Vanguard™ MK2

Operating Manual

Allen-Vanguard Allen-Vanguard
Protecting tomorrow – through innovation today

Vanguard™ MK2B
Operating Manual

ALLEN-VANGUARD 5459 Canotek Road, Ottawa, Ontario, K1J 9M3, Canada Sales Toll Free No. 1 866 747-3590 Sales Tel. No. + 613 747-3590 Sales Fax No. + 613 747-0723

Issue: Version 1
22/02/05

AVA-MKTG-022_C.000

Vanguard™ MK2
Operating Manual

Table of Contents
Section 1.0 1.01 1.02 1.03 1.04 1.05 2.0 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12 3.0 3.01 3.02 3.03 3.04 3.05 3.06 4.0 4.01 4.02 5.0 6.0 7.0 7.01 7.02 7.03 8.0 8.01 9.0 9.01 10.0 10.01 10.02 Calling for Technical Help MK2 Overview Modular Design Standard Equipment Standard Features and Capacities Optional Features Command & Control Unit (CCU) Interface Overview Desk top overview Running on AC power Running on DC power Adjusting /muting volume RF link & battery status Joystick Set up Running on Tether Tether Reel Parts Charging CCU Storing the CCU Restoring the MK2 Software F1-Drive Function Attaching Wheel Kit Attaching Anti-Flip Mount Driving Tips/Climbing stairs Removing Tracks Removing Drive System Drive Parts List F2-Turret Function Removing the Turret Turret parts list F3-Elbow Function F4-Shoulder Function F5-Arm Function Removing the Arm Arm Parts Deploying the arm F6-Claw Function Removing the Claw F7-Camera Select Function Camera Settings (brightness, contrast) F8-Pan & Tilt Function Removing Pan & Tilt Pan & Tilt parts list Pg 4 Pg 5 Pg 6 Pg 7 Pg 8 PG 9 Pg 10 Pg 11 Pg 12 Pg 13 Pg 14 Pg 15 Pg 16 Pg 17 Pg 18 Pg 19 Pg 20 Pg 21 Pg 22 Pg 23 Pg 24 Pg 25 Pg 26 Pg 27 Pg 28 Pg 29 Pg 30 Pg 31 Pg 32 Pg 33 Pg 34 Pg 35 Pg 36 Pg 37 Pg 38 Pg 39 Pg 40 Pg 41 Pg 42 Pg 43 Pg 44 Pg 45

Section

Section

Section

Section Section Section

Section Section Section

AVA-MKTG-022_C.000 2

Vanguard™ MK2
Operating Manual

Table of Contents
Section Section Section Section 11.0 12.0 12.01 13.0 14.0 14.01 14.02 14.02 15.0 F9-Light, Laser & Photo Functions T-2 way digital audio S-Speed, P-Speech Functions W-Weapons Enable Function Robot Chassis Removing and Charging Battery Packs Battery Station Parts Removing Internal Electronics Maintenance Kit Pg 46 Pg 47 Pg 48 Pg 49 Pg 50 Pg 51 Pg 52 Pg 53 Pg 54

Section

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Calling for Customer Service

Vanguard™ MK2
Operating Manual

Section

When calling for service or support, please ensure that you have at least one of the following information ready for our Technical Customer Support or Sales Representative to assist you: 1) 2) 3) 4) Product Serial No. Who Purchased the product (Name or Company) Purchase Order Number Manual Version

Please photocopy, mark up and fax the relevant section of the Operating Manual that contains the drawing or detail that will help clarify the problem you are having with the product. More detailed drawings may be requested, if necessary. Some restrictions may apply.

TECHNICAL CUSTOMER SUPPORT Call + (613) 749-8343 Fax + (613)-749-3590 Toll Free 1 800 429 9198 customer.service@allen-vanguard.com

SALES Call + (613) 747-3590 Fax + (613) 747-0723 Toll Free 1 866 747-3590 sales@allen-vanguard.com

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Vanguard™ MK2 Overview

Vanguard™ MK2
Operating Manual

Section 1.01
Color Claw camera with dual LED lights. 2-independent firing circuits Video transmitter with flexible Antenna mount (Data transceiver located internally) PTZ-Color Zoom Camera with continuous Pan Elbow

3 Axis Claw -Wrist -Pincer -Continuous Rotate

Shoulder & Turret (2) High & Low beam LED light system

Battery Compartment

(2) 3”.0 wide Track System

(2) Lifting Handle 2 Way Digital Audio Microphones & Speaker

Color Drive Camera

Allen-Vanguard continues to design and supply leading edge technologies with its next generation robot the Vanguard™ MK2. This lightweight, portable, tactical robot maintains excellence of quality with its additional features and improved functionallity.The Vanguard™ MK2 continues to break new ground in mission support for HAZMAT operations, tactical and suveillance situaions. The MK2 is the newest version of the Vanguard robot voted best performing and most applicable system in a major performance evaluation of competing systems conducted by Battelle, for the Technical Support Working Group (TSWG) of the National Institute of Justice. The MK2 incorporates the enhancements recommended by Battelle-and more-making it “a major asset for bomb squads” and law enforcement personnel.

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The MK2’s Modular Design

Vanguard™ MK2
Operating Manual

Section 1.02

The MK2 is designed to be modular for maintaining and repairing the different components within the platform. We understand the importance of having the equipment in good running order at all time in case of emergency. The small size is beneficial, allowing for ease of shipping replacement parts or spare parts for your system. Our maintenance manual includes the basic steps to repair or maintain your robot. The following sketch details the main components of the MK2 robot that can easily be replaced.

1

2

4

3 10 6 8 9

5

5 7

Modular Sections
(1)-RF Assembly (2)-PTZ Assembly (3)-Arm Assembly (4)-Claw Assembly (5)-Left & Right Drive Assembly (6)-Turret Assembly (7)-Chassis Assembly (8)-Electronics Box Assembly (9)- Data Box Assembly (10)-Shoulder

Assembly part #
3VRF221000 (Video Modem), 3VRF220000 (Video Antenna) 3VPT200000 3VAR200000 3VCL100000 3VDS100000-L (left side), 3VDS100000-R (right side) 3VDK200000 3VCH200000 3VEE210000 3VRF210000 3VSH200000

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Standard MK2 Equipment

Vanguard™ MK2
Operating Manual

Section 1.03 The Vanguard MK2 robot comes with these following items (List includes optional RF System)

Battery Station
• • • (2)- 24-volt DC quick change battery pack (2)- 24-volt chargers (1)- 6-foot direct-access charge cable

Wheel Conversion Kit & Anti-Flip Mount
• • • • • • (2) 6” Front-Drive Wheels (1) Swivel Wheel (4) 2 ¼” socket head screws (2) Quick-release pins 1.0” Anti-Flip/curb relief mount (1) 3/16” “T” Handle Hex Driver

Tether Storage Reel
• • • 500 feet (150 meters) of tether cable With slip ring (includes reel) (1) Quick release pin 1.5”

Command & Control Unit (CCU)
• • • • • • • • • • • • Storage Case PC-based control software (2) 12-Volt Batteries Built-in charger Laptop computer Video Modem (Optional) Data Modem (Optional) 2-Way Communications Headset Mounted Joystick Screen Sun visor AC Power Cord Laptop recovery boot CD for operational maintenance

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Standard Vanguard MK2 Features & Capacities

Vanguard™ MK2
Operating Manual

Section 1.04

Feature
Drive System Wheel Kit Turret Shoulder Elbow Claw-Wrist Claw-Rotate Claw-Pincer Pan & Tilt Drive Camera Claw Camera Main Lights Battery Packs Charger Tool Outlet Communications

Qty
1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1

Description
(2) 3.0” wide independent tracks (2) 6.0” Wheels & (1) rear swivel +/- 80 Degrees 0-180 Degrees 0-270 Degrees 0-300 Degrees Continuous 0-20 cm (8.0 inches) wide with rubber gripper PTZ, color zoom camera, continuous Panning Color CCD Color CCD with LED illumination Dual LED Lights with High & Low Beam 24 VDC quick change packs 24 VDC 110 or 220 24VDC power source for remote tools RS232 Com port for remote sensors Laptop with Robot interface software Photo Capture 150 meter Tether DC remote power 3 + hours AC power (110 or 220 volts) Rugged waterproof Case 8.5” H x 21” L x 15” W Weight 45 lbs (20.5 kg) Telescopic Video Receiver Mount Laptop sun visor Headset & Joystick 2 Way Digital Audio

Command Station 1

General Capacities
Lift Capacity (arm extended) Lift Capacity (arm retracted) Vertical Reach Horizontal Reach Ground Clearance Overall Length Overall Width Stowed Height Overall Weight Mission Duration Stair Climbing Angle 8.0 kg (17.6 lbs.) 18.2 kg (40 lbs.) 132 cm (52.0 inches) 96.5 cm (38.0 inches) 5.75 cm (2.25 inches) 91.5 cm (36.0 inches) 43.5 cm (17.0 inches) 40.5 cm (16.0 inches) 48.0 kg (105.6 lbs.) 2-3 Hours +(quick change battery pack) 40 Degrees

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Optional Features for MK2

Vanguard™ MK2
Operating Manual

Section 1.05

RF System

P/N 3VCS10580

The RF system refers to both the data and video system to make the MK2 completely remote. The data transceivers work on 900 MHz. The video system works on 2.4 GHZ. The data system is , internal, only exposing the antenna. The video transmitter is protected by the rear cage and has a flexible mount for the antenna to avoid damage if up righted.

