Service Bulletins, Volume 2

Transcription

1 Service Bulletins, Volume 2 For Manipulator Systems, Slave Arms, & Accessories Bulletins (September 2005) through the present DOCUMENT NO

2 Copyright 2009 by Schilling Robotics, LLC. All rights reserved. Schilling Robotics, the Schilling Robotics logo, and their frameworks are trademarks and service trademark applications of Schilling Robotics. No part of this document may be reproduced or used in any form without the express written permission of Schilling Robotics. Descriptions and specifications are subject to change without notice. We invite your comments about our products and technical manuals. Please contact: Schilling Robotics, LLC 260 Cousteau Place, Ste 200, Davis, CA Ph: (530) Fax: (530) Web Site: TECHNICAL MANUAL REVISION LOG PRODUCT: Manipulator Systems, Slave Arms, and Accessories TECHNICAL MANUAL: Service Bulletins, Volume 2, Description Date Rev. Manual release January 2009 Ø Manual update (bulletins added December PAGE BREAK Service Bulletin Page ii

3 ISSUE DATE September 8, 2005 Service Bulletin Upgrading Titan Master & Slave Controller EPROMs Compliance: Recommended* AFFECTED PRODUCTS Titan 2, 3, and 4 Manipulator Systems AFFECTED COMPONENTS Master controller and slave controller EPROMs SERVICE INFORMATION If you operate any combination of standard Titan 2, Titan 3 and Titan 4 manipulator systems, upgrading the EPROMs in all Titan master controllers and Titan 2 and 3 slave controllers is recommended. With the newest EPROMS installed, any Titan master controller can operate any standard Titan 2, 3, and 4 manipulator systems without error messages or the need to overwrite existing software and settings. The operator sees only the normal startup, operation, and configuration screens, and, existing settings for joint travel limits, stow sequence, error checks, and servo valve offsets are retained.! Caution Never connect a T3 slave arm to a T2 slave controller. The voltage difference (24VDC versus 120/240 VAC) will cause damage to slave arm components. FIELD ACTION 1. Inspect all master controller EPROMs and Titan 2 and 3 slave controller EPROMS. 2. Install master controller EPROM , Rev D if not present. 3. (Titan 2 and 3 only) Install slave controller EPROM , Rev C (introduced mid-1999) if not present. NOTE: No EPROM change is necessary for Titan 4 in-arm slave controllers. REQUIRED RECOMMENDED OPTIONAL *BULLETIN COMPLIANCE LEVELS Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

4 Service Bulletin Other Features of Master Controller EPROM , Rev D The new EPROM also provides clear options when it is installed in a master controller with incompatible software (previously used with an incompatible system) or it is used to control an incompatible system. If the master controller was previously used to operate a non-standard/custom Titan system, the new software will detect an incompatibility with the software code on the master controller CPU board EEPROM and display the alert screen below. You then have two options. 1. If you want to implement operation, press the 4> Yes key to overwrite the EEPROM with software appropriate for the Titan slave arm that is detected ( T4 in the sample screen at right) and proceed with normal startup and operation of the Titan slave arm. Overwriting installs factory default settings. Joint travel limits, stow sequence, error checks, and servo valve offsets must be reset as necessary. SCHILLING ROBOTICS, LLC TITAN MANIPULATOR SYSTEM The ID Code indicates that this Master Controller may have been configured for a non-titan manipulator. Select [Yes] only if you would like to change ID Code to T4 and to overwrite saved values for joint limits and stow. 4> Yes If you don t want to lose existing joint travel limits, stow sequences, error checks, and servo valve offsets, replace the original EPROM and install the new EPROM in a different master controller where it is OK to overwrite existing values. When the master controller is connected to an incompatible Titan slave controller/slave arm, such as a Titan 7F or a non-standard/custom Titan, you will see the alert screen below. You then have two options. 1. Recommended option: Do not use the master controller. Connect a compatible model instead. 2. Use the 4> Yes option only if emergency operation is absolutely necessary as the slave arm may display uncontrolled or inconsistent operation. SCHILLING ROBOTICS, LLC TITAN MANIPULATOR SYSTEM The Master Controller software is not compatible with the slave arm. Further operation may risk damage to equipment. Select [Yes] only if you would like to proceed anyway. 4> Yes Non-Titan Systems A Titan master controller/eprom cannot communicate with a NON-TITAN slave arm and, if connected, will display a Fatal Telemetry Error screen at startup. Service Bulletin Page 2

5 Service Bulletin New Potentiometer Expands Master Controller Display Adjustability Compliance: OPTIONAL* ISSUE DATE September 2, 2005 AFFECTED PRODUCT(S) Titan 3, Titan 4, Conan P, and Orion P Manipulator Systems AFFECTED COMPONENT Newer Master Controllers with a blue gray LCD. Older master controllers with a greenish yellow LCD are NOT affected by this bulletin. SERVICE ISSUE Newer Titan 3, Titan 4, Conan P and Orion P master controllers (with the blue-gray LCD) have automatic and manual adjustments for keeping the viewing angle consistent under varying temperature conditions. However, the range of temperature in some environments may be greater than the range of adjustability. This condition can be corrected with a new adjustment potentiometer ( ) that extends the adjustment range to approximately 0 to 100 F (-18 c to +40 c). Field replacement of the potentiometer (Figure 1, arrow) requires PCB-level soldering and mechanical skills. Figure 1 Display adjustment potentiometer on the display transition PCB Potentiometer is available upon request at no charge for field installation and will be installed at no charge on master controllers returned to the factory for other service. REQUIRED *BULLETIN COMPLIANCE LEVELS Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

