Congratulations on the purchase of your "OUTLAND 1000" ROV!

Outland Technology takes great pride in supplying this high quality

underwater video system.
Your "Outland 1000" ROV has been rigorously tested. The quality and performance of this system
comes with the full confidence and backing of Outland Technology, Inc.. As a measure of that
confidence, your ROV comes with a Limited one-year warranty that the unit remains free of defects in
workmanship and materials. A complete copy of the warranty statement can be found in the Manual.

Please familiarize yourself with the entire manual and view the Video before placing your ROV into
service.

Owner’s Record
Record the serial number of your ROV and have it available whenever contacting Outland Technology
regarding this product.

Serial Number: ________________

Besides the Paper Manual a CD can be found that contains the following:

1) Acro Reader, (Adobe Acro reader for viewing PDF files)

2) Easysync software, (Contains drivers for the sonar to USB adapter)
3) Photos, (Photos of the complete ROV system).
4) ROV drawings (Contains drawings and a solid works 3d drawing of the ROV)
5) ROV Manual, (Electronic copy of the paper manual)
6) ROV Video, (Complete video on how to hook up and use the ROV) Done originally for the US Army.
7) Sonar Manual
8) Sonar Software, (Sonar drivers and software for using the Sonar)
9) ROV706.pdf and ROV706a.pdf, (Spec/data sheet on the ROV).
 OUTLAND TECHNOLOGY INC.
38190 Commercial Court
Slidell, Louisiana U.S.A. 70458
Ph.(985)847-1104, Fax 1106
Email: sales@outlandtech.com
Website: www.outlandtech.com

ROV MODEL 1000 QUICK NOTES

I. POWER SUPPLY
A) Makes absolutely sure the power connection has a good ground.
B) Connect the Green wire to earth ground for added protection.
C) If using a generator or Inverter it must be at least a 2,000 watt (2kw)
device. The console can be powered with 100-240 VAC, 50/60 Hertz.

II. ROV DEPLOYMENT

A) Be sure to clean and use silicon grease (very lightly) on the Umbilical
connectors.
B) When mating umbilical, hold electronics bottle.
C) Only turn the lights on in the water. Turn off before taking out of the
water.
D) Never activate the Auto Hover or Heading in air.
E) Activate Auto-Heading when you hit the water. This keeps the ROV from
spinning on the way down. (Gyro may take a few minutes to stabilize
completely)
F) Activate Auto-Hover when you are ready to dive.
G) Tapping the up/dwn button in auto-hover will move the ROV in 3 to 4 inch
increments.

III. ROV DISCONNECTING

A) When disconnecting the Umbilical, ROV or Console, disconnect power.
B) Unplug the connectors by holding the body of the connector. Not by
pulling on the wire.

IV. ROV storage and shipping.

A) Clean and flush with fresh water.
B) Remove props clean and dry coupling inside and replace props.
Caution: port stern thruster is reverse pitch (left hand).
C) Dry the cable and ROV before closing the lids on the boxes.
This will minimize mold, mildew and corrosion inside the boxes.
 OUTLAND TECHNOLOGY INC.
38190 Commercial Court
Slidell, Louisiana U.S.A. 70458
Ph.(985)847-1104, Fax 1106
Email: sales@outlandtech.com
Website: www.outlandtech.com

LIMITED WARRANTY

Outland has a strong commitment to high quality production. Each ROV system has a twelve (12) month
limited warranty against defects in workmanship or materials with the exception of those outlined in the
limitations and exclusions. Outland will repair or replace at its discretion the defective components.
Limitations and Exclusions
• The limited warranty does not cover damage caused by improper use, poor maintenance or
accidental damage of the ROV or it's components.
• The limited warranty does not cover items subject to wear including but not limited to view ports, o-
rings, frame, umbilical and propellers unless found to be defective in workmanship and/or materials.

• The limited warranty does not cover any modification made to ROV without authorization from
Outland Technology Inc.
• The limited warranty does not cover lamps.
• The limited warranty does not cover components damaged due to incorrect power connection per
user’s manual.

Advertising claims made by us represent our honest opinion of the qualities and features offered by the products
described. We disclaim any warranties expressed or implied, including warranties of merchantability and fitness
for a particular purpose, except as provided herein. In no event shall Outland Technology be liable for
consequential damages of any kind.

Shipping
All returns for warranty service must be authorized by Outland. You must call or email Outland for a RMA#.
The assigned RMA (Returned Materials Authorization) number which must be clearly indicated on each
item returned for service.

NOTE: To submit a ROV or its components for warranty a RMA form must be completed.
Please complete as best and detailed as possible.

For warranty shipping within the first 30 days, Outland will pay for ground shipment on ROV System
domestic orders incoming and outgoing to a maximum of $75.00 each way. International shipments will be
credited up to $75.00 US for incoming and outgoing freight charges to Outland Technology.

After 30 days the client is solely responsible for shipping to and from Outland Technology Inc.

During the first 30 days of the warranty period, should faster delivery service be requested, a $75.00 US
credit towards expedited freight for each applicable leg will be given.

