VERSION 2011-02

SeaPerch Construction Manual Version 2011-02

2700 South Quincy St., Suite 400, Arlington, VA 22206

www.seaperch.org

Welcome to your SeaPerch journey!

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

Susan Nelson
Executive Director, SeaPerch Program
AUVSI Foundation

SeaPerch Construction Manual Version 2011-02

UNIT 1 ASSEMBLY OF SUBSYSTEM ONE -- THE VEHICLE FRAME

Inthisunit,youwillcutpipepiecesandassembletheSeaPerch'sframe.Holes
willbedrilledintheelbowsandportionsoftheframestoallowventingand
drainingoftheSeaPerchframeandmotormountingslaterinthebuild.

Tools and Materials Needed

Tools
Eye Protection (Always Worn)

Materials

Ruler and Pencil (or Marker)

72" (1.8 m) PVC Pipe (Or Six, one foot.

Lengths)

PVC Pipe Cutter (or Saw)

10

PVC Elbows

Wire-Cutting Pliers (Flush-Cutting

Type Preferred)

PVC Tees

Electric Hand Drill

Floats

Drill Bit

12 x 6.5 (31 x 17 cm) Payload Net

3/32 Drill Bit

6 Tie Wraps (small black)

Procedure 1.1 Cut the Frame Parts

Construction Steps:
1. MeasureandcutthepieceslistedbelowfromlengthsofPVCpipe.Cutthelongestpieces
first,incaseamistakeismade(smallerpiecescanbecutfromamiscutlongerpiece).Try
tocutstraightacrossthepipe,butdontworryiftheyarenotperfect.
TwoPieces6.5(16.5cm)long

FourPieces5(12.7cm)long

TwoPieces4(11.4cm)long

TwoPieces4(10.2cm)long

TwoPieces2(6.4cm)long

FourPieces1(3.8cm)long

2. Useapencilormarkertowritethelengthon
themiddleofeachpiecetokeeptrackof
cutsandtoeasilyidentifythemlater.Figure
1.11showsthepiecesneededtoassemble
theROVframe.Figure1.12(onthenext
page)showsonewaytocutthepipepieces
fromsix,onefootpipes.

Figure 1.1-1: PVC Pipe Cutter and Cut PVC Pipe

Sections, Elbows, and Tees

SeaPerch Construction Manual Version 2011-02

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

Procedure 1.2 Drill the Drain Holes

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

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

Figure 1.2-1: Drilling Elbow

Hole over a Wastebasket

" Hole

Figure 1.2-2: Drain Hole

Drilled in a PVC Elbow
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5 pieces

4.5 piece

Figure 1.2-3: Motor Mounting holes in two

5 pieces and one 4.5 piece

Procedure 1.3 Assemble the Vehicle Frame

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

SeaPerch Construction Manual Version 2011-02

Figure 1.3-1: Initial Frame Assembly

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

SeaPerch Construction Manual Version 2011-02

Procedure 1.4 Attach the Payload Net

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

Figure 1.4-1: Payload Netting Attached to Frame

Congratulations! You have completed the frame for your SeaPerch!

SeaPerch Construction Manual Version 2011-02

UNIT 2 ASSEMBLY OF SUBSYSTEM TWO -- THE THRUSTERS

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

Tools and Materials Needed

Tools
Eye Protection (Always Worn)
Electric Hand Drill

Materials
~50 (15 m) CAT 5 Tether Cable with RJ-45 Connector
Installed on One End
3

35 mm Film Canisters, with Caps

3/32 Drill Bit

12-Volt DC Motors

1/4 Drill Bit

Propellers

Pliers

4-40 Threaded Propeller Shaft Couplers

4-40 Tee Nuts

Needle-Nose Pliers

4-40 Lock Nuts

Wire Stripper (18 - 26 AWG Size)

Super Glue

Wire-Cutting Pliers

1/3

Wax Bowl Ring

Vise

1/2

Butyl Rubber Tape

12-Volt Battery

6 (15 cm) Tie Wraps (small black)