6 Service Bulletin FIELD ACTION To replace the adjustable potentiometer: 1. Confirm the master controller has a blue gray display, with raised black bars to the left and right sides of the LCD (see Figure 2). Do not continue if the display has no bars or is greenish yellow. BARS Figure 2 Blue/gray display with bars 2. Open the master controller and remove the display transition PCB from the master controller (see the master controller drawing in your manipulator technical manual for hardware details). 3. Remove the existing adjustable potentiometer. 4. Install the new adjustable potentiometer ( ). 5. If necessary, adjust the viewing angle of the display as directed in the Maintenance and Service chapter of your manipulator technical manual. Service Bulletin Page 2

7 Service Bulletin New Non-Fuse Jaw Bolt for Manipulator Systems & Slave Arms Compliance: Advisory* ISSUE DATE December 12, 2005 AFFECTED PRODUCTS Titan 4, Orion, Conan, and RigMaster manipulator systems and slave arms AFFECTED COMPONENTS Jaw bolts and T-bar plates SERVICE INFORMATION Because a number of customers have found the failure-rate of the fuse -type jaw bolts unacceptable, all new manipulator systems and slave arms are configured with non-fuse bolts. In addition, the material of the t-bar plate has been changed from Titanium to Inconel to increase it's strength. Customers purchasing replacement parts can select the fuse or non-fuse jaw bolt. Jaw bolt and T-bar plate part numbers for common models are listed in the table below. Manipulator or Slave Arm Models Non-Fuse Jaw Bolt Fuse Jaw Bolt Inconel T-Bar PLate Std. Titan 3 and 4 Manipulator Systems Orion and custom Titan 3 models using Nose Block Kit (jaw kits , 4106, 4107) Orion, Conan, and Rigmaster models using Nose Block Kit (jaw kits , 4103, REQUIRED *BULLETIN COMPLIANCE LEVELS Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

8 Service Bulletin Replacement of Titanium Azimuth Block on RigMaster Slave Arms Compliance: Recommended* ISSUE DATE August 22, 2006 AFFECTED PRODUCTS RigMaster slave arms AFFECTED COMPONENTS Azimuth block SERVICE INFORMATION The cast titanium azimuth block supplied on RigMaster slave arms delivered between May 2005 and March 2006 may experience failure. A replacement part will be provided at no charge. RigMaster slave arms delivered before May 2005 and after March 2006 have azimuth blocks made of 17-4 stainless steel and are not subject to failure. ACTION The titanium azimuth block should be replaced. To determine if the azimuth block is titanium, look at the section that holds the azimuth pivot pin. The titanium part has a gap and has a more sculptured finish (figure below, left). The stainless steel part has no gap (figure, right). REPLACE! OK If you have a titanium part, contact the Customer Service Department and provide the serial number of the slave arm, along with a contact name and shipping address. A replacement part will be sent immediately. REQUIRED *BULLETIN COMPLIANCE LEVELS Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

9 Service Bulletin Remote Systems Products ISSUE DATE February 12, 2007 Changes to the Titan 4 Upper Arm Assembly & Spares Kits Status: Advisory* AFFECTED PRODUCTS Titan 4 Manipulator Systems , PAL, , , & AFFECTED COMPONENTS Slave Arm and Upper Arm Assemblies SERVICE INFORMATION To enhance reliability and improve access to the filter element in the upper arm, Titan 4 Manipulator Systems shipped after February 1, 2007 include stainless steel hydraulic pressure lines and a new isolation valve assembly (see Figure 1). Figure 1 New hard lines (left) and isolation valve assembly (right) in the upper arm. The changes have resulted in new part numbers for the upper arm assembly (now ), the slave arm (now ), and Titan 4 standard and enhanced spares kits. The top level model numbers for Titan 4 manipulator systems (199-xxxx) have not changed. The new spares kits include the hard lines, new isolation valve, solenoid, and associated parts. They apply only to Titan 4 models built after February 1, 2007 with upper arm part number stamped into the underside of the upper arm assembly near the elbow (see Figure 2). Required *BULLETIN STATUS LEVELS Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly Recommended increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to Optional the discretion of the owner/operator. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. Advisory If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (US) or +44 (0) (UK) Fax: (US) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

10 Service Bulletin ELBOW UPPER ARM Figure 2 Part number of upper arm (arrow) The new spares kit part numbers are shown in Table 1. NOTE: The new spares kits are NOT interchangable with spares kits for Titan 4 models built before February 1, 2007 and/or with upper arm part number Consult your existing service documentation for the correct spares kit part numbers. Table 1 New Titan 4 Spares Kits Model (with upper arm ) Standard Spares Kit Enhanced Spares Kit PAL Page 2