If you have any questions regarding the installation and operation of this equipment, or if more
information is needed contact:
OUTLAND TECHNOLOGY,INC.,
38190 Commercial Ct.,Slidell, LOUISIANA USA 70458
(985)847-1104 FAX (985)847-1106
(Email) sales@outlandtech.com
(Website) http://www.outlandtech.com

1
 ROV MODEL
“OUTLAND 1000”

JULY,2006

2
 Contents

INTRODUCTION………………………………………………………………………………………..4

I) System startup. …………………………..………………………………...….. 6

II) Power supply controls and connectors………………….…. 7

III) Hand controller ……………. …………………………………………………….…… 8

IV) ROV Video Overlay Programming.……...…..……………….……9

V) Schematics and wiring diagrams ……………………………..…… 14

Appendix A. Thruster manual

3
 INTRODUCTION

The “OUTLAND 1000” ROV system has 4 major components.

1) ROV, 2)Cable, 3)Power supply/Video Overlay, Hand controller.

1) ROV: The ROV has 7 basic components. They are:

a) Cameras
b) Frame
c) Flotation
d) Thrusters
e) Electronics Bottle
f) Compass
g) Lights

a) Cameras, The Primary Camera is what makes the Outland ROV

unique. The camera was actually designed and the ROV was
built around it. There are 2 cameras in the housing. Both
cameras are mounted on a rotating mechanism and can tilt 360
degrees for viewing. A slip ring assembly makes this
possible.
1) B&W camera is a 1/3” CCD, 570 line and .0003 lux
sensitivity. It has a 2.6mm lens and very wide
angle. It was designed for flying and navigating
the ROV into position for serious inspection with
the on board color camera.
2) Color camera is the latest Ex-view CCD chip
available. It is a 1/3” CCD with 480 line of
resolution and .1 lux. Sensitivity with a 3.6mm lens.
b) Frame, The OUTLAND 1000 frame is made of 6061-T6 aluminum.
The frame is bead blasted and protected with anodes. All
attached components are isolated with plastic shoulder
washers. Stainless Steel screws and nylok nuts are used.
c) Flotation, is a closed cell polyurethane Foam with Fiberglass
covering. The foam has been pressure tested to 300 PSI.
d) Thrusters, All four 1/3hp thrusters are designed and
manufactured by Tecnadyne Inc. A special appendix is included
in this Manual covering care and maintenance of these
thrusters. The stern thrusters are counter rotating. The port
side has a left hand pitch propeller.
e) Electronics bottle, Mechanical and schematics are not
included in this manual.
f) Compass, The compass is specially built by Outland and
requires the electronics bottle to condition the signal and
transmit it to the surface computer for overlay on the Video
screen.
g) Lights, These lights are standard off the shelf lights from
Outland. They are the UWL-100 with 75 watt bulb. Mechanical
and electronic drawings are included. (Dwg# 0010487)

4
2) The cable (C-3405) is special built for Outland and contains 1
cat5e cable (4 Twisted Pair 24 awg) and 12 #22awg wires. A drawing
of its connections is included. (Dwg# 0011006)
3) Power supply/video overlay/monitor (PS-1050), The power supply
contains all circuitry to send 165 VDC down to the ROV. Also
included in the console is the Video Overlay board. The console
has all connectors to the hand controller, video monitor,
Keyboard and ac power in. (Dwg# 0201502). Hand Controller (HC-
1000), contains all electronics that condition and control the
ROV and Video Overlay unit. Dwg# 020150?) Keyboard controls the
Video Overlay for time/date, text, graphics, Video ruler and
Diagnostics. Also included is a 12" LCD Color Monitor.

5
System Start up:
Drawing #0011001K shows all the components that make up
the OUTLAND 1000 ROV. The PS-1050 power supply can accept 100-240
VAC 50/60 Hz power (1500) watts. Use a minimum of 1800 to 2000 watt
generator or Inverter. Any outlet used should be fused at 15 to 20
amps. The Ground lug mounted on the console faceplate must be
properly grounded to insure safe operation in the event of a
component failure. The console has a built-in GFCI that will power
down the high voltage in the event of a leak in the cable, connector
or ROV bottle, thrusters or lights.

To power up the system and check all functions please follow these
procedures.

1) Plug the umbilical into the ROV by pushing the 2 connectors

through the pipe located just above the electronics bottle. Route
the connectors to the rear of the ROV and plug the connectors in
using a very light bit of silicon grease and secure using the
locking sleeves.
NOTE: Do not tighten the locking sleeves too much just finger tight.

2) Secure the "Kelleum" grip to the ROV using the "J" clip on the
ROV frame.
3) Plug the topside end of the cable into the Power supply (PS-1050).
4) Plug the Keyboard into the power supply.
5) Plug the Hand controller into the power supply.
6) If connecting a VCR unplug the Coax jumper on the console and
connect the video in and out to the video in and out of the VCR.
This allows playback on the same screen used for viewing. If the
VCR is not used the short jumper must be connected to the BNC
connectors on the console panel.
7) Check the main power source to determine if the power is a stable
Voltage.
8) Make sure the Main power switch on the power supply is off.
9) Plug the power cord into the AC power source.
10) Make sure nothing is obstructing the thrusters.
11) Turn the monitor power switch on.
12) Turn the Main power switch on the Power Supply, ON.
13) In a few seconds a red LED on the hand controller should light
up. This indicates all communications is OK and power is on.
14) Video should appear on the monitor. It will be B&W.
NOTE: When doing the next functions please limit the testing to a
second or 2.
15) Move the J-stick forward to see the 2 stern thrusters turn.
16) Move the J-stick left/right to see the Lateral Thruster turn.
17) Touch "U" or "D" on the keypad to see the Vertical Thruster
move.
18) Touch "Lights Bright" on the keypad and the lights should go up.
Touch "Lights Dim" until they go off.