11 Heavy-Duty Tie Wraps (large Blue)

Permanent Ink Marking Pen

Ruler and Scissors
Soldering Iron and Solder

Alcohol Pads

Fine Sandpaper or Steel Wool

Paper Towels
Electrical Tape

Gloves (Disposable Type)

SeaPerch Construction Manual Version 2011-02

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

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

Figure 2.1-1: Tape Sealing Process

Ontheterminalend,gentlypushapieceoftapeoveroneterminaltopokeit
throughthetape.Carefullyplacetheedgeofthistapeupalongthesideofthe
motorshaftboss(raisedareainthecenter).

Continuedoingthisforallfivetapepieces,overlappingthemaroundtheterminal
endofthemotortofullycoverit.

Thentrimoffalltapethat
extendspasttheedgeofthe
motorshell(cutwithscissors
tiltedtowardthemotorendto
getaclean,flushedge).

3. Repeatthistapingprocessontheother
endofthemotor.Besuretocutthe
tapepiecesflushattheedgeofthe
motorasbefore.

One, Thin,
Layer Of
Tape on
Sides
NO Folds
or Gaps

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

SeaPerch Construction Manual Version 2011-02

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

Procedure 2.2 Drill Holes in the Thruster Housings

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

Figure 2.2-1: Holes Drilled in Thruster Housings

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

SeaPerch Construction Manual Version 2011-02

Procedure 2.3 Connect the Tether Cable Wires to the Motors

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

Construction Steps:
1. Ontheendofthetethercablethat
hasnoconnectorinstalled,use
scissorstoslitopentheouterjacket
andexposethefirstinchofwiresas
showninFigure2.31
2. Thenpullingthebrownpairofwires
tearthejacketbackabout15(38
cm)asshowninFigure2.32and
Figure2.33

Figure 2.3-1

Figure 2.3-2

3. Trimthetorncoveroffbeingvery
carefulnottonickanyofthewiresas
showninFigure2.34
4. Threadabout2(5cm)ofeachpair
throughtheholeinathrusterhousing
cap,andtieaknotontheinwardside
ofthecaps,asshowninFigure2.35.

Figure 2.3-3

5. Stripabout(7mm)ofinsulationfromthe
endofeachwire,forthegreen,blue,and
orangepairs.
6. Selectapairofwiresandoneofthetaped
motors.Attachthesolidcolorwiretothe
positiveterminalmarkedinstep2.1.The
stripedwireattachestotheotherterminal.
Bendthestrippedendofeachwirethrough
theterminal,andsqueezethewiretightly
ontotheterminalusingneedlenosepliers.

Figure 2.3-4

About 2

Figure 2.3-5: A Motors Wires Passed through a

Thruster Housing Cap and Knotted

7. Solderthewiresontothetwoterminalsof
themotor,asshowninFigure2.36.
8. RepeatSteps5and6fortheothermotors
andtheirtetherwirepairs.
Figure 2.3-6: Tether Cable Wires Soldered Onto a Thruster
Motor's Terminals

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Procedure 2.4 Pot (Waterproof) the Motors with Wax

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

Construction Steps:
1. Rollanacornsizeballofwaxinyourgloved
handsforaminuteorsountilitissoftened,
asshowninFigure2.41.
2. Pushandflattenthehandwarmedballof
waxacrosstheendofthemotor,about1/4"
thickandthediameterofthemotor,as
showninFigure2.42.

Figure 2.4-1

3. Insertthecoatedmotorintothethruster
housing,untiltheshaftpokesthroughthe
holeinthebottomofthehousing,asshown
inFigure2.43.
4. Pressfirmlyonthebackofthemotorto
slowlymoveittothebottomofthehousing
whilethewaxinthebottompushesup
aroundthemotoruntiltheshaftfully
protrudesfromthebottom,asshownin
Figure2.44.
5. Coilthewiresintotheendofthehousing
andpressamarblesizedpieceofroom
temperaturewaxontopofthecoiledwires
toholdtheminplace,andthenpressthe
waxdowntofillinanyremainingspace
aroundthesidesofthemotor.Adjustthe
amountofthewaxtofilltheremainderof
theareaatthetopofthehousing,leaving
justenoughspaceforthecaptogoon,as
showninFigure2.45.