11 Service Bulletin Remote Systems Products ISSUE DATE March 19, 2007 Changes to the Titan 4 Forearm Assembly Status: Advisory* AFFECTED PRODUCTS Titan 4 Manipulator Systems , PAL, , , & AFFECTED COMPONENTS Forearm Assembly SERVICE INFORMATION A relief valve has been added to prevent ambient pressure from locking the shoulder actuator if the manipulator hydraulics are turned off when operating at depth. The new parts are shown in Figure 1. Figure 1 Titan 4 Forearm Assembly Required *BULLETIN STATUS LEVELS Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly Recommended increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to Optional the discretion of the owner/operator. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. Advisory If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (US) or +44 (0) (UK) Fax: (US) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

12 Service Bulletin To minimize this risk, enable the hydraulic power when surfacing the slave arm or install relief valve kit The relief valve will be factory installed on Titan 4 models built after February 1, Relief Valve Kit, Rev. 2 Item P/N Description Qty RLF V,UNIV P SHCS,10-32X1.25,316SST,NLK O-RING,2-010 BUNA Page 2

13 Service Bulletin Remote Systems Products ISSUE DATE August 31, 2007 Changes to the Titan 4 Forearm Assembly Status: Advisory* AFFECTED PRODUCTS Titan 4 Manipulator Systems , PAL, , , & AFFECTED COMPONENTS Forearm Assembly SERVICE INFORMATION The T4 Lock Valve has been modified for serviceability. The new Lock Valve is factory installed on Titan 4 models with serial number and higher built starting on September 1, The new Lock Valve assembly, part number , is shown as item 10 in Figure 1. The new, longer screws, part number P, are shown as item 11 in Figure 1. Figure 1 New Titan 4 Forearm Assembly Required *BULLETIN STATUS LEVELS Field action is REQUIRED to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly Recommended increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to Optional the discretion of the owner/operator. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. Advisory If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (US) or +44 (0) (UK) Fax: (US) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

14 Service Bulletin The previous Lock Valve assembly, part number , is shown as item 4 in Figure 2. The previously used, shorter screws, part number P, are shown as item 2 in Figure 2 4 Figure 2 Previous Titan 4 Forearm Assembly To service a Titan 4 Lock Valve built after September 1, 2007, kit should be used. Titan 4 Lock Valve Kit, e 0 Item P/N Description Qty PSTN,LOCK V VALVE,LOCK SPR,LC-029B-3 MW,LEE O-RING,2-003 BUNA TOOL,LOCKV TEST O-RING,2-007 BUNA O-RING,2-011 BUNA SHCS,6-32 X 1/4 ALLOY, ST ADH,#271 RED LOCTITE 50ML WI WORK INSTRUCTIONS 0 To replace a Titan 4 Lock Valve built prior to September 1, 2007, kit should be used Page 2

15 Service Bulletin Titan 4 Lock Valve Kit, Item P/N Description Qty LOCK VALVE ASSY,3000 PSI,T P SHCS,10-32 X 1.125,SS,NLK O-RING,2-010 BUNA O-RING,2-013 BUNA P SHCS,10-32 X 1.625,SS,NLK 4 New Titan 4 Lock Valve Assembly, Rev.C Item P/N Description Qty BLOCK,LOCK VALVE,3000 PSI, PSTN,LOCK V VALVE,LOCK SPR,LC-029B-3 MW,LEE PLATE,COVER,LOCK VALVE,T PLUG,LOCK VALVE,3000 PSI,T O-RING,2-003 BUNA TOOL,LOCKV TEST O-RING,2-007 BUNA O-RING,2-011 BUNA WSHR,FLAT,M4,FENDER,316 SS SHCS,6-32X1/4,SS ADH,#271 RED LOCTITE 50ML WI WORK INSTRUCTIONS Page 3

16 Service Bulletin B A 2 NOTES: 1. ITEMS LISTED BELOW TO BE TORQUED AS INDICATED: ITEMS: TORQUE: INCH LBS. 2 ADD SERIAL NUMBER IN APPROXIMATE LOCATION SHOWN PER WORK INSTRUCTIONS. A REF 5 2 A PROPRIETARY THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO SCHILLING ROBOTICS. ANY REPRODUCTION, DISCLOSURE, OR USE OF THIS DOCUMENT IS EXPRESSLY PROHIBITED EXCEPT AS SCHILLING ROBOTICS MAY OTHERWISE AGREE TO IN WRITING REF SECTION A-A REV ZONE DESCRIPTION DATE BY APPR A RELEASED FOR PRODUCTION 6/5/07 PK B - UPDATED MODEL AND DRAWING DUE TO PART 8/20/07 NLH MODEL ECO'S SLW SLW ISOMETRIC VIEW SCALE 1.5:1 GENERAL NOTES INTERPRET DIMENSIONING AND TOLERANCING PER ASME Y14.5M IN ADDITION, S DENOTES REGARDLESS OF FEATURE SIZE. REMOVE ALL BURRS AND BREAK ALL SHARP EDGES NEXT ASSEMBLY ALL MACHINED SURFACES TO BE 63 RMS FINISH UNLESS OTHERWISE NOTED. DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED..X DECIMALS ±.1.XX ±.02.XXX ±.005 TOLERANCES FRACTIONS ±1/16.X.XX ANGLES ±30' ±15' DRAWN DESIGNED CHECKED LEAD PK SLW SLW SIGNATURE DATE 6/5/07 6/5/07 RELEASED FOR PRODUCTION 1 PROJECT TITLE 2:1 T4 LOCK VALVE, 3000 PSI, T4 SCALE: DRAWING NUMBER SIZE SHEET REV B 1 OF 1 B B A Page 4