6
 NOTE: DO NOT LEAVE THE LIGHTS ON WHEN OUT OF THE WATER FOR MORE
THEN 3 SECONDS.
19) Touch "Camera select" and the video picture will switch from
Color to B&W. Touch it again and it will switch back, etc.
20) Touch the "Camera Up" key and the camera will tilt up.
21) Touch the "Camera Down" key and the camera will tilt down.
22) The "Auto-hover" or "A" key is used to put the ROV in Auto-
hover mode. The Hover LED will light when it is active.
23) The "Auto-Head" or "G" key is used to put the ROV into Auto
heading mode. When this key is pressed the ROV will maintain the
heading is was last at. It can only be changed by turning off the
Auto-heading or rotating the Z axis knob located on the end of the
Joy-stick handle. Every time you rotate the ROV the Gyro will
reset to where you let it go. When moving the ROV with
forward/back "X" movement or Left/right "Y" movement the ROV will
maintain the same heading always.
NOTE: DO NOT LEAVE AUTO-HOVER or AUTO-HEADING ON WHILE ON THE
SURFACE. The motors may start and if left unattended they could
burn up the water bearings on the propeller.
24) The "Power Level" "P" key turns the power level to the thrusters
to 50% gain.
25) The numbers 1,2 on the keypad are for future Options.
26) Test the GFIC by pushing the test switch to line 1 of the high
voltage. Reset the GFCI and test the 2nd line of the high voltage.
Reset the GFCI and the system is ready to operate.

POWER SUPPLY, PS-1050

7
 HAND CONTROLLER, HC-1000

PWR COMM
GOOD GOOD

ROV LIGHTS HOVER AUTO

UP BRIGHT ON/OFF HEADING
AUTO AUTO 50%
HOVER HEADING POWER

ROV LIGHTS THRUST

DOWN DIM SELECT

FORWARD

CAMERA MANIP CAMERA

UP OPEN SELECT
RIGHT
LEFT

CAMERA MANIP
DOWN CLOSE

REVERSE

"PWR Good" = DC power to Hand controller is OK.

"Comm Good" = Transmit and Receive from ROV is OK.
"Auto Hover" = Indicates when auto hover is on or off.
"Auto Heading" = Indicates when auto heading is on or off.
"50% Thrust" = Indicates when thruster power level is at 50%.

8
ROV Video Overlay programming.

Outland's Video Overlay system monitors the Data Communications line

to and from the ROV and pulls data from the ROV and displays it on
the Video picture. The Overlay is fully programmable from the
Keyboard. This is what the main menu looks like:

(KEY) (FUNCTION)
E EDIT PAGE (N)
C CLEAR PAGE (N)
G EDIT TITLE LINE
T TIME (ON/OFF)
D DATE (ON/OFF)
S SET TIME
R RESET SYSTEM
P COMPASS/SCALE/CROSS HAIR
I SET VIDEO INTENSITY
O SET HORIZ SCALE GAIN
F SET DEPTH GAIN/OFFSET
M SET COMPASS CONSTANTS
Q ENABLE DIAGNOSTIC DATA

After power up the video screen goes to the default run screen and
Page "0". To see the above menu touch the "H" key. To change to
another text page just hit the number key 1-9.

1) E; Go to the Page you want to edit by touching the number key.

Touch the letter “E”. This will bring you into the edit
mode and you should see a Blinking cursor at the top left
corner of the screen. Type in anywhere on the screen and when
you finish hit the “ESC” key. The text will store in memory
and the cursor will disappear.

2) C; Go to the page you want to clear and hit the letter C. The

9
 following will appear:
ARE YOU SURE YOU WANT TO
CLEAR PAGE 0 ? (Y/N)

This will clear the page of all characters except the

time and date. Select yes or no.

3) G; To add a text line of information such as your company name

just hit the G key and type your company name followed by the
enter key and you name will appear over the time and date.

4) T; Hitting this key will turn the time either on or off.

5) D; Hitting this key will turn the date either on or off.

4) S; Hitting this key will allow you to set the time and date. The
following will appear:
( 12,51,5,21,99)
ENTER HR,MIN,MONTH,DAY,YEAR
Input the time and date as shown with comas between each item.

7) R; Hitting this key will clear all pages. The

following will appear:

ARE YOU SURE YOU WANT TO

CLEAR ALL MEMORY ? (Y/N)

Select yes or no. The time and date will remain on screen.

8) P; Hitting this key once will cause the compass to appear on

the screen.
P; Hitting this key again will cause the Video Ruler to appear
on the bottom of the screen. The Video typewriter time date
features will continue to operate. The active keys to use
this feature are:
“O”, sets scale factor. 1=1, 2=2, 3=3, etc. for every
tic mark. Minus for tic marks to the left and +
for each tic mark to the right. The digital
display below and to the left of the scale is
where on the Ruler the cursor marker is in
relation to the center of the scale.
“Left Arrow” Key moves the cursor to the left on the
ruler.
“Right Arrow” Key moves the cursor to the right on the
ruler. The digital display moves up and down as
these arrow keys are used.
“Home” Key moves the ruler tic marks wider.
“End” Key moves the ruler tic marks closer.
“Page Down” moves the center (offset) of the ruler Left.
“Page Up” moves the center (offset) of the ruler Right.

10
 To use this feature set the scale factor for the required
measurement. Move the center (offset) of the ruler to the
center of the item to be measured. A reference must be
used to accurately measure with the Video Ruler. If Laser
dots are use then scale the ruler to those dots. Once the
ruler is scaled using the “end” and “Home” Keys, use the
arrow key to show the measurement.