Reusable Transit Case

P/N 3VPA15845

The transit case is an optional weatherproof case that stores the MK2 robot and all the accessories, including the command station and tether reel. This case ideal for storage or transportation where weather or dusty conditions may be a problem. The transit case and robot with all accessories weigh approximately 320 lbs.

Recoilless PAN Disrupter Mount P/N 3VOE500000
Firing the PAN Disrupter has never been easier, with the new recoil system from Ideal Products Inc. Allen-Vanguard provides a mounting system for the PAN disrupter with the recoil adapter tube which also includes a color CCD camera and dual flashing lasers for pinpoint accuracy. The Recoil system is a simple add-on to any PAN disrupter.

IR Camera

P/N 3VOE210000

The IR Camera is light-sensitive and automatically changes from a color CCD to a B&W camera in low-light situations. This camera is mounted on the upper arm and becomes the forth camera. This camera is great for surveillance when searching poorly lit areas.

20 MM Recoilless Disrupter

P/N 3VPA15840

The 20mm recoilless disrupter from Proparms mounts to the upper arm, and has a color CCD camera and laser as part of the mount. Ammunition is bought directly from Proparms and requires an end user certificate.

Remote RF System

P/N 3VLS10580

Extend your video range with this simple remote system. Using your existing tether, attach your video receiver along with a power source and tripod up to 500 away from the command station. Work from within your Bomb truck and place the receiver around or into building giving you direct line of site at all times. This can only be used with the optional RF system.

Heads Up Display

P/N 3VPA15841

The Heads-Up Display is used when the screen becomes difficult to see in direct sunlight. The HUD is powered by AC or DC, the command station is equipped with a DC power plug located behind the laptop. This product can be added at any time.

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Command & Control Unit (CCU)

Vanguard™ MK2
Operating Manual

Section 2.0

RF video modem

Telescopic pole for video modem

RF data modem MK2 interface software Laptop On/Off power button Video, Headset & Joystick connections Interface help menu Cooling fan for charger turns on automatically Joystick

CCU-battery voltage meter 2 way Communications Headset Main power On/Off breaker switch

RF to tether switch

DC power, laptop On/Off

Features behind the laptop
Tether connector Video & audio RCA output-2 sets DC power plug for heads-up display (9 Volts) Data modem connector AC Power receptacle and on/off switch AC Power receptacle fuse panel Telescopic pole mount

Video modem connector

The above photo shows most of the CCU features. The CCU is portable and ready to go at all times. You can choose from AC or DC power. The DC power source can run from 3 to 5 hours before recharging. The batteries and charger are located internally. To charge the system, plug it into the AC receptacle to charge the batteries and laptop. AVA-MKTG-022_C.000 10

Software Interface

Vanguard™ MK2
Operating Manual

Section 2.01

Help menu, guides you through all information for each function when selected.

Simple Functionality-how it works The user interface is a guide to operating your robot, by matching the function you want to use in the interface menu and the keys on the laptop keyboard. For example, on the above screen, in the Drive box you will see “F1.” This tells you that by pressing your “F1” key you will activate the Drive function of the robot. All motor functions use the arrow keys on your keypad or joystick to operate the function. Other functions are toggle on/off such as the lights “F9”. After choosing your function, use the Help menu for instructions until you are fully familiar with all the functions and operations, the help menu changes with each key pressed. The interface is the source for your robot’s information; the laptop automatically boots up into the interface screen. From this menu screen, you can check battery status of the robot, communication link, what functions you are using and so on. Along with the visual information, selecting the “P” button activates your speech feedback, giving you audio confirmation of what button was pressed. Keyboard overlay matches the functions on the interface

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Desktop information

Vanguard™ MK2
Operating Manual

Section 2.02

1 2 3

When the laptop is first turned on, it automatically loads the MK2 software. There are other features on the desktop you may want to access. You can either minimize the MK2 interface once the software is loaded or close the software completely. These are the files you may need or want to access: 1) MK2 Software-should you close the software for any reason and want to start again press this icon. 2) MK2 Manual- the operating manual in PDF format. 3) My Documents file- here is where your photos are saved from the MK2 interface. When you press F11, the image you are viewing is stored by date and time.

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Running on AC power

Vanguard™ MK2
Operating Manual

Section 2.03 Follow these steps to set up your CCU; this is the best way to maximize the performance of your system on AC power. All systems are preset to run on 110AC, and can be changed to run on 220AC, if you are running 220AC and did not request it do not plug CCU or battery chargers in any outlets. Call Allen-Vanguard for more details.

Battery Pack 1

Robot on/off switch located on the back of the chassis (Green LED light will light up on upper arm of robot) Video receiver connector 4 Data modem connector 5

AC Power receptacle and on/off switch 3

Telescopic pole mount

4

It is always best to turn the robot on first before turning on your laptop computer and main power. Robot will take approximately 20 seconds to boot up before LED light comes on. Place charged batteries in robot and turn on switch located in back of robot. Green LED light marked “power” on upper arm will come on. (Robot takes 25 seconds to boot up) 2. Open the Laptop’s protective case and check that all connections to the Laptop are properly secured. including the PCMCIA card, video connections and power cable on the back. 3. Plug in AC cord to AC receptacle located in the upper right hand side of CCU deck. Make sure switch next to receptacle is turned on (line (-) on the switch is on, circle (o) on the switch is off). 4. Attach the video antenna box to the telescopic pole and place pole into pole mount. Plug in the video receiver connector to the receptacle on the CCU deck behind the laptop. 5. Place the data box on the inside of the protective case lid with the Velcro provided, and plug in the data modem connection on the deck of the CCU next to the video connection. 6. Open laptop and turn on power, Laptop must be fully booted up before turning on main power switch 7. Turn on main power switch located on lower right side of CCU deck. (After Laptop is powered up) 8. If running on RF make sure switch marked RF/Tether is on RF, located lower right side of CCU deck. 9. Make sure the AC/DC switch next to the main power switch is on AC (Auxiliary) 10. Once the interface is loaded on the laptop screen wait for the Radio Link to read “connected” indicating that the CCU is now communicating with the robot.
Laptop on/off 6

1.

Only plug in if using RCA outputs. Plugging in will eliminate laptop speakers sound.

Video input Joystick Input Tether communications input Main power switch 7

RF to Tether switch 8

AC/DC laptop switch 9

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Running on DC power

Vanguard™ MK2
Operating Manual

Section 2.04 The following steps should be followed to set up your CCU; this is the best way to maximize the performance of your system using DC power. For DC applications it is very important that your laptop battery is fully charged before running DC power. Trying to run on DC with the laptop unchanged will greatly reduce run time.
Battery Pack 1 Robot on/off switch located on the back of the chassis (Green LED light will light up on upper arm of robot) Data modem connector 4 Video receiver connector 3 Telescopic pole mount 3

It is always best to turn the robot on first before turning on your laptop computer. Robot will take approximately 20 seconds to boot up before LED light comes on. 1. 2. 3. 4. 5. 6. 7. 8. 9. Place charged batteries in robot and turn on switch located in back of robot. Green LED light marked “power” on upper arm will come on. (Robot takes 25 seconds to boot up) Open the Laptop’s protective case and check that all connections to the Laptop are properly secured, including the PCMCIA card, video connections. Attach the video antenna box to the telescopic pole and place pole into pole mount. Plug in the video receiver connector to the receptacle on the CCU deck behind the laptop. Place the data box on the inside of the protective case lid with the Velcro provided, and plug in the data modem connection on the deck of the CCU next to the video connection. Open laptop and turn on power, Laptop must be fully booted up before turning on main power switch Turn on main power switch located on lower right side of CCU deck. (After laptop is powered up) If running on RF make sure switch marked RF/Tether is on RF, located lower right side of CCU deck. Make sure the AC/DC switch next to the main power switch is on DC. Once the interface is loaded on the laptop screen wait for the Radio Link to read “connected” indicating that the CCU is now communicating with the robot. How to maximize your DC power

When running on DC power, both of the RF modems and laptop are drawing power form the internal 12 Volt battery supply. For best results drain the **CCU batteries to 11.20 volts (looking at battery indicator above AC/ DC switch) Now switch the AC/DC switch to AC auxiliary, this switches off the laptop from DC power and is now running on its own laptop battery power. And the CCU batteries are only powering the RF modems. Always fully charge your system after use when running on DC power
Laptop on/off power switch 5

Only plug in if using RCA outputs. Plugging in will eliminate laptop speakers sound.

