheholes fromthecomponentsideofthePCB,asshowninFigure 3.42.Bendthewiresovertohelpholdtheminplace duringsoldering. 3. Solderthetwopowerwires,usingenoughsolderto makegood,solidelectricalconnections.Thensnipoff theexcesswirebeyondthesolderjoints. Figure 3.4-2: Power Cord Wires Through the Holes in the +12V and 12V Pads

Figure 3.4-1: Power Cord Passed Through the Hole in the Box Lid, and Knotted

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Procedure 3.5 Conduct Tests and Finish the Control Box Construction Steps:
1. Locatethefuse.Ifitsleadsarelongerthanabout" (6mm),cutbothleadstothatlength,asshowninFigure 3.51. 2. Installthefuseintothefusesocket,asinFigure3.52. 3. Locateamultimeterwithan"ohmmeter"function (measureselectricalresistance)toconductafewquick Figure 3.5-1: Cutting the Fuse Leads tests.Thesetestswilltellyouiftherearesoldering to " Length problemsonthePCB(whichcancausethefusetoblow andstopyourROVfromworking)oraswitchproblem. DONOTconnectthebatteryuntiltheelectricaltestingin thefollowingstepshasbeensuccessfullycompleted.Set themetertomeasureresistance(ohms),andmakesure youcantellthedifferencebetweena"short"circuit(~0 ohmstouchtheprobestogether)andan"open"circuit ("infinite"resistanceprobesnottouching).Somemeters haveabeeptoindicatecontinuity,suchascausedbya Figure 3.5-2: Fuse shortcircuit. Installed in Fuse Socket 4. Totestforshorts,connectyourmeter'sprobestothe twoalligatorclipsonthepowercord(thepolarityofthe leadsdoesnotmatter).Leavethetethercable unconnected.
TIP:Youmayfindithelpfultoreferto theTroubleshootingGuidediagrams onPages27and28ifthetestsin Procedure3.5identifypossible electricalproblems.

5. Nowactivateeachofthefourswitchesindividuallyand inallcombinations.Atnotimeshouldyougetalow resistancereading(anycontinuity).Tryallswitchcombinationsandmakesurethereisno combinationthatshowsashortcircuit.Themetershouldreadinfiniteresistanceatall times. 6. Thentesttheswitcheswiththetethercableconnected.Youshouldseealow(NOTzero) readingofabout5to15ohmswheneveryouactivateanyswitch,asthemetershowsthe resistanceofthecoilofwirethatisinsideeachofthemotors.Ifyoudonotseesuchlow readingsforanyengagedswitchposition,youmayhaveeitherapoorsolderconnection,a badswitch,adamagedwireorconnectorinthetethercable,orathrusterproblem.

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7. Onceyouaresurethattherearenoshort circuitsandthatthethrustermotorsshow properreadings,youcanfinishassemblingthe controlbox.PlacethePCBintothecontrolbox, passingthepushbuttonswitchactuatorbuttons carefullythroughthetwoholesinthefrontof thebox,andsecurethePCBintotheboxusing thefoursmallsilverscrews,asshowninFigure 3.52. 8. Pressthetwopushbuttonswitchcapsontothe actuatorbuttons,asshowninFigure3.53. 9. Installthelidontothecontrolbox,carefully foldingthepowercordwiresinsidetheboxas thelidisloweredintoplace.Securethelidwith thefourblackscrews. 10. Connectthetethercable'sRJ45connectorplug intotheRJ45jackonthecontrolbox. CONGRATULATIONS, you have finished the construction of your SeaPerch ROV! Now its time to get it ballasted and try it in water! Figure 3.5-3: A Completed Control Box Figure 3.5-2: PCB Board Installed

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CONTROL BOX TROUBLESHOOTING GUIDE

NOTE: This decision-tree style troubleshooting guide may be helpful in determining what is wrong when a SeaPerch control box does not function properly. The first section is for use with multimeters that have an audio continuity-testing function. The second is for testing with an ohmmeter. Both tests should be done with the meter's leads connected to the power cord alligator clips.