P; Hit this key again and a Crosshair will appear on Screen.

Use the cursor keys to move the crosshair (Video
Pointer) around the screen. In this mode the Scale and
compass will disappear. The time and date will remain
on Screen and all page functions will work also.

9) I; Hitting this key will bring up the following:

SET INTENSITY LEVEL

0 MIN, 15 MAX >

Default is 3. If you enter 0 then the characters will

turn black. If 14 or 15 are entered then the character
will probably be a little too bright. Play around with
this and set for best display.

10) O; Hitting this key will bring up a question asking for

the Video ruler Scale factor.

Example 1= 1 per tic mark.

11) F; Hitting this key will allow the user to set the pressure
transducer gain and select fresh or salt water use.
The following will appear:
DO YOU WANT TO SET ZERO DEPTH? Y/N
"Y" will Zero the depth and go back to the run screen.
"N" will bring up the following text:
DO YOU WANT TO CHANGE
PRESSURE TRANSDUCER SCALING? Y/N
"N" will go back to the run screen.
"Y" will bring up the following text:
INPUT PSI AT 5 VOLTS <250>
Key in the PSI. The above 250 is the current setting.
250
The following will appear:
FRESH WATER OR SALT WATER? F/S
Touch either key will cause the unit to scale the transducer
to scale the readout for fresh or salt water.
The following will then appear:

DISPLAY IN METERS? Y/N

Selecting "Y" will go back to the run screen and display

11
 Depth in meters
Selecting "N" will go back to the run screen and display
Depth In feet.

12) M; Hit this key and the following questions will be asked.
DO YOU WANT TO CHANGE
COMPASS SETTINGS? Y/N

Selecting "N" will bring you back to run.

Selecting "Y" will bring up the following question:
DO YOU WANT TO RESET
THE TURNS COUNTER?
Y/N
Selecting "Y" will zero the turns counter on the screen and
bring you back to the run screen.
Selecting "N" will bring up the following question:
DO YOU WANT TO SET THE COMPASS
TO ZERO? Y/N
CAUTION: WHEN SETTING THE COMPASS TO ZERO THE ROV MUST BE CLEAR OF
ALL METAL AND BE POINTING TO NORTH.
Selecting "Y" will zero the Compass to the direction the
ROV is pointing at and will return to the Run screen.
Selecting "N" will bring up the following question:
DO YOU WANT TO SET COMPASS GAIN? Y/N
Selecting "N" will return to the run screen.
Selecting "Y" will bring up the following question:
INPUT COMPASS MIN,MAX VOLTAGE
EXAMPLE <.5>,<4.5>
The standard Outland Compass settings are ".5,4.5"
Hit return and the run screen will appear.

13) Q; Enable Diagnostic Data,

Actual Screen

HA1,2 &3 are Hand controller voltages and should read:

12
 HA1 = Forward/Reverse command
Full Forward 5.00 VDC
Full Reverse 0.00 VDC

HA2 = Turn Command

Starboard 5.00 VDC
Port 0.00 VDC

HA3 = Lateral Command

Starboard 5.00 VDC
Port 0.00 VDC

HX1 & HX2 spare channels, Not used at present.

HID = Hand Controller, firmware release number.

HS1 is not used

HS2 = Keypad toggle status

HS3 = Keypad status

DPH = Depth transducer voltage

PHA = Compass Phase A Voltage
PHB = Compass Phase B Voltage

VX1, VX2 & VX3, spare channels, not presently used.

VID = Vehicle firmware release number.

VS1 = Vehicle status. Everything the vehicle transmits and

receives is shown at this location. The data is very
complex but suffice to say this data will constantly be
changing. If it is not then check the status of the
hand controller. If the hand controller is OK and the
"Comm Good" LED on the Hand controller is lite then
check to see if the ROV is responding properly. If it
is then the Video Overlay may have a problem.

Touch any key and the unit will go back to the run screen and wait
for your command.

13
14
15
16
17
MCIL8M to Bottle
1 2
14
1 8

MCIL8F 2
6 7

RED

RED
OR OR

14 8 YEL YEL
BLU BLU

6 1
GRN GRN
7 BRN BRN

MCIL8F

OPTIONAL 3RD CAMERA

3
RED RED

YEL YEL

GRN GRN
BRN BRN

18
19
20
21
22
23
 OUTLAND TECHNOLOGY INC.
UWL-100 UNDERWATER LIGHT
Operating and Maintenance Procedures

Reference: DRAWING 0010487

Installation and Operation:

(CAUTION: WHEN OPERATING THIS LIGHT, WITH 115 VAC, A ISOLATION TRANSFORMER
OR GROUND FAULT INTERRUPTER IS REQUIRED).

A. The UWL-100, can be mounted to your Camera, ROV, Helmet or Hand

bracket by using DH-50 OR HM-300 helmet bracket.
B. With Power Off, lubricate the light mating connector with a light
coating of silicon lubricant. Slide the locking sleeve of the mating
connector back. Align the raised dot on the connector with the large
connector pin on the light connector and plug in. Securely tighten the
locking sleeve. (Do not over tighten.)
C. Do not Operate the Light in air for more then 5-10 seconds.