CCU battery status indicator **Drain to 11.20, than switch AC/DC back to AC auxiliary. Main power switch 6 -turn on after laptop has booted up RF to Tether switch 7

Video & Joystick connectors

2

AC/DC laptop switch 8

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Adjusting /Muting Volume

Vanguard™ MK2
Operating Manual

Section 2.05 The MK2 comes with three features that uses the volume control. The first is the microphones located on the front of the robot that allow you to listen to the robot for feedback on the motors or people talking. The “P” button that activates the speech function. This function gives the users audio feedback on what function has been selected. In both cases the volume has been already set up at our factory at an acceptable volume. Selecting “T” activates the 2 way digital audio, when selected you will turn of the robots microphones, use the space bar or joystick to talk. Adjusting Volume To adjust the volume up or down you must first press and hold the *(FN) button on the keyboard located at the lower left side. While holding this button down press the volume up, or volume down buttons on the right side of the keyboard. Muting Sound/Speaker Reset To mute the sound completely press and hold the *(FN) button and press the Volume mute button on the right side just above the volume adjust keys. Pressing the mute button without holding the (FN) button will reset the speaker volume, if you have raised or lowered the volume.

Volume Mute Hold (FN) and then press once to mute or un-mute volume. Volume Control Hold (FN) button on far side, and press up or down volume.

*(FN) button
Press & hold to adjust volume or mute volume

2 Way Digital Audio For speaker volume use the same PgUp, PgDn buttons but do not use the (FN) button. IF you are using the 2 way audio simply press PgUp or PgDn to raise or lower the speaker output volume. Home Button The Home returns the speaker volume to a preset volume. (For full details on 2 way audio see page 46)

Trouble shooting Audio No audio at all IF you do not have audio coming from either the microphones or speech function check that you did not accidentally press the mute button while adjusting your volume or your volume is completely turned down. Holding the (FN) button press the volume up button and at the same time try your mute button to make sure it is off. You can tell if your mute is on or off by checking the upper left side of the laptop screen it will indicate if the volume is muted or not. No audio microphones only If you do not have audio from the microphones but do have audio on the speech function; first check the audio input plug on the left side of the laptop incase it has come partially out. To test that the laptop is receiving audio use the RCA audio outputs located behind the laptop on the left. Plug in a TV to the audio and video outputs. If there is audio the problem is not at the robot end. If this does not work please contact Allen-Vanguard for further assistance.

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Radio Link, Battery Status & Mission Time

Vanguard™ MK2
Operating Manual

Section 2.06
Mission time

Battery voltage on robot Radio Link Status

Note: Turn on robot before turning on laptop. This will allow the interface to load more quickly, since it is trying to communicate. Radio Link With any remotely controlled vehicle, it is important to know that you are sending and receiving the commands back and forth. On both RF and Tether, the only way to know that you can operate the vehicle is when the Radio Link status bar reads “connected”. Trouble shooting -No Radio Link If the Radio link does not say “connected” within 30 seconds of the interface appearing on the screen, check the following. 1) The main power switch is turned on for the CCU. 2) IF using RF or Tether that the RF/Tether switch is on the right selection. 3) Make sure robot is on-check that the green LED on the upper arm for confirmation. 4) If there is no green LED after turning on robot, turn robot off and check the battery connection on both terminals of the battery pack by opening the battery bag. Also try another battery pack in case batteries are dead. If after trying all these suggestions and you still have no link call Allen-Vanguard for further assistance. Battery Status The battery status is feedback from the robot to let you know the voltage left on the batteries. A fully charged battery back should register 25.2 volts or more. It may vary from pack to pack based on the overall conditions of the batteries and that proper maintenance has been done to keep the batteries is good working condition. Battery Warning Indicator The Battery Status has 3 warning stages. When the batteries are fully charged the voltage reading will be approximately 25.0 to 27.0 volts. When the batteries are very low and you must change batteries. To get the best results for you battery status stop all motor functions and let the robot sit still for approximately 15 seconds.

Battery Indicator Chart 27.0 volts to 24.0 volts 23.99 volts to 23.51 23.5 or less Fully charged Limited time Change batteries

Mission Time Mission time can be used to give you an idea of how long each of your missions are, and can be used with the battery status. If a fully charged battery only lasts 10 minutes, you may have damaged batteries. Most missions are relative to the amount of driving-the more driving, the less mission time. For surveillance operations, if you are just using the robot as camera support in a fixed position, the robot may last all day.

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Vanguard™ MK2

Joystick Set Up

Operating Manual

Section 2.07 The main advantage of the joystick is that it offers variable speed on motor functions. The joystick works the same way as the arrow keys, up, down, left and right. It is important to note that when climbing stairs is better to use the arrow keys to maintain a constant even speed. It’s the slow speed momentum the keeps the robot properly balance while climbing. Too jerky movement might cause the robot to tip back. Operation: 1. Plug the USB cable from the Joystick into the laptop USB receptacle, located in the lower left of the laptop. (Joystick is plug and play application) 2. Turn on laptop (wait for MK2 software to boot up) 3. Select the desired function by press keypad key F1-F8. (not including F7 camera select) 4. Press and hold the trigger button on the joystick, move in the direction you wish to go. Speeds, the joystick overall speed is determined by what speed you choose with the “S” button. If you choose slow speed the maximum speed on the joystick will be slow. And the same when using medium or fast. 2 Way Digital Audio, the 2 thumb switches can be used to turn on the microphones and activate “push to talk” function for the speaker. (See page 46 for details)

The joystick must be plugged in before starting powering up the Laptop.
A B C

.
Joystick USB connection (A) Place mount on edge of case, (B) rotate gate under edge. (C) Tighten knob. Mount is steadiest near corner of case.

Troubleshooting What to do if your joystick does not work. 1. MK2 interface must be off. 2. Joystick must be plugged in. 3. Click on the Start menu and navigate to "Control Panel". 4. In Control Panel, there's an icon that says either "Gaming Options" or "Game Controllers". Double click on this icon to bring up the Gaming Options window. 5. This brings up the gaming options window. In the "Game Controllers" section of this window, you should see a list of all the currently installed joysticks. If you do not see the joystick in the list, then reboot the computer and try again. 6. To test the joystick's configuration, highlight the joystick's name in the "Game Controllers" list and then click on "Properties". This will bring up the Joystick Properties dialog box. 7. There are two tabs on top. One of them is "Settings", the other is "Test". Click on the "Settings" tab. 8. In the "Settings" window, click on the "Calibrate" button. 9. Follow the calibration procedure as per the instructions on the screen and hopefully the joystick will be ready to go once the procedure is finalized. If your joystick is still not operating after trying this please contact AllenVanguard for further assistance. AVA-MKTG-022_C.000 17

Running on Tether

Vanguard™ MK2
Operating Manual

Section 2.08

The MK2 comes with a basic operational tether. Due to size and weight of the tether, it can only be used with the track configuration. The tether is best used where the possibility of interference in the area can cause poor video. This tether is designed for the robot to drive in a relatively straight line to the destination. The tether is spooled out from a fixed location next to the CCU. Please practice with the tether to know its limits and advantages. The tether is durable enough for the robot to drive over it if you have to. Running On Tether Do not turn on the robot until the tether has been installed on the robot and CCU. 1. 2. 3. 4. 5. 6. 7. The anti-flip mount must be used to attach the tether strain relief mount. Place the anti-flip mount on the back of the robot. Use only (1) of the 1.0” quick pins in the lower hole. Attach the strain relief mount on top of the anti-flip mount using the 1.5” quick pin in the upper hole of the anti-flip mount. Remove cover from tether connector located just in front of the battery compartment-plug in tether. Using the 10-foot adaptor cable located on the side of the reel, attach the cable to the tether connector located on the upper left side of the CCU behind the laptop. Change the RF/Tether switch to tether on the lower right side of the CCU deck. Turn on laptop. Turn on robot and wait for Radio Link and Battery Status to turn green. You are now fully operational.

Note: when finishing on Tether if you are going to use RF again, make sure you unplug the 10-foot tether adapter cable front the CCU deck. It causes interference when plugged in and you are using the RF system.
Mounting the Tether Tether mount to robot deck Tether strain relief mount Anti-flip mount, must be used to install tether mount to robot.

1.0” quick pin

1.5” quick pin

10-foot tether adapter plug in, plugs into CCU deck

Tether communication to the laptop goes through this PCMCIA card, make sure it is properly secured

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Vanguard™ MK2
Operating Manual

Tether Reel Parts
1 2 3 4 5 6 7 8 9 10 21 22 23 24 25 27 28 VTR 110 000 (ASSEMBLY) VTR 120 000 (ASSEMBLY) VTR 130 000 (ASSEMBLY) VTR 140 000 (ASSEMBLY) VTR 100 005 VTR 100 006 VTR 100 007 VTR 100 008 VTR 100 009 VTR 100 010 VHSW-S-08C-1250 VHWS-S-25C-0625 VHWS-B-25C-0625 VHSW-S-10C-0625 VHSW-F-08C-0500 VHWS-B-25C-0500 VHWM-0005

Section 2.09

Item 4 & 6-Robot & CCU Connectors The tether hooks directly up to the Robot and CCU to give uninterrupted video and communications. If you have any problems communicating on tether, check the following. First make sure that you are properly connected to the Robot and CCU before turning on Robot. Second make sure that you have switched the RF/Tether switch to Tether (switch located on your CCU deck) Also take a visual check of all the connectors to ensure that all pins and sockets are in properly and not pushed back into the connector. To check the cable from end to end with a use the following pin outs. Connector Pin outs CCU Connector (9 Pin) Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9

Function Ground Video Audio Data Transmit Data Receive Disable RF Ground (empty) (empty)

Robot Connector (16 Pin) Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 to 16

Item 10-(far side) Slip Ring Cover For the tether reel to work while unwinding, there is a slip ring located inside the hub of the reel. If you not get continuity through the cable open the cover to the slip ring and make sure all terminals are properly fastened. There are similar terminals located internally. Do not access these without further instructions from an Allen-Vanguard technician.