Troubleshooting Testing Using an Audio Continuity Tester

RemoveExcessSolder (SolderBridges)to CreateSpaceBetween AllConnections

CheckthePCB Visuallyfor Problems

DoesEach SolderConnectionHave NO ClearSpace AroundIt? YES

Set theMeter toAudio YES ContinuityMode Connect the Meter Probes totheAlligatorClips Connect the Tether Cable totheControlBox

Conduct Continuity Tests

ActivateEach ControlBoxSwitch Individually, InAll SwitchPositions

Fixthe PowerCord Connectionsand Retest

Doesthe NO MeterBeepWhenYou ActivateEach Switch? YES

Checkthat Each Solder Joint Looks LikeaShiny LittleHersheys Kiss ReSolder withMoreHeat or MoreSolder IfNeeded

RETEST

NO ArethePowerCord ConnectionsatBothEnds Good? YES

STILL NO

RETEST Doesthe MeterShow~5to ~15 NO OhmsWhenEachSwitch IsActivated? YES

Mount thePCB Intothe ControlBox Repeat theContinuity ChecksAfter PCB Mounting IfSuccessful, Attachthe PushbuttonCaps IftheMeter ShowsLess than ~1Ohm,There isProbably a HiddenShort Circuit Repeat Visual Checks and Remove Any Excess Solder ChecktheRJ45 Connector

TheSwitch that Doesnt Cause aBeep MayBe Bad(Check For ContinuityDirectly AcrossItsSolder Connections) OR aThruster Wire MayBe Broken (Inspect andFix)

Good!NoShort Circuits! FinishAssembling the ControlBox

ConnecttheBatteryto YourSeaPerchand ConfirmProperThruster Operation

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Troubleshooting Testing With an Ohmmeter

CheckthePCB Visually for Problems

DoesEach SolderConnectionHave NO ClearSpaceAroundIt? YES

Set theMeter toMeasure YES Resistance (Ohms) Mode Connect the Meter Probes totheAlligatorClips Connect the Tether Cable totheControlBox

RemoveExcessSolder (SolderBridges)to CreateSpaceBetween AllConnections

Conduct Ohmmeter Tests

ActivateEach ControlBoxSwitch Individually, InAll SwitchPositions

Fixthe PowerCord Connectionsand Retest

Does MeterShowYES MegohmsofResistance WhenAnySwitchis Activated? NO

Checkthat Each Solder Joint Looks LikeaShiny LittleHersheys Kiss ReSolder withMoreHeat or MoreSolder IfNeeded

RETEST

NO ArethePowerCord ConnectionsatBothEnds Good? YES

STILL YES

RETEST Doesthe MeterShow~5to ~15 NO OhmsWhenEachSwitch IsActivated? YES

Mount thePCB Intothe ControlBox Repeat theContinuity ChecksAfter PCB Mounting IfSuccessful, Attachthe PushbuttonCaps IftheMeter ShowsLess than ~1Ohm,There isProbably a HiddenShort Circuit Repeat Visual Checks and Remove Any Excess Solder ChecktheRJ45 Connector

TheSwitch that Didnt CauseaLow OhmReading May Be Bad(Check Resistance ReadingDirectly Across ItsSolderConnections) OR aThruster Wire MayBe Broken (Inspect andFix)

Good!NoShort Circuits! FinishAssembling the ControlBox

ConnecttheBatteryto YourSeaPerchand ConfirmProperThruster Operation

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BALLASTING YOUR SEAPERCH ROV

NOTE: When using standard foam floats, their physical size will often decrease with increasing depth (over about six feet of depth) and they may absorb some water, due to increasing water pressure; this results in reduced displacement and thus reduced buoyancy at deep depths. For example, when the ROV is sent to the bottom at the deep portion of a swimming pool (often 12 feet or more in depth), it may no longer be able to return to the surface easily. For this reason, it is best to have the ROV ballasted to be more positively buoyant while at the surface when using foam style floats. This will also enable the foam-float-equipped ROV to more easily bring payloads to the surface.

Ballast and Trim Considerations for SeaPerch ROVs

ThestandardcylindricalfoamfloatsthataresuppliedinSeaPerchROVkitshaveasignificantamount ofbuoyancywheninshallowwater.Thisbuoyancymustbecounteractedbyaddinguptoabout10 ouncesormoreofballastweightinordertoattainthenearneutralbuoyancypreferredforROV operation.Ifdesired,thefoammaybecutshorterbyuptohalftheirlength,reducingtheamountof oftenexpensiveballastitemsneeded.Smallslicesoffloatmaterialcanthenbeusedtoadjust buoyancy. TrimreferstoforeandaftadjustmentstotheplacementofballastandflotationitemsontheROVto makeitlevelwhensubmerged,whichwillenabletheROVtopickitemsupoffthesea(orpool)floor aswellasturnleftandrightwithoutalsochangingdepth.StandardSeaPerchfloatsareinfixed positionsontheROV,sopropertrimisbestachievedbyminoradjustmentstoplacementofballast items,afterneutralbuoyancyisattained. Differenttypesofballastmaterialsmaybeused,buttheyshouldalwaysbeitemsthatcanbesafely placedinwaterwithoutdamagingthem(orthewater).Also,forballasttodoitsjobwell,itshould notmovearound,whichcanchangetheROVstrimandevenitsdynamicsasitacceleratesand decelerates.Therefore,bagsofmaterials(whichcanalsocreateexcessdrag)andsuspended weightsarenotgoodchoicesforballast. BallastitemscanbeattachedtotheROVinvariousways,suchasusingtape,tiewraps,orfasteners suchasscrewsorclamps.Theweightscanbeattachedtotheframeortothepayloadnet;however, itisbesttokeepthefrontcenterareaofthenetcleartoenabletheROVtopickupitemswithout interference.