Bulb Replacement Procedure:

A. Prepare a clean dry area for disassembly and assembly.
B. Make certain power to the light has been turned off.
C. Unscrew the locking sleeve and remove the mating connector from
the light. Securely grasp the mating connector as close to the
light as you can and unplug from the light by holding onto the
light as you pull.
D. Remove the connector from the light by unscrewing it from the
base. Use a crescent wrench or channel locks (on the flats of
the connector), being careful not to damage the sealing
surfaces of the connector.
E. Remove the bulb by grasping it near the base and unscrewing it.
F. Clean and inspect the connector "O"-Ring. Replace the "O"-Ring
if it appears damaged in any way.
G. Put a light coat of silicon on the "O"-Ring, and the sealing
surfaces which contact the "O"-Ring and place it back on the
connector.
H. Unwrap the replacement bulb being extremely careful not to
touch the quartz envelope. If it is accidentally touched, clean
the bulb thoroughly using alcohol and a soft tissue before
installing.
I. Screw-in the new bulb and replace the connector. Tighten snug.
CAUTION: DO NOT OVER-TIGHTEN.

Dome Replacement Procedure:

A. Unplug the light from the cable.
B. Remove the bracket if attached and any other 1/4"-20 bolt holding the
reflector.
C. Slide the reflector off the housing.
D. Remove the 2 ea. 10-24 screws from the side of the body. The light
should come apart.
E. Clean the entire assembly and install the "O" rings.
F. Reassemble the housing as shown in the drawing. The locking ring must
be compressed to be able to install the 10-24 screws. A short piece of
1.5" PVC pipe can be used and clamped in a vise to compress the
assembly. You must be very careful not to over compress the assembly
as the globe may break.
G. Reinstall the reflector and brackets as you disassembled them.

24
 J16
RCA
U5 R9 JACK
U2 (RED) +9V J4-8 J4-2 RELAY SW (BLUE) VIDEO OUT Video Out 1
12 1 (BLACK) +12V RTN J4-5 12V OC OUT
COMM+ CAM VIDEO
13 COMM+ VIN 2 GND
COMM- CAM VIDEO SH 51
COMM- GND J4-4 (YELLOW)
COMM+ VIDEO OUT SH
1 (BLACK) +12V RTN J5-7 COMM+ J4-6 (ORANGE)
VIDEO OUT COMM-
J2 1 VOUT 2 ANALOG GND COMM- J17
KCLK VIDEO OUT SH
2 KCLK GND (WHITE) RTAP J5-2 J4-1 (YELLOW) RCA
KDTA RCV
1 5 KDTA IN4 SIN J4-3 (ORANGE) R10 JACK
+5V XMIT
2 4 +5V 1 SOUT Video Out 2
GND SW +12V PS CONTROLLER VIDEO OUT
3 GND +V 2 +12V RTN 0202252
4 GND
5 VIDEO OVERLAY #0010460 51
VIDEO OUT SH
6
MODEL 5100
6 PIN MINI DIN
IBM KEYBOARD

J1
U1 J12
(CAT 5 SYSTEM)
1 NJM78M09 +12V RTN SONAR SHIELD 5
+9V
2 SW +12V 1 2 +9V SPARE+ 9
+12V RTN VIN VOUT
3 VIDEO+ CAM VIDEO 4
4 VIDEO BALUN D SUB FEMALE
COMM+ SPARE- 8

GND
5 VIDEO- CAM VIDEO SH 3 TOP
COMM-
6 C1 7 SONAR CONNECTOR
7 SONAR+ 2
8 10uF 25V
3 6
9 SONAR- 1
AMP #211769-1
HAND CONTROLLER +12V RTN
J13
+12V RTN 5
9
4
8
D SUB FEMALE BOTTOM
RCV 3
PS1 SW +12V
RTAP RTAP 7 RS232 COMM
LINE 1 9 +12V 0202255 XMIT 2
L V+ POWER SUPPLY FILTER V- 6
+12V RTN
NEUTRAL 2 R11 D1 1
N 5KP30A HV ON
1K LED
3
CHASSIS 7 +12V RTN
V- HV CABLE FAULT TEST (CAT 5 SYSTEM)
MEANWELL #RS25-12 D2 S2 J14
LED VIDEO-
V+ 1 2 8
SW +12V VIDEO+
2
SPARE+
3
ROV LV 1
COMM+ 3 7
4
COMM- #MCBH8F
5 4 6
SONAR+
6 5
SONAR-
7
PB #T92P11D22-12 SPARE-
8
LINE PS2
SWL 1 4 HV+ ROV+
L V- 5 -HV
NEUTRAL PB #T92P11D22-12
2 -S 6
SWN
3 N -S1 D3
SW +12V ROV+ J15
CHASSIS
RELAY SW HV- ROV-
1.5KE62A

1
PS1
V+
7 ROV-
2
ROV HV 1 3
8 #MCBH3F
+S 9 SW +12V 3
+S1
RELAY SW 2
MEANWELL #SP-480-48
PS3
SWL 1 4
L V- 5
2 -S 6 J10 J11 J11
SWN
3 N -S1 D4 NEUTRAL
CHASSIS
CHASSIS
1.5KE62A

PS2 7 LINE
V+ 8
+S 9
+S1 PLUG AC MALE AC POWER JACK AC POWER JACK
MEANWELL #SP-480-48 NOTES:
PS4 OUTLAND TECHNOLOGY
SWL 1
L V-
4 1. ADJUST POWER SUPPLIES SP2,SP3 AND SP4 FOR 55 VOLTS ON OUTPUT.
5 38190 Comercial Court
1.5KE62A