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Vanguard™ MK2
Operating Manual

Charging the CCU & Laptop
If you are running your CCU on AC power you are always recharging the Laptop & CCU internal 12 Volt batteries. Charging your system is more important after running your system in DC mode. Running in DC mode will drain the CCU & laptop batteries. Batteries should always be stored in a charged state to ensure longer life, and that you are ready for the next mission. Note: The changing system and AC power can be set to either 110 AC or 220 AC. All systems by default are set to 110 AC unless specified otherwise by customer. If you are using 220 and did not consult AllenVanguard do not plug in your system. Please contact Allen-Vanguard for further instructions. Quick Steps-charging your CCU & Laptop Make sure your laptop is turned off in order to properly charge the batteries. Video & Data modems should be unplugged and stored away. (1) Plug in your AC power cable to electrical outlet. (2) Check that your AC receptacle is switched to the ON position. (3) Check that your Main power switch is turned OFF. (Battery indicator for CCU should be off) (4) Check that your AC/DC switch is ON AC Auxiliary (5) The laptop battery indicator shows if the laptop is fully charged or charging.
(2) AC receptacle On/Off (1) AC cord receptacle

Section 2.10

(3) Main CCU On/Off (4) AC/DC switch

(5)

Laptop battery charge indicator Orange =Charging Green =fully charged

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Storing the CCU

Section 2.11

Proper storage of your CCU is important so you do not damage your laptop. It is always easy to unpack something but to remember how it was before you took everything out might be more difficult. This is just a simple reminder on how to properly pack up your CCU for safe storage or travel. Note: Do not sit or place heavy objects on top of the closed storage case. Never leave the data modem stored in the lid of the case. Quick Steps to Packing away your CCU Make sure that you have fully charged batteries if you are storing the CCU for any extended period of time. (1) Make sure that you have turned off your Laptop. It is possible for it to run when the lid is closed. There is a green power LED light that will flash if the computer is on. If it is flashing open the laptop and properly shut it down. (2) Make sure that that the Main power switch is turned of. (3) Unplug your Data and Video modems and store them in the pocket to the right of the laptop. Bundle up the video modem cord next to the modem. Place data modem in front cable along front of computer. (4) Place the telescopic pole in the clamps located at the lower end of the lid. (5) Fold up the AC cable and place next to the video modem. (6) Carefully shut the lid of the storage box, checking that no cables are in the way of the edge of the box.

(5) AC Cord storage

(4) Telescopic pole storage

(3) Video Modem storage

(3) Data Modem storage (3) Bundle video cable next to receiver and place data cable in front of laptop.

(2) Turn off Main ON/OFF switch (1) Make sure there is no flashing LED light that indicates the laptop is still running. Turn off if necessary.

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Restoring the MK2 software

Section 2.12

There might be a time where you have to re-install your MK2 software. The disk provided from Allen-Vanguard quickly restores your system if there are any problems. The process is automatic and takes about 15 minutes to complete. Please note that after the software is installed you must reboot twice after installation please follow the below steps. Quick Step for re-installing your MK2 software Plug in your laptop to AC power to make sure that the laptop does not lose power while installing your software. (1) With the laptop off open your CD drive located on the right hands side of your laptop. (2) Push the CD in and turn your laptop on. (3) The system will automatically boot up, do not do anything at this point. (4) The screen will open to a help screen for the installation that shows you how long the installation will take. (5) When the software is finished the screen will have a message to prompt you to do the following; Please remove the CD form the CD-Rom drive and reboot your computer. At this point you need to turn off the computer by pressing the power button. (6) Now start your computer back up using the power button. (7) Your software will now go to the MK2 menu screen, once this is completely loaded you will need to shut down your system again for the installation to be complete. Close down the MK2 software and then shut the computer down using normal windows procedures. (8) For the last step re-start your computer for the last time. Your system is now ready for use.

(2) Insert the CD with the laptop turned off

(4) Installation screen with time menu

CD Information Allen-Vanguard makes a duplicate CD for each of the robots and keeps it with your personal file. Each CD is marked with your laptop and robot serial # for future use incase you loose yours and need duplicate copy. Your CD is for your MK2 robot only at no time shall this software be used in any other computer without the written consent of Allen-Vanguard. No copies of this CD can be make without the written consent of Allen-Vanguard. The CD also contains other information you might need to access such as the operating manual in PDF format.

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F1 Drive Function

Section 3.0

F1 on your keypad selects your drive function. This function allows the robot to drive from one point to the other. The drive system is the largest draw of power from your batteries. Always choose the most direct route to and from your destination. Always drive with the arm in the stowed position, this gives the robot its best balance for skid steering and climbing over obstacles. This also reduces unnecessary wear and tear on the arm gears. MK2 offer simultaneous functions such as forward and left or right steering. Keypad operation
Forward Gradual steering hold forward and left Gradual steering hold forward and right Forward Right turn Trigger

Joystick operation

Left Turn Reverse

Right Turn

Quick Start Guide-Keypad operation Press F1 to select your drive command.

Left Turn

Reverse

Press S button on the keypad to toggle your speed-slow, medium or fast. Using the arrow keys on the keypad the robot will move in the direction of the arrows at the speed you selected.. Gradual Steering –MK2 is capable of two functions at the same time. While driving forward with the keys hold the left or right turn arrow button. This allow the operation to continue driving and turn left or right without having to stop.

Quick Start Guide-Joystick operation Press F1 to select your drive command Pull the trigger on the joystick than move the joystick in the direction you want to move. The joystick is variable speed the further you push away from the home position the faster the robot will go. If you release the trigger the robot will stop moving. Driving with the wheel kit Press V button on the keypad changes from track to wheels this function changes the rate at which the robot turns to better control the robot. Note: This function is only required when the wheel kit has been installed on the robot. See wheel kit installation on the following page for more details.

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Attaching Wheel Kit

Section 3.01

MK2 can be converted from a tracked vehicle to a wheeled vehicle. Both methods have advantages and disadvantages. When using tracks, you have the most versatile method; tracks can go just about any where in any terrain, but at a slower speed. The wheeled method only allows for greater speed-wheels are approximately twice the speed as tracks but you lose the versatility. How to choose between Tracks or Wheels In most cases, tracks will be your method of choice; they are more versatile, have more control and can overcome obstacles. The basic wheel kit is great for open flat terrain where you do not have any obstacles, such as curbs or slopping ground to overcome. The track method must always be used when operating on tether; the design of the wheel kit makes it difficult to control when pulling a load such as the tether. When choosing the wheel kit don’t forget to change the interface from tracks to wheels by pressing the “V” on the keypad. This change is done so you have better control in steering while in the fast speed. Components of the Wheel Kit
2 1/4” Socket Head Cap Screws (2 per Wheel) 6” Rubber Wheels “T” handle 3/16’ Hex Drive 1.0” quick pins (2 pieces) Swivel Wheel

Installing the wheel kit Step 1-Located on the *lower front drive wheels are (2) ¼-20 treads, this is where you will attach the 2 ¼” socket head screws. Step 2-Screw the 2 ¼” socket head screws through the wheel hub onto the lower front drive wheel. Install the wheels using the 3/16” hex drive. Step 3-Using the 1.0” quick pins, attach the swivel mount to the rear accessory mount located on the back of the robot. Step 4-Press V on the keypad to change your interface from tracks to wheels. Why to select “V” wheels button The “V” button for the wheel kit is designed to control the rate of speed during skid steering. If you are using the keys in fast speed and you try and turn without this button activated the robot will spin very fast due to the swivel wheel in the back. This feature controls the speed of the skid steer no matter what speed you select to drive. This featured keeps the skid steer at an easy rate of speed to control the robot.
*Lower front drive Rear accessory mount

Wheel kit installed

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Attaching the Anti-Flip Mount

Section 3.02

The MK2 robot comes with an anti-flip mount to aid in driving. This is a safety measure we have added to help in the wear and tear of your vehicle. We have designed a mount that can be used to reduce the risk of overturning the robot on stairs or high curbs. Using Anti-Flip Using the (2) 1.0” quick pins install the mount with the horizontal side down. This configuration will prevent your vehicle from flipping over should you encounter an obstacle that appears to be high but you need to approach it for your mission. Judging the angle of stairs can be difficult, especially from a distance. Use this mount whenever you are in unfamiliar territory. This configuration can be used at all times and helps ease the robot of curbs. This is important so the robot does not slam down off curbs, possibly damaging electronic components or cameras.

Install with the (2) 1.0” quick pins

Helps stabilize robot on stairs & high curbs

The Anti-flip as shown helps keep the robot steady on the stairs, and keep it from tipping back. Do not attempt stairs without the Anti-flip mount installed

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Driving tips

Section 3.03

Keep Arm Stowed Always keep the arm in the stowed position until it is needed. The reason is simple; the lower the arm, the more stability and control you have. Furthermore, the arm is resting on rubber stoppers, which alleviates wear and tear of the gears. This is even more important when carrying the Disrupter, which weighs 12 Lbs. Keep in mind that, with the arm fully extended, the weight on the tracks is no longer central and turning may become more difficult. Stair climbing and descending should be done in slow speed only. This reduces the impact on your electronic and camera systems. Slow speed should also be used when turning with the arm extended, or with a load such as the disrupter.