Figure 2.4-2

Figure 2.4-3

Figure 2.4-4

Figure 2.4-5

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

Figure 2.4-6
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Testing:
1. Ifapremade,"knowntobegood"controlboxisavailable,testthethrustersbyattaching
thetethercable'sRJ45connectortothecontrolbox.Presseachswitch,oneatatime,and
observetheoperationofeachthrustermotor.
2. Themotorshaftshouldspinrapidly,indicatingthatthethrusterisgood.

Ifyoumotordoesnotspin,orspinsslowly,gentlytwistitinbothdirectionsbyhand,orifitseems
stuck,useplierstoturntheshaft,andrepeatthetest.

Ifitstilldoesnotwork,inspectthewiresfornicksthatmayhavebrokenawire.Repairabreakby
strippingofinsulationfromtheendsandsplicingthembacktogether(twistthewires,solder,and
covertheconnectionwithelectricaltape).

Ifthethrusterstilldoesnotwork,itmayhaveabrokenwireinsidethethrusterhousing.Thethruster
canbeopenedtoseeifawiremayhavebrokenawayfromoneoftheelectricalterminalsonthe
motor.Waxcanberemovedfromthebackareaofthehousingtoallowtheconnectiontobe
repaired,andthenthewaxandcapcanbereplaced.Ifthatisnottheproblemandthemotorstill
doesn'twork,waxmayhaveenteredthemotor,anditwillneedtobereplacedbycuttingthe
thrusterwireascloseaspossibletothenonworkingthrusterhousingandrepeatingprocedures2.2
through2.4foranewthruster.

Testanyneworrepairedthrustersasabovetomakesurethattheyspinproperly.

Procedure 2.5 Mount the Propellers onto the Shafts

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

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SeaPerch Construction Manual Version 2011-02

2. Useaviseorpairofplierstoholda
threadedcoupler,asshowninFigure2.51.
3. Threadtheteenutallthewaydownthe
threadedcoupler.Apairofpliersmaybe
requiredtogettheteenutstartenonthe
threadedcoupler,asshowninFigure2.52
andFigure2.53
4. Lookcloselyatapropellerandnotethat
onesidehasaslot(groove)init,asshown
inFigure2.54.Thisisthesidethatmust
beplacednearestthemotor.Placethe
propellerontothethreadedcouplerwith
theslotsidetotheteenut,asshownin
Figure2.55.

Figure 2.5-1

5. Threadalocknutontothethreaded
coupler,asshowninFigure2.56.

Figure 2.5-2

Figure 2.5-3

Figure 2.5-4

Figure 2.5-5

Figure 2.5-6

6. Usingpliersornutdriver,drivethe
assemblytogetherbytighteningthelock
nut.AfinishedassemblyisshowninFigure
2.57.
7. RepeatSteps26fortheotherpropellers.

Figure 2.5-7: Finished

Propeller assembly

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SeaPerch Construction Manual Version 2011-02

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

Figure 2.6-1: Adhesive on Tip of Roughened

Motor Shaft and In Hollow End of Shaft Coupler

11. After10minutes,turneachmotorbyhandtofreeup
thenewlyintsalledasemblies.

Procedure 2.6 Mount the Thrusters onto

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

Construction Steps:
1. Threadalarge,heavydutytiewrapthroughthetwothruster
mountingholesateachofthethreethrusterlocations,asshownin
Figure2.64.
2. Placetheappropriatethrusterintheloopformedbyeachtiewrap,
andtightenthetiewraparoundthethruster,asshowninFigure
2.65.RefertoTable2.61forthrusterplacement.Besureto
mounttheverticalthrusterwithitspropellerpointingupward.
Table2.61ThrustersIdentificationforPlacementonthe
VehicleFrame
Green/GreenStriped