-S
SWN 2
N -S1
6 2. ABOVE THE LINE ARE LV (LOW VOLTAGE) CIRCUITS BELOW THE Slidell, LA 70458
3 D5 985 847 1104
CHASSIS LINE ARE HV (HIGH VOLTAGE) CIRCUITS
PS3 7 Title
V+
+S
8 +HV 3. USE 18AWG WIRE FOR HV WIRING PS-1050 ROV Power Supply
9
+S1
4. USE 22AWG WIRE FOR LV WIRING Size Document Number Rev
MEANWELL #SP-480-48 B 0203310 B

Date: Tuesday, August 15, 2006 Sheet 1 of 1

 MODEL 300 THRUSTER
FIELD AND DEPOT LEVEL
MAINTENANCE MANUAL

TECNADYNE INC.
PO Box 676086
14627 Calle Diegueno
Rancho Santa Fe, CA 92067
Voice 858.756.9660
Fax 858.756.9660
Email tecsales@tecnadyne.com
November 2002
 WARNING
DO NOT OPERATE MODEL 300 THRUSTER OUT OF
WATER AT HIGH SPEEDS OR FOR EXTENDED
PERIODS OF TIME. THE WATER LUBRICATED
PROPELLER BEARINGS & THE WATER COOLED
MOTOR/ELECTRONICS ASSEMBLY WILL OVERHEAT IF
NOT SUBMERGED IN WATER.
 WARNING
PROPELLERS MUST BE REMOVED AND FLUSHED
WITH FRESH WATER AFTER EACH USE TO PREVENT
CORROSION.
 Model 300 Thruster
CONNECTOR PIN ASSIGNMENTS

SeaCon
MCBH5M PIN
PIN NO. ASSIGNMENT

1 Instrumentation / Signal Ground

2 Motor Power Ground
3 +140-165vdc, 3-3.5A Power
4 ±5V, 5 mA Speed Command Signal
5 +12 V, 200 mA Instrumentation Power

1
5 2

4 3

SeaCon MCBH5M
Face View

NOTE: Power line conditioning must be provided in close proximity to

thruster motors (330µF, 250v low ESR per thruster is prefered).
NOTE: Power line overvoltage protection must be provided (185v-200v
MOV is prefered).
NOTE: Motor Power Ground and Instrumentation / Signal Ground must be isolated to prevent
ground loops.
NOTE: Motor must be protected with a Fast Blo fuse of no greater than 5A.
NOTE: Voltage ripple not to exceed +/-15v.
 MODEL 300 THRUSTER FIELD & DEPOT REPAIR PROCEDURES
(Please reference drawing 286-999 & associated parts list)

1 Propeller Assembly (P/N 286-851)

1.1 General
The Propeller Assembly includes the Propeller (Item 4) with its integral magnetic
coupling which enables the magnetically coupled drive through the Membrane
Assembly (Item 7), the Propeller Hub (Item 6) and the Sleeve Bearing (Item 22). The
Propeller Assembly is a field level replacement item.

1.2 Indications for Replacement

a. Replace if significant wear or damage is apparent on the blades of the Propeller
(Item 4).
b. Replace if the Propeller Assembly cannot be rotated freely by hand when the
thruster is unpowered and if interference is detected between the inner surface of
the Propeller and the Membrane Assembly. This indicates damage to the inner
surface of the Magnet Shield (Item 14).

1.3 Removal Procedures

a. Remove Propeller Screw (Item 23) using 1/8in Allen key.
b. The Propeller Washer (Item 25) and (2) Hub Wave Washers (Item 24) will come
off with the Propeller Screw.
c. Remove Propeller Assembly by pulling from exhaust end of Nozzle (Item 15).
WARNING
Due to the magnetic coupling used in the MODEL 300,
considerable force (approx. 5-10 Ibs) will be required
to remove the Propeller Assembly from the Nozzle
Assembly. Exercise caution to avoid injury from the
propeller blades, which can have sharp edges.

1.4 Installation Procedures

a. It is not necessary to lubricate the Propeller Bearing (Item 8) and Sleeve
Bearing (Item 22) as they rely on sea water for lubrication.
b. Insert the new Propeller Assembly into the open end of the Nozzle.
c. If the blades of the new Propeller Assembly interfere with the inside diameter of
the Nozzle (Item 15) use a file or coarse sandpaper to remove material at the ends
of the blades. Remove sufficient material so that the Propeller Assembly rotates
without interference, but try to keep tip clearance less than 0.04 in. (1 mm).
d. Install the (2) Hub Wave Washers (Item 24) and then the Propeller Washer
(Item 25) onto the Propeller Screw (Item 23).
 e. Using the 1/8in Alien key, install the Propeller Screw into the Sleeve Bearing
(Item 22) and thread into the Membrane (Item 7). Tighten to approximately 50 in-
lbs (6 Newton meters) of torque.

2 Sleeve Bearing (Item 22. P/N 66-808)

2.1 General
The Model 300 has a Sleeve Bearing (Item 22) which is mounted into the outer end of
the Propeller Hub (Item 6) and which rotates upon the shaft end of the Propeller Screw
(Item 23). This bearing is sea-water lubricated and can be imbedded with abrasive
particles, especially when the thruster is operated in or around silt or sand. The Sleeve
Bearing is a field level replacement item.

2.2 Indications for Replacement

a. Inspect after thruster has been operated in extremely abrasive water.
b. Replace if any scoring detected on the bearing shaft of the Propeller Screw
(Item 23).
c. Replace if wear in Sleeve Bearing causes inside diameter to exceed 0.260 in
(6.6 mm).