When climbing stairs the arm should be fully stowed and the anti-flip mount must be installed on the rear of the robot.

Important!

Anti-Flip mount

Climbing stairs moving forward in slow speed

Descending stairs moving backwards only in slow speed.

Note: Descend stairs is in reverse, creeping in slow speed. Driving in different terrain
The best way to become familiar with driving in different conditions is to go out and try different scenarios. In some conditions, such as grass, and depending on the length, try and make small turns. The tracks will grip very hard in soft grass. Doing a complete 360 turn will drain a lot of power from your batteries and grass, gravel or sand may get caught in the drive wheels, making the turn that much harder. In these situations, use gradual steering. The same can be said for situations were there is a lot of debris on the ground. Making 360 degree turns in sand, snow or gravel may only cause trouble; always go in a direct line to your target. In difficult situations, make as short a turn as needed. Using the audio to monitor the sound of your drives will help you to hear when Always make small steering movements in rugged terrain, when driving forward use you left or right turn while moving forward in small increments to avoid filling the tracks with unwanted debris.

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Removing Tracks
There are times that you may need to remove a track, repairing, replacing or for general cleaning and maintenance. The track only takes a few minutes to remove and only requires the upper front drive wheel to be removed. The first step is to loosen the tension put on the track from the rear tension spring. See the following steps. The tracks can be replaced in the same way in the opposite order.
Step 1-Reduce the track tension before removing the track, you will need a 1/2” open-ended wrench. Step 2-Grab hold of the track and lift upwards. This will compress the spring, place the 1/2” wrench between the locknut and wall. Leave the wrench in place for the next steps.

Step 3-Remove the two hex bolts from the upper front drive wheel.

Step 4-Once the wheel is off, slide the track over the front end, off the opposite drive wheel. Using the side handle lift tip the robot up to slide the track from underneath

Replacing track Follow the same procedures in reverse to place the track back on. Start by lifting the robot up to slide the track under the drive system and over the rear wheel. Next pull the track over the upper front drive wheel fitting the track into the grooves of the remaining front wheel. Place the other drive wheel back on, line up the grooves in the track. Now that the wheels are on lift up the track at the back end to loosen the wrench and remove it.

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Removing Drive System

Section 3.05

Follow these steps to remove the drive system. This should only take a few minutes for each side. The track must first be taken off, so follow the steps from the previous page. Step 1-First remove the track from the drive system (see previous page) Step 2-Remove the drive motor cover plate located at the front of the drive system (6 screws). Step 3-Disconect the power connector from the drive motor. Step 4-Remove the three bolts that secure the drive system to the chassis. Step 5-Slide the drive system off the chassis mount.

1-First remove track

5 3

4

2

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Drive System Parts

Vanguard™ MK2
Operating Manual

Section 3.06 The MK2’s Drive system consists of two sets of drives on each side of the chassis. The parts on each side are basically identical accept for the main side plates that slide on each side of the chassis.

1) 2) 3) 4) 5) 6) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 25)

VDS 100 001 VDS 100 002 VDS 100 003 VDS 100 004 VDS 100 005 VDS 100 006 VDS 100 008 VDS 100 009 VDS 100 010 VDS 100 011L VDS 100 012L VDS 100 013 VDS 100 014 VDS 100 015 VDS 100 016 VDS 100 017 VDS 100 018 VDS 100 019 VDS 100 020 VDS 100 021 VDS 110 000

DRIVE WHEEL (28 TEETH) IDLER WHEEL (22 TEETH) IDLER WHEEL AXLE IDLER WHEEL HUB TENSION IDLER HUB TENSION IDLER HUB BUSHING TENSION IDLER SPRING SPACER TENSION IDLER ROD TENSION IDLER BLOCK LEFT DRIVE INNER SIDE PLATE LEFT DRIVE OUTTER SIDE PLATE DRIVE SIDE PLATE SPACER DRIVE SIDE PLATE STANDOFF DRIVE MOTOR GUARD DRIVE MOTOR COVER TOP IDLER SHAFT TOP IDLER WHEEL SS DRIVE GB DRIVE NUT IDLER DRIVE NUT IDLER WHEEL MOD (22 TEETH W/ THREADS) GEARBOX ASSEMBLY

30) 31) 32) 33) 34) 35) 36) 37) 39) 40) 42) 43) 44) 45) 48) 49) 50) 51)

VHSW-H-25C-0625 VHSW-F-06C-0500 VHSW-F-06C-0250 VHSW-S-06C-0375 VHSW-S-08C-0S00 VHSW-B-10C-0500 VHNT-L-38C VHNT-J-38C VHWR-L-250 VHBE-T-008 VHBE-B-001 VHBE-B-002 VHWM-0050 VHWM-0160 VHBE-R-004 VHWM-0216 VHTR-0034 VHWM-0303

HEX HEAD SCREW FLAT PHILLIPS MS FLAT PHILLIPS MS SOCKET HEAD CAP SCREW SOCKET HEAD CAP SCREW (ALLOY) BUTTON HEAD CAP SCREW LOCKNUT HEX JAM NUT LOCKWASHER THRUST WASHER BALL BEARING BALL BEARING BELT MODIFIED COMPRESSION SPRING RETIANING RING FOLDING HANDLE BRONZE BUSHING ROUND STANDOFF

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F2 Turret Function

Section 4.0

F2 on your keypad selects your turret function. This function allows the turret & arm to move from left to right. The turret can only be used when the arm has been lifted from the stowed position. The turret allows the operation to move the arm from one side to the other to either pick up an object or to aim a water disrupter. You must know the position of the arm at all times before moving the turret. Using the Main camera, watch that the claw or claw camera will not hit the track. Keypad operation
No action No Action Turret Right Trigger

Joystick operation

Left No Action

Right

Turret Left

No Action

Warning: Turret may only be used once the Arm has been raised. When the robot is fully stowed away, the claw camera may hit the drive system. Also watch when stowing the arm Do not lower the arm if turret is not centered or slightly to the right. Use the pan and tilt camera to view where the turret is positioned. Move the turret over to the right side if the claw camera is too close to the drive system. Use slow speed to stow claw and arm.

Quick Start Guide-Keypad operation Press F2 to select your turret command. (Use F5 to un-stow arm first) Press S button on the keypad to toggle your speed-slow, medium, or fast. Using the arrow keys on the keypad the turret will move in the direction of the arrows is the speed you selected.. Quick Start Guide-Joystick operation Press F2 to select your turret command (Use F5 to un-stow arm first) Pull the trigger on the joystick than move the joystick in the direction you want to move. In this case only left or right. The joystick is variable speed the further you push away from the home position the faster the turret will go. If you release the trigger, the turret will stop.

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Removing the Turret

Section 4.01

Before the turret can be removed you must first follow 2 steps on page 36 to remove the arm, and the other on page 53 removing the electronics box. First follow the steps on removing the arm, once the arm is off you can follow the steps to remove the electronics box. Follow the first three steps in order to remove the deck. Once these steps are finished you can proceed with the following steps to remove the turret. Step 1-Unscrew the (9) screws holding the turret motor housing in place. Step 2-Remove the (6) flat head screws from the upper part of the turret. Step 3-Slide the turret housing off from the deck plate. After this step you can remove the turret gear and upper plate from the chassis deck.

2

3 1

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Turret Parts

Section 4.02

1 2 3 4 5 6 7 8 9 11 12 14 15 16 17 18 19 20 21 22 23 25 26 28 29

VDK 110 000 Assembly VDK 120 000 Assembly VDK 130 000 Assembly VDK 140 000 Assembly VDK 150 000 Assembly VDK 100 006 VDK 100 007 VDK 100 008 VDK 100 009 VDK 100 011 VDK 100 012 VHWM-0808 VHSW-S-10C-0500 VHSW-F-25C-0750 VHSW-B-06C-0375 VHSW-S-08C-0375 VHSW-F-08C-0500 VHSW-S-25C-0500 VHSW-S-25C-0500 VHSW-S-06C-1000 VHSS-R-06C-0500 VHCA-1027 VHWM-0664 VHBE-T-011 VHBE-T-012

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F3 Elbow Function

Section 5.0

F3 on your keypad selects your elbow function. This function allows the elbow to move up or down. Before using the elbow use your F5 Arm function to first raise the arm to approximately 90 degrees. The elbow is located in the upper arm of the robot and can lift about 20 lbs. For heavier lifting you must use the shoulder function. When carrying loads try and keep the weight as close to the robot as possible. This will reduce wear and tear on arm gears and helps balance the robot while driving. Keypad operation
Up Trigger

Joystick operation

Up No Action No Action Down Down No Action No Action

If the arm is in a stowed position, you should use F5 Arm function to raise the arm and elbow to about 90 degrees. Once the arm is up, you have full use of all functions.