Starboard(Right)

Blue/BlueStriped

Port(Left)

Orange/OrangeStriped

Vertical(upandDown)

14

Figure 2.6-4: Tie Wrap

Threaded Through ThrusterMounting Holes

SeaPerch Construction Manual Version 2011-02

3. Installasecondheavydutytiewraparoundthefirsttiewrap,betweenthethrusterandthe
pipe,ateachofthethreelocations,andtighteneachsecurelytoholdthethrustersinplace.
4. Cutoffthetiewraptailsasflushaspossibletoavoidleavingsharpends.
2ND TIE WRAP
AROUND
THE 1ST

Figure 2.6-6: Thruster Angles Can Be Easily

Adjusted By Inserting a Screwdriver into the
Angle-Adjustment Holes and Twisting the Pipes

Figure 2.6-5: One Heavy-Duty Tie Wrap Holds the

Thruster to the Pipe, and a Second Tie Wrap Tightens
the First to Secure the Thruster Tightly to the Frame

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

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Procedure 2.7 Waterproof and Mount the Tether Cable

Construction Steps:
1. Usinga(1.5cm)pieceofbutylrubbertape,stretchthetapetoabouttwiceitsrelaxed
lengthandwinditamongandaroundthefourwirepairswheretheyemergefromtheouter
jacketofthethrusterendofthetethercable.Pressitoverthejacketopeningsothatit
extendsatleastoneachsideoftheopening,asshowninFigure2.71.Kneadandwork
itinbetweenthewireswellsothatitsealsbotharoundandbetweenthewiresandformsa
smoothsealoverthejacketopeningtopreventwaterfromgettinginsidethetethercable.

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

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

USE TWO
CROSSED
TIE WRAPS

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

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

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UNIT 3 ASSEMBLY OF SUBSYSTEM THREE -- THE CONTROL BOX

In this unit, you will build the ROV's control box by mounting electrical
componentsonaprintedcircuitboard,assemblingandconnectingthepower
cord,andmountingthecircuitboardintheplasticcontrolbox.

Tools and Materials Needed

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

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

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

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

Procedure 3.2 Assemble the Power Cord

Construction Steps:
1. Findthepowercordwire,anddeterminewhichofitstwo
conductorswillbepositiveandwhichwillbenegative.For
thisproject,wewillcallthecoppersidethepositive(+)
wire,andthesilversidethenegative()wire.
2. Oneachendofthewire,carefullyseparatethetwo
conductorsforalengthofabout3inches(7.6cm).
3. Strip5/8inch(16mm)ofinsulationoffofallfourendsof
thepowercordwire.Twistthestrandsoneachofthe
ends(individually,notalltogether)tightlytoprevent
fraying.

Figure 3.2-1: Alligator Clip

Covers Installed on Power Cord
Wires

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

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SeaPerch Construction Manual Version 2011-02

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

Procedure 3.3 Install the Printed Circuit

Board Components

Figure 3.2-2: Wire Properly

Connected to an Alligator Clip

Screw

Figure 3.2-3: Completed

Power Cord

Construction Steps:
7. ReviewFigure3.31,andrefertoitasneededduringthefollowingassemblysteps.The
partswillbeinstalledinorderaccordingtotheirsize,smallestfirst.DONOTINSTALL
COMPONENTSUNTILISISCALLEDFORINTHEINSTRUCTIONS