17 Service Bulletin Correct hardware essential to safely mounting RigMaster Slave Arm Compliance: Mandatory* ISSUE DATE February 20, 2008 AFFECTED PRODUCT(S) RigMaster Slave Arm and earlier models SERVICE INFORMATION RigMaster Technical manual incorrectly lists M12 hex-head cap screws as a mounting hardware option. M12 hardware will NOT secure the slave arm and it will come loose from the vehicle. CORRECTIVE ACTION If M12 hardware is currently used to mount the slave arm, do not operate the slave arm. Replace the M12 hardware as soon as possible with 1/2-20 UNF-2B hardware ONLY. Refer to Figure 1, below. The mounting base should engage a minimum.5-in or 1.2 cm of the fastener threads. Replacement pages for the RigMaster technical manual are provided on the following page. Print as many as needed to correct all existing manuals. Figure 1 Correct Slave Arm Mounting Hardware (arrow) MANDATORY *BULLETIN COMPLIANCE LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

18 4 Installing the Slave Arm 2. Create a sturdy mounting platform that will provide a flat surface for the three mounting holes in the base as shown in Figure 2-5. NOTE: A full-size 1:1 drilling template, drawing , is located in a plastic sleeve at the back of this manual. Figure 2-5 Slave Arm Mounting Dimensions 3. Move the slave arm to the mounting platform. Lower the base onto the platform and align the mounting holes in the base and mounting platform. 4. Three 1/2-20 UNF-2B hex-head cap screws and lockwashers are required to attach the base to the mounting platform. CAUTION! Mounting fasteners must be long enough to engage a minimum of.5-in or 1.2 cm of the base Lubricate the threads of the fasteners with AquaShield (Aqualube) and add the lock washers. Install the fasteners through the mounting platform and into the RigMaster base. Torque the fasteners to 75 ft/lb (102 Nm). 4.2 Installing the Control and Drain Hoses Ten hoses are supplied for connecting RigMaster functions to your control manifold or intermediate bulkhead fittings. The eleventh hose provides case drain from, and compensation to, Installation Page 5 of 10

19 4 Installing the Slave Arm the wrist assembly. This line must be connected to the return system. The wrist actuator also has a drain pressure relief valve. NOTE: IMPORTANT INSTALLATION DIMENSIONS: 1. Bulkhead hose fittings must be located no closer than 24 in (610 mm) from the slave arm as shown in Figure 2-4, Minimum Distance to Bulkhead Hose Fittings on page Minimum bend radius for slave arm hoses is 2 in (51 mm). 3. If control hose lengths exceed 20 feet, consult Schilling Robotics for information about increasing the hose diameter to maintain adequate pressure and flow. A hydraulic schematic diagram of the RigMaster manipulator system can be found in the Drawings & Part Lists chapter. Table 2-1 lists the control and drain hose connections at the slave arm, and identifies actuator functions, hose codes, and actuator movements. The slave arm hydraulic hoses are fitted with female -4 JIC fittings for connecting all user-supplied hydraulics. Table 2-1 Slave Arm Hose Connections Slave Arm Actuator/Function Joint Travel Hose Code Actuator Movement Azimuth yaw Shoulder pitch Boom Wrist rotate* Jaw Right 1A Extend Left 1B Retract Up 2A Extend Down 2B Retract Out 3A Extend In 3B Retract N/A 4A Rotate CCW N/A 4B Rotate CW Open 5A Extend Close 5B Retract Wrist Drain** N/A C N/A *Forearm and wrist roll CW/CCW movements are referenced from behind the slave arm. **The maximum wrist drain/return pressure is 350 psi or less. If the wrist drain/return line passes through a filter or is manifolded with other equipment returns, check the return pressure when all equipment is running to be sure it does not exceed the maximum. Page 6 of 10 Installation