Quick Start Guide-Keypad operation Press F3 to select your elbow command. (Use F5 to un-stow arm first) Press S button on the keypad to toggle your speed-slow, medium fast. Using the arrow keys on the keypad the elbow will move in the direction of the arrows is the speed you selected.. Quick Start Guide-Joystick operation (Use F5 to un-stow arm first) Press F3 to select your elbow command Pull the trigger on the joystick than move the joystick in the direction you want to move. In this case only up or down. The joystick is variable speed the further you push away from the home position the faster the elbow will go. If you release the trigger the elbow will stop moving.

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F4 Shoulder Function

Section 6.0

F4 on your keypad selects your shoulder function. This function allows the shoulder to move from forward to deploy the arm or to back to stow the arm. Before using the shoulder it is best to use your F5 Arm function to first raise the arm to approximately 90 degrees. The shoulder is used when picking up heavy objects, any item over 20 lbs will have to be lifted by the shoulder the best position for lifting is directly in front of the tracks. The closer you are to the robot the more weight you can lift. Keypad operation
Trigger Forward Forward No Action

Joystick Operation

No Action Back

No Action

No Action

Back

If the arm is in a stowed position, you should use F5 Arm function to raise the arm and elbow to about 90 degrees. Once the arm is up, you have full use of all functions. Quick Start Guide-Keypad operation Press F4 to select your shoulder command. (Use F5 to un-stow arm first) Press S button on the keypad to toggle to your speed-slow, medium fast. Using the arrow keys on the keypad the elbow will move in the direction of the arrows is the speed you selected.. Quick Start Guide-Joystick operation Press F4 to select your shoulder command. (Use F5 to un-stow arm first)

Pull the trigger on the joystick than move the joystick in the direction you want to move. In this case only forward or back. The joystick is variable speed the further you push away from the home position the faster the shoulder will go. If you release the trigger the shoulder will stop moving.

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F5 Arm Function

Section 7.0

F5 on your keypad selects your arm function. This is always the first function to choose when operating the either the shoulder, elbow, claw, or turret. The arm should be in the stowed position at all time until needed for a specific task. When first un-stowing the arm use fast speed and bring the arm to approximately 90 degrees before engaging any of the above mentioned functions. Please read carefully page 38 on stowing and un-stowing the arm. Keypad operation
Un-stow Elbow & Shoulder Brings arm forward

Joystick Operation
Trigger

Un-stow Elbow & Shoulder Brings arm forward

Turret Right

Turret Left Stow Elbow & Shoulder Brings arm back

Turret Right

Turret Left

Stow Elbow & Shoulder Brings arm back

Warning: Always lift arm to approximately 90 degrees before engaging turret. Quick Start Guide-Keypad operation Press F5 to select your arm command. This moves both Elbow & Shoulder at the same time as well the turret is activated using your left & right arrow keys. Un-stow arm before using the turret. Press S button on the keypad to toggle to your speed-slow, medium fast. (use fast speed to un-stow) Using the arrow keys on the keypad the arm & turret will move in the direction of the arrows is the speed you selected. Quick Start Guide-Joystick operation Press F5 to select your arm command. This moves both Elbow & Shoulder at the same time as well the turret is activated moving the joystick to your left or right. Un-stow arm before using the turret. (use fast speed to un-stow) Pull the trigger on the joystick than move the joystick in the direction you want to move. In this case both Elbow & Shoulder at the same time, also you can move the turret. The joystick is variable speed the further you push away from the home position the faster the arm will go. If you release the trigger the arm will stop moving.

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Removing the Arm

Section 7.01

To remove the arm from the robot you only need to remove 4 screws. The diagram below also illustrated removing the arm supports. Removing the arm supports is only necessary if you with to remove the upper arm that houses the elbow motor and claw motor. Step 1-To remove the arm from the turret remove these 4 screws, 2 on each side. Step 2-To remove the arm supports remove these screws. Step 3-To open motor housing remove these screws and slide off steel collar, 2 on each side.

3

2

1

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Arm Parts

Section 7.02

Claw Wrist 1

2 3 4 Elbow 6 7

5 10 8 9

12 13 11 Shoulder

(1) WRIST GEAR ASSEM. (2) ARM MOTOR HOUSING (3) RUBBER TIP (4) FIRING CONNECTOR ASSEM. (5) ELBOW GEAR ASSEM. (6) ELBOW SPACER (7) FOREARM MOUNT (8) FOREARM SPACER (9) FOREARM RIGHT (10) FOREARM LEFT (11) SHOULDER ASSEM. (12) UPPER RUBBER BUMPERS (13) LOWER RUBBER BUMPERS SHOULDER MOTOR ELBOW AND WRIST MOTOR

VAR 140 000 VAR 100 010 VHWM-0607 VAR 250 000 VAR 13 000 VFA 100 004 VFA 100 003 VFA 100 005 VFA 200 001 VFA 200 002 VSH 200 000 VHWM-0603 VHWM-0606 VSH 110 000 (Not Shown) VAR 170 000 (Not Shown)

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Deploying and Stowing Arm
The MK2 has 6 different movements in the arm. There is a specific order needed to deploy and stow the arm. It is important to stow it in as tight a package as possible. This has allowed for a stable driving platform with low center of gravity for climbing stairs. Note: Unlike the drive system motors that have feedback capabilities, all the arm functions do not. What this means is that when choosing a speed (slow, medium, fast) under load, the arm will not have the same torque in slow as it would in fast. You can move the arm in any speed but when it comes to picking up a load you may need medium or fast to complete your task.

Section 7.03

Stowed position

Deploying the Arm
Follow and practice these steps. Practice first by looking at the robot until you are comfortable will all the movements. Once you understand what all the functions are, use the pan & tilt camera to deploy and stow the arm. It is highly recommended to use audio when using the functions. Audio will give you feedback on the load of the motors. Step 1-Whenever the robot is in a stowed position, your first move will be function F5 (keyboard arrow up). This arm function on your interface will bring both the shoulder and elbow up and forward from the stowed position. Bring the arm position to approximately 90 degrees. Step 2-Once you have lifted the arm, you can now bring the wrist function from the claw down. Choose F6 (keyboard arrow down) to deploy the claw from its stowed position. Now that the claw is out, you can continue safely with all other arm functions. Step 3-The turret can be used at this time. Keep in mind that it is good practice to use your pan & tilt camera to view all moves by the turret. It is possible to hit the claw or tracks, depending on arm position, so keep an eye out for this at all times. Note: It is recommended to only deploy the arm when using it for a specific task. Always drive with the arm in a stowed position. This will save on wear and tear of all arm mechanical joints.
Turret function F2 Wrist function F6

Arm function F5

Stowing the Arm
Step 1-Close Claw completely. Rotate in line with arm. Use slow speed to rotate claw to rubber stop. Step 2-Check that turret is centered or slightly to the right of center. Step-3-Bring shoulder and elbow close to stowed position using medium or fast speed, then stop. Step 4-In slow speed bring shoulder completely down to rubber stops. Step 5-In slow speed bring elbow completely down to rubber stops.

Step 3

Step 4

Step 5

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F6 Claw

Section 8.0

F6 on your keypad selects your claw function. Before using the claw you must first un-stow the arm until approximately 90 degrees. The claw consists of three functions, wrist, rotate, & open-close. The wrist and rotate can be used on both the keypad or joystick, the open and close are only the letters “O” for open and “C” for close. When using the claw choose the claw camera through the F7 function and the claw light can be activated by selecting “L” button. Keypad operation
Trigger Stow claw, lift Stow claw, lift Claw rotate right Claw rotate left Un-stow Open Claw Claw rotate right

Joystick Operation

C Close Claw
Claw rotate left

Un-stow

Claw open & close are always keypad operations even for the joystick.

Use your F5 function to bring the elbow and shoulder to approximately 90 degrees before using claw. You also must use only the wrist to bring claw forward before opening or rotating. Quick Start Guide-Keypad operation Press F6 to select your claw command. (Use F5 to un-stow arm first) Press S button on the keypad to toggle your speed-slow, medium fast. Using the arrow keys on the keypad the elbow will move in the direction of the arrows is the speed you selected.. Quick Start Guide-Joystick operation Press F6 to select your claw command (Use F5 to un-stow arm first) Pull the trigger on the joystick than move the joystick in the direction you want to move. In this case only the joystick moves the wrist function and the rotate function.. The joystick is variable speed the further you push away from the home position the faster the claw will go. If you release the trigger the claw will stop moving. Claw lights-Claw lights are activated from the “L” button on your keypad. This is an on/off function.

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Removing the Claw
There are only 3 screws that secure the claw to the arm. Before removing the claw please see how the cable is wrapped around the wrist, in order to properly replace it. To remove the claw; Step 1-Remove the 2 screws located in the inner part of the claw housing. Step 2-Remove the screw located in the upper part of the motor housing. 3 Step 3-Slide the claw off the wrist shaft.