2.3 Removal Procedures

a. Remove the Propeller Assembly per Section 1.3, above.
b. Use a long screw driver (or similar tool) to press the Sleeve Bearing from the
Propeller Hub.

2.4 Installation Procedures

a. Press new Sleeve Bearing (Item 22) into the outboard end of the Propeller Hub
(Item 6) portion of the Propeller Assembly. Light finger pressure will be required to
seat the bearing firmly in the bore.
b. Reinstall the Propeller Assembly per Section 1.4, above.

3 Propeller Bearing (Item 8. P/N 286-111)

3.1 General
The Propeller Bearing (Item 8) is made from a green plastic material and is used to
stabilize the Propeller Assembly over the Membrane (Item 7). The Propeller Bearing is
a field level replacement item.

3.2 Indications for Replacement

a. Replace if excessive radial play between the Propeller Bearing and the
Propeller Assembly exceeds 0.015 in. (0.4 mm).
3.3 Removal Procedures
a. Remove the Propeller Assembly per Section 1.3, above.
b. Remove the Propeller Bearing by sliding from the Membrane Assembly by
hand. Take care not to loose the Propeller Wave Spring (Item 27) which is
underneath the Propeller Bearing.

3.4 Installation Procedures

a. Make sure that the Propeller Wave Spring (Item 27) is nested in the groove on
the back of the Propeller Bearing (Item 8).
b. Slide the Propeller Bearing over the Membrane.
c. Reinstall the Propeller Assembly per Section 1.4, above.

4 Propeller (Item 21. P/N 286-141)

4.1 General
The Propeller (Item 4) is a cast stainless steel part and can become damaged,
particularly when operated in abrasive environments. The Propeller is a field level
replacement part.

4.2 Indications for Replacement

a. Replace if excessive wear or breakage detected on Propeller blades.

4.3 Removal Procedures

a. Remove Propeller Assembly per Section 1.3, above.
b. Using a hammer and small block of wood or plastic, drive the Propeller Hub
(Item 6) from the Propeller.

4.4 Installation Procedures

a. Using or a hammer and block of wood or plastic, drive the Propeller Hub (Item
6) over the end of the new Propeller. Make sure that the Propeller Hub is installed
to the end of the Propeller with the longer extension.
c. Reinstall the Propeller Assembly per Section 1.4, above.

5 Nozzle (ltem 15. P/N 286-119)

5.1 General
The Nozzle (Item 15) can be damaged in the field when installed on the outer
perimeter of the ROV. It is fabricated from a cast Nylon material which, for the most
part, is highly impact resistant. The Nozzle is a field level replacement item.

5.2 Indications for Replacement

a. Replace the Nozzle if broken or damaged to the point that it fouls the propeller.
5.3 Removal Procedures
a. Remove the Propeller Assembly per Section 1.3, above.
b. Remove the Nozzle by removing the (3) Nozzle Screws (Item 39) using a
7/64in. Alien key.

5.4 Installation Procedures

a. Place the new Nozzle onto the Gearbox Housing (Item 3), taking care to align
the (3) Nozzle Screws (Item 39) and the (3) Nozzle Struts (Item 16) with the
matching holes in the Gearbox Housing.
b. Reinstall the Propeller Assembly per Section 1.4, above.
 Item Qty P/N Type Title Detail Vendor Vend-P/N
Top Assy 286-999 CAT Model 300 Thruster, 150vdc. Outland Config
1 286-811 PL Connector Endbell Assy, Model 300, Outland Config
1 286-821 PL Motor Housing Assy, Model 300, 150vdc
1 286-831 PL Gearbox Assy, Model 300
1 286-841 PL Membrane Assy, Model 300
1 286-851 PL Propeller Assy, Model 300
1 286-861 PL Nozzle Assy, Model 300
1 1 286-105 DWG End Bell, Model 300
2 1 286-103 DWG Motor Housing, Model 300
3 1 286-101 DWG Gearbox Housing, Model 300
4 1 286-125 PS Propeller, RH, Model 300
5 1 286-107 DWG Drive Hub, Model 300
6 1 286-129 PS Propeller Hub, Model 300
7 1 286-109 DWG Membrane, Model 300
8 1 286-111 DWG Prop. Bearing, Model 300
9 1 190-133 DWG Ring Gear Allied Devices 190-133
10 1 286-113 DWG Bearing Carrier, Model 300
11 1 190-129 DWG Pinion Shaft, Model 250 Allied Devices
12 3 190-131 DWG Planet Gear, Model 250 Allied Devices
13 1 190-117 DWG Planet Carrier, Model 250 Atlas Precision
14 1 286-123 PS Magnet Shield, Model 300 Tecnadyne
15 1 286-119 PS Nozzle, Model 300 Tecnadyne
16 3 286-121 PS Nozzle Strut, Model 300 Tecnadyne
17 1 286-801 PL Elex Assy, Model 300
18 1 190-203 DWG Brushless Motor, 150vdc, D Winding RBE-00712-D00 Inland Motor, Kollmorgen Corp. RBE-00712-D00
19 1 286-591 PS Connector, Model 300, Outland Config Impulse MCBH5MP
20 10 54-403-3 DWG Magnet, Coupling, .125 Thick, .250 Wide Pacific Century Enterprises
21 10 54-403-2 DWG Magnet, Coupling, .093 Thick, .238 Wide Pacific Century Enterprises
22 1 66-808 PS Sleeve Bearing DRF-0406-4 Furon-Dixon Industries DRF-0406-4
23 1 190-505 PS Propeller Screw, Model 250 1/4 x 0.63L, 10-32 Shoulder Screw, SS McMaster Carr 94035A539
24 1 286-509 PS Wave Washer, Hub, Model 300 Allied Devices DD61
25 1 190-515 PS Propeller Washer, Model 250 1/4 AN, SS McMaster Carr 98017A660
26 3 286-505 PS Screw, Membrane, Model 300 4-40 x 0.18L, Flt Hd Ph, SS McMaster Carr 91771A111
27 1 286-531 PS Wave Spring, Propeller, Model 300
28 6 286-503 PS Set Screw, Housing, Model 300 McMaster Carr 90291A103
29 1 54-824 PS Nut, Penetrator 7/16-20 Jam Nut,SS McMaster Carr 91847A515
30 3 190-146 PS Motor Bearing, Model 250 DDRI-814ZZ-LG20 National Precision DDRI-814ZZ-LG20
31 2 190-518 PS Motor Shim, M250 .005 thick DB3D2 Allied Devices DB3D2
32 1 190-146 PS Motor Bearing, Model 250 DDRI-814Z-LG20 National Precision DDRI-814ZZ-LG20
33 2 190-509 PS Drive Hub Set Screw, Model 250 #4-40 x .25, Sockt Set Screw McMaster Carr 91375A106
34 2 286-511 PS O-ring, Housing, Model 300 2-028, Buna N, 60D McMaster Carr 9452K115
35 2 286-515 PS O-ring, Magnet Shield, Model 300 2-023, Bun N, 60D McMaster Carr 9452K77
36 1 286-513 PS O-ring, Membrane, Model 300 2-019, Buna N, 60D McMaster Carr 9452K73
37 1 190-519 PS Carrier Spacer, Model 250 DB8D12 Allied Devices DB8D12
38 3 190-531 PS Planet Gear Bearing, Model 250 JP-23-FV National Precision JP-23-FV
39 3 286-501 PS Nozzle Screw, Model 300 #6-32 x1.5L,Sockt Hd Cap,SS McMaster Carr 92196A157
40 3 190-521 PS Planet Pin M250 D27D375 Allied Devices D27D375
 CN1
1