20 Service Bulletin Install Pressure Relief Valves on Rigmaster Slave Arms Compliance: Recommended* ISSUE DATE March 17, 2008 AFFECTED PRODUCTS Rigmaster Slave Arms AFFECTED COMPONENTS Pressure relief valves and cross-port check valves SERVICE INFORMATION Earlier revisions of the Rigmaster hydraulic schematic showed pressure relief valves on azimuth, boom, and shoulder functions only. This can result in failure of the wrist slip-ring manifold due to the actuator over-pressurizing the jaw circuit. All Rigmaster functions should have pressure relief valves as per the updated hydraulic schematic (Figure 1). FIELD ACTION Install pressure relief valves on wrist and jaw functions in addition to the existing azimuth, shoulder, and boom function valves. It is also recommended to add cross-port check valves to the azimuth, shoulder, and boom functions only. A check valve can be installed to the wrist function but may not be effective due to internal leakage of the wrist motor. Do not install a check valve to the jaw function as a hydraulic failure will leave the jaw locked in place (if the jaw is clamped on structure it cannot be disengaged). MANDATORY *BULLETIN COMPLIANCE LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

21 Figure 1 Rigmaster Hydraulic Schematic Page 2 Service Bulletin

22 Service Bulletin Relief valves prevent damage to wrist motor slip ring housing Compliance: Mandatory* ISSUE DATE April 23, 2008 AFFECTED PRODUCTS Rate-controlled Slave Arms (RigMaster, Conan 7R, Orion 4R and 7R models) and Hydraulic Pan & Tilt Units AFFECTED COMPONENT All Wrist Motor Assemblies SERVICE ISSUE Over pressurization of the Jaw Close 5B circuit/tilt circuit inside the wrist motor may cause the slip ring housing to fracture and allow hydraulic fluid to flow directly into the wrist case drain (hydraulic return). Properly installed over-pressure relief valves will prevent this from occurring. Without relief valves, housing fractures may occur when the pressure in the cylinder exceeds 5000 psi. This typically occurs when the jaw or tilt assembly is involved in a collision and the piston is forced open. An typical fracture is shown at right (arrow). Slip-ring housings manufactured after March 10, 2008 have been strengthened in the critical area, but relief valves are still recommended. FIELD ACTION To prevent an over-pressure event, a relief valve must be installed on each hydraulic circuit including the jaw/tilt function (see sample RigMaster and Pan & Tilt schematics on following page). Verify that all rate slave arms and pan & tilt units have properly positioned and adjusted over-pressure relief valves installed for all functions. If a circuit has an adjustable flow control valve (throttle valve), as shown in the RigMaster jaw and Pan & Tilt tilt schematics, the relief valve must be located between the actuator and the flow control valve. MANDATORY *BULLETIN COMPLIANCE LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left OPTIONAL to the discretion of the owner/operator. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. ADVISORY If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

23 Service Bulletin RigMaster Pan & Tilt Figure 1 Placement and adjustment of over-pressure relief valves Service Bulletin Page 2

24 Service Bulletin ISSUE DATE September 2, 2008 Removing the Titan 4 Wrist Camera Compliance: Advisory* AFFECTED PRODUCT(S) Titan 4 Manipulator Systems AFFECTED COMPONENT PAL Wrist Camera, and NTSC Wrist Camera, SERVICE INFORMATION Titan 4 Manipulators Systems with wrist cameras are equipped with a pitch/yaw wire cover and four additional screws ( P). It is important to keep these items in a safe place; they will be required if the camera is removed due to damage or for service. In addition to the pitch/yaw wire cover, four shorter manifold screws ( P) are required to install the wrist manifold when the camera is removed. To remove a Titan 4 wrist camera, or , follow the instructions below. MANDATORY *BULLETIN STATUS LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

25 Service Bulletin Wire cover screws, P (qty 4) Manifold plate screws, P (qty 4) A - Camera Installed Pitch/Yaw wire cover, (PAL camera) or (NTSC camera) B - Camera Removed Wire cover screws, P (qty 4) Manifold plate screws, P (qty 4) Figure 1 1. Remove the four wire cover screws (Figure 1, A) and save for step Remove the four manifold plate screws (Figure 1, A). These screw will not be reused. 3. Cut off the shrink tubing from the coax cable connector and disconnect from the PCB camera board. See Figure Disconnect the white harness cable connector from the PCB camera mount. See Figure 2. NOTE: The coax cable and white harness cable can be tucked into the yaw actuator housing for future camera installation. If doing so, install a piece of heat shrink ( ) onto the coax cable connector to insulate it against a ground fault. Sockethead cap screws, P Yaw actuator housing Coax cable connector, White harness connector, PCB camera board, Figure Page 2

26 5. Before installing the pitch/yaw wire cover (Figure 1, B): Inspect the O-ring ( ) and replace if necessary. Service Bulletin Check the two sockethead cap screws (Figure 2) and confirm that they are torqued to 7.3 Nm (65 lbf/in). 6. Secure the pitch/yaw wire cover with the four wire cover screws removed in step 1. Lubricated the bolts with AquaShield and torque to 28.5 Nm (21 lbf/ft). See Figure 1, B. 7. Re-install four new manifold plate screws ( P) to the yaw actuator (Figure 1, B). Lubricated the bolts with AquaShield and torque to 28.5 Nm (21 lbf/ft). The Titan 4 wrist camera has been successfully removed and the slave arm is ready for normal operation. Refer to the Titan 4 Technical Manual specific to your system for further information Page 3