Section 8.01

2

1

1

2 & (11)

Claw Parts
6 5 3 1 & (12,13) 7 10 (1) CLAW MOTOR HOUSING (2) CLAW CAMERA HOUSING (3) GRIPPER FINGER (4) O-RING CORD (5) STANDOFF (6) GRIPPER OUTER FINGER (7) GRIPPER INNER FINGER LEFT (8) GRIPPER INNER FINGER RIGHT (9) LOCK NUT (10) GRIPPER CHEEK PLATE (11) COLOR CAMERA (12) PINCER MOTOR (13) ROTATE MOTOR VCL 110 000 VCL 130 000 VCL 120 008 VHWM-0663 VHWM-0301 VCL 120 004 VCL 120 005 VCL 120 006 VHNT-L-25C VCL 120 002 VHEC-0003 (not Shown) VHEM-0005 (not Shown) VHEM-0004 (not Shown) 9 8 4

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F7 Camera Select

Section 9.0

F7 on your keypad selects your camera select function. The camera select function allows the operator to choose what camera the robot will use. There are three camera to choose from on the robot and a fourth camera is used when adding optional disrupters or specialized cameras. Camera select only selects the camera views if you use F7 to look thought the main camera (Pan & Tilt) it will not operate the Pan & tilt function, you can just hit the keyboard direction keys or select F8 function key. Keypad operation
Trigger No Action No Action No Action No Action No Action No Action No Action

Joystick Operation

No Action

The system is automatically set to show main camera (pan and tilt) on start up. Each time you press F7 it will change to the next camera. They will always be selected in the following order: (Default) Main Camera (pan & tilt) (2) Claw Camera (3) Drive Camera (4) Weapons Camera (only when water disrupter is mounted) Note: If the weapon camera is not on the robot you will still toggle through this screen, it will appear as a blue screen. Under the viewing area of the screen there are 3 large function keys, one displays what function you are in, one displays what speed you are using and the third is what camera you are using. Each time you press F7 the camera selected will appear in the camera select box, also by using the “P” speech button you will get audio confirmation of what camera you selected. There are no other keys needed for this operation, there is no joystick operation for this function. If you wish to move the pan & tilt you can just hit the keyboard direction keys or select F8 function key. To save a picture in the viewing area select F11 on your keypad, this will store the image in :my documents” folder.

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B Camera Settings
(1) Drag your Video Source menu to the right of the video image (2) Select Video Proc Amp menu to control camera settings. Section 9.01

(3) To save your setting press on Apply before exiting menu.
Picture with not enough brightness. Picture with to much brightness.

Press B to select your camera settings These settings will allow you to adjust the image you see on the screen to the appropriate setting for brightness, contrast, hue & saturation. The brightness may have to be changed when driving from a poorly lit area to a brightly lit area. After choosing this function use your mouse to drag the pop up (1) Video Source menu to the right of the video image. Now select (2) Video Proc Amp on the top menu bar. In this setting you will find your brightness, contrast, hue, and saturation adjustments. In most cases you will only need to adjust the brightness to get a better picture; you can try and play with all the settings to get exactly what you need. Once you have adjusted your picture you must press (3) Apply to hold your settings before exiting the menu. If you feel that you have made to many changes and have a hard time adjusting the settings press the Default to set the picture back to its factory settings. Note: A good way to check your settings is to plug in a TV monitor to the auxiliary RCA connectors located behind your laptop and compare the picture color and brightness.

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F8 Pan, Tilt Zoom (PTZ)

Section 10.0

% Zoom

Selecting arrow keys in the center of the keypad selects your pan, tilt function. This function moves the main camera from side to side or up and down. Selecting [ to zooms out and selecting ] zooms in to an object. Along with this feature is auto speed, the more you zoom in the slower the pan & tilt motors will move. If you are in another camera view simple hit any of the PTZ keys and this automatically switches back to the PTZ camera or press F8.

Keypad operation

] Zoom In & [ Zoom Out

These four keys operate your Pan & Tilt function, these can be used simultaneously while driving the robot. Quick Start Guide-Keypad operation Press to tilt up Press to tilt down Press to Pan left Press to Pan Right Press [ to zoom out (Z) Press ] to zoom in (Z) PTZ features Continuous Pan–The Pan function has continuous 360 degree freedom. An internal slip ring allows for continuous panning in either direction. Auto Speed selection-The PTZ zoom function has auto speed function. Above the F8 key is a window this % of zoom. The zoom % is from 0% to 100%. As the zoom percentage goes up the speeds for panning and tilting will automatically slow down. This allows for precise movement when fully zoomed in on an object. No joystick operation-The PTZ camera is only operated from the keyboard keys. All other motor function use the arrow keys or joystick. This allows you to both drive with the arrow keys or joystick and pan the camera at the same time.

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Removing the Pan & Tilt
The illustration below shows both the Pan & Tilt and Video system removal.

Section 10.01

To remove the Pan & Tilt Camera assembly, remove these two screws

To remove the Video modem, first remove lower deck mount, then remove this screw and slide the video modem assembly off the tubes.

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Section 10.02

PTZ Parts
(1) (2) (3) (11) Pan Assembly Tilt Assembly Zoom Camera Assembly Spring Plunger P/N VPT 110 000 P/N VPT 120 000 P/N VPT 140 000 P/N VHSS-P-10F-0895

Zoom camera can be replaced with our optional IR camera for low light situations.

Note: If the PTZ assembly starts to tilt side to side, you may need to adjust these spring plunger screws. There are four screws located around the base of the Pan Assembly. Do not over-tighten. The Pan assembly should still be able to rotate by hand.

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L Claw Light

F9 Main Light

F10 Laser

F11 Photo

Section 11.0

Press L to toggle the Claw lights on and off. Press F9 to activate the main LED lights on the front of the robot. This function is a 3 way toggle. When the lights are off, select F9 to turn on high beam, the second time you press F9 is will go to low beam and a third time to turn \off the lights. On the menu screen you will see F9(H) for high beam and F9(L) for low beam, when the lights are completely off only F9 will be displayed.

Warning: Avoid direct eye contact with laser
Press F10 to toggle the Disrupter laser on and off. The laser is attached to the water disrupter mount, and will only go on if this is installed. Lasers, in general, are difficult to spot in daylight conditions, so this laser beam flashes to make it more visible. Press F11 to save a picture at any time. The photo function allows you to save the picture that appears in the viewing area. By pressing F11 at any time, it will save that picture in the folder My Documents. The folder is located on the desktop-simply hide the Interface by pressing the (-) minimize button located in the upper right hand corner of the screen. Each photo is saved by date/time-you can take as many as you want and each one will appear in “My Documents” folder in the order they are taken.

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T 2 Way Digital Audio

Section 12.0

The audio is digital and travels over the communication link instead of the more traditional method of having audio “Piggy back” over the video transmitter as analog. This ensures that the audio is crisp and clear at all times. The audio is bi-directional and behaves as a CB radio. The two way audio requires the headset to be plugged in and can be activated by either the keyboard keys or joystick. The speaker volume is controlled by Page UP, Page DN keys located on the right side of the keyboard, for this function do not use the (FN) button as you would to adjust the microphone volume. There is no volume control on the joystick Keypad operation
“Home” button resets speaker output volume to a central level. (1) Press Right thumb switch to activate Listening, from the robot microphones

Joystick operation

Speaker Volume Up Page UP Speaker Volume down Page DN (2) Press and Hold the Left Thumb switch to talk through the robots speakers, release to listen.

(1) Press T to activate Listening, from the robot microphones

(2) Press and Hold the Space Bar to talk through the robots speakers, release to listen.

Quick Start Guide-Keypad operation Press T to activate the robots microphones for listening. Press a second time to shut of the microphones. The sound will come from the laptop speaker unless you plug in the headset. To adjust microphone volume refer to page 15. Press Space Bar if you want to talk through the robots speaker. While you are holding the space bar the T menu button will change from Listen to Talk to let you know that it is properly working. Speaker Volume Use the PgUp, PgDn buttons on the right side keypad to adjust the volume from the speaker. The volume loudness is displayed in the help menu. Practice with the different settings so you understand how loud the volume is compared to the db setting in the menu screen. Home Button will reset your speaker volume to 0dB. The volume loudness is displayed in the help menu as dB level. Home button sets the level to 0, and you can use the PgUp, PgDn button to go louder or softer from the 0 level. Quick Start Guide-Joystick operation Press the Right Thumb Switch to activate the robots microphones for listening. Press a second time to shut of the microphones. This is the same as pressing the T button on the keyboard. Press the Left Thumb Switch if you want to talk through the robots speaker. While you are holding the thumb switch the T menu button will change from Listen to Talk to let you know that it is properly working

Headset-Plug in both connectors for headset.

Note: You must unplug the audio plug to the RCA output before connecting the Headset. Replace after headset use.

they are loaded or having trouble.