Figure 3.3-1: Component Placement for

the Control Box PCB Assembly

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8. Locatethefusesocket.Placeitstwopinsthrough
theholesatthelocationontheboardlabeled
"F1,"asshowninFigure3.32(remember,all
componentsgoonthesideofthePCBthathas
thewhitelettering).Useasmallpieceof
electricaltapetoholdthesocketinplace.Flipthe
boardoverandplaceitonatabletop.Pressdown
onthePCBtoholdthesocketflatagainstthe
board,andsolderthetwoconnections.Meltonly
Figure 3.3-2: Fuse Socket Installed at the
Location Labeled "F1"
about1/4"ofsolderintoeachconnection,let
themcoolforafewsecondsbeforemovinganything,andmakesurethatthereareno
solderbridgesbetweentheconnections.(Removeexcesssolderifneededbytouchingthe
solderbridgebrieflywithaclean,hot,solderingirontip.)

TIPSPCBandComponentSoldering:
Whensoldering,alwaysweareyeprotection!
BesurethatthecomponentsareplacedfirmlyagainstthePCBbeforesolderingthem;althoughit
ispossibletomakecorrectionslater,itcanbedifficult.
CleanthesolderingirontipbeforeEVERYsolderingstep,andthentouchsoldertotipofthe
solderingironto"tin"itbrieflybeforestartingtosolderacomponent.Keepsolderonthetip
betweenuses.
Whilesoldering,touchthesolderonlytothe"pad"(theroundcontactonthePCB)andthe
componentwireorpin,nottothesolderingirontip.
Touchtheiron'stiponlyonthepads,nottheboard.
Heateachconnectionforafewsecondsbeforeapplyingsoldersothatthesolderwillflow
completelyoverthepadaswellasthecomponentwirethatpassesthroughtheholeinthepad.
However,donotoverheatthepads,astheymightliftoffoftheboardoritmaybecome
scorched;severalsecondsofheatingisusuallyenough.
Whendonesoldering,removethesolderfromthepadfirst,thentheiron.
Whensolderingtheswitches,pauseafewsecondsbetweeneachconnection,sothatplasticparts
insidetheswitchesdon'toverheatandpossiblygetdamaged.
AftersolderingeachconnectionletthesoldercoolforseveralsecondsbeforemovingthePCB,so
thatthesolderwillformagoodconductiveconnection.Theyshouldbeshiny,notroughordull
looking;iftheydon'tlookshiny,simplyreheatthemandkeepthemstillwhilecooling.
Usejustenoughsoldertocovertheconnection;toomuchcancausetheexcesstobridge
betweencloselyspacedconnections.Checkforsolderbridgesaftersolderingeachcomponent.

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9. Placethepinsofthetwopushbuttonswitchesthrough
thepadsinthePCBatthelocationslabeled"SW3"and
"SW5,"asshowninFigure3.33,aftermakingsurethat
theirpinsareallstraight(perpendiculartotheswitch
body).[Youmayhavelargerswitchesthanshown,
whichfitinsteadintotheothersetofthreeholesatthe
"SW4"and"SW6"locations.]Whileholdingthe
switchesinplacewithapieceofelectricaltape,flipthe
PCBoverandplaceitonatabletop.Pressdownonthe
PCBtoholdtheswitchesflatagainsttheboard,and
solderallconnectionsoneachswitch.
10. Findthetwotoggleswitchesandthecontrolboxlid.
Placetheswitchesinthe"SW1"and"SW2"locations
onthePCB,asshowninFigure3.34.Itisalso
importanttokeeptheseswitchesflatagainstthe
boardwhiletheyaresolderedintoplace,sothatthey
willbestraightwhenthecontrolboxisfinished.A
goodwaytodothisistousethecontrolboxlidto
holdtheswitcheswhilesoldering.Putthetoggle
handlesthroughthetwocenterholesinthecontrol
boxlid(theymaybetight).Then,whileholdingthe
PCBagainstthebackoftheswitches,turnthe
assemblyoverandplaceitacrosstheopentopofthe
controlbox,asshowninFigure3.34.HoldthePCB
downflatwhilesolderingthefirstofthe12switch
connections,tomakesurethatitwillbetightagainst
theswitches.