27 Service Bulletin ISSUE DATE December 19, 2008 New Customer Service Bulletins Compliance: Advisory* AFFECTED PRODUCT(S) All systems SERVICE INFORMATION You are receiving this bulletin because you are a customer, partner, or associate of Schilling Robotics. If you would like to add additional recipients or unsubscribe from this bulletin, please reply to this . Schilling Robotics Customer Service Department s goal is to provide reliable information, technical support and solutions to all Schilling Robotics Customers. To further assist our customers, Schilling has developed this Service Bulletin Information System to broadcast service updates to customers and partners. All recipients of the Bulletin will be able to reply with questions, concerns, and changes relating to Schilling Robotics products. The Bulletin Information System is in its final stages of completion, and should be ready for use in the next few weeks. FIELD ACTION If there is a need for a recipient to be added or removed from this distribution list, please notify us by replying to this at any time. MANDATORY *BULLETIN STATUS LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

28 ISSUE DATE March 31, 2009 Service Bulletin New Torque Specification for Jaw Bolt Compliance: Advisory* AFFECTED PRODUCTS Conan, Orion, and Rigmaster systems; Titan systems with 7.8-in. intermeshing jaw AFFECTED COMPONENT Non-fused jaw bolt SERVICE ISSUES The torque specification for jaw bolt has been changed from 300 ft-lb (407 Nm) to160 ft-lb (217 Nm). When jaw service is performed, jaw bolt must be used and torqued to 160 ft-lb. Replace older fuse type jaw bolts ( and ) with bolt FIELD ACTIONS No action is needed for currently installed bolts. The next time a bolt is removed or replaced, follow the steps below to avoid damage to the manipulator while un-installing and re-installing the jaw bolts at the new torque setting. You should have the following tools before beginning: A bench vice 11/16 12 pt. socket (1/2-in. drive) and breaker bar Conan Jaw Bolt tool or CLP Jaw Tool To Un-install Jaw Bolts Torqued to 300 ft-lb: Refer to the drawing and part list Nose Block Kit, Conan/Rigmaster, on page 3 while performing the following steps:! Caution Shut off and isolate all hydraulics before beginning this procedure. NOTE: It is recommended that you have a bucket available to capture oil from the jaw. MANDATORY *BULLETIN COMPLIANCE LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. Field action may be useful under certain circumstances. Compliance is OPTIONAL and left OPTIONAL to the discretion of the owner/operator. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. ADVISORY If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

29 Service Bulletin Remove the four HHCS (item 14) and remove the nose block assembly from the manipulator wrist. 2. Install the nose block assembly into tool or and clamp the tool in a bench vise. 3. Use an 11/16 twelve-point socket (1/2-in. drive) with breaker bar and remove the jaw bolt ( HHCS, item 13). If an older fused bolt or is removed, replace it with a non-fused bolt Inspect piston (item 2) and T-bar plate (item 12) for damage, and replace if necessary. 5. Check for worn seals and replace as needed (spares are in Kit, Soft Goods, Nose Block w/ Adapter, on page 7). To Install Jaw Bolts: Refer to the drawing and part list Kit, Jaw Piston, Conan, on page 5 while performing the following steps: 1. Apply anti-seize (item 6) under the jaw bolt head and on the threads. 2. Install the bolt (item 3) and torque to 160 ft-lb (217 Nm). 3. Remove tool or from the bench vise and remove the nose block assembly from the tool. 4. Apply Aqua lube to the threads of the four HHCS (item 14) and re-attach nose block to the manipulator wrist with HHCS Torque the HHCS to 73 ftlb (99 Nm). Service Bulletin Page 2

30 Nose Block Kit, Conan/Rigmaster, Rev.U Item P/N Description Qty PISTON,1 PIECE,2.25 DIA,JAW BRG,PSTN,2.25DIA,ORKOT SEAL,PSTN,SHAMBAN,34G02250-A BLK,NOSE,W/BRG,CON O-RING,2-034 BUNA RING,BACKUP,8-034 BUNA BRG,ROD,1.0DIA,ORKOT SEAL,ROD,LIN ACTR,GAMMA PLATE,T-BAR,LOCKING BOLT,12 POINT,NAS ,MOD NAS 6406U SVCE INSTR,ITMSHG JAW NOSE BLK WSHR,3/8ID,5/8OD WI WORK INSTRUCTIONS TOOL,CONAN JAW BOLT ANTI-SIEZE,1 OZ TUBE 0 Page 3 Service Bulletin

31 Nose Block Kit, Conan/Rigmaster, Page 4 Service Bulletin

32 Kit, Jaw Piston, Conan, Rev.D Item P/N Description Qty PISTON,1 PIECE,2.25 DIA,JAW PLATE,T-BAR,LOCKING BOLT,12 POINT,NAS ,MOD SEAL,PSTN,SHAMBAN,34G02250-A BRG,PSTN,2.25DIA,ORKOT ANTI-SIEZE,1 OZ TUBE TOOL,CONAN JAW BOLT DOC,JAW PSTN KIT S4205,CONAN 1 Page 5 Service Bulletin