Microphones

Speaker

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S Speed

P Speech

Z Tool

Section 12.01

Press S to select your function speed. Toggle through the 3 speeds: Slow, Medium and Fast. By default, upon startup the fast speed is selected. The claw open and claw close functions also respond to the speed select toggle. Speed with Joystick Slow-in slow speed the joystick will to a maximum of slow. Medium-in medium the joystick will go to a maximum of medium speed Fast-in fast the joystick has full range of speed. Press P to initiate the speech function and again to turn function off. When enabled, the command station will speak the current function. For example, when the F1 key is pressed and Drive mode is selected, the command station will audibly say "Drive". Speech confirmation ensures that the proper function has been selected and minimizes mistakes when most of the concentration is focused on the video screen. Make sure that the volume on the laptop is turned up. This may be used when the microphones “T” are on. Note: If you turn on speech and you do not hear any audio feedback-check that you did not accidentally hit the mute button that is next to your volume control buttons. Hold the (Fn) button and press the mute button again. The tool function is an additional feature to the MK2 robot. It basically gives the operator auxiliary power to operate tools or devices that require 24 Volts. It is possible to hook up 24 Volt cordless tools to be used with this feature. This is up to the end user to determine what they may be able to use with this feature. It is highly recommended that you check with an Allen-Vanguard engineer before hooking up any device. Tool outlet-The tool outlet is located on the outer part of the electronics box on the deck of the robot. Press Z to activate the tool function for use. No power is on at this point. Press ALT-Z to open the 24 volt circuit to the tool circuit, press Z again to turn power off power to the tool circuit. Note:All user commands can be made while the tool function is enabled except for the weapon circuit.

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W Weapons Enable

Section 13.0
Warning: Never pass in front of a Disrupter once it has been loaded and mounted on the robot. Choose the safest and most direct path towards your target.

Safe to load disrupter Green LED Countdown Clock Warning: power in disrupter terminal Red LED

Weapon outlets for 1 and 2 are clearly marked on the arm.

Upper arm of robot

Weapon Outlet (2)

Weapon Outlet (1)

The Weapons Enable is the start of the firing sequence these steps must be followed in order to fire the Disrupter. You must be lined up with your shot before arming the weapons systems. There are two separate firing circuits located on the upper arm of the robot. They are independently fired, one at a time. You cannot fire from both weapon circuits at the same time. Step 1- Press W to enable the firing sequence. Step 2-Choose from the number keys on the keyboard (1) for weapon outlet one, or (2) for weapon outlet two. Step 2-Press A to arm the Weapon you have chosen. After selecting (A) to arm the firing sequence, a 20 count clock will show up on the screen. If you do not fire the shot in 20 seconds the, Weapons Enable will reset and you will have to start the sequence again. Step 3-Press Shift & F12 to fire the Weapon, while holding the shift key down, press the F12 key. The firing circuit is activated for 5 seconds. After 5 seconds, the firing sequence is complete and full control is restored to the operator. It is always good practice to test you firing circuit before loading any weapons. Using a volt meter go through the firing sequence to make sure they are functioning properly. Note: Do not hit any other keys once the firing sequence is armed. If you hit any key other then the Shift + F12, the firing sequence will abort.

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Chassis

Section 14.0

The Chassis is the base of the MK2’s modular system. Most of the other components attach directly to the chassis. The Chassis also contains the electronics box and batteries used control your robot. All of the robots electronics are conveniently stored in the electronics box making it very easy to replace or upgrade.

1

2 3

10 11 4

5

6

9 7 8

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Battery Lid Assembly VDK 230 000 Deck Plate VDK 200 007 Light Assembly VDK 220 000 Turret Assembly VDK 110 000 Drive Camera Assembly VCH 120 000 Waterproof Speaker VHEC-0012 Speaker/Microphone Mount VCH 250 001 MK2 Microphones VHEC-0011 Control Box Assembly VEE 210 000 Anti-Flip Mount VDS 130 000 Rear Swivel Assembly VDS 121 000

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Removing Batteries

Section 14.01

Located in the rear of the MK2 chassis is the battery compartment. To simply change battery packs do the following steps: 1. Make sure robot is turned off. Check that the green LED located on the upper arm marked power is off. 2. Loosen the (2) black knobs located on the battery lid, rotate the knobs to the side. 3. Holding onto the rear cage assembly tilt it back to expose the battery compartment. 4. Using the strap on the battery pack, lift and place battery pack on the right track. 5. Disconnect connector between the battery pack and robot. 6. Place used batteries on charging station. 7. Reverse steps to install freshly charged batteries.
Step 2-Loosen black knobs. Rotate knobs to the side.

Step 3-Holding onto the rear cage assembly, carefully tilt it back to expose the battery compartment.

Step 4-Lift battery out and place on right track.

Step 5-Disconnect battery connector.

Charging Batteries
The MK2 comes with a charging station complete with (2) 24-volt chargers, (2) battery packs and (1) 6 foot charge cable. The battery packs can both be charged on the charging station or by using the 6 foot charge cable. Charge one battery while it’s still in the robot. On each charger, there is a LED that lets you know if your battery is charging (orange), fully charged (green). Batteries can be left on charge at all times-charger will not overcharge or damage batteries.

Turn robot off before plugging in charger
Note: Always charge batteries after use. Do not store uncharged batteries.

6-foot charge cable Chassis charge cable

Charging both packs

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Battery Station
Parts List 1-P/N VPA-1534,-(2) 24VDC,1.5amp Chargers 2-P/N VPA-15823,-(2) Battery Packs 3-P/N VEA-15907,- 6 foot direct access charge cable 4-P/N VCC-10750,- Base with carrying handle

Section 14.02
2

4

3 1

Item 1-24VDC Chargers
The Battery Station consists of (2) 24VDC chargers that are fastened to the main base. Each charger has its own power cable and battery connector. The chargers can be used on either 110 or 220, suitable anywhere in the world. These battery chargers have an automatic cut-off and true float. These can be connected indefinitely without harming the battery. These chargers have built in protections such as, reverse polarity, short circuit, over-voltage, over current, and AC surge protection. Trouble Shooting-If the light indicator does not come on check that AC power cable is properly fastened to the back of the charger. Connecter Pin out -check that you batteries are getting voltage from the 4 Pin charger connector. Pin 1 (+) Positive 24-27 Volts Pin 2 (+) Positive 24-27 Volts Pin 3 (-) Ground Pin 4 (-)Ground Using pins 1 & 3 or 2 & 4 check with a voltage meter that all line are delivering proper voltage.

Item 2-Battery Packs
Each battery pack contains (2) 12 VDC batteries hooked together in series to give a 24VDC output to the robot. If you are having any difficulty with the battery voltage simply remove the Velcro cover and check that all leads are attached to the battery terminals. Connector Pin out (Cable P/N VEA-15906) -even if your batteries are reading the proper voltage from the terminals always double check the connector pins. Pin 1 (+) Positive 24-27 Volts Pin 2 (+) Positive 24-27 Volts Pin 3 (-) Ground Pin 4 (-) Ground

Item 3-6 foot charge Cable (P/N VEA-15907)
This cable is used to charge a battery while still inside the robot. It runs from the charger connector to the connector located on the back end of the robot. Cable Connector Pin outs Pin 1 (+) Pin 2 (+) Pin 3 (-) Pin 4 (-)

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Replacing Internal Electronics Box
Robot must be turned off and batteries removed. Step 1– open battery lid compartment to see internal connectors. Step 2-Remove all connectors to the electronics box located on the deck and inside the battery compartment, including the connection to the data antenna. Step 3-Remove all screws located on the out edge of the deck plate. Step 4-Remove the screws holding the electronics box to the deck.

Section 14.03

Step 4 Step 3 Step 2

Data Antenna

Step 5– Once all of the screws have been removed, the electronics box will drop through to the bottom of the chassis. Step 6-You can now carefully remove the deck plate from the chassis. Step 7-Remove the remaining connectors in the front of the electronics box. Step 8-Remove the electronics box. Step 7

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Section 15.0

Maintenance Kit
As with any mechanical devices, regular maintenance will have to be done at some point in time. We have chosen a few tools to help maintain or repair the MK2 robot. Some tools are for a specific use; see the list below for more information.

1) 2) 3) 4) 5) 6) 7) 8) 9)

#2 Phillips Screw Driver Allen hex key set 3/16” T-Handle hex 5/64” Ball end hex drive 5/16” Wrench 7/16” Wrench ¾” Wrench RCA cable Laptop Hood

(Main deck screws) (.050, 1/16, 3/32, 7/16, 1/8, 9/64, 5/32) General use (Adding and removing wheel kit) (Laser calibration) (Arm screws) (Arm and rear cage removal) (Track tension) (to hook up VCR or TV to CCU) (hood used to shade laptop in sunlight)

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Contact Office
If you have any queries please contact us.

Allen-Vanguard 5459 Canotek Road Ottawa, Ontario, Canada, K1J 9M3 Tel: +1 613 747-3590 Fax: +1 613 747-0723 TOLL FREE: 1-866-747-3590 email: sales@allen-vanguard.com e-mail: customer.service@allen-vanguard.com

Allen-Vanguard (Canada) 5459 Canotek Road Ottawa Ontario Canada K1J 9M3 Tel: +1 613 747-3590 TOLL FREE: 1-866-747-3590 Fax: +1 613 747-0723 email: sales@allen-vanguard.com

Allen-Vanguard (USA) 11490 Commerce Park Drive, Suite 360, Reston, Virginia, 20191 USA Tel: +1 613 747-3590 TOLL FREE: 1-866-747-3590 Fax: +1 613 747-0723 email: sales@allen-vanguard.com

Allen-Vanguard (UK) Allen House, Alexandra Way Ashchurch Business Centre Tewkesbury, Glos. GL20 8TD UK Tel: +44 (0) 1684 851111 Fax: +44 (0) 1684 851101 email: sales@allen-vanguard.co.uk

AVA-MKTG-022_C.000
www.allen-vanguard.com

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