Figure 3.3-3: Pushbutton Switches

Installed in the "SW3" and "SW5"
Locations

Figure 3.3-4: Toggle Switches Held

Straight by the Control Box Lid uring the
Soldering Process

11. Soldertheremaining11connections,takingcarenot
tooverheattheswitches(waitafewsecondsbetween
connections,oralternatebetweenthetwoswitches).
Thenremovethenutsandthelid.
12. CheckthesmallpinsonthebottomoftheRJ45
connectorjacktomakesurethattheyarenotbent,
andthencarefullyputthemthroughthePCBholesat
location"J1,"asshowninFigure3.35.Pressonthe
jacktosnapitintoplace.

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Figure 3.3-5: Toggle Switches

Installed in the "SW1" and "SW2"
Locations

SeaPerch Construction Manual Version 2011-02

Figure 3.3-6: Bottom of a PCB after

Soldering All Components

Figure 3.3-5: RJ45 Connector Jack

Installed at Location "J1"

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

Figure 3.3-7: A Completed PCB

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SeaPerch Construction Manual Version 2011-02

Procedure 3.4 Connect the Power Cord

Construction Steps:
1. Twistthestrandsofthetwopowercordwires,andpass
themthroughthecordholeinthecontrolboxlid,from
thetopside.Thentieaknotinthetwowires,about
oneinchfromtheends,ontheundersideofthelid,as
showninFigure3.41.
2. Retwistthestrandsofeachofthetwowiressothat
theycanpassthroughthePCB'ssolderpadholes,and
placethepositive(copper)wireintothe"+12V"(RED)
powerwirehole,andthenegative(silver)wireintothe
"12V"(BLK)powerwirehole,bothenteringtheholes
fromthecomponentsideofthePCB,asshowninFigure
3.42.Bendthewiresovertohelpholdtheminplace
duringsoldering.

Figure 3.4-1: Power Cord

Passed Through the Hole in the
Box Lid, and Knotted

3. Solderthetwopowerwires,usingenoughsolderto
makegood,solidelectricalconnections.Thensnipoff
theexcesswirebeyondthesolderjoints.

Figure 3.4-2: Power Cord Wires

Through the Holes in the +12V
and 12V Pads

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SeaPerch Construction Manual Version 2011-02

Procedure 3.5 Conduct Tests and Finish the Control Box

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

TIP:Youmayfindithelpfultoreferto
theTroubleshootingGuidediagrams
onPages27and28ifthetestsin
Procedure3.5identifypossible
electricalproblems.

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

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SeaPerch Construction Manual Version 2011-02

7. Onceyouaresurethattherearenoshort
circuitsandthatthethrustermotorsshow
properreadings,youcanfinishassemblingthe
controlbox.PlacethePCBintothecontrolbox,
passingthepushbuttonswitchactuatorbuttons
carefullythroughthetwoholesinthefrontof
thebox,andsecurethePCBintotheboxusing
thefoursmallsilverscrews,asshowninFigure
3.52.
8. Pressthetwopushbuttonswitchcapsontothe
actuatorbuttons,asshowninFigure3.53.
9. Installthelidontothecontrolbox,carefully
foldingthepowercordwiresinsidetheboxas
thelidisloweredintoplace.Securethelidwith
thefourblackscrews.

Figure 3.5-2: PCB Board Installed

10. Connectthetethercable'sRJ45connectorplug
intotheRJ45jackonthecontrolbox.
CONGRATULATIONS, you have finished the
construction of your SeaPerch ROV!
Now its time to get it ballasted and try it in water!
Figure 3.5-3: A Completed Control Box

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CONTROL BOX TROUBLESHOOTING GUIDE

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

Troubleshooting Testing Using an Audio Continuity Tester

CheckthePCB
Visuallyfor
Problems

DoesEach
SolderConnectionHave
NO
ClearSpaceAroundIt?