33 Jaw, Piston, Conan, Page 6 Service Bulletin

34 Kit, Soft Goods, Nose Block w/adapter, Rev.A Item P/N Description Qty BRG,PSTN O-RING,2-129 BUNA BRG,ROD SEAL,ROD STEP RSW Z48NA, SEAL,JAW PSTN,GAMMA O-RING,2-127 BUNA RING,BACKUP,8-034 BUNA O-RING,2-034,N90 2 Page 7 Service Bulletin

35 Service Bulletin Preventing Titan 4 Azimuth Movement When Hydraulics Are Disabled Compliance: Optional* ISSUE DATE: February 20, 2009 AFFECTED PRODUCT(S) Titan 4 Manipulator Systems AFFECTED COMPONENT Azimuth actuator SERVICE INFORMATION The azimuth actuator of the Titan 4 slave arm can be moved when hydraulic power is disabled and an external force is applied (including movement by the vehicle against the slave arm mass). This movement may cause unintended contact between the slave arm and the vehicle (or other equipment). This is a normal condition of the azimuth actuator and does not indicate that the seals or other components require replacement. The movement is caused by hydraulic fluid that is allowed to pass through the azimuth servo valve spool. The flow rate varies, depending on the location of the spool when hydraulic power was turned off (with some azimuth movement possible even when the spool is centered). Action options to prevent azimuth movement are described below. FIELD ACTION There are two corrective options if azimuth movement (while hydraulics are disabled) is a problem. Option 1 To prevent movement of the azimuth when the arm is stowed (or in any other position), leave hydraulics to the slave arm enabled. To prevent accidental movement of the slave arm, EXIT from any one of seven screens (OPERATE, OPTIONS, SLAVE DIAGNOSE, SET LIMITS, SET STOW, SET OFFSET AND SHUT DOWN) to enter a menu where the slave arm is in the LOCK mode ( LOCK text in upper right-hand corner of screen). A typical screen (MAIN menu) in LOCK mode is shown in Figure 1. MANDATORY *BULLETIN STATUS LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. RECOMMENDED Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. OPTIONAL Field action may be useful under certain circumstances. Compliance is OPTIONAL and left to the discretion of the owner/operator. ADVISORY Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service. @schilling.com For bulletins & manuals online, go to: Service Bulletin Page 1

36 Service Bulletin ! Caution Failure to enter a LOCK mode after stowing or immobilizing the slave arm while hydraulics enabled can result in unintended slave arm movements and damage to equipment. MAIN MENU LOCK > ROBOTICS SET UP <5 2> OPTIONS DIAGNOSE <6 3> OPERATE SHUT DOWN < UP key turns hydraulics OFF Figure 1 MAIN menu Option2 Install Lock/Relief Valve Kit under the Azimuth servo valve in the forearm (see part list, below). After installation, the azimuth joint locks when hydraulics are disabled, and cannot be rotated accidentally or by hand for service purposes. To order this kit, contact the Customer Service Department at: service. @schilling.com. NOTE: This kit can be used to lock any joint on the slave arm with unwanted movement except the wrist (due to an internal bypass) and the jaw, where a hydraulic failure could cause it to remain clamped to anything in its grasp. Kit, Lock Valve, Relief Valve, T4, Rev. 1 Item P/N Description Qty LOCK VALVE ASSY,3000 PSI,T RLF V,UNIV O-RING,2-010 BUNA O-RING,2-013 BUNA P SHCS,10-32 X 1.625,SS,NLK MNL,KIT,T4,AZ LOCK/REL VALVE 2 Page 2 Service Bulletin

37 Service Bulletin Con/Rig Tool Kit Status: Advisory* ISSUE DATE June 9, 2009 AFFECTED PRODUCTS Conan & Rigmaster Tool Kit , Revision D or older AFFECTED COMPONENT Wrist Clamp Tool SERVICE INFORMATION The Conan/Rigmaster Tool Kit , revision D or older, contains only one Wrist Clamp Tool (see figure 1). The correct quantity is 2. The additional part will be supplied at no cost. Figure Wrist Clamp Tool, 1 of 2 FIELD ACTION Part A Inspect Tool Kit for revision. Part B Contact Schilling Robotics. Part C Update affected part list. *BULLETIN STATUS LEVELS MANDATORY RECOMMEND- ED ADVISORY Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com Web site: SERVICE BULLETIN 7253.docx Page 1

38 Part A Determine Revision of Con/Rig Tool Kit Inspect each Tool Kit and determine its revision. If the Tool Kit is Revision D or older, one additional Wrist Clamp Tool will be needed. Continue to Part B. NOTE: Revision E or newer kits are supplied with both clamp halves, and no upgrade is necessary. Part B Contact Schilling Robotics Please contact Schilling Robotics at customerservicebulletins@schilling.com to request an additional Wrist Clamp Tool. Continue to Part C. Part C Update affected part Replace Part List as needed. Service Bulletin Page 2