Attaching Ballast to the ROV

1. PlaceSeaPerchROVinwater(alargebucketoradeepsink,suchasfoundinmanyschool janitor'sclosets,willworkifalargewatertankorpoolisnotavailable). 2. AttachweightstotheframeuntiltheROVisjustslightlypositivelybuoyant,meaningthat itsitsinthewaterwiththefloatsjustoutofthewaterbyabout1/4(5mm)orless,and returnstothesurfaceslowlyifpushedunderwater.Usuallyabout4to10ounces(125to 300grams)isneededtoachieveproperbuoyancy.IfyourSeaPerchsinkswithout applyingthedownwardthruster,itistooheavy.IfyourSeaPerchhastroublediving,or floatsuptothesurfaceveryquickly,thenitistoolight.
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USING YOUR SEAPERCH ROV

Safety Precautions
AllROVoperators(pilotandtethermanager)aswellaswatersideobserversshouldexercise cautionandstayawareofthemovementofotherswhileneartheedgeofthepool,dock,or otherwatersidelocation.Evensimpleinattentiontowhatisgoingonintheareawhile focusedonoperatinganROVcanleadtounexpecteddips.Wearingapersonalflotation deviceisrecommendedifoperatingtheROVfromapierthatextendsintodeepwaterorfroma boat(asisoftenrequiredbylaw). Batteriesareheavy,andifoneispulledoffatabletopbyatugonthepowercord,itcancause aninjury(ifdropped),aswellasdamagetothebattery.Becarefulinbatteryplacement; keepingitonthegroundorpooldeck.

Environments Suitable for Using a SeaPerch ROV

SeaPerchROVscanbeusedinfreshwaterorsaltwater,inmanmadepoolsornaturalmarine environments.However,ballastingaswellaspostoperationcleaningrequirementsare differentforthetwotypesofenvironments.Duetothedifferingwaterdensities,adjustments totheballast,andtotheROVstrim,areusuallyneededwhenmovingfromoneenvironment totheother. Fordeepwateruse,thefoamfloats(whichchangeinbuoyancywithdepth)shouldbereplaced withsolid(noncompressible)floats.

Post-Run Cleaning and Maintenance of the ROV System

PostRunCleaning.TheROVshouldalwaysberinsedwellwithfreshwaterafteruse.Both poolwaterandsaltwatercanbecorrosivetothrustersandmetalparts.Biologicorother materialspickedupinnaturalmarineenvironmentscanbedamaginganddifficulttocleanoff lateriflefttodryontheROV.Besidesrinsingthevehicleandcleaningoffanydebris,itis helpfultosubmergeitinatuboffreshwaterandrunthethrustersabittobetterclear corrosivematerialsfromthemotorshafts.Allowingthevehiclestodrybeforestorageis recommended.EveniftheROVwillbedisassembledtohaveitspartsreutilized,havingclean partsthatarefreefromcorrosivematerialsandcontaminantsisimportant.Insuchcases,the usedthrusterscanprovideoftenneededspares,sotheyshouldbecleanedcarefully. BatteryMaintenance.Makesuretochargeyourbatteryafterusingit.Leadacidbatterieswilllast muchlongeriftheyarestoredcharged.

Enjoy Using Your SeaPerch ROV!

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NOTES
TIPS:SolderingIronMaintenanceandSolderingRecommendations

1. Holdthesolderingironlikeapen,notlikeaclub,andrestyourhandonahard surfacetoengageyourfinemotorskills,foreasier,moreprecisesolderingthan tryingtoguidetheironwithyourarmmuscles. 2. Whensoldering,firstheattheconnectionforafewseconds,withthesideofthe tip(notitssmallerpoint),andthenfeedsolderintotheconnection,notontothe tip.Afterthesolderflowsovertheconnection,removethesolder,waitasecond ortwo,andthenremovethesolderingirontip.Don'tdisturbtheconnectionfor severalsecondswhileitcoolsandhardens.

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NOTES

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NOTES

The SeaPerch program website at http://www.seaperch.org contains valuable information and educational resources. 32