A1 A2 A3 140VDC BUS
+12 HP3100 +12 HP3100 +12 HP3100
1 7 1 7 1 7 C3

8
1.0MFD 250V
6 6 6
R5 R6 R7
2 100 1% 2 100 1% 2
5 5 5 100 1%

PS1A R12 PS2A R13 PS3A

+12 +12 +12
+12 Q1 1.0K 1% +12 Q2 1.0K 1% +12 Q3
R11 VCC VCC VCC IRGBC30UD2
IRGBC30UD2 IRGBC30UD2
1.0K 1% G G G
CN2
GND GND GND
-12 -12 -12
1
HPR110 HPR110 HPR110
CN3
1

CN4
CN7
1
5
4
3
2
1
HEADER 5 Q4 Q5 Q6
R2 R3 R4
IRGBC30UD2 IRGBC30UD2 IRGBC30UD2
CN6 100 1% 100 1% 100 1%
5
4
3
2
1
HEADER 5
+12

R9 R8
4.7K 1% 4.7K 1%

C2
R10 470PFD 50V
4.7K 1% R1
.025 3W 1% CN5
1
POWER GROUND

Model 300 Power PWA

 6 5 4 3 2 1

C6 1uf

C7 U1 C1
1
+ R14 1
+12 INPUT
3 C5 18nf 16v
J7 10uf PUMPOUT .01uf
47.5k 1% 2
CHARGECAP
4 7
EOUT BIAS
R15 10k
5 6
TACH RIPPLE < 25mv COUT VCC
8
GND

TACH 1 LM2917-8
J2
R16
U2A

8
R2 J3
-10 < Vin(max) < +10 470
3 1

V+
+
D1 C2 2
-5 < Vin(nom) < +5 10k R17 100k
1 3
OUT
R6 4
LL4148 .1uf
CONT 1 2 5
- Q1

V-
C

C10
J4 15k LM358/NS
C3

4
C11 .1uf MPS3904 1nf
Q3 .1uf
R13 C8
Q4
MPS3904

17

18
15k 1nf
MPS3904 U3
C9

VCC

VC
4 D3 R8
1nf SA
5 14
U2B SB FAULT

8
R12 6
SC
J1
LM358/NS 1k
5 LED 1

V+
+ R4 47k
2 2
4.7k DIRECTION AT
7 3 3
OUT F/R
R10 CONTROL 22
60/120 BT
1 4
6 7 5
- OE

V-
R38 24
5.6k CT
R3 15k

4
LL4148 75k
8
REFOUT
R11
21
D8 AB
11 J6
B
4.7k EA_N
D2 12 20 1
EA_I BB
2
R1 13 19 3
LL4148 EA_O CB
4
6.8k
R9 5
10 9
OSC CUR_SNS
R7 15
CS_REF 4.7k
10k
BRAKE 23
Q2 BRAKE

GND
R5
C14 .01uf C4
MPS3904 MC33035DW
15k 1nf

16
GND 1

J5

Model 300 Signal PWA

A

6 5 4 3 2 1
MODEL 300 THRUSTER RECOMMENDED TOOLS
0.050 in. Alien key
7/64 in. Alien key
1/8 in. Alien key
Silicone grease (Dow Corning DC-4 or equivalent)
Anti-seize thread compound (Loctite 767 or equivalent)