39 Service Bulletin Page 3

40 SERVICE BULLETIN Titan 4 Camera Video Quality Status: *Advisory* ISSUE DATE August 26, 2009 AFFECTED PRODUCTS Titan 4 Manipulator Systems (NTSC), (PAL) AFFECTED COMPONENT NTSC Camera , PAL Camera, SERVICE ISSUE We have received customer complaints of unacceptable video quality on Titan 4 systems using customer specified connectors in place of the standard Seanet. FIELD ACTION We have identified modifications to the Titan 4 system that will improve video quality when using customer-specified connectors. The initial testing has been completed and production parts are expected to arrive the week of August 24. Approximately one week will be required for implementation and testing to qualify the final design. In early September, we will be contacting customers that are experiencing this problem and will define individual corrective action plans. *BULLETIN STATUS LEVELS MANDATORY RECOMMENDED ADVISORY Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly increased levels of personnel safety and/or equipment functionality. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance status is not rated. If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com Web site: Service Bulletin Page 1

41 Service Bulletin Customer Service 24 hr Support Line Status: Advisory* ISSUE DATE: August 31, 2009 SERVICE ANNOUNCEMENT Our 24hr Technical Support Line has been upgraded to provide a new level of technical assistance to our customers. Within the U.S.A Outside the U.S.A +44(0) Please refer to the information sheet on page 2 for details on using the new hot line. PAGE BREAK MANDATORY *BULLETIN STATUS LEVELS Field action is MANDATORY to ensure personnel safety, equipment functionality, and/or continuation of warranty coverage. Field action is not required but is highly RECOMMENDED and will result in significantly RECOMMENDED increased levels of personnel safety and/or equipment functionality. Bulletin contains advisory information to assist the owner/operator in more effective operation or service of the product. Compliance is not rated. ADVISORY If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com Web site: Service Bulletin Page 1

42 24-hr Technical Support MANIPULATOR SYSTEMS Availability and Support When You Need It. Within the U.S.A.: Outside of the U.S.A.: +44 (0) Schilling is proud to launch an upgraded Technical Support System to ensure that we provide prompt attention to all of our customers worldwide. Technical Support 24-hours per Day, 7 Days per Week Prompt, Accurate, Personal Support One Centralized Point of Contact Comprehensive Engineering and Technical Support In line with Schilling s expanding global business, we understand that customer access to the best technical support is essential. Schilling s 24-hour call center operators will log your request, give you a reference number, and directly transfer you to a Schilling technical support representative. Information that Will be Requested When Calling: Your Name and Company Telephone Number that You are Calling From Your Address Brief Description of the Problem So Deep, No One Comes Remotely Close

43 SAFETY BULLETIN Fused Jaw Bolt May Shear at High Velocity Status: SAFETY CRITICAL* ISSUE DATE August 26, 2009 AFFECTED PRODUCTS All Rigmaster, Conan, and Orion slave arms and manipulator systems, Titan Manipulator Systems AFFECTED COMPONENTS Fuse-type jaw bolts and (based on jaw type). They have a machined hole in the bolt head and are located as shown in Figure 1 on the following page. BACKGROUND A fuse-type jaw bolt was designed to shear when overloaded in order to prevent damage to other jaw components. As noted in Service Bulletin , the use of fuse-type bolts was discontinued beginning in November of 2005 because field users found the shear rate unacceptable. Because fuse-type jaw bolts are in many older spares kits and could have been used as replacements, they may be on slave arms of any age, old or new. 1 SERVICE ISSUE We have been informed that a fused jaw bolt sheared as the jaw function was being tested on-deck. Part of the bolt was ejected from the jaw at a high velocity, narrowly missing a crew member. This incident highlights the importance of always using PPE and staying clear of the slave arm s range of motion at all times to avoid risk of injury. FIELD ACTION Inspect each slave arm jaw to determine if a fuse-type bolt is used in the jaw. Fused jaw bolts have a machined hole in the bolt head as shown in Figure 1 on the following page. 1. Slave arms that use fused jaw bolts can continued to be operated under the following conditions:! WARNING Use extreme caution when testing a slave arm on deck: Move all personnel outside the slave arm s range of motion when hydraulic pressure is applied and functions are tested. Direct the slave arm to point away from personnel and critical or sensitive areas while testing jaw functions. Do not stand in front of the jaw assembly while testing jaw functions. *BULLETIN STATUS LEVELS SAFETY CRITICAL Field action is CRITICAL to ensure the SAFETY of personnel and must be performed IMMEDIATELY If you have any questions about this service bulletin, contact the Schilling Customer Service Department at: Tel: (USA) or +44 (0) (UK) Fax: (USA) or +44 (0) (UK) service.schilling@schilling.com Web site: Page 1

44 2. If you decide to replace a fuse bolt, use the slave arm or manipulator system technical manual to determine the part number for the existing fused jaw bolt. Then determine if a non-fused, replacement jaw bolt is available in spares: Fused jaw bolt (shaft length in.): Replace with jaw bolt Fused jaw bolt (shaft length in.): Replace with jaw bolt Jaw bolts and can be found in many slave arm, manipulator system, and Schilling ROV system spares kits issued since Figure 1 Fuse-type jaw bolt: location (left), machined hole in head (center, right) Page 2