RemoveExcessSolder
(SolderBridges)to
CreateSpaceBetween
AllConnections

YES

Conduct
Continuity
Tests

SettheMetertoAudio
YES
ContinuityMode
ConnecttheMeterProbes
totheAlligatorClips
ConnecttheTetherCable
totheControlBox

ActivateEach
ControlBoxSwitch
Individually,InAll
SwitchPositions
FixthePowerCord
Connectionsand
Retest

Doesthe
NO
MeterBeepWhenYou
ActivateEach
Switch?

CheckthatEachSolder
JointLooksLikeaShiny
LittleHersheys Kiss
ReSolderwithMoreHeat
orMoreSolderIfNeeded

YES
IftheMeterShowsLessthan
~1Ohm,There isProbablya
HiddenShortCircuit
RepeatVisualChecksand
RemoveAnyExcess Solder
ChecktheRJ45Connector

YES

Good!NoShort
Circuits!
FinishAssemblingthe
ControlBox

STILL
NO

NO
ArethePowerCord
ConnectionsatBothEnds
Good?
YES

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

RETEST

MountthePCBIntothe
ControlBox
RepeattheContinuity
ChecksAfterPCBMounting
IfSuccessful, Attachthe
PushbuttonCaps

26

TheSwitchthat
DoesntCauseaBeep
MayBeBad(Check For
ContinuityDirectly
AcrossItsSolder
Connections)
OR aThrusterWire
MayBeBroken
(InspectandFix)

ConnecttheBatteryto
YourSeaPerchand
ConfirmProperThruster
Operation

SeaPerch Construction Manual Version 2011-02

Troubleshooting Testing With an Ohmmeter

CheckthePCB
Visuallyfor
Problems

DoesEach
SolderConnectionHave
NO
ClearSpaceAroundIt?

RemoveExcessSolder
(SolderBridges)to
CreateSpaceBetween
AllConnections

YES

Conduct
Ohmmeter
Tests

SettheMetertoMeasure
YES
Resistance (Ohms)Mode
ConnecttheMeterProbes
totheAlligatorClips
ConnecttheTetherCable
totheControlBox

ActivateEach
ControlBoxSwitch
Individually,InAll
SwitchPositions
FixthePowerCord
Connectionsand
Retest

Does
MeterShowYES
MegohmsofResistance
WhenAnySwitchis
Activated?

CheckthatEachSolder
JointLooksLikeaShiny
LittleHersheys Kiss
ReSolderwithMoreHeat
orMoreSolderIfNeeded

RETEST
IftheMeterShowsLessthan
~1Ohm,There isProbablya
HiddenShortCircuit
RepeatVisualChecksand
RemoveAnyExcess Solder
ChecktheRJ45Connector

YES

Good!NoShort
Circuits!
FinishAssemblingthe
ControlBox

STILL
YES

NO
ArethePowerCord
ConnectionsatBothEnds
Good?
YES

NO

Doesthe
MeterShow~5to~15
NO
OhmsWhenEachSwitch
IsActivated?

RETEST

MountthePCBIntothe
ControlBox
RepeattheContinuity
ChecksAfterPCBMounting
IfSuccessful, Attachthe
PushbuttonCaps

27

TheSwitchthat
DidntCauseaLow
OhmReading MayBe
Bad(Check Resistance
ReadingDirectly Across
ItsSolderConnections)
OR aThrusterWire
MayBeBroken
(InspectandFix)

ConnecttheBatteryto
YourSeaPerchand
ConfirmProperThruster
Operation

SeaPerch Construction Manual Version 2011-02

BALLASTING YOUR SEAPERCH ROV

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

Ballast and Trim Considerations for SeaPerch ROVs

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

Attaching Ballast to the ROV

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

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

Environments Suitable for Using a SeaPerch ROV

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

Post-Run Cleaning and Maintenance of the ROV System

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

Enjoy Using Your SeaPerch ROV!

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NOTES
TIPS:SolderingIronMaintenanceandSolderingRecommendations

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

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NOTES

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NOTES

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